Upright SL-26 Service & Parts Manual
Upright SL-26 is a self-propelled work platform designed for elevating personnel and materials to overhead work areas. Featuring a reinforced steel platform, guardrails, toeboards, and an entry gate, it provides a secure and accessible workspace. The machine offers both high and low-speed drive modes for efficient maneuvering, along with steering controls for precise direction. The platform's elevating function is limited to firm, level surfaces, ensuring stability and safety during operation.
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SL26-30 WORK PLATFORM SERVICE & PARTS MANUAL POWERED ACCESS SL26/30SL Series Serial Numbers 50000 – 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. TEXT FOR ILLUSTRATION PURPOSE ONLY Stamped Serial Number SL26/30SL SERVICE AND PARTS MANUAL MANUAL PART NUMBER : 505561-000 SERIAL NUMBER : 50000 - CURRENT FOREWORD HOW TO USE THIS MANUAL This manual is divided into six sections. S ECTION 1 I NTRODUCTION General description and machine specifications. S ECTION 2 O PERATION AND S PECIFICATION Information on how to operate the work platform and how to prepare it for operation. S ECTION 3 M AINTENANCE Preventative maintenance and service information. S ECTION 4 TROUBLESHOOTING Causes and solutions to typical problems. S ECTION 5 S CHEMATICS Schematics and valve block diagram with description and location of components. S ECTION 6 I LLUSTRATED P ARTS B REAKDOWN Complete parts lists with illustrations. SPECIAL INFORMATION ! D A N G E R ! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ! W A R N I N G ! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. ! C A U T I O N ! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTE: Gives helpful information. 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 also includes text, figures and tables. ! C A U T I O N ! Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual contains 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 carried out, 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. ii 1. INTRODUCTION 1.1 INTRODUCTION P URPOSE The purpose of this service and parts manual is to provide instructions and illustrations for the operation and maintenance of this work platform manufactured by UpRight Powered Access. S COPE The manual includes procedures for proper operation, maintenance, adjustment, and repair of this product as 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. ! W A R N I N G ! DO NOT use the work platform without guardrails properly assembled and in place. Figure 1: SL26/30SL Work Platform P LATFORM The platform has a reinforced steel floor, 1.1m (43.5 inch) high guardrails with midrail, 152 mm (6 inch ) toeboards, and an entry gate at the rear of the platform. The guardrails can be folded down for access through doors or for shipment. 1. Platform 2. Platform Controller Assembly 3. Elevating Assembly 4. Power Module 5. Control Module 6. Chassis 1-1 2 1 3 4 6 5 1. Introduction P LATFORM C ONTROLLER The platform controller contains the controls to operate the machine. It is located at the front of the platform cage. A complete explanation of control functions can be found in Section 2. E LEVATING A SSEMBLY The platform is raised and lowered by the elevating assembly. The hydraulic pump, driven by the engine, powers the cylinders. Solenoid operated valves control raising and lowering. C HASSIS The chassis is a structural frame that supports all the components of the SL26/30SL work platform. P URPOSE OF E QUIPMENT 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 L IMITATIONS Travel with the platform raised is limited to a creep speed range. Elevating of the work platform is limited to firm, level surfaces only. Any degree of slope greater than 2° will sound a warning alarm when the machine is elevated. ! D A N G E R ! 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 when elevated. 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 aerial work platform. Safety Rules Electrocution Hazard THIS MACHINE IS NOT INSULATED! Tip Over Hazard Collision Hazard NEVER elevate the platform or drive NEVER position the platform the machine while elevated unless the without first checking for overhead machine is on a firm, level surface. obstructions or other hazards. Fall Hazard NEVER climb, stand, or sit on platform guardrails or midrail. 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, roof structures, buildings 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 electrical equipment! Exceeding the specified permissible maximum load is prohibited! See “Special Limitations” for details. The use and operation of the aerial work platform as a lifting tool or a crane (lifting of loads from below upwards or from up high on down) is prohibited! NEVER exceed the manual force allowed for this machine. See “Special Limitations” on 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 operate machine to avoid 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” for details. NEVER attach notice boards etc. to the platform, as this will increase the wind loading effect. 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 swing gate or other railing components is prohibited! Always ensure that the swing gate is closed and securely locked! It is prohibited to keep the swing gate in an open position (held open with tie-straps) 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. .NEVER use a machine that is damaged, not functioning properly, VERIFY that all labels are in place and legible before using. 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 both key-switches off and removing key. The driving of MEWP’s on the public highways is subject to Regulations made under the Road Traffic Acts. 2-1 C ONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Platform Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Manual Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Beaufort Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lift Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pre-Operation Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 System Function Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Travel With the Platform Lowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Elevating the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Travel With the Platform Elevated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lowering the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Levelling the Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fold Down guardrails, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fold Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Erection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Towing or Winching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parking Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 After Use Each Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transporting the Work Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Preparation for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lifting By Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lifting By Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Driving or Winching onto a Truck or Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Blocking The Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Scissor Brace Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Scissor Brace Stowage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Daily Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2-2 2. Operation and Specification 2. Operation and Specification 2.1 INTRODUCTION GENERAL DESCRIPTION Figure 1: SL26/30 SL Series 6 1. Platform 7 1 2. Elevating Assembly 3. Chassis 4. Power Module 5. Control Module 6. Platform Controls 2 7. Manual Case 8. Chassis Controls 3 9. Hydraulic Fluid Reservoir 5 8 9 4 ! W A R N I N G ! DO NOT use the maintenance platform without guardrails properly assembled and in place 2-3 Special Limitations 2.2 SPECIAL LIMITATIONS Travel with the platform raised is limited to creep speed range. Elevating the Work Platform is limited to firm, level surfaces only. ! D A N G E R ! The elevating function shall ONLY be used when the work platform is leveled and on a firm surface. The work platform is NOT intended to be driven over uneven, rough, or soft terrain. PLATFORM CAPACITY The maximum capacity for the MACHINE, including occupants is determined by model and options, and is listed in “Specifications”. ! D A N G E R ! 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 lbs.) of force per occupant, with a maximum of 400 N (90 lbs.) for two or more occupants. ! D A N G E R ! DO NOT exceed the maximum amount of manual force for this machine. BEAUFORT SCALE Never operate the machine when wind speeds exceed 12.5m/s (28 m.p.h.) [Beaufort scale 6]. BEAUFORT RATING m/s 3 3,4~5,4 4 5,4~8,0 5 8,0~10,8 6 10,8~13,9 7 13,9~17,2 WIND SPEED km/h ft/s 12,25~19,4 11.5~17.75 19,4~28,8 17.75~26.25 28,8~38,9 26.25~35.5 38,9~50,0 35.5~45.5 50,0~61,9 45.5~56.5 m.p.h. 7.5~12.0 12.0~18 18~24.25 24.5~31 31.~38.5 GROUND CONDITIONS Papers and thin branches move, flags wave. Dust is raised, paper whirls up, and small branches sway. Shrubs with leaves start swaying. Wave crests are apparent in ponds or swamps. Tree branches move. Power lines whistle. It is difficult to open an umbrella. Whole trees sway. It is difficult to walk against the wind. LIFT OVERLOAD ALARM If a load equivalent to 90% of safe working load is lifted a fault code “03” will be displayed on the digital display on the platform control box. If a load which is greater than the safe working load is present in the basket all machine functions will cease to operate and an acoustic warning will sound. In order to return to normal operation a load equal to or less than the safe working load must be present in the basket and the power must be re-cycled, power can be re-cycled by pushing the emergency stop button and releasing it again. ! D A N G E R ! Never operate the machine with a platform load greater than the rated capacity. 2-4 Controls and Indicators 2.3 CONTROLS AND INDICATORS Figure 2: Controls and Indicators Platform Controls 8 7 10 6 1 Drive (Hi Speed) 2. Drive (Low Speed) 3. Level 4. Horn Button 5. Lift/Lower Button 6. Glow Plug 7. Engine Start 8. Emergency Stop Button 9. Display 10. Joystick 3 2 1 4 5 9 Chassis Controls 6 5 1 2 1. Emergency Stop 2. Elevate 3. Descend 4. Enable 5. Glow Plug 6. Start 3 4 2-5 Pre-Operation Safety Inspection 2.4 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. Figure 3: Hydraulic Tank 2. Check the level of the hydraulic fluid with the platform fully lowered. The hydraulic reservoir is located in the Control Module Door. The fluid level must be between the MIN and MAX lines. Add hydraulic fluid if necessary. 3. Check that fluid level in the starter battery is correct. 4. Check the level of the Diesel fuel with the engine switched off. The fuel tank is located in the Power Module. Add fuel as required. 5. Check that all guardrails are in place and all fasteners are properly tightened. 6. Inspect the machine thoroughly for cracked welds and structural damage, loose or missing hardware, hydraulic leaks, damaged control cable, loose wire connections and wheel bolts. 2.5 SYSTEM FUNCTION INSPECTION Refer to Section 2.3 for the locations of various controls and indicators. ! W A R N I N G ! 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. 1. Move the machine, if necessary, to an unobstructed area to allow for full elevation. 2. Twist Chassis Emergency Stop Switch to the ON position. 3. Twist Platform Emergency Stop Switch to the ON position. 4. Turn the Key Switch to the ON position. 5. Visually 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. 6. Push the Chassis ELEVATE and ENABLE buttons and fully elevate the platform. 7. Partially lower the platform by pushing Chassis DESCEND and ENABLE buttons, and check for proper operation of the audible lowering alarm. 2-6 Operation 8. Open the Emergency Lowering Valve (see Figure) by pulling the knob out to check for proper operation. When the platform is lowered, release the knob. 9. Push the Chassis Emergency Stop Switch to check for proper operation. All machine functions should be disabled. Twist the Chassis Emergency Stop Switch to resume. 10. 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. 11. Mount the platform and properly close the entrance. 12. Select DRIVE mode. NOTE: Use both HI and LOW drive (if applicable) when performing the following step. 13. While engaging the Safety Interlock Trigger, move the Joystick to FORWARD, then REVERSE, to check for speed control. 14. Push the Steering Switch RIGHT, then LEFT, to check for steering control. 15. Select LIFT mode. Grasp the Joystick, engaging the Safety Interlock Trigger, and push it forward to check platform lift controls. Raise the platform to full elevation. 16. Pull back on the Joystick. The platform should descend and the audible lowering alarm should sound. 17. 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. 2.6 OPERATION Before operating the work platform, 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. STARTING THE ENGINE 1. Mount the platform and properly close the entrance. 2. Depress and hold the GLOW PLUG button for approximately 5 seconds. 3. Press green START button. TRAVEL WITH THE PLATFORM LOWERED 1. 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 loads. 2. Verify that the Engine is started and the Chassis Emergency Stop Switch is ON (pulled out). 3. Mount the platform and properly close the entrance. 4. Check clearances above, below, and to the sides of platform. 5. Twist the Platform Emergency Stop Switch out to the ON position. 6. Select DRIVE mode. NOTE: Choose between standard drive and extra torque depending on the gradient. 7. Engage the Safety Interlock Trigger and move the Joystick to FORWARD or REVERSE to travel in the desired direction. The speed of the machine will vary depending on how far from center the Joystick is moved. 2-7 Operation STEERING 1. Turn the Drive/Lift Switch to DRIVE. 2. While engaging the Safety Interlock Trigger, push the Steering Switch to RIGHT or LEFT to turn the wheels in the desired direction. Observe the tires while maneuvering the work platform to ensure proper direction. NOTE: Steering is not self-centring. Wheels must be returned to the straight ahead position by operating the Steering Switch. ELEVATING THE PLATFORM 1. Select a firm, level surface. 2. Select LIFT mode. 3. While engaging the Safety Interlock Trigger, push the Joystick forward. 4. If the machine is not level the tilt alarm will sound and the machine will not lift or drive. 5. If the tilt alarm sounds the platform must first be fully lowered, then elevate the platform approximately 600mm (2ft), stop, press and hold the LEVEL button until the tilt alarm is silenced. Only then can you elevate fully. If the platform is not levelled correctly the tilt alarm will continue to sound and lift functions will be cut at a height of approximately 2m (6ft). TRAVEL WITH THE PLATFORM ELEVATED NOTE: The machine will travel at reduced speed when the platform is elevated. 1. 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 loads. 2. Check clearances above, below, and to the sides of platform. 3. Select DRIVE mode. 4. Engage the Safety Interlock Trigger on the Joystick and move to FORWARD or REVERSE to travel in the desired direction. The speed of the machine will vary depending on how far from center the Joystick is moved. 5. 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 firm, level surface before attempting to re-elevate the platform. LOWERING THE PLATFORM 1. Select LIFT mode. 2. Check around the base of the platform to ensure that no one is in contact with the machine. Engage the Safety Interlock Trigger and pull back on the Joystick to lower the platform. 3. The platform will stop when it reaches the PPE 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. LEVELLING THE PLATFORM The AUTO LEVEL feature is designed to level the platform in a situation where the ground has no more than a 13 degree slope side to side and 9 degrees fore and aft, if the slope is greater than 13 degrees side to side and 9 degrees fore and aft the AUTO LEVEL feature will not function. NOTE: The tilt alarm will continue to sound until the platform is level 2-8 Operation 1. 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 loads. 2. Check clearances above, below, and to the sides of platform. 3. Elevate the platform approximately 600mm (2ft). 4. Press and hold the AUTO LEVEL and Engage the Safety Interlock Trigger until the platform is level and the tilt alarm is silenced. 5. In this condition only the ELEVATE and DESCEND functions will work. 6. If you need to drive you must descend and return the platform to it’s normal inclination. EMERGENCY LOWERING ! W A R N I N G ! 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 The Emergency Lowering Valve for the SL26/30 is located in the control module of the machine and is accessible through an opening in the control module door. 1. Open the Emergency Lowering Valve by pulling and holding the handle. 2. To close, release the knob. The platform will not elevate if the Emergency Lowering Valve is open. Emergency Lowering Handle FOLD DOWN GUARDRAILS This procedure applies only to the SL26/30 Speed Level model for the purpose of passing through a standard double doorway. NOTE: Guardrails must be returned to proper position before using the machine. FOLD DOWN PROCEDURE 1. Unhook the controller from the side guardrail and place it on the floor of the platform. 2. Starting at the front of the platform, remove nuts, bolts and washers from the top of the front guardrail. Fold the front guardrail down onto the platform. 3. Close and latch gate. 4. Remove nuts, bolts and washers from the top of the rear guardrail. Fold the rear guardrail down onto the platform being careful to keep latched at all times. 5. Remove nuts, bolts and washers from the top of the side guardrails. Lift up and fold one side guardrail in so it rests on the deck. Repeat with other side guardrails. 2-9 Towing or Winching ERECTION PROCEDURE Figure 5: Fold-down Guardrails 1. Raise side guardrails, making sure each is pushed down to secure the guardrail in the vertical position. 2. Install bolts, washers and nuts between the side guardrails, tighten securely. 3. Raise rear guardrail assembly, aligning holes and install bolts, washers and nuts. Tighten securely. ! D A N G E R ! Before entering platform, guardrails must be securely fastened in their proper position. 2.7 TOWING OR WINCHING Perform the following only when the machine will not operate under its own power and it is necessary to move the machine or when winching onto a transport vehicle (see “Transporting the Work Platform” on page 13). C A U T I O N DO NOT tow or winch the machine faster than 0,3 m/s (1 ft./s). Faster speeds will damage drive components and void the warranty. BRAKE RELEASE PUMP Perform the following only when the machine will not operate under it’s own power and it is necessary to move the machine or when towing the machine up a grade or onto a trailer to transport. 1. Close the needle valve by turning the allen screw clockwise. Figure 6: Hydraulic Manifold Hand Pump 2. Pump the Brake Release Pump until the Parking Brake Cylinder Rod clears the wheel rotor. 3. The machine will now roll when pushed or pulled. 4. Be sure to open needle valve and verify that the cylinder rod has extended before the machine is operated. 2-10 Needle Valve Transporting the Work Platform ! W A R N I N G ! Never tow faster than 0,3 m/sec. (1 ft./sec.). Never operate the work platform 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. 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 & 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 accumulated 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. 2.8 TRANSPORTING THE WORK PLATFORM PREPARATION FOR SHIPMENT 1. Fully lower the platform. 2. Disconnect the battery negative (-) lead from the battery terminal. 3. Band the controller to the front guardrail. 4. Band the elevating linkage to the frame. LIFTING BY CRANE 1. Secure straps to chassis tie down/lifting lugs only. 2. Place the platform onto the transport vehicle in transport position. 3. Chock the wheels. 4. Secure the work platform to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down/lifting lugs. 2-11 Transporting the Work Platform LIFTING BY FORKLIFT ! D A N G E R ! Forklifting is for transport only. See specifications for weight of work platform and be certain that forklift is of adequate capacity to lift the work platform. Forklift from the side by lifting under the Chassis Modules. DRIVING/WINCHING ONTO A TRUCK OR TRAILER Figure 7: Transporting the Work Platform NOTE: Do not winch faster than 0,3 m/s (1 ft/s). 1. Move the machine onto the truck or trailer; A. To Drive the machine onto the transport vehicle: a. Move the work platform up the ramp and into transport position. b. Set the wheels straight and turn off the machine. c. Chock the wheels. B. To Winch the machine onto the transport vehicle: a. Move the work platform up to the ramp. b. Attach the winch cable to the tie down/lifting lugs. c. Release the parking brakes (refer to “Towing or Winching” on page 12). d. Winch the platform into transport position e. Chock the wheels. Front Tie Down and Lifting Lugs Forklift Rear Tie Down/Lift Lugs 2. Secure the work platform to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down/lifting lugs. C A U T I O N Overtightening of the chains or straps attached to the Tie Down/Lifting Lugs may result in damage to work platform. 2-12 Maintenance 2.9 MAINTENANCE ! W A R N I N G ! 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 8: Scissor Brace INSTALLATION 1. Park the work platform on firm, level ground and leave the engine running. 2. Ensure the Chassis Emergency Stop Button is twisted to the ON position. 3. Press and hold the Chassis LIFT and ENABLE buttons to elevate the platform approximately 305 mm (12 inches). 4. Place a jackstand with a minimum rating of 1814 kg (4000 lbs.) between the lower mast and chassis, just behind the front axle. 5. Press and hold the Chassis DESCEND and ENABLE buttons to lower the platform until jackstand is secured tightly between lower mast and Chassis. REMOVAL 1. Press and hold the Chassis LIFT and ENABLE buttons to elevate the platform until the jackstand can be removed. 2. Remove jackstand. 3. Press and hold the Chassis DESCEND and ENABLE buttons to completely lower the platform. BATTERY MAINTENANCE ! W A R N I N G ! 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. • Check the battery fluid level daily, especially if the work platform is being used in a warm, dry climate. • If electrolyte level is lower than 10 mm (3/8 in.) above the plates add distilled water only. DO NOT use tap water with high mineral content, as it will shorten battery life. • 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 The battery is charged while the engine is running. 2-13 Maintenance FAULT CODES 01 - SYSTEM INIT ERROR 02 - SYSTEM PLATFORM COM ERROR 03 - PLATFORM OVERLOAD 04 - SYSTEM LOWER PANEL COM ERROR 05 - OIL PRESSURE LOW 06 - COOLANT TEMP HOT 21 - PLATFORM START ON 22 - PLATFORM LEFT TURN SW ON 23 - PLATFORM RIGHT TURN SW ON 24 - PLATFORM LIFT SW ON 25 - PLATFORM HISPEEDDRIVE SW ON 26 - PLATFORM GLOWLP SW ON 27 - PLATFORM LOSPEEDDRIVE SW ON 28 - PLATFORM AUTOLEVEL SW ON 29 - PLATFORM JOYSTICK ENABLE SW ON 31 - PLATFORM JOYSTICK NOT NEUTRAL 34 - GROUND PANEL ENABLE SW ON 37 - GROUND PANEL DOWN SW ON 38 - GROUND PANEL UP SW ON 43 - GROUND PANEL START SW ON 45 - GROUND PANEL GLOWLP SW ON 51 - Coil Fault HiSpeed1 52 - Coil Fault HiSpeed2 55 - Coil Fault LiftUp 56 - Coil Fault LiftDown 57 - Coil Fault TiltLeft 58 - Coil Fault TiltRight 59 - Coil Fault SteerRight 61 - Coil Fault SteerLeft 62 - Coil Fault TiltRear 63 - Coil Fault TiltForward 66 - Coil Fault Forward 67 - Coil Fault Reverse 71 - Coil Fault CushionValve 72 - Coil Fault AxleFloat 73 - Coil Fault SteerDump 68 – LOW BATTERY FAULT 2-14 Inspection and Maintenance Schedule 2.10INSPECTION 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 intervals. Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures. ! W A R N I N G ! Before performing preventative maintenance, familiarize yourself with the operation of the machine. Always ensure there is sufficient space around the machine for safe working conditions. Always block the elevating assembly whenever it is necessary to perform maintenance while the platform is elevated. The daily preventative maintenance checklist has been designed for machine service and maintenance. Please photocopy this page and use the checklist when inspecting the machine. 2.11DAILY 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 Battery Chassis Control Cable INSPECTION OR SERVICES Check welds for cracks. Check the exterior of the cable for pinching, binding or wear. Check switch operation. Check for operation and leaks. Elevating Assembly Inspect for structural cracks. Operate the emergency lowering valve and check for serviceability. Check for and repair collision damage. Hydraulic Fluid Check fluid level. Hydraulic Pump Check for hose fitting leaks. Hydraulic System Check for leaks. Labels Check for peeling, missing, or unreadable labels & replace. Platform Deck and Rails Check welds for cracks. Platform Deck and Rails Check condition of deck. Tyres and Wheels R Check hoses for pinch or rubbing points. Drive Motors Entire Unit N Check battery cable condition. Controller Emergency Lowering System Y Check electrolyte level. Check for damage. 2-15 Specifications 2.12SPECIFICATIONS ITEM SL26SL SL30SL Standard 1,71 m x 4,22 m [67.5 in. x 166.5 in.] 1,71 m x 4,22 m [67.5 in. x 166.5 in.] Slide Out Deck Extended 1,71 m x 4,61 m [67.5 in. x 181.5 in.] N/A Standard 680kg [1,500 lbs.] 590 kg [1,300 lbs.] w/ Extension 680kg [1,500 lbs.] N/A On Extension 227g [500 lbs.] N/A Standard 5 people 5 people on Extension 2 people N/A Working Height 9.75 m [32 ft.] 10.97 m [36 ft.] Max. Platform Height 7.93m [26 ft.] 9,14 m [30 ft.] Min. Platform Height 1.5 m [59 in.] 1.5 m [59 in.] Max. Drive Height 7.93 m [26 ft.] 9.14 m [30 ft.] Diesel: 3,216 kg [7,090 lbs.] Diesel: 3.216 kg [7,090 lbs.] Platform Size (Inside Toeboards) Max. Platform Capacity Max. No. of occupants Height Dimensions Weight Overall Width, Standard 2,13 m [84 in.] 2,13 m [84 in.] Overall Height 2,6 m [102.5 in.] 2,6 m [102.5 in.] Overall Length, Standard 3.79 m [149 in.] 4,39 m [173 in.] Platform Lowered 0 to 5.0 km/h [0 to 3.1 m.p.h.] 0 to 5.0 km/h [0 to 3.1 m.p.h.] Platform Raised 0 to 0.8 km/h [0 to 0.5 m.p.h.] 0 to 0.8 km/h [0 to 0.5 m.p.h.] Surface Speed System Voltage 12 Volt DC 12 Volt DC 74 l [19.5 US Gallons] 74 l [19.5 US Gallons] 210 bar [3000 psi] 210 bar [3000 psi] Above 32° f [0° c]) ISO #46 ISO #46 Normal use, below 32° f [0° c]) ISO #32 ISO #32 Below 0° f [-17° c] ISO #15 ISO #15 One Single Stage Lift Cylinders Hydraulic Tank Capacity Maximum Hydraulic System Pressure Hydraulic Fluid Lift System One Single Stage Lift Cylinders Lift Speed Raise, 48 sec./Lower, 40 sec. Raise, 48 sec./Lower, 40 sec. Platform Leveling 13° side to side, 9° Fore and Aft 13° side to side, 9° Fore and Aft Power Source 20 HP (Diesel) 20 HP (Diesel) Drive Control Proportional Proportional Control System Joystick Controller with Safety Interlock Trigger and Thumb Rocker Steering, Toggle Selector and Emergency Stop Switches Joystick Controller with Safety Interlock Trigger and Thumb Rocker Steering, Toggle Selector and Emergency Stop Switches Horizontal Drive Four Wheel, Hydraulic Motors Four Wheel, Hydraulic Motors Tyres (Standard) 26 x 12.00 - 12 NHs Super Terra-grip with Trac Seal 26 x 12.00 - 12 NHs Super Terra-grip with Trac Seal ANSI Spec. Pneumatic Tire Pressure Do Not Exceed 57 PSI Do Not Exceed 57 PSI Dual Spring Applied, Hydraulic Release, multi-disc Dual Spring Applied, Hydraulic Release, multi-disc Turning Radius (inside) 3,96 m [13 ft.] 3,96 m [13 ft.] Maximum Gradeability 35% [19°] 35% [19°] 2,54 m [100 in.] 2,54 m [100 in.] Parking Brakes Wheel Base Guardrails 1,11 m [43.5 in.] high, Fold Down with 1,11 m [43.5 in.] high, Fold Down with gate. gate. Toeboard 152 mm [6 in.] High 152 mm [6 in.] High Fuel Tank Capacity 45.5 l [12 US Gallons] 45.5 l [12 US Gallons] *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 requirements of OSHA and ANSI A92.6-1999. 2-16 Specifications 2-17 3. S ERVICE AND R EPAIR 3.1 INTRODUCTION ! W A R N I N G ! 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 SL26/30SL work platform. This section contains instructions for the maintenance of the SL26/30SL Work Platform. Procedures for the operation inspection, adjustment, scheduled maintenance, and repair/removal are included. Referring to Section 2 will aid in understanding the operation and function of the various components and systems of the SL26/30SL work platform, and help in diagnosing and repair of the machine. Refer to page 3.2 for recommended maintenance intervals. Note: Unless otherwise specified, torque all fittings according to “Torque Specifications for Fasteners”, and “Torque Specifications for Hydraulic Components” on page -16. 3.2 SPECIAL TOOLS The following is a list of special tools which may be required to perform certain maintenance procedures on the work platform. • 0-600 PSI (0-41 bar) Hydraulic Pressure Gauge (p/n 014124-006) • 0-3000 PSI (0-207) Hydraulic Pressure Gauge (p/n 014124-030) • Inclinometer (p/n 010119-000) • Tilt Sensor Adjustment Tool (p/n 030622-000) • Quick Disconnect Gauge Port (p/n 063965-002) 3.3 PREVENTATIVE MAINTENANCE The Complete inspection consists of periodic visual and operational checks, together with all necessary 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 ONLY performed by personnel who are trained and familiar with mechanical and electrical procedures. ! W A R N I N G ! Before performing maintenance, familiarize yourself with the operation of the machine. Always block the elevating assembly whenever it is necessary to enter the scissor assembly. The preventative maintenance table has been designed to be used primarily for machine service and maintenance repair. Please photocopy the following page and use this table as a checklist when inspecting the machine for service. 3-1 3. Service and Repair Preventative Maintenance Table Key Interval Preventative Maintenance Report 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 Date: Owner: Model No: Serial No: Serviced By: Service Interval: Table 3-1: Preventative Maintenance Check list COMPONENT COMPONENT Battery System Engine Oil INSPECTION OR SERVICES INTERVAL 30d 30d Clean exterior 6m Check mounting pin pivot bolts for proper torque Check battery cable condition Daily Check linkage gear for wear. 6m Clean terminals 6m Check level and condition Daily Check for leaks Daily Daily Check air cleaner Daily Check coolant level (with engine cold) Daily Chassis 6m Lift Cylinder Check elevating arms for bending 6m Grease linkage pins 30d Grease linkage gear 30d Check hoses for pinch or rubbing points Daily Check component mounting for proper torque 6m Check welds for cracks Daily Check the cylinder rod for wear 30d Check mounting pin pivot bolts for proper torque 30d Check seals for leaks 30d 3m Check oil level Daily Inspect pivot points for wear 30d 6m Check fittings for proper torque 30d Check the cylinder rod for wear. 30d Drain and replace oil 2y Check for leaks Daily Check hose connections 30d Check hoses for exterior wear 30d Emergency Operate the emergency lowering valve and Hydraulic check for serviceability System Daily Controller Check switch operation Daily Check the exterior of the cable for pinching, binding or wear Daily Check fasteners for proper torque Platform Deck Check welds for cracks and Rails Check condition of deck Daily Check for damage Daily Check lug nuts (torque to 90 ft. lbs.) 30d Wipe clean 30d Axle Cylinder Daily 30d Check for hose fitting leaks Daily Check mounting bolts for proper torque Fore/Aft Check mounting pin pivot bolts for proper Cylinder & torque Side/Side Check seals for leaks Cylinder Inspect pivot points for wear. Daily Check for leaks at mating surfaces Drive Motors Check for operation and leaks 3-2 Elevating Assembly Replace coolant Hydraulic Oil Change filter Steering System Daily Check pivot points for wear Engine Fuel Check for leaks System Replace fuel filter Hydraulic Pump INTERVAL 6m 30d Tires INSPECTION OR SERVICES Inspect for structural cracks Daily Daily Control Cable R Check specific gravity Check fuel level Hydraulic System N Check electrolyte level Change oil filter Engine Coolant Y 30d Daily Check hardware & fittings for proper torque 6m Grease pivot pins 30d Oil king pins 30d Check steering cylinder for leaks 30d Entire Unit Labels Bubble Level Wheel Bearings 30d 30d 30d Check fittings for proper torque 30d Check the cylinder rod for wear. 30d Check mounting pin pivot bolts for proper torque 30d Check seals for leaks 30d Inspect pivot points for wear 30d Check fittings for proper torque 30d Check for and repair collision damage Daily Check fasteners for proper torque 3m Check for corrosion-remove and repaint 6m Lubricate 30d Check for peeling, missing, or unreadable labels & replace Daily Check bubble level and target ring for damage Daily Check wheel assembly for play 30d Repack wheel bearings (replace wheel bearings and seals at 2000 hours). 2y Y N R 3. Service and Repair 3.4 BLOCKING ELEVATING ASSEMBLY ! C A U T I O N ! DO NOT support or raise the front of the platform during any maintenance operation as this may result in damage to the tension members. ! W A R N I N G ! BEFORE performing, maintenance on work platform, while elevated, ensure that elevating assembly is properly supported. DO NOT stand in elevating assembly area while installing or removing jackstand. Installation Figure 3-1: Blocking Elevating Assembly 1. Park the work platform on firm, level ground and leave the engine running. 2. Select LIFT mode and use the ENABLE BUTTON to elevate platform approximately 305 mm (12 inches). 3. Place a jackstand with a minimum rating of 1814 kg (4000 lbs.) between the lower mast and chassis, just behind the front axle. 4. Select LIFT mode and use the ENABLE BUTTON to gradually lower platform until jackstand is secured tightly between lower mast and Chassis. Removal 1. Select LIFT mode and use the ENABLE BUTTON to elevate platform until jackstand can be removed. 2. Remove jackstand and select LIFT mode and use the ENABLE BUTTON to completely lower platform. 3.5 BATTERY MAINTENANCE ! W A R N I N G ! Hazard of explosive gas mixture. Keep sparks, flame, and smoking material 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. Battery Inspection & Cleaning Check battery fluid level daily, especially if work platform is being used in a warm, dry climate. If required, add distilled water ONLY. Use of tap water with high mineral content will shorten battery life. The battery and cables should be inspected regularly for signs of cracks in the case, electrolyte leakage and corrosion of the terminals. Inspect cables for worn spots or breaks in the insulation and for broken cable terminals.Clean the battery when it shows signs of corrosion at the terminals or when electrolyte has overflowed during charging. Use a baking soda solution to clean the battery, taking care not to get the solution inside the cells. Rinse thoroughly with clean water. Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed. 3-3 3. Service and Repair Battery Charging The battery is charged by the alternator whenever the engine is running and should not require any other charging. If the machine has not been in service or if for some other reason the battery has been discharged, perform the following: ! W A R N I N G ! Charge the battery only in a well ventilated area. Do not charge the battery when the work platform is in an area containing sparks or flames. Always follow the charger manufacturer instructions. Never disconnect the cables from the batteries when the charger is operating. Check the battery fluid level. If the electrolyte level is lower than 10 mm (3/8 in.) above the plates, add clean, distilled water only. Battery Specific Gravity After charging, if necessary, the specific gravity of all cells should be checked with a hydrometer. The temperature corrected specific gravity should be 1.260. If the battery contains any cells with corrected readings below 1.230, the battery should be replaced. Do not check the specific gravity in a cell to which water has just been added. If there is not enough electrolyte in a fully charged cell to obtain a sample for the hydrometer, add water and continue charging for 1 to 2 hours to adequately mix the water and electrolyte. 3.6 LUBRICATION Figure 3-2: Lubrication Points Refer to Table 3-1 for lubrication intervals and Figure 3-2 for location of items that require lubrication service. Refer to the appropriate sections for lubrication information on the hydraulic tank and filter. 1. Grease Fittings 2. Linkage Gears 3. Steering Linkage Grease Fittings Wipe each grease fitting before and after greasing. 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, wipe off any excess grease. Linkage Gears 1. 2. 3. 4. Raise platform fully. Using another work platform or ladder, get up high enough to comfortably reach gears. Use a long handled brush to apply multipurpose grease to the face of the gears Lower the platform after greasing.. ! C A U T I O N ! Do not use hands to apply grease or allow any body part to enter the elevating assembly. Steering Linkage Apply one or two drops of motor oil to each pivot and king pin bearing. 3-4 3. Service and Repair 3.7 HYDRAULICS Hydraulic Pump Remove the capscrews that mount the pump to the engine. Remove the pump from the engine and apply high pressure molybdenum grease to the splines. Re-install the pump and secure with the capscrews. Hydraulic Oil Tank & Filter Fluid Level With the platform fully lowered, the oil should be visible in the sight gauge. If the oil is NOT visible, fill the tank until the oil can be seen. DO NOT fill above the sight gauge or when the platform is elevated. Oil & Filter Replacement 1. Operate the work platform for five minutes to warm up the oil. To change filter only, go to step 5. ! C A U T I O N ! The hydraulic oil may be hot enough to cause burns. Wear safety gloves and safety glasses when handling hot oil. Figure 3-3: Hydraulic Oil Tank & Filter 2. Provide a suitable container to catch the drained oil. The hydraulic tank has an oil capacity of 74 L. 3. Remove the drain plug and allow all oil to drain into the container, be sure to dispose of oil properly. 4. Reinstall the drain plug. 5. Unscrew the filter top from the filter body. 6. Lift the filter element from the filter body. 7. Remove filter cup and clean cavity, reinstall cup. 8. Insert the replacement filter into the filter body and press into position. 9. Fill the hydraulic oil tank to the level of the Sight Gauge with ISO #32 (see Table 1-1) hydraulic oil by pouring the oil into the filler breather cap. Since the oil is being strained as it is going into the tank, it may take a while to fill the tank. 1 2 1. Filler Breather 2. Drain Plug (under tank) Setting Hydraulic Pressures Referring to Figure 0-1 along with the other Figures will aid in the following procedures. Note: Check the hydraulic pressures whenever the pump, manifold, or relief valve(s) have been serviced or replaced. ! W A R N I N G ! 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. 3-5 3. Service and Repair Main Relief Valve Figure 3-4: Hydraulic Manifold Assembly, Front View 1. Operate the hydraulic system 10 to 15 minutes to warm the oil. 2. Remove the cap or loosen the locknut on the Main Relief Valve. 3. Install a 0-250 bar (0-3000 psi) pressure gauge to the gauge port. 4. Select LIFT mode and elevate the machine fully. 5. While holding the Chassis Lift Button, adjust the Main Relief Valve until the pressure gauge reads 172 bar (2500 psi). 6. Release the Chassis Lift Button. 7. Replace the cap, or tighten the locknut on the Lift Relief Valve, and torque to 8N-m (6 ft-lbs). 8. Lower the platform. 1. Main Relief Valve 2. Overcentre Valves 3. Lift Coil 2 3 1 4 5 6 4. Steering Relief Valve 5. Test Port 6. Manual Brake Release Pump Counterbalance Valves 1. Operate the work platform for 10-15 minutes to bring the hydraulic oil up to normal operating temperature. 2. Remove the gauge port cap and install the pressure gauge assembly. 3. Using two 1-ton jack stands and a 2-ton jack, jack the work platform up to raise the rear wheels off the ground and block the machine securely. 4. Loosen the locknuts on Counterbalance Valves. 5. 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 34.5 bar (500 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 34.5 bar (500 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. Remove the gauge from the gauge port and re-install cap. 12. Check for proper operation of the drive system and brake. Fore/Aft Tilt Cylinder Relief Valve (CT4) 1. 2. 3. 4. 5. Operate the hydraulic system for five minutes. Remove the quick disconnect plug and install a 0-100 bar (0-600 psi) pressure gauge. Remove the plug from the end of the valve to expose the adjusting screw. With the engine running, tilt the platform fully forward using the fore/aft level switch. While holding the level switch forward, set the pressure to 13 bar (500 psi) maximum by slowly turning the adjusting screw, clockwise increases pressure. 6. Replace the valve plug. 7. Remove the gauge and reinstall the plug. 8. Level the platform. 3-6 3. Service and Repair Steering Relief Valve 1. 2. 3. 4. 5. 6. Remove the top steering hose from back of the manifold and replace it with a 0-250 bar pressure gauge. Block the end of the hose with a cap fitting. Remove the plug from the end of the valve to expose the adjusting screw. With the engine running, push the Steering Switch RIGHT and set the pressure to 80 bar (1200 psi) max. Replace the valve plug. Remove the gauge and reinstall the hose. 3.8 AXLE CENTER SWITCH Figure 3-5: Axle Center Switch 1. Check tires for proper pressure. 2. Place the work platform on a level surface with the front and rear axles parallel (on the same plane). 3. Adjust the switch so it is centered in the front axle actuator linkage. When centered, the switch will close the circuit. 4. Test the switch function by positioning the front axle offcenter and raising the platform 2 m above the ground. The work platform should not drive. Retest with axle off-center in the opposite position. Axle Centre Switch Actuator Linkage 3.9 DOWN PROXIMITY SWITCH Figure 3-6: Limit Switch Location The down limit switch is a dual proximity switches which allow the machine to run at HI speed when the platform is lowered. 1. Raise the platform 30 cm (12 in.) from its’ fully lowered position. 2. Disconnect the wires at the proximity switches and connect an ohmmeter or continuity tester. 3. Place a piece of steel across the receiver end to varify the switch is functioning correctly. 4. Disconnect ohmmeter and reconnect wires. 5. Lower platform. Down Proximity Switch 3.10TILT SENSOR Figure 3-7: Tilt Sensor Adjustment The tilt sensor has three wires; red-power (12v in), black-ground, whiteoutput (12v out). To verify the sensor is working properly, there is one LED under the sensor; red indicates the sensor is out of level and the white wire is “hot” (12v out). Setting the Tilt Sensor & Level 1. Level the platform with the platform controls using a digital level to ensure the platform is level ±1/4°. side-to-side and front-to-back. 2. Adjust the bubble level with the three leveling screws until the bubble is centered in the circle on the bubble level. 3. The tilt Sensor is located at the rear of the 1st post weldment. 4. Adjust the three leveling locknuts on the tilt sensor until the bubble is centered in the circle. 3-7 3. Service and Repair 3.1 HYDRAULIC MANIFOLD Though it is not always necessary to remove the manifold to perform maintenance procedures, a determination should be made prior to beginning as to whether or not the manifold should be removed before maintenance procedures begin. Removal 1. 2. 3. 4. 5. Disconnect the battery ground cable. Tag and disconnect the solenoid valve leads. Tag, disconnect and plug hydraulic hoses. Remove the bolts that hold the manifold to the mounting bracket. Remove manifold block. Disassembly Note: Mark all components as they are removed so as not to confuse their location during assembly. Refer to Valve Block Drawing and Schematic often to aid in disassembly and assembly. 1. Remove coils from solenoid valves. 2. Remove spool valve covers and spool valves. 3. Remove solenoid valves, main relief valve, counterbalance valves and emergency lowering valves. Remove fittings, plugs, springs, balls and orifices. Cleaning and Inspection 4. Wash the manifold in cleaning solvent to remove built up contaminants and then blow out all passages with clean compressed air. 5. Inspect the manifold for cracks, thread damage and scoring where O-rings seal against internal and external surfaces. 6. Wash and dry each component and check for thread damage, torn or cracked O-rings and proper operation. 7. Replace parts and O-rings found unserviceable. Assembly Note: Lubricate all O-rings before installation to prevent damage to O-rings. Seat all balls in manifold block by lightly tapping on the ball with a brass drift. 1. Install fittings, plugs, balls and orifices. Use one drop of Locktite #242 on each screw-in orifice. 2. Install emergency lowering valve, counterbalance valves, main relief valve, brake pressure reducing valve, solenoid valves and spool valves. 3. Install coils on solenoid valves. Installation 1. 2. 3. 4. 5. 3-8 Attach manifold assembly to mounting plate with bolts. Connect solenoid leads (as previously tagged). Connect hydraulic hoses. Be certain to tighten hoses to manifold. Operate each hydraulic function and check for proper operation and leaks. Adjust all hydraulic pressures according to instructions. 3. Service and Repair Figure 3-8: Hydraulic Manifold TOP 6 PART NUMBER DATE CODE CUSTOMER NUMBER 1. 1/4" BSP - C/W MALE/MALE FITTINGS Used on : S1, S2, B1, TA, TF, TR & TL 2. 3/8" BSP - C/W MALE BULKHEAD FITTING Used on : L 3. 1/2" BSP - C/W MALE/MALE FITTINGS Used on : RR, RF, LF,LR, T & P 4. 1/4" BSP - C/W TEST POINT Used on : PT 5. 1/4" BSP - C/W 1/4" BSP PLUG Used on PS1 & B2 6. 1/2" BSP - C/W 1/2" BSP PLUG Used on :T1 1 3 1 2 FRONT 5 3 3 5 3 3 4 BOTTOM TO P HIG H SPEED SERIES PARALLEL LIFT C O IL PART NU MBER D AT E C ODE C USTO MER NUM BER C USHIO N TILT RIG HT TILT LEFT STEER RIG HT STEER LEFT TILT AFT TILT FO RW ARD PRO PO RTIO NAL FRO NT DRIVE : FO RW ARD D RIVE : REVERSE LIFT D UM P STEER D UM P BO TTO M 3-9 3. Service and Repair 3.2 REPLACING HYDRAULIC PUMP Note: If the hydraulic tank has not been drained, suitable means for plugging the hoses should be provided to prevent excessive fluid loss. Removal 1. Mark, disconnect and plug the hose assemblies. 2. Loosen the capscrews and remove the pump assemblies from the engine. Figure 3-9: Typical Hydraulic Pump Installation 1. Lubricate the pump shaft with extreme high pressure molybdenum grease and attach the pumps to the engine with capscrews. 2. Using a criss-cross pattern, torque each capscrew a little at a time until all four capscrews are torqued to 27 Nm (20 ft. lbs.). 3. Unplug and reconnect the hydraulic hoses. 4. Check the oil level in the hydraulic tank before operating the work platform. 1 1. Inlet Hose 2. Outlet Hose 2 3.3 HYDRAULIC BRAKES, DRIVE MOTORS & HUBS Rear Axle Removal 1. 2. 3. 4. 5. 6. Park the work platform on firm, level ground and block the wheels to prevent the work platform from rolling. Loosen the wheel lug bolts on the motor to be removed. Raise the rear of the work platform using a 2-ton jack. Position 2 1-ton jack stands under the rear axle to prevent the work platform from falling if the jack fails. Remove the wheel lug bolts and wheel. Remove the cotter pin, nut, hub, and shaft key. ! C A U T I O N ! ONLY use a wheel puller to remove the hub. Using any other method of removal may damage the drive motor housing or shaft and void the warranty. Clean all fittings before disconnecting the hose assemblies. Plug all port holes and hose assemblies IMMEDIATELY to prevent contamination from dust and debris. 7. Tag and disconnect the hose assemblies. 8. Remove the capscrews, washers, brake and drive motor assembly from the rear axle. 9. Remove the socket screws from the drive motor and then separate the brake from the drive motor. 3-10 3. Service and Repair Installation Figure 3-10: Rear Axle Assembly 1. Insert the drive motor with O-ring installed into the brake and secure with socket screws using Locktite #242 retaining compound on the screw threads. 2. Position the drive motor and brake in the rear axle and secure with washers and H.H. setscrews. 3. Reinstall the adaptor and crossover block assembly to the hydraulic motor. 4. Reinstall the hose assemblies. 5. Reinstall the shaft key, hub, and nut. Torque each wheel hub nut to 475 Nm (350 ft. lbs.). 6. Align the slot in the nut with the hole in the shaft and insert the cotter pin. DO NOT back off the nut to align. 7. Reinstall the wheel and lug on the hub. Torque the bolts to 123 Nm (90 ft. lbs.). 8. Remove the jack stands used to block the wheels. Lower the jack and remove. 9. Operate the drive system to check for leaks and proper function. 1. Lug Bolt 2. Tire/Wheel Assembly 3. Cotter Pin 4. 5. 6. 7. Slotted Nut Adapter Hub Shaft Key Drive Motor Front Axle (Figure 3-11) Removal Figure 3-11: Front Axle Assembly 1. Park the work platform on firm, level ground and block the wheels to prevent the work platform from rolling. 2. Loosen the wheel lug bolts on the motor to be removed. 3. Raise the front of the chassis using a 2-ton jack. 4. Position 2 1-ton jack stands under the front axle to prevent the work platform from falling if the jack fails. 5. Remove the wheel lug bolts and wheel. 6. Remove the cotter pin, nut, hub and shaft key. 7. Tag and disconnect the hose assemblies. 8. Remove the adaptor from the hydraulic motor. 9. Remove the capscrews and nuts and then remove the drive motor from the front axle steering mount. 1. Lug Bolt 2. Tire/Wheel Assembly 3. Cotter Pin 4. Slotted Nut 5. 6. 7. 8. Adaptor Hub Shaft Key Drive Motor Steering Mount 3-11 3. Service and Repair ! C A U T I O N ! ONLY use a wheel puller to remove the hub. Using any other method of removal may damage the drive motor housing and void the warranty. Clean all fittings before disconnecting the hose assemblies. Plug all holes assemblies IMMEDIATELY to prevent contamination from dust and debris. Installation 1. 2. 3. 4. Position the drive motor into the steering mount and secure with capscrews and nuts. Reinstall the adaptor on the hydraulic motor. Reinstall the hose assemblies. Reinstall the shaft key, hub, and nut. Torque each wheel hub nut to 475 Nm (350 ft. lbs.). Align the slot in the nut with the hole in the shaft and insert the cotter pin. DO NOT back off the nut to align. 5. Reinstall the wheel and lug bolts onto the hub. Torque the lug bolts to 123 Nm (90 ft. lbs.). 6. Remove the jack stands used to block the wheels. Lower the jack and remove. 7. Operate the drive system to check for leaks. 3.4 AXLE CYLINDER Removal Be sure platform is fully down and that machine is on level ground. 1. Remove and cap the hoses. 2. Remove the pivot pins 3. Remove the cylinder. Installation 1. Completely fill both ends of cylinder with hydraulic oil. a. Lay the cylinder on its’ side on a level table with the pilot operated check valves up. b. Remove the pilot operated check valves from the ports. c. Pour hydraulic oil into the cylinder through the pilot operated check valve ports. d. The opening to the cylinder is small. Be careful to ensure all air is removed and the cylinder is full of oil. e. Reinstall the pilot operated check valves. 1. Attach both ends of the cylinder to mounts with pivot pins and retaining bolts. 2. Torque the retaining bolts to 203 Nm (150 ft. lbs.). 3. Operate the work platform over rough terrain and check for proper function and leaks. 3.5 STEERING CYLINDER Removal 1. Mark and disconnect the hose assemblies from the fittings and immediately cap the openings to prevent foreign material from entering. 2. Remove the setscrews securing the rod ends to the steering linkage. 3. Remove the setscrews and locknuts that fasten the cylinder assembly to the chassis. 4. Remove the cylinder from the chassis. 3-12 3. Service and Repair Disassembly 1. 2. 3. 4. 5. 6. 7. Remove the headcaps from the barrel tube. Mark which end of the barrel tube the headcap was removed from. Withdraw the entire shaft assembly from either end of the barrel tube. Remove the rod wipers, rod seals and static O-rings from the headcaps. Discard all the seals. Unscrew the No. 1 shaft from the No. 2 shaft and remove the piston. Remove the piston seal and static O-ring from the piston and discard. Cleaning and Inspection Figure 3-12: Steering Cylinder Assembly 1. Wash all the metal parts in cleaning solvent and blow dry with filtered compressed air. 2. Inspect all the threaded components for stripped or damaged threads. 3. Check the inside surface of the barrel tube for scoring or excessive wear. 4. Check the piston and head caps for scoring or excessive wear. 5. Inspect the surface of both shafts for scoring or excessive wear. Assembly and Installation 1. Install a new piston seal and static O-rings. 2. Install the piston on the No. 1 shaft. 3. Thread the No. 2 shaft onto the No. 1 shaft and tighten securely. 4. Lubricate the piston seal with clean hydraulic fluid and install the shaft assembly in the barrel tube. 5. Lubricate and install new rod seals and static O-rings on the headcaps. 6. Lubricate and install new rod wipers in the headcaps. 7. Install headcap in the barrel tube and tighten until the mounting holes are in-line. 1. 2. 3. 4. 5. No. 2 Shaft Headcap (2) Rod Wiper (2) Rod Seal (2) Static O-ring (2) 6. 7. 8. 9. Cylinder Barrel Piston Piston Seal Piston Static Oring Note: Headcaps must be reinstalled in the same end from which they were removed. 8. Install the fittings in the ends of the cylinder. 9. Position the cylinder assembly in the chassis and install the capscrews and locknuts, but DO NOT tighten. 10. Tighten the nut and bolt in front of the cylinder that goes through the frame and then tighten the cylinder mounting capscrews. 11. Install the cylinder rod ends. 12. Set rod ends to allign front wheels. 13. Connect the hose assemblies to the fittings. 14. Operate the steering circuit several times throughout its’ entire range of travel to expel trapped air and check for leaks. 3-13 3. Service and Repair Adjustment 1. 2. 3. 4. 5. Disconnect the cylinder rod ends (if connected). Operate steering so that both ends of the cylinder rod are equal length i.e. within (.8 mm, ±1/32 inch). Position both tires so they are parallel with the frame, with each other and with the rear wheels. Adjust the rod ends until they align with the holes on the steering linkage bars. Reinstall the bolts through the steering linkage bars and rod ends. Tighten the jam nuts on the rod ends and all hardware. 6. When properly adjusted, the wheels must turn the same amount in each direction. 3.6 LIFT CYLINDER Note: DO NOT support or raise the front of the platform during any maintenance operation as this might result in damage to the tension members. Removal 1. Raise and block the front of the elevating assembly approximately 305 mm (12 inches) above the chassis. Support with a jackstand with a minimum rating of 1814 kg (4000 lbs.). (See Figure 0-2) 2. Open Emergency Lowering Valve to be sure all pressure is off the Lift Cylinder. 3. Remove and cap both hoses and fittings. 4. Support the Lift Cylinder to prevent falling. 5. Remove the set screw from the end of the cylinder rod. 6. Remove the retaining ring from the upper cylinder pin. Remove the upper cylinder pin by tapping out using a soft punch. 7. Remove the retaining bolt from the lower cylinder pin and remove the pin using a soft punch. 8. Remove the cylinder by sliding it out towards the front of the machine. Figure 3-13: Lift Cylinder Assembly 1. Cylinder Barrel 2. Velocity Fuse 3. Fitting, Adapter 4. Hose Assembly 5. Breather 6. Piston Nut 7. Piston Seal 8. Piston 9. Piston Static O-ring 10. Static O-ring 11. Head Cap 12. Cylinder Rod 13. Set Screw 14. Rod Wiper 15. Rod Seal 16. Nut 3-14 15 14 11 10 12 10 16 1 13 2 3 6 9 8 7 5 17 4 3. Service and Repair Disassembly 1. 2. 3. 4. 5. 6. 7. 8. Unscrew the head cap from the cylinder barrel. Remove the piston and rod assembly from the cylinder barrel. Unscrew the piston nut and remove piston and head cap from the piston rod. Remove the piston static O-ring from the cylinder rod and discard. Remove the piston seal from the piston and discard. Remove the static O-ring, rod seal and rod wiper. Remove the rod end breather. Do not remove the velocity fuse unless replacement is necessary. Cleaning and Inspection 1. 2. 3. 4. Clean all the metal parts in cleaning solvent and blow dry with filtered compressed air. Check the working surfaces of the piston head cap, cylinder barrel and rod for excessive wear or scoring. Replace parts found to be unserviceable. Replace all seals, O-rings and wipers. Reassembly 1. Lubricate the static O-ring, rod seal and rod wiper and then install in the head cap. 2. Install the piston seal on the piston. 3. Install the head cap, piston static seal, piston and piston nut on the cylinder rod. Torque nut to 96 Nm (70ft.lbs.). Note: The head cap should be installed from the piston end of the cylinder rod. Sliding the head cap over the pivot pin hole may damage the rod seal and rod wiper. 4. Lubricate and piston seal and install the piston and rod assembly into the cylinder barrel. 5. Screw the head cap into the cylinder barrel hand tight and then turn 1/4 turn further. Installation Note: Before installing the cylinder, check the pins and bearings for excessive wear. Replace if necessary. 1. 2. 3. 4. 5. Place the cylinder in position taking care to support the cylinder to prevent falling. Install the lower pin and retaining bolt. Install the upper pin and retaining ring. Install both hoses. Raise the machine and check for leaks. Note: The cylinder may need to be extended and retracted so as to allign the rod end pivot hole. 3-15 3. Service and Repair 3.7 TORQUE SPECIFICATIONS Fasteners Use the following values to torque fasteners used on UpRight Work Platforms unless a specific torque value is called out for the part being installed. Hydraulic Components Use the following values to torque hydraulic components used on UpRight Work Platforms. Note: Always lubricate threads with clean hydraulic oil prior to installation Table 3-1: Torque Specifications for Fasteners AMERICAN STANDARD CAP SCREWS SAE GRADE Cap Screw Size (inches) 8 METRIC GRADE TORQUE Cap Screw Size (millimeters ) 5 TORQUE Ft./Lbs Nm. MIN MAX MIN 1/4 - 20 6.25 7.25 1/4 - 28 8 9 5/16 - 18 14 5/16 - 24 17.5 3/8 - 16 3/8 - 24 METRIC CAP SCREWS Ft./Lbs. Nm. 8.8 10.9 8.8 10.9 TORQUE TORQUE Ft./Lbs. MIN MAX Nm. MIN Ft./Lbs. MIN MAx MAX 9.5 11 13 M6 x 1.00 6 8 8 11 12 14 16 M8 x 1.25 16 20 21.5 27 MIN Nm. MAX MIN MAX MAX MIN 8.5 10 8.25 11 12 10.5 9 11 12 15 23 27 31 36.5 15 19 20 18.5 20 25 27 M10 x 1.50 29 35 39 47 42 52 57 70 19 23 26 23 25 31 34 M12 x 1.75 52 62 70 84 75 91 102 123 26 28 35 38 35 37 47.5 50 M14 x 2.00 85 103 115 139 120 146 163 198 31 34 42 46 41 45 55.5 61 M16 x 2.50 130 158 176 214 176 216 238 293 7/16 - 14 41 45 55.5 61 55 60 74.5 81 M18 x 2.50 172 210 233 284 240 294 325 398 7/16 - 20 51 55 69 74.5 68 75 92 102 M20 x 2.50 247 301 335 408 343 426 465 577 1/2 - 13 65 72 88 97.5 86 96 116 130 M22 x 2.50 332 404 450 547 472 576 639 780 1/2 - 20 76 84 103 114 102 112 138 152 M24 x 3.00 423 517 573 700 599 732 812 992 863 1055 898 1098 1217 1488 9/16 - 12 95 105 129 142 127 140 172 190 M27 x 3.00 637 779 9/16 - 18 111 123 150 167 148 164 200 222 M30 x 3.00 872 1066 1181 1444 1224 1496 1658 2027 5/8 - 11 126 139 171 188 168 185 228 251 5/8 - 18 152 168 206 228 203 224 275 304 3/4 - 10 238 262 322 355 318 350 431 474 3/4 - 16 274 302 371 409 365 402 495 544 7/8 - 9 350 386 474 523 466 515 631 698 7/8 - 14 407 448 551 607 543 597 736 809 1070 1-8 537 592 728 802 716 790 970 1 - 14 670 740 908 1003 894 987 1211 1337 NOTE: These values apply to fasteners as received from the supplier, dry or when lubricated with normal engine oil. They do not apply if special graphited or molydisulphide greases or other extreme pressure lubricants are used Table 3-2: Torque Specifications for Hydraulic Components Type: SAE Part Series #4 3-16 MAX Cartridge Poppet Fittings Hoses Ft/Lbs Nm Ft/Lbs Nm Ft/Lbs Nm N/A N/A N/A N/A 135-145 15-16 #6 N/A N/A 10-20 14-27 215-245 24-28 #8 25-30 34-41 25-30 34-41 430-470 49-53 #10 35-40 47-54 35-40 47-54 680-750 77-85 #12 85-90 115-122 85-90 115-122 950-1050 107-119 #16 130-140 176-190 130-140 176-190 1300-1368 147-155 4. TROUBLESHOOTING Section 4 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. Refering 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 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. ! W A R N I N G ! 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. 4-1 4. Troubleshooting 4.2 TROUBLESHOOTING 1. Verify your problem. • Do a full function test from both the platform and chassis controls, and note all functions 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 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 SL-Series work platforms. • Flow Meter with Pressure Gauge • 0-69 bar (0-1000 psi ) Hydraulic Pressure Gauge with Adapter Fittings • 0-207 bar (0-3000 psi) Hydraulic Pressure Gauge with Adapter Fittings • Adapter Fitting • Inclinometer • Crimping Tool • Terminal Removal Tool 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 manifold pump port and connect pressure gauge. 4-2 4. Troubleshooting 4.3 TROUBLESHOOTING GUIDE T R OUB LE All functions inoperable, engine does not start. E ngine does start but no hydraulic power. E ngine does start, have hydraulic power but no electrical function. P R OB AB LE C AUS E R E ME DY 1. F aulty battery After completely charging batteries, test each battery. R eplace as 2. Loose or broken battery lead. C heck continuity of all battery and motor leads. R eplace if necessary. 3. E mergency S top switch(es) failed open. With emergency stop switch in the ON position, check continuity 1. Oil level in hydraulic reservoir is low. C heck hydraulic fluid level, top off as required. 2. F aulty hydraulic pump. C heck pressure and delivery of the hydraulic oil. R eplace if necessary 1. E mergency Lowering valve open. C lose emergency down valve. 2. P latform overloaded, alarm sounds. Observe maximum load rating. (see Operation section of this manual) 3. F aulty controller at upper controls. C heck functionality of controller. R eplace if faulty. 4. B attery level low. C heck B attery V oltage. C harge if necessary. P latform drifts 1. E mergency down after being lowering valve elevated open. E nsure that emergency lowering valve is completely closed. R eplace if necessary. 2. Leaking piston seals in lift cylinders C heck for leakage at cylinder return line, replace seals if necessary. 4-3 4. Troubleshooting 4.4 FAULT CODES INTRODUCTION The SL26/30 SpeedLevel 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 - 45 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 51 - 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 harness. 6. If signal is reaching the component but the component is not functioning replace the component (refer to section 7 of this manual for part number information). 4-4 4. Troubleshooting 4.5 FAULT CODES SpeedLevel Fault Codes 1-31-05 01 - SYSTEM INIT ERROR 02 - SYSTEM PLATFORM COM ERROR 03 - PLATFORM OVERLOAD 04 - SYSTEM LOWER PANEL COM ERROR - OIL PRESSURE LOW 4.6 F05 AULT CODES 06 - COOLANT TEMP HOT 21 - PLATFORM START ON 22 - PLATFORM LEFT TURN SW ON 23 - PLATFORM RIGHT TURN SW ON 24 - PLATFORM LIFT SW ON 25 - PLATFORM HISPEEDDRIVE SW ON 26 - PLATFORM GLOWLP SW ON 27 - PLATFORM LOSPEEDDRIVE SW ON 28 - PLATFORM AUTOLEVEL SW ON 29 - PLATFORM JOYSTICK ENABLE SW ON 31 - PLATFORM JOYSTICK NOT NEUTRAL 34 - GROUND PANEL ENABLE SW ON 37 - GROUND PANEL DOWN SW ON 38 - GROUND PANEL UP SW ON 43 - GROUND PANEL START SW ON 45 - GROUND PANEL GLOWLP SW ON 51 - Coil Fault HiSpeed1 52 - Coil Fault HiSpeed2 55 - Coil Fault LiftUp 56 - Coil Fault LiftDown 57 - Coil Fault TiltLeft 58 - Coil Fault TiltRight 59 - Coil Fault SteerRight 61 - Coil Fault SteerLeft 62 - Coil Fault TiltRear 63 - Coil Fault TiltForward 66 - Coil Fault Forward 67 - Coil Fault Reverse 71 - Coil Fault CushionValve 72 - Coil Fault AxleFloat 73 - Coil Fault SteerDump 68 – LOW BATTERY FAULT 4-5 4. Troubleshooting Notes : 4-6 Section 5 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. C ONTENTS Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Cable Assembly (J1 Harness). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Schematic (J1 Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Cable Assembly (J2 Harness). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Schematic (J2 Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5-1 5. Schematics 5.2 ELECTRICAL SCHEMATIC Hydraulic Schematic 5-2 5. Schematics 5.3 C ABLE A SSEMBLY (J1) 5-3 5. Schematics 5.4 J1 C ABLE S CHEMATIC 5-4 5. Schematics 5.5 C ABLE A SSEMBLY (J2) 5-5 5. Schematics 5.6 C ABLE S CHEMATIC (J2) 5-6 5. Schematics 27 28 1 2 14 29 26 25 5 18 19 5.5 H YDRAULIC S CHEMATIC 5-7 Section 66. ILLUSTRATED PARTS 14 Section 6 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. C ONTENTS General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8 Slide out Section. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10 Power Module Assembly . . . . . . . . . . . . . . . . . . . . 6 - 12 Control Modulel Assembly . . . . . . . . . . . . . . . . . . . 6 - 13 Valve Block Assembly . . . . . . . . . . . . . . . . . . . . . . 6 - 14 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15 Lower Controls Assembly. . . . . . . . . . . . . . . . . . . . 6 - 16 Upper Controls Assembly. . . . . . . . . . . . . . . . . . . . 6 - 17 Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . 6 - 18 Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Hydraulic Cylinder Assembly . . . . . . . . . . . . . . . . . 6 - 21 Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 Decal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25 6-1 6. Illustrated Part List General Assembly SL30SL ~ 505500-000 ITEM 1 2 3 4 5 PART 505503-000 505501-000 505502-000 505504-000 505505-000 DESCRIPTION QTY. PLATFORM ASSEMBLY CHASSIS ASSEMBLY ELEVATING ASSEMBLY POWER MODULE CONTROL MODULE 1 1 1 1 1 1 SL26SL ~ 505600-000 ITEM 1 2 3 4 5 PART 505603-000 505501-000 505602-000 505504-000 505505-000 DESCRIPTION QTY. PLATFORM ASSEMBLY CHASSIS ASSEMBLY ELEVATING ASSEMBLY POWER MODULE CONTROL MODULE 1 1 1 1 1 1 3 4 5 2 6-2 6. Illustrated Part List Chassis Assembly 505501-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 PART NUMBER 064320-001 064331-001 064300-002 064324-002 064343-001 011256-014 011238-008 064383-000 062642-030 064811-000 011754-012 014122-001 069129-000 069129-001 505201-000 011257-014 063905-101 067606-013 505565-000 505564-000 505202-000 064812-000 011754-012 064034-001 062642-001 063927-001 062642-030 064336-000 508020-000 064346g-100 064296-002 064367-001 064339-001 508021-000 064345-100 064349-000 011256-040 011239-008 011240-000 011248-008 QTY DESCRIPTION WELDMENT, 1ST POST WELDMENT, LEVEL PIVOT WELDMENT, CHASSIS WELDMENT, FRONT AXLE TRUNION SCREW, TRUNION WASHER THRUST BEARING, LEVEL PIVOT BUSHING, LEVEL PIVOT HUB, REAR SPLIT PIN WHEEL BOLT WHEEL, RIGHT HAND WHEEL, LEFT HAND DRIVE MOTOR, REAR BOLT, DRIVE MOTOR, REAR CYLINDER, STEER BUSHING, AXLE / MOTOR MOUNT STEER LINK ARM MOTOR MOUNT DRIVE MOTOR, FRONT HUB, FRONT SPLIT PIN PIN, MOTOR MOUNT BUSHING, MOTOR MOUNT ROSE BEARING, STEERING CYL BUSHING, AXLE TO CHASSIS PIVOT PIN, FRONT AXLE PIVOT PIN, FLOAT CYL - AXLE CYLINDER, CHASSIS - AXLE LIMIT SWITCH, FLOAT, BODY BRACKET, LIMIT SWITCH MOUNT PIN, 1ST POST / LEVEL PIVOT / CHASSIS PIN, LEVEL CYLINDER - 1ST POST CYLINDER, FLOAT SPACER M16 BOLT, ROSE BEARING M16 BOLT, STEARING LINKAGE BOLT, FRONT MOTOR MOUNT WASHER, FRONT MOTOR WASHER, REAR MOTOR NUT, REAR MOTOR 1 1 1 1 2 8 8 4 4 2 4 20 2 2 2 8 1 2 2 2 2 2 4 4 4 2 1 2 1 1 1 4 1 1 1 1 4 4 4 4 6-3 6. Illustrated Part List Chassis Assembly 505001-000 6-4 6. Illustrated Part List Elevating Assembly 6-5 6. Illustrated Part List Elevating Assembly SL30SL ~ 505502-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PART 011254-024 064090-000 011248-006 064111-002 062649-020 064536-000 064521-000 064538-000 062642-030 011248-016 064089-000 013336-001 064070-002 064094-000 062649-010 011253-008 064095-000 064530-000 064542-000 064093-000 064531-001 114918-048 064356-000 027931-057 064354-000 063904-101 064320-001 064331-001 064092-000 DESCRIPTION BOLT, PIN LOCK 3/8’ PIVOT PIN, UPPER T-BAR & UP BOOM - PED NUT, PIN LOCK 3/8’ WELDMENT, PEDESTAL (PLATFORM SUP) BUSHING, ALL 1.75” PINS UPPER TENSION BAR UPPER BOOM CHANNEL, WIRE COVER (UPPER BOOM) BUSHING, ALL 2.75 PINS LOCKNUT 1’ GEAR SEGMENT GREASE NIPPLE (1/8 BSP) 2nd POST WELDMENT PIVOT PIN, LOWER T-BAR BUSHING, LIFT CYLINDER ROD - BOOM NUT (ROLLER) PIVOT PIN, LOWER BOOM & UP BOOM - 2nd LOWER BOOM CHANNEL, WIRE COVER (LOWER BOOM) PIVOT PIN, CYL ROD - LOWER BOOM LOWER TENSION BAR BOLT (ROLLER, BOOM REST) ROLLER PIN BUSHING, ROLLER ROLLER CYLINDER, MAIN LIFT 1st POST WELDMENT LEVELLER WELDMENT PIVOT PIN, CYL BODY - 1st POST QTY. 9 3 9 1 12 1 1 1 6 6 2 10 1 2 2 1 3 1 1 1 1 1 1 2 1 1 1 1 1 SL26SL ~ 505602-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 6-6 PART 011254-024 064090-000 011248-006 064111-001 062649-020 064087-000 064078-002 064451-000 062642-030 011248-016 064089-000 013336-001 064070-002 064094-000 062649-010 011253-008 064095-000 064060-003 064450-000 064093-000 064084-001 114918-048 064356-000 027931-057 064354-000 063904-101 064320-001 064331-001 064092-000 DESCRIPTION BOLT, PIN LOCK 3/8’ PIVOT PIN, UPPER T-BAR & UP BOOM - PED NUT, PIN LOCK 3/8’ WELDMENT, PEDESTAL (PLATFORM SUP) BUSHING, ALL 1.75” PINS UPPER TENSION BAR UPPER BOOM CHANNEL, WIRE COVER (UPPER BOOM) BUSHING, ALL 2.75 PINS LOCKNUT 1’ GEAR SEGMENT GREASE NIPPLE (1/8 BSP) 2nd POST WELDMENT PIVOT PIN, LOWER T-BAR BUSHING, LIFT CYLINDER ROD - BOOM NUT (ROLLER) PIVOT PIN, LOWER BOOM & UP BOOM - 2nd LOWER BOOM CHANNEL, WIRE COVER (LOWER BOOM) PIVOT PIN, CYL ROD - LOWER BOOM LOWER TENSION BAR BOLT (ROLLER, BOOM REST) ROLLER PIN BUSHING, ROLLER ROLLER CYLINDER, MAIN LIFT 1st POST WELDMENT LEVELLER WELDMENT PIVOT PIN, CYL BODY - 1st POST QTY. 9 3 9 1 12 1 1 1 6 6 2 10 1 2 2 1 3 1 1 1 1 1 1 2 1 1 1 1 1 6. Illustrated Part List Platform Assembly SL30SL ~ 505503-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART 064540-011 064119-000 064111-002 026554-002 064700-000 064696-000 064698-000 064702-002 064702-001 067764-001 067883-000 067712-000 003570-005 062642-026 066526-004 064688-001 064688-002 064447-000 064448-000 067695-000 DESCRIPTION DECK WELDMENT LADDER WELDMENT PEDESTAL WELDMENT RIVET (MAIN DECK) GUARDRAIL, FRONT KICKPLATE, SIDE GUARDRAIL, SIDE GUARDRAIL, END LEFT HAND SIDE GUARDRAIL, END RIGHT HAND SIDE KICKPLATE, GATE GATE WELDMENT GATE PIVOT TUBE PLUNGER ASSEMBLY BUSHING, GATE PIVOT GATE SPRING PIVOT BRACKET RH PIVOT BRACKET LH SKIRT PLATE (RUBBER SKIRT) RUBBER SKIRT SPACER, GUARDRAIL SL26SL ~ 505603-00 QTY. ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 1 1 24 1 4 4 1 1 1 1 1 1 2 1 2 2 1 1 6 PART 064100-011 064119-000 064111-001 026554-002 ~ 064695-000 064697-000 064702-002 064702-001 067764-001 067883-000 067712-000 003570-005 062642-026 064526-004 064688-001 064688-002 064447-000 064448-000 067695-000 DESCRIPTION DECK WELDMENT LADDER WELDMENT PEDESTAL WELDMENT RIVET (MAIN DECK) ~ KICKPLATE, SIDE GUARDRAIL, SIDE GUARDRAIL, END LEFT HAND SIDE GUARDRAIL, END RIGHT HAND SIDE KICKPLATE, GATE GATE WELDMENT GATE PIVOT TUBE PLUNGER ASSEMBLY BUSHING, GATE PIVOT GATE SPRING PIVOT BRACKET RH PIVOT BRACKET LH SKIRT PLATE (RUBBER SKIRT) RUBBER SKIRT SPACER, GUARDRAIL QTY. 1 1 1 24 ~ 4 4 1 1 1 1 1 1 2 1 2 2 1 1 6 4 2 3 1 6-7 6. Illustrated Part List 9 12 15 11 14 16 17 13 10 8 20 7 6-8 19 6 18 5 Platform Assembly 6. Illustrated Part List Platform Assembly (Slide-out Section) SL26SL ~ 064617-002 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 PART DESCRIPTION 06785-000 ~ 064778-000 064763-000 064761-000 063727-000 064233-000 064234-000 064235-000 064776-000 064425-000 063990-003 064249-000 064256-000 064795-000 064267-000 003570-001 064774-000 064769-001 064769-002 064773-000 026553-008 026553-002 011240-004 064240-001 011254-018 011254-032 011254-010 067685-000 011248-004 011252-014 011248-006 011240-006 064775-000 ~ ~ 011240-002 064247-000 011254-020 011252-016 011252-006 066550-006 066551-003 ~ 011254-008 064688-001 064688-002 101251-001 SIDE RAIL ~ FRONT RAIL DECK WELDMENT FLOOR (ALUMINIUM) BLOCK WHEEL (narrow) WHEEL (wide) WASHER TUBE, RAIL SUPPORT SLIDE BRACKET AXLE BUSHING (spanner) BEARING STRIP GUSSET PLATE BUMPER PAD RETAINING PIN ASSEMBLY ROLLER BRACKET R.H HANDLE L.H HANDLE HANDLE BRACKET POP RIVET - 3/16DIA 1/2-5/8 GRIP POP RIVET - 3/16DIA 1/8-1/4 GRIP FLAT WASHER 1/4 STD BUSHING SCREW - CAP 3/8-16 X 2 1/4 SCREW - CAP 3/8-16 X 4 SCREW - CAP 3/8-16 X 1 1/4 SPACER LOCKNUT - 1/4-20 SCREW - 1/4-20 UNC HEX HD X 1 3/4 LOCKNUT - 3/8-16 FLAT WASHER 3/8 STD FRONT ANGLE ~ ~ WASHER #8 GUIDE SLIDE SCREW - CAP 3/8-16 X 2 1/2 SCREW - CAP 1/4-20 X 2 SCREW - CAP 1/4-20 HEX HD X 3/4 DECAL - DANGER DECAL - DANGER ~ SCREW - 3/8-16 HEX HD X 1 BRACKET - TOEBOARD PIVOT RH BRACKET - TOEBOARD PIVOT LH DECAL - DANGER TIP OVER QTY. 2 ~ 1 1 1 4 4 2 4 2 4 2 2 1 2 4 2 2 1 1 2 12 30 22 2 4 2 10 2 22 10 26 12 2 ~ ~ 6 3 6 4 2 1 1 ~ 4 1 1 1 6-9 6. Illustrated Part List Platform Assembly (Slide-out Section) 6-10 6. Illustrated Part List Power Module Assembly 505504-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART DESCRIPTION 064724-000 064732-000 064736-000 064752-000 064731-000 064740-000 063650-012 065918-000 503992-000 062299-002 505558-000 503934-000 500052-000 500465-001 503684-000 064725-000 064040-000 503991-000 067559-000 500032-000 508063-000 QTY. POWER MODULE WELDMENT COVER, POWER MODULE WELDMENT DOOR, LEFT HAND DOOR, RIGHT HAND HINGE, MODULE COVER HINGE, DOOR GAS STRUT RADIATOR GRILL DIESEL TANK BATTERY 12V ENGINE EXAUST BRACKET HANDLE DOOR LATCH COVER LATCH STIFFENER BAR BATTERY RETAINING ANGLE EXAUST SOLENOID, THROTTLE SPRING, THROTTLE CLAMP 1 1 1 1 1 2 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 13 7 5 11 1 18 2 19 20 17 12 8 10 9 16 4 1 15 6 14 3 6-11 6. Illustrated Part List Control Module Assembly 505505-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART 064721-001 064732-000 064735-002 064734-000 064730-000 064731-000 064725-000 503935-000 502607-000 505555-000 503994-000 064642-000 063650-012 025427-002 502608-000 500465-001 064378-001 067659-001 067877-000 067902-000 503684-000 DESCRIPTION QTY. CONTROL MODULE WELDMENT COVER, CONTROL MODULE DOOR, RIGHT HAND DOOR, LEFT HAND HINGE, DOOR HINGE, MODULE COVER STIFFENER BAR LCP MOUNTING BRACKET LOWER CONTROL PANEL MANIFOLD BLOCK MOUNTING BRACKET, MANIFOLD TANK, HYDRAULIC OIL GAS STRUT HANDLE ECU DOOR LATCH EMERGENCY DOWN BRACKET EMERGENCY DOWN CABLE EMERGENCY DOWN COUPLER BRACKET, GAS STRUT LATCH, MODULE COVER 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 20 14 13 2 12 6 10 11 17 18 19 7 15 4 1 9 16 3 6-12 5 8 21 6. Illustrated Part List Hydraulic Valve Block 505555-020 505555-000 Serial Numbers from 50,065 Serial Numbers to 50,064 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART 058722-002 505555-010 505555-004 058722-002 505555-011 505555-009 505555-003 505555-008 501534-000 505555-007 501538-000 505555-002 505555-004 501533-000 505555-012 500261-002 501485-000 501533-000 505555-005 505555-013 505555-006 505555-001 508055-000 508056-000 057106-000 505555-018 DESCRIPTION (CT1) MAIN RELIEF 1 (CT2) FLOW REGULATOR CARTRIDGE 1 (CT3) STEERING DUMP 1 (CT4) RELIEF CARTRIDGE 1 (CT5) FLOW REGULATOR CARTRIDGE 1 (CT6/7/8) SOLENOID CARTRIDGE 3 (CT9) PROPORTIONAL VALVE 1 (CT10/11/19/21/22/) SOLENOID CARTRIDGE 5 (CT12) SHUTTLE VALVE 1 (CT13/14) OVERCENTRE CARTRIDGE 2 (CT15) CHECK CARTRIDGE 1 (CT16) SOLENOID CARTRIDGE 1 (CT17) SOLENOID CARTRIDGE 1 (CT18) CHECK CARTRIDGE 1 (CT20) JET 1 (CT23) HAND PUMP 1 (CT24) NEEDLE CARTRIDGE 1 (CT25) CHECK CARTRIDGE 1 (CT26) PRESSURE REDUCING CARTRIDGE 1 (CT27) JET 1 12V SOLENOID COIL 14W 3 12V SOLENOID COIL 22W 6 12 V SOLENOID COIL 29W 5 12 V SOLENOID COIL 19W 1 PRESSURE GAUGE PORT 1 MANIFOLD BLOCK 1 QTY. ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART 058722-002 505555-010 505555-004 058722-002 505555-011 505555-009 505555-003 505555-008 501534-000 505555-007 501538-000 505555-002 505555-004 501533-000 505555-012 500261-002 501485-000 501533-000 505555-005 505555-013 505555-015 505555-016 505555-014 505555-017 057106-000 505555-018 DESCRIPTION QTY. (CT1) MAIN RELIEF 1 (CT2) FLOW REGULATOR CARTRIDGE 1 (CT3) STEERING DUMP 1 (CT4) RELIEF CARTRIDGE 1 (CT5) FLOW REGULATOR CARTRIDGE 1 (CT6/7/8) SOLENOID CARTRIDGE 3 (CT9) PROPORTIONAL VALVE 1 (CT10/11/19/21/22/) SOLENOID CARTRIDGE 5 (CT12) SHUTTLE VALVE 1 (CT13/14) OVERCENTRE CARTRIDGE 2 (CT15) CHECK CARTRIDGE 1 (CT16) SOLENOID CARTRIDGE 1 (CT17) SOLENOID CARTRIDGE 1 (CT18) CHECK CARTRIDGE 1 (CT20) JET 1 (CT23) HAND PUMP 1 (CT24) NEEDLE CARTRIDGE 1 (CT25) CHECK CARTRIDGE 1 (CT26) PRESSURE REDUCING CARTRIDGE 1 (CT27) JET 1 12V SOLENOID COIL 14W 3 12V SOLENOID COIL 22W 6 12 V SOLENOID COIL 29W 5 12 V SOLENOID COIL 19W 1 PRESSURE GAUGE PORT 1 MANIFOLD BLOCK 1 6-13 6. Illustrated Part List Hydraulic Valve Block 6-14 6. Illustrated Part List Engine Assembly 505558-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 PART 505558-007 505558-008 505558-009 505558-010 505558-011 505558-012 505558-013 505558-014 505558-015 505558-005 505558-016 505558-017 505558-018 505558-019 505558-020 505558-021 505558-022 505558-023 505558-024 505558-025 505558-026 505558-006 503953-000 503998-000 067599-000 508032-000 508057-000 1 2 3 4 4 5 6 508059-000 508060-000 DESCRIPTION PRESSURE SWITCH FAN COOLANT TEMP SWITCH CRANKSHAFT PULLEY (NOT SHOWN) INDUCTION MANIFOLD COOLANT OUTLET EXHAUST MUFFLER (NOT SHOWN) EXAUST MANIFOLD (90O) EXHAUST MANIFOLD GASKET (SQUARE) (NOT SHOWN) EXHAUST MANIFOLD (3 TO 1) EXHAUST MANIFOLD GASKET (3 TO 1) EXHAUST, EXTENDED TAIL PIPE (NOT SHOWN) STARTER MOTOR ALTERNATOR DRIVE BELT ENGINE BREATHER COOLANT DRAIN PLUG THERMOSTAT & GASKET (NOT SHOWN) LUBRICATING OIL FILTER LUBRICATING OIL DRAIN PLUG LUBRICATING OIL FILLER CAP ATOMISER FUEL SHUT OFF SOLENOID FUEL INJECTION PUMP SPEED CONTROL LEVER FUEL PUMP LUBRICATING OIL DIPSTICK VOLTAGE REGULATOR (NOT SHOWN) PUMP IN LINE (PRIMER) (NOT SHOWN) THROTTLE BRACKET THROTTLE SOLENOID THROTTLE SPRING FUEL FILTER CARTRIDGE FLEXIBLE FUEL PIPE (PUMP TO FILTER) FLEXIBLE FUEL PIPE (FILTER TO INJECTION PUMP) FLEXIBLE FUEL PIPE (LEAK OFF) (NOT SHOWN) GLOW PLUGS FLYWHEEL BELL HOUSING FLYWHEEL ADAPTOR PLATE SPLINED SHAFT COUPLING HYDRAULIC PUMP ADAPTOR PLATE SCREW FLYWHEEL ADAPTOR PLATE SCREW PUMP MOUNTING SCREW AIR FILTER CARTRIDGE AIR FILTER AIR FILTER HOSE AIR FLOW INDICATOR FAN BELT (NOT SHOWN) RADIATOR RADIATOR TOP HOSE RADIATOR BOTTOM HOSE (NOT SHOWN) RADIATOR COVER RADIATOR COVER ANTI VIBE MOUNT QTY. 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 8 6 4 1 1 1 1 1 1 1 1 1 1 6-15 6. Illustrated Part List Engine Assembly 6-16 6. Illustrated Part List Lower Control Panel Assembly 502607-000 ITEM 1 2 3 4 5 PART 502457-000 502610-000 502611-000 501867-000 501880-000 DESCRIPTION CIRCUIT BOARD MOUNTING PLATE DECAL EMERGENCY STOP PLUG QTY. 1 1 1 1 1 6-17 6. Illustrated Part List UPPER CONTROL BOX ASSEMBLY 505505-000 ITEM PART 1 2 3 4 5 6 7 8 9 10 11 501867-000 501882-002 501882-000 501882-001 502612-000 501592-000 502591-000 502453-000 502587-001 502495-000 502496-000 DESCRIPTION QTY. EMERGENCY STOP BUTTON RUBBER BOOT, STEERING JOYSTICK RUBBER BOOT, JOYSTICK DECAL MOUNTING PLATE SEAL CIRCUIT BOARD SOCKET, MAIN HARNESS SOCKET, OVERLOAD UCB, BOX ONLY 1 1 1 1 1 1 1 1 1 1 1 2 3 4 1 5 6 7 8 11 10 6-18 9 6. Illustrated Part List Tank Assembly 503990-000 ITEM 1 2 3 4 5 6 7 8 PART 503993-000 064642-030 057377-000 057358-000 057108-000 057534-000 503991-001 057107-000 DESCRIPTION TANK LEVEL INDICATOR ADAPTOR 3/8” M/M BSP ADAPTOR 1/4” M/M BSP DRAIN PLUG 3/8” (NOT SHOWN) FILLER, BREATHER & DIPSTICK CAP INSPECTION COVER OIL FILTER QTY. 1 1 1 2 1 1 1 1 6-19 6. Illustrated Part List Hydraulic Assembly 505507-000 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART 503954-000 503955-000 503956-000 503957-000 503958-000 503959-000 503960-000 503961-000 503962-000 503963-000 503964-000 503965-000 503966-000 503967-000 503968-000 503969-000 503970-000 503977-000 503978-000 503797-000 503971-000 503972-000 503973-000 503974-000 503975-000 503976-000 503976-000 503990-000 057107-001 503953-000 505555-000 064346-100 064345-100 063905-101 063904-101 505201-000 505202-000 DESCRIPTION HOSE, SUCTION 1 HOSE, PUMP - PUMP TEE 1 HOSE, PUMP TEE - MANIFOLD 1 HOSE, RETURN (MANIFOLD - FILTER) 1 HOSE, RETURN (FILTER - TANK) 1 HOSE, MANIFOLD - FR TOP LH MOTOR 1 HOSE, MANIFOLD - FR BOT RH MOTOR 1 HOSE, FR LH MOTOR - FR RH MOTOR 1 HOSE, MANIFOLD - REAR TOP LH MOTOR 1 HOSE, MANIFOLD - REAR BOT RH MOTOR 1 HOSE, R LH MOTOR - R RH MOTOR 1 HOSE, FR LH MOTOR DRAIN - TEE 1 HOSE, FR RH MOTOR DRAIN - TEE 1 HOSE, FR MOTOR DRAIN TEE - TANK 1 HOSE, R LH MOTOR DRAIN - TEE 1 HOSE, R RH MOTOR DRAIN - TEE 1 HOSE, R MOTOR DRAIN TEE - TANK 1 HOSE, LH BRAKE - TEE (REAR MOTOR) 1 HOSE, RH BRAKE - TEE (REAR MOTOR) 1 HOSE, BRAKE TEE - MANIFOLD 1 HOSE, MANIFOLD - STEERING CYL 2 HOSE, MANIFOLD - LIFT CYL 1 HOSE, LIFT CYL - TANK (RETURN) 1 HOSE, PUMP TEE - AXLE FLOAT 1 HOSE, AXLE FLOAT - TANK (RETURN) 1 HOSE, MANIFOLD TO TILT (FORE / AFT) 2 HOSE, MANIFOLD TO TILT (LEFT / RIGHT) 2 HYDRAULIC TANK 1 FILTER & HEAD 1 PUMP (PTO DRIVEN) FOR PERKINS 403c11 1 MANIFOLD BLOCK 1 CYLINDER, AXLE FLOAT 1 CYLINDER, TILT 2 CYLINDER, STEER 1 CYLINDER, LIFT 1 REAR MOTORS 2 FRONT MOTORS 2 Complete Hose Kit : 508084-000 6-20 QTY. 6. Illustrated Part List Hydraulic Assembly 6-21 6. Illustrated Part List Hydraulic Cylinder Assembly (Main Lift) 063904-101 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART 063904-010 062649-010 058819-000 062649-020 DESCRIPTION QTY. CYLINDER BODY SOLENOID VALVE (EM DOWN) 12V LOCK NUT PISTON HEAD SEAL KIT SPACING SLEEVE CAP, BODY END CYLINDER ROD FLANGED BUSHING M6 GREASE NIPPLE CYLINDER BODY BUSHING 1 1 1 1 1 1 1 1 2 2 1 2 10 9 8 3 4 5 6 7 1 2 11 6-22 6. Illustrated Part List Hydraulic Cylinders: Steer, Axle Float, Tilt Steer Cylinder 063905-101 ITEM 1 PART DESCRIPTION 063905-010 SEAL KIT QTY. 1 Tilt Cylinder 064345-100 ITEM 1 PART DESCRIPTION 064345-010 SEAL KIT QTY. 1 Axle Float Cylinder 064346-100 ITEM 1 PART DESCRIPTION 064346-010 SEAL KIT QTY. 1 6-23 6. Illustrated Part List Electrical Assembly 505508-000 ITEM 1 2 3 4 5 6 6-24 PART 505559-005 505559-002 064296-004 505558-015 505559-004 501868-000 ITEM DESCRIPTION QTY. ELECTRICAL HARNESS, J2 LEVEL SENSOR LIMIT SWITCH ALTERNATOR ELECTRICAL HARNESS, J1 HORN 1 1 1 1 1 1 7 8 9 10 11 12 PART 067193-001 062299-002 505558-014 502607-000 501559-002 501559-001 DESCRIPTION QTY. PROXIMITY SWITCH BATTERY STARTER LOWER CONTROL PANEL UPPER CONTROL BOX (COMPLETE) ECU 1 1 1 1 1 1 6. Illustrated Part List 6-25 6. Illustrated Part List Decal Assembly 6-26 6. Illustrated Part List Decal Kit, (EN) SL30SL 505506-000 6-27 6. Illustrated Part List Decal Kit, (EN) SL30SL 505506-000 ITEM 1 2 3* 4* 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART 067770-011 067770-005 061683-005 061683-007 066550-006 010076-001 066551-003 066551-002 066554-000 502480-000 066555-000 064374-000 066563-000 101210-000 066556-900 057430-000 505573-000 067822-001 058531-000 060197-000 027898-001 010076-901 068635-001 DESCRIPTION SL30SPEED LEVEL SL30SL UpRIGHT 4 1/2” UpRIGHT 5 1/2” WARNING DOCUMENTS ENCLOSED TIPPING HAZZARD TIPPING HAZZARD CAUTION, READ OPERATION MANUAL EMERGENCY LOWER DO NOT ADJUST TO LEVEL DISTANCE TO GROUND RISK OF HYD GAS AND BATTERY LEAKAGE RISK FROM ABOVE RISK OF EXPLOSION SAFE WORKING LOAD ATTENTION GLOW PLUGS LIFT/TIE DOWN POINT HYDRAULIC FLUID DIESEL FUEL DECAL, ATTENTION DOC’S ENCLOSED HARNESS ANCHOR POINT QTY. 2 5 5 2 1 1 1 2 1 1 1 1 1 1 1 1 2 2 4 1 1 1 2 SL26SL 508045-000 Item Part 1 2 3* 4* 5 6 7* 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 067770-008 067770-005 061683-005 061683-007 066550-006 010076-001 066551-003 066551-002 066554-000 502480-000 066555-000 064374-000 066563-000 101210-000 066556-900 057430-000 508046-000 067822-001 058531-000 060197-000 027898-001 010076-901 068635-001 6-28 Description DECAL, SL26 SPEED LEVEL SL30SL UpRIGHT 4 1/2” UpRIGHT 5 1/2” WARNING DOCUMENTS ENCLOSED TIPPING HAZZARD TIPPING HAZZARD CAUTION, READ OPERATION MANUAL EMERGENCY LOWER DO NOT ADJUST TO LEVEL DISTANCE TO GROUND RISK OF HYD GAS AND BATTERY LEAKAGE RISK FROM ABOVE RISK OF EXPLOSION SAFE WORKING LOAD ATTENTION GLOW PLUGS LIFT/TIE DOWN POINT HYDRAULIC FLUID DIESEL FUEL DECAL, ATTENTION DOC’S ENCLOSED HARNESS ANCHOR POINT QTY. 5 5 2 2 1 2 2 1 1 1 1 1 1 1 1 2 2 4 1 1 1 2 6. Illustrated Part List Decal Kit, (DE) SL30SL 508028-000 Item Part 1 2 3* 4* 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 067770-011 067770-005 061683-005 061683-007 066550-206 508035-000 508038-000 508037-000 508039-000 502480-000 508040-000 064374-000 508041-000 101210-000 066556-900 057430-000 508043-000 508042-000 058531-000 060197-000 508036-000 010076-901 068635-001 Description SL30SPEED LEVEL SL30SL UpRIGHT 4 1/2” UpRIGHT 5 1/2” WARNING DOCUMENTS ENCLOSED TIPPING HAZZARD TIPPING HAZZARD CAUTION, READ OPERATION MANUAL EMERGENCY LOWER DO NOT ADJUST TO LEVEL DISTANCE TO GROUND RISK OF HYD GAS AND BATTERY LEAKAGE RISK FROM ABOVE RISK OF EXPLOSION SAFE WORKING LOAD ATTENTION GLOW PLUGS LIFT/TIE DOWN POINT HYDRAULIC FLUID DIESEL FUEL DECAL, ATTENTION DOC’S ENCLOSED HARNESS ANCHOR POINT QTY. 2 5 5 2 1 1 1 2 1 1 1 1 1 1 1 1 2 2 4 1 1 1 2 6-29 6. Illustrated Part List 6-30 6. Illustrated Part List 6-31 Local Distributor: Lokaler Vertiebshändler: Distributeur local: El Distribuidor local: Il Distributore locale: USA Europe TEL: +1 (559) 443 6600 FAX: +1 (559) 268 2433 TEL: +44 (0) 845 1550 058 FAX: +44 (0) 195 2299 948 www.upright.com PN- ">

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Key features
- Self-propelled
- Variable height
- Platform with guardrails
- High and low speed drive
- Steering control
- Tilt alarm
- Emergency lowering system
- Fold-down guardrails
Frequently asked questions
The maximum capacity varies depending on model and options. You can find this information in the 'Specifications' section of the manual.
The Emergency Lowering Valve is located in the control module door. Pull and hold the handle to lower the platform in case of an emergency.
No, the elevating function is limited to firm, level surfaces only. Operating on uneven terrain could result in instability and potential accidents.