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MANUAL - Simeri

1. OLLO e e 2 ui a ca y e sell e TY gt lt gt lt 1 LE EZ CLO m E 219 2 8 ty gt E 619 SE 919 919 4 Le VN A 5 EN AT ez L TW ar LT epuijA9 ejoujod f CH dl jepuijA9 yr1 508244 002 Page 5 6 508244 002 Page 5 7 ILLUSTRAITED PARTS LIST SECTION 6 ILLUSTRATED PARTS LIST INTRODUCTION This section lists and illustrates the replaceable assemblies and parts of the 26 Work Platform as manufactured by UpRight Po
2. re 15 Blocking The Elevating Assembly 15 Scissor Brace Installation 15 Scissor Brace 15 SENSOR DC 16 Testing the Level Sensor 16 Hydraul cc or bus eee 17 Check Hydraulic Fluid os ie icono dei rd Ie ie 17 Battery MaI lenanee aT 17 ENEE Gass deos cose wet QE aaa a wana BN 17 Daily Inspection and Maintenance 18 Daily Preventative Maintenance Check 16 18 Maintenance Table Key 2 18 Maintenance 18 TO DOCCHICAUONS ca das DIUTIUS 19 rU 20 El 10051 RE 21 Page 2 1 INTRODUCTION 1 INTRODUCTION This manual covers the X26N Work Platform Figure 1 Manual Storage Information The manual MUST be stored in the box provided in the machine cage AT ALL TIMES LL 010076 901 Rea
3. 8 OMS rum 9 Platform ExIENSIOM T 9 Travel With the Platform Lowered hn 9 vicio Ge eg odio E e ME EE adrede a e E 9 Elevating the Platform aaa 4 10 Travel with Work Platform Elevated 10 Lowering the 10 Emergency LOWEIING min c car na deos c a CU cached de ca 10 Guardrails 4 11 Lowering Procedure vun aaa kapoi e daa SRS awaq Wa 11 Raising teen EE 11 Parking Brake Release un yd V dr 12 Release the Parking Brake 12 Engage the Parking Brake X aha bn a 12 After Use Each 12 8 Transporting the 13 ie 26 0 eo 13 Moving By 13 Driving or Winching onto Truck or 14
4. Sec 6 NOTES Sec 7 ILLUSTRAITED PARTS LIST Scissor ASSEMBLY 114200 001 Item Part Description 1 BEARING OILITE EP3236 24 2 LIFT CYLINDER 504129 002 ANSI SEAL KIT LIFT CYLINDER WELDMENT MID INNER TUBE 1 8 WELDMENT TOP BOTOM OUTER 114202 001 WELDMENT BOTTOM INNER 3 16 504103 000 WELDMENT MID OUTER 1 4 504122 003 WELDMENT PIVOT PIN 504122 001 PIN LIFT CYLINDER 501187 000 PIN SHAFT LOCKING 011764 032 RET RING TRUARC 5100 200 114203 001 WELDMENT SAFETY STAND 011248 005 NUT HEX 5 16 18 9 10 11 12 13 011248 006 NUT HEX 3 8 16 14 SCREW SHOULDER 3 8 16 X 3 1 2 011254 044 SCREW HHC GRS 3 8 16 X 5 1 2 WELDMENT MID OUTER ARM 1 8 PIPE RING 19 CHANNEL CABLE 2 025m 20 NUT HEX 1 4 20 SCREW HHC GRS 1 4 20 X 1 504108 002 WELDMENT MID INNER ARM 3 16 WELDMENT TOP INNER ARM 1 8 WASHER 2 DIA ASTM 25 ROLL PIN 1 2 X3 26 065367 001 BEARING TORRINGTON YCRS32 504176 002 WELDMENT TORSION ARM L H 011257 028 SCREW HHC 5 8 11 X 3 1 2 011246 010 5 8 11 THIN HEX 504123 000 PIN LIFT CYLINDER 31 503790 001 CHANNEL CABLE 1 054m 32 504122 006 WELDMENT PIVOT PIN 33 504176 003 WELDMENT TORSION ARM RH 011239 010 WASHER FLAT 5 8 ASTM PLUG 3 4 DIA CAP PLUG HOSE CLAMP 38 PIVOT PIN 39 PIVOT PIN 40 PIVOT PIN 41 PIVOT PIN 42 PIVOT PIN 15 18 21 22 23 24 21 28 29 30 34 35 36 Sec
5. 0 o E 5 5 alejo g 810 9 9 Saje 2 28 SERE o o gt 1 9 1 5 u 0 S 0 5 90 0 5 O 2 2 SE E 18 8 s os 9 z 5 2 5 lt 10 lt 9 Jo 2 2 6 9 5 O lt m lo je gt z S IH JH X lu Page 4 6 4 7 Hydraulic 4 7 HYDRAULIC Table 4 2 Hydraulic Troubleshooting Table Component LL 5 15 o 5 E 6 a lo gt 16 214 Counterbalance Valve _ 1111111141111 11 s lll PL ET pese 2 PLETE 9 o w o Page 4 7 Notes Page 4 8 Section 5 SCHEMATICS 5 1 INTRODUCTION This section contains electrical and hydraulic power schematics and associated information for maintenance purposes The diagrams are to be used in conjunction with the information in Section 4 They allow understanding of the makeup and functions of the systems for checking tracing and faultfinding during troubleshooting analysis CONTENTS Electrical Schematic 5 2 Cable Assembly 11 55 5 3 Schematic J1 55 5 4 Overload Schematic
6. rubbing points Chassis Daily Check level Daily Check welds for cracks Daily SE Change Filter Check component for Oil Drain and replace oil lo y wanne D Zeg zag 2 11 s System Check hoses for exterior wear 300 RAR pre operation osy i n n Drive Motors Check for operation and leaks Daily inspectio Entire Unit for and repair collision Daily damage Lubricate 300 Emergency Check procedure for Dail Down Emergency Down y Check for wesen leaks Daily EE fasteners for proper SHH Hydraulic eege for leaks at mating 30d Check for corrosion remove UMP X surfaces and repaint 6m Check mounting bolts for proper crag kT labels eck for peeling missing or Daily labels amp EEN Wheels Check for loose components Daly Check fasteners for proper Oil pivot pi torque Daly 1 Platform Oil Oil king pins Oil king pins Check welds for cracks Dail Deck amp Rails E Check steering cylinder for 300 Check condition of deck Daly steering Check entry way closure Daily System Check hardware amp fittings for proper torque Check Wheel Yoke Securing Bolt and Nut 30d NOTE Use ISO 46 during
7. wisa S S S Saas 3 10 Malli FIyarauli on cu tse da des do RR e o dice oe ege d ded 3 11 Setting Hydraulic Manifold Pressures 3 12 3 9 CVINGGIS 5 ecg ee cet pew Godna DIG Ed E WEG RETE GE GiG wane canes 3 13 Depression CYINJEM ws as E OR de CR d Roa Dor era 3 13 SIEH CYINdER sus nenne oan Esa w ce 3 14 Emne ESAS eS 3 15 3 10 Drive e de CEET 3 16 2525 56 55 EE 16 A eee eee as Ka 3 16 A o EE 3 17 011 018 64 4664 cas 3 17 Chassis Controls 3 18 508244 002 Section 3 Service Repair Supporting Elevating Assembly 3 1 SUPPORTING ELEVATING ASSEMBLY AWARNINGA Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace Figure 3 1 Elevating Assembly Brace INSTALLATION 1 Park the machine on a firm level surface 2 Pull Chassis Emergency Stop Switch to
8. 5 7 5 2 394 2140441 E 07 p E R o o yoa AX Are 16 985 2054935 SNUIN ajqvuj As 185 3 57 491 04 4010 9 5014 E 4O40WN dung Ausqqog B penddns lt a 91414080 rer 36 10 lt 24010 rar lt Da RES 521009475313 lt sn oj IE emer COT 33984 49131086 mE 5214043391 A yz Jir 91 17 N 5 IT 4504 31980 99551 5 3 A A R A 2 1 S 9 Ca SAUINHU TOY O sm du 10400 GSHILIMS 20 2 GND 1 86 10 VI IF 201 17 901 17 NG NA NG M M d bd 2 rd 3 bd 9 3 bd WAS VO ISOd 340 93 23 1048 2 UMOT dois 3 doys 3 ES O O AUSNOALUOI 40410 JAS UDLIMS Asy Jeuod PUNOAD ENSCH PZYD IMS 30 2 Eo IS 508244 002 Page 5 2 2 WIRE IN VATION TABLE 1 Y ITEM POSITION COLOR LENGTH ITEM
9. 508244 002 Section 3 Service amp Repair Cylinders 3 9 GYLINDERS DEPRESSION GYLINDER REMOVAL 1 W Place a support under the depression guard Remove the circlips from the pivot pins Remove the pivot pins while supporting the Remove the cylinder Figure 3 14 Depression Cylinder Mark and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering cylinder REPAIR DISASSEMBLY 1 Unscrew the head cap from the barrel removing the head cap piston and shaft assembly from the barrel tube Unscrew the piston Remove all rod wipers U cups O rings and backup rings from the headcap and discard Remove the piston ring and O ring from the piston and discard CLEANING AND INSPECTION ON Wash all the metal parts in cleaning solvent and blow dry with filtered compressed air Inspect all the threaded components for stripped or damaged threads Check the inside surface of the cylinder barrel for scoring or excessive wear Check the piston and headcaps for scoring excessive wear Inspect the surface of the shaft for scoring or excessive wear ASSEMBLY 1 Install the headcap onto the shaft Install the new piston rings and O ring on the piston Re install the piston O N Lubricate and install new wiper U cup O ring and backup ring on the headcaps Lubricate the pist
10. PLATFORM CAPACITY The maximum capacity for the MACHINE including occupants is determined by model and options and is listed in Specifications on page 20 A DANGER DO NOT exceed the maximum platform capacity or the platform occupancy limits for this machine MANUAL FORCE Manual force is the force applied by the occupants to objects such as walls or other structures outside the work platform The maximum allowable manual force is limited to 200 N 45 Ibs of force per preson with a maximum of 400 N 90 Ibs for two or more occupants A DANGER DO NOT exceed the maximum amount of manual force for this machine LIFT OVERLOAD ALARM All models include a feature that alerts the operator when the platform load is exceeded If the alarm sounds during the lift function lower the platform and reduce the platform load A DANGER A NEVER operate the machine with a platform load greater than the rated capacity and never in wind conditions that exceed the maximum allowable for this machine Beaufort 4 Refer wind chart on page 7 Page 2 5 Page 5 4 CONTROLS AND INDICATORS 4 CONTROLS AND INDICATORS The operator shall know the location of each control and indicator and have a thorough knowledge of the function and operation of each before attempting to operate the unit Figure 3 Controls and Indicators Platform Controls Drive Selectors Horn Button Lift Lower Button Emergency Stop Button Displa
11. POSITION COLOR LENGTH ITEM NO POSITION COLOR LENGTH 1 Al YELLOW FROM ITEM 85 11176mm 4409 3 Bl ORANGE FROM ITEM 85 11176mm 440 25 1 BROWN FROM ITEM 85 11176mm 4407 A 2 Ae BLACK FROM ITEM 85 11176mm 4407 14 Be 1 RED SINGLE WIRE 252mm 107 PE Ce WHT SINGLE WIRE 544mm 2149 3 BLACK SINGLE WIRE 544mm 21 4 5 B3 BLUE SINGLE WIRE 544mm 2147 27 E PINK FROM ITEM 88 864mm 347 4 4 NOT USED 6 B4 PINK FROM ITEM 88b 508mm 209 28 C4 GRAY FROM ITEM 88b 508mm 209 5 5 URANGE SINGLE WIRE 924mm 36 47 7 BS BLACK SINGLE WIRE 924mm 36 47 29 C5 GRAY FROM ITEM 88a 3810mm 1505 6 PINK FROM ITEM 88a 3810mm 1505 8 B6 LIGHT BLUE SINGLE WIRE 750mm 29 57 30 06 WHITE BLUE SINGLE WIRE 750mm 2959 7 A7 WHITE BLACK SINGLE WIRE 750mm 295 9 87 BLUE BLACK SINGLE WIRE 750mm 29 57 31 C7 ORANGE SINGLE WIRE 750mm 2959 lt 8 8 WHITE SINGLE WIRE 750mm 29 57 20 B8 BLACK SINGLE VIRE 750mm 29 57 3e C8 GRAY FROM ITEM 88c 864mm 34 9 9 NUT USED 21 39 RED SINGLE WIRE 1500mm 595 33 09 BLACK SINGLE WIRE 696mm 27 47 10 10 RED SINGLE WIRE 696mm 27 47 22 B10 BLUE SINGLE WIRE 1500mm 59 34 C10 BLUE PURPLE SINGLE WIRE 1500mm 597 11 AU BLACK ORANGE SINGLE WIRE 1500mm 597 23 811 PINK 81 FROM ITEM 89a 695mm 27 47 35 cu GRAY 2 FROM ITEM 89a 695mm 27 32 er 12 Ale GRAY 82 FROM ITEM 89b 495mm 4959 24 Bie BLUE 83 FROM ITEM 89b 495mm 1959 36 12 PINK 81 FRO
12. S Snorkel MANUAL Part Number 511107 200 Feb 2010 Serial Number 53119 and after 26 English When contacting Snorkel for service or parts information be sure to include the MODEL and SERIAL NUMBER from the equipment Nameplate Should the nameplate be missing the SERIAL NUMBER is also stamped on top of the chassis above the front axle pivot Front View Stamped Serial Number Access Rear View Nameplate is fitted to rear of Chassis FOREWORD How TO USE THIS MANUAL This manual is divided into six sections SECTION 1 INTRODUCTION General description and machine specifications SECTION 2 OPERATION AND SPECIFICATION Information on how to operate the work platform and how to prepare it for operation SECTION 3 MAINTENANCE Preventative maintenance and service information SECTION 4 TROUBLESHOOTING Causes and solutions to typical problems SECTION 5 SCHEMATICS Schematics and valve block diagram with description and location of components SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations SPECIAL INFORMATION DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or modera
13. PSUDLIMS 24 ER ayoung 48 43 880 pua y uo 0 23 602 9 pua y uo UO4D8UU0D je ua 81 Um youbis ayy Siop usy pua Xy 9 SAM OMY BI au uo 40428uuo02 U4N48142041848 04104 1204481J8 0U 0d pua ay uo 404328uu02 fua 344 uo 40328Uuu02 Dua y uo 40428Uuu02 BUS 844 uo 40328UuUu02 DAV 8 DAV S40129uuUo02 04 828 OMY ur m Sum 81 4211 81 4 0 FNRUSS gv I 6262S dwy X Hnpuod 0 Hnpuod 8 4052 18 3 0 814062 714 0 81 3062 8la 41 3062 81 pua6a 40428uu03 y uo 40 D UUOD ULM OMY BI maf pua y uo 40428uu02 OMY 81 58072 18 493 24 MS
14. Thoroughly study hydraulic and electronic schematics in Section 5 Check for loose connections and short circuits Check repair replace each component in the Truth Table that is listed under each machine function that does not operate properly Use the charts on the following pages to help determine the cause of a fault NOTE Spike protection diodes at components have been left out of the charts to eliminate confusion When troubleshooting ensure that the work platform is resting on a firm level surface When performing any service that requires the platform to be raised ensure that the platform and booms are supported by a crane capable of supporting the load Unplug the machine or disconnect the battery when replacing or testing the continuity of any electrical component Page 4 1 Troubleshooting 4 2 Troubleshooting 4 2 TROUBLESHOOTING 1 Verify your problem Do a full function test from both the platform and chassis controls and note all func tions that are not operating correctly 2 Narrow the possible causes of the malfunction Use the troubleshooting guide to determine which components are common to all circuits that are not functioning correctly 3 Identify the problem component Test components that are common to all circuits that are not functioning correctly Remember to check wires and terminals between suspect components Be sure to check connections to battery negative 4 Repair or rep
15. elevate or elevates slowly 1 Blown electric motor fuse 2 Faulty battery charger Faulty battery ies Loose or broken battery lead Emergency Stop switch es failed open Blown control fuse Oil level in hydraulic reservoir 15 low Faulty hydraulic pump Emergency Lowering valve open Check 160 amp electric motor fuse Replace if blown Check the voltage output of the battery charger If less than 24 VDC After completely charging batteries test each battery Replace as Check continuity of all battery and motor leads Replace if necessary With emergency stop switch in the ON position check continuity Check 7A circuit control fuse Replace if blown Check hydraulic fluid level top off as required Check pressure and delivery of the hydraulic pump Replace if Close emergency down valve Platform Observe maximum load rating see Operation section of this manual overloaded Faulty controller at upper controls Check functionality of controller Replace if faulty Blown control fuse Check 7A circuit contrrol fuse Replace if blown 5 Battery level low Check for fault code 68 Check Battery Voltage Charge if necessary Platform drifts 1 Emergency down after being lowering valve elevated open Ensure that emergency lowering valve is completely closed Replace 2 Leaking piston seals in lift cylinders Check for leakage at cylinder return li
16. 503724 000 x2 d ww 100076 901 18 501453 000 x4 014222 903 MAX 340 kg MAX 340 kg 014222 903 x4 066522 900 502480 000 060197 001 066551 950 005221 000 503723 000 Sec6 27 CE DECALS Control Module Upper Control Box Sec 27 ILLUSTRAITED PARTS LIST ANSI DEcALs 1 UpRight X26N 508667 000 UpRight 508661 000 Qty 2 A Failure to read understand and obey the following safety rules will cause death or serious injury Collision Hazard Impact from decending platform may cause injury stand clear TIP OVER HAZARDS ELECTROCUTION HAZARD FALL HAZARD NOT elevate or drive elevated on DO NOT operate within ten feet of power DO NOT climb guardrail THIS MACHINE IS NOT INSULATED Make sure guardrails are fastened securely Look up down and around for electrical cure gate or chain across entrance wires DO NOT use ladders or scaffolding on platform 066556 000 mes ee 066550 000 DANGER TIP OVER HAZARD MAXIMUM DISTRIBUTED LOAD 250 LBS OR 1 OCCUPANT ON EXTENDED DECK MAXIMUM SIDE LOAD 100 LBS 101251 000 Explosive gas is generated when charging batteries DO NOT expose to sparks or flames 066561 900 066552 000 066552 000 066561 900 OPERATORS C
17. e SMAHU 103 OT TW 3 zk Elan ae SIAMM S91909 17 199 do s 3 19 y ANd 0402 102 do4s 35 3 19 Ze z w 0402 JOD 9 02 2003 I 40j Asso SseuJoy aes 19404 ci a e NIA vZ t 6Lbv0l SUI 4201409 1d IND 3094 YIM 6 06169 a gt oqdooau p Geb0l S a l Dat SNUIW gt U 193 9 221195 1109 245 014 OL 5g we a a a NADG ISNA 3983 3 18 A ND JIDIHIA NA 8 Na 11012412 NADA AONADJAWI 508244 002 Page 5 4 Schematics 5 5 OVERLOAD SCHEMATIC K dd TEN NON 038 3 ONILSIX 4 OL 3 dd 9 A ANA 31 QL 4 91907 3H1 3 e 93 IV SI y Se x aet 40 X 3AO8V N3dO GIN ey 93N 11 SSVdAH Y Veal VO al GU 318 3 3400 9 doo CY AVI3M GE Page 5 5 508244 002 Schematic 5 6 Hydraulic
18. instruction manual 066554 000 061220 002 066554 000 005221 000 All personnel shall be qualified read undrestand and obay all safety rules operating instructions and manual of reponsibilities before performing maintenance on or operating any mobile elevating work platform 508772 000 068635 001 2 MEETS EXEEDS THE REQUIREMENTS OF ANSI A92 6 1999 Sec6 29 Sec6 30 Local Distributor Lokaler Vertiebshandler Distributeur local El Distribuidor local Il Distributore locale EUROPE MIDDLE EAST AFRICA 8 ASIA PHONE 44 0 845 1550 057 FAX 44 0 845 1557 756 NORTH 8 SOUTH AMERICA PHONE 1 785 989 3000 TOLL FREE 1 800 225 0317 FAX 1 785 989 3070 AUSTRALIA PHONE 61 2 9725 4000 FAX 61 2 9609 3057 NEW ZEALAND PHONE 64 6 3689 168 FAX 64 6 3689 164 snorkel
19. on the chassis between the scissor sections and is covered with a protective metal box Figure 10 Level Sensor ON SANSAR SS 8 MZ SJ The Level Sensor is located on the chassis of the machine These units are sealed and pre set and require no recalibration or adjustment HYDRAULIC FLUID The hydraulic fluid reservoir is located in the cont Figure 12 Hydraulic E 1 14 4 gt d di gt m t x 4 maA ME NOTE Never add fluid if the platform is elevated 0 Fluid Reservoir and Dipstick CHECK HYDRAULIC FLUID 1 Make sure that the platform is fully lowered 2 Open the chassis door 3 Remove the filler cap from the hydraulic fluid reservoir 4 Check the fluid level on the dipstick on the filler Cap 5 Add the appropriate fluid to bring the level to the FULL mark See Specifications on page 21 Page 2 16 9 MAINTENANCE BATTERY MAINTENANCE AWARNINGA Hazard of explosive gas mixture Keep sparks flame and smoking material away from batteries Always wear safety glasses when working near batteries Battery fluid is highly corrosive Thoroughly rinse away any spilled fluid with clean water Always replace batteries with UpRight batteries or manufacturer approved replacements weighing 30 kg 66 Ibs each Check the battery fluid level daily especially if the machine is being used in a warm dry climate f electrolyte level is lowe
20. platform NOTE The Pothole Support Rails will deploy automatically as the platform elevates and will remain deployed when traveling in the Elevated position refer fig 5 They will automatically retract when the platform has been lowered completely and machine is about to be driven refer fig 2 4 TRAVEL WITH WORK PLATFORM ELEVATED NOTE The machine will travel at reduced speed when the platform is elevated a LOWERING THE PLATFORM 1 Select LIFT mode 2 Check around the base of the platform to ensure that no one 3 The platform will stop when it reaches the pre determined EMERGENCY LOWERING AWARNING A If the platform should fail to lower NEVER climb down the scissor assembly A second operative should operate the Emergency Lowering Valve Knob while keeping clear of the scissor assembly The Emergency Lowering Valve Knob is located at the rear of the machine behind the ladder 1 Check that the route is clear of surface hazards such as holes drop offs bumps curbs or debris Check that the route is level and is capable of supporting the wheel loads Check clearances above below and to the sides of platform Select DRIVE mode Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction The speed of the machine will vary depending on how far from centre the Control Handle is moved If the machine is not level the level sensor alarm
21. the hole in the steering link 5 Remove the plugs from the hose assemblies and connect to the drive motor 6 Install the shaft key wheel washer and slotted nut Torque the locknut to 102 N m 75 ft Ibs Install a new cotter pin DO NOT back off the nut to install cotter pin 7 Remove blocks lower the jack and remove Operate the drive system and check for leaks Page 3 16 508244 002 Section 3 Service Repair Controls 3 11 GONTROLS PLATFORM GONTROLS The Proportional Controller can be disassembled to replace defective switches See the Parts Manual for replacement part numbers Figure 3 19 Platform Control Box 1 Control Box 5 Mounting Plate 2 Emergency Stop 6 Box Seal 3 Joystick 7 Circuit Board 4 Decal 8 Socket Main Harness 508244 002 Page 3 17 Controls Section 3 Service Repair 5515 GONTROLS Figure 3 20 Lower Control Box The chassis control assembly is mounted on the inside of the chassis door to the left of the Hydraulic tank LCB Box Lid LCB Box Emergency Stop Toggle Switch Enable Button Key Key Switch Page 3 18 508244 002 508244 002 Page3 19 Maintenance Torque Specifications TORQUE SPECIFICATIONS HYDRAULIC COMPONENTS NOTE Always lubricate threads with clean hydraulic oil prior to installation Use the following values to torque hydraulic components used on UpRight Work Platforms Table Torque Specifications for Hy
22. two on each steering pivot see Figure Lubricate the steering pivots every 125 hours or three months 1 Deploy the maintenance brace see Blocking the gt Elevating Assembly A 2 Clean the grease fittings and surrounding area UN R 3 Using multipurpose grease in a grease gun pump the grease into the fitting until grease just begins to appear at the edges of the pivot 4 Wipe off any excess grease lt lt N Figure 3 4 Lift Ram Scissor Pin Lubrication Points 3 6 BATTERIES The batteries are located in a slide out tray in the rear of the machine Electrical Energy for the motor is supplied by four 6 volt batteries wired in series for 24 volts DC Correct care and maintenance of the bat teries and motor will ensure maximum performance from the work platform CAUTION If battery water level is not maintained batteries will not fully charge creating a low discharge rate WARNING Hazard of explosive gas mixture Keep sparks flame and smoking materials away from batteries Always wear safety glasses when working with batteries Battery fluid is highly corrosive Thoroughly rinse away any spilled fluid with clean water Always replace batteries with UpRight batteries or manufacturer approved replacements Before disconnecting the battery negative lead make sure all switches are OFF If ON a spark will occur at the ground terminal which could cause an explosion i
23. without blocking elevating assembly INSPECT the machine thoroughly for cracked welds loose or missing hardware hydraulic leaks loose wire connections and damaged cables or hoses before using VERIFY that all labels are in place and legible before using NEVER use a machine that is damaged not functioning properly or has damaged or missing labels To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platform and in its working range NEVER charge batteries near sparks or open flame Charging batteries emit explosive hydrogen gas Modifications to the aerial work platform are prohibited or permissible only at the approval by UpRight AFTER USE secure the work platform from unauthorized use by turning the Keyswitch OFF and removing key Page 1 CONTENTS PAGE Ve e e e D de WEE 3 Special Information 2 SR agent ae e ie 3 2 General Deschipllon saa aaa KOSSACK aR SSSA 4 3 Special LimitationS hes UR ai na W E 5 Platform can eos ene is 5 ee 5 Lift Overload Alam piro EL edad e a 5 4 Controls and EE EEN 6 5 Pre Operation Safety 7 6 System Function
24. 00 SOCKET OVERLOAD 11 502496 000 UCB BOX ONLY Sec 19 ILLUSTRAITED PARTS LIST ELECTRICAL ASSEMBLY 8 e Sec6 20 ELECTRICAL ASSEMBLY Item Part Description Jl HARNESS MAIN MANIFOLD BLOCK UPPER CONTROLS LOWER CONTROLS 505566 001 TILT SENSOR wmr MN SI EE 10 502494 000 FUSE 1 12 502594 000 HARNESS BATTERY DISCONNECT BATT 1 069 199 001 058783 000 CHARGER DISCONNECT PLUG 502597 000 HARNESS CHARGER DISCONNECT LINE CON4 502598 000 HARNESS CHARGER DISCONNECT BATT 502599 000 HARNESS CHARGER DISCONNECT LINE CON2 502600 000 LINE CONTACTOR 3 FUSE 502601 000 LINE CONTACTOR 5 LINE CONTACTOR 3 502489 000 LINE CONTACTOR 502602 000 LINE CONTACTOR 2 MOTOR CONT B 16 17 18 19 20 21 22 23 24 2 26 21 28 Sec 21 ILLUSTRAITED PARTS LIST ILLUSTRAITED PARTS LIST HYDRAULIC ASSEMBLY Sec6 22 HYDRAULIC ASSEMBLY Item Part Description 09420 000 HYDRAULIC HOSE BLOCK SERIES PARA BLOCK 2 1 09421 000 HYDRAULIC HOSE BLOCK D2 SERIES PARA D2 1 509416 000 HYDRAULIC HOSE SERIES PARA BLOCK MOTORS 4 1 509417 000 HYDRAULIC HOSE BLOCK BRAKE TEE 509422 000 HYDRAULIC HOSE BRAKE TEE MOTORS 509423 000 HYDRAULIC HOSE BLOCK STEERING CYLINDER 2 5 509425 000 HYDRAULIC HOSE BLOCK POTHOLE TEE 509418 000 HYDRAULIC HOSE
25. 000 STOP 502131 000 WEAR PAD 502097 000 WASHER SAE 1 1 4 PLATED 502145 000 LEVER BRACKET Item Part Description Qty 18 003570 005 PULL PIN WITH KEY RING 1 504138 000 WELDMENT 1 502132 001 PLATFORM ROLLER 4 504138 000 EN T m 14 505300 006 SWING BAR 1 Sec 13 ILLUSTRAITED PARTS LIST CONTROL MODULE ASSEMBLY tem Part Description Qty 2 062791 002 LATCH 1 Part Description Qty 503800 001 MAIN MANIFOLD BLOCK GUIDE PAD Item 12 5 HYD CYLINDER POTHOLE 8 19 04132 000 HYD CYLINDER POTHOLE 1 057534 000 FILLER amp DIPSTICK 058359 000 SUCTION FILTER 066310 026 WDMENT CONTROL MODULE 504126 000 BUSHING MODULE HINGE 504135 000 BUSHING POTHOLE PIVOT 504153 001 PIVOT PIN POTHOLE WDMENT 1 2 Sec 14 Power MODULE ASSEMBLY Part 501074 000 Description BATTERY WELDMENT DOOR MODULE Qty 7 066309 01 1 066713 002 504132 000 LATCH WELDMENT POTHOLE BRACKET GUIDE PAD ANGLE HINGE HYDRAULIC CYLINDER HOLE ILLUSTRAITED PARTS LIST Part Description Qty Item ww rara 9 504153 001 PIVOT PIN POTHOLE Sec6 15 ILLUSTRAITED PARTS LIST HYDRAULIC MANIFOLD ASSEMBLY 503800 001 Part Description Qty 058358 000 FITTING 1 4 1 4 MALE MALE 057122 000 FITTING 3 8 3 8 MALE MALE 05737
26. 4 O O 2 4 SUldX8 4 6 O U ANI 29 4 92104 0d si O O APIO 84 89 x 8y pus1x3Ja 04104 ev 3 O sol 429044888 0u140g ASUBAS 22 78 Z UIN184120422848 044 04 AOMAO 4 18 y Cy O 19044 10 4 1 53 339149215 92 O O 9a DAY 81 at O ONY 81 sl 2118 Umoq ER 52 O O BER aquo UANJIYUMO 4 HT SJ cg O cg O O Gy JAY BI up 401v cy ro OMV 81 8 AND UUNYSHUUCH UJNL8 UJOH v2 k ANd UTUYOH a by pua ayy uo 6n Bula 2 6026 ULIM BI uaploy SNJ 205 01 81 3 ON O 403 oT pua ayy uo 8m 026 ULM 8I ABE E 136 EES El ed a V pua ayy uo 2 pGI96 2 DAY 81 2 230 8 eu pus ayy uo 2 pCI9E 2 ULM DMY 1 970 4933987 V 23 9349 25 0 23 pua out uo Bm 2 6086 81 205 ASMIJSIFI 04 eo OMY 81 6 310 E E 28 434 NOGE VES 31 3504 13086 24 oui uo On 2 YS19E 2 UMM SUM OMY 81 1 010 SC T ER IND 2 PIYIFIMS JUALZ 12 ds UN SNUINAUITOL oq
27. 5 5 Hydraulic Schematic 26 5 6 Page 5 1 5 2 ELECTRIC SCH Era D IA UMO Josua ver s us 428493 FUIT a fus1x38 0410d and z lt asuanej 20 GND 821 28 5 a2 nd ng sa u 921 1 040840 4 E 54 CC 281 17 1 PIOHIUON x r UUNL8JUMOTLJ m ISI 99 17 lt lt 4 e 8311 8 GND lt 339749945 29 17 YST Ave 28 10 lt lt uan19N12941 2839 0u30gd ESA 8 57 913517 12041 ENER ES zaa E 88 17 WAO 10110 UO ON ETE 757 6 618 44 9 L eld 7 E 2 4u8110g 1 1 saa o er 4 77 Y SLI 4 IND S2lu0u138 3 Si DND 192 21 2 av g l 2 EN
28. 6 8 ILLUSTRAITED PARTS LIST INSTALL WITH SPACER BLUCKS DOWN NOTE PRESS A BEARING IN FRUM EACH SIDE 3 X 3 TUBE UNTILL FLUSH WITH COLLAR USE WASHERS AS SPACERS DN BOTH SIDES ROLLER AS REQUIRED ALLOW FREE MOVEMENT ARMS UN PIN ITEM 48 REF INSTALL WITH N SPACER BLOCKS DOWN 42 PLUS Co PLE See 17 2 PLC S END GUSSETS TO INSIDE 48 PLACES PLUG LARGE HOLES IN END CAPS INSTALL WITH SPACER BLOCKS UP ILLUSTRAITED PARTS LIST PIN ASSEMBLY TYPICAL Scissor LIFT ASSIST ASSEMBLY Sec 10 ILLUSTRAITED PARTS LIST Item Part Description Qty 504122 001 PIVOT PIN STANDARD MEDIUM 504120 001 PLAIN BUSH 50mm 501449 000 FLANGED BUSHING 16mm 504176 002 WELDMENT TORSION ARM LHS 504176 003 WELDMENT TORSION ARM RHS 6 12 Sec 11 ILLUSTRAITED PARTS LIST MAIN DEck ASSEMBLY Item Part Description Qty Item Part Description Qty 066480 000 GATE 10 505300 010 SWING BAR 3 066497 026 WELDMENT GATE KICKRAIL 11 502204 001 TORSION SPRING 1 5 066441 000 PIVOT GATE 12 27899 000 U BOLT 1 0 505300 017 WELDMENT UPPER R H 13 066519 000 WELDMENT GATE HINGE 505300 012 GUARDRAIL MID 505300 015 WELDMENT UPPER L H Sec 12 ILLUSTRAITED PARTS LIST EXTENSION Deck ASSEMBLY Item Part Description 1 066251 026 WELDMENT DECK EXT 502148 000 WEAR PAD 502129
29. 642 001 BEARING GARLOCK 10DU12 58819 000 M6 GREASE NIPPLE 03673 000 BUSH 12DU08 503673 000 BUSH 12000006 510668 000 SPACER 504155 001 STEERING LINK SLIDE PAD 503755 000 CASTLE NUT 15 16 17 18 PIN BELL CRANK 19 503673 20 1 21 22 3 2 ILLUSTRAITED PARTS LIST Item Part Description 066865 100 COUNTERWEIGHT R BULKHD 502152 000 COTTER PIN 0 24 25 26 066866 000 COUNTERWEIGHT CASTING 27 28 502097 000 FLAT WASHER ASTM 504157 001 CUP BEARING With Seal 28a 504157 000 CUP BEARING TA 1 MES 32 510672 000 OLITE BUSH small 2 2 Sec6 5 ILLUSTRAITED PARTS LIST CHASSIS Scissor amp DEck ASSSEMBLY Part Description Qty Description 504001 011 CHASSIS ASSEMBLY 11 066183 001 BEARING EAGLE PICHER 114200 001 SCISSOR ASSEMBLY 323632 504003 011 PLATFORM WELDMENT 504186 000 MOUNTING PIN 12 066189 000 WEAR PAD 1 4 MOPDIEINSEIN NOTES LOCTITE ITEM 11 BEARING TO ITEM 1 CHASSIS AND PEEN 4 PLACES e 90 OUTSIDE EDGE OF BORE IN ITEM 1 TYP 2 PLC S SECLIR 2N USE WEAR PAD COMBINATION AS REQUIRED T AND ALIGN FRONT END SCISSUR STACK N AN UNA 4 EACH SIDE 5 3 EACH SIDE
30. 7 000 FITTING 1 2 1 2 MALE MALE 503803 000 CROSS LINE RELIEF VALVE DRIVE 503804 000 VALVE SOLENOID DRIVE E INE 10 11 12 Hydraulic Block Series Parallel 504151 000 ltem Part Description QTY 500303 000 SOLENOID COIL 18V 057122 000 HYDRAULIC FITTING 3 8 X 3 8 MALE MALE Sec6 16 ILLUSTRAITED PARTS LIST POTHOLE CYLINDER ASSEMBLY STEERING CYLINDER ASSEMBLY 504132 000 504148 001 Part Description Qty Part Description Qty LIFT CYLINDER ASSEMBLY PS 504129 001 ANSI 504129 002 Item Part Description Qty 058819 000 M6 GREASE NIPPLE 2 504120 000 FLANGED BUSHING 4 504129 011 SEAL KIT REF Sec6 17 ILLUSTRAITED PARTS LIST LOWER CONTROL Box ASSEMBLY tem Part Description Qty 504141 001 COVER LOWER CONTROL BOX 1 504142 000 BOX LOWER CONTROL BOX 501867 000 EMERGENCY STOP BUTTON 501866 001 KEY SWITCH 00 EMERGENCY STOP BUTTON 4 502251 000 TOGGLE SWITCH Sec 18 ILLUSTRAITED PARTS LIST UPPER CONTROL Box AsSEMBLY 504349 000 Item Description Qty EMERGENCY STOP BUTTON EMERGENCY STOP BUTTON 4 501882 001 RUBBER BOOT JOYSTICK 5092 00 SS SS 502453 000 CIRCUTT BOARD 502587 001 SOCKET MAIN HARNESS 10 502605 0
31. E ASSY W CONNECTOR 00996 000 HARNESS ASSY CABLE 88 14 CABLE ASSY X 9 064195 005 CABLE ASSY X 5 30 029601 039 CONN RING 5 16 10 12 19 20 21 22 23 24 23 26 27 28 29 30 ROUTE CABLE ACROSS FRONT ROUTE CABLE FRUM EMERGENCY LOWERING VALVE ALONG SCISSUR ARM THRU CABLE ACCESS HULE TO REAR MACHINE ILLUSTRAITED PARTS LIST SEE NOTE VEN THRUST WASHER BOTTOM EACH SIDE ILLUSTRAITED PARTS LIST CHASSIS ASSSEMBLY FRONT Item Part Description Qty Item Part Description Qty mr 2 504144 001 BEARING 2 066159 001 L H STEERING LINK 3 504148 001 STEERING CYINDER I l 10 504150 000 BEARING 2 114055 002 MOTOR HYDRAULIC 2 n 114057 000 L H STEERING ANGLE 1 502170 000 WHEEL 8 TYRE l 4 12 114058 000 R H STEERING ANGLE 1 1 6 066869 000 CHASSIS 1 13 066313 001 BELL CRANK 7 502171 000 HUB FRONT 066158 001 R H STEERING LINK m USE DNE DR MORE THRUST BEARINGS BETWEEN STEERING PIN AND CHASSIS FUR 1 16 TO 3 16 CLEARANCE UNTIL IT CONTACTS SPINDLE SHAFT BACK DFF 1 8 TU 1 4 TURN AND LOCK IN PLACE WITH JAM NUT ITEM 44 SCREW IN SET SCREW ITEM 418 SET DOUTER BEARING FLUSH WITH END DF BURE SET INNER BEARING BOTTOM DF BURE Sec6 4 CHASSIS ASSSEMBLY REAR Item Part Description Qty 504151 000 VALVE ASSEMBLY 0 062
32. HECKLIST INSPECT AND OR TEST THE FOLLOWING DAILY OR AT THE BEGINING OF EACH SHIFT 1 UWHLE FUWEHLI LEULIEO WEUBF 2 JDHW LUIOHLWNC EIOFLEI 3 SISJDL 4 DIFJWPEIOFJDN KJ UUNHFL 6 H HUOI JKHILHB IJPIJ BN 7 HJBUIHO YT YUGHIU IOJ PJJ 9 JNIKMNMNEV N NMBJ NLINL JKN J 10 UGVUVUV GUY YGUYY BNDFSES 11 HJGVJ JHB H BPLKLIO PO OPP OPO 300699 KEEP CLEAR OF SCISSORS BLOCK SCISSORS BEFORE SERVICING 066553 000 2 066553 000 908770 000 BATTERY DISCONNECT MAXIMUM LOCATED INSIDE 1 4 WHEEL LOAD USE DISCONNECT BEFORE SERVICING WORK PLATFORM OR BATTERIES 066555 000 101252 005 107051 000 1750lb CRUSHING HAZARD KEEP ALL BODY EMERGENCY RUES 6 LOWERING 16 17 066556 001 4 014222 003 x2 066558 000 010076 001 DO NOT REPLACE COMPONENTS CRITICAL TO MACHINE STABILITY SUCH AS BATTERIES AND WHEEL EQUIPMENT WITH A D A N E R LIGHTER WEIGHT OR NON FACTORY APPROVED SUBSTITUTES TIP OVER HAZARD 7 MAXIMUM DISTRIBUTED 1 8 1 9 BATTERIES ACT AS COUNTERWEIGHTS 50077 1 000 PLATFORM LOAD 700 155 EACH REPLACEMENT BATTERY SHALL WEIGH OR 3 OCCUPANTS 60LBS OR MORE MAXIMUM SIDE LOAD 150 Ibs 066522 000 062562 001 101250 005 x2 8 POWER TO PLATFORM 20 qu 068639 000 siis 057507 010 x4 066559 000 060197 001 BEFORE operating this equipment read understand 30 and then follow all safety information in
33. M ITEM 890 495mm 19 5 07 E STOP e Y KEYSWITCH ENABLE SWITCH 5 a E ECU EM 12 000000000000 SOLENOID MANIFOLD Q 87 CONTACTOR 09 76 lt N POT HOLE 66 62 gt 27 14 Po 63 32 02 HOLE PLATFORM Page 5 3 508244 002 5 4 JI CABLE SCHEMATIC SUOPDSUUOD 9 30 10301 40328uu02 450 SYR 204 JOUW 5 5 0 3 S SJIM DAV UPM pouBis ay uay pua aux UOLDSUUOD D UJIM SAM DMY 8 UM 31 5 aux u203 u040328uu02 OMY 8l ULIM psqojndod pua uo lt Gmd gt 0 00208b 1 4 21852 OMY 81 sud ajow 1 81 2055 p jyolndod 6md 0 0 089 1 03 Hx 405495 411 ania S AVAD I Td Suid aow 8120S 3078 UHM AIM OMY 8I 2 AN SD U U231MS3 IuI UDFIMS woog I
34. N MIN qoe SPF 4 dE T zs ves 202 mi 103 202 mr wes 882 3381 mau sia 2 i608 TE n 75065 5872 Table Torque Specifications for Metric Fasteners SI Units p N Nominal Thread ah Size Grade 8 8 Tightening Torque K 15 K 20 122 OA Grade 10 9 Clamp Tightening Torque Load K 15 K 20 Grade 12 9 Clamp Tightening Torque Load K 15 K 20 12 EN PS RR RE 4 6 387 54 75 503 38600 8 52475 15 60328 0 10 zu i 71 LZ 758813 IN DAE n 5 Page3 21 Page 3 22 508244 002 Section 4 TROUBLESHOOTING 4 1 INTRODUCTION The following section on troubleshooting provides guidelines on the types of problems users may encounter in the field helps determine the cause of problems and suggests proper corrective action Careful inspection and accurate analysis of the symptoms listed in the Troubleshooting Guide will localize the trouble more quickly than any other method This manual cannot cover all possible problems that may occur If a specific problem is not covered in this manual call our number for service assistance Referring to Section 2 0 and 5 0 will aid in understanding the operation and function of the various components and systems and help in diagnosing and repair of the machine GENERAL PROCEDURE
35. Page 2 19 ILLUSTRAITED PARTS LIST CE DECALS UpRight X2 GN 508669 000 x2 9 gt UpRight Failure to read understand and obey the following safety rules i use death or i inj will ca dea serious injury TIP OVER HAZARDS ELECTROCUTION HAZARD FALL HAZARD DO NOT elevate or drive elevated on DO NOT operate within ten feet of power DO NOT climb on guardrail 508661 000 x2 066556 900 x2 Nn 3 10 17 101210 000 066561 900 A 062562 951 x4 11 100076 901 501453 000 4 066522 900 014222 903 014222 903 4 340 kg MAX 340 kg qe Ze 060197 001 066551 950 005221 000 503723 000 Page 2 20 CE DECALS Control Module Upper Control Box View DZA Battery Module Page 2 21 Page 2 20 Section 3 SERVICE AND REPAIR INTRODUCTION This section contains instructions for the maintenance of the Work Platform Refer to the General Information section for information relevant to all UpRight work platforms Referring to the Operator Manual will aid in understanding the operation and function of the various com ponents and systems of the work platform and help in diagnosing and repair of the machine AWARNINGA Be sure to read understand and follow all information in the Operation
36. Section of this manual before attempting to operate or perform service on any Work Platform DANGER A Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace 508244 002 Page 3 1 Section 3 Service amp Repair TABLE OF GONTENTS Page 3 2 3 1 Supporting Elevating Assembly 3 3 hcic uy zn go tine EE le EE e E N 3 3 Rule EE 3 3 3 2 Preventative 3 3 3 3 Preventative Maintenance Check List 3 4 3 4 Pans da we eee ee ei ee ee WAW ee ee 3 5 3 5 General 3 6 3 6 BANENES Dao EE e EE EE espias 3 6 Battery Maintenance Nr nee Reo Re oa SEENEN a e en PR d 3 7 Battery Replacement seua ch a ee ne ee an dera Eua ee quine we 3 7 3 7 Safety Ancillary 11 TEEN 3 8 TEE 3 8 EN SENSOR EZ ou 3 8 Emergency 0 3 8 S Msc os TES Tm 3 9 Hydraulic Oil Tank And Eiter 3 9 Hydraul PUMD aa
37. TEE RHS POTHOLE CYL 0 509424 000 HYDRAULIC HOSE BLOCK POTHOLE TEE 9427 000 HYDRAULIC HOSE TEE RHS POTHOLE CYL 5 509426 000 HYDRAULIC HOSE TEE LHS POTHOLE CYL 504128 001 HYDRAULIC TANK PUMP ASSEMBLY 503800 001 BLOCK MAIN MANIFOLD 504129 001 HYDRAULIC CYLINDER LIFT 504148 001 HYDRAULIC CYLINDER STEER 504151 000 HYDRAULIC BLOCK SERIES PARALLEL 114055 002 MOTOR HYDRAULIC 1 7 10 11 12 13 14 15 16 17 18 19 20 gt 22 23 24 5 2 Sec 23 ILLUSTRAITED PARTS LIST ILLUSTRAITED PARTS LIST OVERLOAD ASSEMBLY tem Description Qty 503950 001 MOUNTING PLATE ELECTRICAL BOX 4 2 504560 000 PRESSURE TRANSDUCER 1 504559 000 ANGLE TRANSDUCER 24 NOTES Sec 25 CE DECALS Control Module Upper Control Box View DZA Battery Module Sec 26 ILLUSTRAITED PARTS LIST CE DECALS 1 UpRight X2 GN 508669 000 x2 9 gt UpRight 508661 000 x2 066556 900 x2 067 195 001 Failure to read understand and obey the following safety rules i use death o i inj will ca dea r serious injury TIP OVER HAZARDS ELECTROCUTION HAZARD FALL HAZARD DO NOT elevate or drive elevated on DO NOT operate within ten feet of power DO NOT climb on guardrail A 101210 000 066561 900 17 062562 951 4 11 100102 900 A
38. UMOSISSOUJ 134729 TS pua UO 03 29 02 YPM DAV 8 ana nog pua y uo 40328Uu02 YPM DMY ev uoximsdnsissoug eng 3 483 UP4 KS9 0U S404128uu02 2 10101 Ouse BS NE OAT ey OF 24M DAV gp YPM jous ayy uroy gt stop T3ALW 545 3 Kou AND pus y uo 2129 52 929 DAY 81 jeuvd PUNDAD ajdund ANd aux YO 40328uuO2 Ty ULM SAM DAV umoug NYE 134 a6u04 530 Dua ayy uo UO01J8UU02 SAM DAV 81 El ME GORGE fua ay uo 24M OMY BI I nig ped 38 D T 129g ATB 911 za 5954 ui 06169 ABE T aids yous 0 adlujs 9 51 40103 puo2es G 9 9 18 nl8 PASZ S E Ti 1 MANISAPIOJIUOW Y 1 pus1x3e 0U 0g 2 DT 18 1 E 22 1yBIgus81S g 89421 5 old 218 aa 148148848 coma IND 51 8 2 11 PlogluoW piousjos UTUDIZIMS FIL 1908 H2 C 622385 gH O O UJ2IMSUMOTSISSOUJ O 012 YP1IWSANSISSOYJ 013 018 UMS CIE O 6 Naz 1044103380910 4010W aw ASDF 48 001 211 ES EISE EES 631 417 pay1Ims JUAL2 6
39. ble hoisting device and sling to the cylinder and remove upper pivot pin 7 Carefully remove cylinder 1 Lift Cylinder 2 Pivot Pit 3 Capscrew and Lockplate 4 Solenoid Emergency Down 5 Hose Connections HEPAIR Refer to Pothole Steering Cylinder Repair on previous page INSTALLATION 1 Coat both pivot pins with anti seize compound 2 Attach a suitable hoisting device and sling to the cylinder Carefully position cylinder in the elevating assembly and install the upper pivot pin W Install the capscrew and locknut Caretully lift the cylinder and align the lower mount and install the pivot pin Install the capscrew and locknut securing the pivot pin Install the cable bracket Connect the emergency lowering valve cable and down valve wires Unplug hydraulic hoses and attach to the cylinder Replace hydraulic fluid removed from lift cylinder Y Test with weight at rated Platform load to check system operation Check for leaks 508244 002 Page 3 15 Drive Motors Section 3 Service Repair 3 10 DRIVE MOTORS REMOVAL 1 Use a 1000Kg one ton capacity jack to raise the front of the machine Position blocks under the machine to prevent the work platform from falling if the jack fails 2 Block the rear wheels to prevent the machine from rolling 3 Remove the cotter pin nut and washer 4 Remove the wheel NOTE Before disconnecting hoses thoroughly clean off all outside dir
40. crews 2 Using a crisscross pattern torque each capscrew a little at a time until all capscrews are torqued to 27N m 20 ft Ibs 3 Unplug and reconnect the hydraulic hoses 4 Check the oil level in the hydraulic tank before operating the work platform en ker Kg eem 1 Inlet Hose 4 Pump Assembly 2 Outlet Hose 5 Electric Motor 3 Capscrew Page 3 10 508244 002 Section 3 Service amp Repair Hydraulics MAIN HYDRAULIC MANIFOLD Though it is not necessary to remove the manifold to perform all maintenance procedures a determination should be made prior to beginning as to whether or not the manifold should be removed before mainte nance procedures begin Figure 3 11 Valve Location 1 TEST PORT1 7 VALVE SOLENOID DRIVE LIFT 2 FITTING 1 4 1 4 MALE MALE 8 PRESSURE RELIEF MAIN LIFT 3 FITTING 3 8 3 8 MALE MALE 9 VALVE SOLENOID STEERING 4 FITTING 1 2 1 2 MALE MALE 10 FLOW RESTRICTOR STEERING 5 CROSS LINE RELIEF VALVE DRIVE 11 RELIEF VALVE STEERING 6 VALVE SOLENOID DRIVE 12 RELIEF VALVE MAIN RELIEF Figure 3 12 SETTING HYDRAULIC MANIFOLD PRESSURES AWARNINGA The hydraulic oil may be of sufficient temperature to cause burns Wear safety gloves and safety glasses when handling hot oil The oil in the hydraulic system 15 under very high pressure which can easily cause severe cuts Obtain medical assistance immediately if cut by hydra
41. d understand and follow all safety rules and operating instructions before attempting to operate the machine SPECIAL INFORMATION A DANGER A Indicates an imminently hazardous situation which if not avoided WILL result in severe injury or death AWARNINGA Indicates a potentially hazardous situation which if not avoided could result in severe injury or death ACAUTIONA Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Page 2 3 2 GENERAL DESCRIPTION 2 GENERAL DESCRIPTION DO NOT use the machine if all guardrails are not properly in place and secured Figure 2 X26 Narrow Platform Controls Manual Case Platform Extension Platform Elevating Assembly Chassis Batteries Charger Outlet Plug O NO M A Chassis Controls gt Emergency Lowering Valve Knob 11 Hydraulic Fluid Reservoir 12 Pothole Support Rails not visible when machine is Stowed in raised Drive position see fig 5 page 10 Page 2 4 3 Siti 3 SPECIAL LIMITATIONS DANGER Travel with the platform raised is limited to creep speed range Elevating the Work Platform is limited to firm level surfaces ONLY DANGER The elevating function shall ONLY be used when the work platform is level and on a firm surface The work platform is NOT intended to be driven over uneven rough or soft terrain
42. depress the interlock lever and slowly pull the control lever to REVERSE to drive the wheels Adjust the Forward Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 83 bar 1200 psi Slowly push the Control Lever to FORWARD to drive the wheels Adjust the Reverse Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 83 bar 1200 psi Check the settings by slowly moving the Control Lever FORWARD then REVERSE checking the gauge to ensure pressures are properly set Re adjust as needed Tighten locknuts on valves to 8N m 6 ft Ibs Remove blocks and lower work platform to ground Reconnect the red Control Cable wire to terminal 9 Remove the gauge from the gauge port and re install cap Check for proper operation of the drive system and brake STEERING RELIEF VALVES 1 Operate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating temperature Install gauge in the gauge port Loosen locknut or remove cover on the Steering Relief Valve and turn adjusting screw counter clockwise two full turns While one person holds the Steering Switch to steer right or left slowly turn the Steering Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 69 bar 1000 psi Tighten locknut or replace Steering Relief Valve cover and torque to 8N m 6 ft Ibs Remove gauge and replace cap
43. draulic Components Type SAE Part Series Cartridge Poppet Fittings Ft Lbs Nm Ft Lbs Ft Lbs Nm NA 8515 151 N A N A 10 20 14 27 215 245 24 28 25 30 34 41 25 30 34 41 430 470 49 53 35 40 47 54 35 40 47 54 680 750 77 85 85 90 115 122 85 90 115 122 950 1050 107 119 130 140 176 190 130 140 176 190 1300 1368 147 155 FASTENERS This standard applies to the preloading of fasteners measured by installation torque NOTE For other preloading methods or fasteners consult UpRight Engineering Department This general standard applies to all SAE and Metric fasteners unless otherwise specified THREAD CONDITION For lubed or zinc plated fasteners use K 15 For dry unplated fasteners use K 20 TORQUE TABLES Table Torque Specifications for SAE Fasteners SAE J429 Grade 5 SAE J429 Grade 8 SAE J429 Grade 5 SAE J429 Grade 8 Nominal Nominal Thread Size Thread Size C1 R M 4 I O 2 62 EH A 1 o m ft lbs 5 ce 5 5 S LL e lt o cO Page3 20 Maintenance Table Torque Specifications for Metric Fasteners U S Customary Units N Grade 8 8 2 Grade 10 9 12 9 Grade 12 9 u Clamp Tightening Torque Clamp Tightening Torque Clamp Tightening Torque Size Load 15 K 20 Load k 15 K 20 Load K 15 K 20 ER ER
44. essive wear ASSEMBLY 1 Lubricate and install new rod wiper U cup O ring and backup ring on the headcaps 2 Install the headcap onto the shaft 3 Install the new piston rings and O ring on the piston Re install the piston 4 Lubricate the piston seal with clean hydraulic fluid and install the shaft assembly in the cylinder barrel Install the head cap into the cylinder barrel and tighten the head caps INSTALLATION Figure 3 16 Steering Cylinder Assembly a 0 FLANGED BUSHING CYLINDER ROD RETAINING RING 1 Position the cylinder assembly in the chassis and insert pivot pins and secure with new cotter pins 2 Connect the hose assemblies to the fittings 3 Operate the steering circuit several times throughout its entire range of travel to expel trapped air and check for leaks Page 3 14 508244 002 Section 3 Service amp Repair Cylinders LIFT CYLINDER HEMOVAL Figure 3 17 Lift Cyminder Assembly 1 Provide a suitable container to catch the hydraulic fluid then disconnect the hydraulic hoses Immediately plug hoses to prevent foreign material from entering 2 Remove emergency lowering valve cable and down valve wires from the emergency lowering down valve 3 Remove the cable bracket from the lift cylinder 4 Remove capscrews and locknuts securing lift cylinder pivot pins o Remove lower pivot pin and lower cylinder to rest on chassis 6 Attach a suita
45. f hydrogen gas or fuel vapors are present Page 3 6 508244 002 Section 3 Service Repair Batteries BATTERY MAINTENANCE Refer to the Operation Manual included in this Service Manual for specific maintenance and charging instructions NOTE If system voltage drops below 17 volts on a 24 volt system the charger will not recharge the batteries If this extreme voltage drop occurs disconnect and recharge each battery separately using a 6 volt charger to bring the voltage in each up to at least 4 1 2 volts BATTERY REPLACEMENT Battery cables must be installed as shown in the Battery Cable Installation Diagram Figure 3 5 Battery Cable Installation Diagram 1 Turn the Chassis Key Switch to the OFF position and push the Chassis and Platform Emergency Stop Switches down to the OFF position NOTE If switches are ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present 2 Open the power module 3 Disconnect battery pack connector 4 Disconnect the battery negative lead IMPORTANT Disconnect the battery negative lead first 5 Disconnect the remaining battery leads 6 Lift the batteries out of the module Batteries Installed INSTALLATION IMPORTANT Connect the battery negative lead last 1 Verify that the Chassis Key Switch and the Chassis and Platform Emergency Stop Switches in the OFF position Place the batter
46. ies into the power module Connect the battery to battery leads Connect the battery positive lead Connect the battery negative lead Connect the battery pack connector O OT 508244 002 Page 3 7 Safety Equipment Section 3 Service Repair 3 7 SAFETY ANCILLARY EQUIPMENT PROXIMITY SWITCH Figure 3 6 Proximity Switch The Proximity Switch cuts power to the High Speed Drive when the platform is elevated The switch is located on the left side of the chassis at the rear of the machine No adjustment of the switch should be necessary LEVEL SENSOR The Level Sensor is located on the chassis of the machine These units are sealed and pre set and require no recalibration or adjustment EMERGENCY LOWERING AWARNINGA If the platform should fail to lower NEVER climb down the elevating assembly Stand clear of the elevating assembly while operating the Emergency Lowering Valve Knob Figure 3 8 Emergency Lowering Knob The Emergency Lowering Valve is mounted on the base of the lift cylinder The cable is routed from the valve along the elevating assembly tube to the front of the machine e through the cable access hole to the rear of the machine REPAIR 1 Deploy the maintenance brace see Blocking the Elevating Emergency pere emeng Assembly Emergency Lowering Knob 2 Inspect the cable Replace if damaged 3 Inspect the valve Re
47. ift Pockets Page 2 13 8 TRANSPORTING THE MACHINE DRIVING OR WINCHING ONTO A TRUCK OR TRAILER AWARNINGA Never winch faster than 0 3 m sec 1 ft sec Never operate the machine with the parking brakes released Serious injury or damage could result 1 Loading the machine onto the truck or trailer A To Drive the machine onto the transport vehicle Turn the Lift Drive Switch to DRIVE LOW hi torque mode and drive the machine up the ramp and into transport position e Set the wheels straight and turn off the machine e Chock the wheels To Winch the machine onto the transport vehicle Drive the machine up to the ramp Attach the winch cable to the tie down lifting points Release the parking brakes refer to Parking Brake Release on page 12 e Winch the machine into transport position e Chock the wheels Re engage the parking brakes 2 Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down lifting points refer to Figure 8 A CAUTION A Overtightening chains or straps attached to the Tie Down points may result in damage to the machine Page 2 14 9 MAINTENANCE 9 MAINTENANCE AWARNINGA Never perform service while the platform is elevated without first blocking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing the brace BLOCKING THE ELEVATING ASSEMBLY Figure 9 Sci
48. in in the retracted position c Hold the mid rail with one hand as you retract the final retaining pin ACAUTIONA 7 OPERATION Figure 6 Guardrails Platform Extension Platform Controls Platform Extension Retaining Pins Side rail Retaining Pins Rear Top rail Retaining Pins The guardrail could drop suddenly when the final retaining pin is retracted Keep hands away from the slide tubes to prevent injury d Push down on the platform extension guardrail to lower it completely e he retaining pins will remain in the retracted position 4 Lower the side guardrails and rear guardrail as a single unit Repeat steps 3a through 3c 5 Lower the rear top rail Pull the two retaining pins and lower the rear top rail completely RAISING PROCEDURE 1 Raise the side guardrails and rear guardrail as one unit Pull up on the side guardrails and raise them until all the retaining pins engage 2 Raise the rear top rail Pull up on the rear top rail until the retaining pins engage 3 Raise the platform extension guardrail Pull up on the platform extension guardrail and raise it until all the retaining pins engage 4 Hang the controller on the platform extension guardrail Page2 11 7 OPERATION PARKING BRAKE RELEASE Perform the following only when the machine will not operate under
49. its own power and it is necessary to move the machine or when winching onto a transport vehicle see Transporting the Machine AWARNING A NEVER winch or move the machine faster than 0 3 m sec 1 ft sec NEVER operate the machine with the parking brakes released Serious injury or damage could result DO NOT release the parking brakes if the machine is on a slope The parking brakes are integral to the drive motors Each drive motor has two brake release screws Release and engage the parking brakes one wheel at a time Turn the brake release screws in stages 22 turn at a time to prevent possible binding of the brake mechanism Figure 7 Parking Brake Release RELEASE THE PARKING BRAKE The front wheel motors each have two brake release nuts IMPORTANT Turn the nuts alternately in 72 turn increments to insure uniform adjustment and prevent binding 1 Chock the rear wheels to prevent the machine from rolling 2 Using a 5mm Allen Key remove the two G1 8 plugs from the motor body turning counter clockwise 3 Using a 5mm Allen Key turn the inner G1 8 plug as far as possible in a clockwise direction 4 The brake 16 released 1 Motor Mount 3 Brake Release Nut 2 Drive Motor 4 Wheel CAUTION To avoid confusion the outer plugs should not b ENGAGE THE PARKING BRAKE 1 Chock the rear wheels to prevent the machine from rolling 2 Using a 5mm Allen Key turn the i
50. l Select LIFT mode Grasp the Control Handle engaging the Interlock Switch and push it forward to check platform lift controls Raise the platform to full elevation Pull back on the Control Handle The platform should descend and the audible lowering alarm should sound Push the Platform Emergency Stop Switch to check for proper operation All machine functions should be disabled Pull out the Platform Emergency Stop Switch to resume 7 OPERATION OPERATION Before operating the work platform ensure that the Pre Operation Safety Inspection and System Function Inspection have been completed and that any deficiencies have been corrected NOTE Never operate a damaged or malfunctioning machine The operator must be thoroughly trained on this machine PLATFORM EXTENSION 1 TRAVEL WITH THE PLATFORM LOWERED 1 6 the platform extension Push the platform front stop Pull the Platform Emergency Stop Switch out Figure 4 Platform Extension Mount the platform and properly close and secure the entrance Depress the foot lever located at the rear of extension forward until the pin engages the To retract the platform extension depress the foot lever and pull the platform extension toward the rear of the machine until the pin engages the rear stop Check that the route is clear of obstacles persons obstructions holes drop offs bumps and debris is level and is capable of supporting the wheel load
51. lace any component found to be faulty 5 Verify that repair is complete o Do a full function test from both the platform and chassis controls to verify that all functions are operating correctly and that the machine is performing to specified val ues SPECIAL TooLs Following is a list of tools which may be required to perform certain maintenance proce dures on the X Series work platforms Flow Meter with Pressure Gauge P N 067040 000 0 69 bar 0 1000 psi Hydraulic Pressure Gauge with Adapter Fittings P N 014124 010 0 207 bar 0 3000 psi Hydraulic Pressure Gauge with Adapter Fittings P N 014124 030 Adapter Fitting P N 063965 002 o Inclinometer P N 010119 000 e Crimping Tool P N 028800 009 Terminal Removal Tool P N 028800 006 ADJUSTMENT PROCEDURES Hydraulic settings must be checked whenever a component is repaired or replaced Remove counterbalance valves and bench test them if they are suspect Connect a pressure gauge of appropriate range to the test port located on the hydraulic manifold Correct pressure settings are listed in the hydraulic schematic CHECKING PUMP PRESSURES Remove hose from pump port and connect pressure gauge Page 4 2 4 3 TROUBLESHOOTING GUIDE 4 3 Troubleshooting Guide TROUBLE PROBABLE CAUSE REMEDY All functions inoperable electric motor does not start All functions inoperable Electric motor starts when control is actuated Platform will not
52. lly inspect the elevating assembly lift cylinder cables and hoses for cracked welds and structural damage loose hardware hydraulic leaks loose wire connections and erratic operation Check for missing or loose parts Verify that the Pothole Support Rails have rotated into position under the machine REMOVE THE SCISSOR BRACE AS DESCRIBED ON page 2 15 Push the Chassis Lift Lower Switch to the UP position and fully elevate the platform Partially lower the platform by pushing Chassis Lift Lower Switch to LOWER and check for proper operation of the audible lowering alarm Open the Emergency Lowering Valve see Figure 5 by pulling the knob out to check for proper operation When the platform is lowered release the knob Push the Chassis Emergency Stop Switch to check for proper operation All machine functions should be disabled Pull out the Chassis Emergency Stop Switch to resume Check that the route is clear of obstacles persons obstructions holes and drop offs bumps and debris is level and is capable of supporting the wheel loads Mount the platform and properly close the entrance Mount the platform and select DRIVE mode NOTE Use both HI and LOW drive if applicable when performing the following step 16 17 18 19 20 While engaging the Interlock Switch move the Control Handle to FORWARD then REVERSE to check for speed control Push the Steering Switch RIGHT then LEFT to check for steering contro
53. mponent but the component is not functioning replace the component refer to section 7 of this manual for part number information 4 5 Fault Codes 4 5 FAULT CODES 01 System initialization error 02 System communication error 22 Platform Left Turn Switch ON at power up 23 Platform Right Turn Switch ON at power up 25 Platform Hi Drive Switch ON at power up 27 Platform Lo Drive Switch ON at power up 28 Platform Lift Switch ON at power up 29 Platform Joystick Enable Switch ON at power up 31 Platform Joystick not in neutral at power up 32 Lower Control Up DownToggle ON at power up 39 Lower Control Enable Switch ON at power up 51 Hi Speed Low Speed Col fault 54 Pothole Retract Coil fault 55 Lift Up Coil fault 56 Lift Down Coil fault 59 Steer Right Coil fault 61 Steer Left Coil fault 66 Forward Coil fault 67 Reverse Coil fault 68 Low Battery fault Page 4 5 4 6 Electric 4 6 ELECTRIC Table 4 1 Electrical Troubleshooting Table esso aowe 111111 ET rrr EEE pe ze A ed DE KL pepe EEE EEE TEE a pe FE mme 4 S 5 6 o S Ig S 5 2 E S gt gt lt gt
54. ne replace seals if necessary Page 4 3 Fault Codes introduction FAULT CODES INTRODUCTION The X Series is equipped with a fault detection system if you have a faulty component bad electrical connection or start up error a fault code will be displayed on the read out located on the upper control box For fault codes 01 39 the following procedure should be followed Ensure that no selector buttons are depressed Ensure that the deadman switch on the joystick is not held Ensure that the joystick is in neutral Ensure that the steer rocker is not activated Ensure that toggle switch is in neutral Then re cycle power do this by pushing and releasing the emergency stop button If the fault code is still displayed you may have a faulty upper or lower control box consult the error code list to identify the problem component and replace if necessary For fault codes 54 68 the following procedure should be followed 1 Check the fault code list to identify the problem component 2 Ensure that the wiring harness is connected secure in good condition and fully intact 3 Ensure that the problem component is receiving electrical signal consult the sche matics in section 6 of this manual to identify the ECU output and harness test points 4 If no ECU output is present replace the ECU 5 If ECU output is present but no signal is reaching the component replace the wiring harness 6 If signal is reaching the co
55. nner G1 8 plug as far as possible in the counter clockwise direction 3 Fit the two outer G1 8 plugs then using the 5mm Allen Key screw in clockwise until tight AFTER USE EACH DAY 1 Ensure that the platform is fully lowered 2 Park the machine on a firm level surface preferably under cover secure against vandals children and unauthorized operation 3 Turn the Chassis Key Switch to OFF and remove the key to prevent unauthorized operation Page 2 12 8 TRANSPORTING THE MACHINE 3 TRANSPORTING THE MACHINE Always use a transport vehicle when moving a machine to a work site Towing the machine over long distances will damage the machine and void the warranty LIFTING BY CRANE Figure 8 Secure Crane Straps DANGER See specifications for the weight of the machine and be certain that the crane is of adequate capacity to lift the machine Secure straps to chassis tie down lifting points only see Figure 8 MOVING BY FORKLIFT Fork lifting is for transport only See specifications for the weight of the machine and be certain that the forklift is of adequate capacity to lift the machine Forklift from the rear of the machine using the forklift pockets provided If necessary the machine may be forklifted from the side by lifting under the Chassis Modules see Figure 9 Figure 9 Tie Down and Lift Points Rear Tie Down Lift Point Rear Tie d s Down Lift Point W Forkl
56. on seal with clean hydraulic fluid and install the shaft assembly in the cylinder barrel Install the head cap into the cylinder barrel and tighten the head caps INSTALLATION Installation is reverse of removal 508244 002 Page 3 13 Cylinders STEERING GYLINDER REMOVAL 1 Mark and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering 2 Remove the cotter pins from the pivot pins 3 Remove the pivot pins while supporting the cylinder Remove the cylinder REPAIR DISASSEMBLY 1 Unscrew the head cap from the barrel removing the head cap piston and shaft assembly from the barrel tube 2 Unscrew the piston 3 Remove all rod wipers U cups O rings and backup rings from the headcap and discard 4 Remove the piston ring and O ring from the piston and discard Cleaning and Inspection Section 3 Service amp Repair Figure 3 15 Steering Cylinder Mount Assemblt 1 Steering Cylinder 2 Steering Link 3 Pivot Pin 4 Bushing 5 Wheel Yoke 1 Wash all the metal parts in cleaning solvent and blow dry with filtered compressed air Inspect all the threaded components for stripped or damaged threads Check the inside surface of the cylinder barrel for scoring or excessive wear 2 3 4 Check the piston and headcaps for scoring or excessive wear 5 Inspect the surface of the shaft for scoring or exc
57. ontrol module door 4 Remove the drain plug and allow all the fluid to drain Dispose of hydraulic fluid properly contact your local fluid recycler 5 Install the drain plug 6 Fill the hydraulic reservoir with the appropriate hydraulic fluid until the fluid is up to the full mark on the dipstick Refer to Specifications at the end of the Operator Manual included in this Service Manual to identify the proper fluid for your conditions FLUID OUTLET SCREEN Clean or replace the outlet screen at the same time that the fluid is changed 1 Drain the fluid see Fluid Replacement 2 Disconnect and plug the outlet hose to prevent foreign material from entering the hose W Remove the suction screen Clean or replace as necessary Install the suction screen Fill the hydraulic reservoir see Fluid Replacement 508244 002 Page 3 9 Hydraulics Section 3 Service Repair HYDRAULIC PUMP The Hydraulic Pump is located in the Power Module and is mounted on the rear of the motor REMOVAL NOTE If the hydraulic tank has not been drained suitable means for plugging the hoses should be provided to prevent excessive fluid 1055 1 Mark disconnect and plug the hose assemblies 2 Loosen the capscrews and remove the pump assembly from the motor INSTALLATION Figure 5 10 Hydraulic Pump Assembly 1 Lubricate the pump shaft with general purpose grease and attach the pump to the motor with the caps
58. orm PURPOSE OF EQUIPMENT The objective of the work platform is to provide a quickly deployable self propelled variable height work platform to elevate personnel and materials to overhead work areas SPECIAL LIMITATIONS Travel with the platform raised is limited to a creep speed range Elevating of the work platform is limited to firm level surfaces only AA DANGER A The elevating shall ONLY be used when the work platform is level and on a firm surface The work platform is NOT intended to be driven over uneven rough or soft terrain when elevated Page 1 2 WARNING All personnel shall carefully read understand and follow all safety rules and operating instructions before operating or performing maintenance on any UpRight Powered Access work platform Safety Rules Electrocution Hazard Tip Over Hazard Collision Hazard Fall Hazard THIS MACHINE IS NOT NEVER operate the boom or drive NEVER position the machine NEVER climb stand or sit on the INSULATED with the platform elevated unless without first checking for overhead platform guardrails or midrail on firm level surface obstructions or other hazards USE OF THE AERIAL WORK PLATFORM This aerial work platform is intended to lift persons and his tools as well as the material used for the job It is designed for repair and assembly jobs and assignments at overhead workplaces ceilings cranes buildings etc All other uses of the aerial work
59. performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to enter the scissor assembly to perform maintenance while the platform is elevated The preventative maintenance table has been designed for machine service and maintenance repair Please copy the following page and use the table as a checklist when inspecting the machine for service Page 3 3 Preventative Maintenance Check List Section 3 Service Repair 3 3 PREVENTATIVE MAINTENANCE CHECK LIST PREVENTATIVE MAINTENANCE KEY PREVENTATIVE MAINTENANCE REPORT Interval Date Daily each shift or every day 50h 30d every 50 hours or 30 days mn TEEN 250h 6m every 250 hours or 6 months Model No 1000h 2y every 1000 hours or 2 years Serial No Y Yes Acceptable N No Not Acceptable Serviced By R Repaired Acceptable Service Interval COMPONENT INSPECTION OR SERVICES INTERVAL Y N COMPONENT INSPECTION OR SERVICES INTERVAL Y N Check bary cable canon Daly Check battery cable condition Daily dents loose rivets or cracks Charge batteries _ Daly Elevating Check welds for cracks Daily Check charger condition 8 SE Lubricate operation Check specific gravity LE LI cables for pinch Daily Clean terminals 6
60. place if damaged 4 Check for and clear any blockage in the orifice Install the orifice with the beveled side toward the cylinder block 5 Adjust the valve At the cable mount adjust the cable cover to stop the inner cable when the valve is fully open 6 Store the maintenance brace and lower the platform Page 3 8 508244 002 Section 3 Service Repair Hydraulics 3 8 HYDRAULICS HYDRAULIC OIL TANK AND FILTER FLUID LEVEL Figure 5 9 Hydraulic Tank d z Check the fluid level daily With the platform fully lowered open the control module and remove the reservoir breather cap Fluid should be at the full mark NOTE Drain plug underneath tank OIL AND FILTER REPLACEMENT Replace the filter every 250 hours or six months 1 Unscrew the filter from the filter assembly 2 Apply athin film of clean hydraulic fluid to the gasket of the replacement filter 3 Screw the replacement filter onto the filter head until gasket makes contact then turn filter of a turn CAUTION The hydraulic oil may be of sufficient temperature to cause burns Wear safety gloves and safety glasses when handling hot oil FLUID REPLACEMENT Replace the hydraulic fluid every 1000 hours or two years 1 Operate the machine for 10 15 minutes to bring the hydraulic fluid up to normal operating temperature 2 Provide a suitable container to catch the drained fluid Hydraulic reservoir capacity 15 L 4 U S gal 3 Open the c
61. platform are prohibited THIS AERIAL WORK PLATFORM IS NOT INSULATED For this reason it is imperative to keep a safe distance from live parts of electrical equipment Exceeding the specified permissible maximum load is prohibited See Platform Capacity on page 5 for details The use and operation of the aerial work platform as a lifiing tool or a crane is prohibited This machine is designed for INDOOR USE ONLY DISTRIBUTE all platform loads evenly on the platform NEVER operate the machine without first surveying the work area for surface hazards Holes drop offs bumps curbs and debris etc should ALWAYS be AVOIDED OPERATE machine only on surfaces capable of supporting wheel loads IN CASE OF EMERGENCY push Emergency Stop Switch to deactivate all powered functions IF ALARM SOUNDS while platform is elevated STOP carefully lower platform Move machine to a firm level surface Climbing up the railing of the platform standing on or stepping from the platform onto buildings steel or prefab concrete structures etc is prohibited Dismantling the entry gate or other railing components is prohibited Always make certain that the entry gate is closed and securely locked It is prohibited to keep the entry gate in an open position when the platform is raised To extend the height or the range by placing of ladders scaffolds or similar devices on the platform is prohibited NEVER perform service on machine while platform is elevated
62. r raise Breeze Small Branches begin to sway ELE Breeze omall Trees Sway Waves apparent in ponds NH Breeze Large Branches in motion Whistling Heard in overhead wires Umbrella use is difficult Near Gale Whole trees in motion Effort to walk against the wind If in doubt always check wind conditions before machine use Note that wind speeds vary considerable at higher levels Page2 7 6 SYSTEM FUNCTION INSPECTION 6 SYSTEM FUNCTION INSPECTION Page 2 8 NOTE Refer to Figure 3 for the locations of various controls and indicators AWARNINGA STAND CLEAR of the work platform while performing the following checks Before operating the work platform survey the work area for surface hazards such as holes drop offs bumps and debris Check in ALL directions including above the work platform for obstructions and electrical conductors Protect the control console cable from possible damage while performing checks SCH Ee Move the machine if necessary to an unobstructed area to allow for full elevation Twist and pull the Chassis Emergency Stop button to the ON position Twist and pull the Platform Emergency Stop button to the ON position Turn and hold the Chassis Key Switch to the ON position Push the Chassis Lift Lower Switch to the UP position and raise the platform approximately 2 1 m 7 feet 5 BLOCK THE ELEVATING ASSEMBLY AS DESCRIBED ON page 2 15 11 12 13 14 15 Visua
63. r than 10 mm gin above the plates add distilled water only DO NOT use tap water with high mineral content as it will shorten battery life e Inspect the battery regularly for signs of cracks in the case electrolyte leakage and corrosion of the terminals nspect cables regularly for worn spots or breaks in the insulation and for broken cable terminals Keep the terminals and tops of the batteries clean Refer to the Service Manual to extend battery life and for complete service instructions BATTERY CHARGING Figure 13 Battery Charger Charge the batteries at the end of each work shift or sooner if the batteries have been discharged AWARNINGA Charge the batteries in a well ventilated area Do not charge the batteries when the machine is near a source of sparks or flames Permanent damage to the batteries will result if the batteries are not immediately recharged after discharging Never leave the battery charger operating for more than two days Never disconnect the cables from the batteries when the charger is operating Keep the charger dry 1 Battery Charger 1 Check the battery fluid level If the battery fluid level is lower than 2 Charge Indicator 10 mm in above the plates add distilled water only 3 Charger Plug 2 Connect an appropriate extension cord to the charger outlet plug in 4 Batteries the left module door Plug the extension cord into a properly grounded outlet of proper
64. ration and maintenance of this work platform manufactured by UpRight SCOPE The manual includes procedures for proper operation maintenance adjustment and repair of this product well as recommended maintenance schedules and troubleshooting 1 2 GENERAL DESCRIPTION The work platform consists of the platform controller elevating assembly power module control module and chassis DO NOT use the work platform without guardrails properly assembled and in place Figure 1 1 X26N through doors or for shipment PLATFORM 1 Platform The platform has a reinforced steel 7 floor 1 1m 43 5 inch high guardrails 3 Chassis Controls with midrail 152 mm 6 inch 4 Chassis toeboards and an entry chain at the 9 Elevating Assembly 45 rear of the platform The guardrails can be folded down for access T PLATFORM CONTROLLER The platform controller contains the controls to operate the machine It is located at the front of the platform cage A complete explanation of 5 control functions can be found in Section 2 4 1 h 3 Page 1 1 Introduction 1 2 General Description ELEVATING ASSEMBLY The platform is raised and lowered by the elevating assembly The hydraulic pump driven by the engine powers the cylinder Solenoid operated valves control raising and lowering CHASSIS The chassis is a structural frame that supports all the components of the X26N work platf
65. s Verify that the Chassis Key Switch 15 turned to ON and the Chassis Emergency Stop Switch is ON pulled out Mount the platform and properly close the entrance Check clearances above below and to the 1 Platform Extension sides of platform 2 Foot Lever deck lock assembly to the ON position Select DRIVE mode NOTE Choose between standard drive and extra torque depending on the gradient 7 Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction The speed of the machine will vary depending on how far from centre the Control Handle is moved STEERING 1 Turn the Lift Drive Switch to DRIVE 2 While engaging the Interlock Switch push the Steering Switch to the RIGHT or LEFT to turn the wheels in the desired direction Observe the tires while manoeuvring the machine to ensure proper direction NOTE Steering is not self centering Wheels must be returned to the straight ahead position by operating the Steering Switch Page 2 9 7 OPERATION Page 2 10 ELEVATING THE PLATFORM ge 180285 Locate a firm level surface Select LIFT mode While engaging the Interlock Switch push the Control Handle FORWARD If the machine is not level the level sensor alarm will sound and the machine will not lift or drive If the level sensor alarm sounds the platform must be lowered and the machine moved to a firm level surface before attempting to elevate the
66. ssor Brace SCISSOR BRACE INSTALLATION 1 Park the machine on a firm level surface 2 Pull Chassis Emergency Stop Switch to the ON position 3 Pull Platform Emergency Stop Switch to the ON position 4 Turn and hold the Chassis Key Switch to CHASSIS 5 Push the Chassis Lift Lower Switch to LIFT to saa elevate the platform until the scissor brace can Block ise 10 be rotated to the vertical position 6 From the rear of the machine lift the scissor w brace from its stowed position Rotate upward and outward then down until it is hanging vertically below its attachment point Counterclockwise to Store 7 Lower the platform by pushing the Chassis Lift Switch to LOWER and gradually lower the platform until the scissor brace 15 supporting the platform SCISSOR BRACE STORAGE 1 Using the Chassis Controls gradually elevate Brace Rests on the platform until the scissor brace 16 clear Weldment when in Blocking 2 Rotate the scissor brace outward and upward Position over its mounting point until it rests in the stowed position 3 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER to completely lower the platform Page 2 15 9 MAINTENANCE LEVEL SENSOR AWARNINGA Never perform service while the platform is elevated without first blocking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing the brace The Level Sensor 16 located
67. summer and ISO 32 during winter Page 3 4 508244 002 Section 3 Service amp Repair 3 4 PARTS LOCATION CON O OI R W gt uk Ak CON O OI N O 19 20 21 22 23 24 25 26 21 28 29 30 31 32 33 34 35 36 37 38 Entry Gate Deck Lock Assembly Work Platform Fold Down Guardrails Platform Extension Platform Controls Rear Guardrail Retaining Pin Guardrail Retaining Pin Elevating Assembly Control Module Chassis Controls Circuit Board Motor Controller Hydraulic Fluid Reservoir Hydraulic Fluid Filter Hydraulic Pump and Motor Main Valve Manifold 175 AMP Fuse Overload Protection Solenoid Motor Relay Audible Alarm Depression Mechanism Depression Mechanism Cylinder Battery Charger Plug Battery Charger Battery Pack Cable Connector Power Module Drive Motors Steering Cylinder Lift Cylinder Maintenance Brace Level Sensor Proximity Switch Height Limit Switch Series Parallel Valve Emergency Lowering Valve Emergency Lowering Valve Knob Horn 508244 002 Parts Location Figure 3 2 Parts Location Page 3 5 General Lubrication Section 3 Service Repair 3 5 GENERAL LUBRICATION NOTE Apply grease to each grease fitting Figure 3 3 Steering Lubrication Points There are four lubrication points on the machine steering lt Wei system
68. t around fittings After disconnecting hoses and before removing from vehicle IMMEDIATELY plug port holes 5 Tag disconnect and plug the hose assemblies to prevent foreign material from entering 6 Support the drive motor wheel yoke assembly and remove the retaining ring at the top of the wheel yoke pivot Remove the drive motor wheel assembly from the machine 7 Remove the locknuts flat washers capscrews and drive motor from the wheel yoke INSTALLATION Figure 3 18 Drive Motor Assembly 1 Position the drive motor in the wheel yoke and secure with capscrews flat washers and locknuts 2 Install the drive motor wheel yoke assembly into the pivot bearing along with the lower thrust washer thrust bushing and retaining ring 3 To ensure that the Wheel Yoke Assembly does nat fall out of the Chassis when the vehicle 15 lifted off the ground fit a 3 8 UNC nut and a 1 1 4 long bolt screw nut onto bolt until from bolt head Hand screw bolt into Chassis thread and tighten until bolt hits inner pin groove Loosen bolt by a HALF turn of the bolt head Whilst 1 Drive Motor still holding bolt head with either 2 Wheel Yoke ratchet socket or spanner turn 3 Wheel down the nut till it hits Chassis 4 Cotter Pin outer casing and then tighten using 5 Slotted Nut a 9 16 spanner until nut is tight to 6 Shaft Key outer material This is to lock the bolt 7 Capscrew in position 8 Locknut 4 Align the steer pin with
69. te injury NOTE Gives helpful information Page i Foreword WORKSHOP PROCEDURES All information contained in this manual is based on the latest product information available at the time of printing We reserve the right to make changes at any time without notice No part of this publication may be reproduced stored in retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the publisher This includes text figures and tables Detailed descriptions of standard workshop procedures safety principles and service operations are not included Please note that this manual does contain warnings and cautions against some specific service methods which could cause personal injury or could damage a machine or make it unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommended by UpRight might be done or of the possible hazardous consequences of each conceivable way nor could UpRight investigate all such ways Anyone using service procedures or tools whether or not recommended by UpRight must satisfy themselves thoroughly that neither personal safety nor machine safety will be jeopardized Page ii Section 1 INTRODUCTION 1 1 INTRODUCTION PURPOSE The purpose of this service and parts manual is to provide instructions and illustrations for the ope
70. tension 1 person Maximum Wheel Load 9 18 kg 1 800 Ibs Height Working Height 9 93 m 32 5 ft Max Platform Height 7 93 m 26 ft Min Platform Height 1 09 m 43 in Dimensions Weight 2358 kg 5200 Ibs Overal Width 0 82 m 32 5 in Overal Height 2 19 m 86 in Overal Height Rails Lowered 1 99 m 78 25 in Overal Length Extension In 2 35 m 92 5 in Overal Length Extension Out 3 26 m 128 5 in Drive 5 Platform Lowered 0 to 3 2 km h 0 to 2 0 mph Platform Raised 0 to 0 8 km h 0 to 0 50 mph Hydraulic Fluid Normal Temperature 0 C gt 32 ISO 32 Low Temperature 0 C lt 32 F ISO 32 Extreme Temperature 17 C lt 0 F ISO 15 Lift System One Single Stage Lift Cylinder Lift Speed Lift 42 sec Lower 40 sec Proportional Control Handle with Interlock Switch Rotary Lift Drive Switch and Red Control System Mushroom Emergency Stop Switch Dual Front Wheel Hydraulic Motors 381 mm 15 in Diameter Solid Rubber non marking Parking Brake Dual Spring Applied Hydraulic Release Ground Clearance 69 mm 3 5 in Taming Ra Sound Power Level 69dBA Max Wind speed for this machine is Beaufort wind force 4 refer page 7 Specifications are subject to change without notice Hot weather or heavy use may affect performance Refer to the Service Manual for complete parts and service information Meets or exceeds all applicable CE and machinery directive requirements MD98 37 EC
71. the ON position 3 Pull Platform Emergency Stop Switch to the ON position 4 Turn and hold the Chassis Key Switch to CHASSIS 5 Push the Chassis Lift Lower Switch to LIFT to elevate the platform until the maintenance brace can be rotated to the vertical position 6 From the rear of the machine lift the maintenance brace from its stowed position Rotate upward and outward then down until it is hanging vertically below its attachment point 7 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER and gradually lower the platform until the maintenance brace is supporting the platform REMOVAL 1 Using the Chassis Controls gradually elevate the platform until the maintenance brace is clear 2 Rotate the maintenance brace outward and upward over its attachment point until it rests in the stowed position 3 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER to completely lower the platform 3 2 PREVENTATIVE MAINTENANCE 508244 002 The complete inspection consists of periodic visual and operational checks along with periodic minor adjustments to assure proper performance Daily inspection will prevent abnormal wear and prolong the life of all systems The inspection and maintenance schedule is to be performed at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures A WARNING Before
72. the checklist when inspecting the machine MAINTENANCE TABLE KEY MAINTENANCE REPORT Y Yes Acceptable Date N No Not Acceptable Owner R Repaired Acceptable Model No Serial No serviced By COMPONENT INSPECTION OR SERVICES Y N R e LLL Check battery cable coral Check Roses for ine _ 17 Control Cable Checkthe exterior ofthe cable or pinching tang Cowole Checkswiehaperaien p Drive Motors Elevating Assembly Emergency Lowering System Operat the emergency lowering valve and check for Ente Unit Checktorandreparcotsondamag ECU Check mie E raue Pump 688 587 Widac System TT Labels Checktorpeaing missing orunresdabi labels A repo Fees Deck and Ras Checkweldsforoacts Platform Deck and Rails Check 1 Tires and Wheels Page 2 18 11 SPECIFICATIONS 11 SPECIFICATIONS ITEM Platform Size Platform Extension In 0 71 m x 2 21 m 28 in x 87 in Platform Extension Out 0 71 mx 3 20 m 28 in x 126 in Standard 340 kg 750 Ibs on Extension 110 kg 250 Ibs No of occupants Standard total 3 People Indoors 1 Person Outdoors Max Wind Speed 7m s on Ex
73. ulic oil NOTE Check the hydraulic pressures whenever the pump manifold or relief valves have been serviced or replaced 508244 002 Page 3 11 Hydraulics Page 3 12 Section 3 Service Repair MAIN RELIEF VALVE Operate the hydraulic system 10 to 15 Install a 0 207 bar 0 3000 psi pressure Turn the Chassis Keyswitch to CHASSIS While holding the Chassis Lift Switch to Lower the platform Figure 3 13 Hydraulic Manifold with Valves minutes to warm the oil Remove the cap or loosen the locknut creck valve POOLE MAIN RELIEF VALVE the Main Relief Valve gauge to the gauge port and elevate the machine fully the UP position adjust the Main Relief Valve until the pressure gauge reads 165 bar 2400 psi gt RELIEF VALVE Release the Chassis Lift Switch CROSSLNEREEF jJ TE 4 FLOW RESTRICTOR Replace the cap tighten the locknut on STEERING the Lift Relief Valve and torque to 8N m 6 ft lbs COUNTERBALANCE VALVES 1 OT 10 11 12 13 Operate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating temperature Remove the gauge port cap and install the pressure gauge assembly Lift work platform and block front wheels off ground Loosen the locknuts on Counterbalance Valves With the machine fully powered up depress the DRIVE button on the upper control box
74. voltage and frequency 3 The charger turns on automatically after a short delay The LED charge indicator will illuminate After completion of the charge cycle the LED will blink indicating that the charger is in a continuing maintenance mode DO NOT leave the charger plugged in for more than 48 hours as permanent damage to the batteries may occur NOTE The battery charger circuit must be used with a GFI Ground Fault Interrupt outlet NOTE DO NOT operate the machine while the charger is plugged in Page 2 17 DAILY INSPECTION AND MAINTENANCE SCHEDULE DAILY INSPECTION AND MAINTENANCE SCHEDULE The Complete Inspection consists of periodic visual and operational checks along with periodic minor adjustments that assure proper performance Daily inspection will prevent abnormal wear and prolong the life of all systems Perform the inspection and maintenance items daily Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures AWARNINGA Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to perform maintenance while the platform is elevated DAILY PREVENTATIVE MAINTENANCE CHECK LIST The daily preventative maintenance checklist has been designed for machine service and maintenance Please photocopy the Daily Preventative Maintenance Checklist and use
75. wered Access Each parts list contains the component parts for that assembly indented to show relationship where applicable TABLE OF CONTENTS PAGE BASIC ASSEMBLY 6 2 CHASSIS ASSEMBLY FRONT 6 4 CHASSIS ASSEMBLY REAR 6 5 SCISSOR DECK ASSEMBLY 6 6 OCISSOR ASSEMBLY 6 8 Deck ASSEMBLY 6 12 CONTROL MODULE ASSEMBLY 6 14 POWER MODULE ASSEMBLY 6 15 HYDRAULIC MANIFOLD 6 16 CYLINDER ASSEMBLYS 6 17 LOWER CONTROL Box ASSEMBLY 6 18 UPPER CONTROL Box ASSEMBLY 6 19 ELECTRICAL ASSEMBLY 6 20 HYDRAULIC ASSEMBLY 6 22 PLATFORM OVERLOAD 6 24 CE DECAL 6 26 ANSI Kit 6 28 Sec6 1 ILLUSTRAITED PARTS LIST BAsic ASSEMBLY Part Description 066309 011 POWER MODULE 066310 026 CONTROL MODULE 069199 001 CHARGER 501425 000 SWITCH PROXIMITY 5 f 010076 000 MANUAL CASE MEME ATT CONTROLLER ASSEMBLY 9 501074 000 BATTERY 6 V 11 066250 026 PLATFORM GUARDRAIL ASSY 504033 000 TILT ALARM COVER WELD MENT 02164 000 CONTROLLER GUIDE WIDE 15 066713 001 WELDMENT DOOR HINGE R H WELDMENT DOOR HINGE L H CABLE MOUNT SUPPLIED WITH LIFT CYLINDER EMERGENCY LOWERING CABLE ADJUST EMERGENCY LOWERING CABLE COVER TO STOP INNER CABLE WHEN EMERGENCY LOWERING VALVE IS FULLY CIPEN Sec6 2 Item Part Description 04348 000 LOWER CONTROL 55 1 065943 102 WIRE HARNESS 55 J3 5 066623 020 LIFT OVERLOAD ALARM 5 504160 001 LOWERING CABLE 101182 008 CABL
76. will sound and the machine will not lift or drive If the level sensor alarm sounds the platform must be lowered and the machine moved to a firm level surface before attempting to elevate the platform Fig 5 Travel With Scissors Elevated is in contact with the machine Engage the Interlock Switch and pull back on the Control Handle to lower the platform safety cutout height Inspect around the machine to ensure no one is in contact with the machine After a four second time delay lower the platform as in step 2 Pothole Protection Rails Lowered Figure 5 Emergency Lowering Knob Emergency Open the Emergency Lowering Valve by pulling and holding XV the knob To close release the knob The platform will not elevate if the Emergency Lowering Valve is open GUARDRAILS The guardrails may be lowered for the purpose of passing through a standard doorway Guardrails must be returned to proper position before using the machine AWARNINGA DO NOT use the machine if all guardrails are not properly in place and secured LOWERING PROCEDURE 1 Ensure that the platform extension is fully retracted and the deck lock pin is engaged see Platform Extension on page 9 2 Place the Platform Controls on the deck of the platform extension 3 Lower the platform extension guardrail a Pull to retract the retaining pins b As the retaining pin is pulled the rail will drop slightly and hold the p
77. y Joystick O Oo Chassis Controls 1 Keyswitch 2 Enable Button 3 Toggle Switch Up 8 Down 4 Emergency Stop Button Page 2 6 5 PRE OPERATION SAFETY INSPECTION 5 PRE OPERATION SAFETY INSPECTION NOTE Carefully read understand and follow all safety rules operating instructions labels and National Safety Instructions Requirements Perform the following steps each day before use 1 Open modules and inspect for damage fluid leaks or missing parts 2 Check the level of the hydraulic fluid with the platform fully lowered See Hydraulic Fluid on page 16 Add recommended hydraulic fluid if necessary See Specifications on page 21 3 Check that fluid level in the batteries is correct See Battery Maintenance on page 17 4 Verify that the batteries are charged 5 Check that the A C extension cord has been disconnected from the charger plug 6 Check that all guardrails are properly in place and secured 7 Inspect the machine thoroughly for cracked welds loose or missing hardware hydraulic leaks damaged cables or hoses loose wire connections and wheel bolts Note X26N operates in Maximum Wind conditions equivalent to Beaufort 4 TABLE OF WIND SPEED VELOCITY BEAUFORT CONDITIONS 3 7 Beaufort Average Wind Wind Velocity Description Conditions Number Speed km h m sec 3 17 4 5 Gentle Breeze Leaves 4 Twigs in constant motion flags wave Moderate Dust amp Loose pape

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