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option hyd-1330-5 - Versalift East, LLC

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2. S IOHLNOO VERSALIFT S IOHLNOO 5 455 UNV SLYVd ON ond JOLvAd1T3 IN A34 0114152534 3 4H 91 SSY 791 LAOS 813 25 313 LW A34 5151 SV ATA TAIN OHH 5 SOHH 0914 4484 91 331 331 0873 06 3TVN 37 NNOS 815 WHOL Td LIL 3403 MLSS 25344 7001 JH T m 33 d VERSALIFT lt
3. 5 51 585 HO in A WALI 1311 03007 ava uas 1659466539 VERSALIFT VO 265E 270E 39IAd3S EY emo ate pm sev 11713709 DECAL KIT UPPER CNTRLS 5 5 BTWN BM AND 260REV 02 DECAL KIT UPPER CNTRLS S STK BM s AND VO x DECAL KIT UPPER CNTRLS S STK BTWN BM i AND EKT 270 4 DECAL KIT UPPER AND DECAL KIT UPPER CNTRLS STK BTWN BM AND WITH PLATFORM TILT 5 DECAL KIT UPPER CNTRLS S STK BTWN gt 29 8 7 7 6 5 4 7 3 2 AND 26 1 amp Mires oe S STK CNTRL LH HR DECAL KIT UPPER CNTRL l m 1 _ E N AL S STK CNTRL BM AND REF REF REF REF REF REF REF REF MERGENCY POWER Gi RECA DBBER EF REF REF EF REF REF FEI EMERGE E 2 BM AND 8 REF REF REF REF REF REF REF REF L ENGINE
4. 0 ISI ON W3ll ALO ALO ALD AID ALO 9 V l l 8 l ES 1 18 z 60000 3 ft 1 43473 8 I 7 i egios 8 8 8 SF 0873 331 5317349 68106 0045 ZcgvG 3 E _ Q 3300033 amp 1 9 M Z 2 T 0873 06 NS Or e v0006 s Wed Wed Gof s FG 34 S IOHLNOO VERSALIFT S IOHLNOO 5 455 UNV SLYVd 01 168 00 N d anasey WIHALVW 40 1517 EL lOMLNOO 58 27 41 LL ST H Vert ae UNE E rT a gummi SE od mE DEL 41
5. TEER ELE LES EE LIST OF MATERIAL 2 2 VERSALIFT VO 265E 270E 104 15 INSTALLATION VO 265E 270E REVERSE MOUNT MINIMUM VEHICLE SPECIFICATIONS Frame Section 18 295 cm Frame Resisting Bending 900 000 in Ibs 101 700 N m Cab to Rear Axle 138 3 5 With One Set of Outriggers behind GVWR acna sh I TI 32 000 Ibs 14500 kg Erde 13 000 Ibs 5900 kg GAWR REAR ua 19 000 Ibs 8620 kg Approximate Curb Weight for Stability esses 20 000 Ibs 9100 kg VO 265E 270E REAR MOUNT MINIMUM VEHICLE SPECIFICATIONS Frame Section uu a 15 245 cm Frame Resisting Bending 4 0 6 1 em 750 000 in Ibs 85 000 Cabito Hear Axle DImeriSISna u uuu un Aen 102 in 2 59 m With Two Sets of A Frame Outriggers and Full Length Subframe GVWR E 29 000 Ibs 13200 kg GAWR FRONT 10 000 Ibs 4540 kg
6. 3 08 335 01020 ond ims AT Nou ON 2 T u Ceu 3 Pu 5 r Taleo 970 LEL ul EE z z _ 33 7 a 1 Ol 1 6 1 L 1 E tall 1714 B 1 rz 3ATW 390141373 i cl gt Lava 1973 14311 12211 0122 aL SLHvd JOIAM3S GAH SAL 1 f SE 1 14 0002 01 081 SE 5 ANAL T nodu NDILY307 5141 19 dWels 01 T aH Lg _ KI e NN ANN Z App 2 A f 4 x N T ma 2 50 lt E T md 60 031294134 0619 SLIVA ICOM IAD MOOG 5 70 d 334 115 6 VERSALIFT KNUCKLE SECTION 116 KNUCKLE LINKAGE ASSEMBLY REVERSE OPTION KN 1330 1 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 116 1 3uu aid 18 40 19152539 ALO SOH 034471 HLI 11 43330 039971 LAOHLL 4344 3 vid 1
7. 102M TOP OF TRUCI FRAME Y 120 gt 505 11 0 28M O270EREAR SHOWN 194 4 93M FOR REFERENCE ONLY Di BY DATE TE MANUFACTURING xl IRE 97 ANY LBR 4 16 09 VC E 270EREAR NOTES eer SIZE SCALE XAS ONGITUDINA 1 ALL DIMSENSIONS ARE IN INCHES WITH METRIC PROJECTION OF VIE A 1 46 LONGITUDINAL EQUIVALENTS IN METERS TEs EN MATERIAL EST WT wa INSTALL OUTLINE 56 Et FINISH SHEET DWG Ne PERI x TE MANDELE TORIS OF 1 34244 DWG VERSALIFT VO 265E 270E 104 19 INSTALLATION SECTION 105 HYDRAULIC SCHEMATICS VERSALIFT VO 265E 270E 105 1 HYD SCHEMATICS HYD SCHEMATICS VERSALIFT VO 265E 270E PAGE INTENTIONALLY LEFT BLANK 105 2 SOILVIN3HOS GAH 3097388 13 32 3t 7 n 19 1409 alow smage SEN YOMH 3uu Vy 141 1 4 33 39 E 4
8. T 34 e VERSALIFT Lu Ox c fee on EE z jg ide E 8 x 5 mum 5 lt 4 55 1 lt T zd m r J lz EA lt tit En Ll BUE o l O oc Z O LLI e 2 VERSALIFT 123 8 S IOHLNOO 5 455 UNV SLYVd SMO Lr Vv dO ON SMT 133 5 18 1355 mio 88 311 1 avaj Nma NOV Aion 35 EM WidslvW dO 151 ASSV 3 MOOT OMI 17 bv V GON 58072 8 doy 310 JA331S 201 ONIddS NOISS3HdMOO TENASSV 8NS 331 al 414 3 AAAS GCL X BW INI 1 2 EHI
9. J ELEVATOR WELDS ALE 1 5 2 a TOLER cue 6 BY bate a A COMPANY LBR 9 28 08 VO265E 270E reo 111 aco TEXAS a 50 CRITICAL O AU DIMENS MATERIEL EST WT MANUAL ELDS cc FINISH SHEET DWG 2 OF 2 34033 D LLI gt tc LLI o VERSALIFT VO 265E 270E 103 13 Tears gee O0 D none 3714 AVIHALYN 30 1 DLAI lN3M3Ovld 17930 9 278 31919 VIVO 31714 717 1 wo 431134 373 031 419313 H35Nvd 92340 31 01 q3ddiHS 38 OL OlL v d3dO Ivo3d 435170 17230 43401 71423 18031770 717230 1495434 717234 70230 14230 41423 19230 1923 08129313 7923 QdvZvH 719230 4 8 19230 44144 330 335 gt e 1003819313 H35Nvd 719230 335 INO W930 lN3NHOvIIV 8 70230
10. IN3AQIJA 3NV3d4 V 5 1 5 3 5 3 1 OlLdO 33992 SALON N 30 es 41338 j OHV 335 1M 153 17143171 mx gt N x 3ivd Bo 350143 O ish NOILdIdOS 3d ON ALO 1004 LOAld ATENSSSY LEO 9 LNANTIAM 3WVHHJ V LO ld A SSv 931 J3MNI V l 1104 34 15 3349918100 G 0813 06 90 OL y YANO SOHH 91 t 4 5 3 20 8 5 y 333 3345913100 AO HI gt a LINSSY LH ANVUA lI S SI 6 00 1 80 SAA 304 534 169 NIV 01103 AHL JSN 303 01 91 6 585 Hrd 1 1 1574144 15415 3170 003 48 530 Jd daisn 1 LV INSOJNI ne e N VERSALIFT 1 w 1714317 3111 3170 Me 3191 3SWM33HL 1915429539 ALO ALD 18 J3UNFIAO INIT LAY J33ONITAO 54310 1004 3 z OddvN LN3AG13 Vdd dd LNdNAd 1
11. Ec VERSALIFT MA 43385 HZ 13385 3 1 453 g 21725 321 STALNO 397 LES 37114 avaj 48 8 8 NOILO3S IP udi 33 LIM 1V23d 1OHLNOO VERSALIFT EMERGENCY POWER SECTION 111 EMERGENCY POWER INSULATED 12VDC OPTION EP 1340 1 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 111 1 PAGE INTENTIONALLY LEFT BLANK Lu O gt Lu Lu VERSALIFT 111 2 d3MOd AON39H3Il3 5 455 UNV SLYVd 13507 LOTAN
12. 38 A18N3SSV SH3QNl1AO e s VERSALIFT Lot No 1134 100029377 CYLINDERS Lam e INSTALL FLUSH TO OUTER EDGE OF ROD END 07 1 6 SAE O RING SWIVEL JOINT FITTING BEARING A 22105 1 LOWER CYLINDER ASSEMBLY QTY ITEM PART NO DESCRIPTIOI LIST OF MATERIAL DWN BY DATE TITLE MANUFACTURING Tr COMPANY 5 29 LOWER CYLINDER uu WACO TEXAS 478 ASSY W BRG S MATERIAL LOCATION MANUAL 7 2 5 5 2 SEE MATERIAL LIST FINISH SHEET DWG NO CYLINDERS l m 0 lt a 2 lt lt XPRESSED OF TIME MANUFACTURING VERSALIFT 115 3 Lot No 1134 100029377 1 13316 A eyoaode Jogy 335 6 Z SNW3LI SNIVLH 19153191 SyX3dl WOO 83801 HL 1413111297 JA NS FA IUIL lt 41 14 00572 01 0661 FD sa1 14 02 01 SI ane 27 gt lt ane 19201 lt 19 dWYLS anos le ET SPESE a
13. L WELDED JOINTS TO BE INSI TED ARE INDIC 5 THE JOINTS MAY INCLUDE WELDS ON SIDES OR INSIDE AND OU DE AS APPLI LE 2 THERE ARE ADDITIONAL CRITI MOUNTING HARDWARE AND DWN BY DATE 3 ALL WELDED ELDS gt OF 4 SHOULD BE MATERIAL FINISH VERSALIFT VO 265E 270E oa D CALE 15 DWN BY DATE TITLE LER 265E 270E T Hs CRITICAL MATERIEL EST WT MANUAL ELDS FINISH SHEET DWG NO 20F2 VERSALIFT VO 265E 270E 104 13 INSTALLATION LN3N3OV ld 21 25 0 7 8 3714 ais TALON 55310 TWMaALy 40 1 als 41 133714 1753 lN3W3ovid 17934 g Ova 31770 VIVO avid 7170 12373 23940 92340 Ollvd3dO 1723 q39Nvd 717230 2 amol 719230 41 4 230 13075 03177 SNKTIOH 79230 35333 5305 vid 14 9543
14. m 0 4 lt PARTS LIST NUMBERS REFERENCE LETTER EACH DASH NUMBER INDICATES A DIFFERENT ASSEMBLY MODEL ITEM E IS USED ON DASH 1 ONLY V ITEM C IS USED ON DASH ONLY a ITEMS A DY F AND G TEE WEINE 205 10 095259 57216 APE USED ON BOTH DASH AND 2 TIlE TUBE E n FITTING STR 1 4 MOR 1 4 DUANTITIES PEDUIFED ARE LISTED z E VED OR AEE KIA IN THE COLUMNS UNDER SPECIFIC 1 4 HYD HOSE X 1 4 X 1 4 DASH NUMBER 1 1 T HOSE POLE GUIDE HOSES 7 11 ITEM PART ND DESCRIPTION Tee TUNE SED TEXAS POLE Pepe GUIDE HOSES epee cones EN 51 REVISION LEVEL RETRACTED 09 39 50 SERVICE PARTS LIST SERVICE PARTS ITEM TIME PART DESCRIPTION PART HD OTY xe OU MAY RECIEVE PAGE 2 IN THE MANUAL 1 AND NOT PAGE 1 HAS ENGINEERING i INFORMATION THAT 15 NOT NEEDED FOR SERVICE E U CUP DUAL LIP 34
15. DASH NC DESCRIP TION BLUE BOOT FOR AIR CYLINDERS OPTION RUBBER BOOT AIR CYLINDER B 54174 1 J0 D AIR CYLINDER QTY ITEM PART NO DESCRIP TION LIST OF M ATERIAL o LLI gt lt oc LL o m LLI D m IN INCHES MANU COMPANY FACTURING ACO TEXAS CONFIDENTIAL E PROPERTY EXPRESSED IUFACTURING TITLE BOOT AIR CYLINDER DWG NC VERSALIFT 107 2 lt lt SECTION 108 DECAL PLACEMENT OPTION DE 1330 24 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 108 1 LN3A3Ov ld Tv 37114 118317 30 1N3N39v1d 197234 ONDOVE 31778 VIVO l 31770 7170 l 4 Wd 230 17234
16. 2 VERSALIFT 8 TOOL VALVE PARIS AND ADJUSTMENT P N 54250 1 2 PRESSURE REDUCING CARTRIDGE ADJUSTMENT 1 PRESET 2000 PSI BUT CAN BE ADJUSTED FROM 100 TO 3000 PSI zm 2 LDDSEN JAM NUT 4 3 TURN SET SCREW DESIRED PRESSURE SETTING CLOCKWISE TO INCREASE SETTING 4 TIGHTEN JAM NUT Z 12 q ip 7 FLUV CONTROL CARTRIDGE ADJUSTMENT 1 PRESET AT 5 GPM BUT BE ADJUSTED 25 DF SETTING 2 75 GPM TD 6 65 GPM e LOOSEN JAM NUT 3 TURN SET SCREW DESIRED FLOW RATE SETTING CLOCKWISE TO INCREASE SETTING 4 TIGHTEN JAM NUT o NOTE TOOL VALVE IS USED ON THE UPPER CONTROLS AND ITH OPTIONAL TOOLS THE GROUND CONTROLS tc 5 5 o PART DESCRIPTION P 2 E E OF TME Me NOE TURIY A he A ES TO BE DISCLOS ED COPIED __ BODY REPRODUCED THC mi p PREG SED 2 REDUCING VALVE CARTRIDGE PERMISSION OF TIME MANUFACTURING 3 FLOW CONTROL VALVE CARTRIDGE Y1534 2 UNLESS OTHERWISE NOTED EN Viel e S TOLERANCES DECIMALS MG 1 9
17. 3uu 3174 014142539 ALO SSv 118 3 MT z CONT E S amI 75730 gt OHS LON SNOILYA 1 SOHH SS 51 2 1 1 1121 1 7738 ane 1 339 1 SAALI Su3N315v4 Nid 300301 Z Ger 311 3731 HIM 4 WELD Nid SOHH 911 3 5 3 308 8 9 0 c c 303 HL 7 1 4 8 8 2 454 GHL 5 9 9 1 n 433 339 4 v 3 v 8 3 8 8 qe _ 7 727 lt he 7 3 ao a TN K OM e a e ahi fe y x yao 2 uo E Lap a 3 8 gt gt penal Se eg TN 7 i e lt LI INOOd 117 2 VERSALIFT SECTION 118 VALVE KIT LOWER CONTROLS OPTION HYD 1330 6 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers VERSALIFT 118 1 l O 2 o l PARTS AND ASSEMBLIES PAGE INTENTIONALLY LEFT BLANK l O 2 o VERSALIFT 118 2 S IOHLNOO d3A O1 5 455 UN
18. 19 000 Ibs 8620 kg Approximate Curb Weight for Stability sse 20 000 Ibs 9100 kg Notes 1 Actual GVWR and GAWR S should be based on the weight and weight distribution of the chassis body lift ballast if required and accessories plus the desired payload 2 Curb weight for stability will vary based on rated platform capacity mounting configuration frame amp stiffness and stability test requirements VERSALIFT VO 265E 270E 104 16 FEV NO DESCRIPTION EY APPR DATE FIRST RELEASE LBR DJH TOP OF TRUCK Se FRAME o 1 Y Y i 3 814 Y m DWN BY DATE TITLE NOTES PS FACTURING ERES 1 ALL DIMSENSIONS ARE IN INCHES WITH METRIC MPANY SERE EQUIV
19. 070 8 33201 113 313 35 8 A313 MIEWASSVY 440 25173 313 33 s hi JOLVA3I3 34 330119 10 8 A 1IBW3SSV 43 0 AMT 8731 d3dd 43dd S OHLNOO 330 AMO Na d3ddn 35d HOLvAdTl3 01 1 313 SMT 414 3SOH 128 4 VERSALIFT MOUNTING HARDWARE SECTION 129 ELEVATOR MOUNTING HARDWARE OPTION MH 1330 10 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 129 1 T 13316 4 HONMIASY TN OLN EE S di2 WALI ALO HOMfrdss 34 14 HH 21 2 1 2 S 8 239 3 8 43 57 2 2 jdlLN3 JHL Jd3 O0 t dv3HS ONY d3MOHHVN ALVOIMEV4 ANY 3 1734 v 39034
20. 104 2 iden iio 104 2 mica ce t 104 3 Welding nenne 104 3 Vehicle and Mounting Specifications 104 3 Bolt Marking and Torque Chart 1 nnne nnne nen 104 4 Installation and 12 0 19 8 VR T 104 5 Mounting 1168146110118 m 104 5 Pre Delivery Testing and Inspection sessiun 104 7 E 104 16 Section 105 Hydraulic Schematics Hydraulic Schematic JIC u uuu uuu aaa E 105 3 Section 106 Parts and Assemblies Parts Ordering and Product Support 106 3 As Built Options and Parts Index VERSALIFT VO 265E 270E o LL l lt SLNALNOO dO 3 18V L SECTION 100 INTRODUCTION VERSALIFT VO 265E 270E 100 1 INTRODUCTION INTRODUCTION INTRODUCTION NOTE As the aerial device users you must read understand and follow the instructions in this manual and other manuals supplied with this aerial lift unit This manual is furnished with your Versalift aerial lift to provide practical and essential information required maintaining
21. 2 a gt 2 a oc a gt oc VERSALIFT VO 265E 270E ATTHE TURRET 6 Applytension to the lower boom leveling system Refer to the Leveling System Assembly drawing in Parts amp Assemblies Section to set the correct tension AT THE PLATFORM AND THE KNUCKLE 7 Pull the chain over the sprocket so that the connector link aligns with the mark on the sprocket Orientthe chain on the sprocket at the knuckle until the platform shaft is oriented nearly vertical Install the connector link and tension the upper boom leveling system Refer to the Leveling System Assembly drawing in Parts amp Assemblies Section 8 Pullthe hoses through the upper boom The hose bundle should be to the lower boom side of the upper boom and come out of the access hole and through the platform shaft 9 Raise the upper boom to clear the pin hole secure the upper boom cylinder then extend or retract to line up the upper link holes and install the pin A CAUTION EXERCISE CAUTION WHEN INSTALLING OR REMOVING THE UPPER BOOM CYLINDER AND LINK WELDMENTS THE UPPER BOOM LINK WELDMENTS AND UPPER BOOM CYLINDER MUST BE SUPPORTED BEFORE REMOVAL AND INSTALLATION OF LINK PINS KEEP HANDS AND FINGERS OUT OF PINCH POINTS 10 Secure the platform to the platform shaft 11 Connect the hoses to the appropriate fittings on the control p
22. Mz vc Wl E 34 1 VERSALIFT ELEVATOR SECTION 127 LONGITUDINAL ELEVATOR ASSEMBLY OPTION E 1330 3 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 127 1 PAGE INTENTIONALLY LEFT BLANK ELEVATOR VERSALIFT 127 2 1 56 455 548 4 vid 33843 2 qo SZ 0 5505 3 3801 37 71234 ANN 4133 ANN 1 5 373 1 53 1 E 2 i T 4 331 Sa s a 1 E 69 Ly VV a gt JS 4 1 E 1 c 96 43H t l 3344 ONILLAS 55384 HOA OILVvI3HOS AHL OL 83438 WJTIvIS 1211443012 43113
23. Addn ASIVY HV N 1938 NOO8 H3ddf zt VERSALIFT PLATFORM SUPPORT PLATFORM SUPPORT stk BTWN BOOM amp BUCKET W TILT REV MT OPTION PS 1330 12 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 122 1 PAGE INTENTIONALLY LEFT BLANK oc a 5 lt l a VERSALIFT 122 2 53118 355 UNV SLYVd LYOddNS 1 SM tvIZSe 40 1 133
24. as 1 daddIHS 38 Ol 513473 5317 A IBN3SSY 5 8 HALdy WALI 51708 35 Jf 1311 MOL HLM MYYN v 8 OWL 330 S WALI 51708 9 10301 HIM olv 438 3 11311 21 Hv WALD d HLI 311 337 H 4v38 2 39117 37 WALD 357349 dT3IHS 8739 Hv35 33111 1 OLYAN JHL HLM XxO8Hv39 JHL N33W138 3ONvHviIO JO lh 55393 v 3140 5 gt NIVOY HS 453H234 IHLAY3A3 N3LHOIL ANY 59315 1v3d34 51708 0839739 AHL 35001 5300 11 4l S 1 2 LON 4 3HL ATJ3dOHd 135 SI HSY 3H1 31 HS 3Hl 3 C CLL IHS JHL 33 A 131313 v38 NOILYLO Y JHL JO HLOOL HOIH 3HL N 1 18 15 31H91L34 JHL 1 OS 1311 JHL 31 108 SIOHLNOO H3MO JHL 8 735 3HL TIOH HOIHM 0 1334 0 WALL 5 3825 ANY 53108 JO 135 0387 3Hl ova 4 JHL 3197104 ONY 3HL 40 8 1 v ATALVW 4 3 ILIS 33510 5 NI ONY 21529 AM HOS 2 TIM NO LOY SIHL 138401 JO MIA 404 OllO3Id JHL NI SNIH OldLN3223 JHL 3171 3 WALD 3425 O A 131 7WDX O38447 27 JHL 3 78 5 1334 JHL 3iv1OH OL d WALD 1708 3003
25. 1 7 Torque Mark In Acceptable Condition 19 9 TORQUE SEAL N my f MARK MISALIGNED Y n gi rr E T E 252 8 1 Torque Seal Mark Misalignment Condition Figure 1 WELDING SPECIFICATIONS Some mounting configurations require welding at installation Welders must be AWS certified in accordance with ANSI A92 2 requirements general purpose welding rod or wire should be used Time Manufacturing Company uses AWS 705 6 welding wire or a AWS E7018 welding rod 60 000 PSI 4218 Kg cm yield and 25 elongation minimum Always position the components to provide proper access for welding Make certain the weld size is according to engineering specifications Repair welds must be repaired in accordance with ANSI A92 2 requirements Consult factory for material specifications and proper welding specifications VEHICLE AND MOUNTING SPECIFICATIONS All proposed aerial lift installations must be thoroughly 104 3 reviewed The chassis must meet or exceed the dimensional structural and aesthetic requirements Dimensional specifications are important Overall height length overhang and clearances around the turret or under the booms are specific concerns The position of the cross members of the chassis frame may affect mounting location Varying the location of the aerial lift slightly may simplify the mounting procedure Before moun
26. N 43 2 ES lt 1 1 THN M3ovdS v 8 s qasn 3H 01 X2 102 6 0 L HN IYL all 1115 1544 WOOS8 53M0 NOLLdO NOLLdIdOS 3d 0 Hsva 34 1938 NOOS8 H3M0O1 VERSALIFT ra z m cc a A D SECTION 121 UPPER BOOM REST OPTION MH 812 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 121 1 32 1 31119 me Oma 4338 ZA 1917 TWIN 335 NU OIL V T Iv mE arn i938 HL 22 3 5 C2 ME 310 351433H10 ANN JILL 3170 NVAALIVN dO 14152539 WALI IN3WOT13 1534 NOOB 14 81222 1534 SOHH Z X C 2 3 2 SSY dv4lS 3 5 H 2 4 3 0 OHS 42 NO Ya 30 5 133301 30 3903 NOO8 48 qavnot dO 972 JHL 33 42 11 3 91 HOMOYHL 5 SvH WdOsL 91d A TIVLISNI 4
27. u 30 Days after In Service Date one time service 5 555555 Three Months after In Service Date one time service Three Months or 250 Hours e a u ee Six Months or 500 Hours Service anita anise aad One Yearor 1500 SetvICO i denen ga e Two Years or 3000 Hours Service 0220000 000 MOP GUS iT Critical Fasteners and Welds I Decal PICONET E ferte dieu 108 17 ae e a EE 103 19 Cartridge Holding 6 aa aaa a aA 103 19 BoomActuation SPCCOS 103 19 Outrigger Boom keane rahe as 103 20 Rotation Motor Counterbalance Valves assassinate utawa 103 20 Hydraulic Oil Recommendations nnns 103 21 Gare of Fib iglass 103 23 Trouble Shooting E 103 23 Hydra lie Cylinder e aqa 103 25 Upper Boom Replacement Procedures sse 103 27 Section 104 Installation Introduction ur
28. 2002 011 25 avo 153034 9 318 3 3 n ALON 33S A S p A H HLM 3 331 7 _ TYL z 7 SNOlLdO 33d M a H3OMITA2 847 S3SOH HLI S3A331S NI KEY TOHLNOO Vd1X3 e VERSALIFT BOOM HOSE KIT SECTION 113 BOOM HOSE KIT OPTION HK 1330 17 When ordering replacement parts confirm the actual part number with the Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 113 1 PAGE INTENTIONALLY LEFT BLANK BOOM HOSE KIT VERSALIFT 113 2 350 11009 53118 355 UNV SLYVd TOA 2841423530 3 Qge3enng 8 vad NS N E 4 r r 1 z m fh 2 344416 3SOH MAAS 3SOH MANS 3SOH 3 3315 3SOH 31415 2508 N 3 3315 3SOH e eo VERSALIFT Lov 3553893 E ULL 1 S3HSINAS 3234
29. Od SHL 478 32 3NIIH3LN39 3HL N 213 SI HSV ove 135 I V HSVINOVE 8 35 34 NOILVLOH 5 VERSALIFT 5 455 UNV SLYVd N q 133HS mE 171 4317 40 1511 335 A4 IHWNdJSSV 701931711 32 divos 3215 NOLLV LOM 80 91 91 38 75 quu 3170 48 dO NOLLdIdOS 3d WALI ALO MIANASSV 3 OILVLOM 8 3 SOLON j lv JONY Iv333lNI SOHS 91 321791 NNOO MIS 8 0 OL 43 O8 1A 06 331 Nid N 340439 HOLON OL 3ZISS ILNY 1371 A ldav ONITIVISNI e eo VERSALIFT H 17 4317 1 JO LSM 335 71931 140 415 140 15 0873 0873 51041 4344 44 Wa MT L
30. 2 o l PARTS AND ASSEMBLIES A THIN3ISS V d 3Nvd 10 41 3401 997 15001 134 3145 SI 147 LYHL SALVO 4 55423 TANYd 10411 S lOHLNOO d3A O1 e VERSALIFT m o o lt o oc a l gt SECTION 115 CYLINDERS ASSEMBLY OPTION HYD 1330 5 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 115 1 9 31vg 1914317 14152530 A IgN3SSV M3ONIM 83 O SSH3QNIIAS
31. F 31 1 TALON cu aio 4 134 I Wa LOY 113 33430 MvA 313 11911355 LVL VANS 134 1 03 N 134 AIAN 33d svg ONY 008 N3 Jo d3dd 413441 i F 4 134 514 HALA SH qoa 3307 81 5 gi 3 0 313 a 358 A313 SSdHd d 33041 tye A 4 103 gi 1001 s e jd J3MO1 LY dadan 1v 133301 17 1 2 108 710 134401 1v LOAld 8 1 43 5 11714 SIS 1 lJvHS 1321 535 1 350 11009 113 4 VERSALIFT SECTION 114 LOWER CONTROL PANEL OPTION HYD 1330 11 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers VERSALIFT 114 1 l O
32. 7 EAR RING 1 s FETAINING RING 1 COTTER 1 11 Eu i MANUFACTURING m EOD i COMPANY PISTI 1 ACO 15 HEAD 2 MATERIAL 6 eT T p NSS QUT SOLD SEPARATELY p COMPONENT IDENTIFICATION EXAMPLE 2 VERSALIFT VO 265E 270E 106 4 Section 107 Blue Boot for Air Cylinders SD 1200 22 Air Cylinder Boots ie u E eene m eam des 107 2 Section 108 Decal Placement VO270E DE 1330 24 Decal Placement o cae deed vee e 108 2 Section 109 Outrigger Control Decals DE 1400 4 Outrigger Control Decals e P 109 2 Section 110 Decal Kit Upper Controls S Stk Btwn Boom amp Bucket DE 1330 18 Decal Kit Upper Controls Btwn Boom amp Bucket sss 110 2 Section 111 Emergency Power Insulated 12VDC EP 1340 1 Emergency Power Installation sse enne 111 3 Section 112 Prep Kit Air Operated Platform Controls CC 1330 5 Prep Kit For Platform Controls 112 2 Section 113 Hose Kit HK 1330 17 Boom au a m c 113 3 Section 114 Lower Control Panel HYD 1330 11 Lower Control Panel Assembly istriani aigearan Qa a a i ha pp 114 2 Section 115 Cylinders Assembly HYD 1330 5 Cylinders Assembly y u ce dat es 115
33. The stabilizer system is securely mounted and works properly The platform mounting bolts are tight Hydraulic system has no leaks Platform levels properly Platform override control selector switch operates properly Emergency power optional operates properly Continuous rotation optional operates properly Hydraulic hoses are not stretched too tight or kinked as the booms are actuated All controls operate smoothly and perform the functions indicated on the decal Tool power circuit operates properly Hydraulic oil reservoir is full All boom movements are smooth and quiet All optional equipment operates properly Warranty Registration properly completed and mailed Qualification electrical test has been performed 2 All decals are positioned on the lift and truck and are legible lt By l Tire pressure is correct There no visible defects or loose objects on Date the Versalift or the truck There are no hoses near the exhaust system or the drive line Belt pump operates properly Belt Drive option Stability test performed Throttle control optional is operational and properly adjusted PTO operates properly PTO drive option All boom actuation speeds are within the specified time ranges Engine start stop is operational and properly adjusted 104 11
34. lt VERSALIFT 133 1 9 06906 ON 43385 441138 HIIN T LIM MINO H395 J Ag NMG 40 151 NOLLdldos30 WALI A10 SATIVA JOMINOO M O OMG V HOLIMS UUM NJOSIMLRO H S 310NVH M lOMLNOO g Gea 513557 5 OMINO2 53221541 37911 35001 d3ddHS 38 SWALI 5 FE 5 N JS 38 NYO 583991 a e 59 dv 5 2 e alll LMS 428 HLM 0 dl45S3d ON SLD VERSALIFT AS BUILT OPTIONS amp PARTS INDEX AS BUILT OPTIONS AND PARTS INDEX This As Built Options and Parts Index includes a list of the components used in the production of this unit VERSALIFT PAGE INTENTIONALLY LEFT BLANK AS BUILT OPTIONS amp PARTS INDEX VERSALIFT Option Assemblies VO270EREV SD 1200 22 CA 853 DE 1330 24 DE 1400 4 DE 1330 18 EP 1340 1 CC 1330 5 HK 1330 17 HYD 1330 11 HYD 1330 5 KN 1330 1 LB 1330 1 HYD 1330 6 LO 1330 2 MH 1330 9 MH 812 RE DELETE PS 1330 12 SC 1330 37 S
35. DECAL KIT UPPER CNTRLS 5 5 FEF REF REF REF REF REF FEF REF THROTTLE me BM AND BKT gi eR pee um DANGER PLATFROM TILT 1 1 1 1 1 1 1 1 H TOOL SELECT 1 1 1 E 1 1 1 G CONDUCTIVE HOSE 1 1 1 I 1 1 F TOOL PRESSURE 1 1 1 1 1 1 1 E EMERGENCY STOP P d ms ELEVATOR 1 1 5 5TK CNTRL LH H 1 E 1 E 5 5 CHTRL FH l 1 1 l 1 l 1 1 1 KIT UPPER CNTRLS QTY QTY QTY QTY QTY QTY QTY QTY QTY ITEM PART NO DESCRIPTION LIST OF MATERIAL cc LER DECAL KIT UP CHURU BM 210 SEE LIST OF MATERIAL 1 OF m 5 gt 6 THE DECAL KIT UP CNTRL BM AND BET EE LIST OF MATERIAL 888 EREET 2 0F2 VERSALIFT VO 265E 270E 103 15 PAGE INTENTIONALLY LEFT BLANK 5 a m a gt VERSALIFT VO 265E 270E 103 16 MAINTENANCE AND INPECTION CHECKLIST AND RECORD VERSALIFT VO 265E 270E SERIAL N
36. 6 11 J Q T T eem N l 1 N A Y i 1 1 ONSE Y 1 3 1 1 2 a 6 a RV 4 NON N N EN IN ST 4 2 01 S s 2 581 14 0S OL ce 60 F 0212784128 SLIVA ADAGIS SN LAS MOOG eO WN 43 1 AAT 3501413479 MOlLdld2S3Q 1474 WALI SLYVA 321 43 JAH SNL 115 4 VERSALIFT Lot No 1134 100039258 REV Bl CYLINDERS TO 3 8 JIC JPPER CYL ASS Y 0 250 255 CYLINDERS QTY QTY TEI DWN BY MANUFACTURING CKR 06 20 9 vM A R HHH gt l m 0 lt a 2 lt lt VERSALIFT ON AND L TURIN LOSED COPIE RODUCED C SION OF TIME ENTIAL ESSED NUFACTURING MATERIAL SEE MATERIAL LIST LOCATION MANUAL FINISH SHEET F DWG 22211 SEE ABOVE 115 5 Lot No 1134 100039258 40
37. 8O1v33dO Cals 717234 75 31 70230 LANYSYAA 1v23 4 1235 TALYINSNI 71923 1 19234 H3M01 A 234 q vid LJIIvVSH3A lv 5 81 dIHSJ3NMO 717234 1 51 3 1 20412313 777234 QHvZvH HO W 14 6 43 1723 IN3WHOVLLY WOU ANANSI 331134 717234 819313 d39NvO 1903 t 1NI d HON 70230 08109313 835 70 717234 43d N23 313117 vg L W C YVAN 13192071 38 387 SANA 34138 HV3N AAL ANY 8 33 31 435001 d3ddlHS 38 Ol 51873 gt 13 2 8 34 IN3W3OV ld 1V23G 3 VERSALIFTI SECTION 109 OUTRIGGER CONTROL DECALS OPTION DE 1400 4 OUTRIGGER CONTROL DECALS When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate
38. CRITICAL FASTENERS WELDS eran no 57343 FIRST RELEASE LEF bo ses s py 980 eee pate 1 48014 24 DIA SNAP RING 1 48048 325 3 1 DIA SNAP RING 1 BHCS LTN 5 8 PTLN AT ELEVATOR 2 X 1 HHCS 3 4 HHCS ELEVATOR 2 5 DIA RING NOTE 1 ALL FASTENERS ARE STRUCTURAL OR RETAIN ANOTHER STRUCTURAL MEMBER ARE CRITICAL NEAR SIDE E 2 BOLTS ARE E 5 NUTS ARE x 1 3 AND WASHERS ARE HARDENED STEEL UNLESS OTHERWISE 4491 y MINIMUM OF TWO THREADS THROUGH ANY LOCKNUT ALLOUTS READ AS FOLI ER DWN BY DATE TITLE AL FASTENERS TO BE MARKED WITH TORQUE FRACTIONS MANUFACTURING LER BRE ON OF TURNING ANGLES COMPANY 3K VO265E SIZE SCALE 4 4 TEXAS 2ITICA HEX HEAD E A 1 CRITICAL OCKET HE MATERIAL EST WT MANUAL ASTENERS FASTENERS HARDENED PTLN PREVAILIN OCKNUT FINISH HEET D NO LEF 1 E FE ERCN DESCRIPTION BY CHKD APPR DATE 57 FIRST RELEASE LEF DJH R 9 25 08 INSTALLATION
39. JHL 3173 J 303 Add IHS lgvg 521 OWL Ydd 3 sv 34 Vdd 1108 3 D UD 1 33 DEN 1 4 7 o 4 gt i P d f o N o edid SS Ot 3 3 gt 3HVMQHVH ONILNNOW o Q VERSALIFT SECTION 130 OUTRIGGER ASSEMBLY OPTION OR 1400 49 OUTRIGGER ASSEMBLY When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers l m 0 lt a 2 lt lt VERSALIFT 130 1 PAGE INTENTIONALLY LEFT BLANK gt 2 m 0 0 lt 2 2 x 2 VERSALIFT 130 2 A18IW3SSV 84399 5 455 ANV SLYVd
40. d3MOd AON3Sd3NW3 VERSALIFT EXTRA CONTROL CIRCUIT SECTION 112 PREP KIT AIR OPERATED PLATFORM CONTROLS OPTION CC 1330 5 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 112 1 Sl LOVE SILO SSHOLIMS 1041 H3MO1 ONY SONY 4019771709 53 211 lyg 504 v 5 3 3 HM OL 0 034 SV 4 WALI Lio 3772 3215 41 S 30 9 181 3 quu TALON 3SW33H1O _ JO 1SH dO QN3 OL d Tv OL 11735 3NOC 4 4340 114 0380 2 18 NI 14 5 9 2 0 STOMINO 93170 M3dO 8 LIM 1242788 HOLMS 38 3S9ZOA SJTONINO 1141 4 H3dO 111 3 4 SJOHLNO WYALTA Ol vH 114 d3dd 2 ZO 144114 H3dO HIY d3ud 20 620 144114 H3dO
41. 315 v NOLL v ILC 1 034 SILVINSHOS OFIMVHGAH OL 3334 1 1343 85 lHvd SALVO N T VERSALIFT 8 ass ane 557 A313 8 6 8 AB 31v9S 9 W 1 2 NS N A 5 7 N 127 4 NU VERSALIFT Lot No 1134 100029377 5 455 UNV SLYVd 2 40 Z OMG 13388 4 peu E 4121747335 0357 28 3 38 ISNAN ANY 114 7735 1 du vavdds Q35vHOdfk SAW NV LIM 1935 4 5 TEE m Ova N3HW 38 i15 W 109 LIN 1936 NI LON 38v SW3ll 353HL 4131787325 0105 LON SSN LIM 1936 NI SHILI 353H1 5 2 G zia 2 5813 6 2 2 G YZLZA Gu EE EZLZA 5 22724 1191435 c
42. E E N n zou lt 5 ZW JL B Eu ED o lt I O o a gt UF FE VERSALIFT VO 265E 270E 105 4 00 l lt o lt SECTION 106 PARTS AND ASSEMBLIES Parts Location and Ordering Confirm part numbers in As Built Section located in the back of this manual PARTS AND ASSEMBLIES VERSALIFT VO 265E 270E 106 1 PARTS LOCATION DETAIL SHJONITAO HIOA HSJA O Id HOLVA313 N HOLON ONY XO8sv49 NOILvIOS 1 j N30NI OS SONI MA WOOg RO WOOF 4addn S los NOS 1 43444 ed e e 1445 33320 VERSALIFT VO 265E 270E 5 55 8 SLYVd PART ORDERING AND PRODUCT SUPPORT INFORMATION The following
43. m WALI 13 13 0 3l 834 NMI 333 3 4 401231102 1317 10SNI Tv OL 8343 3117 151 041714 1Y 13400 SWALI TIVLSNI HOIMS 2314 1394 4 Ol 83433 14 1 14 7081 4 30422110 315501 40 darnddns 4311915 N Od 3 HOA OILVIN3HOS 48 d3lldd 38 OL 1114 ONY 3 OL SWALI SALVO SNOILY O S31d 438 11 ONILSIXA lt SAV 13 Ny 5310 111 3 VERSALIFT 43365 TSN 11321 3uvo 5 7373 anal ON3 10S NOlLdl4O 30 13743 1373 ANIL Sldvd dOl ddS HOSHVNON i i 4 Mab 131 9 315 91 1404 131100 34
44. 14230 33 OL 431133 3 SISSVHO 40 3015 LNOHJ 931 21 d3ddiHS 38 OL SLYVd 531 3 0 Ivl diHSH3NMO 719230 00810313 1 230 33 38 230 18190313 3 LANANHOFLIY 37 53015 Hlo8 um lt e 5395 DECAL PLACEMENT NOILVTIVLSNI VERSALIFT VO 265E 270E rev eren no PTZ seme ITEMS 76 S 14408 1 oon SK ITEM N WAS 11 15 09 ITEM TP WA 7 AND Y DECAL KIT UPPER CHTRL 1 26 AND BKT vO DECAL KIT UPPER DECAL KIT UPPER K BTW
45. 44013 7 58036 1 61025 1 6556 3 22085 00 28093 01 28457 1 39024 02 39025 02 E 1330 3 FB 60 HK 1330 18 MH 1330 10 OR 1400 49 OR 1400 9 RO 1330 2 SK 1330 4 VK 1400 21 12340 1 13366 1 26855 1 33877 1 33988 DWG 34259 1 35500 1 35537 1 8285 1 11099 1 12337 1 14014 1 14110 1 15732 1 27648 1 30593 1 34004 2 34005 1 35878 DWG 35878 DWG 426 011 4541 1 4541 2 4542 12 4542 12 4542 2 4542 4 4542 4 As Built Material List Description Decal Platform Capacity Prep Kit for Platform Controls 1 4 Hex Head Screws 1 1 2 Hex Locknut 1 4 Hardened Washer 1 4 1 8 Airline Bundle 14 5 Electrical Wire Pressure Switch Bracket Batchweld Zinc Plated EMI Safety Manual Manual of Responsibility MRA92 2 2009 Collector Ring Assembly 1 Pass VO 265 270E Operators Manual VO265 270E Custom Service Manual Longitudinal Elev Assy Asplundh 39 Fiberglass Bucket SHV32 36 SS Elevator Hose Kit Elevator Mounting Hardware VO270EREV Asplundh Outrigger Assy Pivot Foot Less Outer Housing Weld VO265E 270EREV 01 Outrigger Pin Option Continuous Rotation Assembly Shipping Skid Elevator Asplundh VO270EREV One Outrigger Valve with Relief and Switch Decal Conductive Hoses Decal Tool Pressure Decal Tool Selector Decal Elevator Decal Kit Up Cntrls Btwn Bm and Bkt VO255 260 02 VO265 270E Decal Single Stick HR Ctrl Left Hand Decal Upper Control Not Insulated Decal Test Point Decal
46. Nid 4 Sg 15434134 2 1 Nid H Ql 1 gl vid 3333 1 4 3333 L SOHH 91 9 X ON amp 1 43 57 d3N3quyH 2 LAN 201 031770 2 1 5p gt SOHH X ON 8 1 8 j 8 d3HSvM Q3N3QdvH S 33 d3ddfi 334 VERSALIFT LOWER BOOM SECTION 117 LOWER BOOM ASSEMBLY OPTION LB 1330 1 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 117 1 Jo 1511 33 5 Jenae 717139 335
47. 0A MB 807 n 1 CON 87330 8 381 A 31 sv y 3 1 x gt 719140 338 gt 8 83011 dv 14 5 YAT VAL V n cz 40 m 137 NIHO Em IWALSAS SNIT3A31 VERSALIFT LOWER BOOM REST SECTION 120 LOWER BOOM REST SLED ONLY OPTION MH 1330 9 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 120 1 1 30 1 4438 HSINIA NOILV TIVLSNI un 68 _ 0 6 NO 511230 JALIL 3170 9 NWO AJLON 3SIW33H1 IVIASALVW NOIL dlIdOS 34 NOILV TIVISNI 1544 S340 TIVLSNI e LVN MO LNSWOTS 31S NOOB 01 LSIX3 SOHH Z L X 91 lt 000 8 WALI LNdAG 13 LAN MOOI 29N 81I p 900Z q y d3HSvA 91 27 6 10 77 3 LAN WYP 8 6 6O00cv d GdddiIHS 38 OL SWALI _ 1 f
48. 9 OR 1400 9 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 RO 1330 2 VERSALIFT Part 8441 7 8527 2 8527 9 8527 9 8527 9 89225 1 12803 1 40006 11 42005 5 44013 3 8817 5 3281 57 3281 58 33878 DWG 55678 1 5960 28 89088 28 89088 29 89164 10 35874 DWG 40054 11 42027 7 44013 1 12196 1 12213 1 14284 2 18935 1 35870 DWG 40004 3 44013 6 45008 23 48000 12 50011 3 50045 3 5487 3 8267 1 20080 DWG 8764 2 12478 1 12518 1 12519 1 12524 1 12593 1 12739 1 15035 1 32763 DWG 33880 DWG 33881 DWG 40003 5 40003 5 40004 7 40006 7 40006 9 As Built Material List Description Bearing Bearing Bearing Bearing Bearing Plug Rectangular Tube Shim 1 2 NC Head Cap Screw NC Hex Locknut 1 2 Hardened Washer 1 2 Platform 39 One Man 3 8 Hose Assembly 3 8 Hose Assembly Elevator Hose Kit VO265E 270E 1 4 Hose Assembly 1 2 Hose Assembly Hose Protective Cover Hose Protective Cover Hose Protective Cover Elevator Mtg Hrdwr Asplundh 5 8 NC Hex Head Cap Screws Prevailing Torque NC Hex Locknut Grd G Hardened Washer 5 8 Outrigger Slide Pad Outrigger Cylinder Assembly Inner Leg Batch Weld Cover Rear Mount Outrigger Outrigger Assembly Pivot Foot 3 8 NC Hex Head Cap Screw Hardened Washer 3 8 Roll Pin Snap Ring Waldes SAE O Ring to Male Jic 90 Deg Adjustable Elbow JIC Cap Pin
49. Cylinder Outrigger Pivot Foot Batch Weld Outrigger Pin Option Pin Outrigger Cyl Base End Chrome Plated Gearbox Spacer Brace Drive Strap Drive Strap Batch Weld Rotary Joint 13 Pass Dual C Balance Valve Assy Plastic Shim Rotary Joint Mount Plate Zinc Plated Rotation Gearbox Assembly Sub Assembly Rotary Joint 13 Pass Continuous Rotation Assy Elevator 5 16 NC Hex Head Cap Screw 5 16 NC Hex Head Cap Screw 3 8 NC Hex Head Cap Screw 1 2 NC Head Cap Screw 1 2 NC Head Cap Screw Qty 4 00 2 00 4 00 2 00 2 00 8 00 4 00 4 00 4 00 8 00 1 00 2 00 2 00 1 00 8 00 3 00 1 00 1 00 1 00 1 00 20 00 20 00 40 00 2 00 2 00 2 00 1 00 1 00 2 00 4 00 2 00 4 00 4 00 4 00 2 00 2 00 1 00 2 00 2 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 2 00 4 00 3 00 2 00 2 00 As Built Material List Option Part Description Qty RO 1330 2 40033 13 5 16 NC Socket Head Cap Screw 4 00 RO 1330 2 40054 10 5 8 NC Hex Head Cap Screws 18 00 RO 1330 2 40076 12 5 16 18 Taptite Screw 3 4 2 00 RO 1330 2 40077 15 5 8 NC Socket Head Cap Screw 4 00 gt lt RO 1330 2 42027 7 Prevailing Torque NC Hex Locknut Grd C 4 00 LLI RO 1330 2 44000 10 Helical Spring Lock Washers 2 00 RO 1330 2 44000 10 Helical Spring Lock Washers 4 00 RO 1330 2 44000 11 Helical Spring Lock Washers 3 00 E RO 1330 2 44000 13 Helical Spring Lock Washers 2 00 tc RO 1330 2 44013 1 Hardened Washer 5 8 22 00 lt RO 1330 2 44013 3
50. Emergency Stop Data Plate Backing Decal Responsibilities Decal Platform Instruction Decal Electrocution Hazard Decal Emergency Lowering Decal Pinch Warning Decal Lanyard Attachment Decal Lower Control Decal Pinch Point Decal Placement Asplundh Decal Placement Asplundh Versalift Nameplate Decal Versalift Decal Versalift Decal Danger Qualified Operator Decal Danger Qualified Operator Danger Electro Decal Decal Danger Decal Danger Qty 1 00 1 00 2 00 2 00 4 00 70 00 25 00 1 00 1 00 1 00 1 00 2 00 2 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 4 00 1 00 1 00 2 00 7 00 1 00 1 00 1 00 1 00 2 00 1 00 1 00 4 00 1 00 1 00 As Built Material List Option Part Description Qty DE 1330 24 4542 5 Decal Caution 1 00 DE 1330 24 4542 5 Decal Caution 1 00 DE 1330 24 5098 1 Decal Insulated Section 16 00 DE 1330 24 7500 1 Decal Holding Valve 4 00 gt lt DE 1330 24 7584 1 Decal Relief Adjustment 1 00 DE 1330 24 8928 1 Data Plate 1 00 DE 1400 4 12341 1 Decal Outrigger Operation 2 00 o DE 1400 4 20088 DWG Outrigger Control Decals 1 00 DE 1400 4 4992 1 Decal Caution Outriggers 2 00 lt DE 1400 4 8773 1 Decal Ground Control Selector 1 00 n DE 1400 4 8845 1 Decal Outrigger Control 2 00 1340 1 10274 1 Decal Emergency Power 1 00 2 EP 1340 1 10310 1 Decal Emergency Power 1 00 O EP 1340 1 12596 1 Air
51. MOISS34dlo2 3 Y 1 557 L3vHS 174 pn h i W Y NE 7 W30O34171d4 32 M3N3ISV4 H3 00 T3Nvd TOHLNOO 21 ala WALI 40 33843 HOVLLV LYOddNS NYOALV 1d VERSALIFT UPPER CONTROLS SECTION 123 HR SINGLE STICK CONTROLS REV MT BTWN BOOM amp BUCKET W REG TOOL PRESS FLOW OPTION SC 1330 37 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 123 1 SAGd Z9 S ON ond HOLYA313 IN Ada Lg NALS STHLNO 5 5 HH fo ui T L
52. Section 6 6 of the ANSI A92 2 standard reads as follows 6 6 1 Operational Tests In addition to the manufacturer s prototype tests and quality assurance measure each aerial device including mechanisms shall be tested by the manufacturer to the extent necessary to ensure compliance with the operational requirements of this section Some examples are 1 Boom s elevating and lowering mechanism INSTALLATION INSTALLATION VERSALIFT VO 265E 270E Boom extension mechanism Rotating mechanism Stability tests Safety devices Each aerial device shall be operated to verify the function of all safety devices Sp 63 N When the mobile unit is not completed by the manufacturer such tests which be performed only after complete assembly and installation shall be the responsibility of the final installer Section 4 5 Stability reads as follows 4 5 1 Stability On Level Surfaces Each aerial device when mounted on a vehicle meeting the manufacturers minimum vehicle specifications without readily removable tools and material and used in a specific configuration shall comprise a mobile unit capable of sustaining a static load one and one half times its rated load capacity in every position in which the load can be placed within the definition of the specific configuration when the vehicle is on a firm and level surface The load shall be applied at one and one half times the platform capacity at the center
53. Weldment Upper Arm Weldment Knuckle Assembly w Bearings Pedestal Assembly w Bearings Lower Arm Assembly w Bearings Upper Arm Assembly w Bearings Equalizer Link Assembly w Bearings Pedestal Weldment Pedestal Cover Plastic Base Outrigger Weldment Base Outrigger w Bearings Longitudinal Elev Assy Asplundh Longitudinal Elev Assy Asplundh 3 8 NC Hex Head Cap Screw 1 2 NC Head Cap Screw Wing Screw 5 16 18NC Hardened Washer 1 2 Hardened Washer 3 8 5100 Retainer Rings Cylinder Assembly Elevator Check Valve Pin Washer Zinc Plated Bearing Bearing Bearing Bearing Qty 1 00 1 00 1 00 1 00 1 00 2 00 1 00 20 00 4 00 3 00 6 00 3 00 1 00 1 00 4 00 3 00 180 00 14 00 12 00 1 00 8 00 4 00 4 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 3 00 1 00 1 00 1 00 1 00 28 00 14 00 12 00 14 00 28 00 16 00 2 00 1 00 14 00 2 00 4 00 2 00 4 00 gt lt LLI 00 lt 2 a 5 m lt AS BUILT OPTIONS amp PARTS INDEX Option E 1330 3 E 1330 3 E 1330 3 E 1330 3 E 1330 3 E 1330 3 FB 60 FB 60 FB 60 FB 60 FB 60 HK 1330 18 HK 1330 18 HK 1330 18 HK 1330 18 HK 1330 18 HK 1330 18 HK 1330 18 HK 1330 18 MH 1330 10 MH 1330 10 MH 1330 10 MH 1330 10 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400 49 OR 1400
54. allowed to operate in this manner the properly torqued bolts will eventually fatigue and failure may occur All load supporting bolts should be inspected visually each day and checked for proper torque every six months at minimum and more frequently if the unit is subjected to severe use NOTE Torque values are based on torquing the bolt head in all applications NOTE Ifthe rotation bearing is removed ensure the mounting surfaces are smooth and clean to endure full contact between the bearing and mounting surface Retorquing Procedure Retorque the rotation bearing bolts to the specifications included on the torque chart in this section and also according to the appropriate pattern shown on Figure 6 on the following page Understand the entire procedure before starting the torque inspection Select the torque wrench that is verified to the correct value for the bolt in use Torque the bolts in a diametrically opposed pattern bolts directly across the diameter move 90 degrees and then tighten bolts directly across the diameter Repeat untill all bolts are torqued to the specified value BOX MOUNTING BOLTS GEAR Z TORQUE PER 778 N 5 TURRET TO PEDESTAL MTG BOLTS TORQUE PER TMC XL ROTATION BEARING Sy X PEDESTAL TO TURRET MTG BOLT TOROUE PER TMC 778 BEARING BOLT CLASSIFICATION Rotation Bearing Bol
55. being removed Be sure the Versalift is well balanced before completely removing the mounting bolts at the turret DANGER NEVER REUSE SHIPPING BOLTS WHEN MOUNTING THE VERSALIFT TO THE PEDESTAL USED BOLTS MAY FAIL RESULTING IN DEATH OR SERIOUS INJURY Remove all paint and grease from the rotation bearing mounting surface Mount the Versalift to the pedestal using the socket head cap screws and hardened washers supplied Lining up of the turret and the pedestal can be simplified by using guide bolts Guide bolts can be made by cutting the heads off two 5 8 in x 11 NC bolts and screwing them into the rotation bearing The protruding ends of the guide bolts will align the turret as it is lowered onto the pedestal Remove the guide bolts and replace them with the Socket head cap screws provided Torque seal mark the bolts after torquing the bolts as specified on the chart Refer to the Continuous Rotation Assembly illustration in Parts amp Assemblies Section Install the 1 2in Inner Diameter grommet in the drive strap Bolt the drive strap to the rotary joint Rotate the drive strap until the holes on the drive strap brace are in line with the drive strap brace holes provided in the pedestal Bolt the drive strap brace to the pedestal as shown Connect the rotary jointto the filter using the hoses provided The return hoses to the filter should be connected to ports 1 and 3 Port 2 is for the pressure hose from the control selector v
56. by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 110 1 SLND d 104 WO ISM 335 IL 3 3714 NOILdl339S30 511 341 1 1 HA ALND HT ML 419 q ni d gt 70330 433 444 444 334 433 328 324 333 03 438 328 333 334 433 444 324 334 A 334 434 334 434 434 444 434 434 HH 4H HU TINO YH lt X ai l 1041 29 0066 1 3d Le66 as m E LIM 1V23d 1OHLINOO y VERSALIFT 5 455 UNV SLYVd e
57. control drain line to the 1 4 in fitting in the return line between the return filler and reservoir A CAUTION PUMP DAMAGE WILL OCCUR IF THE PUMP IS RUN WITHOUT HYDRAULIC OIL Before initial operation check the following items and correct if necessary This will allow pump start up at minimal pressure 1 Transmission is full of fluid 2 Pump case is full of oil 3 Suction hose is full of oil 4 Ground controls have been selected 5 Oil reservoir is full 6 Pump hoses are clear of drive line and exhaust system INSTALLATION INSTALLATION VERSALIFT VO 265E 270E Start the engine and release the clutch gradually to rotate the pump as slow as possible The pump and PTO should operate quietly If excessive noise occurs check for these problems 1 Improper backlash of PTO Should be 006 to 012 backlash 2 Hydraulic pump is not primed 3 Air leak in the suction line 4 Shutoff valve in the suction line is not open The ground controls can be operated once the hydraulic pump is operating Adjustment of the engine speed should be done after installation of the aerial lift and are discussed later INSTALLING THE AERIAL LIFT The center of gravity of the Versalift sitting on the shipping skid is about 14 in 356 mm beyond the turret end of the lower boom insert Attach the hoist to the lower boom insert at 2 points Lift up the Versalift while the bolts holding the Versalift to the shipping crate are
58. defective control valve NO RESPONSE TO UPPER CONTROLS LOWER CONTROLS 1 Platform override valve in wrong position 2 Safety trigger not actuated or adjusted properly 3 Plugged or defective control valve 103 23 2 a gt 2 a oc a gt VERSALIFT VO 265E 270E 4 Pinched or kinked pressure or return hose in boom 5 Emergency stop valve is activated SLOW OPERATION ALL FUNCTIONS 1 Valve spools not fully open 2 Oiltoo heavy or cold 3 Low hydraulic fluid supply 4 System operating pressure or main system relief set too low 5 Dirt or foreign matter in hydraulic system filters valves etc 6 Pinched or kinked hydraulic lines 7 Engine speed too low 8 Excessive leakage in pump or control valve due to wear 9 Safety trigger not adjusted properly SLOW HYDRAULIC CYLINDERS OPERATION ROTATION O K 1 Holding valves defective 2 Mainrelief valve settoo low or open due to contamination 3 Excessive pump leakage 4 Internal cylinder leakage 5 System operating pressure set too low SLOW OPERATION OF ROTATION SYSTEM BOOM MOTION O K 1 Rotation motor defective EXCESSIVE SLACK OR ERRATIC MOVEMENT IN ROTATION SYSTEM 1 Gearbox mounting bolts loose 2 Rotation bearing needs greasing 3 Excessive clearance between pinion and turntable bearing 4 Turntable bearing or pi
59. hoses at the upper controls which go through the booms 3 Remove the clamps securing the hose bundle to the upper control panel 4 Pullthe hose bundle through the platform shaft and leave it hanging out the side of the boom Wrap the ends of the hoses with tape to keep the hoses in a bundle This makes it easier to pull them through the boom 5 Disconnect the platform from the platform shaft Leave the control panel attached to the platform 6 Toremove the platform shaft disconnect the snap ring and special washer and slide the shaft out AT THE KNUCKLE 7 Remove the covers from the upper and lower boom knuckle area Pull the hoses out of the upper boom and then out of the upper boom pivot shaft from the knuckle 8 Use a paint pen or torque stripe material and place an index mark on the chain and sprockets atthe knuckle and the platform to allow the leveling system to be reinstalled in the same orientation 9 Loosenthe upper and lower leveling through the access holes 10 Disconnect the snap ring and remove the idler sprocket assemblies 11 Remove the pin bolts and pin cap from the upper link at the boom connection 12 Raise the upper boom for clearance for the pin to be removed Secure the links and upper boom from moving and then remove the pin from the upper boom and upper links 103 27 CAUTION EXERCISE CAUTION WHEN INSTALLING OR REMOVING THE UPPER BOOM CYLINDER AND LINK WELDMENTS THE UPPER BO
60. later The selector valve consists of a two position spool valve that directs hydraulic oil flow either to the lift or to the remaining ground controls The outrigger controls consist of two four way control valves connected in a series A relief valve is integral to these control valves Hydraulic oil is directed to either end of a double acting hydraulic cylinder that extends or retracts the outriggers A lock valve or double pilot operated check valve is mounted on each outrigger cylinder effectively blocking the flow out of both ends When the four way control valve is actuated pressure is applied to one end of the cylinder and to a pilot piston that opens the check valve allowing flow out of the other end Flow now extends or retracts the outrigger cylinder as desired A thermal relief is incorporated into the lock valve The thermal relief valve allows excessive pressure created by thermal expansion to bypass the check valve Asaresult the check valve traps oil in the rod end of the outrigger cylinder On reverse mount units an additional four way control valve is used for dump body control A shutoff or needle valve is included to prevent inadvertent operation of the dump body As an option they can be installed on the outrigger circuit for the same purpose as well as additional protection against the outriggers retracting under load This valve must be manually opened or closed The optional tool circuit control consists
61. minimum of two threads must protrude beyond the nut after tightening 6 The marks shown on this chart are for our current fastener suppliers 7 Refer to the critical fastener drawings for each Versalift for identification of specific fasteners 8 HHCS Hex Head Cap Screw HW Hardened Washers PTLN Prevailing Torque Lock Nut SHCS Socket Head Cap Screw SHFH Socket Head Flat Head VERSALIFT VO 265E 270E 104 4 March 1 2007 TMC 778 VERSALIFT VO 265E 270E INSTALLATION AND PRE DELIVERY MOUNTING INSTRUCTIONS Refer to the specific mounting hardware options in Parts and Assemblies Section in this manual for lift installation drawings REVERSE MOUNT INSTALLATION The elevator is designed to be shear plate mounted to the chassis frame Place the elevator assembly and outriggers on the chassis and position as required Weld the outriggers to the elevator and weld the shear plates as shown on the installation drawing Install the lower controls and ground controls in an accessible location in accordance with ANSI A92 2 Connect the hydraulic hoses as shown in the hydraulic schematic in this section REAR MOUNT INSTALLATION For a rear mount installation the elevator is designed to be attached to a full length subframe Place the elevator outriggers and subframe components on the chassis frame and position as required Weld all components as shown in the installation drawing Install the lower controls and
62. necessary Failure to use tie down strap can damage the upper boom structurally 2 STRUCTURAL INSPECTION Verify structural integrity of the aerial lift Certain structural components of the aerial lift are deemed critical These items must be inspected for any signs of degradation or impending failure Any suspect item should be further inspected using an acceptable non destructive test procedure such as magnetic particle or dye penetrant 103 5 2 a gt A Any fastener that is structural or retains structural member is considered critical and is shown in the Critical Fasteners drawing included in this section These fasteners must be visually checked for rotation and signs of failure Do not use the lift if a torque seal mark is not aligened If any loose fasteners are found both the nut and bolt must be replaced and tightened to the proper torque Nuts and bolts must never be reused A new torque seal mark must be installed Refer to Maintenance amp Inspection Schedule in this section Critical welds are shown on the Critical Welds drawing included in this section Any defective structural welds must be repaired in accordance with ANSI A92 2 requirements Consult factory for material specifications and proper welding specifications Inspect all structural components and replace if RC is less than shown below If there is any doubt a
63. of the platform simultaneously with one and one half times the lifting attachment supplemental capacity in its position of maximum overturning moment when so equipped Simultaneous application of platform capacity and supplemental capacity shall be performed only on the aerial devices that are designed for use with both types of load applied simultaneously If having outriggers or other stabilizing components utilized is part ofthe definition of the configuration they shall be so utilized according to the manufacturer s instructions for the purposes of determining whether the mobile unit meets the stability requirements With the truck on firm level ground the lower boom fully raised and the upper boom horizontal rotate to the front or rear and suspend the appropriate weight from the platform Rotate the lift to the side adding ballastto the truck frame if required to achieve stability The placement of any ballast will affect the stability and the final weight distribution and must be evaluated 4 5 2 Stability On Slopes Each aerial device when mounted on a vehicle meeting the manufacturer s minimum vehicle specifications without readily removable tools and material and used in a specific configuration shall comprise a mobile unit capable of sustaining a static load one 104 8 and one third times its rated load capacity in every position in which the load can be placed within the definition of the specific configuration whe
64. part numbers PARTS AND ASSEMBLIES VERSALIFT 109 1 17193171 28 3 191273 3i Ag a JALON 351 83910 53 IVIHALYW 40 1SN 2114152539 ON 19792 WALI ALD ALO ALO ALO ALO ALO 51921408 lOdLNOO V 1 43291 g T s 30103135 1O31N009 719230 17230 2 13 010 3 13 140 15230 3 _ _ lt N 17930 9 ES E Saf 6 9 35001 d34dIHS 38 OL SWALI 4 Vv H4 H 4 40123136 31 4 Ei 15345 Wy g 1 0 42111 HET S3 d 0103135 10 2 T 334 S 1V23G 9 5 VERSALIFT x lt O a 2 o oc a A 2 SECTION 110 UPPER CONTROL DECAL KIT SINGLE STICK BETWEEN BOOM amp BASKET OPTION DE 1330 18 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged
65. system must be maintained to provide reliable performance The return flow filter should be replaced the first 30 days of operation and every 6 months thereafter Whenever the filter is changed the oil should be examined for foreign particles or water If contamination is found the oil should be changed or reclaimed 3 MONTHS OR 250 PTO HOURS AFTER IN SERVICE DATE ONE TIME SERVICE 1 MAINTENANCE NOTES A Re torque all load supporting bolts Rotation bearing bolts Pedestal Subframe mounting bolts Platform rotator bolts A new torque seal mark must be installed B All other critical fasteners must be visually inspected for rotation and signs of failure Prevailing torque nuts are used in structural applications to prevent loosening from vibration To be effective 2 threads must protrude beyond the locknut once tightened Only install unused locknuts and bolts Torque seal marks are used on critical fasteners This procedure provides a means for quick visual inspection of fastener condition Do not use the lift if the Torque Seal mark between the bolt head and mounting surface are not in alignment gt TORQUE SEAL ALIGNED hy ong Torque Seal Mark In Acceptable Condition f I TORQUE SEAL N V MISALIGR Y MARK MISALIGNED in ATI i H gel Torque Seal Mark In Misalignment Con
66. the performance and life of the Versalift The scope of this manual includes maintenance inspection service and installation information Personnel responsible for maintaining inspecting and servicing the aerial lift must be familiar with this manual and the operator s manual A working knowledge of all the information included in both manuals is required THIS MANUAL CONTAINS CONFIDENTAL INFORMATION AND IS SOLE PROPERTY OF TIME MANUFACTURING AND IS NOT TO BE DISCLOSED COPIED OR REPRODUCED WITHOUT EXPRESSED PERMISSION OF TIME MANUFACTURING In addition to dealers owners operators renters lessors and lessees are required to comply with the requirements of the applicable section or sections found in ANSI A92 2 NOTE For additional safety information and required responsibilities refer to the accompanying EMI Safety Manual and Manual of Responsibilities Detailed information for the efficient operation of the Versalift aerial device can be found in the accompanying Operator s Manual A DANGER THIS EQUIPMENT SHOULD BE OPERATED AND SERVICED ONLY BY COMPETENT PERSONNEL FAMILIAR WITH GOOD SAFETY PRACTICES THIS INSTRUCTION IS WRITTEN FOR SUCH PERSONNEL AND IS NOT INTENDED AS A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE IN SAFE PROCEDURES FOR THIS TYPE OF EQUIPMENT A DANGER READ AND UNDERSTAND THIS MANUAL BEFORE ATTEMPTING TO SERVICE THIS AERIAL EQUIPMENT A DANGER THIS IS NOT MAINTENANCE VER
67. throttle control should be regulated to provide speeds within the specific ranges given for each function To aid in warming the hydraulic oil select the warmup mode to allow oil to circulate OUTRIGGER BOOM INTERLOCK Optional Refer to Parts amp Assemblies Section ROTATION MOTOR COUNTERBALANCE VALVES The rotation motor counterbalance valves are located manifold mounted to the motor 1 Unbolt the rotation motor and disengage it from the rotation gearbox 2 Tee 3000 psi minimum pressure gauges into each ofthe two motor ports as shown in diagram below CCW CW 3 It is necessary to set the holding valve pilot pressure to obtain smooth rotation while maintaining adequate rotation speed The higher the pressure setting the more restrictive the valves are providing smoothest operation However as the pressure is increased a reduction in rotation speed may occur The sugested pressure range is 1100 psi plus or minus 200 psi Adjustments can be made on the pressure setting to obtain smooth operation on a slope and adequate rotation speed on level ground Do not exceed 1300 psi Excessive back pressure can adversely affect the life of the motor shaft seal 4 Start the unit and from the lower controls fully actuate the rotation control for clockwise CW rotation Read the pressure gauge opposite the clockwise CW port and set the pressure to 1100 103 20 psi To adjust the pres
68. 0 1 00 1 00 1 00 5 00 1 00 1 00 3 00 5 00 2 00 1 00 1 00 1 00 2 00 1 00 3 00 1 00 8 00 3 00 3 00 3 00 8 00 1 00 1 00 3 00 1 00 1 00 1 00 1 00 1 00 7 00 1 00 1 00 2 00 1 00 6 00 18 00 2 00 2 00 2 00 2 00 1 00 2 00 2 00 2 00 1 00 1 00 As Built Material List Option Part Description Qty LO 1330 2 15375 13 Leveling Rod Assy 1 2 Dia Rods 1 00 LO 1330 2 15375 21 Leveling Rod Assy 1 2 Dia Rods 1 00 LO 1330 2 15375 23 Leveling Rod Assy 1 2 Dia Rods 1 00 LO 1330 2 15375 25 Leveling Rod Assy 1 2 Dia Rods 1 00 gt lt LO 1330 2 15614 1 Level Tension Eye Bolt Zinc Plated 2 00 LLI LO 1330 2 15614 2 Level Tension Eye Bolt Zinc Plated 2 00 LO 1330 2 15622 4 Pin Idler 1 00 LO 1330 2 15689 1 Idler Sprocket w BRGS 1 00 E LO 1330 2 22201 1 Leveling Anchor ZINC PLATED 1 00 tc LO 1330 2 27833 1 Hose Divider Zinc Plated 1 00 lt LO 1330 2 32770 1 Sprocket Platform Zinc Plated 1 00 LO 1330 2 33922 1 Sprocket Batch Weld Zinc Plated 1 00 o LO 1330 2 33925 1 Leveling Idler Batch Weld Zinc Plated 1 00 z LO 1330 2 33928 DWG Leveling System Assembly VO 255 260 1 00 O LO 1330 2 40004 18 3 8 NC Hex Head Cap Screws 1 00 1 3 1330 2 40007 9 5 8 NC Hex Head Cap Screws 100 LO 1330 2 40083 1 Button HD Hex Socket Capscrew 4 00 LO 1330 2 40083 10 Button HD Hex Socket Capscrew 2 00 LO 1330 2 42000 5 NC Hex Nuts 2 00 LO 1330 2 42000 7 NC Hex Nuts 2 00 o LO 1330 2 42005 3 NC Hex Lock
69. 0 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 As Built Material List Option Part Description Qty SC 1330 37 35482 1 Trigger Plastic 1 00 SC 1330 37 35767 DWG HR S STK Cntrls Btwn Bm and Bkt Rev Mt 1 00 Elevator SC 1330 37 35768 1 1 2 OD Tube Assembly 1 00 gt lt 5 1330 37 35769 1 1 2 OD Tube Assembly 1 00 LLI SC 1330 37 35770 1 1 2 OD Tube Assembly 1 00 SC 1330 37 35772 1 1 2 OD Tube Assembly 1 00 SC 1330 37 35773 1 1 2 OD Tube Assembly 1 00 E 5 1330 37 40002 3 1 4 Hex Head Cap Screws 3 4 1 00 SC 1330 37 40003 1 5 16 NC Hex Head Cap Screw 2 00 lt SC 1330 37 40003 11 5 16 NC Hex Head Cap Screw 2 00 SC 1330 37 40003 18 5 16 NC Hex Head Cap Screw 3 00 o SC 1330 37 40004 10 3 8 NC Hex Head Cap Screw 2 00 z SC 1330 37 40016 4 1 4 20 NC Nylon Bolt 4 00 O SC 1330 37 40070 11 1 4 NC Socket Head Cap Screw 2 1 2 1 00 SC 1330 37 40070 7 1 4 NC Socket Head Cap Screw 1 1 2 300 5 1330 37 40116 1 5 16 Dia Shoulder Bolt 2 00 SC 1330 37 40117 1 M5 X 0 8MM Metric Cap Screw 4 00 SC 1330 37 40125 5 5 6NF Socket Head Cap Screw 2 00 SC 1330 37 40171 12 3 8 NC Fiber Flanged HD Cap Screw 4 00 o SC 1330 37 42000 1 NC Hex Nuts 6 00 lt SC 1330 37 42000 3 NC Hex Nuts 3 00 SC 1330 37 42001 1 NF Hex Nuts 5 00 SC 1330 37 42001 2 NF Hex Nuts 2 00 SC 1330 37 42005 1 NC Hex Locknut 1 4 1 00 SC 1330 37 42005 1 NC Hex Locknut 1 4 1 00 SC 1330 37 42005 2 NC H
70. 005 1 UB 1330 2 44013 7 UB 1330 2 650990 48 UB 1330 2 8526 6 VO270EREV 33996 DWG VO270EREV PAINT VO270EREV PRIMER PAINT SubAssembly Kits 39025 02 Paper E 1330 3 10143 12 E 1330 3 10226 23 E 1330 3 152 015 E 1330 3 22135 13 E 1330 3 33831 1 E 1330 3 33832 1 E 1330 3 33837 1 E 1330 3 33839 1 E 1330 3 33841 1 E 1330 3 33842 1 E 1330 3 33855 DWG E 1330 3 33857 DWG E 1330 3 33858 DWG E 1330 3 33859 DWG E 1330 3 33860 DWG E 1330 3 34270 1 E 1330 3 34359 1 E 1330 3 35867 1 E 1330 3 35868 DWG E 1330 3 35869 DWG E 1330 3 35869 DWG E 1330 3 40004 3 E 1330 3 40006 5 E 1330 3 40177 1 E 1330 3 44013 3 E 1330 3 44013 6 E 1330 3 48014 62 E 1330 3 53031 1 E 1330 3 54070 1 E 1330 3 7766 1 E 1330 3 8441 7 E 1330 3 8441 7 E 1330 3 8441 7 E 1330 3 8441 7 VERSALIFT As Built Material List Description Cover Inspection Hose Cover Pf and Side Upper Boom Final Weldment VO260 01 Reverse Mount Upper Boom Assembly VO255 260 01 02 Boom Tip Cover 1 4 NC Hex Head Cap Screws 1 1 4 NC Hex Head Cap Screws 1 1 4 5 16 18 Taptite Screw 3 4 10 24 NC Nylon Hex Head Machine Screw NC Hex Locknut 1 4 Hardened Washer 1 4 Clamp Steel Cush Loop Bearing VO265E 270E Base Bill STD Versalift White Paint PRIMER PAINT PAPER 8 1 2x11 FOR MANUALS Pin Assembly 12612 7 Pivot Spacer Rego Check Valve Washer Special Zinc Plated Pin Elevator Pivot Chrome Plated Compensation Link Weldment Link Equalizer Knuckle Weldment Lower Arm
71. 1 TOOL FRACTIONS 1 16 H COMPAN CHKD BY DATE ANGLES 1 ACO TEXAS ALVE B MATERIAL SIZE SCALE AC N SURFAC S EI a M d SEE MATERIAL LIST I A PROJEC TION OF MEWS 2 FINISH SHEET DWG NO ALL DIMENSIONS ARE IN INCHES 2 4930 VERSALIFT 123 10 SLOPE INDICATOR SECTION 124 SLOPE INDICATOR INSTALLATION OPTION SD 1200 13 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 124 1 37111 31vO AB 3 40 1517 NOILdld2S 3d ON Lavd 10 ALO ALO ALO VTIVISNI 34015 V L L YOLVOIGNI 34015 8 Z 2 ET DU 0 JHL OL 3 930 214 1 17 1 3 31 SHL SLVOIGNI OL 0377 34015 c 34015 320 4 10 1 230 9 E 2 y 8 01 353841 LVOIGNI 34015 3dO IS Val v lt O4 dc 53
72. 2 Section 116 Knuckle Linkage Assembly KN 1330 1 Knuckle Linkage 116 2 Section 117 Lower Boom Assembly 1330 1 Lower Boom Assembly u u ER ihe atheist 117 2 Section 118 Valve Kit Lower Controls HYD 1330 6 Valve Kit Fower Gontrols aa fence au sata eect A 118 3 Section 119 Leveling System LO 1330 2 Leveling System Assembly L u un aa Aqa Rae 119 2 Section 120 Lower Boom Rest Sled Only 1330 9 Lower Boom Rest Installation ns 120 2 Section 121 Upper Boom Rest MH 812 121 2 Section 122 Platform Support SS Btwn Boom 8 Bucket W Pltfm Tilt Rev Mt PS 1330 12 Platform Support ASsembly etm e e eh alse 122 3 00 tu l m N 0 lt 2 lt lt Section 123 HR S Stk Ctrls Rev Mt Btwn Bm amp Bkt w Reg Tool Press Flow SC 1330 37 HR S Stk Ctrls Btwn Boom amp Bucket Rev Mt 123 2 Section 124 Slope Indicator Installation SD 1200 13 Slope Indicator Installation U a 124 2 Section 125 Upper Boom Assembly UB 1330 2 Upper Boom Assembly u u y u 125 3 Section 126 Turret Assemb
73. 2 Steel 15 20 3 8 16 Grade 5 5 Loctite 262 Steel 3 8 16 5 5 SHFH Loctite 262 Aluminum 27 37 15 20 3 8 16 Grade 8 HHCS Loctite 262 Steel 37 50 1 2 13 SHCS INSTALLATION Loctite 262 Steel 89 121 5 8 11 SHCS 30W Motor Oil Rotation Bearing 160 218 5 8 11 Grade 8 HHCS 30W Motor Oil Rotation Bearing 160 218 3 4 10 Grade 5 Threaded Rod Loctite 262 Grade B Nut 145 197 3 4 10 Grade 8 5 30W Motor Oil Rotation Bearing 315 428 NOTES 3 4 10 Grade 8 HHCS Loctite 262 A572 50 Steel 210 286 1 Lubricate bolt threads liberally with 30W motor oil unless fastener application is to be used on tapped material Then use Loctite 262 on these fasteners with exception of rotation bearing 2 Since the flat washers are stamped one side will have a rought and sharp edge the other is smooth and radiused ALWAYS place the rounded side of the flat washer towards the head of the bolt to protect the fillet 3 Apply torque to nut unless bolt is used in a tapped hole 4 All torque values are running torques for initial and replacement installation only the nut bolt head must turn Use of an impact wrench is permissible only for run up not for tightening During confirmation of previously torqued fasteners the nut bolt head should not turn if proper torque is maintained 5 A
74. 3 19103557 YADSIELNO e VERSALIFT OUTRIGGER PIN OPTION SECTION 131 OUTRIGGER PIN OPTION OPTION OR 1400 9 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 131 1 1 3711 1533 TALON ISMYJHLO fF Hf tA 2 el Wea s MIT IGA 1 H 89534 ALO ALD ALO ALO ALD ALO ALO ALO ALO Nid 3991 1 0 79 L L l L L l L L S X VIO v HO Nd v 19 YO d 6 v d v l L 7049 YO d E i i 7 80 Nld 6 99 H gt y l 1 MO Z n 2 y S 9 8 6 1500 Q
75. 3ddlHS 38 OL MOO THALN 290 1 dO N dO T 5 r dO N dO N B a O xi Yay 8 JAL IY NOILdO Nid 9 Add 131 2 VERSALIFT z lt x 0 2 SECTION 132 CONTINUOUS ROTATION ASSEMBLY OPTION RO 1330 2 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 132 1 TESTED 13553803 1 13345 05 1511 335 edlen azis 544 1 1 38 CN OX WV 18233 3141 aval Jon 351 4898 SSS 1713317144 4 119143557 dv31S YA dV31S Yd Z 3lddlN 14 m 17074 OL 3384 38 Qq3N3Q0JvH 8 6 3745 3 1 OL
76. 487 10100 399lMl ALAS 319715 M c 31719 3579 l 1 HS 1 1 8 N N d l 1 c c f gv 3835 91811 5 80 p 4 Y Y 4 4 SOOT 10 dl 4178 33 G3TI 15NI 38 SAJTO ULNA Ol SWALI S 310 WALI 1311 S 3 311 1 NV OIA NIHO 0123302252 5531 211178 3 vH 61291 ad S IOHLNOO VERSALIFT 5 455 UNV SLYVd S1OHLNOO 43000 SMAq rS9 e lt ON 41338 A 55 XGZ 37725 34 I8IN3SSV AAV SVX31 02 ANY dl TOHLINN 3714 Sold 33 VERSALIFT nsi 15153171 Jo LSM 33 nale
77. 6 1 Tilt Arm 2 00 VERSALIFT AS BUILT OPTIONS amp PARTS INDEX Option PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 PS 1330 12 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 VERSALIFT Part 35717 1 35722 1 35723 1 35724 1 35781 1 40003 10 40171 10 40171 16 40171 24 42005 2 42024 6 44002 8 44013 1 44013 2 44013 5 45008 10 45008 19 45008 8 45013 4 72041 1 7442 10 80015 3 80042 1 89021 2 12735 1 13109 3 14003 1 28489 1 33166 1 33174 1 33177 1 33401 1 33654 DWG 33884 2 33884 4 33886 5 33886 6 33887 4 33887 5 33891 DWG 34053 1 34057 1 34058 1 34059 1 34059 1 34060 1 34071 2 34113 2 34140 DWG 34141 DWG 34163 1 34167 1 34189 1 34551 1 34564 DWG As Built Material List Description Platform Support Panel Batchweld Cover Control Panel Rev Mt Cover Tool Power Cover Control Panel Lower Closure Pivot Rod Zinc Plated 5 16 NC Hex Head Cap Screw 3 8 N
78. 8 4 LEVELING SYSTEM SECTION 119 LEVELING SYSTEM ASSEMBLY OPTION LO 1330 2 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 119 1 9 01 SHS oud 13385 2 5 y 211726 09c 66 O i c 719130 Wana 1 W3LAS 113 31 i i F wh 211 11715 46 XZ 31 25 3 i LL x TWAT 7q ASS V MA E J 38 1 133301 OL 532508 13330 o z z z mm WE EB 5 3 OL S3S0H 2 2 2 y T 5 3015 0 EE E r Oh 1404 1 11009 w
79. 8048 325 5531 1 8546 12 20575 DWG 22142 1 22184 1 29532 1 29534 1 32754 1 32767 2 40004 5 40007 5 40076 12 40076 8 40109 7 42003 3 44000 11 44013 6 5531 2 8441 1 10226 19 14643 7 14643 8 14643 9 As Built Material List Description Control Panel Control Cover Lower Control Panel Assembly 1 4 20 Hex Washer Head Taptite Screw Vinyl Trim Cylinder Assembly Lower Cylinder Assy wBRGS Upper Cylinder Assy wBRGS VO250 260 Handle Upper Control Valve Valve Kit Lower Controls Lower Control Valve Open Center Spacer Stainless Steel Pivot Spacer Pivot Spacer Knuckle Linkage Assembly Upper Link Upper Link Washer Special Zinc Plated Washer Special Zinc Plated Pin Assembly 22145 1 Lower Link Assy w Brgs Rev Mount 3 8 NC Hex Head Cap Screw 1 2 13NC X 6 HHCS NC Hex Locknut 1 2 Hardened Washer 1 2 Hardened Washer 3 8 5100 Retainer Rings RETAINING RING 3 006 FREE DIA Pin Washer Zinc Plated Pin Assembly 22185 1 Lower Boom Assembly Cover Elbow Pin Assembly Hose Cover Elbow Cover Inspection Plastic Lwr Boom Assy VO255 260 01 RV Lower Boom Cover Zinc Plated 3 8 NC Hex Head Cap Screw 5 8 NC Hex Head Cap Screws 5 16 18 Taptite Screw 3 4 5 16 18 Tapite Screw 1 2 3 8 16NC HHC St Steel Castle Nut 3 8 NF Helical Spring Lock Washers Hardened Washer 3 8 Pin Washer Zinc Plated Bearing Pivot Spacer Roller Chain Extension Chain Extension Chain Qty 1 00 1 00 1 00 6 0
80. 99 14015 14 076 avail 131539905 YOLVOIGNI 44015 124 2 VERSALIFT UPPER BOOM SECTION 125 UPPER BOOM ASSEMBLY OPTION UB 1330 2 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 125 1 PAGE INTENTIONALLY LEFT BLANK UPPER BOOM VERSALIFT 125 2 INOOS8 H3ddf 5 455 UNV SLYVd L 40 19143171 13385 HSIN 11311 1 uo uo uo 1m 153 4 n i 557 88 66 Madan Ld 8 d
81. ALENTS IN METERS 5 LLATION MATERIAL EST WT MANUAL LINE FINISH DWG OF 1 5 REV EREN NO DESCRIPTION cheo 5 FIRST RELEASE LER DJH SF 144 1 22 9 73M 145 3 66m 3 71M un i Y i 40 1 02M Y Y Y NOTES 1 5 ALL DIMSENSI EQUIVALENT 5 ARE IN INCHE 5 IN METERS ITH METRIC SURFACE FINISHE PROJECTION OF ALL DIMEN THIS PRIN EY Toate TTE TURING y ese ANY LER O270ERE TEXAS SR 6 INSTALLATION MATERIEL EST WT MANUAL OUTLINE FINISH SHEET DWG NI 1 OF 1 34028 DWG VERSALIFT VO 265E 270E INSTALLATION DESCRIPTION BY CHKD APPR DATE CHARTED DIMENS AND REVISED LBR DJH SRS 4 16 09 TITLE TO INCLUDE E AND ERSE 12 1 4 WAS DIM A HIGH DIM B LO DIM C 7 TOP TRUCK FRAME SEREAR SHOWN FOR REFERENCE ONLY TITLE UF ACTURING NOTES oM 1 AL
82. C Fiber Flanged HD Cap Screw 3 8 NC Fiber Flanged HD Cap Screw 3 8 NC Fiber Flanged HD Cap Screw NC Hex Locknut 5 16 3 8 16 Hex Nut Standard Flat Washer Hardened Washer 5 8 Hardened Washer 1 Hardened Washer 5 16 Plated Roll Pin Roll Pin Roll Pin Lock Pin Flange Bearing 72011 6 Spacer Stainless Steel Shock Absorber Compression Spring Zinc Plated Grip 250 740 52 RE R 1200 Red Spacer Selector Valve Handle 14 5 8 Base Plate Single Stick LH Saftey ArmTrigger Zinc Plated Handle Plastic Control 3 Axis Control Handle Body Plastic Link Backing Plate Zinc Plated Unitrol HR 3 Axis Assembly 1 2 OD Tube Assembly Control Valve Ret 1 2 OD Tube Assembly Control Valve Ret 1 2 OD Tube Assembly Pressure 1 2 OD Tube Assembly Pressure 1 2 OD Tube Assembly Return 1 2 OD Tube Assembly Return Single Stick Control Valve Assembly Locking Knob Upper Locking Knob Tip Zinc Plated Locking Handle Sleeve Knob Knob Handle Rod Zinc Plated Plastic Dash Control Linkage Hr Locking Lever Sub Assembly Drawing Hr Locking Lever Assembly Drawing Unitrol 3 Function HR Ctrl Shell Boot 3 Axis Single Stick Handle Rod M8 Threads Zinc Plated Rod Cover M8 Covered Control Handle Assembly Qty 1 00 1 00 2 00 1 00 1 00 4 00 2 00 6 00 4 00 4 00 8 00 4 00 2 00 3 00 5 00 2 00 2 00 2 00 1 00 2 00 4 00 2 00 1 00 1 00 7 00 1 00 1 00 1 00 1 00 1 00 2 00 2 00 1 00 1 00 1 00 1 0
83. D 1200 13 SK 34 SS DELETE UB 1330 2 TT 1330 1 COLORCODE Materials 22085 00 28093 01 28457 1 39024 02 39025 02 E 1330 3 FB 60 HK 1330 18 MH 1330 10 OR 1400 49 OR 1400 9 RO 1330 2 SK 1330 4 VK 1400 21 33996 DWG PAINT PRIMER PAINT VERSALIFT As Built Option List Description VO270EREV Base Bill Blue Boot for Air Cylinder Decal Platform Capacity 350LB 160KG Decal Placement Asplundh VO270E Outrigger Control Decals single valve and single valve with interlock HR Decal Kit Upper Cntrls S Stick Btwn BM and BKT VO265E 260EREV 02 Emergency Power Insulated 12VDC Prep Kit Air Operated Platform Controls Boom Hose Kit VO270EREV Lower Control Panel Asplundh VO270E Oylinders Knuckle Linkage Assy Reverse Lower Boom Assembly Valve Kit Lower Controls Leveling system VO 260Rev 02 Lower Boom Rest Sled Only 11 Tall Upper Boom Rest VO250 2551 PC Config Placeholder Asplundh Pltfrm Supt S Stick Btwn Bm and Bkt with Pltfrm Tilt Rev Mt Asplundh HR S Stick Cntrls Rev Mt Btwn Bm and Bskt w Reg Tool Press Flow for Tilting Platform Slope Indicators with Outriggers English Shipping Skid VO255RV SS Config Placeholder Upper Boom VO260REV 01 02 Turret Assembly Special Color Urethane DUPONT L2958 TANGIER ORANGE EMI Safety Manual Manual of Responsibility MRA92 2 2009 Collector Ring Assembly 1 Pass VO 265 270E Operators Manual VO265 270E Custom Service Manual Longitudinal Elev Assy Asplundh 39 Fiber
84. E WEIGHT CAREFULLY AND APPLY THE LOAD SLOWLY During a stability test either on a level surface or on a 5 slope extend the outriggers as far as practical to adequately support the aerial lift The aerial lift must be tested with the booms in two positions to verify the position most likely to cause overturning The first and most likely least stable position is with the lower boom fully raised and the upper boom horizontal while on the 5 slope With the booms in this position rotated either to the front or rear suspend the specified weight 1 1 3 times the rated capacity from the aerial lift and slowly rotate the lift to the down hill side of the vehicle Add ballast to the chassis frame if required to achieve VERSALIFT VO 265E 270E stability The placement of any ballast will affect the stability as well as the final weight distribution and must be evaluated in these respects Once the aerial lift has been stabilized in this configuration position the lower boom horizontal and the upper boom unfolded to a horizontal position and verify the unit is stable in this position on the 5 slope Add ballast if required to provide stability Verify the aerial lift is stable on a level surface in both boom positions described above while applying the appropriate load 1 1 2 times the rated capacity Having met the stability requirements the data plate provided must be completed with the empty curb weight of the mounted configuratio
85. ETY VERSALIFT SAFETY 101 1 SAFETY SAFETY VERSALIFT SAFETY SAFETY Throughout this manual there are danger and caution notes to warn of safety hazards while installing maintaining or servicing the Versalift Any personnel performing these procedures should be aware of these concerns and responsibilities One hazard associated with installing or servicing this machine is lifting heavy objects This is true whether the lifting is being done manually or mechanically The weight length and other characteristics of the booms pedestal turret and outriggers make it imperative that care be taken to balance and support them adequately when they are lifted Care must be taken to balance these items and to keep personnel clear when lifting Never clean oil or adjust a machine while it is in motion Special care must be used while the guards or protective covers are removed The moving parts of the lift will cause crushing injuries if precautions are nottaken The guards and protective covers must be replaced as soon as the service work is complete Hydraulic oil is flammable so contact between hydraulic oil and sources of high heat or open flames must be avoided Contact with hot hydraulic oil may cause serious burns which require immediate medical attention Failure to relieve pressure before disconnecting of the hydraulic hoses or fittings may result in a high pressure hydraulic oil spray This spray or mist can
86. Figure 4 Rotate the aerial lift to allow a grease application around the entire gear This can be done while lubricating the rotation bearing as explained in Item A WARNING CLEAR OF THE GEARS WHILE ROTATING THE AERIAL LIFT AND ALWAYS REINSTALL THE COVERS AFTER COMPLETING THE LUBRICATION ANYTHING CAUGHT BETWEEN THE GEARS WILL BE CRUSHED ROTATION BEARING p GREASE FITTING A GREASE THE PINION AND THE ROTATION BEARING GEAR TEETH Lubrication Points Figure 4 C Purge any moisture accumulation from air lines Disconnect both ends of air line and force dry air through them until no moisture is discharged If unused air lines are present purge them as well 6 MONTH OR 500 PTO HOURS MAINTENANCE AND INSPECTION 1 INSPECTION 103 7 2 a gt A B 2 A B 00 LLI 2 a gt LLI VERSALIFT VO 265E 270E Inspect hydraulic oil for contamination If the hydraulic oil is cloudy or dirty drain and replace it Refer to Hydraulic Oil Recommendation information in this section to determine which type of hydraulic oil to use Inspect slope indicators for true adjustments MAINTENANCE Check the hydraulic system return line filter by reading the indicator gage on the side of the pedestal If the gage read
87. H5 19 1357 E E Dn 37114 s LAY l N 118114567 1804 i SOHH 09734 97 g 2 1708 5 1 amp SOHH 51 q N 43 J J 1 H d dYN N 4 b L T ce 5 ilis zie a L 18 SOHH 57 8 TAZ B in 3 2 K 097 6 m P N b 3177 6 x m IW 3 LIL W331ld HLM 138 zi o ti Sd Wa NMLA gt 15 6 dns dee EOL u 1 VERSALIFT d silise A 835 E 1 4273 553 140 1714 1 gos LOAld MSHSYMLY TA 2 1 g e 3199 370 LOAld CN i N H3HSYM O33N30HvH Xr 14 TOY 2 X 7 1 300 2 Se dd5
88. Hardened Washer 1 2 2 00 RO 1330 2 50000 3 1 8 Std Galv Steel Nipples 2 00 N RO 1330 2 50004 3 Jic Swivel 90 Elbow 2 00 Z RO 1330 2 50004 3 Jic Swivel 90 Elbow 4 00 RO 1330 2 50009 20 Male SAE O Ring to Male JIC Adapter 8 00 RO 1330 2 50009 3 Male SAE O Ring to Male JIC Adapter 2 00 RO 1330 2 50011 25 SAE O Ring to Male Jic 90 Deg Adjustable Elbow 8 00 RO 1330 2 50011 4 SAE O Ring to Male Jic 90 Deg Adjustable Elbow 3 00 RO 1330 2 50012 1 High Pressure 90 Elbow Pipe 2 00 RO 1330 2 50046 2 Male JIC to Male O Ring Long Adapter 3 00 o RO 1330 2 50048 2 JIC Tee w Swivel Nut on Run 4 00 lt RO 1330 2 50048 2 JIC Tee w Swivel Nut on Run 2 00 RO 1330 2 50081 1 SAE O Ring Plug 4 00 RO 1330 2 50113 1 Steel Coupling 2 00 RO 1330 2 56000 3 Hydraulic Motor 1 00 RO 1330 2 72020 2 Rotation Bearing 1 00 RO 1330 2 73020 2 Gearbox Assembly Nodular Iron 1 00 Lot No 2396 100038543 RO 1330 2 80000 1 Knob 1 00 RO 1330 2 80008 10 Greasfitting Lincoln 5200 2 00 RO 1330 2 8181 1 Eccentric Ring Zinc Plated 1 00 SK 1330 4 35863 1 Skid Weldment 1 00 SK 1330 4 35872 DWG Shipping Skid Installation 1 00 SK 1330 4 40007 10 5 8 NC Hex Head Cap Screws 4 00 SK 1330 4 42005 7 NC Hex Locknut 5 8 4 00 SK 1330 4 44013 1 Hardened Washer 5 8 8 00 VK 1400 21 20620 DWG Outrigger Cntrl Valve Kit with Relief 1 00 VK 1400 21 54022 15 Control Valve 1 00 VERSALIFT AS BUILT OPTIONS amp PARTS INDEX VERSALIFT PAGE INTENTIONALLY LEFT BLANK
89. IC THROTTLE CONTROL OPTIONAL Wire the automatic throttle control as drawn on the schematic in this section EMERGENCY HYDRAULIC POWER OPTIONAL For reverse mount units position the emergency power unit in the pedestal and drill four 7 16 in 11 mm mounting holes Bolt the unit in place The rear mount pedestal has mounting holes located on the outrigger cover Connect the hydraulic lines as drawn on the hydraulic schematic in this section The check valve with emergency power must be installed as shown to prevent leakage back through the emergency pump Wire the motor as illustrated on the electrical schematic in Parts amp Assemblies Section Remove the collector ring assembly cover Push the 14 gauge orange white wire up through the grommet in the rotary joint strap Keep feeding the wire through the grommet until it comes out of the collector ring assembly at the top Using the wire nut provided connect the wire to the number two wire in the center of the collector ring A CAUTION FAILURE TO PRIME THE PUMP BEFORE INITIAL OPERATION MAY CAUSE PUMP DAMAGE 104 7 If the emergency power motor doesn t work make certain the truck ignition switch is on and the pressure switch is adjusted properly If the motor still does not operate it may be insulated from the mounting by paint The motor must be grounded directly to the truck body or frame Mount the motor cover on reverse mount units AUXILIARY OUTRIGGER INSTALLAT
90. ION Auxiliary outriggers may be mounted between the cab and body or in the front of the body A body 6 in 152 mm shorter than normal An 8 in 203 mm gap between the cab and body is required Check the weight distribution especially the load on the front axle before selecting the outrigger positions Attach the outriggers to the frame as shown on the Auxiliary Outrigger Installation illustration in Parts amp Assemblies Section Mount the outrigger control valves They may be mounted anywhere clearance will allow However ANSI A92 2 requires that the outrigger controls are located where the operator can watch the outriggers move PREDELIVERY TESTING AND INSPECTION The American National Standards Institute Standard A92 2 entitled American National Standard for Vehicle Mounted Elevating and Rotating Aerial Devices requires that each aerial device be tested to ensure compliance with the prescribed requirements Such predelivery testing and inspection are the responsibility of the final installer All paragraphs identified by number are part of ANSI 92 2 The installer of an aerial device shall before the mobile unit is placed in operation perform stability tests in accordance with requirements of 4 5 1 and 4 5 2 the operational and visual tests in accordance with requirements of 6 6 1 and 6 6 2 and the appropriate electrical tests required in 5 4 3 of this standard MECHANICAL TESTS AND INSPECTION
91. JIC Tee 2 00 VERSALIFT AS BUILT OPTIONS amp PARTS INDEX Option SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SC 1330 37 SD 1200 13 SD 1200 13 SD 1200 13 SD 1200 22 SD 1200 22 SK 34 SK 34 SK 34 SK 34 SK 34 SK 34 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 TT 1330 1 UB 1330 2 UB 1330 2 UB 1330 2 UB 1330 2 UB 1330 2 VERSALIFT Part 50081 4 50081 4 50101 8 50113 4 50113 4 50130 4 50163 4 50189 1 50189 3 50189 3 54022 19 54027 6 54230 2 54325 1 54327 1 55683 1 58082 1 72028 2 72030 2 72038 1 72046 1 7442 5 88000 3 88002 1 89061 1 33656 3 33657 2 33658 DWG 34174 1 35890 DWG 25728 1 40007 8 40054 9 42005 7 44013 1 8273 24 10226 2 14024 1 20570 DWG 33788 1 40000 23 40004 5 40007 5 44013 1 44013 6 5531 2 8076 10 8076 8 13517 1 22142 1 22209 1 29532 1 29534 1 As Built Material List Description SAE O Ring Plug SAE O Ring Plug SAE O Ring to Male JIC 90 Adjustable Elbow Steel Coupling Steel Coupling Male NPT 90 Deg Union Tee JIC with O Ring on Run Vacuum Breaker Vacuum Breaker Vacuum Breaker Control Valve Single Selector Valve Tool Val
92. L WALI 4343 3334 43341 43440 4334 3344 83441 IV8IS3I v8lS3l SONVELSAL 1791531 338 INOOS8 H3ddf 125 4 VERSALIFT TURRET SECTION 126 TURRET ASSEMBLY OPTION TT 1330 1 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 126 1 191431711 451 335 Y13317 ATEWASS B 3uu Y dli WALL ALG v 13323 V 13110 130 13441 ey 3 3 H SOHS4 91 3 YAHSYM Q3N3O0Jd H 4 SOHH 91 1 YIJHSYM Q3N3QJvH c H V N AALI 1936 3 144 ANY LL ONL 41 ONY SW3LI 300 0 1 11
93. L DIMSENSIONS ARE IN INCHES WITH METRIC EQUIVALENT 1 METERS AAS MATERIAL EST WT MANUAL FINISH SHEET DWG NO 1 OF 1 gt FE DESCRIPTION cHKD 4 FIRST RELEASE LBR DJH DIM B INSTALLATION 3 8 2 17M 72 7 8 1 85M 4 7 1 7 NS TOP OF TRUCK 40 1 02M FRAME b Y Y 37 1 4 0 95M O265SEREV SHOWN FOR REFERENCE ONLY NOTES DWN BY DATE TITLE 1 ALL DIMSENSIONS ARE IN INCHES WITH METRIC I LEF E 270ERE EQUIVALENTS IN METERS 5 LONGITUDINAL MATERIAL EST WT INSTALL OUTLINE T FINISH SHEET DWG FERE OF 1 VERSALIFT VO 265E 270E DIM A HIGH STO LO FEV ERCN NO DESCI RIPTION BY appr DATE FIRST RELEASE LBR DJH
94. Lube Control Handles B Lube Leveling Chain TWO YEARS OR 3000 PTO HRS 1 MAINTENANCE A Rotation Bearing Inspection and Measurement 1 Initially measure turret tilt as a baseline Check rotation bearing every 2 years until it measures 0 050 increased wear from initial measurement After reaching 0 05 increased wear measure every 6 months Refer to the Maintenance and Inspection section for proper procedures 5 m TC a TT gt VERSALIFT VO 265E 270E 103 18 VERSALIFT VO 265E 270E ADJUSTMENTS CARTRIDGE HOLDING VALVES Cartridge type holding valves are integralto the boom cylinders and elevator cylinders Holding valves provide two important safety features The holding valves provide smooth boom operation and in the event of hydraulic line failure the holding valves prevent the booms from dropping These holding valves are factory set and no adjustments are required To determine if a holding valve is functioning properly the following procedure mustbe followed To check the rod end holding valve for the upper boom cylinder raise the upper boom a few inches with the lower boom stowed With the hydraulic pump off and aload in the platform slowly operate the upper boom fold function The upper boom should not move To check the rod end holding valve for the lower boom cylinder fully extend the lower boom cylinder andthen retract it a few inches With th
95. MAC p LB 12224 3901 i6 I ALO ON Ldvd NOlLdlJ2S30 HS N Z SH1 14 S 0 3nouoi amp TT JAIL 1 1 3 N 3d39IA33S D N ul x 4 2 269 3 8 lt 5 TT IT G Dg 6 T 5 H li 11 44 7 7 7 A al RA Ar iw maur AO AVENISSW SON LAS TOL TS VERSALIFT 127 6 HOSE KIT SECTION 128 ELEVATOR HOSE KIT OPTION HK 1330 18 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 128 1 PAGE INTENTIONALLY LEFT BLANK HOSE KIT VERSALIFT 128 2 414 3SOH 5 455 UNV SLYVd ESTE i 3046 346920 3SOH HOLVv idl3 5 34 e co N T VERSALIFT 10
96. N AT 6 WILD 1323 31770 SIHL 47 LN3NOTAN 33701 SNF13A31 25855 Ya WALI LISOd 5285 H L Wall 34501 53191 3 Lv LN3IA 8 8 1331 1011 Ep e WAHL 3 NIHO 3111001 3780 a 8 8 8 Od Lh HAAJ 81140 1 2 Z Z 1311 J3 2010v34Hl 1447 z 2 Z 0738 wolina 97 2 CU z z z 3 4 13 333 Ov 2 Y 55 d3H JINA d 2 c SOUS N 9173 37 SNIT3 31 JHL 1338301 IHL Ly 13 2 WHOodlvl d JHL Lsnrdy I 5 1 L 55 TY EE E 1 NHL 39011 1221430 1 TINOHS 5008 JHL 27 TEN 5408 9NILO31430 2 3H3HL TUNNA A WIL 31 2 1 l MLSNI LNINLS 6 6 5 fe P Y 1 o 2 2 i d T z 2 N HSv i ERES T Se _ 1384 5 6 1 87 l xx B 2 vlad 33 781136 NAIT I 102ZZ 3351 3 3301 19 37 4 Wa x WHOALY1d 13 dv 1 l 1 0 an ASSY 9v gt 1 Hv i 2 eem MS 3 Ww N 1 VLA 5 OND YUSYA SIMON EE 448 9 Ls LEM 2 1 Oc SyND 30 ale 31 2 x TO Wada Y34097
97. N BM EREAR L KIT UPPER CNTRLS S STK BTWN EM z AND BKT WITH PLATFORM TILT _ DECAL KIT UPPER CNTR TK BTN 726 Fcp d cu ABO AND BIKT 58 1 HR DECAL S STK CNTRL LH 25 HR DECAL KIT UPPER CNTRLS 1 Pie DECAL S STK CNTRL RH BM AND V0255 2 REF REF REF REF REF REF REF REF M Y POWER DECAL KIT UPPER CNTR EE REE f RER 1 B 8 BM AND BKT REF REF REF REF REF FEF FEF eer L ENGINE DECAL KIT UPPER REF REF REF REF REF REF FEF REF THROTTLE 9 152 BM AND BKT V E se Ime pfe ere DANGER FLATFFOM TILT TOOL SELECT 1 1 1 1 5 CONDUCTIVE HOSES 11111111 1 1 PRESSURE 1 1 1 1 TE EMERG ERENT ELEVATOR gt ee E em UA 5 STK CNTRL LH e fs fie Treat ISTK CNTRL FH 111111111 1 1 1 11 1 KIT UPPER CNTRLS QTY QTY QTY QTY QTY QTY QTY ITEM PART NO DESCRIPTION LIST OF MATERIAL 822 a oo company LER DECAL KIT UP CHTELS ut ACO TEXAS BM AND BKT SEE LIST OF MATERIAL i 1 2 5 PAC ETE URNG y 4 DECAL HT CURL 11 aco TEXAS AND BKT
98. O VEHICLE NO Fill in date and initial boxes when each check is made All inspections adjustments repairs and lubrication must be made according to the Service and Installation Manual Additional copies of this form can be obtained from Time Manufacturing Company Refer to preceding pages for instructions PERFORM DAILY CHECKS LISTED IN OPERATOR S MANUAL EVERY DAY PRIOR TO PLACING UNIT IN SERVICE DATE 1 MANTENANCE A Perform the Daily Visual Maintenance and Inspection Checks refer to Operators Manual U B Check Rotation Bearing Deflection new bearing initial tilt measurement 30 DAYS OR 85 PTO HRS AFTER IN SERVICE DATE ONE TIME SERVICE DATE 1 MAINTENANCE A Replace Return Line Filter 3 MONTHS OR 250 PTO HRS AFTER IN SERVICE DATE ONE TIME SERVICE DATE 1 MANTENANCE A Re Torque AllLoad Supporting Bolts Rotation Bearing Bolts Platform Rotator Bolts Pedestal Subframe Mounting Bolts B Visually Inspect All Critical Fasteners EVERY 3 MONTHS OR 250 PTO HRS 1 GENERAL INSPECTION A Remove Trash Debris Inspect Controls Damage Wear C Check For Interference Inspect Hoses Damage Wear Inspect Decals 2 a gt 5 E Wires Electrical Damage Wear G inspect Boom Rests Tie Down Strap UCTURAL INSPECTION Inspect Critical Fasteners Insp
99. OM LINK WELDMENTS AND UPPER BOOM CYLINDER MUST BE SUPPORTED BEFORE REMOVAL AND INSTALLATION OF LINK PINS KEEP HANDS AND FINGERS OUT OF PINCH POINTS 13 Remove the snap ring from the lower boom access hole and slide the boom out 14 Remove the connector link on the lower side of the lower boom leveling system and remove the chain from the knuckle sprocket 15 Remove the entire leveling system through the access hole 16 Support the platform end of the upper boom and slide the upper boom off the lower boom Remove the knuckle leveling sprockets from the knuckle 17 Lower the upper boom to the ground 18 Remove the platform shaft and the sprocket after driving the two spring pins out of the shaft INSTALL THE UPPER BOOM THE FOLLOWING STEPS MUST BE FOLLOWED 1 Install the platform shaft and the sprocket in the new boom Orient the sprocket on the platform shaft as it was previously 2 Position the upper boom on the lower boom and start the knuckle leveling sprockets into the bearings oriented as shown in the Leveling System Assembly drawing in Parts amp Assemblies Section AT THE KNUCKLE 3 Align the upper boom pivot bearings and slide the upper boom onto the lower boom 4 Install the lower boom leveling chain over the sprocket and install the connector link 5 Pullthe upper boom leveling system into the boom with the tensioner to the bottom of the boom and install the chain over the sprocket
100. ON LIM 1725 AHL NI 33v SWALI 3S3Hl el 2 141 ONT 1 1 1 ANH 1 1193557 Fan ALO ON MOlLdld2S39 1579 WAL SLYVd 321 435 2 e n N N N xr XE at Nel Sh SU ALT SCR REA gt XA lt lt x 2 gt a 7 y 70 c NOILVLOH 5 VERSALIFT Lot No 2396 100038543 SS 4 P Z 6 SK INI SI MESE PW AY Z p S Vy 5 5 EA A B i 5 455 UNV SLYVd VERSALIFT 132 8 VALVE KITS SECTION 133 ONE OUTRIGGER VALVE W RELIEF amp SWITCH OPTION VK 1400 21 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers l m 0 lt a 2 lt
101. OY 0703 WE 334 35 dj HOLVA313 0163 33330 43401 MOLVA3d13 104 35 8 SM 02 244 3 Sold dA1 34 NOILVLOH 5 VERSALIFT 53118 355 UNV SLYVd su 0000 11317474356 LON LNA LIN 1735 3HL NI 337 SILI 3S3HL iw 1 453 C Y N e 5 3uu 3170 S J 2 1 3 E E a ALO WALI SLYVd 3 35 LL Jl aeri 2222 3 34 to VERSALIFT RETE 0000 O fa HIANNN 1474 YOANI SNL 3 3 8337 21 3uu 31 8 35 ddsvHO4fd L
102. SALIFT VO 265E 270E 100 2 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 any time without any obligation to incorporate new features into products previously sold To better understand this manual it is important that the associated personnel be thoroughly familiar with the aerial lift The following illustration identifies the major components of the aerial lift These terms are used throughout the manual REV EREN NO DESCRIPTION BY APPR FIRST RELEASE LBR DJH SRS 1 LOWER BOOM INSERT ASSEMBLY A A TO m O UPPER CONTROLS 4 Tm 00 CYLIND T X NY TURRET e iw N S 7 ES N LOWER BOOM CYLINDER PLATFORM SD ROTATION GEARBO ELEVATOR P AND MOTOR B 1 i CALE 5 DWN BY TITLE LBR 0265 270E IZE TEXAS MAJOR MATERIAL EST WT MANUAL COI VENTS FINISH VERSALIFT VO 265E 270E 100 3 INTRODUCTION SECTION 101 SAF
103. Service and Installation VERSALIFT Manual Model VO270EREV Aerial Device NA110018 SERIAL NUMBER 39025 02 MANUAL PART NUMBER A PLEASE NOTE THE ANSI A92 2 2009 STANDARD AND THE MANUAL OF RESPONSIBILITIES CONTAINS RECENTLY UPDATED INFORMATION DEALERS OWNERS USERS OPERATORS LESSORS AND LESSEES MUST ADHERE TO THESE UPDATED STANDARDS ATTENTION A DO NOT ATTEMPT TO OPERATE THIS VERSALIFT UNTIL YOU HAVE READ AND UNDERSTOOD ALL INFORMATION IN BOTH OPERATOR S AND SERVICE MANUALS PROVIDED WITH EACH VERSALIFT A THIS MANUAL CONTAINS CONFIDENTIAL INFORMATION AND IS THE SOLE PROPERTY OF TIME MANUFACTURING CO CONTENTS IS NOT TO BE DISCLOSED COPIED OR REPRODUCED IN ANY MANNER WITHOUT THE EXPRESSED WRITTEN PERMISSION OF TIME MANUFACTURING CO 0 TIME Time Manufacturing Co 7601 Imperial Drive Box 20368 Waco Texas 76702 Phone 254 399 2100 Fax 254 751 0775 Time Manufacturing Co reserves the right to improve the design or change specifications at any time without notice 08 10 TIME MANUFACTURING COMPANY 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 Those parts of the Versalift that are manufactured by Time M
104. Switch Boot 1 00 1340 1 3051 2 Switch Guard 100 EP 1340 1 34174 1 Rubber Boot Air Cylinder 1 00 EP 1340 1 34823 DWG Emergency Pwr Installation Insulated 1 00 EP 1340 1 34823 DWG Emergency Pwr Installation Insulated 1 00 EP 1340 1 4383 1 Air Cylinder D 38606 A 1 06NSRS01 5 1 00 o EP 1340 1 50065 1 90 Tubing Connector 1 00 lt EP 1340 1 50105 1 Tubing Connector 1 00 EP 1340 1 55007 1 Motor Pump 12 V DG 1 00 EP 1340 1 60002 3 One Pole Standard Toggle Switch 1 00 EP 1340 1 60015 1 Pressure Switch 1 00 EP 1340 1 61003 11 WHT 14GA Stranded Copper Wire WHITE 1 00 EP 1340 1 61007 1 4 AWG Type THW Battery Cable 600 Oil 20 00 Resistant EP 1340 1 68046 1 Ring Terminal for Cable 4 00 EP 1340 1 68144 2 Fuse or Holder 1 00 EP 1340 1 68144 3 Fuse or Holder 1 00 EP 1340 1 68176 1 Terminal Insulator 1 00 EP 1340 1 80000 3 Knob 1 00 HK 1330 17 10286 24 1 4 Hose Assy w 3 8 Swvl Ends 2 00 HK 1330 17 10286 25 1 4 Hose Assy w 3 8 Swvl Ends 2 00 HK 1330 17 10286 7 1 4 Hose Assy with 3 8 Swivel Ends 2 00 HK 1330 17 33879 DWG Boom Hose Kit VO265E 270E 1 00 HK 1330 17 3864 177 3 8 Hose Assembly Non Cond 2 00 HK 1330 17 3864 18 3 8 Hose Assembly Non Cond 2 00 HK 1330 17 3864 183 3 8 Hose Assembly Non Cond 4 00 HK 1330 17 4532 107 1 2 HYD HOSE ASSY NON COND 2 00 HK 1330 17 4532 119 1 2 Hydraulic Hose Assembly Non Cond 1 00 HK 1330 17 50054 3 Bulkhead JIC Union 2 00 HK 1330 17 50056 3 Bulkhead Nut 2 00 HK 1330 17 50075 3 Branch Tee Fem
105. Tapped Material Steel Torque ft lb N m 16 Grade 5 HHCS Loctite 262 Steel 16 SHCS amp SHFH Loctite 262 Aluminum 16 Grade 8 HHCS Loctite 262 Steel 13 SHCS Loctite 262 Steel 11 SHCS 30W Motor Oil Rotation Bearing 11 Grade 8 HHCS 30W Motor Oil Rotation Bearing 10 Grade 5 Threaded Rod Loctite 262 Grade B Nut 10 Grade 8 5 30W Motor Oil Rotation Bearing 315 428 10 Grade 8 HHCS NOTES 1 Lubricate bolt threads liberally with 30W motor oil unless fastener application is to be used on tapped material Then use Loctite 262 on these fasteners with exception of rotation bearing 2 Since the flat washers are stamped one side will have a rought and sharp edge the other is smooth and radiused ALWAYS place the Loctite 262 A572 50 Steel rounded side of the flat washer towards the head of the bolt to protect the fillet 3 Apply torque to nut unless bolt is used in a tapped hole 4 All torque values are running torques for initial and replacement installation only the nut bolt head must turn Use of an impact wrench is permissible only for run up not for tightening During confirmation of previously torqued fasteners the nut bolt head should not turn if proper torque is maintained 5 A minimum of two threads must protrude beyond the nut after tightening 6 The marks shown on this chart are for our cur
106. UFACTURING SEAL TO PR ABBREVIATION NG 121018 HHCS MATERIEL H H HARDENED 6 No PTLN PREVAILING TORQUE LOCKNUT PEPRODU UT 5550 SNR e Mit PERMISSION OF TIME MANUFACTURING 1 OF 1 G DESCRIPTION APPR DATE FIRST RELEASE LBR DJH 2 TC a gt fr SEE SHEET 2 FOR ELEVATOR ELDS ELDED JOINTS TO BE INSPECTED ARE INDIC THE JOINTS MAY INCLUDE WELD N BOTH INSIDE AND OUTSIDE AS APPLICABLE 2 THERE ARE ADDITIONAL CRITICAL WELD N MOUNTING HARDWARE AND d 3 ALL WELDED PIN RETAINER ARE CRITICAL WELD ND DEFFECTIVE SHO ELDS MUST BE TITLE MANUFACTURING NEVER SURFACE FINISH OJECTION OF VIEWS NIIS ONSI ALL DIMENSIONS ARE IN INCHES MATERIAL NSULT FACTORY FOR MATERIAL THIS PRINT CONTAINS C SPECIFICATION PROPER WELDING SPECIFICATIONS NF _ 10 FINISH SHEET DWG N VERSALIFT VO 265E 270E 103 12 FE
107. V SLYVd ON 41338 13 31 vA JO 1517 335 S IOJLNO2 4 153 i HAMO Em AAV 80 7 8 381 JULU alvd NMA IWISALYN 40 1592539 WALI AIO 35001 S S S3IVOIONI 3 STYLNO SM LIM TV V ALON 10045 S d QN38 51 7 91 33 g 3 O1 3 ver REM 4 13M95v48 SNI IOdLNOO E If 1 3 N M d f d L 5 N N J L P Y qv 33 o VERSALIFT LOWER CONTROL VALVES WITH WINCHCONTROL PARTNO 54135 2 Item Part No Description Qty 54135 2 o 1 X989 106 5 Spool Body 1 ol 2 X989 86 Spool Meter out 3 8 X989 51 Spool Selector 1 4 X989 15 O Ring 10 O 5 X989 19 O Ring 1 6 989 21 Replacing Plug 1 7 X989 71 Lever 5 8 X989 32 Screw 10 9 989 73 VR5 Kit 1 10 X989 17 Plug 2 12 X989 42 MD Kit 4 13 X989 3 End Cap 5 14 X989 43 Screw 10 15 X989 69 Ring 1 16 X989 75 Kit 1 17 50190 1 Open Center Plug 1 54135 2 Open Center System Valve VERSALIFT 11
108. addn S q 230 ISSY 43300 5 ze 4 30 1517 n l 1 1 NOU 152539 ON 1474 WALI ALO ALO ALD ALD ALO ALD l 8 v gt 8 wadan z zezzc 8 m Saf gol eJ 8 3344 e zezze 3 aul g 81531 Addn 43 3 33 EE 12345 83 02 n sal Ee WO813 HAO SQNvB8lIS3l 43341 s 3505 11904 07334 21 02 81 02 al Z 5 1 815 31 4343 31 107 931 f 6 2 2 2 Addn 2 3 XAH 3 G 2000 gt 2 1 t n W 2 2 2 N 5 1 HSv GQ kp 5 4 6 d 0739 Tf 5 tf wf 5 8 i 3 5 Y m o o o to 45 m mod LA a H Bo b j 1 4 N CREE QC il X N J areal T4 I Es T Bede ub pomme i pS 30629 9 B r M 33SOH 341 5 5 1 VERSALIFT 17143171 VAA
109. ale Swivel JIC 2 00 HK 1330 17 50077 3 JIC Tee 2 00 HK 1330 17 55679 4 5 16 NC Hose Assembly w 3 8 Ends 2 00 HK 1330 17 6580 98 5 16 Hose Assy w 3 8 Ends Non Cond 2 00 HK 1330 17 89088 12 Hose Protective Cover BPP 2 00 HK 1330 17 89088 4 Hose Protective Cover 1 00 HK 1330 17 89088 6 Hose Protective Cover 1 00 HK 1330 17 89128 11 Hose Protective Cover 1 00 HK 1330 17 89164 6 Hose Protective Cover 1 00 HK 1330 17 89164 7 Hose Protective Cover 1 00 HYD 1330 11 28100 1 Valve Mount Plate 1 00 VERSALIFT AS BUILT OPTIONS amp PARTS INDEX Option HYD 1330 11 HYD 1330 11 HYD 1330 11 HYD 1330 11 HYD 1330 11 HYD 1330 5 HYD 1330 5 HYD 1330 5 HYD 1330 6 HYD 1330 6 HYD 1330 6 HYD 1330 6 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 KN 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LB 1330 1 LO 1330 2 LO 1330 2 LO 1330 2 LO 1330 2 VERSALIFT Part 28102 1 28104 1 35877 DWG 40047 5 89003 1 20574 DWG 22210 1 Lot No 1134 100029377 22211 2 Lot No 1134 100039258 10424 10 33999 DWG 54135 2 7442 6 10226 14 10226 15 20576 DWG 22107 1 22107 2 22135 1 22135 2 22146 1 22207 1 40004 5 40006 21 42005 5 44013 3 44013 6 48014 87 4
110. alve A CAUTION REMOVE TOOLS SLINGS HARDWARE AND ANY OTHER LOOSE OBJECTS BEFORE OPERATING THE MACHINE FALLING TOOLS MAY CAUSE SERIOUS INJURY TO PERSONNEL A CAUTION OPERATE THE LIFT FROM THE LOWER CONTROLS FOR SEVERAL CYCLES TO PURGE THE AIR FROM THE HYDRAULIC SYSTEM From the lower controls operate the outriggers and all lift functions through several cycles to purge the air from the hydraulic system Check the hydraulic oil level in the reservoir and refill if necessary LOWER BOOM SUPPORT Rotate the Versalift until the bottom boom is in line with the centerline of the chassis and body See the illustration entitled Lower Boom Rest Installation in Parts amp Assemblies section for further information UPPER BOOM SUPPORT Position the upper boom so that the platform has adequate clearance over the cab if reverse mounted Approximately 8 in 203 mm is required for a cab guard For further information regarding the installation of the upper boom support see the illustrations in Parts amp Assemblies Section A CAUTION TO AVOID STRESS OR DAMAGE TO THE UNIT THE WEIGHT OF A STORED BOOM SHOULD BE SUPPORTED BY THE BOOM SUPPORT AND NOT BY THE HYDRAULIC CYLINDER ELECTRICAL BOX MOUNTING The electrical box may be mounted anywhere inside the cab Do not mount the electrical box in the engine compartment because it is not waterproof Holes may be drilled in the box for mounting purposes Mount the dash accessori
111. anel 12 Secure the hose bundle to the bottom of the control panel OPERATIONAL TEST AND INSPECTION 1 Operate the lift several cycles from the lower controls Check the hose bundle for proper routing during operation Check the fittings for hydraulic oil leaks 2 Apply 1 1 2 times the rated capacity on the platform to confirm structural integrity of the new upper boom 103 28 Check the platform leveling for proper operation If required level the platform making adjustments at the turret Attach all of the covers that were removed Perform dielectric test per ANSI A92 2 paragraph 8 2 4 item 16 SECTION 104 VO 265E 270E INSTALLATION VERSALIFT VO 265E 270E 104 1 INSTALLATION INSTALLATION VERSALIFT VO 265E 270E INSTALLATION INTRODUCTION Versalifts are designed to provide a safe and efficient method of placing workers at elevated work stations however the Versalift must be installed tested inspected and maintained according to the manufacturer s instructions Care and attention to detail will result in a properly installed unit which functions as it was designed NOTE On some Assembly and Installation drawings included in this section some components are marked as shipped loose items These items will require installation during the Versalift installation procedure Refer to any componentidentification instructions in the ship loose box Also refer to Parts a
112. anufacturing Company are warranted for one full year from date of purchase Structural components will carry a lifetime warranty for defects in material and workmanship which existed at the time of initial delivery wear components are not covered by this statement This warranty is issued only to the original purchaser and promises that Time Manufacturing Company manufactured products are free from defects in material and factory workmanship when properly installed serviced and operated under normal conditions according to the manufacturer s instructions Manufacturer s obligation under this warranty is limited to correcting without charge at its factory any part or parts thereof which shall be returned to its factory or one of its Authorized Service Stations transportation charges prepaid within one year after being put into service by the original user and which upon examination shall disclose to the Manufacturer s satisfaction to have been originally defective Correction of such defects by repair to or supplying of replacements for defective parts shall constitute fulfillment of all obligations to original user This warranty shall not apply to any of the Manufacturer s products which must be replaced because of normal wear which have been subject to misuses negligence or accident or which shall have been repaired or altered outside of the Manufacturer s factory unless authorized by the Manufacturer in writing products which have not
113. are described below Outrigger Limit Switch This switch is mounted near the upper cylinder pin of each outrigger When the outrigger contacts the ground the upper pin moves upward actuating the switch Toggle Switch This switch is located near the outrigger control valves It is used to select between lift controls and outrigger controls provided the interlock requirements are met Lower Boom Limit Switch This switch is mounted at the lower boom rest to indicate the position of the lower boom The switch is open when the boom is stored Solenoid Valve This valve directs the hydraulic flow from the pump to either the lift controls or the outrigger controls When the solenoid is energized hydraulic flow is directed to the lift controls Override Switch Not Included If required this switch may be installed as shown in the schematic It allows the interlock to be temporarily defeated VERSALIFT VO 265E 270E Continuous actuation is required to accomplish this condition As an example a reverse mount unit with a dump body requires that the booms be raised to dump the body OPERATION The outrigger boom interlock system operates by energizing or de energizing the solenoid valve There are two circuits that can energize the solenoid One circuit is through the lower boom limit switch and the other circuit is through the outrigger limit switches and toggle switch With the lower boom stored and the outriggers ret
114. been maintained and operated in accordance with Time Manufacturing Company s operators maintenance manuals and bulletins products which are repaired without using original Time Manufacturing Company parts This limited warranty does not cover transportation fees and or consumables used for the repair Manufacturer shall not be liable for loss damage or expense directly or indirectly from the use of its product or from any cause The above warranty supersedes and is in lieu of all other warranties expressed or implied and of all other liabilities or obligations on part of Manufacturer No person agent or dealer is authorized to give any warranties on behalf of the Manufacturer or to assume for the Manufacturer any other liability in connection with any of its products unless made in writing and signed by an officer of the Manufacturer TABLE OF CONTENTS Section 100 Introduction x ae dre ayau ka Ee Deve aaa Section 101 Safety Section 102 Theory of Operation Mechanical System nea II S Sua sss Hydraulic System iiit uuu suited tae Ee usn de ea eger da Elgctical SVSEOITI Gon cR Section 103 Service Procedures Maintenance and InspectiOli u ct Ferrer n tex tee Prior to Placing Unit Into u
115. dition Figure 3 3 MONTHS OR 250 PTO HOURS MAINTENANCE AND INSPECTION AFTER THE INITIAL ONE TIME SERVICE 1 GENERALINSPECTION A Remove any accumulated trash or debris from inside booms around turret and pedestal and in area of the controls Inspect the unit for physical wear or damage including the following items B Checkcontrol handles and actuators for binding Two way controls valves should return to center position Use spray lubricant to free sticky valves C Check for interference between moving components particularly around the turret and knuckle area Evidence of interference may appear as bent or scratched components Replace or repair any damaged components D Hydraulic hoses should be inspected for separated or frayed jackets especially at the turret knuckle and from the boom tip to the platform If the protective sleeve has been damaged examine the hoses closely in that area Replace the hoses if damaged and replace sleeves that are damaged and do not protect the hoses E Inspect electrical system for damaged components Check for bare electrical wires and remove any trash or debris from around electrical components Repair all damaged wires and secure any loose electrical components or wires F Inspect and replace any identification operational or instructional decals that are lost damaged or illegible G Verify that the upper boom tie down strap and rubber pad are in place and adjust if
116. e double throw latching relay which is mounted in the electrical box 102 6 Pressure Switch And Air Cylinder The pressure switch is mounted on the turret wing and the air cylinder is mounted on the platform control panel A small air line connects the two components together When the air cylinder is operated air in the line is compressed When adequate air pressure is produced the electrical contacts in the pressure switch close and the electrical solenoid on the engine is activated or deactivated depending on the position of the latching relay Toggle Switch The single pole three position maintained toggle switch is mounted on the panel of the lower deck The throttle control relay is energized when the toggle switch is operated in either direction Throttle Actuator The throttle actuator is mounted in the engine compartment It is activated by an electrical signal from the throttle control latching relay Gas and diesel engine models use an electrical solenoid actuator OUTRIGGER BOOM INTERLOCK ELECTRICAL HYDRAULIC THEORY The outrigger boom interlock option is a safety feature designed to prevent the lift from being operated until the outriggers are properly extended The interlock also prevents the outriggers from being retracted before the lift is properly stored Refer to the Outrigger Boom Interlock Installation in Parts amp Assemblies Section The outrigger boom interlock components and their functions
117. e booms torque not to exceed 13 ft lbs 17 6 N m This adjustment is made through the turret end of the lower boom and through the knuckle end of the upper boom If itis necessary to remove links from the leveling system in either the upper or lower boom always remove them from the chains at the knuckle Inspect the fiberglass leveling rods which are epoxy bonded to the rod ends Inspect epoxy bonds for cracks or signs of movement between the bonded components Refer to leveling rod inspection criteria below Fiberglass Rod Damage Leveling rods with minor damage may be left in service without repair if the depth of the damage F boom insert for cracks nicks or evidence of fatigue Damage to fiberglass components not only affects the structural integrity but also degrades the insulating property For additional information refer Care of Fiberglass Booms in this section Inspect the fiberglass to steel epoxy bonded joints located at both ends of the lower boom insert and at the knuckle end of the fiberglass boom Inspect Jib pole for any signs of cracks nicks or evidence of fatigue Damage to the pole will affect the structural integrity Inspect the platform for cracks in the mounting ribs floor and flange around the top Repair any cracks or replace the platform if required The first step in successful platform repair is to analyze the damage and determine the cause Cracks in the gelcoat or outer surface of the platf
118. e grooves The balls allow the rotation of the inner ring and the attachment components relative to the stationary outer ring Motion is controlled by a hydraulic driven gear train Gear teeth on the outside diameter of the outer bearing ring engage a drive gear supported on the turret As the drive gear rotates the turret rotates relative to the outer bearing ring The drive gear is actuated by the hydraulic motor through a self locking worm gear speed reducer Smooth and controlled rotational movements of the turret lower boom upper boom and platform are provided LOWER BOOM The lower boom pivots about a horizontal centerline on the turret A double acting hydraulic cylinder attached to the turret and lower boom actuates the lower boom With the cylinder fully retracted the lower boom is horizontal As the cylinder extends the lower boom rotates to a raised position At full extension the hydraulic cylinder limits the maximum lower boom articulation to 35 past vertical UPPER BOOM The upper boom pivots about a horizontal centerline at the knuckle The linkage at the knuckle provides 270 245 for the VO 260 of 102 2 upper boom articulation relative to the lower boom The linkage consists of an upper link and the pivot link The upper boom unfolds as the upper cylinder is retracted ELEVATOR The elevator assembly consists of a base structure arms knuckle and a pedestal These components are driven by 2 identical d
119. e upper boom horizontal a load in the platform and the hydraulic pump off slowly operate the lower boom raise function The lower boom should not move To check the base end holding valve for the upper boom cylinder unfold the upper boom until the platform is a few inches from the ground with the lower boom still stowed With the hydraulic pump off and a load in the platform slowly engage the upper boom unfold function The upper boom should not move To checkthe base end holding valve for the lower boom cylinder raise the lower boom a few inches and unfold the upper boom until the platform is a few inches off the ground With the hydraulic pump off and a load in the platform slowly engage the lower boom lower function The lower boom should not move To check the base end holding valves for the elevator raise the elevator a few inches out of the stowed position With the hydraulic pump off and a load in the platform slowly operate the elevator lower function The elevator should not move DANGER NEVER REMOVE HOLDING VALVES WITHOUT SUPPORTING THE BOOMS FALLING BOOMS MAY CAUSE DAMAGE TO THE UNIT OR RESULT IN DEATH OR SERIOUS INJURY If any holding valve does not hold the load during the test described the holding valve may be removed from the cylinder Identification of the proper holding valve is as follows The rod end of the upper boom cylinder holding valve is the cartridge nearest the ports or the lower boom The car
120. earing initial tilt measurement The rotation bearing is designed and manufactured with tightly controlled internal clearance to provide smooth rotation at low torque requirement without excessive looseness between the inner and outer rings The bearing clearance will increase slightly during the initial 103 2 run in period but should then remain essentially constant for many years if the bearing raceway starts to wear out the clearance will begin to increase steadily at first and accelerating toward the end of the bearing life This may be noticed as a marked increase in the tilting or rocking of the turret with respect to the pedestal top plate during load reversals Other factors will be present in a bearing that is wearing excessively i e roughness or noise in the rotation bearing Measurement of the turret tilt under load reversal using a magnetic base dial indicator is a good means of determining the bearing condition Perform this initial tilt measurement check when the unit is delivered This will provide a baseline for future bearing tilt measurements Future bearing tilt measurements will be compared to this baseline to determine how much the bearing tilt has increased since the initial new bearing measurement Rotation Bearing Deflection Check 1 With rated load in the platform position the unit on a level suitable working area Apply the parking brakes and chock the wheels engage the PTO and properly set the
121. ect Welds Inspect Structural Components Deformation Corrosion Inspect Leveling System Damage Wear Inspect Fiberglass Boom s Damage Inspect Platform Cracks Damage 3 OPERATIONAL CHECKS A Check PTO Pump Check Control Operation Holding Valves Check Clearances During Operation Check Leveling Operation Check For Hydraulic Oil Leaks G Check For Cylinder Rod Damage 4 MAINTENANCE A Lube Rotation Bearings B Lube Pinion C Purge Air Lines VERSALIFT VO 265E 270E 103 17 MAINTENANCE AND INPECTION CHECKLIST AND RECORD VERSALIFT VO 265E 270E SERIAL NO VEHICLE NO Fill in date and initial boxes when each check is made Allinspections adjustments repairs and lubrication must be made according to the Service and Installation Manual Additional copies of this form can be obtained from Time Manufacturing Company Refer to preceding pages for instructions PERFORM DAILY CHECKS LISTED IN OPERATOR S MANUAL EVERY DAY EVERY 6 MONTHS OR 500 PTO HRS 1 INSPECTION A Check Hydraulic Oil Contamination Water B Check Slope Indicators Adjustments 2 MAINTENANCE A Replace Return Filter B Clean Suction Strainer C Adjust Relief Valve D Adjust Pinion Backlash E Retorque Load Supporting Bolts Visually Inspect Critical Fasteners 3 TESTING A Dielectric Test Per ANSI A92 2 EVERY YEAR OR 1500 PTO HRS 1 MAINTENANCE A
122. ection of the four section control valve With the safety trigger in neutral system oil is available to the hydraulic tools Activating the safety trigger directs oil to the lift functions and prevents flow to the tool 102 7 circuit To vent the tool line for hook up or removal use the tool power valve This two position valve functions as adump valve On Category B and C units 50 ft and taller avacuum prevention system is installed on the upper controls This system prevents a vacuum from forming in any hydraulic lines that crosses the insulated portion of the boom since oil vacuum may result in reduction in dielectric strength z lt oc O LL O gt oc SECTION 103 SERVICE PROCEDURES 2 a 2 gt VERSALIFT VO 265E 270E 103 1 2 a oc a gt VERSALIFT VO 265E 270E SERVICE PROCEDURES MAINTENANCE AND INSPECTION The maintenance and inspection of certain items the responsibility of a competent operator Being alert for evidence of a problem is essential in providing satisfactory service The items deserving daily attention are given in the operator s manual Included are general visual inspection guidelines lubrication instructions hydraulic oil and filter maintenance and field adjustments Any failure or malfunction should be repor
123. ed in ANSI A92 2 6 5 any decal or placard damaged or removed during shipment or installation must be replaced Refer to the Decal Placement illustration in this section for the location and description of each decal In addition to the minimum curb weight placard provided to indicate stability requirements three decals are included for placement on the chassis or body to warn of electrocution hazards One is to be placed on each side and the rear of the completed unit ELECTRICAL TESTS The purpose of dielectric or electrical certification tests is to verify the protective level of insulation fiberglass on an insulated aerial lift A CAUTION THE PLATFORM IS NOT INTENDED TO PROVIDE ANY INSULATION FROM ELECTRICAL SOURCES FOR THE PLATFORM TO BE CONSIDERED INSULATED THE ADDITION OF AN ELECTRICALLY CERTIFIED PLATFORM LINER IS REQUIRED Time Manufacturing Company performs a dielectric test on each insulating Versalift aerial device to the qualification voltage ratings as shown on Table 1 of ANSI A92 2 in accompanying Manual of INSTALLATION Responsibilities The following excerpts from ANSI A92 2 Responsibilities of Dealers and Installers reads as follows 7 5 Installations For insulating aerial devices the installer shall assure conformance to the Qualification test requirements of 5 3 2 by either obtaining certification of the test and performing a periodic test after installation or by performing the Qualificati
124. em is activated OPERATION THEORY OF THE MASTER CONTROL The master control option provides a toggle switch on the truck dash to energize and de energize the start stop system With the master control toggle switch activated and the ignition switch in the on position current flows from the ignition switch through a 20 amp fuse to terminal 2 on the toggle switch Through the toggle switch current flows from terminal 2 to terminal 3 From terminal 3 on the toggle switch current flows to terminal 7 on the terminal block located in the ELECTRICAL BOX ASSEMBLY In addition current flows from terminal 3 on the toggle switch to the dash light The dash light will illuminate as current flows through it to a ground With the master control toggle switch deactivated there is no electrical current flow to the dash light or terminal 7 on the terminal block The truck ignition system will function normally OPTIONS START STOP CONTROL COMPONENTS The electrical schematic will aid in understanding the start stop control electrical system Refer to the specific option schematics The electrical components and their functions are described in detail below Dash Push Button Control This is a spring loaded push button control that can be used by ground personnel to start or stop the truck engine when the master control system is on 102 5 Start Relay The 12 volt single pole start relay is mounted in the electrical box and is normall
125. en timing boom functions to avoid reaching the end of boom travel while at full operating speed 104 9 The operational tests required include verifying that all aerial lift functions controls and safety devices are operable Included as an operational requirement is the speed at which boom functions are accomplished Slow operation is impractical for the user and excessively fast operation can create unsafe conditions It is recommended that the hydraulic oil flow rate and the system operating pressure be measured to guarantee proper boom actuation speeds The correct flow rate is 7 gpm 26 lpm The correct system operating pressure is 2900 psi 205 kg cm This procedure is explained in the service procedures of the Service Manual An alternative means of verifying proper boom actuation speeds is to time one cycle with on operator in the platform To accurately test the boom actuation speeds the hydraulic oil must be first warmed to operating temperatures between 70 F and 90 F 21 C and 32 C Cold hydraulic oil produces slower boom operation and increasing the engine speed will have no effect on the boom speed The engine speed whether controlled by a manual throttle or an optional two speed throttle control should be adjusted to provide speeds within the specific ranges given for each function DECALS Caution and operational decals or placards provided with this Versalift must be in place and clearly legible As specifi
126. es as shown on the Electrical Controls Switch Mounting illustration in Parts amp Assemblies Section Position the dash accessories where there is enough room for the decals 104 6 VERSALIFT VO 265E 270E ENGINE START STOP CONTROL OPTIONAL When mounting the toggle switch the key way should be down so switch movements correspond to decal instructions Follow the wiring schematic in Parts amp Assemblies Section Remove the collector ring assembly cover and push the 14 gauge yellow wire up through the grommet located in the rotary joint strap Keep feeding the wire through the grommet until it comes out of the top of the collector ring assembly Using the wire nut provided connect the wire to the number one wire in the center of the collector ring MANUAL THROTTLE CONTROL OPTIONAL If the engine start stop control has been installed locate this electrical box adjacent to the start stop electrical box Electrical power for the throttle control can be taken from terminal six in the start stop control electrical box Wire according to the wiring schematic in Parts amp Assemblies section Remove the collector ring assembly cover Push the 14 gauge blue wire up through the grommet in the rotary joint strap Keep feeding the wire through the grommet until it comes out of the top of the collector ring assembly Using the wire nut provided connect the wire to the number three wire in the center of the collector ring AUTOMAT
127. et or approach MIL H 5606A VERSALIFT VO 265E 270E 103 21 A list of some suitable hydraulic oils is given below with their respective properties This information will be helpful in the selection of hydraulic oil or equivalent oilfor a particular application Hydraulic Oil Specifications Brand Name Exon Univis N32 Univis Exon UnivisN32 32 Mobil DTE 13M Mobil Multipurpose ATF Dextron Ill 5 a a gt Meets or approaches MIL H 5606A VERSALIFT VO 265E 270E 103 22 VERSALIFT VO 265E 270E CARE OF FIBERGLASS BOOMS BOOM CLEANING RECOMMENDATIONS Fiberglass booms and inserts must be kept clean and in good condition to preserve their dielectric properties and appearance 1 Thefiberglass outer surface of the boom should be cleaned daily with a lint free cloth 2 DO NOT Steam Clean Any Fiberglass or Insulated Components 3 When the boom is dirty raise the boom slightly so it will drain and wash the boom with a mild dish washing detergent using a cloth or sponge Once the boom is washed inside and out wipe the outer boom clean and dry with a lint free cloth and allow the inner boom to air dry completely 4 In extremely difficult cleaning situations pressure washing using a garden hose and nozzle can be usedto clean the fiberglass boom CAUTION If the water pressure is too high the boom hoses and fittings could be damaged 5 Ifthe boo
128. ex Locknut 5 16 7 00 SC 1330 37 42005 3 NC Hex Locknut 3 8 2 00 SC 1330 37 42008 1 Thin NF Hex Nylon Locknut 1 00 SC 1330 37 42014 3 Metric Hex Nut 8mm 1 25mm 1 00 SC 1330 37 42014 3 Metric Hex Nut 8mm 1 25mm 1 00 SC 1330 37 44005 4 Internal Tooth Lockwasher 1 00 SC 1330 37 44013 5 Hardened Washer 5 16 Plated 10 00 SC 1330 37 44013 6 Hardened Washer 3 8 5 00 SC 1330 37 44013 7 Hardened Washer 1 4 1 00 SC 1330 37 45002 31 Clevis Pin 2 00 SC 1330 37 45002 37 Clevis Pin 2 00 SC 1330 37 45003 2 Cotter Pins 4 00 SC 1330 37 45008 31 Roll Pin 1 00 SC 1330 37 50004 3 Jic Swivel 90 Elbow 8 00 SC 1330 37 50004 4 JIC Swivel 90 Deg Elbow 1 00 SC 1330 37 50007 7 Male Pipe to Male Pipe Adapter 1 00 SC 1330 37 50009 3 Male SAE O Ring to Male JIC Adapter 4 00 SC 1330 37 50009 4 Male SAE O Ring to Male JIC Adapter 2 00 SC 1330 37 50011 4 SAE O Ring to Male Jic 90 Deg Adjustable Elbow 5 00 SC 1330 37 50011 4 SAE O Ring to Male Jic 90 Deg Adjustable Elbow 3 00 SC 1330 37 50012 4 High Pressure 90 Elbow Pipe 1 00 SC 1330 37 50036 4 NPT Female Tee with Male NPT on Run 1 00 SC 1330 37 50038 16 Pipe to JIC Nipple 3 00 SC 1330 37 50042 4 NPT Steel Plugs Socket Head 4 00 SC 1330 37 50046 1 Male JIC to Male O Ring Long Adapter 4 00 SC 1330 37 50048 2 JIC Tee w Swivel Nut on Run 8 00 SC 1330 37 50048 3 JIC Tee w Swivel Nut on Run 1 00 SC 1330 37 50048 3 JIC Tee w Swivel Nut on Run 2 00 SC 1330 37 50074 4 Male SAE O Ring to Male JIC 45 deg Elbow 1 00 SC 1330 37 50077 4
129. glass Bucket SHV32 36 SS Elevator Hose Kit Elevator Mounting Hardware VO270EREV Asplundh Outrigger Assy Pivot Foot Less Outer Housing Weld VO265E 270EREV 01 Outrigger Pin Option Continuous Rotation Assembly Shipping Skid Elevator Asplundh VO270EREV One Outrigger Valve with Relief and Switch VO265E 270E Base Bill STD Versalift White Paint PRIMER PAINT Qty 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 2 00 2 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 4 00 3 00 gt lt LLI 00 lt 2 a 5 m lt AS BUILT OPTIONS amp PARTS INDEX Option CA 853 CC 1330 5 CC 1330 5 CC 1330 5 CC 1330 5 CC 1330 5 CC 1330 5 CC 1330 5 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 CFG VO255 270 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 18 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 DE 1330 24 VERSALIFT Part 14015 1 20578 DWG 40002 7 42005 1
130. ground controls in an accessible location in accordance with ANSI A92 2 Connect the hydraulic hoses as shown on the assembly drawings in Parts amp Assemblies Section PTO amp PUMP INSTALLATION The PTO and pump selection will determine the hydraulic pump flow that will be produced and the speed at which the engine must operate for proper aerial lift performance Insufficient hydraulic oil flow will result in unsatisfactory speeds of operation Excessive hydraulic oil flow will reduce the ability to control movement of the aerial lift generate excessive dynamic loads and cause elevated hydraulic system operating temperatures The rated hydraulic oil flow to an aerial lift should never be exceeded The selection of a PTO depends primarily on the transmission make and model Refer to the PTO manufacturer s application for the best results The open center fixed displacement vane pump provided has a straight keyed shaft and an SAE A flange This pump has a volumetric efficiency of 92 percent and pump displacement is 2 02 in 33 cm per revolution To calculate the engine speed required for proper operation use the following formulas Engine Speed 231 INS GAL x Pump Flow GPM x 10 000 RPM Displacement INS REV x Pump Efficiency x 104 5 Use the information given above to find the desired engine RPM If the PTO has a 1 1 ratio and the pump has 92 volumetric efficiency and the standard open center p
131. he initial tilt measurement or a total axial movement exceeding 125 3 17 mm indicates that the bearing may be reaching the end of its useful life Other factors related to the condition of the bearing must be considered Determine if the increase in the turret tilt measurements has been steady which is normal or if it shows a trend of accelerated wear which would indicate bearing replacement may be necessary 2 Evaluating the feel of the unit If there is no trend toward accelerated wear consider the feel of the unit during load reversals Operators may notice an increase in the tilting 103 10 or rocking of the turret with respect to the pedestal top plate during load reversals 3 Checking for rotation bearing noise and roughness Determine whether there is any presence of roughness or noise in the rotation bearing during rotation Severely worn bearings commonly exhibit grinding snapping and popping noises during rotation 4 Inspecting the condition of the purged bearing grease Grease from a well worn poorly maintained or damaged bearing will typically contain fairly large rust or metal particles instead of metal dust specks which might be found in any bearing Fairly large rust or metal particles indicate the bearing has reached an accelerated wear condition and immediate bearing replacement is required Rust is commonly indicated by extremely dirty grease This situation must be corrected to optimize the perfo
132. icipated operating temperatures 6 A flash point that is above anticipated operating temperatures 7 Good demulsibility or water separation characteristics 8 Dielectric properties compatible with current leakage limitations for aerial lifts Insulated aerials only Based on the requirements for a particular aerial lift application one hydraulic oil can generally provide year round service If a wide variation in start up and operating temperatures is expected hydraulic oil with a high viscosity index is recommended Start up at extremely cold temperatures will require oil with a low pour point Therefore make certain the viscosity range requirements are still met when oil with a low pour point is needed 5 gt 6 The oil recommendations below are based on typical operating conditions Certain operating conditions additions or changes to the standard hydraulic system may require different oil grades Time Manufacturing does not guarantee the use of any brand or grade of hydraulic oil Areputable oil supplier should be consulted in any hydraulic oil application Recommended Hydraulic Operating Conditions ISO Viscosity Grade Ambient Temperature Range Fahrenheit Celsius Stalled gt 22 OF to 110 18 to 43 C most applications Severe Cold 15 20 F to 95 F 29 C to 35 Extreme Heat 32 32 F to 120 0 to 49 Oil to me
133. il flows from the main hydraulic line through the outrigger control valves Shifting the control valve spool directs oil flow to the lock valve located inside the outrigger tubing Oil enters the lock valve pushes a spring loaded check off its seat flows out of the lock valve and into the outrigger hydraulic cylinder Oil trying to escape from the other side is blocked by a check valve in the return side of the holding valve This check valve keeps the circuit locked until adequate pilot pressure is produced on the pressure side of the lock valve to unseat the check valve The pilot oil pressure moves a pilot piston which pushes the check valve off its seat The return oil then flows out of the lock valve to the control valve allowing the outrigger to move VERSALIFT VO 265E 270E ELECTRICAL SYSTEM The electrical schematics will aid in understanding the electrical system Refer to the specific option schematics Descriptions of the major components in the electrical system are given below MASTER CONTROL COMPONENTS Truck Ignition Switch The current used when operating the start stop control comes from the truck ignition system The key must be in the ignition and turned to the on position before current is available to operate the electrical system Toggle Switch The single pole two position toggle switch is mounted on the truck dash board Red Dash Light The red 12 volt dash light indicates when the master control syst
134. inder on unit Perform the holding valve checks as described in section to determine if a holding valve is functioning properly and to verify there is no internal leakage Re check for any leaks 2 a gt EXPLODED VIEW OF TIMEMANUFACTURING CYLINDER TYPICAL Note To order replacement parts refer to cylinders drawings in Cylinders Option section of this manual CYLINDER TUBE VERSALIFT VO 265E 270E NUT Bea SET SCREW if applicable o 2 LLI O RETAINING EAR RING gt LLI o STATIC O RING PISTON SEAL ASSEMBL 103 26 BACK UP RINGS 30 U CUP SEAL O RING OD WIPER EAR RING Bearing 4 r O RING r WEAR RING Bearing rice D 7 d cr 1 I 1221 YLINDER ROD VERSALIFT VO 265E 270E UPPER BOOM PROCEDURE REPLACEMENT In order to disassemble the upper boom the steps below must be followed in the sequence given and performed atthe indicated locations AT THE PLATFORM 1 Remove the upper cover and boom tip cover 2 Disconnect and identify all hydraulic
135. ion relay supplies current to the start or stop relay depending upon the latching position The latching position is toggled between the start and stop position each time one of the start stop switches is operated In order for the start system to operate the ignition relay must be latched in the start position and one of the start stop switches must be held in the start position With the start relay energized current from the battery flows to the starter solenoid To activate the stop system the ignition relay must be latched in its stop position and one of the start stop switches must be held in the stop position With the stop relay energized the ignition circuit and the start relay control circuit are broken and the engine stops z lt oc O LL O gt oc z 9 lt tc LL O gt tc VERSALIFT VO 265E 270E POWER The electrical schematic will aid in understanding the emergency power electrical system Refer to the specific option schematics The electrical components and their functions are described in detail below Motor The motor is a 12 volt DC motor and is used to operate an auxiliary hydraulic pump in the event that the main pump cannot be used Power to operate the motor is obtained from the truck battery Solenoid The solenoid is mounted on the motor and is used to complete the circuit between the truck batter
136. l systems are used in the operation of this aerial lift They are described in detail below OUTRIGGERS Two outriggers are provided as standard with this aerial lift The outriggers consist of two rectangular tubes one tube inside the other tube The outer tube is attached to the pedestal A double acting hydraulic cylinder is housed within each outrigger This hydraulic cylinder is attached to the larger tube near the top and to the smaller tube near the bottom When the hydraulic cylinder is retracted the inner tube is wholly within the outer tube providing the necessary clearance from the ground and minimal width for road travel As the hydraulic cylinder is extended the inner tube telescopes down and away from the center of the aerial lift chassis Sufficient extension is provided to allow the outriggers to contact the ground and elevate the chassis slightly The outriggers increase vehicle resistance to overturning when the tipping point is moved further from the center of gravity ROTATION The turret lower boom upper boom and the platform of the aerial lift rotate about the vertical centerline of the pedestal supported by a shear ball bearing This bearing consists of two concentric rings The inner ring is attached to the turret and has a groove around the outer diameter The outer ring is attached to the pedestal and has a groove around the inner diameter Spherical rollers or balls are positioned between the two rings in th
137. ly TT 1330 1 Turret Assembly ccrte dee bahay Yaqa 126 2 Section 127 Longitudinal Elevator Assembly E 1330 3 Longitudinal Elevator Assembly edelas esteia gee krene nennen RES ii 127 3 Section 128 Elevator Hose Kit HK 1330 18 Elevator HOSE KIS heim 128 3 Section 129 Elevator Mounting Hardware 1330 10 Elevator Mounting Hardware usin hehehehehe hades 129 2 Section 130 Outrigger Assembly OR 1400 49 Outrigger Assembly Pivot 130 3 Section 131 Outrigger Pin Option OR 1400 9 Outrigger Pin hakuwa 131 2 Section 132 Continuous Rotation Assembly RO 1330 2 Continuous Rotation Assembly 7 rte eer esi E 132 2 Section 133 One Outrigger Valve W Relief amp Switch VK 1400 21 Outrigger Control Valve Kit W Relief 133 2 SECTION 107 o Lu gt lt oc LL o m LLI D m BLUE BOOT FOR AIR CYLINDERS OPTION SD 1200 22 When ordering replacement parts confirm the actual part number with the As Built Material List located in the back of this manual This list is arranged by option code to provide an easy method to locate part numbers PARTS AND ASSEMBLIES VERSALIFT 107 1
138. m has creosote grease or other deposits that cannot be removed as suggested above stronger cleaners may be used However be sure that these cleaners are not either 1 abrasive because they may damage the boom surface or 2 some other type that may leave a conductive residue on the boom Time Manufacturing suggests Donar Chemicals Electra Clean and Costa Chemicals Formula Five as an acceptable product for the cleaning of these fiberglass booms When heavily soiled booms are cleaned make sure they are thoroughly rinsed and allowed to air dry as described in Item 3 6 Once the fiberglass boom is clean it should be coated with a product designed to protect its surface A good wax designed for use on fiberglass not only protects the boom s glossy surface but also provides a barrier against dirt creosote etc Hasting Fiberglass Product Inc Costa Chemicals and Kearney offer a waxes designed for use on fiberglass Donar Chemicals also offer a product called Electra Guard for use on fiberglass For best results fiberglass booms should be polished by hand 7 After a boom is cleaned and dried it should be dielectrically tested in accordance with ANSI Standards Section 5 4 3 to verify its dielectric integrity and to detect conductivity changes in its insulating section 8 Fiberglass booms and inserts should always be cleaned before any dielectric test Remember that cleaning and testing is required after repair or m
139. meets the piston and the check valve again both identical to those in the holding valve However the oil is on the back side of them now It is on the same side of the check valve as its spring The combination of the oil pressure and the spring holding the check valve on its seat effectively blocks this passage The oil also pushes against the back side of the piston the side opposite the spring The oil tries to push the piston off its seat by compressing the spring Normally the load induced pressure of the trapped oil is not sufficient to overpower the spring and push the piston off its seat Thus the oil remains trapped This is what produces the holding action which prevents the booms from creeping down or free falling should hydraulic lines be damaged Torelease this trapped oil hydraulic oil pressure must be applied to the pilot piston to push it off its seat This pilot pressure is obtained from the third passage for incoming oil The combination of the pilot pressure and the trapped oil pressure overpowers the spring pushes the piston off its seat and allows a controlled flow of oil out of the cylinders returning to the control valve and back into the reservoir 102 4 As mentioned before normal load induced pressures are not adequate to overpower the spring that acts on the piston However excessively high pressures such as those generated from the thermal expansion of the oil will open the piston sufficiently to relieve
140. mp Assemblies section and this section in this manual for any additional information This installation section includes pertinentinformation about the following Planning the installation Actual hardware considerations Mounting location considerations e Hydraulic and electrical schematics supplementary information Test and inspection requirements for a newly installed unit and pre delivery inspection check list As with the installation of any heavy equipment there will be many hazards that can occur No manual can adequately warn against all potential hazards Only by the attitude of the worker being constantly aware of the possibility of danger can most hazards be avoided Warnings are provided throughout this section of this manual they should be read studied and understood before any installation is started Failure to follow the steps in the appropriate section will result in Anunsafe installation either the installation will not be complete or the lift will be inappropriately mounted on the chassis inappropriately tested lift and therefore a possible hazard to the user incorrectly connected hydraulically to the chassis worker being injured during the installation process electrically or If you have questions during an installation please call our Customer Service Department Toll Free number at 866 543 8887 By successfully 104 2 completi
141. n It must then be installed on the aerial lift as shown on the decal placement drawing The data plate certifies that the completed installation meets the stability requirements of the Occupational Safety and Health Act and American National Standard Institute Stability Test Capacity Options Time Manufacturing Company has prepared a stability test capacity option drawing to identify the appropriate capacity options that are currently available for this model This drawing also will identify the different boom positions in which the static load can be placed during stability testing when the vehicle is on a level surface 5 slope Refer to the options section of this manual for the specfic capacity option drawing Inspection 6 6 2 Visual Inspection After testing a visual inspection of all components shall be made for evidence of defects such as deformation of any component loose connections damaged wire rope hydraulic leaks and other items critical to the safe operation of the aerial device The recommended range for each boom function at 8 GPM 30 LPM is given below These times are approximate and may vary with platform load boom position and other factors Rotation CW or CCW 55 65 Seconds Upper Boom Unfold 40 50 Seconds Upper Boom Fold 32 42 Seconds 52 62 Seconds 42 52 Seconds 40 50 seconds 30 40 seconds Lower Boom Raise Lower Boom Lower Elevator Raise Elevator Lower Exercise care wh
142. n the vehicle is on a slope of 5 degrees in the direction of least stability The load shall be applied at one and one third times the platform capacity at the center of the platform simultaneously with one and one third times the lifting attachment supplemental capacity in its position of maximum overturning moment when so equipped If having outriggers or other stabilizing components utilized is part of the definition of the configuration they shall be utilized according to the manufacturer s instructions for the purpose of determining whether the mobile unit meets the stability requirements Simultaneous application of platform capacity and supplemental capacity shall be performed only on aerial devices that are designed for use with both types of load applied simultaneously 4 5 3 Effects of Stability Test None of the stability tests described in 4 5 1 and 4 5 2 shall produce instability of the mobile unit or cause permanent deformation of any component Note During the stability test the lifting of a tire s or outrigger s onthe opposite side of the load does not necessarily indicate a condition of instability It is recommended that any weight applied to an aerial lift during a stability test be suspended near the ground This will prevent overturning in the event an unstable condition is encountered A CAUTION EXERCISE CARE WHEN PERFORMING STABILITY TESTS KEEP PEOPLE CLEAR AND OBSERVE WHAT IS HAPPENING HANDLE TH
143. ng on the piston rod Pull out carefully to avoid scratching the inner finish Inspect the inside of the case for gouges that would make an overhaul useless 3 Remove all components from rod Examine all components for wear rust or other signs of dete rioration Clean all components of rust espe cially inside the cylinder case Make sure that all components are free of dirt or other contami nation After cleaning coat all components with light grease before installing new seals and other parts 4 Install new seals wear rings and other parts as needed Reassemble the cylinder assembly Torque piston retaining nut Refer to Cylinders section of this manual for cylinder and its piston nut torque values Line inside of cylinder case seals and threads with light grease Insert the assembly into the cylinder case making sure that cylinder wall is not scratched Also make sure that no dirt is introduced into the cylinder tube 5 Use unit system pressure to cycle cylinder on work bench or on a test stand to purge air from cylinder and test for possible leakage A DANGER THECYLINDER WILL BE EMPTY OF OIL AND FULL OF AIR AFTER REPAIR WHICH MAY MAKE INITIAL OPERATION DANGEROUS THUS THE CYLINDER SHOULD BE PURGED OF AIR AFTER PURGING FILL THE HYDRAULIC RESERVOIR TO THE FULL LEVEL IF NEEDED WITH ALL CYLINDERS RETRACTED DO NOT RIDE THE PLATFORM WHILE AIR IS BEING PURGED SERIOUS INJURY OR DEATH COULD RESULT 6 Install cyl
144. ng the installation testing the stability and dielectric strength if insulated of the installed unit and performing the items listed on the pre delivery checklist we can be certain that our customer is receiving the quality they expect from their new Versalift The instructions of the following pages describe the recommended installation procedures This information includes the tests and inspections necessary to determine that the unit has been correctly installed and is ready for use Consult the illustrations provided to help clarify the text These instructions are written for competent service personnel and are not intended as a substitute for adequate training and experience All the details and variations involved in an installation cannot be adequately covered by instructions If further information is required contact your local Versalift dealer or Time Manufacturing Company SHIPPING AND HANDLING A skid has been included with the Versalift to provide a means of handling the unit during shipment without damaging it A DANGER NEVER CONNECT HYDRAULIC POWER AND OPERATE THE VERSALIFT WHILE IT IS ON THE SKID FAILURE OF THE SKID MAY RESULT CAUSING DEATH OR SERIOUS INJURY TO PERSONNEL OR DAMAGE TO THE EQUIPMENT The shipping skid is designed for lifting the unit at its center of gravity with a forklift When lifting the unit with a hoist determine thatthe unit is balanced by initially lifting it a short distance off the gro
145. nion teeth damaged Gearbox worn or defective Rotation motor mounting bolts loose EXCESSIVE VIBRATION OR NOISE 1 Pressure relief valve set too low 2 Holding valve defective 3 Airin hydraulic system due to low oil supply 4 Pumpcavitating due to dirty suction strainer PLATFORM LEVELING SLOPPY OUT OF LEVEL OR ERRATIC 1 Improper system tension 2 Chain or rods are catching on something in the booms BOOM DRIFTS DOWN WHEN CONTROLS ARE IN NEUTRAL 1 Holding valve defective 2 Leakage past seals in hydraulic cylinder 103 24 REMOTE ENGINE START STOP INOPERATIVE Engine start stop system not engaged Pressure switch defective Airline pinched or leaking Electrical box not grounded Air cylinder defective HENE TRUCK ENGINE PULLS DOWN OR STALLS WHEN CONTROLS ARE OPERATED 1 Idle speed too slow 2 Engine still cold 3 Engine needs tune up OVERHEATING OF HYDRAULIC SYSTEM 1 Main system relief valve set too low or open due to contamination 2 System operating pressure too high 3 Excessive hydraulic oil flow due to improper PTO ratio or overspeeding of truck engine VERSALIFT VO 265E 270E HYDRAULIC CYLINDER REPAIR WARNING HYDRAULIC CYLINDERS ARE CRITICAL LOAD HOLDING COMPONENTS AND MUST ONLY BE SERVICED BY QUALIFIED PERSONNEL IMPROPER SERVICE MAY CAUSE A FALL RESULTING IN DEATH OR SERIOUS INJURY Shut down the hydraulic system before removing any cylinder Remove lines to cylinder and plug or cap them
146. nut 3 8 5 00 lt LO 1330 2 42005 5 NC Hex Locknut 1 2 2 00 LO 1330 2 42005 7 NC Hex Locknut 5 8 2 00 LO 1330 2 42041 5 NC Hex Nuts Left Hand 1 00 LO 1330 2 44013 1 Hardened Washer 5 8 2 00 LO 1330 2 44013 3 Hardened Washer 1 2 2 00 LO 1330 2 48063 1 Turnbuckle Barrel 2 00 LO 1330 2 70025 1 Connecting Link 10 00 LO 1330 2 8681 1 Lev Adjustment Rod ZINC PL 1 00 MH 1330 9 35865 1 Lower Boom Sled Batchweld 1 00 MH 1330 9 35866 DWG Lower Boom Rest Installation 1 00 MH 1330 9 40005 7 7 16 NC Hex Head Cap Screws 4 00 MH 1330 9 42002 7 NC Hex Jam Nuts 2 00 MH 1330 9 42005 4 NC Hex Locknut 7 16 4 00 MH 1330 9 44013 9 Hardened Washer 7 16 8 00 MH 812 12865 1 Flat Zinc Plated 1 00 MH 812 22218 1 Boom Rest Batch Weld 1 00 MH 812 22249 1 Upper Boom Rest Installation 1 00 MH 812 22342 1 Boom Rest 1 00 MH 812 40006 9 1 2 NC Head Cap Screw 2 00 MH 812 4163 1 Pin Washer Zinc Plated 2 00 MH 812 42005 2 NC Hex Locknut 5 16 2 00 MH 812 42005 5 NC Hex Locknut 1 2 2 00 MH 812 42005 5 NC Hex Locknut 1 2 2 00 MH 812 8993 3 Boom Tie Down Strap Assy 1 00 PS 1330 12 11199 1 Cable Assembly 1 00 PS 1330 12 12848 3 Limit Strap 1 00 PS 1330 12 13344 1 Pivot Shaft Zinc Plated 1 00 PS 1330 12 13517 1 Polyethylene Bolt Cover 1 00 PS 1330 12 14076 1 Tilt Shaft Assembly Zinc Plated Batch Weld 1 00 PS 1330 12 14424 1 Shock Mount Zinc Plated 1 00 PS 1330 12 35714 DWG Platform Support Assembly 1 00 PS 1330 12 35715 DWG Platform Tilt Assembly 1 00 PS 1330 12 3571
147. odification of any component that crosses the insulating system s or the repair or replacement of an insulating component s 9 If fiberglass accessories such as line hose boxes or saw scabbards are attached to the boom they should be removed during dielectric testing of the unit They should also be washed and cleaned on a regular basis because they could reduce the dielectric integrity of the boom Care should be exercised in the selection and placement of such accessories to ensure that the insulation is not compromised 10 If while inspecting or cleaning the boom you discover chips scrapes or abrasions that would allow moisture to get into the fiberglass boom it should be recoated or sealed in accordance with manufacturer s recommendations Any time there is a doubt regarding damage to the fiberglass booms or inserts contact Time Manufacturing Company before any repairs are done TROUBLE SHOOTING The following is a list of problem conditions which may occur during operation of the Versalift along with some possible causes NO RESPONSE TO EITHER UPPER OR LOWER CONTROLS Truck engine not running PTO not engaged Low hydraulic fluid supply Relief valve set too low Pinched pressure or return line Defective hydraulic pump Pressure compensated pump set too low Lift controls not selected ONO PRON gt NO RESPONSE TO LOWER CONTROLS UPPER CONTROLS 1 Platform override valve in wrong position 2 Plugged or
148. of one two position selector valve Hydraulic tools can be operated when the ground controls are engaged and the tool selector is actuated When the ground controls are selected oil circulates 102 3 through the control valves and back to the reservoir because they are open center valves This allows warming of the hydraulic oil in cold weather ROTARY JOINT A rotary joint mounted between the turret and the pedestal allows for continuous rotation A cylindrical case which houses a spool is bolted to the turret and the spool is fastened to the pedestal The turret and the case rotate about the spool which remains stationary Oil from the pump enters port 2 of the spool flows up adrilled passage in the spool and into a groove which completely encircles the surface of the spool Oil flows along the groove until it comes to the outlet port 2 in the case wherever it is at that particular time Because the case outlet moves along the groove as the lift rotates oil flows out of the case port uninterrupted Return oil flows through port 1 or 3 of the case along the groove in contact with port 1 or 3 and then out port 1 and 3 of the spool on its way back to the oil reservoir Since all of the relative motion takes place between the spool and the case continuous rotation is possible SYSTEM PRESSURE RELIEF The relief valve is located in the pressure line between the pump and the lift ground control selector valve The relief val
149. on test After the Versalift is in service Time Manufacturing Company recommends dielectric testing be arranged every six months on a regular basis and after every major inspection or whenever the insulation value is suspect Only certified technicians are qualified to conduct these tests Consult ANSI A92 2 paragraph 8 2 2 for further testing frequency guidelines Prior to testing the Versalift should be inspected for dirt water or any other contamination that might bridge the insulated sections Make the necessary corrections to prevent bridging before proceeding to the dielectric tests INSTALLATION VERSALIFT VO 265E 270E 104 10 VERSALIFT VO 265E 270E WARRANTY REGISTRATION The Warranty Registration Card is an important part of your Versalift package Fill in the requested information and return the card to Time Manufacturing Company Of particular importance is the date your Versalift is put in service thus initiating the proper warranty period This information also helps Time Manufacturing Company send important correspondence to you concerning your specific Versalift PREDELIVERY CHECKLIST After the mounting ofthe Versalift is complete check the following items All bolts are torqued properly Mounting hardware is installed properly and bolts torqued All hoses and electrical wires are secured Hoses and wires are properly protected All welding has been completed
150. orm are easily repaired Damage to the fiberglass structure can be more serious and should be carefully evaluated before attempting to repair the platform if the top lip mounting flange or the bottom of the platform is damaged repair should not be attempted 3 OPERATIONAL CHECKS Perform operational checks on the following items 103 6 A VERSALIFT VO 265E 270E If so equipped verify proper engagement of the PTO without excessive noise or vibration during operation Refer to the PTO manufacturer installation manual if adjustment is necessary Verify the hydraulic pump is functioning properly without excessive noise vibration or overheating Noise in a hydraulic pump can indicate cavitation or the intake of air into the suction line This could result from a low level of oil loose suction line fitting or operating in temperatures too cold for the type of oil used If overheating occurs check the main system relief pressure as described in Adjustments in this section Verify that the lift functions according to the control instructions Consider all hydraulic and electrical control systems including optional equipment and audible or visual warning systems Refer to Boom Actuation Speeds in this section to verify the boom function speeds Adjust the pump flow by varying engine speed as required Verify the holding valves are functioning properly per instructions in Adjustments section Check clearances be
151. ouble acting cylinders equipped with counterbalance valves The arms articulate through a range of approximately 85 while providing a 10 ft 3 0 m vertical lift A link located in the knuckle connects between the upper and lower arm This link synchronizes the arms and ensures that the pedestal only travels in the vertical direction PLATFORM LEVELING The platform remains level to the ground through all boom movements Fiberglass rods and 60 roller chain are interconnected to form a completely enclosed parallelogram system The lower rod and chain system rolls over the turret sprocket and over the idler assembly at the knuckle The upper boom rod and chain system operates similarly in the upper boom The fiberglass leveling rods maintain the insulation gap in all boom positions The leveling system is adjusted by threaded rods which are easily accessed at the turret and the knuckle The platform can be adjusted to level at the turret sprocket using the sprocket anchor bolt Refer to the Leveling System Assembly illustration in Parts amp Assemblies Section for leveling system components and their orientation HYDRAULIC SYSTEM The hydraulic schematics will aid in understanding the hydraulic system Refer to Hydraulic Schematics Section for these schematics Descriptions of the major components in the hydraulic system are given below PUMP Open center systems are best described as constant flow systems The open center hydra
152. outrigger stabilizers if equipped A DANGER NEVER OPERATE WITHOUT EXTENDING THE OUTRIGGERS IF EQUIPPED WITHOUT PROPER OUTRIGGER EXTENSION THE UNIT MAY TIP RESULTING IN DEATH OR SERIOUS INJURY 2 Rotate the turret to the position to be used for the tilt measurement Position the aerial device over the working side of the vehicle For consistent measurement always use the same rotational position each time the tilt measurement is done Record the rotational position in the maintenance log 3 Position the booms in Position Aas shown on Boom Position Diagram Figure 1 4 Attach the magnetic base of the dial indicator to the pedestal and the pointer of the indicator positioned against the under side of the turret base plate as close as possible to the bearing gear cover Figure 2 shows three recommend positions for the dial indicator pointer Once the a correct indicator pointer position is chosen it is very important that the same pointer position is used for each subsequent till measurement Therefore record the pointer position in the maintenance or log where the tilt measurements are recorded Some inspectors prefer to permanently mark the location where the dial indicator pointer contacts the bearing base plate to ensure that subsequent measurements are made in the exactly the same spot 4 Set the dial indicator at zero with booms in Position A 5 Slowly position the booms to Position B Do not rotate the
153. puncture and become embedded beneath the skin or contaminate the eyes Relieve pressure by activating the control valve while the hydraulic power source is off or disengaged Loosen connections slowly to make certain pressure is relieved A stability test per current ANSI A92 2 requirements must be performed on the unit after it is mounted This must be done before anyone operates the lift from the platform After servicing any portion of the hydraulic system extend and retract all of the hydraulic cylinders several times to force any trapped air from the system Never operate the lift from the platform until this has been accomplished Warning and instructional decals are installed at numerous locations on the aerial lift to warn personnel of the potential hazards during the use and operation of the Versalift aerial lift If any decals are defaced illegible or lost they must be replaced immediately No manual can address every conceivable hazard while installing maintaining or servicing an aerial lift The prevention of accidents is dependent on good judgement and common sense on the part of the service personnel 101 2 SECTION 102 THEORY OF OPERATION z lt oc LL O gt oc VERSALIFT VO 265E 270E 102 1 z lt tc LL O gt tc VERSALIFT VO 265E 270E THEORY OF OPERATION MECHANICAL SYSTEM Several mechanica
154. racted the lower boom limit switch is open and both outrigger limit switches are open Therefore both circuits to the solenoid are open and the solenoid is de energized With the solenoid de energized the hydraulic flow is directed to the outrigger controls Note that under these conditions the toggle switch has no effect on the solenoid This system prevents operating the lift without extending the outriggers When the outriggers are extended to ground the outrigger limit switches close and the circuit to the toggle switch is completed If the toggle switch is open the solenoid remains inactive Closing the toggle switch energizes the solenoid thereby directing hydraulic flow to the lift controls Raising the lower boom off the boom rest closes the lower boom limit switch This completes a second circuit to the solenoid If the toggle switch is now opened or if one outrigger raises off the ground the solenoid valve remains energized through the lower boom limit switch Therefore hydraulic flow remains directed to the lift controls If the optional override switch is installed the solenoid can be de energized by opening the switch This directs hydraulic flow to the outrigger controls regardless of the other system conditions SINGLE STICK UPPER CONTROL Upper Controls The single stick controls consists of three 4 way spools connected internally in a parallel circuit The tool selector and safety trigger are on the first sel
155. re To reach an optimum setting adjust the gear backlash with the pinion positioned on the high tooth of the bull gear The high tooth location on the bull gear is either marked with three center punch marks or a H stamped on the front face of the tooth Refer to the Turret Assembly illustration in option section for adjustment procedure E Allload supporting bolts rotation bearing bolts pedestal subframe mounting bolts and platform rotator mounting bolts must be physically retorqued to the specifications included on the torque chart in this section All other critical fasteners must be visually inspected for rotation and signs of failure If any loose fasteners are found both the nut and bolt must be replaced and tightened to the proper torque Nuts and bolts must never be reused A new torque seal mark must be installed Refer to Figure 3 WARNING IMPROPERLY TORQUED OR IMPROPER BEARING BOLTS CAN CAUSE DEATH OR SERIOUS INJURY Rotation Bearing Bolt Inspection The bolts fastening the rotation bearing to the turret and pedestal of the Versalift aerial device are one of the load supporting components and because of their location could be overlooked Remove pedestal covers to allow access to the pedestal to turret mounting bolts Refer to Figure 5 If one or more bolts loosen or stretches the loading is transferred to the properly torqued bolts making them support more than their share of load Should the unit be
156. rent fastener suppliers T Refer to the critical fastener drawings for each Versalift for identification of specific fasteners 8 HHCS Hex Head Cap Screw HW Hardened Washers PTLN Prevailing Torque Lock Nut SHCS Socket Head Cap Screw SHFH Socket Head Flat Head VERSALIFT VO 265E 270E 103 11 145 197 210 286 March 1 2007 TMC 778 5 gt xc rev eren DESCRIPTION cao erre 42 57345 FIRST RELEASE LER DJH SRS 9 5 4 DIA SNAP RING 3 1 DIA SNAP RING am NOTES 1 ALL FASTENERS THAT ARE STRUCTURAL MEMBER ARE STRUCTURAL OR RETAIN ANOTHER 2 HEX HEAD BOLTS ARE GRAD 5 ARE ADE B AND WASHERS ARE HARDENED STEEL UNLESS OTHERWISE NOTED 3 MINIMUM OF TWO THREADS THROUGH ANY LC NUT 4 gt OWHEAD DESCRIPTION 5 QUE ALL CRITICAL FASTENERS PER THE JE CHART THE OPERA AMD SERVICE MANUALS LINLESS DWN BY DATE TITLE 6 ALL THREADED 5 5 TO BE MARKED WITH TORQUE MAN
157. rmance of the bearing Always check the purged bearing grease at each inspection and turret tilt measurement procedure even if there is no presence of roughness noise in the bearing or significant change in the turret tilt measurement One or more of these evaluation criteria should detect the need for rotation bearing replacement long before there is a threat of failure By maintaining proper rotation bearing lubrication and avoiding overload conditions the replacement bearing should provide many years of service TORQUE CHART BOLT MARKINGS amp TORQUE CHART Bolts With Nuts Bolt Head Markings Grade 5 Bolt Highland nfasco Nucor Grade 8 Bolt 7 Highland C47 Infasco Nucor Socket Head SPS SHCS amp SHFH Nut Markings Grade B PTLN Gripco Aztec Grade C PTLN Gripco Aztec 66 Gripco Aztec Bolt Thread amp Size Torque ft lb Torque ft lb Torque ft Ib N m 1 4 20 74 in b 8 155 18 5 16 18 145 16 240 inb 27 3 8 16 21 29 32 44 7 16 14 1 2 13 55 75 55 75 5 8 11 98 133 160 218 3 4 10 167 227 N A 718 9 1 8 Special Threaded Fastener Applications Bolt Thread Size amp Type 20 Grade 5 HHCS Lubricant Loctite 262
158. s in the red area change the filter Clean any accumulation of foreign material from the suction strainer and the magnetic drain plug if oil shows signs of contamination Suction Strainer The 100 mesh 149 micron suction strainer must be removed and cleaned periodically To remove drain the reservoir unscrew the suction strainer at the bottom of the tank Remove clean and reinstall the suction strainer Pump cavitation is often caused by a dirty or clogged suction strainer Operating in conditions too cold for the type of oil is another common cause for pump cavitation Noisy pump operation is a strong indicator of pump cavitation When the return line filter and suction strainer are changed or cleaned the oil should be examined for foreign particles and water If contamination is found the oil must be changed or reclaimed by adequate filtering Verify settings of main system relief pressure and system operating pressure Refer to next paragraph for adjustment procedures if necessary Main System Relief Pressure The main system pressure relief valve is located in the pressure line between the pump and the lift ground control selector valve The relief valve prevents the hydraulic system from developing excessive pressure Before attempting to adjust the main system relief pressure check and adjust the system operating pressure if necessary To adjust the system relief valve loosen the locknut and turn the adjustment scre
159. s to the extent of damage replace the rod assembly iD DIA DEPTH OF DAMAGE Rod Diameter Depth Of Damage 3 8 125 MAX 5 8 3 4 19 MAX Leveling Rod Ends Rod ends are swaged and bonded to the fiberglass rod The fiberglass rod is painted to indicate movement Check for movement between the rod and rod end by looking for an unpainted area next to the rod If there is any evidence of movement replace the rod assembly corrosion or deformation is present All fiberglass components and the fiberglass to steel epoxy bonded joint are considered critical These components and joints must be repaired or replaced UNPAINTED AREA INDICATES before further use nm D Checkthe leveling system for looseness wear E Inspectthe insulating fiberglass upper and lower 2 a oc gt VERSALIFT VO 265E 270E damaged leveling rods or improper action of roller chain over the sprockets Clear any trash or debris from around sprockets and replace damaged components Refer to next paragraph for adjustment or installation procedures The pretension in the leveling system should be checked periodically To clarify these instructions see the Leveling System Assembly drawing in Parts amp Assemblies Section Adjust the tension by tightening the nut until there is no visible droop of the leveling rods through th
160. sections contains replacement parts information for the VERSALIFT Aerial Device including normal available options Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time When ordering parts always furnish 1 Identification of the Lift Model and serial number of the lift are located on the data plate The serial number can also be found stamped on the turret base plate and or pedestal top plate 2 Part Numbers and Description Each part ordered needs to have correct part number and description The part numbers and descriptions can be found on following pages in this section 00 l m 00 lt ob o lt a An Itemized parts list with illustration is included for each assembly hydraulic circuit control system and electrical circuit All parts are identified by a reference letter corresponding to a like letter in the parts list see assembly identification example 1 on the following page An itemized service parts list with illustration is included for each major component All parts are identified by a reference number corresponding to a like number in the service parts list see component indentification example 2 on the following page The quantities listed are the amount required for one complete assembly or subassembly If there is any doubt as to the correct part numbers please contact your local distributor or
161. sure setting loosen the lock nut on the top of the the cartridge opposite the clockwise CW port and with a 1 8 inch allen wrench turn the set screw counter clockwise CCW to increase the pressure setting and clockwise CW to decrease Return the control to neutral and actuate again to verify pressure setting Next fully actuate the rotation control for counter clockwise CCW rotation and adjust the cartridge opposite the counter clockwise CCW port to 1100 psi in the same manner as before Tighten the lock nuts after adjusting Remove the pressure gauge and reconnect the hoses to the motor Install and bolt the motor to the gear box Startthe unit and verify that the direction of rotation is correct Reverse hose connections at the rotation motor if required Verify smooth operation on a slope and adequate rotation speed on level ground 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 Apetroleum or vegetable based oil 2 A maximum viscosity of 1000 cSt at the minimum start up temperature and a viscosity range of 10 to 40 cSt at the anticipated operating temperatures 3 Anti wear additives to ensure long life of the hydraulic components 4 Anti foam additives to minimize air entrapment 5 Good chemical stability at ant
162. ted oil is diverted either to the upper controls or allowed to flow to the second third and fourth sections which control the lower boom upper boom and rotation functions respectively Oil is available to these sections only when the lower controls are selected UPPER AND LOWER BOOM CYLINDERS AND HOLDING VALVES When the valve controlling the oil flow to the upper and lower boom cylinders is actuated the oil leaves the control valve assembly and flows to the holding valve As the oil is directed to the cylinders it enters three passages One passage is blocked by a piston which is spring loaded against its seat The incoming oil is on the same side as the spring This causes the piston to be pressed tighter against its seat effectively blocking this passage The oil then flows through the other passage which has a spring loaded check valve in it The oil pushes the check valve off its seat flows out of the holding valve and into the hydraulic cylinder The hydraulic cylinders are double acting meaning both ends of the cylinders contain oil In order for the incoming oil to move the cylinder pistons oil on the other side of the cylinder pistons must be able to escape from the hydraulic cylinders The oil cannot escape because the other holding valve is blocking it The passages in this holding valve are identical to the ones described above However the oil is trying to flow through the passages in the opposite direction The oil
163. ted to authorized service personnel for corrective action Reliable and economical service will be achieved if a rigid preventive maintenance and inspection schedule is performed by authorized service personnel Follow the preventive maintenance and inspection schedule provided in this manual The time intervals given are those recommended for anticipated operating conditions These time intervals must be adjusted to specific user conditions When a malfunction or abuse of an aerial lift has occurred service and maintenance of the lift must be administered before further use If a defect is found during scheduled inspections or routine operation repair or adjust the unit before operation Injury to personnel and further deterioration of the aerial lift may result if the aerial lift is operated while a defect exists The Maintenance and Inspection Checklist Record is provided at the end of this section for the items listed below Access covers and protective guards must be removed from the aerial lift before the inspection procedure Once the procedure is complete install all covers and guards replacing any that are damaged beyond repair Covers and guards are designed to protect personnel and prevent foreign material from corrupting components PRIOR TO PLACING UNIT INTO SERVICE 1 MAINTENANCE A Perform the Daily Visual Maintenance and Inspection Checks refer to Operator s Manual B Rotation bearing deflection check new b
164. the customer service department at Time Manufacturing Company 3 Shipping Method Unless otherwise instructed all shipments will be made via motor freight collect or UPS prepaid and charged on our invoice 4 Returns Any parts that may need to be returned must have a return goods authorization number on the outside of the box and the correct paperwork including the invoice number or purchase order number accompanying the part Replacement Parts All parts are original VERSALIFT replacement component Authorized VERSALIFT dealers are assured of being furnished with authentic parts when purchased from Time Manufacturing Company Dealers and customers not using original replacement parts from VERSALIFT may experience operational and safety related premature fatigue wear and or failure of components NOTE On some Assembly and Installation drawings included in the following sections some components are marked as shipped loose items These items will require installation during the Versalift installation procedure Refer to any component identification instructions in the ship loose box Also refer to the Part Details and Installation drawings in this manual for any additional information needed PARTS AND ASSEMBLIES VERSALIFT VO 265E 270E 106 3 REV REVISIUN LEVEL EXFXG
165. this potentially damaging pressure OUTRIGGERS Each outrigger has its own control valve lock valve and hydraulic cylinder Each component is described in detail below Control Valve The reverse mount unit has two four way control valves connected in series for the outrigger controls Selector Valve The control selector valve consists of atwo position spool valve mounted on the ground control panel The purpose of the selector valve is to select between ground controls and lift controls In the out position oil is directed to the outriggers dump body and the tool controls When activated pushed in oil is directed to the aerial lift Shut Off Valve The shut off valve is a needle and seattype valve designed for general purpose restriction of hydraulic circuits This valve must be manually opened and closed When used it prevents unintentional operation of the dump body control Lock Valve The lock valve is designed to lock the outrigger cylinder in position without leakage while the control valve is in the neutral position This valve functions as a check valve allowing flow to the cylinder and blocking reverse flow until pilot pressure is applied to unlock the circuit The lock valve is located inside the outrigger housings close to the outrigger cylinder Outrigger Cylinder The hydraulic cylinder is located inside the outrigger housing and is double acting Operation When the outrigger controls are selected o
166. ting Pressure in this section for the proper adjustment procedure of this function A flow meter can be installed in the tool circuit to measure the flow rate If the proper PTO has been installed the maximum flow rate of 7 26 lpm can be provided by adjusting the engine speed Another method of verifying proper boom actuation speeds is to time one cycle with an operator in the platform The recommended range for each boom actuation is given below These times are approximate and may vary with platform load boom position and other factors Rotation CW or CCW 55 65 seconds Upper Boom Unfold 40 50 seconds Upper Boom Fold 32 42 seconds 52 62 seconds 42 52 seconds 40 50 seconds 30 40 seconds Lower Boom Raise Lower Boom Lower Elevator Raise Elevator Lower 103 19 2 a gt 2 a oc gt VERSALIFT VO 265E 270E Exercise care when timing boom functions to avoid reaching the end of boom travel while at full operating speed To accurately test the flow rate or lift actuation speeds it is critical for the hydraulic oil to be warmed to operating temperatures between 70 F and 90 F 21 C and 32 C Cold hydraulic oil will result in slow operation with increased engine speed having no affect The engine speed whether controlled by a manual throttle or an optional two speed
167. ting the aerial lift a weight distribution study is required to determine if the configuration is acceptable for the vehicle specified Front and rear axle curb weight must be within the vehicle manufacturer s ratings Minimum and recommended vehicle specifications are given for the aerial lift When this information is verified the installation can proceed Properly planning for an aerial lift installation will help guarantee proper performance and reliability of the Versalift aerial device INSTALLATION Bolt Head Markings BOLT MARKINGS amp TORQUE CHART Bolts With Nuts Grade 5 Bolt Highland kay Infasco Nucor Grade 8 Bolt 7 Highland vw Infasco Nucor Socket Head SPS SHCS amp SHFH Nut Markings Grade B PTLN Gripco Aztec Grade C PTLN Gripco Aztec Grade C PTLN o Qripco Aztec Bolt Thread amp Size Torque ft lb N m Torque ft lb N m Torque ft lb N m 74 8 N A 155 in b 18 145 in lb 16 N A 240 in lb 27 15 20 21 29 32 44 39 58 55 75 55 75 29 43 15 102 98 133 160 218 125 170 167 227 170 178 242 378 514 N A N A Bolt Thread Size amp Type Special Threaded Fastener Applications Lubricant Tapped Material Torque ft lb 1 4 20 Grade 5 HHCS Loctite 26
168. to prevent loss of fluid Also plug cylinder ports to prevent loss of fluid Tag or mark lines to prevent reversing connection when reassembling Outrigger cylinders should be repaired when they tend to drift down during road travel or up when extended in working position and the lock valves are not at fault This downward drift indicates leaking cylinder seals Immediate attention should be given to any outrigger cylinder that drifts Damage could result if an outrigger should drift down during road travel Refer to the example of typical cylinder drawing in this section for part identification in the following procedures REPAIR PROCEDURES A WARNING CARE SHOULD EXERCISED WHEN REMOVING CYLINDERS AS THEY ARE HEAVY CYLINDERS SHOULD BE REMOVED BY MEANS OF A HOIST IF AVAILABLE 1 Position the cylinder on a rail if available or a work bench and place the open port over a container in order to catch the hydraulic fluid Extend the piston to the end of its stroke to purge the hydraulic fluid into the container This can be done by using the rail if available or by manually pulling out the piston rod Next push the piston rod approximately one half way back in A WARNING DO NOT USE AIR PRESSURE TO DISASSEMBLE HYDRAULIC CYLINDERS AIR IS VERY COMPRESSIVE AND SERIOUS INJURY COULD RESULT 103 25 2 Remove gland nut or thread ring and plate on end of cylinder Remove entire internal assem bly from cylinder case by pulli
169. tridge furthest from the ports or the lower boom is for the base end of the upper boom cylinder The base end holding valve for the lower boom cylinder is located on the side opposite the lower boom bottom side The holding valve for the rod end of the lower boom cylinder is on the side opposite the ports Care must be taken when removing holding valves A cylinder will not hold a load when a cartridge is removed The booms must be supported or at the end of their travel to prevent the booms from dropping All holding valve cartridges are accessible with both booms stowed and without disconnecting the ends of the cylinder Having removed a defective holding valve check for visible contamination or defective external O ring seals If neither is the apparent replace the entire cartridge Never attempt to disassemble and reuse a defective cartridge Bleeder ports are provided for both upper and lower boom cylinders for emergency lowering These ports are marked as base and rod for the desired boom movement Slowly loosen the setscrew not the hex fitting and be prepared for hot oil flowing from the bleeder ports The bleeder ports should be used to relieve any trapped pressure inside the cylinder before removing the holding valve cartridges to prevent damage to the holding valve seals BOOM ACTUATION SPEED The boom actuation speed is controlled by the system operating pressure and the pump or engine speed Refer to System Opera
170. ts Inspection Figure 5 RACE OUTER RACE Rotation Bearing Bolts Torque Pattern Figure 6 VERSALIFT VO 265E 270E 103 9 2 a gt 2 a oc gt VERSALIFT VO 265E 270E 3 TESTING A Perform dielectrictest per ANSI A92 2 paragraph 8 2 4 item 16 EVERY YEAR OR 1500 PTOHOURS MAINTENANCE AND INSPECTION 1 MAINTENANCE A An application of light oil is recommended to maintain the smooth operation of control handles and actuators B Lubricate the leveling chains at the turret platform and upper and lower boom knuckles A penetrating lubricant designed for chain use such as Lubriplate Chain and Cable Spray should be applied at these four locations EVERY 2 YEARS OR 3000 PTO HOURS MAINTENANCE AND INSPECTION 1 MAINTENANCE A The rotation bearing must be Inspected and evaluated Refer to Maintenance and Inspection in this section for recommended bearing inspection procedures Rotation Bearing Replacement Criteria The rotation bearing must be inspected and evaluated The recommended bearing inspection procedure includes the following 1 Monitoring the trend of turrettilt measurements Bearing inspections and turret tilt measurements can be used to determine when bearing should be replaced Generally an increase in turret tilt of 0 065 1 65 mm above t
171. turret Record the indicator reading 6 Repeat steps 4 and 5 to obtain an accurate reading 7 When an increase in turret tilt of 0 065 1 65 mm above the initial tilt measurement or a total axial movement exceeding 125 3 17 it is generally an indication ball and ball path deterioration is occurring t is recommended the bearing be replaced at this time Refer to Rotation Bearing Replacement Criteria in this section for other factors related to the conditions of the rotation bearing NOTE The axial movement can be monitored and if no increase in axial movement occurs the rotation bearing can be left in service 2 a gt VERSALIFT VO 265E 270E 103 3 TURRET Sex p MEASURING THE AXIAL MOVEMENT DIAL INDICATOR 1111111111 THE OUTRIGGERS ARE LLY EXTENDED Boom Position Diagram Figure 1 PINION GEAR et 5 m a gt N ROTATION BEARING GEAR COVER Dial Indicator Position Figure 2 VERSALIFT VO 265E 270E 103 4 VERSALIFT VO 265E 270E 30 DAYS OR85 PTO HOURS AFTER IN SERVICE DATE ONE TIME SERVICE 1 MAINTENANCE A Any hydraulic
172. tween moving components during operation Observe the knuckle and turret areas through the complete range of motion with aload in the platform In particular observe the pivot link main links and upper and lower booms at the knuckle Repair replace or adjust components to maintain clearance Observe the leveling system during operation Platform leveling should be smooth during boom actuation with minimal looseness or free play Verify that roller chain is free to flex and determine that all connector link components are in place Check tension and adjust according to the instructions given on the Leveling System Assembly option drawing If required remove links in the chain at the knuckle Inspect unit for hydraulic system leakage including all hydraulic components hoses and fittings Replace leaking hoses or fittings with parts meeting or exceeding manufacturer specifications With hydraulic cylinders fully extended look at the cylinders for rough or nicked cylinder rods Refer to hydraulic cylinder repair for inspection procedures 4 MAINTENANCE A Rotation Bearing Lubricate the rotation bearing using the two zerks located inside the turret as shown in Figure 4 Apply grease at 90 intervals to help distribute the grease more consistently B Rotation Bearing Pinion Gear Teeth Remove the pinion gear cover and apply a waterproof gear grease such as Lubriplate s Gear Shield Heavy to the gear teeth as shown in
173. ulic System with a fixed volume pump is standard on the VO unit The PTO and pump configuration must be coupled to produce 2900 psi 205 kg cm at 7 gpm 26 Ipm OIL RESERVOIR The hydraulic oil reservoir holds 25 gallons 94 6 1 in reverse mount unit and 17 gallons 64 3 in the rear mount unit Oil is drawn out and returned to the bottom of the reservoir through pipes which extend from a few inches above the bottom of the tankto above the oil level in the tank This prevents entrainment of air in the hydraulic oil and allows filter to be changed without draining the reservoir The reservoir also includes a baffle to minimize the VERSALIFT VO 265E 270E entrainment of air in the oil FILTRATION The 10 micron return line filter is located on the top of the hydraulic oil reservoir and includes an indicator to show when excessive pressure is required to force the oil through the filter With a closed center system a function or tool must be actuated to check the filter indicator A 100 mesh 149 micron suction screen is located in the reservoir and can be removed and cleaned Oil leaves the tank passing through the suction strainer on the way to the hydraulic pump All of the oil passes through the return line filter on its way to the tank GROUND CONTROLS The ground controls consist of a selector valve four way control valves and optional controls for engaging a tool circuit on the ground or shutoff valves as explained
174. ump the equation would be as follows Engine Speed _ 231 IN GAL x 8 GPM x 10 000 913 RPM RPM 2 2 IN REV x 92 96 x 100 95 In some cases hydraulic tool operation may require a flow less than 7 GPM 26 lpm An effective means of lowering the flow is to select a PTO that will provide the desired flow at idle However on closed center hydraulic systems if the required PTO is not available or if a PTO has already been installed the optional maximum flow stop kit can be installed in the pump to reduce the flow A manual or automatic throttle control will allow higher flow rate when necessary However the closed center flow sensing throttle control does not require the maximum volume stop kit because the engine speed is increased by any lift function including tool operation thus making the 7 GPM 26 Ipm available Mount the PTO according to the manufacturer installation instructions Refill the transmission with an appropriate oil Install the hydraulic pump to the PTO using two 1 2 in Grade 5 fasteners Tighten bolts as specified Before connecting the suction line to the oil reservoir fill the hose with hydraulic oil On initial start up the pump case should be filled with oil and the air bled from the pump outletto prime it If an installation hose kit option was ordered use the hoses provided The pump pressure hose is 1 2 in 13 mm and the suction hose is 1 1 4 in 39 mm Connect the 1 4 in 6 mm pump
175. und If the load is not balanced return it to the ground and make the proper adjustments Remove the skid before lifting the unitinto position for mounting Stand clear of the unit while itis suspended A DANGER ALWAYS DETERMINE THAT A FORKLIFT OR HOIST IS CAPABLE OF SUPPORTING THE LOAD AT THE REQUIRED HEIGHT NEVER ATTEMPT TO ADJUST THE BALANCE OF A LOAD WHILE IT IS SUSPENDED LIFTING WITH INADEQUATE EQUIPMENT OR IMPROPER HANDLING MAY CAUSE THE LOAD TO DROP RESULTING IN DEATH OR SERIOUS INJURY OR DAMAGE OF THE LOAD VERSALIFT VO 265E 270E FASTENERS Numerous fasteners are used throughout the installation process There are minimum specifications required to securely attach the aerial lift components Torque values are listed on the torque chart for the various sizes and grades offasteners used on the Versalift aerial lift Prevailing torque nuts are used in structural applications to preventloosening from vibration Tobe effective 2threads must protrude beyond the locknut once tightened Only install unused locknuts and bolts Torque seal marks are used on critical fasteners This procedure provides a means for quick visual inspection of fastener condition Do not use the lift if the Torque Seal mark between the bolt head and mounting surface are not in alignment Refer to Figure 1 for Torque Seal mark conditions e TORQUE SEAL P MARK ALIGNED 1 le Z S lt RII Ir
176. ve Check Valve In Line 1 2 NPT Single Stick Control Valve Polyurethane Tubing 9 16 OD X 3 8 ID Lever Control Kit Uniball Rod End Rod End Ball Joint Rod End Ball Joint SPM 4S Rod End Ball Joint Spacer Stainless Steel Knob Red Compression Spring Adj Yoke End Plated Decal Slope Warning Slop Indicator 10 Degree Slope Indicator Installation Rubber Boot Air Cylinder Boot Air Cylinder Shipping Skid VO 255 Rev Mount 5 8 NC Hex Head Cap Screws 5 8 NC Hex Head Cap Screws NC Hex Locknut 5 8 Hardened Washer 5 8 Shipping Anchor Bolt Lock Pivot Spacer Pinion Cover Turret Assembly Turret Weldment Socket Head Flat Head Screw 3 8 NC Hex Head Cap Screw 5 8 NC Hex Head Cap Screws Hardened Washer 5 8 Hardened Washer 3 8 Pin Washer Zinc Plated Pin Assembly Pin Assembly Polyethylene Bolt Cover Cover Elbow Bearing Hose Cover Elbow Cover Inspection Plastic Qty 1 00 1 00 2 00 4 00 1 00 3 00 1 00 8 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 0 00 1 00 1 00 2 00 2 00 3 00 3 00 1 00 1 00 2 00 2 00 2 00 1 00 1 00 1 00 1 00 2 00 2 00 2 00 4 00 1 00 2 00 1 00 1 00 1 00 3 00 4 00 2 00 2 00 4 00 2 00 1 00 1 00 1 00 1 00 2 00 1 00 2 00 Lot No 1134 100029377 Option Part UB 1330 2 29535 1 1330 2 29536 1 1330 2 32794 2 1330 2 32798 DWG UB 1330 2 32799 1 UB 1330 2 40002 5 UB 1330 2 40002 6 UB 1330 2 40076 12 UB 1330 2 40182 1 UB 1330 2 42
177. ve prevents the hydraulic system from developing excessive pressure UPPER FUNCTION CONTROLS TOOL POWER The three four way spools connected internally in a parallel circuit have priority over the tool section The upper controls can be operated simultaneously Only open center tools can be used with the open center hydraulic system The emergency stop tool hookup valve dumps flow to the tank for easy tool hookup or removal Each boom function at the upper controls incorporates either locking handles individual controls or a safety trigger single stick control The locking handles and safety trigger are designed to eliminate inadvertent operation of the upper control valve The upper controls can be operated simultaneously On Category B and C units 50 ft and above a vacuum prevention system is installed on the upper controls This system prevents a vacuum from forming in any hydraulic line that crosses the insulated portion of the boom since oil vacuum may reduce dielectric strength LOWER CONTROLS The lower controls are located on the panel of the lower deck When the control selector is positioned to provide flow to the lift the lower controls are operational z lt oc O LL gt oc z 9 lt tc LL O gt tc VERSALIFT VO 265E 270E The platform override control is the first section ofthe control valve When this control is selec
178. w counterclockwise until a hissing is heard indicating oil flow Then slowly turn the adjustment screw clockwise until the hissing stops Continue turning the adjustment screw clockwise for one complete rotation after the hissing stops Retighten the locknuts to complete the adjustment 103 8 A CAUTION NEVER SET SYSTEM OPERATING PRESSURE ABOVE THE RECOMMENDED SETTING OF 2900 PSI 205 Kg EXCESSIVE OPERATING PRESSURE WILL STRESS THE HYDRAULIC SYSTEM AND MAY LEAD TO COMPONENT FAILURE Outrigger Control Relief Pressure The outrigger control circuit is protected by the main system pressure relief system valve and no longer requires a separate outrigger relief valve The outrigger controls may contain a relief valve Disable this relief valve by turning the adjustment screw clockwise until the adjustment bottoms out A CAUTION NEVER CHANGE THE RELIEF SETTING WHILE PRESSURE IS BEING APPLIED TO THE SYSTEM THROUGH AN OPERATING VALVE D Adjust the gearbox pinion clearance per Gearbox Pinion Clearance Adjustment instructions on the next paragraph Gearbox Pinion Clearance Adjustment The gearbox pinion operates against the main bull gear to rotate the booms It is necessary for the pinion gear to have a slight clearance when operating on the bull gear Too much clearance can allow excessive movement of the platform while too little clearance promotes accelerated wear on the gear teeth and can cause possible tooth failu
179. y and the motor The control coil of the solenoid does not have an internal ground for completion of the control circuit Ground connection is controlled by a control in the platform Pressure Switch And Air Cylinder The air cylinder and pressure switch are identical to the ones used for the start stop system Refer to the start stop system theory for a description of how they work Operation of these two components completes the solenoid control circuit Toggle Switch The single pole two position maintained toggle switch is mounted on the lower control cover The emergency power solenoid is energized or de energized depending on the position of the toggle switch OPERATION Control Circuit Power for the control circuit comes from the on terminal of the ignition switch This means that the key must be in the ignition and turned on before the system will operate Current flow is from the on terminal of the ignition switch through the solenoid coil and through the pressure switch to the ground MANUAL THROTTLE CONTROL ELECTRICAL THEORY The throttle control electrical schematic in this section will aid in the understanding the electrical system The manual throttle control components and their functions are described in detail below Truck Ignition Switch All current used for operating the throttle control system comes from the truck ignition switch Throttle Control Relay This relay is a 12 volt double pol
180. y in the open position When activated the start relay forms a connection from the truck battery to the truck starter solenoid Stop Relay The single pole stop relay is mounted in the truck engine compartment and is normally in the closed position When the stop relay is activated the ignition circuit and the start relay control circuit are broken and the engine stops Ignition Relay The 12 volt double pole double throw latching ignition relay is mounted in the electrical box One set of points is in the start circuit and the other set of points is in the ignition circuit Pressure Switch and Air Cylinder The pressure switch is mounted on the turret wing and connected by an air line to an air cylinder mounted on the platform control panel When the air cylinder is operated air pressure is produced and the electrical contacts in the pressure switch close The truck engine is started or stopped depending on the position of the ignition relay contacts Panel Toggle Switch A single pole three position momentary toggle switch is mounted on the panel of the lower deck The truck engine is started or stopped depending on the position of the toggle switch OPERATION THEORY OF START STOP CIRCUITS Start Stop Circuit When the master control toggle switch is activated and the ignition switch is in the on position current flows to terminal 7 on the terminal block Current from terminal 7 flows to the ignition relay The ignit

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