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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 350

E

 of 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 

Summary of Contents for 538

Page 1: ...Universal Crane and Personnel 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 Courtesy of Crane Market ...

Page 2: ...rstand 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 b...

Page 3: ... 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 r...

Page 4: ...E 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...

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Page 6: ...lowing 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 resti...

Page 7: ...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 b...

Page 8: ...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...

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Page 10: ...mum 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 5E slope 1 1 3 x rated load 400 lbs 182 kg BUCKET TRAVEL B...

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Page 12: ...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 traile...

Page 13: ...les 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 Contin...

Page 14: ...ey 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 ...

Page 15: ...4500360 1 1106 Page 1 2B Operation Power jack instructions Courtesy of Crane Market ...

Page 16: ...Courtesy of Crane Market ...

Page 17: ...THIS PAGE LEFT INTENTIONALLY BLANK Courtesy of Crane Market ...

Page 18: ...e 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 furth...

Page 19: ... 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 t...

Page 20: ...ol switch is released the actuator returns to the neutral position and movement stops M Movement 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 operatio...

Page 21: ... any boom function The LOWER function also does not require pump activation so it may be used in conjunction with the RETRACT and ROTATION controls as would be used in returning the boom to the stowed position from a working position To operate the machine from the Lower Control Station M Make sure the EMERGENCY STOP button is pulled out M Hold the PLATFORM LOWER CONTROL switch in the LOWER CONTRO...

Page 22: ... and turn the key switch ON The green light on the Lower Control Station will be lit Raise the boom out of the boom rest and rotate away from the tongue using the lower controls Check to make sure that the bucket is properly installed Check the bucket yoke lock pins to insure it is positioned in the hole and the bucket yoke is securely locked to the boom IMPORTANT A body harness with a 4 ft lanyar...

Page 23: ...boom and move it clear of the work area Loads of 500 pounds maximum can be lifted by the inner lanyard ring with the telescoping boom fully retracted Do not extend the boom when lifting over 300 lbs Loads of 300 pounds maximum can be lifted to approximately 31 feet high with a side reach of approximately 22 feet by using the outer lanyard ring See Figure i 2 Proper sequence of operation to lift ob...

Page 24: ...ed or the Emergency Stop switch on the Platform Control Station controls is activated depress the override switch to LOWER CONTROL This will give the lower control station priority over the system Emergency Stop Switches Emergency Stop switches are located at both the Platform Control Station and the Lower Control Station See Figures 1 4 1 5 To shut off power to the system either Emergency Stop sw...

Page 25: ...red function The red EMERGENCY STOP pushbutton must be twisted clockwise to reset and resume normal operation HYDRAULIC LINE FAILURE If partial failure is experienced and holding valves do not lock use the controls in short intervals to store the booms Should a complete line failure occur the holding valve will lock The failed line must be repaired to release the holding valve POWER FAILURE Standb...

Page 26: ...ructions 1 Connect positive cable to positive post of discharged batteries 2 Connect other end of booster cable to positive post of booster battery 3 Connect second cable to negative post on booster battery 4 Make final connection on unit frame away from battery to prevent sparking 5 Remove cables in reverse order of installation Powered by TCPDF www tcpdf org Courtesy of Crane Market ...

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