Unilift 538 Operator's Manual

Univer sal Cr ane and
Pe r son n e l Lif t

OPERATOR'S
MANUAL

A PRODUCT OF:

Champ-UniLift
850 State Hwy 55
Brooten MN 56316

www.ChampUniLift.com

Publication No. 4500360-1/0410

Courtesy of Crane.Market

OPERATOR SAFETY

Training Checklist For The 538 UniLift

Please review the Checklist items. Initial each item then sign and date this Checklist below.

The ONLY person permitted to operate the 538 UniLift shall be the person who has
received instructions prior to rental.

I have received instructions and understand the operation and proper use of the 538
UniLift controls. I agree to use the 538 UniLift in a manner consistent with its intended
application.

I have received instructions and understand the use of the outriggers to set up and level
the 538 UniLift.

I understand that the maximum bucket capacity of the 538 UniLift is 300 lbs.

I have received instructions and understand the use of the Emergency Manual Lowering
Valve and other emergency procedures.

I will not attempt to alter or disable any safety devices, guards, or interlocks.

I have been shown the location of the Operators Manual, and was instructed to read the
manual prior to operation.

I understand that the 538 UniLift is NOT INSULATED and shall not be used within 10
feet of any power lines.

I will wear the body harness, with the 4 ft. lanyard attached, at all times when operating
the 538 UniLift from the bucket.

I have received instructions and understand the procedures for stowing the boom and
outriggers, and locking the bucket in place before transporting the 538 UniLift.

Before transporting the 538 UniLift, I will verify that the tongue is securely attached and
locked to a 2-inch hitch ball, safety chains are in place, and the trailer lights are operable.

4590004 03/06

Signed: Date:

Courtesy of Crane.Market

EQUIPMENT USE AND SAFETY

Safe Setup And Use Of The 538 UniLift

Please review the following setup and use instructions before operating the 538 UniLift.

1. Make sure the 538 UniLift has been safely set up away from power lines (maintain at least
10 feet of clearance).

2. Disconnect the 538 UniLift from the transporting vehicle before setup. If the unit is parked
on a slope, chock the wheels or set the outriggers first, to prevent rolling.

3. Extend and set up the outriggers (setup instructions are located at each outrigger). Make
sure the outriggers are set on solid footing. The green light on the lower control panel
indicates that the outriggers are properly set. NOTE: If the green indicator light is lit

before all four outriggers are set, the unit is not safe to operate.

4. If the 538 UniLift is set on a slope (5° maximum), the outriggers MUST be used for leveling.

5. Make sure all electrical power cords are safely stored to prevent tangling or crushing.

6. Always wear the proper body harness, and keep the harness secured to the lanyard ring
whenever operating the 538 UniLift from the bucket.

7. DO NOT exceed the manufacturer's rated lifting capacities.

8. The lower controls are for emergency use only, when a worker is present in the bucket.

9. It is PROHIBITED and DANGEROUS to use railings, planks, ladders, or other devices in the
bucket to achieve additional working height or reach.

10. Watch for overhead obstructions when booming up.

11. Keep observers and other workers out of the work area.

12. DO NOT lift materials with the lanyard ring while operating the 538 UniLift from the bucket.

13. When using the 538 UniLift as a crane, DO NOT stand under the load.

14. Make sure the boom and outriggers are properly stowed, and the bucket is securely locked
in place before transporting the 538 UniLift.

15. DO NOT operate the 538 UniLift if it is in need of repairs.

16. Be sure to read and thoroughly understand the Operation Section in the Operators
Manual.

4590004 03/06

Courtesy of Crane.Market

TABLE OF CONTENTS

Subject Page

DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

TRANSPORTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

PARKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SETTING THE OUTRIGGERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Jack-Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Crank-Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CONTROLS (Thru S/N: 2234). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

CONTROLS (S/N: 2235 & Above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4A

Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4A

Lower Control Station.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4A

PRE-START INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

BUCKET LOCK.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

BUCKET OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

CRANE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SYSTEM RECHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

EMERGENCY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Power “ENABLE Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Station Override Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Emergency Stop Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

EMERGENCY MANUAL LOWERING VALUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

EMERGENCY PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

PLATFORM CONTROL STATION SWITCH FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

LOWER CONTROL STATION SWITCH FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

HYDRAULIC LINE FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

POWER FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

BUCKET OPERATOR DISABLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

BOOSTER CABLE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

45 003 60-1 /1 101

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Courtesy of Crane.Market

Page i - 1

DESCRIPTION

The UniLift Model 538 Universal Crane and Personnel Lift functions as both a personnel carrier and crane, in one unit. A
single operator can use the UniLift as a personnel carrier or a universal crane with no conversion time. The unit is also light
enough to be rolled by one person.

The UniLift Model 538 consists of the following basic components:

Figure i-1.

UniLift With Personnel Bucket Attached

ADJUSTABLE OUTRIGGERS

Outriggers are used for absorption of tipping load during use, and are manually set. Adjustable for up to three feet, the
outriggers assure that the unit can be leveled and rest firmly on solid footing. Electrical interlocks prevent lift/crane
operation until all four outriggers are fully extended and resting firmly on the ground. A green light is located on the lower
control panel, indicating that all outriggers are set up on solid footing.

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Page i - 2 - Description

SINGLE AXLE TRAILER FRAME WITH 2" DIAMETER BALL COUPLER AND THIRD WHEEL

A torsion bar type of axle, rated at 3000 pounds, is used for road stability while towing. The 2" diameter ball coupler and
third wheel assembly are provided as standard equipment, allowing the unit to be transported to a job site and unhitched.
WARNING: DO NOT ATTEMPT TO TOW THIS LIFT WITH A HITCH BALL OTHER THAN 2". Safety chains
are also provided and shall always be attached when the unit is to be transported. Tire size is P205/75R14 with a max load
rating of 1532 Lbs. at 35 psi.

PEDESTAL AND UPPER CONTROLS

A full set of controls is provided at both the bucket and the pedestal. ENABLE-OFF-DOWN-OVERRIDE switch is located
at the bucket controls, with an override switch located at the pedestal controls. A key switch is provided at the pedestal
controls for security. A manual boom lowering valve is also provided at the base of the hydraulic pump assembly.

POWER REQUIREMENTS AND CHARGING CAPABILITIES

The unit is powered by two (2) 6 VDC deep cycle batteries, connected in series, yielding 12 VDC for approximately eight
hours of operation under typical use. A built-in 12 VDC, 30 amp battery charger is provided to restore charge to the
batteries, and is equipped with automatic cutoff when full charge is reached. The battery cutout relay permits operation while
the unit is plugged in and the batteries are recharging. (See the section on Inspection and Maintenance for more details on
battery system.)

HYDRAULIC LIFT AND TELESCOPING CYLINDERS

Aerial lift is provided by a 3" single acting cylinder, attached to the upper and lower booms. Telescoping lift is provided
by a 1-1/2" double acting cylinder, located inside the upper boom/telescoping boom assembly. The telescoping boom will
extend up to 9 feet allowing a side reach of approximately 24 feet. Hydraulic power is provided by a 12 VDC hydraulic
system, connected to the 3" lift cylinder attached to the upper and lower booms.

COUNTERWEIGHTS

Four (4) counterweights are mounted at the back of the unit to provide proper stability. These counterweights must always
remain in place when using the aerial lift.

SURGE BRAKES (OPTION)

Hydraulic brakes are available as an option. They are surge activated and use a standard 2" diameter ball coupler. A
breakaway chain is provided for emergency stopping.

LEVELING SAFETY SWITCH (OPTION)

The leveling safety switch continuously monitors the trailer for an unsafe tilt condition (exceeding 5°) during set-up and
operation. The green Trailer Level Indicator Light is on when the trailer tilt is within the 5° range. If the tilt exceeds the
limit during set-up, the controls will not operate. If an unsafe condition occurs during operation, only the "in" and "down"
functions will work.

PERSONNEL BUCKET

The fiberglass personnel bucket is gravity leveled and hydraulically dampened with positive work position locking. The
bucket is made removable for crane operation if required. Travel limits prevent continuous rotation of the boom and bucket.
A body harness is provided with each unit and shall be worn at all times when operating unit from the bucket.

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Description - Page i - 3

UNIVERSAL CRANE

Two (2) anchor points are provided for lifting loads up to 500 pounds with the personnel bucket removed. The inner lanyard
ring has a 500 pound load rating with the boom fully retracted. The outer lanyard ring has a 300 pound crane-load rating
in any position. (See Figure i-2) Note: The 500 pound load rating is ONLY during crane operation, and ONLY on the

inner ring with the boom fully retracted.

WARNING:NEVER LIFT OVER SPECIFIED WEIGHT OR TIPPING CAN OCCUR, CAUSING

SERIOUS INJURY OR DEATH TO OPERATOR.

Figure i-2

Personnel Lift/Crane Work Area

DANGER

ELECTROCUTION HAZARD, STAY AT LEAST 10 FEET FROM POWER LINES. THIS UNIT IS

NOT INSULATED FROM ELECTRIC SHOCK. DEATH OR SERIOUS INJURY TO OPERATORS

AND/OR BYSTANDERS CAN RESULT FROM CONTACT WITH ELECTRICAL WIRES.

45 003 60-1 /1 101

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