Gardner Denver VM 135 Operation, Safety And Maintenance Manual Download Page 46

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H4960700 Date 20.11.08 Issue 002

Summary of Contents for VM 135

Page 1: ...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 01274 683131 Fax 01274 651006...

Page 2: ...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...

Page 3: ...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 2...

Page 4: ...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 continuo...

Page 5: ...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 rep...

Page 6: ...D 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...

Page 7: ...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...

Page 8: ...m 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 Ov...

Page 9: ...ayload 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 h...

Page 10: ...Y 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 c...

Page 11: ...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...

Page 12: ...e 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 st...

Page 13: ...ated 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 stab...

Page 14: ...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 pr...

Page 15: ...H4960700 Date 20 11 08 Issue 002 15 PLATFORM CAGE CONTROLS...

Page 16: ...UTTON 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 re...

Page 17: ...ust 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...

Page 18: ...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 syste...

Page 19: ...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 platf...

Page 20: ...LEW 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...

Page 21: ...ounted on the A frame The left hand tap controls the descent of the middle boom the right hand tap controls the base boom To lower the booms turn the taps anti clockwise NOTE ENSURE THAT BOTH TAPS ARE...

Page 22: ...control panel to Ground Controls Turn the D C power switch on the pendant to ON this will stop the engine if it is running Pushing any of the boom function buttons on the pendant will activate the po...

Page 23: ...t from the cage or climb out to increase work area move the machine closer NEVER Use the platform as a crane NEVER Rest the booms or cage against objects NEVER Deploy stabilisers on soft ground NEVER...

Page 24: ...ched off and a written PERMIT TO WORK must be obtained from a responsible person representing the authority operating the power lines NOTE See Health and Safety Executive Guidance Note G S G entitled...

Page 25: ...erlock Check function of the emergency stop system Grease all stabiliser leg slides and swivel feet Check the function of the cage load sensing system Check all critical fasteners see drawing Grease s...

Page 26: ...e of operations DRAIN SYSTEM 1 Place a container or containers with a total capacity of 70 litres 15 gallons beneath the vehicle and provide a funnel and hose to collect the oil from the reservoir 2 O...

Page 27: ...tions PRIME SYSTEM Start the vehicle s engine During the following procedure replenish the reservoir as necessary Engage the PTO unit and run the system for the shortest time possible while carrying o...

Page 28: ...must be renewed The cylinder valve blocks are retained by banjo bolts these must not be tightened to more than 25Nm RECOMMENDED AND ALTERNATIVE HYDRAULIC OILS LUBRICANTS 1 Platform Manufacturer Hydra...

Page 29: ...45Nm 3 Fastenings for specific components G D K Slew ring M12 x 1 75 100Nm I M O Slew ring M16 x 2 250Nm Harness Eyebolts M12 x 1 75 40Nm Cam plate M12 x 1 75 Soc Cap Screws 45Nm Middle Boom to Base B...

Page 30: ...for correct operation Please contact Gardner Denver UK Service department for vehicle parameters The purpose of the structural inspection is 1 Examine the condition of the structure and check for any...

Page 31: ...eter renew if necessary Dump valve solenoid failure Test using a multi meter renew if necessary Hydraulic oil overheating Hydraulic oil reservoir contents low Replenish Worn main hydraulic pump Connec...

Page 32: ...ailure Test by replacement Complete slew failure Internal damage to slew assembly worm drive Replace complete assembly Slew failure no manual slewing Seized slew motor Test by replacement Complete ele...

Page 33: ...2 Make and type of chassis 3 Components layout section heading 4 Item number component number and its description 5 Quantity required Gardner Denver reserve the right to alter the design construction...

Page 34: ...H4960700 Date 20 11 08 Issue 002 34 ILLUSTRATED COMPONENT LAYOUT AND PARTS LISTS...

Page 35: ...AD 100x80x20mm THICK 1 WPA2065037 3 LOCKING SCREW M8x40 SOC CAP HD 5 M450087040 9 4 WEAR PAD 108x100x14mm THICK 2 WPA2065042 5 FIXING SCREW M8x16 SOC BUTTON HD 8 M44087016 2 6 M8 SPRING WASHER 8 M6100...

Page 36: ...N STRAINER 1 WPA2705000 18 BALL VALVE SUCTION NOT SHOWN 1 DA400111 19 BALL VALVE DRAIN NOT SHOWN 1 H59453000002 20 STABILISER CYLINDER 4 WPA2113041 21 STABILISER LEG OUTER REAR LEGS 2 WPA2004035 21A S...

Page 37: ...H4960700 Date 20 11 08 Issue 002 37 SUBFRAME STABILISER ASSEMBLY...

Page 38: ...PA2118018 1 6 BOTTOM WEIGHING CRADLE 1 WPA2118018 2 7 BELLCRANK 1 WPA2022004 8 BASE LINK 1 WPA2009012 9 BASE CYLINDER 1 WPA2113036 10 MIDDLE CYLINDER 1 WPA2113047 11 CAGE LEVEL CYLINDER MASTER 1 WPA21...

Page 39: ...041031E 6 BASE LINK AND MASTER LEVEL CYL BASE PIN WPA2041031F 7 MIDDLE CYLINDER BASE PIN WPA2041031G 8 SLAVE CYLINDER BASE PIN WPA2041031H 9 CRADLE REAR PIVOT PIN WPA2041031J 10 SLAVE CYLINDER ROD PIN...

Page 40: ...USING 1 6 CAGE SAFETY LABEL 1 WPA2050167 7 KNEE BAR 1 WPA2055006 8 KNEE BAR REST BOX 1 WPA2048102 9 KNEE BAR PIVOT 1 WPA2048093 10 KNEE BAR BRACKET 1 WPA2048092 11 PIVOT BUSH 1 WPA2038022 12 BRACE AND...

Page 41: ...OLT M10x70 HX HD 4 M470107000 2 11 M10 NYLOC HEX NUT 8 M720107000 2 12 TOP BEAM 1 WPA2065053B 13 FIXING SCREW M10x30 HX HD 8 M470107030 2 14 M10 SPRING WASHER 4 M61010000 5 15 BOTTOM BEAM 1 WPA2065054...

Page 42: ...H4960700 Date 20 11 08 Issue 002 42 CRADLE WEIGHING SYSTEM ASSEMBLY...

Page 43: ...ASSEMBLY ITEM DESCRIPTION QTY PART NO 1 RED L E D 12v 2 WPA2577150 2 YELLOW L E D 12v 1 WPA2577151 3 ROTARY SWITCH 1 WPA2577081 4 L E D CONTACT BLOCK 1 WPA2577088 5 WARNING BUZZER UNDER PANEL 1 WPA24...

Page 44: ...A5746091 4 10 MOTION CONTROL VALVE WPA2114020 1 11 VALVE LEVELLING SLAVE WPA2114033S 1 12 SLEW MOTOR RING INCL CL RELIEF WPA2026003 1 13 DUAL O CENTRE VALVE WPA5746020 2 14 REGEN VALVE WPA2109007 1 15...

Page 45: ...H4960700 Date 20 11 08 Issue 002 45 VM135 HYDRAULIC CIRCUIT...

Page 46: ...H4960700 Date 20 11 08 Issue 002 46...

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