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1. Page 3 12 Section 3 Service amp Repair Hydraulics 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 is under very high pressure which can easily cause severe cuts Obtain medical assistance immediately if cut by hydraulic oil NOTE Check the hydraulic pressures whenever the pump manifold or relief valves have been serviced or replaced MAIN RELIEF VALVE Figure 3 9 Hydraulic Manifold 1 Operate the hydraulic system 10 to 15 min utes to warm the oil 2 Remove the cap or loosen the locknut on the Main Relief Valve ee 3 Install 0 207 bar 0 3000 psi pressure gauge to the gauge port 4 Turn the Chassis Keyswitch to CHASSIS and elevate the machine fully 5 While holding the Chassis Lift Switch to the UP position adjust the Main Relief Valve until the pressure gauge reads 165 bar 2400 psi RELIEF VALVE 6 Release the Chassis Lift Switch STEERNG VALVES DRIVE FLOW RESTRIC TOR PRESSURE RELIEF MAIN LIFT STEERING 7
2. Pd ooo ooo 15 lt 6 7 P 18 Ps les i 17 T Wc 5 Le 505115 003 6 25 Illustrated Parts Breakdown Label Kit European English Label Kit European English 505004 000 060197 001 Description DECAL HYDRAULIC FLUID 101210 000 DECAL HYDROGEN GAS 510280 000 DECAL EMERGENCY DOWN 502511 000 DECAL UPPER CONTROLS 107052 000 DECAL SAFE WORKING LOAD 010076 901 DECAL DOCUMENTS ENCLOSED 505079 000 DECAL LOWER CONTROLS 062562 951 DECAL BATTERIES ARE BALLAST 505076 000 DECAL THREE HAZARDS 014222 903 DECAL FORKLIFT POINT 100102 900 DECAL NOT INSULATED 066522 900 DECAL BATTERY SYMBOL 068635 001 DECAL HARNESS HARDPOINT 501453 000 DECAL WARNING FOOT CRUSH 503723 000 DECAL BATTERY DISCONNECT N A N A 508665 000 Page 6 26 DECAL UpRight TM12 505115 003 on Page 6 27 505115 003 Illustrated Parts Breakdown Label Kit German Label Kit German 505004 200 Descript
3. m Lift Cylinder CYL2 E Pothole Cylinders CYL3 ST HE 2 2 T Steering Cylinder CYL1 d E S1 S2 PP1 L PP2 B CT6 NW VW B 5 1 CT9 1 IN NE D1 4 A 1 u Drive Motors G nr gt lt gt lt px 1 AVE D2 M CT11 a CT4 T 003 505115 Page 6 20 Illustrated Parts Breakdown Hydraulic Cylinder Assembly Lift Hydraulic Cylinder Assembly Lift 107060 001 Item Part Description 1 107060 010 LIFT CYLINDER SEAL KIT Hn 107082 000 STANDPIPE ADAPTOR use with Oriface 031006 005 501483 000 EMERGENCY DOWN VALVE 1 4 020495004 NUT HEX JAM 1 4 28 UNF 5 069040 001 STUD THREADED 1 4 28 x 2 1 6 069041 000 KNOB RED 1 PLASTIC 1 4 28 v 7 4 5 86 505115 003 Page 6 21 Illustrated Parts Breakdown Hydraulic Cylinder Assembly Steer Brake Hydraulic Cylinder Assembly Steer Brake 065397 003 Item Part Description 1 065397 010 SEAL BRAKE STEER CYLINDER 2 011934 003 FITTING 6MB 4MJ90 Page 6 22 505115 003 Illustrated Parts Breakdown Hydraulic Cylinder Assembly Pothole H
4. 505115 003 6 13 Illustrated Parts Breakdown Lower Controls Assembly Lower Controls Assembly 505006 000 Item Part Description QTY 1 074800 UDLCBBOX 1 2 50505300 CABLE GLAND 1 3 074000 LCB BOX WELDMENT 4 502520000 ENABLE BUTTON 5 501866 000 KEY SWITCH amp A MOUNT 11 e amp 6 7 501867 000 EMERGENCY STOP BUTTON amp MOUNT _____ 1 9 502521000 TOGGLESWICH 1 10 10951 00 JFRONTPANELLCBBOX 1 0 oo 1 Co Page 6 14 505115 003 Parts Breakdown Hydraulic Tank Assembly Hydraulic Tank Assembly Description 107065 000 HYDRAULIC TANK ROTAMOLDING 104067 000 RETURN FILTER TANK IMMERSED 114068 001 STRAINER 1 25 X 75 068982 001 CAP HYDRAULIC TANK 011939 004 FITTING MALE X MALE TANK VENT 011937 001 FITTING FEMAL X MALE 90deg TANK VENT 5 amp 6 4 505115 003 Page 6 15 Illustrated Parts Breakdown Upper Controls Assembly Upper Controls Assembly 502541 000 Description 501882 000 JOYSTICK 501882 002 JOYSTICK RUBBER BOOT 501882 001 JOYSTICK STEERING BOOT 502511 000 OVERLAY 501592 000 MOUNTING PLATE 502591 000 SEAL 502453 000 PRINTED CIRCUIT BOARD 502529 000 UPPER CONTROL BOX BOX ONLY 501867 000 EMERGENCY
5. wo 505115 003 Page 6 5 Illustrated Parts Breakdown Chassis Assembly 3 of 4 Chassis Assembly 30f4 505001 000 ITEM PART NUMBER DESCRIPTION 40 107404 000 CHASSIS WELDMENT REF 41 504536 001 PUMP UNIT BSP 42 501814 000 VIBRATION MOUNT 43 505024 000 LATCH HINGING DOOR 44 107149 010 DOOR HINGED 45 505025 000 HINGE 46 107065 000 TANK HYDRAULIC RESERVOIR 47 503800 002 HYDRAULIC MANIFOLD BLOCK 48 107152 000 MOUNTING PLATE HYDRAULIC MANIFOLD 49 505012 000 IDLER WHEEL 53 50 505041 000 BUSHING SPACER 51 505038 000 CIRCLIP 52 505027 000 CIRCLIP COVER 53 504536 002 PUMP MOTOR BSP 504536 000 52 6 6 MOTOR ASSY BSP MADE FROM ITEM 53 4 41 40 48 47 505115 003 Illustrated Parts Breakdown Chassis Assembly 4 of 4 Chassis Assembly 4 of 4 505001 000 PART NUMBER DESCRIPTION 107179 000 POTHOLE WELDMENT L H 107180 000 POTHOLE WELDMENT R H 113053 000 HYDRAULIC CYLINDER POTHOLE 065970 011 SEAL KIT POTHOLE CYLINDER 011848 019 PIVOT PIN POTHOLE CYL CHASSIS 011848 036 PIVOT PIN POTHOLE CYL POTHOLE WELDMENT N A N A 502489 000 LINE CONTACTOR N A N A 505566 001 TILT S
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7. 3 3 Installations epesi ara EE 3 3 sn a BE dag dedit de a ees 3 3 3 2 Preventative 3 4 3 3 Preventative Maintenance Check List 3 5 3 4 Parts Location 3 6 3 5 General Lubrication 3 7 Dale 3 8 Battery Replacement reden 3 8 Battery Maintenance ns a rar ihm 3 8 3 7 4 2 Serie a a iE ix 3 9 Hydraulic Oil Tank And 3 9 Hydraulic PUMP 24 2 ets aes UE eee ea TP be Be 3 10 Cylinder valve 3 11 Main Hydraulic Manifold 1 2 2 2 3 12 Setting Hydraulic Manifold Pressures 2 3 13 3 8 Cylinders aa sedis bo oe a he Sw Bee eda AERE 3 15 Depression Cylinder ae mb Gree RR Pann H 3 15 Brake Cylinders a eee eee 3 16 Steering Cylinder TT 3 17 YI 3 18 3 9 Drive 8 u ccc eee ee Rm RR a en 3 19 Removal ee Abad ee ailes 3 19 Installations 2 ea I 3 19 Page 3 1 Sectio
8. 6 15 Upper Controls Assembly 6 16 505115 003 Hydraulic Assembly 6 18 Hydraulic Cylinder Assembly Lift 6 21 Hydraulic Cylinder Assembly Steer Brake 6 22 Hydraulic Cylinder Assembly Pothole 6 23 Electrical Assembly 6 24 Decal Kit English 6 26 Decal Kit 6 28 Decal Kit 6 30 Decal Kit USA 6 32 Page 6 1 Illustrated Parts Breakdown General Assembly General Assembly 505000 000 Description 505001 000 CHASSIS ASSEMBLY 505002 000 MAST PLATFORM ASSEMBLY 505004 000 DECAL ASSEMBLY 505007 000 HYDRAULIC ASSEMBLY 505008 000 ELECTRICAL ASSEMBLY Page 6 2 505115 003 D fe oA Page 6 3 505115 003 Illustrated Parts Breakdown Chassis Assembly 1 of 4 Chassis Assembly 1 of 4 505001 000 ITEM PART NUMBER DESCRIPTION QTY 1 107404 000 CHASSISWELDMENTTMI2 BRAKE BEARING amp LH 6 107131 002_ CHASSISACCESSPANEL 8 065532000 FRONT COVER L9 305023 000 SPRING COMPRESSION 1 10 065474000 TENSION BAR WELDMENT Pag
9. rl a a Page 6 32 505115 001 Illustrated Parts Breakdown 107012 010 Page 6 33 Local Distributor Lokaler Vertiebsh ndler Distributeur local El Distribuidor local Il Distributore locale USA U j Europe TEL 1 559 443 6600 TEL 44 0 845 1550 058 FAX 1 559 268 2433 55 www upright com
10. Page 6 9 505115 003 Illustrated Parts Breakdown Platform Assembly Platform Assembly 505003 000 065543 000 Description COVER PLATE MAST TOP 502541 000 UPPER CONTROLS ASSEMBLY 057094 001 HARDPOINT SAFETY HARNESS 508936 000 DROP BAR ASSEMBLY 065580 001 PLATFORM WELDMENT 065589 000 TOEBOARD 107197 000 Page 6 10 INSPECTION COVER 505115 003 505115 003 Page 6 11 Illustrated Parts Breakdown SAE Build Control Valve Assembly Control Valve Assembly 503800 002 10652 000 Description 1 4 SAE TEST POINT 10653 000 TTING 1 4 SAE 7 16 20UNF JIC ALE MALE 10653 000 NG 1 4 SAE 7 16 20UNF JIC ALE MALE 10653 000 NG 1 4 SAE 7 16 20UNF JIC MALE MALE 10653 000 10654 000 NG 3 8 SAE 9 16 18UNF JIC ALE MALE 10654 000 NG 3 8 SAE 9 16 18UNF JIC TT TT TTING 1 4 SAE 7 16 20UNF JIC MALE MALE T TT ALE MALE 10653 000 ITTING 1 4 SAE 7 16 20UNF JIC BULKHEAD AJ 10654 000 TTING 3 8 SAE 9 16 18UNF JIC ALE MALE 10655 000 F F TTING 1 2 SAE 3 4 16 UNF MALE MALE 10654 000 FITTING 3 8 SAE 9 16 18UNF JIC MALE
11. 11 12 13 14 15 16 17 Partially lower the platform by pushing the Check the Chassis Emergency Lowering Move the machine if necessary to an unobstructed area to allow for full elevation Turn the Chassis and Platform Emergency Stop Switches ON by pulling the buttons out Turn the Chassis Key Switch to ON Push the Chassis Lift Switch to the UP position and fully elevate the platform Visually inspect the mast assembly for damage or erratic operation Check for missing or loose parts Verify that the depression mechanism supports have rotated into position under the machine Check Level Sensor operation Figure 3 Level Sensor Location a Open the door Position the machine off of level c Push the Chassis Lift Switch to the UP position The alarm should sound and the plat Level Sensor form should not lift more than 500mm d Close and latch the door Chassis Lift Switch DOWN and check the operation of the audible lowering alarm Valve for proper operation see Figure 4 a Open the valve by pulling the knob out b Once the platform is fully lowered close the valve by releasing the knob Push the Chassis Emergency Stop Switch down to the OFF position All machine functions should be disabled Pull out the Chassis Emergency Stop Switch to resume Mount the platform Check that the route is clear of persons obstructions holes and drop offs is leve
12. Charge batteries Check charger condition amp operation Check specific gravity Clean exterior PREVENTATIVE MAINTENANCE REPORT Date Owner Model No Serial No Serviced By Service Interval COMPONENT Elevating Assembly INSPECTION OR SERVICES Inspect for external damage dents loose rivets or cracks INTERVAL Y N R Check chains and sheaves for wear Lubricate lift chains Check chain tension Remove and inspect chains Clean terminals Hydraulic Oil Check oil level Change Filter Drain and replace oil Chassis Check cables for pinch or rubbing points Check welds for cracks Check component mounting for proper torque Hydraulic System Check for leaks Check hose connections Lift Cylinder Check for leaks Check for proper torque Check hoses for exterior wear Drive Motors Check for operation and leaks Emergency Down Check procedure for Emergency Down Hydraulic Pump Check for fitting leaks Wipe clean Entire Unit Perform pre operation inspection Check for and repair collision damage Lubricate Check fasteners for proper torque Check for corrosion remove and repaint Check for leaks at mating surfaces Check mounting bolts for proper torque Labels Check for peeling missing or unreadable labels amp repl
13. x x x x gt lt x gt lt x x x x x x x gt lt gt lt x x x x x x x x gt lt x x x gt lt x x x Tilt Sensor Steering Solenoid right Steering Solenoid left Platform Lift Solenoid Down Solenoid Reverse Solenoid Forward Solenoid Page 4 6 Troubleshooting 4 7 Hydraulic 4 7 HYDRAULIC Table 4 2 Hydraulic Troubleshooting Table Depression Mechanism Extend Function Lift Platform Lower Platform Steer Right Steer Left Drive Forward Drive Reverse Component Steering Cylinder Lift Cylinder CYL1 Depression Mechanism Cylinder gt lt i Depression Mechanism Retract gt lt Brake Cylinder Suction Strainer Return Filter Drive Motors 2 Pump Main Relief Valve Steering Relief Valve Lift Relief Valve Tank Steering Right Left Valve Lift Valve Down Emergency Lowering Valve Forward Reverse Valve Counterbalance Valve Page 4 7 Troubleshooting 4 7 Hydraulic 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 t
14. First Light ON Second Light BLINKING Third Light OFF 75 100 Charge First and Second Light ON Third Light BLINKING Charge Complete All Lights ON charger automatically shuts down to low current after charging is complete and all lights turn The charger continues at low current equalizing charge for 3 4 hours then charging current shuts off completely 4 Lights remain ON until the AC power supply is disconnected 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 11 Operation Manual Inspection and Maintenance Schedule 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 The inspection and maintenance schedule should be performed at the specified inter vals 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 The daily preventative maintenance
15. 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 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 Troubleshooting 4 6 Electric 4 6 ELECTRIC Table 4 1 Electrical Troubleshooting Table Depression Mechanism Extend Depression Mechanism Retract High Speed Creep Function Lower Controls Upper Controls Drive Forward Drive Reverse Raise Platform Lower Platform Steer Left Steer Right Tilt Alarm Down Alarm Battery Charge Component Alarm Batteries Battery Charger 5 AMP Circuit Breaker 175 AMP Fuse ECU Motor Control Motor Chassis Emergency Stop Switch Chassis Key Switch x x x x x x x x x x x x x x gt lt x x x x Platform Emergency Stop Switch gt lt x gt lt gt lt x x gt lt x x x gt lt gt lt x gt lt x x x Interlock Switch PQ Control Handle Height Limit Switch Platform Steering Switch gt lt gt lt
16. Upright POWERED ACCESS TM 12 Serial Numbers 53036 Current ENGLISH When contacting UpRight for service or parts information be sure to include the MODEL and SERIAL NUMBERS 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 UpRight were Stamped Serial Number MODEL TM12 sERAL __________ PLATFORM HEIGHT __3 73m UNLADEN WEIGHT I400N Indoor LATERAL FORCE 2Z00N Outside WIND SPEED CHASSIS INCLINATION 27 BATTERY VOLTAGE GRADEABILITY 25 CHARGER INPUT VOLTAGE Skw FORWARD SPEED NOMINAL POWER CAUTION ONLY TRAINED amp AUTHORISED PERSONNEL MAY USE Estampille de num ro de s rie Jd MAX Eingestanzte Seriennummer if PLATFORM LOAD _ 2 Persons Indoor 9 5 EDS 227 Kg 1 Persons Outdoor Equipment THIS MACHINE CONSULT OPERATORS MANUAL BEFORE USE THIS PLATFORM IS NOT ELECTRICALLY INSULATED 505049 000 UpRight POWERED ACCESS www upright com TM12 SEVICE AND PARTS MANUAL 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 SPECIFICATIONS Information on how to operate the work platform and how to prepare it for operation SECTION 3 MAINTENANCE Preventative maintenance and service information SECT
17. LA 1 ie SN nr SX 1 i cnl So EN ls Sea ar M 3 20 Section 3 Service amp Repair Elevating Assembly CHAIN LUBRICATION Refer to Figure 0 16 Elevating Assembly on page Section 3 20 With platform in the stowed position remove the platform mast cover 5 apply enough aerosol chain lubricant to the exposed portion of all four chains to allow the lubricant to run down the chains replace the cover remove the chain inspection cover 8 raise platform approximately 10cm 4 in until the inner set of chains are visible through the chain inspection hole apply enough aerosol chain lubricant to the exposed chain to allow the lubricant to run down the chain replace chain inspection cover ELEVATING ASSEMBLY WEAR INSPECTION Refer to Figure 0 16 Elevating Assembly on page Section 3 20 At the same time as the chain lubrication task inspect all elevating assembly components for wear With the platform in the stowed position inspect the system through the platform mast cover 5 to look for worn pulleys 13 amp 15 or damaged components Inspect the chain anchors 10a amp 10b and visible portions of lift chain as you lubricate it Look for cracks in the chain links kinks in any portion of chain and excessive corrosion From the lower controls raise the platform and block the elevat
18. pua out yo si zeude gt es PAM 510991044 020 o ous eui 012 2 v am D F DTAYZ 9 J N Sua Uana 2041848104 0d UN aRRIOJIUDW 2 40 1040 103524402 t DA Bl iou6ls y Asme uay pua id i PE ES EPP EEE puar ES au 403220400 X UHA DAY BI 43 81045 0 VY m 4943294 4 vun ea 1 943 84810410 d 120178480010 BEER dni4d pua aux uo 4 5 aam DAY 81 pua aui uo JAN BI ic NE DESEE UNE 31 Br upuaoy Uni _ pua aui uo 4013auu02 DAY 81 ay UO 40323uu02 JAY BI sS 80 uanissudoH ugusoy jj RaAdessg _ USH pua YM a4 DMY BI vau 2503 0 25418247 SUN DMY ABSSOWES pua ay uo 2 6086 DAY TE Tas 13984 pua aui g vGISE 2 t DAV pua auy uo Sum DA Tr REEL x eua aui uo Duis DAY BI Japlou ASAJ p 2001 DAV m ON AGE WES IT 1504 1 984 En pua uo
19. tion of travel If the machine is not level the Tilt Alarm will sound and the machine will not lift or drive If the Tilt alarm sounds the platform must be lowered and the machine moved to a level location before attempting to re elevate the Platform LOWERING PLATFORM 1 2 Select LIFT mode While depressing the Interlock Switch pull back on the Control Lever Page 7 Operation Manual Operation 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 4 Emergency Lowering Valve Ask a person on the ground to open the Emergency Lowering Valve to lower the platform The Emergency Lowering Valve is located at the front of the chassis 1 Open the Emergency Lowering Valve by pulling the knob out 2 Toclose release the knob NOTE The platform will not elevate if the Emergency Lowering Valve is open Emergency Lowering Valve PARKING BRAKE RELEASE Perform the following procedure only when the machine will not operate under its own power and it is nec essary to move the machine or when winching onto a trailer to transport Spring Compression Nut Figure 5 Parking Brake Release 1 Remove the spring compression nut so the spring is loose and the brake bars are away from the tires 2 The machine will now roll wh
20. 3 2 Section 3 Service amp 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 Supporting Elevating Assembly INSTALLATION 1 Park the Work Platform on firm level ground 2 Verify Platform Emergency Stop Switch is ON 3 Verify Platform Key Switch is ON 4 Press the Enable button and push Chassis Lift Lower toggle Switch to UP to elevate Platform approximately 1 2m 4 feet 5 Place a wood block 5cm x 10cm x 46cm 2 in x 4 in x 18 in long between the 2 Mast and Chassis just behind the Mast Assembly Number 2 Mast 6 Press the Enable button and push Chassis Lift Lower toggle Switch to DOWN position and gradually lower Platform until the 2 Mast is Wood Block supported by the block 000 REMOVAL 1 Press the Enable button and push Chassis Lift Lower toggle Switch D to UP to gradually raise Platform until wood block can be removed 2 Remove block 3 Press the Enable button and push Chassis Lift Lower toggle Switch to DOWN position and completely lower Platform Page 3 3 Preventative Maintenance Section 3 Service amp Repair 3 2 P
21. 4 SAE 7 16 20UNF MALE MALE 510653 000 FITTING 1 4 SAE 7 16 20UNF JIC MALE MALE 510653 000 FITTING 1 4 SAE 7 16 20UNF JIC MALE MALE 510653 000 FITTING 1 4 SAE 7 16 20UNF MALE MALE 510654 000 FITTING 3 8 SAE 9 16 18UNF JIC MALE MALE 510654 000 FITTING 3 8 SAE 9 16 18UNF JIC MALE MALE 510653 000 FITTING 1 4 SAE 7 16 20UNF JIC BULKHEAD 510654 000 FITTING 3 8 SAE 9 16 18UNF MALE MALE 510655 000 FITTING 1 2 SAE 3 4 16 UNF MALE MALE 510654 000 FITTING 3 8 SAE 9 16 18UNF JIC MALE MALE on gt 502200 002 _ 2 CARTRIDGE FLOW REG 502200 003 _ CARTRIDGE RELIEF 502200 004 CARTRIDGE RELIEF 502200 005 5 CARTRIDGE RELIEF 502200 006 CT6 CARTRIDGE SOLENOID 501526 000 7 CARTRIDGE SOLENOID 502200 007 019 CARTRIDGE OVERCENTRE 502200 007 0710 CARTRIDGE OVERCENTRE 501526 000 CT11 CARTRIDGE SOLENOID
22. 551000959 Wu 23 re Ww sape ME J vai m TIT 350g amp 2 Ir VE9 gy ves 4 En EUER 13 211 5 Es 96 17 vy v E Word Tora Ira Hera 2 cent dois 3 dors 3 o ans pe 2 48043007 lauod Page 5 2 WIRE INF RMATIUN 5 3 CABLE ASSEMBLY TABLE ITEM ND POSITION ITEM POSITION COLOR POSITION COLOR i A 13 BL ORANGE FROM ITEM 85 BROWN FROM ITEM 85 Ae 14 B2 AN RED SINGLE WIRE c2 WHT SINGLE WIRE 3 15 B3 BLUE SINGLE WIRE C3 PINK FROM ITEM 88c 4 4 16 B4 PINK FROM ITEM 880 C4 GRAY FROM ITEM 880 5 AS DRANGE SINGLE WIRE 17 B5 BLACK SINGLE WIRE CS GRAY FROM ITEM 880 6 6 18 B6 LIGHT BLUE SINGLE VIRE C6 WHITE BLUE SINGLE VIRE 7 7 BLACK SINGLE WIRE 19 B7 BLL C7 ORANGE SINGLE WIRE 8 AB WHITE SINGLE WIRE 20 BB C8 GRAY FROM ITEM 88c 9 9 21 89 SINGLE WIRE c9 BLACK SINGLE WIRE 10 A10 22 B10 BLUE SINGLE WIRE cig BLUE PURPLE SINGLE WIRE il All BLACK ORANGE SINGLE WIRE 23 Bil PINK 1 FROM ITEM 89a GRAY 2 FROM ITEM 890 12 Ale GRAY 2 FROM ITEM 89b 24 Bie BLUE SINGLE WIRE Cle PINK 1 F
23. Barrel Head Cap Piston Piston Nut O Ring Backup Ring Rod Wiper U Cup Teflon Piston Ring O Ring under Piston Ring Backup Ring 2 O Ring Page 3 17 Cylinders Section 3 Service amp Repair LIFT CYLINDER REMOVAL Refer to Figure 3 16 Elevating Assembly on page Section 3 20 for details Figure 3 14 Lift Cylinder Seal Kit 1 Fully lower platform 2 Provide a suitable container to catch the hydraulic fluid then disconnect the hydraulic hose Immedi ately plug hoses to prevent foreign material from entering 3 Remove the adapter from the base of the cylinder inside the chassis 4 Remove the Emergency Lowering Valve Knob from the valve the base of the cylinder then remove the Emergency Lowering Valve out the access hole in the bottom of the chassis 5 Remove the snap ring at the bottom of the cylinder under the chassis 6 Detach the 6 35mm 0 25 in vent line tubing from the top of the hydraulic tank and cut any plastic ties that secure the tubing Plug the end of the tubing to prevent contamination 7 Remove the platform mast cover Rod Orifice Spring Cylinder Barrel Orifice 0 063 Headcap Spacer Piston A Piston Seal Ball Bearing 3 8 Piston Seal Spring Static Seal Set Screw Allen Head Rod Seal 90 Fitting Rod Wiper Emergency Lowering Valve 8 Remove the capscrew and locknut securing the inder rod to the upper cylinder mount
24. MALE 121 2 502200 002 2 CARTRIDGE FLOW REG 502200 003 3 CARTRIDGE RELIEF 502200 004 CT4 CARTRIDGE RELIEF 502200 005 5 CARTRIDGE RELIEF 502200 006 T6 CARTRIDGE SOLENOID 501526 000 7 CARTRIDGE SOLENOID 502200 007 9 CARTRIDGE OVERCENTRE 502200 007 10 CARTRIDGE OVERCENTRE 501526 000 11 CARTRIDGE SOLENOID _ Page 6 12 SAE build 505115 003 Illustrated Parts Breakdown SAE Build Control Valve Assembly SAE build
25. Thoroughly rinse away any spilled fluid with clean water Always replace batteries with UpRight batteries or manufacturer approved replacements weighing 26 3 kg 58 Ibs each Check the battery fluid level daily especially if the machine is being used a warm dry climate 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 10 Battery Charge Indicator Charge the batteries 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 Check the battery fluid level If the battery fluid level is lower than 10 mm above the plates distilled water only 2 Connect an extension cord 1 5 mm 12 gauge minimum conductor diameter 15 m 50 ft maximum length to the charger plug located at the left side of the chassis 3 The charger turns on automatically after a short delay Look through the charge indicator cutout to check the state of charge 0 50 charge First Light BLINKING Second and Third Light OFF 50 75 Charge
26. With Platform fully lowered oil should be visible between Tank Max Min lines on the Tank if not fill the tank Hose Fittings Suction Screen DO NOT fill above the Max line when the Platform is Filter Module elevated Filter Cap AND FILTER REPLACEMENT 1 Operate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating tem perature 2 Open module door Filler Cap 3 Remove Hydraulic oil using a suitable pump The Hydraulic tank has a 7 2 liter 1 9 US gal capacity 3 Extract Filter module by removing the 3 screws shown in fig 2 4 Remove Spring and replace Old filter 4 Ensure the filter is sitting correctly and refit Spring 5 Apply a thin film of clean hydraulic oil ISO 46 to the O Ring housed in the Filter Lid 6 Refit the three screws shown in Fig 2 Filter 7 Fill the hydraulic reservoir with hydraulic oil until the oil comes up just past the Min line Filter screws Hydraulic tank has a 7 2 liter 1 9 US gallon capacity CAUTION The hydraulic oil may be of sufficient temperature to cause burns Wear safety gloves and safety glasses when handling hot oil Page 3 9 Hydraulics Section 3 Service amp 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
27. checklist has been designed for machine service and maintenance Please photocopy the Daily Preventative Maintenance Checklist and use the checklist when inspecting the machine Operation Manual Page 12 Daily Preventative Maintenance Checklist DAILY PREVENTATIVE MAINTENANCE CHECKLIST MAINTENANCE TABLE KEY PREVENTATIVE MAINTENANCE REPORT Y Yes Acceptable Date N No Not Acceptable Owner R Repaired Acceptable Model No Serial No Serviced By COMPONENT INSPECTION OR SERVICES COMPONENT INSPECTION OR SERVICES Batter Check electrolyte level Entire Unit Check for and repair collision damage Check battery cable condition Hydraulic Fluid Check fluid level Chassis Check hoses for pinch or rubbing points Hydraulic Pump Check for hose fitting leaks Check welds for cracks Hydraulic System Check for leaks Control Cable Check the exterior of the cable for pinching Labels Check for peeling missing or unreadable binding or wear labels amp replace Controller Check switch operation Platform Deck and Check welds tor cracks Drive Motors Check for operation and leaks Rails Elevating Assembly Inspect for structural cracks Platform Deck and check condition of deck Emergency Hydraulic Operate the emergency lowering valve and Ralls System check for serviceability Tires Check for damage Page 13 Operation Manual Specificati
28. provided to prevent excessive fluid loss 1 Mark disconnect and plug the hose assemblies 2 Loosen the capscrews and remove the pump assembly from the motor INSTALLATION Figure 3 6 Hydraulic Pump 1 Lubricate the pump shaft with general purpose grease and attach the pump to the motor with the capscrews 2 Using a crisscross pattern torque each cap screw a little at a time until all capscrews are torqued to 27N m 20 ft lbs 3 Unplug and reconnect the hydraulic hoses 4 Check the oil level in the hydraulic tank before operating the work platform CYLINDER VALVE ASSEMBLY 1 Inlet Hose 4 Pump Assembly 2 Outlet Hose 5 Electric Motor 3 Capscrew Page 3 10 Section 3 Service amp Repair Hydraulics EMERGENCY DOWN VALVE The Emergency Down Valve located at the front ofthe machine The valve is a 24 Volt DC sole noid mounted on the base of the cylinder Pull to activate Figure 3 7 Emergency Down Valve Emergency Down Valve Page 3 11 Hydraulics Section 3 Service amp Repair MAIN HYDRAULIC MANIFOLD Though it is not necessary to remove the manifold to perform all maintenance procedures a determina tion should be made prior to beginning as to whether or not the manifold should be removed before main tenance procedures begin Figure 3 8 Hydraulic Manifold Exploded View Description 510652 000 1 4 SAE TEST POINT 510653 000 FITTING 1
29. 000 psi Hydraulic Pressure Gauge with Adapter Fittings UpRight P N 014124 010 0 207 bar 0 3000 psi Hydraulic Pressure Gauge with Adapter Fittings UpRight P N 014124 030 Adapter Fitting UpRight P N 063965 002 Inclinometer UpRight P N 010119 000 Crimping Tool UpRight P N 028800 009 Terminal Removal Tool UpRight 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 mani fold Correct pressure settings are listed in the hydraulic schematic CHECKING PUMP PRESSURES Remove hose from pump port and connect pressure gauge Troubleshooting 4 3 TROUBLESHOOTING GUIDE TROUBLE All functions inoperable electric motor does not start All functions inoperable Electric motor starts when control is actuated Platform will not elevate or elevates slowly Platform drifts down after being elevated 4 3 Troubleshooting Guide PROBABLE CAUSE REMEDY 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 is low Faulty hydraulic pump Emergency Lowering valve open Platform overloaded Faulty co
30. 14 5 in Inside Maximum Gradeability 14 25 Wheel Base 97 8 38 5 in Guardrails 1 10 m 43 in Toeboard 152 mm 6 in Noise Level 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 This machine meets or exceeds all applicable CE GS machinery directive requirements Operation Manual Page 14 Specifications NOTES Page 15 Operation Manual Section 3 SERVICE AND REPAIR This section contains instructions for the maintenance of the Work Platform Refer to the General Informa tion section for information relevant to all UpRight Powered Access work platforms Referring to the Operator Manual will aid in understanding the operation and function of the various components 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 Section of this manual before attempting to operate or perform service on any Work Platform 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 TABLE OF 5 3 1 Supporting Elevating
31. 9 Attach a suitable hoisting device and sling to the cyl inder Carefully lift the cylinder approximately 0 5 m 18 in until you can see the vent line tubing attached near the top of the cylinder barrel Detach the tubing by depressing the green ring on the fitting at the same time you pull firmly on the tube Plug the end of the tube and the fitting to prevent contamina tion 1 2 3 4 5 6 7 8 9 10 Raise the cylinder the rest of the way through the top of the mast REPAIR Refer to Cylinder Repair in Section 1 General Information INSTALLATION 1 Attach a suitable hoisting device and sling to the cylinder Carefully lower the cylinder through the top of the mast until you can reattach the vent line tubing Simply push the tubing into the fitting until it goes no further Pull firmly to ensure that it is installed correctly Lower the cylinder the rest of the way and secure the cylinder to the chassis with the snap ring Install capscrew washers and locknut securing cylinder rod to the upper cylinder mount Install platform mast cover Install the Emergency Lowering Valve Knob and adapter to the base of the lift cylinder Remove the plug from the hydraulic hose and attach it to the adapter Attach the vent line to the hydraulic tank o no Test with weight at rated Platform load to check system operation Check for leaks Page 3 18 Section 3 Service amp Repair Drive Motors 3 9 DRIV
32. ATED the machine while elevated unless without first checking for overhead platform guardrails or midrail the machine is on firm level obstructions or other hazards surface 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 assembly jobs and assignments at overhead workplaces ceilings cranes roof structures build ings etc All other uses of the aerial work 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 electri cal equipment Exceeding the specified permissible maximum load is prohibited See Platform Capacity on page 4 for details The use and operation of the aerial work platform as a lifting tool or a crane is prohibited NEVER exceed the manual force allowed for this machine See Manual Force on page 4 for details DISTRIBUTE all platform loads evenly on the platform NEVER operate the machine without first surveying the work area for surface hazards such as holes drop offs bumps curbs or debris and avoiding them OPERATE machine only on surfaces capable of supporting wheel loads NEVER operate the machine when wind speeds exceed this machine s wind rating See Beaufort Scale on page 4 for details IN CASE OF EMERGENCY push EMERGENCY STOP switch to deactivate all powered functions
33. E 5 REMOVAL 1 2 3 4 Use 1000Kg 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 Block the rear wheels to prevent the machine from rolling Remove the cotter pin nut and washer Remove the wheel NOTE Before disconnecting hoses thoroughly clean off all outside dirt around fittings After disconnecting hoses and before removing from vehicle IMMEDIATELY plug port holes 9 6 INSTALLATION 1 Install the drive motor wheel yoke Tag disconnect and plug the hose assemblies to prevent foreign material from entering 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 Remove the locknuts flat washers capscrews and drive motor from the wheel yoke Figure 3 15 Drive Motor Assembly Position the drive motor in the wheel yoke and secure with capscrews flat washers and locknuts assembly into the pivot bearing along with the lower thrust washer thrust bush ing and retaining ring Align the steer pin with the hole in the steering link Remove the plugs from the hose assem Drive Mot blies and connect to the drive motor Bild cid Wheel Yoke Steering Link Bearing Steer Pin Retaining Pin Thrust Bushing Thrust Washer Install the shaft key wheel w
34. ENSOR 107080 000 TM12 TIE DOWN BRACKET 502483 000 ECU 502492 000 MOTOR CONTROLLER 510656 000 MOUNTING PLATE 505288 001 ALARM SOUNDER 501877 000 MOUNTING POST FUSE 502494 000 FUSE 107080 001 TIE DOWN RING D RING 505091 000 BRACKET POTHOLE TEE PIECE MOUNT 505044 000 BUSHING POTHOLE WELDMENT CHASSIS 505115 003 Page 6 7 Illustrated Parts Breakdown Mast Assembly Mast Assembly 505002 000 Item Part Description QTY 2 505065000 ANCHORINNER 2 3 107082000 STANDPIPE ADAPTER dt 4 505064000 OUTERANCHOR dt 6 505057 000 JOUTERAXLE 7 505056000 INNER AXLE 8 065491 001 SECOND INNER MASTWEDMENT4M 1 9 065488001 LOWER INNER MASTWELDMENT st 10 065485 004 MAST WELDMENT dt 11 065450 001 CYL amp PAD WELDMENT 12 505001000 CHASSIS ASSY 13 107060 001 LIFT CYLINDER ASSY 1 501483 000 EMERGENCY LOWERING VALVE REF 16 505060000 PULLEYOUTER 1 17 505059000 PULLEYINNER 18 5504040 pd 19 ANCHOR Pint 29 510230 030 M12 HEAD 30mm GRADE 109 9 Page 6 8 505115 003
35. En Gua 2 pG 9E 2 WM DAY m ING EM Pausyms 12 18 57479351 ly S84IM S81407 Ir n23 9035 3 6403 122 0045 3 9 OMY 02 91995 A UOJ 1003101400359 Hulays 1 ___ 00453 404 Asso ssausoy aas 10704 21002 102 2 ER mp neo 6 Sud 1291405 v X and 2 d e Tak uid dwy 5 San OL e Page 5 4 2 MN 5 5 HYDRAULIC SCHEMATIC sapu ZIAD uri Page 5 5 Notes Page 5 6 Section 6 ILLUSTRATED PARTS BREAKDOWN 6 1 INTRODUCTION This section lists and illustrates the replaceable assemblies and parts of this product as manufactured by UpRight Powered Access Each parts list contains the component parts for that assembly CONTENTS General 6 2 Chassis Assembly 6 4 Mast Assembly 6 8 Platform Assembly 6 10 Control Valve Assembly 6 12 Lower Controls Assembly 6 14 Hydraulic Tank
36. 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 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 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 Powered Access AFTER USE secure the work platform from unauthorized use by turning the keysw
37. ION 4 TROUBLESHOOTING Causes and solutions to typical problems SECTION 5 SCHEMATICS Schematics and valve block diagram with description and location of components Large sche matic drawings may be located in the back of the manual SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations Large parts drawings may be located in the back of the manual SPECIAL INFORMATION ADANGER A Indicates an imminently hazardous situation which if not avoided will result in severe injury or death Indicates a potentially hazardous situation which if not avoided could result in severe injury or death Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTE Gives helpful information Pagei 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 Note that this manual does contain warnings and cautions against s
38. L HARNESS HARDPOINT 501453 000 DECAL WARNING FOOT CRUSH 503723 000 DECAL BATTERY DISCONNECT N A N A 508665 000 Page 6 30 DECAL UpRight TM12 505115 003 4 KCN 6 31 505115 003 Illustrated Parts Breakdown Label Kit USA Label Kit USA Serial Numbers 70000 107012 010 Description 0071927 DECAL HYDRAULIC OIL 060197 001 DECAL HYDROGEN GAS 061205 005 PLATE 005221 000 DECAL BATTERY FLUID 005223 005 DECAL EMERGENCY DOWN 066554 000 DECAL BEFORE OPERATING 508665 000 DECAL UPRIGHT TM12 101250 000 DECAL MAX LOAD 500105 010076 001 DECAL ATTENTION 505079 000 DECAL LOWER CONTROLS 061220 000 DECAL ANSI 058534 000 DECAL BATTERIES 066550 001 DECAL DANGER 014222 003 DECAL FORK LIFT 066555 000 DECAL RELIEF VALVE 066568 000 DECAL LOWER PLATFORM 066556 000 DECAL COLLISION HAZARD 066522 000 DECAL BATTERY CHARGER 101252 000 DECAL MAX WHEEL LOAD 675 066556 001 DECAL WARNING 107051 000 DECAL BATTERY DISCONNECT 300699 DECAL OPERATORS CHECKLIST 508771 000 DECAL DO NOT REMOVE COMPONENTS 308772 000 DECAL WARNING RESPONSIBILITIES 068635 001 DECAL HARNESS HARD POINT co 2 2
39. NING DO NOT use the maintenance platform without guardrails properly assembled and in place Entry Bar Elevating Mast Platform Controls Manual Case Electrical Box Hydraulic Reservoir N Oo DN Level Sensor inside Door 9 Battery Tray 10 Emergency Lowering Valve 11 Battery Charger 12 Drive Relief Valve 13 Charger Outlet Plug Page 3 Operation Manual Special Limitations SPECIAL LIMITATIONS Travel with the platform raised is limited to creep speed range Elevating the platform is limited to firm level surfaces only 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 PLATFORM CAPACITY The maximum platform capacity for the TM12 is 227 kg 500 lbs Two people may occupy the platform indoors while only one may occupy the platform outdoors 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 occupant with a maximum of 400 N 90 Ibs for two occupants DO NOT exceed the maximum amount of manual force for this machine BEAUFORT SCALE Never operate the machine w
40. Place a solid wood block 51mm x 100mm x 45cm 2 x 4 x18 between the second mast section and Chassis just behind the Wood Block mast assembly 6 Push the Chassis Lift Switch to the DOWN position and gradually lower the platform until the second mast section is supported by the block REMOVAL 1 Push the Chassis Lift Switch to the UP position and gradually raise platform until the wood block can be removed 2 Remove the block 3 Push the Chassis Lift Switch to the DOWN position and completely lower the platform HYDRAULIC FLUID The hydraulic fluid reservoir is located in the chassis door Figure 8 Hydraulic Fluid Reservoir and Dipstick NOTE Never add fluid if the platform is elevated CHECK HYDRAULIC FLUID 1 Make sure that the platform is fully lowered Open the chassis door Check the fluid level using the guage on the tank To add Hydraulic fluid remove Filler Cap in Fig 8 Level Guage a A Add the appropriate fluid to bring the level to the FULL mark See Specifications on page 14 Operation Manual Page 10 Maintenance BATTERY MAINTENANCE Figure 9 Access to Batteries 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
41. RELIEF VALVES 1 Operate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating tempera ture 2 Install gauge in the gauge port 3 Loosen locknut or remove cover on the Steering Relief Valve and turn adjusting screw counter clock wise two full turns 4 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 5 Tighten locknut or replace Steering Relief Valve cover and torque to 8N m 6 ft lbs 6 Remove gauge and replace cap Page 3 14 Section 3 Service amp Repair Cylinders 3 8 CYLINDERS DEPRESSION CYLINDER Figure 3 10 Depression Cylinder Remove amp Replace REMOVAL 1 Mark and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from enter ing 2 Place a support under the depres sion guard 3 Remove the cotter pins from the pins 4 Remove the pivot pins while support ing the cylinder 5 Remove the cylinder Depression Cylinder 3 Cotter Pin REPAIR Pivot Pin 4 Depression Guard Refer to Cylinder Repair in Section 1 General Information INSTALLATION Installation is reverse of removal Page 3 15 Cylinders Section 3 Service amp Repair BRAKE CYLINDER The brake cylinder is located inside the right rear cha
42. REVENTATIVE MAINTENANCE 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 mechani cal 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 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 photocopy the following page and use the table as a checklist when inspecting the machine for service Page 3 4 505115 001 Section 3 Service amp Repair Preventative Maintenance Check List 3 3 PREVENTATIVE MAINTENANCE CHECK LIST PREVENTATIVE MAINTENANCE KEY Interval Daily each shift or every day 50h 30d every 50 hours or 30 days 250h 6m every 250 hours or 6 months 1000h 2y every 1000 hours or 2 years Y Yes Acceptable N No Not Acceptable R Repaired Acceptable COMPONENT Battery System INSPECTION OR SERVICES Check electrolyte level INTERVAL Y R Check battery cable condition
43. ROM ITEM 890 Page 5 3 N ERS 22 N N N ASG lt 22 N OD III 5 4 CABLE SCHEMATIC ayeu T 8IZ0GE Wii pazomdod 0 0 08 gt 21002 OMY 81 ok vosuas ql 3078 Aveo THE 814211 814 0 I 62625 duy 19 sud aow I 8Iz0SE 140G2 PININT 3inpuod X pua au 107 92uu09 ES EI A0SZ FTANd Hinpuod O md 0 00 08 1 cv YHA DA BI 2 USERS Juoog 3140 Inpuod woog 1 4o13auuoj Sau ajoung pua aui 40128uu02 44m OMY BI nel 53 45 aui uo JAY 81 Sana REUROUSISS DU rae gt uel NYL pua aui
44. Replace the cap or tighten the locknut on the Lift Relief Valve and torque to 8N m 6 ft lbs 8 Lower the platform Page 3 13 Hydraulics Section 3 Service amp Repair COUNTERBALANCE VALVES 1 Operate the work platform for 10 15 minutes to bring the hydraulic oil up to normal operating tempera ture 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 a fF oO DN With the machine fully powered up depress the DRIVE button on the upper control box depress the interlock lever and slowly pull the control lever to REVERSE to drive the wheels 6 Adjust the Forward Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 83 bar 1200 psi 7 Slowly push the Control Lever to FORWARD to drive the wheels 8 Adjust the Reverse Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 83 bar 1200 psi 9 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 10 Tighten locknuts on valves to 8N m 6 ft lbs Remove blocks and lower work platform to ground 11 Reconnect the red Control Cable wire to terminal 9 12 Remove the gauge from the gauge port and re install cap 13 Check for proper operation of the drive system and brake STEERING
45. STOP BUTTON ASSEMBLY Page 6 16 505115 003 Notes 505115 003 Page 6 17 Illustrated Parts Breakdown Hydraulic Assembly Hydraulic Assembly European Specification 505007 000 Hose Kit with Fittings 505014 007 Item Part Description QTY 5 1070924045 HYDRAULIC HOSE BLOCK TO MOTOR LH DI LH 1 6 1070924049 HYDRAULIC HOSE BLOCK TO MOTOR RH D2 RH 1 8 510246 000 13 8 BSP Male JIC 6 Male Straight Dowty 057125 000 9 510694 000 1 2 BSP Male JIC 12 Male Straight Dowty 601 501603 22 107090095 HOSE BLOCK BRAKE CYL ANNULAR 1 24 107291046 HYDRAULIC HOSE DRAIN BRAKE FULLBORE 1 25 107291033 HYDRAULIC HOSE DRAIN T TANK 26 510469 000 HYDRAULIC HOSE PUMP BLOCK PRESSURE 27 0687444023 HYDRAULIC HOSE TANK PUMP SUCTION 1 28 107090 033 HYDRAULIC HOSE BLOCK POTHOLE T PIECE 29 NA 30 107090013 HYDRAULIC HOSE TEE POTHOLE CYL 3 31 107090 021 HYDRAULIC HOSE TEE POTHOLE CYL 32 020032 001 TEE PIECE POTHOLE SYSTEM 2 33 113053 000 HYDRAULIC CYLINDER POTHOLE 35 107065 000 TANK HYDRAULIC RESERVOIR 1 Page 6 18 505115 003 505115 003 Page 6 19 Hydraulic Schematic
46. ace Controller Check condition amp operation Wheels Check for loose components Platform Deck amp Rails NOTE Use ISO 46 during summer and ISO 32 during winter Check fasteners for proper torque Check welds for cracks Check condition of deck Check entry way closure Steering System Oil pivot pins Oil king pins Check steering cylinder for leaks Check hardware amp fittings for proper torque Page 3 5 Parts Location Section 3 Service amp Repair 3 4 PARTS LOCATION Control Gable Assembly Electrical Box Assembly 107123 000 Hydraulic 2 Reservoir Tilt Sensor Assembly Assembly Batteries Assembly Figure 3 2 Parts Location Motor Control Page 3 61 Section 3 Service amp Repair General Lubrication 3 5 GENERAL LUBRICATION Figure 3 3 Lubrication Points Apply grease to each grease fitting Apply one or two drops of motor oil to each bearing King Pin Bearings Steering Linkage Wheel Bearings Page 3 7 Batteries Section 3 Service amp Repair 3 6 BATTERIES Electrical Energy for the motor is supplied by four 6 volt batteries wired in series for 24 volts DC Proper care and maintenance of the batteries and motor will ensure maximum performance from the work plat form CAUTION If battery
47. asher 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 1 2 3 4 5 6 7 8 Remove blocks lower the jack and remove Operate the drive system and check for leaks Page 3 19 Elevating Assembly Section 3 Service amp Repair 3 10 ELEVATING ASSEMBLY Maintenance of the elevating consists of four separate tasks and maintenance intervals e Chain Lubrication 6months Elevating Assembly Wear Inspection 6 months Chain Tension Inspection 1 year Chain Elongation Inspection 5 years All of the tasks except the Elongation Inspection can be done without removing the chains from the assembly Figure 3 16 Elevating Assembly Base Mast 12 Front Mast Bearing Mast Bearings First Inner Mast 13 Inner Pulley Front Rear Second Inner Mast 14 Bearings 12 11 Platform Mast 15 Outer Pulley Platform Mast Cover 16 Chain Controller Cover 17 Upper Cylinder Mount Controller 18 Lift Cylinder Chain Inspection Cover 19 Adapter Inner Chain Anchor 20 Retaining Ring Outer Chain Anchor 21 Proximity Switch Outer Chain Inner Pulley 22 Emergency Lowering Knob Mount 23 Chassis Rear Mast Bearing ONOaRWND 10b B
48. atform PLATFORM CONTROLLER The platform controller contains the controls to operate the machine It is located at the front of the platform A complete explanation of control functions can be found in Section 2 ELEVATING ASSEMBLY The platform is raised and lowered by the ele vating assembly The hydraulic pump driven 1 by an electric motor powers the cylinder AF attorm controler 3 Elevating Assembly Solenoid operated valves control raising and 4 Chassis Controls lowering 5 Chassis Page 1 1 Introduction 1 2 General Description CHASSIS The chassis is a structural frame that supports all the components of the TM12 work platform The platform is raised and lowered using a scissors mechanism Lift is achieved using a single stage cylinder 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 Page 1 2 2 OPERATION MANUAL 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 aerial work platform Safety Rules Electrocution Hazard Tip Over Hazard Collision Hazard Fall Hazard THIS MACHINE IS NOT NEVER elevate the platform or drive NEVER position the platform NEVER climb stand or sit on INSUL
49. de of the chassis door to the left ofthe Hydraulic tank Emergency Stop 7 Control Box 2 Contact Block Emergency Stop Key Switch Toggle Switch Enable Button Cable Gland Page 3 26 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 possi ble 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 vari ous components and systems and help in diagnosing and repair of the machine GENERAL PROCEDURE 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 platfor
50. e 6 4 ITEM PART NUMBER DESCRIPTION QTY 065397003 CYLINDER ASSY BRAKE 1 065307010 SEALKIT CYLINDER 065469000 BRAKE ACTUATOR WELDMENT 026541016 HANDLE 011848 019 PIVOT PIN BRAKE CYLINDER 065569 000_ SPACER PLATE BATTERY TRAY SECURING PIN 1 065536000 MAIN CHASSIS COVER 1 10 11 13 505115 003 Illustrated Parts Breakdown Chassis Assembly 2 of 4 Chassis Assembly 2 of 4 505001 000 PART NUMBER DESCRIPTION 101125 001 MOTOR HYDRAULIC 101125 010 SEAL KIT MOTOR 505011 000 WHEEL DRIVE 107186 000 WHEEL YOKE L H 107185 000 WHEEL YOKE R H 065517 000 STEER LINK RH 065518 000 STEER LINK LH 065445 000 BELL CRANK WELDMT 065397 003 CYLINDER ASSY BRAKE STEER 065397 010 SEAL KIT BRAKE STEER CYLINDER 505043 000 BUSHING BELL CRANK amp STEER YOKE PIVOT 508108 000 BUSHING FLAT BELL CRANK amp STEER YOKE PIVOT 503673 000 BUSHING STEERING LINK ARMS amp BELL CRANK WELD M 505034 000 PIVOT PIN STEERING LINK ARMS 011848 019 PIVOT PIN STEERING CYLINDER 508108 000 BUSHING FLAT STEER YOKE PIVOT 505038 000 CIRCLIP 505045 000 SPACER STEERING LINK 061817 011 CASTLE NUT DRIVE WHEELS 505116 000 WASHER STEERING LINKARMS 056058 016 M6 X 16 HEX HEAD SCREW 058819 000 GREASE NIPPLE 505075 000 SPACER
51. e elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace Figure 3 18 Tilt Sensor ADJUSTMENT 1 Place machine on firm level surface 4 2 Use the Inclinometer p n 010119 000 to ensure front and rear of Chassis is level 14 3 Attach a 1 meter length of single core wire to the Reset Port shown in Fig 3 18 4 Attach the other end of the Single core wire to the a negitive terminal on a battery cell and hold for 3 4 seconds until a green LED flashes from under the head of the Tilt sensor 5 Test the Sensor as described below before using the machine TEST 1 Raise the platform approximately 2m 7 ft 2 Support the elevating assembly see Sup porting Elevating Assembly on page Section 3 3 3 Jack the machine to the side Past 3 degrees and the tilt alarm should sound Page 3 24 Section 3 Service amp Repair Controls 3 12 CONTROLS PLATFORM CONTROLS The Proportional Controller can be disassembled to replace defective switches See the Parts Manual for replacement part numbers Figure 3 19 Upper Controls Boot Steering Rocker Handle Emergency gt Boot Handle Stop Switch Mounting Plate Upper Control Box Lift Drive Selector Buttons Page 3 25 Controls Section 3 Service amp Repair CHASSIS CONTROLS Figure 3 20 Chassis Controls The chassis control assembly is mounted on Right Side Door the insi
52. ed to the Tie Down lugs may result in damage to the machine Forklift From Side Typical Tie Down Lift Points D Rings Hour METER To access the hour meter function perform the following steps 1 Climb into the basket with the machine powered up 2 Push the platform emergency stop button 3 Hold down the following buttons Horn and Lift 4 While holding the buttons twist the emergency stop button to return power to the machine 5 hr will now be displayed on the readout Pressing the right turn button will scroll through the accumu lated hours two digits at a time For example if pressing the right turn button once displays 20 pressing it a 2nd time displays 58 and pressing it a 3rd time displays hr the elapsed time of operation is 2058 hours Page 9 Operation Manual 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 Figure 7 Supporting the Elevating Assembly BLOCKING THE ELEVATING ASSEMBLY INSTALLATION 1 Park the machine on firm level ground 2 Verify that both Emergency Stop Switches are ON 3 Turn and hold the Chassis Key Switch to CHASSIS 4 Position the Chassis Lift Switch to UP and elevate the platform approximately 1 2 m 4 ft Number 2 Mast 5
53. en pushed or pulled After moving the machine and before normal operation 1 Replace the spring compression nut and tighten until the spring measures 22 2 22 9 cm 834 9 in length verify that the brake bars have fully engaged the tires before the machine is operated 22 2 cm to 4 1 AWARNINGA Never tow faster than 0 3 m sec 1 ft sec Never operate the machine with the parking brakes released Serious injury or damage could result 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 Operation Manual Page 8 Transporting the Machine TRANSPORTING THE MACHINE CRANE Secure the straps to chassis lifting tie down points only By FORKLIFT Forklifting is for transport only See specifications for weight of machine and be certain that forklift is of adequate capacity to lift the machine Figure 6 Transporting the Machine Forklift from the side by lifting under the Chassis By TRUCK 1 Maneuver the machine into transport position and chock wheels 2 Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis lifting tie down points CAUTION Overtightening of the chains or straps attach
54. erlock Switch slowly push or pull the Control Lever to FORWARD or REVERSE position to travel in the desired direction The farther you push or pull the Control Lever from center the faster the machine will travel STEERING NOTE Steering is not self centering Wheels must be returned to straight ahead position by operating the Steering Switch 1 2 Select DRIVE mode While depressing the Interlock Switch push the Steering Switch to RIGHT or LEFT to turn the wheels in the desired direction Observe the tires while maneuvering the machine to ensure proper direction ELEVATING PLATFORM 1 2 Select LIFT mode While depressing the Interlock Switch push Control Lever forward to UP the farther you push the Con trol Lever the faster the Platform will elevate If the machine is not level the Tilt Alarm will sound and the machine will not lift or drive If the Tilt alarm sounds the platform must be lowered and the machine moved to a level location before attempting to re elevate the Platform TRAVEL WITH PLATFORM ELEVATED NOTE The machine will travel at reduced speed when the platform is elevated 1 Check that the route is clear of persons obstructions holes and drop offs is level and capable of sup porting the wheel loads Check clearances above below and to the sides of the platform Select DRIVE mode While depressing the Interlock Switch push Control Lever to FORWARD or REVERSE for desired direc
55. he systems for checking tracing and faultfinding during troubleshooting analysis CONTENTS Schematic J1 5 2 Cable Assembly J1 5 3 Electrical 5 4 Hydraulic Schematic 5 5 Page 5 1 lt lt 9x 23 9 38 idw Josua 1 lt lt 9 MMS 422337 Y sh cena ano 5 T an ann 2 az r H Hc ar r var r 151 221 YOU gr I Fo SA aE Li an wr 2 I IST Are Ave gt 08 C aeg dnigr 3047393104794 8 23 5 JE scissa 5 95 17 YORE I em E aad d 3UA 8 Jt m ES us NS 102 21 E El p i SESS gt cd ul D E R 916 986 2020045 nn ammua Dun 2882941 smd m en panddns lt even a VOL I P SEN
56. hen wind speeds exceed 12 5m s 28mph Beaufort scale 6 BEAUFORT WIND SPEED GROUND CONDITIONS RATING mis kmh tis mph 3 4 5 4 12 25 19 4 11 5 17 75 7 5 12 0 Papers and thin branches move flags wave 5 4 8 0 19 4 28 8 17 75 26 25 12 0 18 Dust is raised paper whirls up and small branches sway 8 0 10 8 28 8 38 9 26 25 35 5 18 24 25 Shrubs with leaves start swaying Wave crests are apparent in ponds or swamps 10 8 13 9 38 9 50 0 35 5 45 5 24 5 31 branches move Power lines whistle It is difficult to open an umbrella 13 9 17 2 50 0 61 9 45 5 56 5 31 38 5 Whole trees sway It is difficult to walk against the wind lol gt Operation Manual Page 4 Controls and Indicators 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 2 Controls and Indicators Platform Controller Chassis Controller Right Side 9 1 00 Side View Top View Joystick Toggle switch chassis Emergency Stop Enable button Lift Button Keyswitch Drive Button Horn Button Emergency Stop chassis Display PRE OPERATION SAFETY INSPECTION NOTE Carefully read understand and follow all safety rules operating instructions labels and National Safety In
57. ine 9 BY Crane 22 ae ase ee ee D NS 9 B Forklifts n ee ee ML ae ee ba ene Es 9 By If ckz 2 a ta ed aca eee ee ea eee Bh lee AGE phe eared deed et 9 Maintenance ia 10 Blocking the Elevating 1 0 10 Installation e bat ad eg eh neces ated Slew RIPE 10 ok eR Se ERGO BA Gat rn aug BOUE 10 Hydraulic Fl ld e A as Y wee ea eee Pe NNUS NR EE 10 Check Flydraulic Fluid aye Par haat oa ers nh ean unse Nat 10 Battery Maintenance xoa er Setar BE ern cee odes Dil 11 Battery Charging prr a rn aii a E tn lu 11 Inspection and Maintenance 12 Daily Preventative Maintenance 13 Specifications en eA ee an a nee 14 Operation Manual Page 2 Introduction INTRODUCTION This manual covers all models of the TM12 Aerial Work Platform This manual must be stored on the machine at all times Read understand and follow all safety rules and operating instructions before attempting to operate the machine GENERAL DESCRIPTION Figure 1 TM12 Series 1 Platform WAR
58. ing assembly see Figure 0 1 Supporting Elevating Assembly on page Section 3 3 Inspect the inner chain anchors 9 and the ends of the chains for damage or worn parts If damage is present replace the components IMPORTANT There are two pairs of two chains each for a total of four chains If only one chain of either pair is damaged both chains in the pair must be replaced Page 3 21 Elevating Assembly Section 3 Service amp Repair CHAIN TENSION INSPECTION Refer to Figure 0 16 Elevating Assembly on page Section 3 20 The lifting chains are self adjusting and should always be close to the same tension This tension should be checked annually to ensure that there are no problems with this system To do this task a spring scale will be needed with 20kg 44 Ib capacity 1 Place 227kg 500 Ibs in the platform including the weight of the person testing the chain tension 2 Remove the chain inspection cover 8 and raise the platform approximately 10cm 4 in until the outer inspection hole lines up with the inner inspection hole 3 Attach the spring scale to one of the outer chains and pull until the chain makes contact with the inner surface of the mast section Note the scale reading 4 Repeat step 3 on the other outer chain 5 Compare the scale readings The readings for each chain in the outer set should be within 20 of each other 6 Repeat steps 3 5 for the inner set of chains The readings f
59. ion 1 060197 001 DECAL HYDRAULIC FLUID 101210 000 DECAL HYDROGEN GAS 510280 000 DECAL EMERGENCY DOWN 502511 000 DECAL UPPER CONTROLS DECAL SAFE WORKING LOAD 010076 901 DECAL DOCUMENTS ENCLOSED 505079 000 DECAL LOWER CONTROLS 2 3 4 5 107052 000 6 7 8 062562 951 DECAL BATTERIES ARE BALLAST 9 505076 200 DECAL THREE HAZARDS 10 014222 903 DECAL FORKLIFT POINT 2 11 100102 900 DECAL NOT INSULATED 1 12 066522 900 DECAL BATTERY SYMBOL 13 068635 001 DECAL HARNESS HARDPOINT 1 14 501453 000 DECAL WARNING FOOT CRUSH 2 15 503723 000 DECAL BATTERY DISCONNECT 1 16 N A N A N A 17 508665 000 DECAL UpRight TM12 2 Page 6 28 505115 003 Page 6 29 505115 003 Illustrated Parts Breakdown Label Kit French Label Kit French 505004 300 060197 001 Description DECAL HYDRAULIC FLUID 101210 000 DECAL HYDROGEN GAS 510280 000 DECAL EMERGENCY DOWN 502511 000 DECAL UPPER CONTROLS 107052 000 DECAL SAFE WORKING LOAD 010076 901 DECAL DOCUMENTS ENCLOSED 505079 000 DECAL LOWER CONTROLS 062562 951 DECAL BATTERIES ARE BALLAST 505076 300 DECAL THREE HAZARDS 014222 903 DECAL FORKLIFT POINT 100102 900 DECAL NOT INSULATED 066522 900 DECAL BATTERY SYMBOL 068635 001 DECA
60. itch off and removing key Page 1 Operation Manual CONTENTS IntroduCtion 31 3 luec cla ee eee eee an Re Ee naeh 3 General Description nn 3 Special Eimitations terra De er 4 Platform Capacity ae RR ea bos aca ES DRE 4 Manual Force See tas re ee He ae Be eee ee Se ee 4 Scalene is um Sop tea DA ae ile 4 Controls and Indicators 5 Pre Operation Safety 5 System Function Inspection 6 Operation u Tm 7 Travel With Platform Lowered 2 14 7 Steering hee tetas E eae act cate een ee 7 Elevating Platform esL ead eee Gee Deas 7 Travel With Platform Elevated 2 7 Lowering Platform ae A a ee ele ad tp NR p ee kre ee wey 7 Emergency Lowering a eier na P En 8 Parking Brake Release Dent dx a et See rn ER Oe pta 8 After Use Each Day x ben tate Poe Balle Pula he Peel hend 8 Transporting the Mach
61. l and capable of sup porting the wheel loads After mounting platform lower the bar across the entrance Select DRIVe mode While depressing the Interlock Switch slowly position the Control Lever to FORWARD then REVERSE to check for speed and directional control The farther you push or pull the Control Lever from center the faster the machine will travel Push the Steering Switch RIGHT then LEFT to check for steering control Push the Platform Emergency Stop Switch down to the OFF position All machine functions should be disabled Pull out the Platform Emergency Stop Switch to resume Operation Manual Page 6 Operation OPERATION Before operating the machine ensure that the Pre Operation Safety Inspection has been completed and that any deficiencies have been corrected Never operate a damaged or malfunctioning machine The operator must be thoroughly trained on this machine TRAVEL WITH PLATFORM LOWERED 1 Check that route is clear of people obstructions holes and drop offs is level and is capable of sup porting wheel loads Verify that the Chassis Key Switch is turned to ON and the Chassis Emergency Stop Switch is ON pull button out After mounting the platform lower the bar across entrance Check clearances above below and to the sides of the machine Pull the Controller Emergency Stop switch up to the ON position Select DRIVE mode While depressing the Int
62. m 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 Page 4 2 Do a full function test from both the platform and chassis controls and note all functions that 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 functioning correctly 3 Identify the problem component Test components that are common to all circuits that are not functioning correctly Remem ber to check wires and terminals between suspect components Be sure to check connec tions to battery negative 4 Repair or replace any component found to be faulty 5 Verify that repair is complete 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 values SPECIAL TOOLS Following is a list of tools which may be required to perform certain maintenance procedures on the TM12 work platforms Flow Meter with Pressure Gauge UpRight P N 067040 000 0 69 bar 0 1
63. n 3 Service amp Repair 3 10 Elevating Assembly ne a du date 3 20 Lift Chain Lubrication 2 sr a eoe 3 21 Elevating Assembly Wear 3 21 Chain Tension Inspect nene ae ee pdt 3 22 Chain Elongation Inspection 3 22 Removal of Elevating 1 1 3 23 Installation of Elevating 1 1 4 3 23 3 11 TiltSensor e a ir ln Pa a 3 24 3 12 Controls 2 22 a een ee ee Pee tee 3 25 Platform Controls Re pike Maine ee eee eae ery 3 25 Ghassis siege ea en Rn woth arena Boek lee et 3 26 LIST OF FIGURES Figure 3 1 Supporting Elevating Assembly 1 14 2 3 3 Eigur 3 2 Parts Location RISE REALI IR 3 6 Figure 3 3 Lubrication 40 3 7 Figure 3 4 Battery Cables 1 3 8 Figure 3 5 Hydraulic Oil Tank and Filter 3 9 Fig
64. ntroller at upper controls Blown control fuse 5 Battery level low Check for fault code 68 1 Emergency lowering valve open 2 Leaking piston seals in lift cylinders 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 Observe maximum load rating see Operation section of this manual Check functionality of controller Replace if faulty Check 7A circuit contrrol fuse Replace if blown Check Battery Voltage Charge if necessary Ensure that emergency lowering valve is completely closed Replace Check for leakage at cylinder return line replace seals if necessary Page 4 3 Troubleshooting 4 4 Fault Codes introduction 4 4 FAULT CODES INTRODUCTION The 12 is equipped with a fault detection system if you have 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 n
65. o 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 analog rocker is in neutral Then re cycle power do this by pushing and releasing the emergency stop button Ifthe 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 schematics 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 har ness 6 If signal is reaching the component but the component is not functioning replace the component refer to section 6 of this manual for part number information Page 4 4 Troubleshooting 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
66. ome specific service methods that 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 When in doubt contact your local distributor or UpRight 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 operation and maintenance of the TM12 manufactured by UpRight Powered Access SCOPE The manual includes procedures for proper operation maintenance adjustment and repair of the TM12 as well as recommended maintenance schedules and troubleshooting 1 2 GENERAL DESCRIPTION The 12 consists of the platform controller elevating assembly power module control mod ule and chassis DO NOT use the work platform without guardrails properly assembled and in place Figure 1 1 TM12 Work Platform PLATFORM The platform has a reinforced steel floor 1 11 m 43 75 inch high guardrails with midrail 6 inch 152 mm toeboards and an entrance gate at the rear of the pl
67. on nut on the tension bar Tighten the nut until at least flush with the tension bar shaft or until the brake bar has full engagement with the tire 6 Lower the machine and operate the drive circuit and check that the brake bars retract and clear the tires when driving and fully engage the tires when stopped Check for leaks Page 3 16 Section 3 Service amp Repair Cylinders STEERING CYLINDER REMOVAL 1 Mark and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from enter ing 2 Remove the cotter pins from the pivot pins 3 Remove the pivot pins while supporting the cylin der Remove the cylinder REPAIR Refer to Cylinder Repair in Section 1 General Information INSTALLATION 1 Position the cylinder assembly 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 1 2 3 4 5 0 Figure 3 12 Steering Cylinder Remove amp Replace Thrust Washer 1 Bearing 1 72 ID Bearing 34 ID Thrust Washer 34 Steer Pin Cotter Pin Steering Link Right Steering Link Left Bell Crank Weldment Steering Cylinder Pivot Pin Drive Motor Wheel Yolk Cylinder
68. ons SPECIFICATIONS 73 7 cm x 1 04 m 29 in x 41 in Maximum Platform Capacity 227 kg 500 Ibs Maximum Number of Occupants 2 People indoors 1 person outdoors Height Working Height Maximum Platform Height Minimum Platform Height 5 83 m 19 ft 3 83 m 12 5 ft 48 3 cm 19 in Dimensions Weight Overall Width Overall Height Overall Length 776 kg 1710 Ibs 76 cm 30 in 165 cm 65 in 1 36 m 53 5 in Drive Speed Platform Lowered Platform Raised 3 65 km h 2 27 mph 0 87 km h 0 54 mph Energy Source 24V battery pack Four 220 ampere hour 6 Volt batteries min wt 26 3 kg 58 Ibs each 4 HP DC electric motor System Voltage 24 VDC Battery Charger 20 AMP 220 V AC 50Hz Battery Duty Cycle 25 for 8 Hours Hydraulic Reservoir Capacity Maximum Hydraulic System Pressure 7 2 L 1 9 gal 165 bar 2400 psi Hydraulic Fluid Normal above 32 F 0 C ISO 46 Low Temp below 32 F 0 C ISO 32 below 0 F 17 C ISO 15 Lift System One Single Stage Lift Cylinder Drive Control Proportional Control System Proportional Control Handle with Interlock Selector Switch Red Mushroom Emergency Stop Switches Horizontal Drive Dual Front Wheel Tires Parking Brakes 30 5 cm 12 in diameter solid rubber Non marking Dual Spring Applied Hydraulic Release Turning Radius 37 cm
69. or each chain in the inner set should be within 20 of each other IMPORTANT If the readings are not within 20 then a problem exists that is causing unequal chain tension Investigate the problem and repair or replace the worn components CHAIN ELONGATION INSPECTION Figure 3 17 Chain Elongation Inspection At five year intervals the MEASURE DISTANCE OF 50 PITCHES chains should be removed from the mast and the entire length of the chain inspected for excessive wear and elongation Follow the procedure below to disassemble the elevating assembly With the lift chains removed hang them vertically from something capable of holding 100kg 220 Ibs Inspect the chains thoroughly looking for cracks in the chain links kinks in any portion of chain and excessive corrosion Complete the following elongation test 1 Attach approximately 25kg 55 Ibs to the lower end of each chain 2 Measure the distance between 50 pins This distance should be 63 5cm 65 5cm 25 in 2534 in 3 Remove the weight and measure the same on the other three chains If the chains have elongated beyond the indicated range replace the lift chain sets Before reinstalling the lift chains take this opportunity to thoroughly clean and lubricate the entire chain Reassemble the elevat ing assembly as described below Page 3 22 Section 3 Service amp Repair Elevating Assembly REMOVAL OF ELEVATING ASSEMBLY Refer to Figure 0 16 Elevating A
70. ssembly on page Section 3 20 Disconnect the batteries using the battery disconnect in front of the batteries in the battery tray Remove the platform mast cover 5 and the controller cover plate 6 Detach the control cable inside the controller 7 remove the cable clamp in the top of the platform mast 4 and feed the cable into the second inner mast section 3 Using a suitable hoisting device carefully raise the platform mast 4 until you can access the outer chain anchor 10a 5 Disconnect the outer chain anchorfrom the platform mast but leave the anchor attached to the chains Remove the lower mast bearings from the platform mast The front two mast bearings may be removed by drilling out the lower pop rivets that retain the bearings 7 Raise the platform mast straight up and off of the remaining mast sections 11 12 13 14 15 16 17 Lay the chain that was detached from the platform mast over the top of the upper cylinder mount 17 and place it down inside the second inner mast section Repeat steps 4 7 on the second inner section 3 The lower mast bearings are removed by unscrewing the two screws on each bearing The upper chain set may now be removed by detaching the upper chain inner pulley mounts from the first inner mast section 2 Carefully set the chain set aside on a clean surface Remove the single bolt that attaches the cylinder to the upper cylinder mount 17 Using a
71. ssis wall above the wheel Figure 3 11 Brake Cylinder Remove amp Replace REMOVAL 1 Block the wheels to prevent the work plat form from rolling when the brake is removed 2 Use 1000Kg one ton capacity jack to raise the rear of the machine Position blocks under the machine to prevent the work platform from falling if the jack fails 3 Block the front wheels to prevent the machine from rolling 4 Remove the spring compression nut and flat washer from the tension bar 5 Remove the retaining ring and right rear wheel 6 Remove the cotter pin and pivot pin from the rear cylinder mount 7 Remove the cotter pin from the tension bar pivot allowing the cylinder to be lowered 8 Disconnect the hose assemblies and cap the openings to prevent foreign material from enterin Brake Oylinder Rear Oylinder Pivot Pin 9 Tension bar Cotter Pin 9 Remove the cylinder from the chassis Spring Rear Cylinder Mount Brake Actuator Left Brake Bar Spring Compression Nut REPAIR Refer to Cylinder Repair in Section 1 General Information INSTALLATION 1 Connect the hose assemblies 2 Install the tension bar pivot through the cylinder clevis and brake actuator and secure with a new cotter pin 3 Install the pivot pin through the cylinder mounting tabs and rear cylinder mount and secure with a new cotter pin 4 Install the wheel and retaining ring 5 Install the flat washer and spring compressi
72. structions Requirements Perform the following steps each day before use 1 Open the Chassis Door and inspect for damage fluid leaks or missing parts 2 Check the level of the hydraulic fluid with the platform fully lowered Open the Chassis Door and remove the reservoir cap fluid should be visible on the dipstick Add recommended hydraulic fluid if necessary See Specifications on page 14 Check that the fluid level in the batteries is correct See Battery Maintenance on page 11 Verify that the batteries are charged Check that the A C extension cord has been disconnected from the chassis outlet Check that all guardrails are in place and all fasteners are properly tightened NO 5 Inspect the machine thoroughly for cracked welds and structural damage loose or missing hardware hydraulic leaks damaged control cable and loose wire connections Page 5 Operation Manual System Function Inspection SYSTEM FUNCTION INSPECTION Refer to Figure 1 and Figure 2 for the locations of various controls and indicators AWARNING A STAND CLEAR of the work platform while performing the following checks Before operating the machine 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 WD
73. suitable hoisting device carefully raise the first inner mast section 2 up several inches Lay the remaining chain set over the top of the cylinder and place it down inside the inner mast section Remove the lower mast bearings from the first inner mast section Raise the first inner mast section straight up and off ofthe remaining base mast section The inner chain set may now be removed If it is necessary to remove the base mast section remove the nine bolts that secure it to the chassis It may be required to remove the lift cylinder to provide easier access to the bolts see Lift Cylinder on page Section 3 18 INSTALLATION OF ELEVATING ASSEMBLY Refer to Figure 0 16 Elevating Assembly on page Section 3 20 Installation of the elevating assembly is the reverse of removal Torque the nine bolts that retain the base mast section to 68N m 50 ft lbs For all of the cap screws that attach the chain anchors to the mast sections apply Locktite 242 to the screw threads and torque to 12N m 107 in Ibs For all of the screws that attach the mast bearings apply Locktite Retainer 405 to the screw threads Do not torque simply tighten securely Check elevating assembly for proper operation Page 3 23 Tilt Sensor Section 3 Service amp Repair 3 11 SENSOR AWARNING A Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking th
74. ure 3 6 Hydraulic PUMP i meie n er ERI ee ee i ee DR 3 10 Figure 3 7 Cylinder 1 2 1 3 11 Figure 3 8 Hydraulic Manifold Exploded View 1 1 4 3 12 Figure 3 9 Hydraulic Manifold 3 13 Figure 3 10 Depression Cylinder Remove amp 1 3 15 Figure 3 11 Brake Cylinder Remove amp 2 1 3 16 Figure 3 12 Steering Cylinder Remove 8 Replace 40 3 17 Figure 3 13 Brake and Steering Cylinder Seal Kit 0 3 17 Figure 3 14 Lift Cylinder Seal Kit 0 3 18 Figure 3 15 Drive Motor Assembly 3 19 Figure 3 16 Elevating Assembly 3 20 Figure 3 17 Chain Elongation 3 22 Eig re 9s18s TIE SENS Of za uita tie atu A ee eit eon DE eed nier Mania Ras 3 24 Fig re 3 19 Upper Controls 2 tae eb RE gr Ee E See FER Rad 3 25 Figure 3 20 Chassis 1 2 3 26 Page
75. water level is not maintained batteries will not fully charge creating a low discharge rate AWARNINGA 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 if hydrogen gas or fuel vapors are present BATTERY REPLACEMENT Figure 3 4 Battery Cables The batteries are located in a slide out tray in the rear of the machine There are four 6 volt batteries wired in series for 24 volts DC Battery cables must be installed as shown in the Battery Cable Installation Diagram BATTERY MAINTENANCE Refer to Section 1 General Information for complete bat tery maintenance instructions Refer to the Operation Manual included in this Service Manual for specific maintenance and charging instruc tions Batteries Installed Battery Cable Installation Diagram Page 3 8 Section 3 Service amp Repair Hydraulics 3 7 HYDRAULICS HYDRAULIC TANK AND FILTER FLUID LEVEL Figure 3 5 Hydraulic Oil Tank and Filter
76. ydraulic Cylinder Assembly Pothole 113053 000 Part Description 065970 011 SEAL POTHOLE CYLINDER 063973 001 VALVE SOLENOID 011934 001 FITTING 4MB FMJ90 505115 003 Page 6 23 Illustrated Parts Breakdown 32 Electrical Assembly 505008 000 Description E Description 502483 000 ECU 1 502596 000 HARNESS BATTERY INTERCONNECT 502498 000 J1 HARNESS 1 069199 001 CHARGER 503800 002 MAIN MANIFOLD BLOCK 1 058783 000 CHARGER DISCONNECT PLUG 502541 000 UPPER CONTROLS 502597 000 HARNESS CHARGER DISCONNECT LINE 505006 000 LOWER CONTROLS 1 502598 000 HARNESS CHARGER DISCONNECT BATT 505566 001 TILT SENSOR 1 502599 000 HARNESS CHARGER DISCONNECT LINE CON2 501868 000 HORN 1 502600 000 NE CONTACTOR 3 FUSE 505288 001 ALARM 1 502601 000 NE CONTACTOR 5 LINE CONTACTOR 3 505072 000 PROXIMITY SENSOR 1 502489 000 NE CONTACTOR 502494 000 FUSE 1 502602 000 NE CONTACTOR 2 MOTOR CONT B 058937 000 BATTERY DISCONNECT PLUG 1 502603 000 NE 1 MOTOR ENABLE 502594 000 HARNESS BATTERY DISCONNECT BATT 502604 000 LINE CONTACTOR 6 PUMP MOTOR 502595 000 HARNESS BATTERY DISCONNECT 1 502492 000 MOTOR CONTROLLER 501074 000 BATTERY 504536 000 PUMP MOTOR BSP Page 6 24 505115 003

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