Upright MX15 Service Manual
The Upright MX15 is a work platform designed for a variety of tasks. Its compact design allows it to maneuver in tight spaces, while its robust construction ensures durability. This machine features a telescopic platform with an extension for reaching greater heights. For easy transport, it can be driven or winched onto a truck or trailer. The MX15 includes a suite of safety features, such as an emergency lowering valve and level sensor, ensuring the operator's safety during use.
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MX15 and MX19 Work Platform Serial Numbers 20600 - Current Publication Number: 113101-000 MX15 / MX19 Serial Number 20600 – Current 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. 801 S. PINE ST. MADERA CALIFORNIA 93637 USA Stamped Serial Number UpRight, Inc. 801 South Pine Street Madera, California 93637 TEL: 559-662-3900 FAX: 559-673-6184 PARTS: 1-888-UR-PARTS PARTS FAX: 1-800-669-9884 Call Toll Free in U.S.A. 1-800-926-LIFT UpRight Unit S1, Park West Industrial Park Friel Avenue Nangor Road Dublin 12, Ireland TEL: +353 1 620 9300 FAX: +353 1 620 9301 FOREWORD This manual contains instructions for the maintenance of the machine. Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the machine, and help in diagnosing and repair of the machine. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. This manual consists of five (5) parts. OPERATOR MANUAL A copy of the Operator Manual that is stored on every UpRight Aerial Work Platform. SECTION 1 - GENERAL INFORMATION Contains generic information relevant to all UpRight Aerial Work Platforms. SECTION 2 - SER VICE AND REPAIR Detailed information specific to this UpRight Aerial Work Platform. S E C T I O N 3 - TR O U B L E S H O O T I N G Causes and solutions to typical problems. SECTION 4 - SCHEMATICS Electric and Hydraulic schematics. Service Manual Page i Foreword N OTES : Page ii Service Manual OPERATOR MANUAL WARNING All personnel shall carefully read, understand and follow all safety rules, operating instructions, and the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES of ANSI A92.6-1999 before performing maintenance on or operating any UpRight Aerial Work Platform. Safety Rules Electrocution Hazard NEVER operate the machine within ten (10) feet of power lines. THIS MACHINE IS NOT INSULATED. Tip Over Hazard Collision Hazard NEVER operate or drive with the NEVER position the platform without platform elevated unless on firm, level first checking for overhead obstructions surface. or other hazards. Fall Hazard NEVER climb, stand or sit on the platform guardrails or midrail. • NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs, bumps, curbs, or debris. • NEVER operate the machine if all guardrails are not properly in place and secured with all fasteners properly torqued. • ALWAYS close and secure the entrance after entering the platform. • NEVER use ladders or scaffolding on the platform. • NEVER exceed the maximum platform load. See “Specifications” on page 16. • NEVER attach overhanging loads or increase platform size. • LOOK up, down and around for overhead obstructions and electrical conductors. • DISTRIBUTE all platform loads evenly on the platform. • NEVER use damaged equipment. (Contact UpRight for instructions. See toll free phone number on inside back cover.) • NEVER change operating or safety systems. • INSPECT the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, damaged cables or hoses, loose wire connections, and wheel bolts. • NEVER climb down elevating assembly when the platform is elevated. • IF ALARM SOUNDS while the platform is elevated, STOP, carefully lower the platform. Move the machine to a firm, level surface. • IN CASE OF EMERGENCY push the Emergency Stop button to cut power to all machine functions. • NEVER perform service on the machine while the platform is elevated without blocking the elevating assembly. • NEVER recharge batteries near sparks or open flame; batteries that are being charged emit explosive hydrogen gas. • NEVER replace any component or part with anything other than original UpRight replacement parts without the manufacturer’s written consent. • VERIFY that all labels are in place and legible before using. • NEVER tow the machine. Transport by truck or trailer only. • AFTER USE, secure the machine against unauthorized use by turning the Chassis Key Switch OFF and removing the key. California Proposition 65 Warning. Battery Posts, terminals and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 113100-000 | MX15 / MX19 - Operator Manual Page 1 C ONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Pre-Operation Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 System Function Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel With the Platform Lowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elevating the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel With the Platform Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Release the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engage the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After Use Each Day. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 6 7 7 7 7 8 8 8 8 Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Lifting By Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Moving By Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Driving or Winching onto a Truck or Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Blocking The Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elevating Assembly Brace Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elevating Assembly Brace Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 10 10 11 11 12 Daily Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Daily Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Page 2 113100-000 | MX15 / MX19 - Operator Manual Introduction I NTRODUCTION This manual covers the application of the MX15 and MX19 Aerial Work Platforms. This manual must be stored on the machine at all times. Read, understand and follow all safety rules and operating instructions before attempting to operate the machine. G ENERAL D ESCRIPTION ! W A R N I N G ! DO NOT use the machine if all guardrails are not properly in place and secured. Figure 1: MX Series 1. Platform Controls 1 2. Manual Case 2 3. Deck Extension 4. Platform 3 5. Elevating Assembly 6. Chassis 7. Batteries 4 8. Charger Outlet Plug 5 9. Chassis Controls 12 10. Emergency Lowering Valve Knob 6 11. Hydraulic Fluid Reservoir 7 8 11 10 12. Lift Cylinder Inside 13 Chassis 13. Level Sensor (inside chassis) 14. Depression Mechanism Support 14 11 9 10 113100-000 | MX15 / MX19 - Operator Manual FRONT Page 3 Controls and Indicators C ONTROLS AND I NDICATORS The operator shall know the location of each control and indicator and have a thorough knowledge of the function and operation of each before attempting to operate the unit. Figure 2: Controls and Indicators Chassis Controls 1. 2. 3. 4. 5. Circuit Breaker Chassis Key Switch Chassis Lift/Lower Switch Chassis Emergency Stop Switch Hour Meter/Voltage Indicator 1 2 4 3 5 Platform Controls 1. Steering Switch 2. Interlock Switch (on front of Control Handle) 3. Control Handle 4. Platform Emergency Stop Switch 5. Lift/Drive Selector Switch 6. Horn Button (optional) 1 2 3 5 4 6 P RE -O PERATION S AFETY I NSPECTION NOTE: Carefully read, understand and follow all safety rules, operating instructions, labels, and the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES of ANSI A92.6-1999. Perform the following steps each day before use. 1. Open modules and inspect for damage, fluid leaks or missing parts. 2. Check the level of the hydraulic fluid with the platform fully lowered. See “Hydraulic Fluid” on page 11. Add recommended hydraulic fluid if necessary. See “Specifications” on page 16. 3. Check that fluid level in the batteries is correct. See “Battery Maintenance” on page 11. 4. Verify that the batteries are charged. 5. Check that the A.C. extension cord has been disconnected from the charger plug. 6. Check that all guardrails are properly in place and secured. 7. Inspect the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, damaged cables or hoses, loose wire connections and wheel bolts. Page 4 113100-000 | MX15 / MX19 - Operator Manual System Function Inspection S YSTEM F UNCTION I NSPECTION Refer to Figure 1 and Figure 2 for the locations of various controls and indicators. ! W A R N I N G ! STAND CLEAR of the machine while performing the following checks. Before operating the machine, survey the work area for surface hazards such as holes, drop-offs, bumps, curbs, or debris. LOOK up, down and around for overhead obstructions and electrical conductors. Protect the control cable from possible damage while performing checks. 1. Move the machine, if necessary, to an unobstructed area to allow for full elevation. 2. Turn the Chassis and Platform Emergency Stop Switches ON by pulling the buttons out. 3. Turn and hold the Chassis Key Switch to CHASSIS. 4. Push the Chassis Lift/Lower Switch to the LIFT position and elevate the platform approximately 2,1 m (7 ft.). 5. Install the Elevating Assembly Brace as described on page 10. 6. Visually inspect the elevating assembly, lift cylinder, cables, and hoses for cracked welds and structural damage, loose hardware, hydraulic leaks, and loose wire connections. Check for missing or loose parts. 7. Verify that the Depression Mechanism Supports have rotated into position under the machine. 8. Check Level Sensor operation (refer to “Level Sensor” on page 10). 9. Remove the Elevating Assembly Brace as described on page 10. 10. Turn and hold the Chassis Key Switch to CHASSIS. 11. Push the Chassis Lift/Lower Switch to the LIFT position and fully elevate the platform. • Check for erratic operation. 12. Partially lower the platform by pushing Chassis Lift/Lower Switch to LOWER, and check for proper operation of the audible lowering alarm. 13. Check the Emergency Lowering Valve for proper operation (refer to “Emergency Lowering” on page 7). 14. Lower the platform. 15. Push the Chassis Emergency Stop Switch to check for proper operation. All machine functions should be disabled. Pull out the Chassis Emergency Stop Switch to resume. 16. Turn the Chassis Key Switch to DECK. 17. Check that the route is clear of surface hazards such as holes, drop-offs, bumps, curbs, or debris, and is level and capable of supporting the wheel loads. 18. Mount the platform and properly close and secure the entrance. 19. Turn the Lift/Drive Switch to DRIVE. 20. Check for speed and directional control. • While engaging the Interlock Switch, slowly position the Control Handle to FORWARD then REVERSE. The farther you push or pull the Control Handle from center the faster the machine will travel. 21. Push the Steering Switch RIGHT, then LEFT, to check for steering control. Check clearances above, below, and to the sides of machine. 22. Turn the Lift/Drive Switch to LIFT to check platform lift controls. • While engaging the Interlock Switch, move the Control Handle to UP to raise the platform. • While engaging the Interlock Switch, move the Control Handle to DOWN to lower the platform. The platform should descend and the audible lowering alarm should sound. 23. 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. 113100-000 | MX15 / MX19 - Operator Manual Page 5 Operation O PERATION Before operating the machine, ensure that the Pre-Operation Safety Inspection and System Function 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. PLATFORM EXTENSION Figure 3: Platform Extension 1. Mount the platform and properly close and secure the entrance. 2. Depress the foot lever located at the rear of the platform extension. Push the platform extension forward until the pin engages the front stop. 3. To retract the platform extension, depress the foot lever and pull the platform extension toward the rear of the machine until the pin engages the rear stop. 1 TR A V E L W I T H T H E P L A T F O R M LOWERED 2 1. Check that the route is clear of surface hazards such as holes, drop-offs, bumps, curbs, or debris. 2. Check that the route is level, and is capable of supporting the wheel loads. 3. Verify that the Chassis Key Switch is turned to DECK and Chassis Emergency Stop Switch is ON (pulled out). 1. Platform Extension 2. Foot Lever 4. Mount the platform and properly close the entrance. 5. Check clearances above, below, and to the sides of platform. 6. Pull the Platform Emergency Stop Switch out to the ON position. 7. Turn the Lift/Drive Switch to DRIVE. 8. Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction. The speed of the machine will vary depending on how far from center the Control Handle is moved. STEERING 1. Turn the Lift/Drive Switch to DRIVE. 2. While engaging the Interlock Switch, push the Steering Switch to RIGHT or LEFT to turn the wheels in the desired direction. Observe the tires while maneuvering the machine to ensure proper direction. NOTE: Steering is not self-centering. Wheels must be returned to the straight ahead position by operating the Steering Switch. Page 6 113100-000 | MX15 / MX19 - Operator Manual Operation ELEVATING THE PLATFORM 1. Locate a firm, level surface. 2. Check clearances above, below, and to the sides of platform. 3. Turn the Lift/Drive Switch to LIFT. 4. While engaging the Interlock Switch, push the Control Handle FORWARD. 5. If the machine is not level the level sensor alarm will sound and the machine will not lift or drive. If the level sensor alarm sounds the platform must be lowered and the machine moved to a firm, level surface before attempting to elevate the platform. NOTE: Depression Mechanism Supports will deploy automatically as the platform elevates and will retract after the platform has been lowered completely and driven. TR A V E L W I T H T H E P L A T F O R M E L E V A T E D NOTE: The machine will travel at reduced speed when the platform is elevated. 1. Check that the route is clear of surface hazards such as holes, drop-offs, bumps, curbs, or debris. 2. Check that the route is level, and is capable of supporting the wheel loads. 3. Check clearances above, below, and to the sides of platform. 4. Turn the Lift/Drive Switch to DRIVE. 5. Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction. The speed of the machine will vary depending on how far from center the Control Handle is moved. 6. If the machine is not level the level sensor alarm will sound and the machine will not lift or drive. If the level sensor alarm sounds the platform must be lowered and the machine moved to a firm, level surface before attempting to elevate the platform. LOWERING THE PLATFORM 1. Turn the Lift/Drive Switch to LIFT. 2. Check around the base of the platform to ensure that no one is in contact with the machine. Engage the Interlock Switch and pull back on the Control Handle to lower the platform. EMERGENCY LOWERING The Emergency Lowering Valve Knob is located beside the ladder at the rear of the machine. Figure 4: 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. Emergency Lowering Valve Knob 1. Open the Emergency Lowering Valve by pulling and holding the knob. 2. To close, release the knob. The platform will not elevate if the Emergency Lowering Valve is open. 113100-000 | MX15 / MX19 - Operator Manual Page 7 Operation PARKING BRAKE RELEASE 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 (refer to “Transporting the Machine” on page 9). IMPORTANT: Do Not release the parking brakes if the machine is on a slope. ! W A R N I N G ! Never winch or move the machine faster than 0,3 m/sec. (1 ft./sec.). Never operate the machine with the parking brakes released. Serious injury or damage could result. The parking brakes are integral to the drive motors. Each drive motor has two brake release nuts. Release and engage the parking brakes one wheel at a time. Turn the brake release nuts in stages (½ turn at a time) to prevent possible binding of the brake mechanism. Figure 5: Parking Brake Release RELEASE THE PARKING BRAKE FRONT The front wheel motors each have two brake release nuts. IMPORTANT: Turn the nuts alternately in ½ turn increments to insure uniform adjustment and prevent binding. 1. Chock the rear wheels to prevent the machine from rolling. 2. Using a 13 mm socket wrench, turn the brake release nuts clockwise until they contact the motor body. 2 3. Alternately turn each nut clockwise in ½ turn increments until resistance is felt (approximately two turns). 3 1 3 4. The brake is released. 4 1 ENGAGE THE PARKING BRAKE 1. Chock the rear wheels to prevent the machine from rolling. 1. Motor Mount 2. Drive Motor 3. Brake Release Nut 4. Wheel 2. Using a 13 mm socket wrench, alternately turn the brake release nuts counter-clockwise in ½ turn increments. • Repeat until there is approximately 3.2 mm (1/8 in.) between the brake release nuts and the drive motor body. 3. Verify that the brakes have fully engaged before operating the machine by testing their ability to hold the machine on a 14.5° (26%) grade. AFTER USE EACH DAY 1. Ensure that the platform is fully lowered. 2. Park the machine on a firm level surface, preferably under cover, secure against vandals, children and unauthorized operation. 3. Turn the Chassis Key Switch to OFF and remove the key to prevent unauthorized operation. Page 8 113100-000 | MX15 / MX19 - Operator Manual Transporting the Machine TRANSPORTING THE M ACHINE Always use a transport vehicle when moving a machine to a work site. Towing the machine over long distances will damage the machine and void the warranty. ! D A N G E R ! See specifications for the weight of the machine and be certain that the crane or forklift is of adequate capacity to lift the machine. LIFTING BY CRANE Figure 6: Crane Straps, Forklift Pockets and Tie Down / Lift Points Secure straps to chassis tie down/lifting points only (refer to Figure 6). MOVING BY FORKLIFT FRONT REAR IMPORTANT: Forklifting is for transport only. Both the MX15 and MX19 may be forklifted from the rear end of the machine between the wheels.They may also be forklifted from the side using the forklift pockets shown in Figure 6. DRIVING OR WINCHING O N T O A TR U C K O R TR A I L E R ! W A R N I N G ift rkl ts Fo cke Po ! Fo t Points rkl n / Lif Never winch faster than 0,3 m/sec. i ft Tie Dow (1 ft./sec.). Never operate the machine with the parking brakes released. Serious injury or damage could result. 1. Loading the machine onto the truck or trailer; A. a. b. c. To Drive the machine onto the transport vehicle: Turn the Lift/Drive Switch to DRIVE and drive the machine up the ramp and into transport position. Set the wheels straight and turn off the machine. Chock the wheels. B. To Winch the machine onto the transport vehicle: a. Drive the machine up to the ramp. b. Attach the winch cable to the tie down/lifting points. c. Release the parking brakes (refer to “Parking Brake Release” on page 8). d. Winch the machine into transport position. e. Chock the wheels. f. Engage the parking brakes. 2. Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down/lifting points (refer to Figure 6). C A U T I O N Overtightening chains or straps attached to the Tie Down/Lift Points may result in damage to the machine. 113100-000 | MX15 / MX19 - Operator Manual Page 9 Maintenance M AINTENANCE ! 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 7: Elevating Assembly Brace ELEVATING ASSEMBLY BRACE INSTALLATION 1. Park the machine on a firm, level surface. Completely unload the platform before deploying the Elevating Assembly Brace. 2. Verify that the Chassis and Platform Emergency Stop Switches are ON by pulling each button out. 3. Turn and hold the Chassis Key Switch to CHASSIS. Push the Chassis Lift/Lower Switch to UP and elevate the platform approximately 2,1 m (7 ft.). Elevating Assembly Arm Weldment 4. Rotate the Elevating Assembly Brace to a vertical position. 5. Carefully lower the platform until the end of the Elevating Assembly Arm Weldment rests on the Brace. Brace Installed Brace Stored ELEVATING ASSEMBLY BRACE STORAGE 1. While holding the Brace, slowly raise the platform using the Chassis Controls until the end of the Elevating Assembly Arm Weldment clears the Elevating Assembly Brace. 2. Rotate the Elevating Assembly Brace forward to rest on the Chassis. 3. Push the Chassis Lift/Lower Switch to LOWER and completely lower the platform. LEVEL SENSOR Figure 8: Level Sensor Location The Level Sensor Is located inside the chassis. To verify the sensor is working properly there are two LED's under the sensor; green indicates the sensor is ON (has power), red indicates the sensor is LEVEL. TESTING THE LEVEL SENSOR 1. Place machine on firm level surface. 2. Open the door. 3. Push and hold the sensor off of level. 4. Push the Chassis Lift Switch to the UP position. • The alarm should sound, and the platform should not lift. 5. Close and latch the door. Level Sensor Page 10 113100-000 | MX15 / MX19 - Operator Manual Maintenance HYDRAULIC FLUID Figure 9: Hydraulic Reservoir Check the level of the hydraulic fluid with the platform fully lowered. The hydraulic reservoir is located at the rear of the machine. The fluid level should be visible through the side of the reservoir, and must be between the MIN and MAX lines (see Figure 9). Add hydraulic fluid if necessary. 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 weighing 26,3 kg (58 lbs.) each. • Check the battery fluid level daily, especially if the machine 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. 113100-000 | MX15 / MX19 - Operator Manual Page 11 Maintenance BATTERY CHARGING Figure 10: Battery Charger Charge the batteries at the end of each work shift or sooner if the batteries have been discharged. ! W A R N I N G ! Charge the batteries in a well ventilated area. Do not charge the batteries when the machine is near a source of sparks or flames. Permanent damage to the batteries will result if the batteries are not immediately recharged after discharging. Never leave the battery charger operating for more than two days. Never disconnect the cables from the batteries when the charger is operating. Keep the charger dry. Charger Outlet Plug 1. Check the battery fluid level. If the battery fluid level is lower than 10 mm (3/8 in.) above the plates add distilled water only. LED Indicator 2. Connect an extension cord (1,5 mm² [12 gauge] minimum conductor diameter; 15 m (50 ft.) maximum length) to the charger plug located at the left side of the chassis. Figure 11: Charge Indicator Lights 3. The charger turns on automatically after a short delay. Look through the charge indicator cutout to check the state of charge. • 0 - 50% charge: • First Light -BLINKING• Second and Third Light -OFF• 50% - 75% Charge: • First Light -ON• Second Light -BLINKING• Third Light -OFF• 75% - 100% Charge: • First and Second Light -ON• Third Light - BLINKING• Charge Complete • All Lights -ON• The charger automatically shuts down to low current after charging is complete and all lights turn ON. • The charger continues at low current (equalizing charge) for three to four hours, then charging current shuts off completely. • Lights remain ON until the AC power supply is disconnected. NOTE: The battery charger circuit must be used with a GFI (Ground Fault Interrupt) outlet. NOTE: DO NOT operate the machine while the charger is plugged in. Page 12 113100-000 | MX15 / MX19 - Operator Manual Daily Inspection and Maintenance Schedule D AILY I NSPECTION AND M AINTENANCE S CHEDULE The Complete Inspection consists of periodic visual and operational checks, along with periodic minor adjustments that assure proper performance. Daily inspection will prevent abnormal wear and prolong the life of all systems. Perform the inspection and maintenance items daily. Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures. ! ! W A R N I N G Before performing preventative maintenance, familiarize yourself with the operation of the machine. Always block the elevating assembly whenever it is necessary to perform maintenance while the platform is elevated. The daily preventative maintenance checklist has been designed for machine service and maintenance. Please photocopy the Daily Preventative Maintenance Checklist and use the checklist when inspecting the machine. D AILY P REVENTATIVE M AINTENANCE C HECKLIST 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 Controller Drive Motors INSPECTION OR SERVICES Check electrolyte level. Y N R COMPONENT Entire Unit INSPECTION OR SERVICES Check battery cable condition. Hydraulic Fluid Check hoses for pinch or rubbing points. Hydraulic Pump Check for hose fitting leaks. 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. Y N R Check for and repair collision damage. Check fluid level. Hydraulic System Check for leaks. Labels Check for peeling, missing, or unreadable labels & replace. Platform Deck and Check welds for cracks. Rails Check condition of deck. Tires Check for damage. Emergency Operate the emergency lowering valve and check Lowering System for serviceability. 113100-000 | MX15 / MX19 - Operator Manual Page 13 Labels L ABELS These labels shall be present and in good condition before operating the machine. Be sure to read, understand and follow these labels when operating the machine. DANGER DANGER Failure to read, understand and obey the following safety rules will cause death or serious injury TIP-OVER HAZARD MAXIMUM DISTRIBUTED LOAD 250 LBS. OR 1 OCCUPANT ON EXTENDED DECK MAXIMUM SIDE LOAD 100 LBS. TIP-OVER HAZARD ELECTROCUTION HAZARD 11 FALL HAZARD DO NOT elevate or drive elevated on slopes or soft ground DO NOT operate within ten feet of power lines. THIS MACHINE IS NOT INSULATED. DO NOT climb on guardrail Make sure guardrails are fastened securely DO NOT drive into holes or over drop offs Look up, down and around for electrical wires Lower top rail and secure gate or chain across entrance DO NOT use ladders or scaffolding on platform DO NOT climb down scissors. No more than one person or 250 Lbs. on slide out platform 1 DANGER TIP-OVER HAZARD BATTERIES ACT AS COUNTERWEIGHT EACH REPLACEMENT BATTERY SHALL WEIGH 60 LBS OR MORE 16 062562-001 17 010076-001 18 066558-000 19 061220-002 101251-000 066550-000 FORK-LIFT HERE FOR TRANSPORTING ONLY 014222-003-99 12 014222-003-99 WARNING Explosive gas is generated when charging batteries. Do not expose to sparks or flames. 2 6 13 066554-000 068639-000 066552-000 MAXIMUM WHEEL LOAD 1050 LBS. WARNING KEEP CLEAR OF SCISSORS BLOCK SCISSORS BEFORE SERVICING 101252-002 14 7 MX15 101252-002 066555-000 MAXIMUM WHEEL LOAD 1150 LBS. 3 066553-003 BATTERY 101252-009 14 MAINTAIN BATTERY FLUID AT RECOMMENDED LEVEL MX19 101252-009 WARNING 20 MAXIMUM DISTRIBUTED PLATFORM LOAD 550 LBS. OR TWO OCCUPANTS MAXIMUM SIDE LOAD 100 LBS. 4 MX15 101250-001 BATTERY DISCONNECT LOCATED INSIDE 8 BATTERY CHARGER USE DISCONNECT BEFORE SERVICING WORK PLATFORM OR BATTERIES 066556-000 15 005221-000 21 066522-000 107051-000 WARNING MAXIMUM DISTRIBUTED PLATFORM LOAD 500 LBS. OR TWO OCCUPANTS MAXIMUM SIDE LOAD 100 LBS. SCISSOR BRACE INSTRUCTIONS POSITIONING STORAGE INSTALLED 1. RAISE PLATFORM USING LOWER CONTROLS FORWARD UP 3. LOWER PLATFORM UNTIL END OF SCISSOR ARM 4 MX19 101250-000 1. SLOWLY RAISE PLATFORM (WHILE HOLDING BRACE) UNTIL THE END OF SCISSOR ARM WELDMENT APPROXIMATELY 7 FT. 2. ROTATE SCISSOR BRACE TO A VERTICAL POSITION. CLEARS SCISSOR BRACE. 2. ROTATE SCISSOR BRACE FORWARD TO REST ON CHASSIS. WELDMENT REST ON BRACE. STORED NEUTRAL 063255-001 22 063255-001 DOWN REVERSE LIFT DRIVE 801 S. PARK ST. MADERA CALIFORNIA 93737 USA EMERGENCY STOP 9 101222-004 5 Page 14 066556-001 10 066559-000 23 061205-005 113100-000 | MX15 / MX19 - Operator Manual Labels Figure 12: Safety Labels Locations 6 9 4 20 16 1 8 17 12 11 2 5 7 (INSIDE) 15 12 22 10 14 3 5 4 20 16 19 12 2 5 23 (INSIDE) 21 12 5 18 13 113100-000 | MX15 / MX19 - Operator Manual 3 12 Page 15 Specifications S PECIFICATIONS ITEM Gross Vehicle Weight (machine + rated load) Maximum Wheel Load Platform Size (Inside minimum) MX15 MX19 1,592 kg (3510 lbs.) 1692 kg (3730 lbs.) 315 kg (1050 lbs.) 345 kg (1150 lbs.) 0,72 m x 2,5 m (28.5 in. x 100 in.) Maximum Platform Capacity 250 kg (550 lbs.) 227 kg (500 lbs.) Working Height 6,57 m (21 ft.) 7,79 m (25 ft.) Maximum Platform Height 4,57 m (15 ft.) 5,79 m (19 ft.) Minimum Platform Height 0,90 m (35.5 in.) 1,02 m (40.25 in.) 1343 kg (2960 lbs.) 1465 kg (3230 lbs.) Maximum Number of Occupants Standard w/Deck Extension 2 People on Extension 1 Person Height Dimensions Weight 0,76 m (30 in.) 0,76 m (30 in.) Overall Height (Lowered) 1,89 m (74.5 in.) 2,01 m (79.25 in.) Overall Length (Deck in) 1,75 m (68.75 in.) 1,75 m (68.75 in.) Overall Length (Deck extended) 2,71 m (106.5 in.) 2,71 m (106.5 in.) 4,57 m (15 ft.) 5,79 m (19 ft.) Overall Width Drivable Height Drive Speed Platform Lowered 3,7 km/h (2.3 mph) Platform Raised 1,0 km/h (0.62 mph) Energy Source 24 Volt Battery Pack (four 220 A hour, 6 Volt batteries, min. wt. 26,3 kg [58 lbs.] each) Motor 24 Volt 4 Horse Power DC Electric Motor System Voltage 24 V DC Battery Charger 20 A, 110/220 VAC Hydraulic Reservoir Capacity 12,9 L (3.4 US gal.) Maximum Hydraulic System Pressure 207 bar (3000 psi) Hydraulic Fluid Normal above 32° F [0° C] ISO #32 Low Temp. below 32° F [0° C] ISO #32 below 0° F [-17° C] ISO #15 Lift System One Single Stage Lift Cylinder Lift, 19 sec. Lower, 20 sec. Lift Speed Control System Lift, 19 sec. Lower, 18 sec. • Proportional Control Handle with Interlock Switch • Rotary Lift/Drive Switch • Red Mushroom Emergency Stop Switch Drive System Dual Front Wheel Hydraulic Motors Tires 305 mm (12 in.) diameter solid rubber, Non-marking Parking Brake Dual, Spring Applied, Hydraulic Release Turning Radius Inside: 152 mm (6 in.) Outside: 1,6 m (64 in.) Maximum Gradeability 29% (16°) Wheel Base 1,24 m (49 in.) Guardrails 1,10 m (43 in.) Toeboard 152 mm (6 in.) Ground Clearance 9 cm (3.5 in.) *Specifications are subject to change without notice. Hot weather or heavy use may affect performance. Refer to the Parts Manual and the Service Manual for complete parts and service information. The MX15 / MX19 meets or exceeds all applicable requirements of OSHA and ANSI A92.6-1999. Page 16 113100-000 | MX15 / MX19 - Operator Manual Section 1 G ENERAL I NFORMATION This section contains generic instructions for the repair and maintenance of UpRight Aerial Work Platforms. Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the machine, and help in diagnosing and repair of the machine. TABLE OF C ONTENTS 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Workshop Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Date Code Identification on Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 UpRight Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Hydraulic Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Electric Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Floor Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 L IST OF F IGURES Figure 1-1: UpRight Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure 1-2: UpRight Male Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure 1-3: UpRight Female Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure 1-4: Locking Finger, UpRight Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure 1-5: Heavy Duty UpRight Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure 1-6: Electric Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Figure 1-7: Electric Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Figure 1-8: Contact Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Figure 1-9: Occupied Surface Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 L IST OF TABLES Table 1-1: Torque Specifications for Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-2: Torque Specifications for SAE Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table 1-3: Torque Specifications for Metric Fasteners, U.S. Customary Units . . . . . . . . . . . . . . . . . . . 1-4 Table 1-4: Torque Specifications for Metric Fasteners, SI Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Table 1-5: Specific Gravity and Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Table 1-6: Battery Charging, UpRight Electric and BiEnergy Machines . . . . . . . . . . . . . . . . . . . . . . . 1-14 Table 1-7: Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Service Manual Page 1-1 Hazard Indicators Section 1 - General Information 1-1 H AZARD I NDICATORS ! 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. C A U T I O N Indicates a potentially hazardous situation which, if not avoided, may result in damage to the machine. 1-2 WORKSHOP P ROCEDURES Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause personal injury, or could damage a machine or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by UpRight, Inc., might be done, or of the possible hazardous consequences of each conceivable way, nor could UpRight Inc. investigate all such ways. Anyone using service procedures or tools, whether or not recommended by UpRight Inc., must satisfy themselves thoroughly that neither personal safety nor machine safety will be jeopardized. ! W A R N I N G ! Be sure to read, understand and follow all safety rules, operating instructions, and the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES of ANSI A92.6-1999 before performing maintenance on or operating any UpRight Aerial Work Platform. ! W A R N I N G ! Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly. DO NOT stand in elevating assembly area while deploying or storing brace. Refer to the Operator Manual for elevating assembly blocking instructions. Page 1-2 Service Manual Section 1 - General Information Torque Specifications 1-3 TORQUE S PECIFICATIONS HYDRAULIC COMPONENTS NOTE: Always lubricate threads with clean hydraulic fluid prior to installation Use the following values to torque hydraulic components used on UpRight Aerial Work Platforms. Table 1-1: Torque Specifications for Hydraulic Components Type: SAE Port Series Cartridge Poppet Fittings Hoses Ft/Lbs Nm Ft/Lbs Nm In/Lbs Nm N/A N/A N/A N/A 135-145 15-16 #4 #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 FASTENERS This standard applies to the preloading of fasteners measured by installation torque. NOTE: For other preloading methods or fasteners consult UpRight Engineering Department. This general standard applies to all SAE and Metric fasteners unless otherwise specified. THREAD CONDITION • For lubricated or zinc plated fasteners use K =,15 • For dry unplated fasteners use K =,20 TORQUE TABLES Table 1-2: Torque Specifications for SAE Fasteners SAE J429 Grade 5 Nominal Thread Size Clamp Load Service Manual K=,15 Clamp Load Tightening Torque lbs. in-lbs. in-lbs. K=,20 in-lbs. in-lbs. K=,15 K=,20 SAE J429 Grade 5 SAE J429 Grade 8 Clamp Nominal Thread Clamp Tightening Torque Load Tightening Torque Size Load K=,15 K=,20 K=,15 K=,20 lbs. in-lbs. in-lbs. lbs. in-lbs. 1/4 -20 2,000 75 100 2850 107 143 1/4 -28 2,300 85 115 3250 120 163 5/16 - 18 3,350 157 210 4700 220 305 5/16-24 3,700 173 230 5200 245 325 lbs. ft-lbs. ft-lbs. lbs. ft-lbs. ft-lbs. lbs. ft-lbs. ft-lbs. lbs. ft-lbs. ft-lbs. 3/8-16 4,950 23 31 6950 32.5 44 3/8-24 5,600 26 35 7900 37 50 7/16-14 6,800 37 50 9600 53 70 7/16-20 7,550 42 55 10700 59 78 120 1/2-13 9,050 57 75 12800 80 107 9/16-12 11,600 82 109 16400 115 154 5/8-11 14,500 113 151 20300 159 211 3/4-10 21,300 200 266 30100 282 376 7/8-9 29,435 321 430 41550 454 606 1-8 38,600 483 640 54540 680 900 Unified Fine Thread Series Unified Coarse Thread Series lbs. Tightening Torque SAE J429 Grade 8 in-lbs. 1/2-20 10,200 64 85 14400 90 9/16-18 13,000 92 122 18300 129 172 5/8-18 16,300 128 170 23000 180 240 3/4-16 23,800 223 298 33600 315 420 7/8-14 32,480 355 473 45855 500 668 1-12 42,270 528 704 59670 745 995 Page 1-3 Torque Specifications Section 1 - General Information Table 1-3: Torque Specifications for Metric Fasteners, U.S. Customary Units 12.9 8.8 10.9 Grade 8.8 Grade 10.9 Nominal Thread Size Clamp Load Tightening Torque K =,15 mm lbs. 3 - 3.5 - Grade 12.9 Tightening Torque K =,20 Clamp Load K =,15 K =,20 in-lbs. in-lbs. lbs. in-lbs. - - - - - - - - Tightening Torque Clamp Load K =,15 K =,20 in-lbs. lbs. in-lbs. in-lbs. - 823 14.6 19.5 - 1,109 22.9 30.5 45.2 4 - - - - - - 1,436 33.9 5 1,389 41.0 54.7 1,987 58.7 78.2 2,322 68.6 91.2 6 1,966 69.7 92.9 2,813 100.0 132.8 3,287 116.8 155.8 7 2,826 4,044 167.3 223.0 4,727 ft-lbs. ft-lbs. 116.8 155.8 ft-lbs. ft-lbs. 195.6 260.2 ft-lbs. ft-lbs. 8 3,579 14.1 18.8 5,122 20.1 26.9 5,986 23.6 31.4 10 11,742 27.9 37.2 8,117 39.9 53.3 9,486 46.7 62.3 12 8,244 48.7 64.9 11,797 69.7 92.2 13,787 81.1 108.4 14 11,246 77.4 103.3 16,093 110.6 147.5 18,808 129.1 172.6 16 15,883 125.4 166.7 21,971 173.3 230.9 25,677 202.1 269.2 18 19,424 171.9 229.4 26,869 238.2 317.2 31,401 278.1 371.0 20 2,304 243.4 325.3 34,286 337.8 449.9 40,070 394.6 525.9 22 30,653 331.9 442.5 42,403 458.8 612.2 49,556 536.2 715.4 24 35,711 420.4 562.0 49,400 583.4 778.1 57,733 682.2 909.4 27 46,435 617.3 84.8 64,235 853.4 1138.1 75,069 997.2 1329.8 1807.0 30 56,753 837.9 1117.4 78,509 1159.4 1545.2 91,751 1354.9 33 70,208 1140.3 1520.1 97,121 1576.9 2102.8 113,503 1843.9 2457.5 36 82,651 1464.1 1952.3 114,334 2025.3 2700.9 133,620 2367.6 3156.0 Table 1-4: Torque Specifications for Metric Fasteners, SI Units Page 1-4 12.9 8.8 10.9 Grade 8.8 Grade 10.9 Tightening Torque Grade 12.9 Nominal Thread Size Clamp Load K =,15 K =,20 Clamp Load K =,15 Tightening Torque K =,20 mm N N-m N-m N N-m N-m 3 - - - - - - 3,5 - - - - - - Clamp Load Tightening Torque K =,15 K =,20 N N-m N-m 3660 1,65 2,2 4932 2,59 3,45 5,11 4 - - - - - - 6387 3,83 5 6177 4,63 6,18 8840 6,63 8,84 10330 7,75 10,3 6 8743 7,87 10,5 12512 11,3 15 14623 13,2 17,6 7 12570 13,2 17,6 17990 18,9 25,2 21025 22,1 29,4 8 15921 19,1 25,5 22784 27,3 36,5 26626 32 42,6 10 52230 37,8 50,5 36105 54,1 72,2 42195 63,3 84,4 12 36670 66 88 52475 94,5 125 61328 110 147 14 50025 105 140 71587 150 200 83663 175 234 16 70650 170 226 97732 235 313 114218 274 365 18 86400 233 311 119520 323 430 139680 377 503 20 10250 330 441 152513 458 610 178238 535 713 22 136350 450 600 188618 622 830 220433 727 970 24 158850 570 762 219743 791 1055 256808 925 1233 27 206550 837 115 285728 1157 1543 333923 1352 1803 30 252450 1136 1515 349223 1572 2095 408128 1837 2450 33 312300 1546 2061 432015 2138 2851 504885 2500 3332 36 367650 1985 2647 508582 2746 3662 594368 3210 4279 Service Manual Section 1 - General Information Date Code Identification on Hoses 1-4 D ATE C ODE I DENTIFICATION ON H OSES G ATES uses an eight digit code: Plant, Month, Day, Year. i.e.: XX 01 07 01 - means Plant XX January 07 2001. P ARKER uses a 4 digit code indicating Quarter and Year. i.e.: 2Q01 - means Second Quarter of 2001. D AYCO stamps month, day and year on each hose. 1-5 S PECIAL TOOLS The following is a list of special tools which may be required to perform certain maintenance procedures on the machine. • 0-69 bar (0-1000 psi) Hydraulic Pressure Gauge with Adapter Fittings • 0-207 bar (0-3000 psi) Hydraulic Pressure Gauge with Adapter Fittings • 0-414 bar (0-6000 psi) Hydraulic Pressure Gauge with Adapter Fittings • Small UpRight Connector Field Kit (UpRight P/N 030899-000) • Large UpRight Connector Field Kit (UpRight P/N 030898-000) • Inclinometer (UpRight P/N 010199-000-00) • MOS90 Calibrator (UpRight P/N 057128-000) • Optimizer with adapter (UpRight P/N 100329-000) • Flow Meter Kit (UpRight P/N 067040-000) • Quadragauge with fitting (UpRight P/N 063971-000) • 0-25 kg (0-50 Lbs.) Chain Tension Scale (UpRight P/N 107078-000) UPRIGHT LIFT TOOL LIST • • • • Service Manual Gland Nut Wrench (UpRight P/N 062521-000) Strap Wrench (UpRight P/N 062482-000) Tierod Tensioner (2 required) (UpRight P/N 062738-000) Tensioner Bracket (2 required) (UpRight P/N 062739-000) Page 1-5 UpRight Connectors Section 1 - General Information 1-6 U P R IGHT C ONNECTORS UpRight connectors are designed so that connector parts, contacts or electrical cables may be replaced without replacing the entire connector. Figure 1-1: UpRight Connector Kits Small Kit Large Kit M A L E C O N N E C T O R (P L U G ) Figure 1-2: UpRight Male Connector 1. Disconnect the male connector (plug) from the female connector (receptacle). 2. Using the flat end of the Removal Tool (or flat blade screwdriver), pry the Locking Wedge from the Male Connector. Care should be taken that the Sealing Gasket is not damaged during this procedure. 3. Check all parts for damage. Replace all parts which are damaged or worn. 4. Replace or re-crimp the wires and contacts. Refer to “Crimping” procedure. F E M A L E C O N N E C T O R (R E C E P T A C L E ) Figure 1-3: UpRight Female Connector 1. Disconnect the male connector (plug) from the female connector (receptacle). 2. Using the notched end of the Removal Tool (or a wire hook), pull the Locking Wedge from the Female Connector. 3. Check all parts for damage. Replace all parts which are damaged or worn. 4. Replace or re-crimp the wires and contacts. Refer to “Crimping” procedure. Page 1-6 Service Manual Section 1 - General Information UpRight Connectors RELEASING LOCKING FINGERS Figure 1-4: Locking Finger, UpRight Connector 1. The Locking Fingers can be released following the removal of the Locking Wedge of either the male or female connector. 2. Use the removal tool (or flat bladed screwdriver) to push the Locking Fingers aside. This will release the grip on the contact. 3. Pull the wire and contact out of the connector. CRIMPING 1. Strip 6 mm (¼ in.) from the wire. NOTE: Complete crimping instructions are included in each Field Kit. 2. Insert the contact into the crimping tool. 3. Insert the stripped wire into the contact. Copper strands should be visible in the bleed hole of the contact and no copper strands should be loose (outside) of the contact barrel. 4. Completely close the handles of the crimping tool. Release the handles of the crimping tool and remove the crimped contact. 5. Inspect the crimped contact to ensure that all strands are secure in the crimp barrel. REMOVING CONTACT FROM HEAVY DUTY PLUG Figure 1-5: Heavy Duty UpRight Connector 1. Slip the removal tool along the wire to be replaced. 2. Push the removal tool into the connector until the contact is released. 3. Pull the wire and contact out of the plug. Service Manual Page 1-7 Hydraulic Manifold Repair Section 1 - General Information 1-7 H YDRAULIC M ANIFOLD R EPAIR REMOVAL Refer to the Service and Repair section for model specific information. 1. Disconnect the battery. 2. Tag and disconnect the solenoid valve leads. 3. Tag, disconnect, and plug hydraulic hoses. 4. Remove the bolts that hold the manifold to the mounting bracket. 5. Remove the manifold block. DISASSEMBLY NOTE: Mark all components as they are removed so as not to confuse their location during assembly. 1. Remove coils from solenoid valves. 2. Remove valves. 3. Remove fittings, plugs, springs, balls, and orifices. CLEANING AND INSPECTION 1. Wash the manifold in cleaning solvent to remove built-up contaminants, then blow out all passages with clean compressed air. 2. Inspect the manifold for cracks, thread damage and scoring where O-rings seal against internal and external surfaces. 3. Wash and dry each component and check for thread damage, torn or cracked O-rings, and proper operation. 4. Replace parts and O-rings found unserviceable. ASSEMBLY Refer to the Service and Repair section for assembly drawings, and the Parts Manual for illustrated parts breakdowns. 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 punch. 1. Install fittings, plugs, springs, balls, and orifices. Use one drop of Locktite #242 on each screw-in orifice. 2. Install valves. INSTALLATION Refer to the Service and Repair section for model specific information. 1. Attach manifold assembly to mounting plate with bolts. 2. Connect solenoid leads (as previously tagged). 3. Connect hydraulic hoses. Be certain to tighten hoses to manifold. 4. Reconnect the battery. 5. Operate each hydraulic function and check for proper operation and leaks. 6. Adjust valve pressures according to the Service and Repair section. Page 1-8 Service Manual Section 1 - General Information Cylinder Repair 1-8 C YLINDER R EPAIR ! W A R N I N G ! Cylinders may be very heavy. Support heavy cylinders before removing pins which secure the cylinder to the machine. REMOVAL NOTE: Refer to the Service and Repair section for the location of cylinders, and the Parts Manual for a list of parts which secure the cylinders. 1. Mark and disconnect hoses and IMMEDIATELY cap the openings to prevent contamination. 2. Remove the cylinder from the machine as described in the Service and Repair section. DISASSEMBLY 1. Remove the head from the cylinder body. 2. Carefully slide the rod assembly out of the cylinder. 3. Remove the seal kit components (wipers, rod seals, o-rings and backup rings) from the head and piston. 4. Inspect parts for scratches, pits or polishing. Check seal grooves and sealing surfaces. Scratches or pits deep enough to catch the fingernail are unacceptable; replace the cylinder. Polishing is a sign of uneven loading. When this occurs, the surface should be checked for roundness. Cylinders not round within 0,18 mm (.007 in.) should be replaced. ASSEMBLY Refer to the Service and Repair section for seal-kit assembly drawings, and the Parts Manual for illustrated parts breakdowns. NOTE: To avoid cutting the seals, do not use sharp edged tools during seal replacement. After installing seals allow at least one hour for the seals to elastically restore to their original shape before assembling the cylinder. NOTE: Torque all hardware to torques according to Table 1-1, “Torque Specifications for Hydraulic Components,” on Page 1-3 unless otherwise specified. 1. Lubricate all components with clean hydraulic fluid. 2. Install new seal kit components. 3. Lubricate the rod wiper and seal with hydraulic fluid and slide the head onto the rod. 4. Lubricate the seals on the piston and head. 5. Carefully slide the rod assembly into the cylinder. 6. Secure the head into the cylinder. INSTALLATION 1. Installation is reverse of removal. 2. Carefully remove the elevating assembly support. 3. Slowly cycle the cylinder several times to remove air from the hydraulic system. 4. Check for proper cylinder operation. Check hydraulic connections for leaks. Service Manual Page 1-9 Electric Motors Section 1 - General Information 1-9 E LECTRIC M OTORS TR O U B L E S H O O T I N G Figure 1-6: Electric Motor Service 1. Read the nameplate to become familiar with the motor, especially the rated voltage. 2. Try to turn the shaft by hand. Keep motor leads separated while doing this. If the shaft turns freely go to Step 3 If the shaft won't turn, proceed to Step A. A. The shaft could be tight for a number of reasons, this check is to determine if the tightness is of a temporary nature only. a. Obtain power to produce the nameplate voltage. Do not Make a Permanent Connection. b. First touch the motor leads quickly to the power supply just long enough to observe if the shaft turns. c. If it does turn, then hold the motor leads on the power supply for a longer time. If the motor sounds normal, go to Step 3. d. If the motor sounds noisy, it should be taken apart as described in the disassembly section. DC Power Supply A Ammeter DC Motor V Voltage Meter A Brushes raised with Brushes and the springs in locked springs in their position on the side final position B of the brush 3. If the motor turned freely, connect an ammeter in the circuit as shown in Figure 1-6A. With rated voltage applied and the shaft running free, the ammeter should read less than 20% of the nameplate full load current. If the motor meets the above conditions, then it can be assumed that the original problem is external to the motor. Keep fingers clear of this space. C DISASSEMBLY 1. Remove the through bolts. 2. Remove the pulley end cover. 3. Pull the armature out of the assembly in one swift motion. 4. Remove the commutator end cover. NOTE: Do not place the stator ring in any mechanical holding device during the disassembly or assembly operation. Permanent distortion or other damage will result. Page 1-10 Service Manual Section 1 - General Information Electric Motors INSPECTION Once the motor has been disassembled, go through the following check-list steps to determine where the problem lies. 1. Bearings should spin smoothly and easily and have ample lubrication and be free of corrosion. 2. The armature should be checked for grounds and shorted turns. Re-finish the commutator surface if it is pitted or excessively worn. (This procedure should be performed by a qualified electric motor shop.) 3. Brushes should be checked for wear and to ensure that they are free in the brush holders. NOTE: Observe how the brushes are assembled in the brush holders, and the position of the brush lead. New brushes must be installed in the same manner. Brushes should be removed as follows: a. b. c. d. Remove the brush spring clip from its mounting on the brush assembly. Lift the brush assembly from the brush holder. Disconnect the brush assembly lead. Install the new brush assembly by reversing the above procedure. 4. Inspect the wire harness and all connections for signs of damage due to overheating. 5. Check the stator to see if it is securely mounted. REASSEMBLY Figure 1-7: Electric Motor Brushes 1. Install new brushes and be sure they are free in the holder. Install the brush with the lead wires positioned as when received. Raise all brushes to the locked position. (See Figure 1-7 and Inspection Step 3). Brushes and springs in their final position Brushes raised with the springs in locked position on the side of the brush 2. Place the commutator cover on a work bench with the brush assembly facing upward. Brushes 3. Place the bearing spring into the bearing bore. 4. Take a complete armature assembly, including bearings, and insert the commutator end bearing into the bearing bore. NOTE: Do not re-use bearings which have been removed from the armature shaft. Keep the assembly in a vertical position. Use extreme care not to damage the armature with bearing pullers. New bearings should be installed by pressing the inner race of the bearing onto proper position on the armature shaft. 5. Set the brushes into their final position as shown in Figure 1-7. Buss Bar Counterclockwise Rotation Buss Bar Typical pump motor viewed from rear. NOTE: This illustration is a 015797-011 pump motor. Other electric motors may rotate in either direction, and may use only two brushes. 6. Place the complete stator down over the vertical armature, and into position on the commutator cover. 7. The stator assembly must be placed in a definite relationship with the commutator covers in order to obtain a neutral brush setting. There is a match-mark on both items. These two marks must line up exactly. Rotate until they do. 8. Assemble the pulley end cover in the proper relationship. Insert the mounting bolts and tighten alternately to ensure a good mechanical alignment. 9. Spin the shaft by hand to see if it is free. Be sure motor leads (if used) are not touching together. If the leads are touching, a generator action will give the effect of friction in the motor. A no-load test can now be performed. At the rated voltage, observe the no-load current. It should be less than 20% of the nameplate full load current. Anything higher indicates: • Brushes are not on neutral setting (check match-marks for exact alignment). • Faulty armature. Service Manual Page 1-11 Battery Maintenance Section 1 - General Information 1-10 B ATTERY M AINTENANCE C A U T I O N If battery water level is not maintained, batteries will not fully charge, creating a low discharge rate. ! W A R N I N G ! Hazard of explosive gas mixture. Keep sparks, flame and smoking materials away from batteries. Always wear safety glasses when working with batteries. Battery fluid is highly corrosive. Thoroughly rinse away any spilled fluid with clean water. Always replace batteries with UpRight batteries or manufacturer approved replacements. Before disconnecting the battery negative (-) lead, make sure all switches are OFF. If ON, a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present. • Check battery fluid level daily. • If electrolyte level is lower than 10 mm (3/8 in.) above plates, add distilled water only. DO NOT use tap water with high mineral content. It will shorten battery life. DO NOT overfill. Battery acid expands during charging and can overflow. • Keep terminals and tops of batteries clean. • The battery and cables should be inspected regularly for signs of cracks in the case, electrolyte leakage and corrosion of the terminals. Inspect the cables for worn spots or breaks in the insulation and for broken cable terminals. • Clean batteries whenever there are signs of corrosion at the terminals, or when electrolyte has overflowed during charging. Use a baking soda solution to clean batteries, 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. Page 1-12 Service Manual Section 1 - General Information Battery Maintenance BATTERY CHECK Electric UpRight Aerial Work Platforms use deep cycle batteries. If poor service life is experienced, batteries should be checked for bad cells. Fully charge batteries for 14 hours minimum, ensuring that the charger has completed its cycle (see “Battery Charging” on page 1-14). Deep cycle batteries do not have their full potential until they have been through 50 charge/discharge cycles. Normal 5-day weeks, charging batteries every day, equals 50 cycles in ten weeks. If bad cells are found in any battery in a battery pack more than two years old, all batteries in the pack should be replaced for balance. BATTERY CELL EQUALIZATION The specific gravity of the electrolyte in the battery cells should be equalized monthly. To do this, charge batteries as outlined in “Battery Charging” on page 1-14. After this initial charge, recheck the electrolyte level in all cells and add distilled water as necessary. Then, turn on the charger for an additional eight hours. SPECIFIC GRAVITY Check the specific gravity of all cells with a hydrometer. The temperature corrected specific gravity of a fully charged battery should be 1.260. If any corrected readings are below 1.230, the batteries containing such cells 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 complete a discharge/ charge cycle before checking. Table 1-5: Specific Gravity and Battery Voltage SPECIFIC GRAVITY VOLTS DC Each Cell Per Cell 6V Battery 12V Battery 24V Battery Pack 48V Battery Pack Fully Charged 1.270 2.10 6.30 12.60 25.20 50.40 Fully Discharged 1.130 1.75 5.25 10.50 21 42 LOAD TESTING BATTERY PACKS 1. Fully charge the battery pack. 2. With the battery pack at rest and under full load, perform steps 3 and 4. a. To put the battery pack under full load, • Activate the steering switch to turn the wheels fully in either direction. • Continue to hold the steering switch while performing steps 3 and 4. 3. Measure the potential across each battery. 4. Measure the potential across the entire battery pack. 5. Compare the measured results Any battery that measures 10% lower voltage than the others has a bad cell and should be replaced. Service Manual Page 1-13 Battery Maintenance Section 1 - General Information BATTERY CHARGING C A U T I O N Permanent damage will result if the battery is not immediately recharged after discharging. ! W A R N I N G ! Charge batteries only in a well ventilated area. DO NOT charge batteries when sparks or open flames are present. Never leave the connected charger unattended for more than two days. Never disconnect the cables from the battery when the charger is operating. Keep the charger dry. • Charge batteries at the end of each work shift or sooner if the batteries have been discharged. • Discharging a deep cycle battery to less than 1.75 Volts per cell can cause permanent damage. NOTE: Do not operate the machine when the battery charger is plugged in. When night temperatures fall below 65°F (18°C), batteries charged in unheated areas should be charged as soon after use as possible. Under such conditions a four hour charge cycle once a week in the early afternoon will improve the state of charge and battery life. 1. Check the battery fluid level. If electrolyte level is lower than 10 mm (3/8 in.) above plates, add distilled water only. 2. Check the charger to determine the AC charging current. If equipped, set the AC voltage selector switch to match the AC power source. 3. Connect an extension cord that meets or exceeds the charger AC current onto the charger plug. 4. Connect the other end of the extension cord to a grounded AC outlet of proper current, voltage and frequency rating. 5. The charger turns on automatically after a short delay. Table 1-6 illustrates charging indicators. Table 1-6: Battery Charging, UpRight Electric and BiEnergy Machines Charger Display AC Charging Current 068574-000 8 Amp - 115 VAC 069112-000 4 Amp - 230 VAC Charging Indicator Ammeter • Charging current is displayed on ammeter. Charger Shutdown • Charger shuts off automatically. • Ammeter shows “0” current. • Current drops off as batteries charge. 063944-001 7 Amp - 115 VAC Green Light 063948-003 4 Amp - 230 VAC • ON during charging cycle. • Blinking at charge completion. 069199-000 & 069199-001 Dual Voltage 8 Amp - 115 VAC 4 Amp - 230 VAC Three Lights • 0 - 50% charge: First Light -BlinkingSecond and Third Light -OFF• 50% - 75% Charge: First Light -ONSecond Light -BlinkingThird Light -OFF• 75% - 100% Charge: First and Second Light -ONThird Light - Blinking- • Charger automatically shuts down to 1 amp trickle charge. • Green Light continues to blink. • Charger automatically shuts down to low current after charging is complete and all Lights turn ON. • Charger continues at low current (equalizing charge) for 3-4 hours, then charging current shuts off completely. • Lights remain ON until the AC power supply is disconnected. • Charge Complete All Lights -ON- Page 1-14 Service Manual Section 1 - General Information Battery Maintenance B A T T E R Y C H A R G E R TR O U B L E S H O O T I N G C A U T I O N Ensure that battery chargers with voltage selector switches are set on the correct AC line voltage before placing chargers in service to avoid charger failure. Connect battery leads in correct polarity to avoid charger damage. ! W A R N I N G ! Remove all power before working on electrical parts to avoid shock. Shock hazard can exist if AC plugs are wired incorrectly. The battery charger troubleshooting procedure is outlined in Table 1-7. The table shows various conditions for each charger type with the problem to be investigated. Follow the table from the top down when troubleshooting. If the problem is not resolved after going through the entire table, the charger should be replaced. NOTE: The majority of chargers returned to UpRight as “failed” test good. Please follow the troubleshooting procedures carefully. Table 1-7: Battery Charger Troubleshooting Problem 068574-000(115V) 069112-000(110/230V) 063944-001 (115V) 063948-003 (110/230V) 069199-000 & 069199-001 (115/230V auto) Solution Battery voltage is below 18 • Ammeter does not move. • No green Light. Volts (too low to allow the • No hum from charger. • No hum from charger. charger to turn on). • Not Applicable. Charge batteries to at least 24 Volts with an external • Charger turns on even with very charger, then disconnect the external charger and plug low battery voltage. in the internal charger. • Ammeter does not move. • No green Light. The charger has been • No hum from charger. • No hum from charger. plugged into an AC outlet with different voltage than the AC switch setting on the charger. • Not Applicable. 063944-001 ONLY • Charger automatically adjusts to • Check the fuse inside the switch box - replace if bad. the incoming AC current. • If the fuse is good, the charger has failed. All Others • Check the AC main circuit breaker and reset if necessary. • Set the voltage selector switch to the proper voltage. Fuse visible on front of charger has failed. • Ammeter does not move. • Not Applicable. • No hum from charger. • Not Applicable. • Ammeter does not move. • No green Light. • No hum from charger. • No hum from charger. • No Lights ON. • No Lights blinking. • AC outlet is bad. • Extension cord is bad • Plug is bad or wired wrong. • AC wire is broken. Check and repair as necessary. • Ammeter does not move. • No green Light. • No hum from charger. • No hum from charger. • All three Lights blink once. Connection to battery; • missing. • corroded. • wrong polarity. • DC wire broken. Check and repair as necessary, and check Fuse. AC power problem. DC connection to batteries. One or more batteries is bad. AC input voltage too high. Check for DC output short circuit and replace the fuse. • Ammeter never shuts off, • Green Light ON but never • Lights one and two are ON or even after 14 hours of starts blinking, even after blinking, but all three Lights ON charging. 14 hours of charging. never occurs, even after 14 hours of charging. • Check water level. • Check for shorted cells. • Replace bad batteries. Check and correct AC source. • Not Applicable. • Not Applicable. • All three Lights blink two times. • Not Applicable. • Not Applicable. • All three Lights blink three times. Move the machine to a cooler area. Allow the machine to cool before connecting to AC source. High current in DC charging • Not Applicable. output. • Not Applicable. • All three Lights blink four times. • Check for shorted DC output wires. • Check for bad batteries. Overheated charger. Service Manual Page 1-15 Hydraulic Fluid Section 1 - General Information 1-11 H YDRAULIC F LUID FLUID LEVEL With the platform fully lowered, check the hydraulic fluid level. If the fluid is NOT in operating range, add hydraulic fluid until the fluid level is in operating range. • DO NOT fill above operating range. • DO NOT add fluid when the platform is elevated. RECOMMENDED HYDRAULIC FLUID C A U T I O N Unless recommended by UpRight, do not mix hydraulic fluids of different brands or types. The required additives and fluid viscosities may vary. If the use of hydraulic fluids other than listed below is desired please contact UpRight Product Support. MOBILFLUID 424 • • • • Viscosity Grade: ISO 46 High V.I. (similar to SAE 10W-30). Viscosity index: 152. Operating Range: -10° C to +96° C (+15° F to +205° F) Reservoir Temperature. Ambient Conditions*: Above -10° C (+15° F). MOBIL DTE 13 M • • • • Viscosity Grade: ISO 32 High V.I. (similar to SAE 5W-20). Viscosity index: 140. Operating Range: -18° C to +80° C (-4° F to +176° F) Reservoir Temperature. Ambient Conditions*: -18° C to +30° C (-4° F to +86° F). MOBIL DTE 11 M • • • • Viscosity Grade: ISO 15. Viscosity index: 140. Operating Range: -35° C to +45° C (-30° F to +115° F) Reservoir Temperature. Ambient Conditions*: -35° C to +20° C (-30° F to +70° F). MOBIL EAL ENVIROSYN 46 H For use where a biodegradable non-toxic hydraulic fluid is required. • Viscosity Grade: ISO 46 High V.I. (similar to SAE 10W-20). • Viscosity Index: 153. • Operating Range: -14° C to +90° C (+6° F to +195° F) Reservoir Temperature. • Ambient Conditions*: -14° C to +41° C (+6° F to +105° F). • Synthetic Ester Base. The anti-wear quality of hydraulic fluid must meet or exceed API Service Classification GL-3. The chemical stability of the hydraulic fluid must be sufficient for mobile hydraulic system service. *Ambient Conditions are for reference only and may vary by model. Refer to operating temperature for final determination of correct fluid. Page 1-16 Service Manual Section 1 - General Information Floor Loading 1-12 F LOOR L OADING Floor Loading is defined as pressure imposed onto load-bearing surfaces, and can be measured as Localized Pressure or Occupied Pressure. To calculate Floor Loading, find the Total Weight of the machine. TOTAL WEIGHT = MACHINE WEIGHT + MAXIMUM PLATFORM CAPACITY. Refer to the machine specifications or contact UpRight or your UpRight dealer. LOCALIZED PRESSURE KG/CM² OR PSI Figure 1-8: Contact Area Localized Pressure is measured in kilograms per square centimeter or pounds per square inch. It is the pressure exerted onto a small area (contact area). Each tire and/or outrigger imposes Localized Pressure which can cause damage to the load-bearing surface. TIRE LUG TIRE OUTRIGGER NOTE: The formulas shown here are for vertical lift machines. Applying these formulas to machines with extending platforms will yield average pressures for machines in stowed position. Extending a platform causes increased localized pressure in the direction of extension, and decreased localized pressure at the opposite end. MEASURE THE CONTACT AREA CONTACT AREA Measure the contact area of the contacting surface (tire or outrigger). The tire contact area can be determined by placing the loaded tire on a clean surface. The tire will leave an imprint from which an area can be determined. Figure 1-9: Occupied Surface Area CALCULATE THE LOCALIZED PRESSURE Find the pressure exerted at each contacting surface. NOTE: The wheel load can usually be found on a label on the machine, or on the serial plate. If you know the wheel load, use this formula: LOCALIZED PRESSURE = WHEEL LOAD ÷ CONTACT AREA If you do not know the wheel load, use this formula: LOCALIZED PRESSURE = (TOTAL WEIGHT ÷ 4) ÷ CONTACT AREA OCCUPIED PRESSURE KPA OR PSF Occupied Pressure is measured in kilopascals or pounds per square foot. It is the total pressure imposed onto the work surface over the area of the machine (occupied surface area). This is especially important when the work surface is supported by beams. The Occupied Pressure must not exceed the maximum load that the surface can support. WIDTH LENGTH OCCUPIED PRESSURE = TOTAL WEIGHT ÷ (LENGTH X WIDTH) Service Manual Page 1-17 Long Term Storage Section 1 - General Information FLOOR LOADING SPECIFICATIONS Personnel Lift Machines Installed Outrigger Area (Length X Width) in. MODEL UL25 cm Unit Weight AC Units lbs. kg Platform Capacity Occupied Floor Area Occupied Floor Pressure (uniform) in.² psf DC Units lbs. kg lbs. kg m² Outrigger Pad Area kPa in.² Maximun Localized Pressure (each pad,) cm² psi kPa kg/ cm² 59 x 56 105 x 142 770 349 810 367 350 159 3304 2,13 50 2,39 12.57 81 23 1,62 159 UL32 81 x 78 206 x 198 920 417 960 435 300 136 6318 4,08 29 1,39 12.57 81 25 1,76 172 UL40 92 x 89 234 x 226 990 449 1030 467 300 136 8188 5,69 23 1,1 81 26 1,83 179 12.57 Small Slab Machines Chassis Length (excluding Ladder) Vehicle Width in. m in. TM12 53.5 1,36 30.0 MX15 68.8 1,74 30.0 MX19 68.8 1,74 SL20 92.5 2,35 X20N 92.5 X20W 92.5 X26N X26UN X31N X32N MODEL m Vehicle Weight lbs. kg Platform Capacity Occupied Floor Area Occupied Floor Pressure (uniform) in.² psf kPa kg/ cm² Maximum Axle Load (including rated load) Tire Width Tire Contact Area lbs. lbs. kg in. in.² cm² psi kPa kg/ cm² kg 0,75 2209 1002 500 227 1602 1,03 243 11,63 0,118 677 307 1354 614 2.75 7 7.9 50,3 85.7 591 6,03 0,75 2961 1343 550 250 2063 1,33 245 11,73 0,119 968 439 1936 878 4 10 10.2 65,8 94.9 654 6,67 30.0 0,75 3100 1406 500 227 2063 1,33 251 12,01 0,122 1050 476 2100 953 33.0 0,84 3100 1406 750 340 3053 1,97 181 522 2300 1044 2,35 32.5 0,82 3828 1736 750 340 3006 1,94 219 10,48 0,106 1400 635 2800 1270 4.5 2,35 48.0 1,22 4273 1938 1000 454 4440 2,86 149 7,13 0,072 1600 726 3200 1452 4.5 92.5 2,35 48.0 1,22 4747 2153 1000 454 4440 2,86 171 8,19 0,083 1750 794 3500 1588 4.5 11,4 16.1 104 108.7 749 7,64 92.5 2,35 32.5 0,82 5200 2358 227 3006 1,94 273 13,07 1,133 1750 794 3500 1588 4.5 11,4 16.1 104 108.7 749 7,64 92.5 2,35 48.0 1,22 5480 2485 700 317 4440 2,86 200 9,58 0,097 1850 839 3700 1678 4.5 11,4 16.3 105 113.5 783 7,98 92.5 2,35 48.0 1,22 5480 2485 700 317 4440 2,86 200 9,58 0,097 1850 839 3700 1678 4.5 11,4 16.3 105 113.5 783 7,98 8,66 0,088 1150 kg cm Maximun Localized Pressure (each tire, platform extended) lbs. 500 m² Maximum Tire Load (including rated load) 4 10 10.2 65,8 102.9 709 7,23 4.5 11,4 13.1 84,5 605 6,17 11,4 11.8 76,1 118.6 818 8,34 11,4 15.6 101 102.6 707 7,21 87.7 1-13 L ONG TERM S TORAGE NOTE: Do not drain the hydraulic system prior to long term storage. If the machine is to be placed in long term storage, follow these recommended preservation procedures. PRESERVATION 1. Clean painted surfaces. If paint is damaged, repaint. 2. Fill the hydraulic reservoir to operating level. IMPORTANT: Do not fill the hydraulic reservoir while the platform is elevated. 3. Coat exposed portions of cylinder rods with a preservative such as multipurpose grease and wrap with a barrier material. 4. Coat all exposed unpainted metal surfaces with preservative. 5. Internal Combustion Models: Service the engine according to the manufacturers recommendations. 6. Electric And BiEnergy Models: Remove the batteries and place them in alternative service. Page 1-18 Service Manual Section 2 S ER VICE AND R EPAIR This section contains instructions for the maintenance of the machine. Refer to the General Information section for information relevant to all UpRight work platforms. Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the machine, and help in diagnosing and repair of the machine. ! 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 Aerial Work Platform. ! W A R N I N G ! Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly. DO NOT stand in elevating assembly area while deploying or storing brace. TABLE OF C ONTENTS 2-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2-2 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Preventative Maintenance Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2-3 Blocking the Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Elevating Assembly Brace Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Elevating Assembly Brace Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-4 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-8 2-8 2-8 2-5 Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Proximity Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Test the Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Test High Speed Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Access to Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Control Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Chassis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Motor Controller and I/O Board Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 113101-000 MX15 / MX19 | Service Manual Page 2-1 Section 2 - Service and Repair 2-6 Hydraulic Fluid Reservoir and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Reservoir Breather/Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Fluid and Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2-7 Hydraulic Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Main Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-16 2-16 2-17 2-8 Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Removal, Repair and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2-9 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 2-10 Hydraulic Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 2-20 2-20 2-21 2-22 2-22 2-22 2-11 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 2-12 Depression Mechanism Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2-13 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 L IST OF F IGURES Figure 2-1: MX15 / MX19 Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Figure 2-2: Blocking the Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Figure 2-3: Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Figure 2-4: Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Figure 2-5: Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Figure 2-6: Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-7: Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-8: Chassis Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Figure 2-9: Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure 2-10: Hydraulic Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Figure 2-11: Hydraulic Manifold Test Ports, from right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Figure 2-12: Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Figure 2-13: Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Figure 2-14: Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Figure 2-15: Drive Motor Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Figure 2-16: Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Figure 2-17: Steering Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Figure 2-18: Steering Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Figure 2-19: Depression Mechanism Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Figure 2-20: Depression Mechanism Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Figure 2-21: Lift Cylinder Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Figure 2-22: Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Page 2-2 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair General Description 2-1 G ENERAL D ESCRIPTION The MX15 and MX19 are self-propelled aerial work platforms designed to provide mobility with the platform elevated or lowered. The elevating function shall only be used when the platform is on a firm, level surface. Travel with the platform elevated is limited to the low speed range. The machine is intended to be self-propelled only when in relatively close proximity to the work area. ! W A R N I N G ! DO NOT use the machine without guardrails properly assembled and in place. Figure 2-1: MX15 / MX19 Work Platform 2 1 4 6 7 3 1. Platform Controls 2. Documentation Compartment 3. Deck Extension 4. Deck-Lock Foot Lever 5. Platform Deck 6. Platform Guardrail 7. Entry-way Closure 8. Elevating Assembly 9. Lift Cylinder 10. Emergency Lowering Valve 11. Chassis 12. Battery Charger 13. Batteries 14. Charger Plug 15. Charger LED Window 16 Proximity Switch 17. Hydraulic Fluid Reservoir 18. Emergency Lowering Knob 19. Cable Connector 20. 175 AMP Fuse, Overload Protection 21. Horn (option) 22. Audible Alarm 23. Solenoid, Motor Relay 24. Chassis Controls 25. Depression Mechanism Cylinder 26. Depression Mechanism Rail 27. Hydraulic Pump Motor 28. Hydraulic Pump 29. Motor Controller 30. I/O Board 31. Hydraulic Manifold 32. Hydraulic Fluid Filter 33. Steering Cylinder 34. Hydraulic Drive Motors 35. Level Sensor 5 28 8 30 31 29 32 9 11 27 25 33 10 24 11 19 12 13 17 18 Left Door REAR Right Door 13 34 20 21 15 14 113101-000 MX15 / MX19 | Service Manual 16 22 23 26 35 FRONT 1 Page 2-3 Preventative Maintenance Section 2 - Service and Repair 2-2 P REVENTATIVE M AINTENANCE The complete inspection consists of periodic visual and operational checks, along with periodic minor adjustments to assure proper performance. Daily inspection will prevent abnormal wear and prolong the life of all systems. The inspection and maintenance schedule is to be performed at regular intervals. Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures. ! W A R N I N G ! Before performing preventative maintenance, familiarize yourself with the operation of the machine. Always block the elevating assembly whenever it is necessary to enter the scissor assembly to perform maintenance while the platform is elevated. The preventative maintenance table has been designed for machine service and maintenance repair. Please photocopy the Preventative Maintenance Check List and use the table when inspecting the machine for service. Page 2-4 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Preventative Maintenance PREVENTATIVE MAINTENANCE CHECK LIST \ MAINTENANCE TABLE KEY PREVENTATIVE MAINTENANCE REPORT Date: ______________________________________ Interval Daily=each shift or every day 50h/30d=every 50 hours or 30 days 250h/6m=every 250 hours or 6 months 1000h/2y=every 1000 hours or 2 years Y=Yes/Acceptable N=No/Not Acceptable R=Repaired/Acceptable Owner: _____________________________________ Model No: __________________________________ Serial No: ___________________________________ Serviced By:_________________________________ Service Interval: ______________________________ COMPONENT Battery Hydraulic Oil INSPECTION OR SERVICES INTERVAL Check electrolyte level Daily Check battery cable condition Daily Clean exterior 3m Check specific gravity 6m Clean terminals 6m Check oil level Daily Change filter 6m Drain and replace oil 2y Check for leaks Daily Check hose connections 30d Check hoses for exterior wear 30d Emergency Hydraulic System Operate the emergency lowering valve and check for serviceability Daily Controller Check switch operation Daily Hydraulic System Control Cable Platform Deck and Rails Check the exterior of the cable for pinching, binding or wear Daily Check fasteners for proper torque 6m Check welds for cracks Check condition of deck Check for damage Tires Hydraulic Pump Y N R COMPONENT Drive Motors Steering System Elevating Assembly INSPECTION OR SERVICES Check for operation and leaks Lift Cylinder Daily Daily 6m Grease pivot pins 30d Oil king pins 30d Check steering cylinder for leaks 30d Inspect for structural cracks Daily Check pivot points for wear 6m Check mounting pin pivot bolts for proper torque 6m Daily 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 6m Check seals for leaks 30d Inspect pivot points for wear 6m Check for and repair collision damage 6m 6m Wipe clean 30d Check for corrosion-remove and repaint 6m Check for leaks at mating surfaces 30d Lubricate 30d Check for hose fitting leaks Daily Check for peeling, missing, or unreadable labels & replace Daily Check mounting bolts for proper torque 113101-000 MX15 / MX19 | Service Manual 6m Labels Check fasteners for proper torque R Daily Check lug nuts (torque to 108 Nm [80 ft. lbs.]) Entire Unit N 6m Check hoses for pinch or rubbing points Check fittings for proper torque Y Daily Check hardware & fittings for proper torque Check elevating arms for bending Chassis INTERVAL 6m Page 2-5 Blocking the Elevating Assembly Section 2 - Service and Repair 2-3 B LOCKING THE E LEVATING A SSEMBLY ! W A R N I N G ! Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly. DO NOT stand in elevating assembly area while deploying or storing brace. Figure 2-2: Blocking the Elevating Assembly ELEVATING ASSEMBLY BRACE INSTALLATION 1. Park the machine on a firm, level surface. Completely unload the platform before deploying the elevating assembly brace. 2. Verify that the Chassis and Platform Emergency Stop Switches are ON by pulling each button out. 3. Turn and hold the Chassis Key Switch to CHASSIS. Push the Chassis Lift/Lower Switch to UP and elevate the platform; • MX15 - approximately 2,1 m (7 ft.). • MX19 - approximately 2,7 m (9 ft,). Elevating Assembly Arm Weldment 4. Rotate the elevating assembly brace towards the rear, holding it perpendicular to the assembly arm weldment. Brace Installed Brace Stored 5. Carefully lower the platform until the end of the elevating assembly arm weldment rests on the brace. ELEVATING ASSEMBLY BRACE STORAGE 1. While holding the brace, slowly raise the platform using the chassis controls until the end of the elevating assembly arm weldment clears the elevating assembly brace. 2. Rotate the elevating assembly brace forward to rest on the chassis. 3. Push the Chassis Lift/Lower Switch to DOWN and completely lower the platform. Page 2-6 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Batteries 2-4 B ATTERIES Electrical Energy for the motor is supplied by four 6 volt batteries wired in series for 24 volts DC. Proper care and maintenance of the batteries and motor will ensure maximum performance from the machine. BATTER Y MAINTENANCE Check the electrolyte level daily. Clean the battery exterior and terminals every 125 hours or three months. Refer to Section 1: General Information for complete battery maintenance instructions. Refer to the Operator Manual included in this Service Manual for specific maintenance and charging instructions. NOTE: If system voltage drops below 17 volts (on a 24 volt system), the charger will not recharge the batteries. If this extreme voltage drop occurs, disconnect and recharge each battery separately using a 6 volt charger to bring the voltage in each up to at least 4 1/2 volts. C A U T I O N If battery water level is not maintained, batteries will not fully charge, creating a low discharge rate. ! W A R N I N G ! Hazard of explosive gas mixture. Keep sparks, flame and smoking materials away from batteries. Always wear safety glasses when working with batteries. Battery fluid is highly corrosive. Thoroughly rinse away any spilled fluid with clean water. Always replace batteries with UpRight batteries or manufacturer approved replacements. Before disconnecting the battery negative (–) lead, make sure all switches are OFF. If ON, a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present. 113101-000 MX15 / MX19 | Service Manual Page 2-7 Batteries Section 2 - Service and Repair BATTERY REPLACEMENT Figure 2-3: Battery Cables There are two batteries located in each door. The four 6 volt batteries are wired in series for 24 volts DC. Battery cables must be installed as shown in the Battery Cable Installation Diagram. RIGHT DOOR Fuse REMOVAL Battery Connector Motor Relay 1. Turn the Chassis Key Switch to the OFF position and push the Chassis and Platform Emergency Stop Switches down to the OFF position. NOTE: If switches are ON, a spark may occur at the negative lead which could cause an explosion if hydrogen gas or fuel vapors are present. Front Charger 2. Open the right-side door and disconnect the battery pack connector. 3. Open the left-side door and disconnect the battery negative (–) lead on battery #1. LEFT DOOR Fuse IMPORTANT: Disconnect the battery negative (–) lead on battery #1 first. Battery Connector Motor Relay 4. Disconnect the remaining battery leads. Battery #3 Battery #4 Controller (B –) Charger 5. Lift the batteries out of the doors. INSTALLATION Controller (B +) Battery #2 Battery #1 Negative Lead NOTE: Replacement batteries must be equal to or greater than the weight of the originals to maintain stability when the platform is elevated. Always replace batteries with UpRight batteries or manufacturer approved replacements weighing 26,3 kg (58 lb.) each. Battery cables must be installed as shown in Figure 2-3. 1. Verify that the Chassis Key Switch and the Chassis and Platform Emergency Stop Switches are in the OFF position. 2. Place the batteries into the doors as shown in Figure 2-3. 3. Connect the battery to battery leads. IMPORTANT: Connect the battery negative (–) lead on battery #1 last. 4. Connect the battery pack connector. Page 2-8 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Switch Adjustments 2-5 S WITCH A DJUSTMENTS ! W A R N I N G ! Always use the elevating assembly brace whenever it is necessary to enter the elevating assembly when the platform is elevated. LEVEL SENSOR INTRODUCTION The Level Sensor has three wires: red-power (24V in), black-ground, white-output (24V out). To verify that the sensor is working properly, there is one LED under the sensor that indicates the sensor is off level. Figure 2-4: Level Sensor ADJUSTMENT 1. Place machine on firm, level surface. 2. Use an Inclinometer (P/N: 10119-000-00) to ensure that the Chassis is level from front to rear and side to side. 3. Open the right door to access the Level Sensor. 4. Adjust the three leveling locknuts until the bubble is centered in the circle on the attached bubble level. TEST 1. Open the right door. 2. Push and hold the sensor off of level while pushing the Chassis Lift Switch to the UP position. • The alarm should sound, and the platform should not lift. 3. Close and latch the door. 113101-000 MX15 / MX19 | Service Manual Level Sensor Page 2-9 Switch Adjustments Section 2 - Service and Repair PROXIMITY SWITCH Refer to Figure 2-5. The Proximity Switch is a magnetically activated switch located near the rear of the chassis on the left side. Its function is determined by the location of the lower elevating assembly tube. PROXIMITY SWITCH FUNCTION A red LED at the rear of the switch should be ON when the elevating assembly tube is next to the switch (the platform is lowered). The Proximity Switch controls the machine operation based upon the proximity of the elevating assembly tube to the Proximity Switch. When Elevating: • The Level Sensor is enabled. • The Depression Mechanism is enabled. • Power to the High Speed Circuit is cut, preventing the machine from travel faster than 1,0 km/h (0.62 mph). When Completely Lowered: • Power is supplied to the High Speed Circuit, allowing the machine to travel up to 3,7 km/h (2.3 mph). TEST ! THE PROXIMITY SWITCH 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 maintenance brace. 1. Turn the Chassis Key Switch ON. • The red LED should be ON. If not, the Proximity Switch may be out of adjustment. 2. Elevate the platform until the elevating assembly tube is clear of the Proximity Switch. • The red LED should turn OFF. 3. Deploy the Maintenance Brace. 4. Place a piece of steel next to the Proximity Switch. • The red LED should turn ON. If it was OFF in Step 1, the Proximity Switch requires adjustment. • If the red LED remains OFF, replace the Proximity Switch. TEST HIGH SPEED CIRCUIT 1. Elevate the platform 30 cm (12 in.). 2. Turn the Lift/Drive Switch to DRIVE and attempt to drive the machine. • If the machine will drive faster than 1,0 km/h (0.62 mph), adjust or replace the switch. REMOVAL AND INSTALLATION 1. Deploy the maintenance brace (see “Blocking the Elevating Assembly” on page 2-6). 2. Disconnect the switch leads. 3. Remove the defective switch and install a new one. 4. Adjust the switch-to elevating assembly tube clearance (see “Proximity Switch Adjustment” on page 2-11). 5. Connect the switch leads. 6. Store the maintenance brace and lower the platform. Page 2-10 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Switch Adjustments PROXIMITY SWITCH ADJUSTMENT Figure 2-5: Proximity Switch Adjustment ! 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 maintenance brace. 1. 2. 3. 4. Maintenance Brace Guide Proximity Switch Adjustment Nuts 1. Deploy the maintenance brace (see “Blocking the Elevating Assembly” on page 2-6). 4 2. Use a clamp to attach a straight guide to the elevating assembly tube. 2 1 3. Measure the gap between the face of the Proximity Switch and the side of the guide that faces the elevating assembly tube. 4. Turn the adjusting nuts on the Proximity Switch to set the gap to within 4,76 mm to 6,35 mm (3/16 to 1/4 in.). 4,75 mm - 6,35 mm (3/16 in. - 1/4 in.) 3 5. Remove the clamp and guide and repeat the test. • If the test fails, the Proximity Switch is defective and must be replaced. 113101-000 MX15 / MX19 | Service Manual Page 2-11 Switch Adjustments Section 2 - Service and Repair PLATFORM CONTROLS Figure 2-6: Platform Controls Refer to Section 4 - Schematics for wiring diagrams. Refer to the Parts Manual for replacement part numbers. ACCESS TO 1 3 2 5 SWITCHES 1. Remove the four screws from the control panel and lift the assembly from the Platform Control box. 9 4 7 2. Unplug the Control Handle wiring harness. 8 6 1. 2. 3. 4. 5. Platform Control Box Platform Control Panel Control Handle Lift/Drive Switch Emergency Stop Switch 6. 7. 8. 9. Horn Button (optional) Contact Block - N.C. Contact Block - N.O./N.C. Contact Block - N.O. CONTROL HANDLE Figure 2-7: Control Handle 1. Remove the Control Handle, if necessary, from Platform Control box. a. Remove the control panel. b. Unplug the control handle wiring harness. c. Remove the four screws from the control handle mounting plate. d. Lower the control handle through the control panel. Boot, Steering Rocker Rocker Pin Rocker, Steering Right Handle Half Steering Switch (2) 2. Remove and replace defective parts. Refer to the Parts Manual for repair parts numbers. Switch, Interlock Left Handle Half Lever, Interlock Boot, Handle Hall Effect Device Page 2-12 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Switch Adjustments CHASSIS CONTROLS Figure 2-8: Chassis Controls Refer to Section 4 - Schematics for wiring diagrams. Refer to the Parts Manual for replacement part numbers. To access the switches and components for repair or replacement; J1 - Platform Controls J2 - Valve Manifold J3 - Chassis J4 - Chassis Controls J5 -Motor Controller 9 1. Disconnect the cable from J4 on the I/O board. 12 J1 J2 10 6 5 4 2 3 7 2 8 1 9 10 11 12 11 2. Remove three capscrews and nuts to remove the controller/ wheel cover assembly, and take the assembly to a workbench. 4 3 3 2 1 5 6 7 1 2 3 4 8 rt Pao. N l 4 3 7 6 5 ria Seo. N 8 3 2 1 1 2 4 J5 5 6 7 8 6 5 4 3 7 2 3. Loosen the cable connector. Remove four screws to remove the cover. • Be careful not to damage the wires as you push the cable through the cover. 8 1 9 10 11 12 J3 J4 Installation is reverse of removal. 4 MOTOR CONTROLLER AND I/O B O A R D D I P SWITCH SETTINGS 5 6 7 Refer to Section 3 - Troubleshooting for motor controller and I/O board dip switch settings. 8 9 MOTOR CONTROLLER To access the motor controller dip switches, open the right door. 1 I/O BOARD To access the I/O board dip switches, open the left door. 10 1. Controller/Wheel Cover Assembly Capscrews and Nuts 2. Cover 3. Cable Connector 4. Hour Meter 5. Emergency Stop Button N.C. Contact Block 6. Lift/Lower Switch - Toggle Switch 113101-000 MX15 / MX19 | Service Manual 7. 8. 9. 10. 11. 12. Key Switch - N.O. Contact Circuit Breaker I/O Board Motor Controller Four Position Dip Switch Eight Position Dip Switch (under cover) Page 2-13 Switch Adjustments Section 2 - Service and Repair E M E R G E N C Y L O W E R I N G VA L V E ! 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 maintenance brace. Figure 2-9: Emergency Lowering Valve The Emergency Lowering Valve is mounted on the lift cylinder. The cable is routed with the power cable along the elevating assembly tubes. REPAIR 1. Deploy the maintenance brace (see “Blocking the Elevating Assembly” on page 2-6). 7 1 2. Inspect the cable. Replace if damaged. 2 3. Inspect the valve. Replace if damaged. 3 4. Check for and clear any blockage in the orifice. Install the orifice with the beveled side toward the cylinder block. 5 5. Adjust the valve. • At the cable mount, adjust the cable cover to stop the inner cable when the valve is fully open. 4 6. Store the maintenance brace and lower the platform. 6 1. Cylinder Block 2. Spring 3. Orifice Page 2-14 4 4. Valve Assembly 5. Cable Mount 6. Cable 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Hydraulic Fluid Reservoir and Filter 2-6 H YDRAULIC F LUID R ESERVOIR AND F ILTER FLUID LEVEL With the platform fully lowered, check the fluid level through the side of the reservoir. The level should be between the MAX (maximum) and MIN (minimum) lines. Figure 2-10: Hydraulic Fluid Reservoir R E S E R V O I R B R E A T H E R /C A P Clean the breather/cap at the same time that the fluid filter is replaced. Use cleaning solvent and blow dry with clean dry compressed air. FLUID AND FILTER REPLACEMENT Drain Hydraulic Fluid 1. Operate the machine for 10-15 minutes to bring the hydraulic fluid up to normal operating temperature. 2. Completely lower the platform and turn the Chassis Key Switch to the OFF position. ! C A U T I O N ! The hydraulic fluid may be of sufficient temperature to cause burns. Wear safety gloves and safety glasses when handling hot fluid. 3. Provide a suitable container to catch the drained fluid. The hydraulic reservoir has a 12,9 liter (3.4 US gal) capacity. 4. Remove the breather/cap and use a pump to remove all hydraulic fluid. IMPORTANT: Dispose of hydraulic fluid properly - contact your local recycler. Filter Replacement 5. Unscrew the filter from the filter assembly (located on the left side of the valve block). 6. Apply a thin film of clean hydraulic fluid to the gasket of the replacement filter. 7. Screw the replacement filter onto the filter head until the gasket makes contact, then rotate the filter ¾ of a turn further. Check Fluid Outlet Screen 8. Disconnect the outlet hose from the reservoir and plug the hose to prevent foreign material from entering. 9. Remove the outlet screen. Clean or replace as necessary. Replenish Hydraulic Fluid 10. Fill the hydraulic reservoir with hydraulic fluid until the fluid level is between the MIN and MAX lines on the reservoir. Do not fill above the MAX line on the reservoir. The hydraulic reservoir has a capacity of 12.9 liter (3.4 US gal). 11. Operate all machine functions and recheck the fluid level. Add fluid if necessary. 113101-000 MX15 / MX19 | Service Manual Page 2-15 Hydraulic Pressure Settings Section 2 - Service and Repair 2-7 H YDRAULIC P RESSURE S ETTINGS Check the hydraulic pressures whenever the pump, manifold, or relief valves have been serviced or replaced. ! W A R N I N G ! The hydraulic fluid may be of sufficient temperature to cause burns. Wear safety gloves and safety glasses when handling hot fluid. The fluid in the hydraulic system is under very high pressure which can easily cause severe cuts. Obtain medical assistance immediately if cut by hydraulic fluid. M A I N R E L I E F VA L V E 1. Operate the hydraulic system 10-15 minutes to warm the fluid. 2. Slowly drive the machine to within 8 cm (3 in.) of a solid, immovable brick wall. Ease the machine forward until the front of the chassis is in solid contact with the wall. 3. Remove the test port cap and install a pressure gauge capable or reading up to 250 bar (3500 psi) onto the test port. 4. Remove the protective end-cap on the Main Relief Valve and turn the adjusting screw counterclockwise two full turns. 5. Unhook the Platform Controls from the guardrail so that the machine may be operated from the ground. Slowly push the Control Handle in the direction of the wall. 6. Slowly turn the Main Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 207 bar (3000 psi). 7. Replace the protective end-cap on the Main Relief Valve. 8. Remove the pressure gauge and replace the test port cap. L I F T RE L I E F VA L V E 1. Operate the hydraulic system 10-15 minutes to warm the fluid. 2. Remove the protective end-cap on the Lift Relief Valve and turn the adjusting screw counterclockwise two full turns. 3. Place the maximum rated load on the platform (see the Specifications Table in the Operator Manual). 4. Turn and hold the Chassis Key Switch to CHASSIS. Push the Chassis Lift Switch to the UP position and hold it there. 5. Slowly turn the Lift Relief Valve adjusting screw clockwise to increase the pressure until the platform just begins to rise. 6. Release the Chassis Lift Switch. Replace the protective end-cap on the Lift Relief Valve. S T E E R I N G R E L I E F VA L V E 1. Operate the machine for 10-15 minutes to bring the hydraulic fluid up to normal operating temperature. 2. Remove the test port cap and install a pressure gauge capable or reading up to 250 bar (3500 psi) onto the test port. 3. Remove the protective end-cap on the Steering Relief Valve and turn the adjusting screw counterclockwise two full turns. 4. While one person holds the Steering Switch to steer to the right or left, slowly turn the Steering Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 82,7 bar (1200 psi). 5. Replace the protective end-cap on the Steering Relief Valve cover. 6. Remove the pressure gauge and replace the test port cap. Page 2-16 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Hydraulic Pressure Settings C O U N T E R B A L A N C E VA L V E S 1. Operate the machine for 10-15 minutes to bring the hydraulic fluid up to normal operating temperature. 2. Remove the test port cap and install a pressure gauge capable or reading up to 250 bar (3500 psi) onto the test port. 3. Lift the machine and support the chassis with jackstands so that the drive wheels are off the ground. 4. Loosen the locknuts on Counterbalance Valves. 5. With the Chassis Key Switch on DECK and the Drive/Lift Switch in DRIVE depress the Interlock Lever and slowly pull the Control Handle to REVERSE to drive the wheels. 6. Adjust the Forward Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 55 bar (800 psi). 7. Slowly push the Control Handle to FORWARD to drive the wheels. 8. Adjust the Reverse Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 55 bar (800 psi). 9. Check the settings by slowly moving the Control Handle FORWARD, then REVERSE, checking the gauge to ensure that the pressures are properly set. Readjust as needed. 10. Tighten the locknuts on the valves to 8 N-m (6 ft./lbs.). 11. Remove the pressure gauge and replace the test port cap. 12. Remove the blocks and lower the machine to the ground. 13. Check for proper operation of the drive system. Figure 2-11: Hydraulic Manifold Test Ports, from right side (M oun Left ting Top Su rfa ce) Bott om Rig ht r ea R t n Fro Test Port Main Relief Valve Steering Relief Valve Flow Divider Valve 113101-000 MX15 / MX19 | Service Manual Reverse Lift Relief Counterbalance Valve Valves Forward Counterbalance Valve Page 2-17 Hydraulic Manifold Section 2 - Service and Repair 2-8 H YDRAULIC M ANIFOLD It is not necessary to remove the manifold to perform all maintenance procedures. Decide beforehand as to whether or not the manifold should be removed before maintenance procedures begin. REMOVAL, REPAIR AND INSTALLATION Refer to Section 1 - General Information for removal, repair and installation instructions. Figure 2-12: Hydraulic Manifold 1. Hydraulic Manifold 2. Fitting, Straight 6MB - 6MJ Lift Cylinder Port 3. Fitting, Straight 4MBH - 4MJ Steering Cylinder Ports 4. Fitting, Straight 4MB - 4MJ Depression Cylinder Ports 5. Fitting, Straight 4MB - 4MJ W/ .031 Orifice Depression Cylinder Ports 6. Fitting, Straight 4MB - 4MJ W/ .031 Orifice Brake Port 7. Fitting, Straight 6MB - 6MJ Drive Motor Port 8. Fitting, Straight 6MB - 6MJ Pressure Port (from hydraulic pump) 9. Fitting, 8MB-8FJX Return Port (to reservoir) 10. Steering Relief Valve 11. Flow Divider Valve 12. Steering Solenoid 3 Position - 4 Way Solenoid W/ Coils 13. Lift Solenoid 2 Position - 4 Way Solenoid W/ Coil 14. Gauge Fitting Test Port 15. Check Valve 16. Main Relief Valve 17. Depression Mechanism Valve 2 Position Poppet Valve W/ Coil 18. Drive Solenoid 3 Position - 4 Way Solenoid W/ Coils 19. Counterbalance Valve 20. Lift Relief Valve (M oun ting Top Su rfa 1 ce) 5 Left ar Re 9 10 6 2 3 8 4 7 ht n Fro 11 Rig Bott om t 12 13 14 15 16 17 18 19 Coils oriented with spades away from work ports Page 2-18 20 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Hydraulic Pump 2-9 H YDRAULIC P UMP REMOVAL Figure 2-13: Hydraulic Pump 5 NOTE: If the hydraulic reservoir has not been drained, suitable means for plugging hoses should be provided to prevent excessive fluid loss. 2 3 ! W A R N I N G ! Before disconnecting the battery negative (–) lead, make sure all switches are OFF. If ON, a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present. 1. Open the right door and disconnect the battery connector. 1 1. Inlet Hose 2. Outlet Hose 3. Capscrew 4 4. Pump Assembly 5. Electric Motor 2. Open the left door and disconnect the negative (–) lead on the number 1 battery. 3. Mark, disconnect and plug the hose assemblies. NOTE: It may not be necessary to remove the motor to service or remove the pump. 4. Disconnect the power supply from the motor. 5. Remove the four cap screws from the vibration mounts and lift the motor and pump assembly. 6. Loosen the capscrews and remove the pump assembly from the motor. INSTALLATION Pump to Motor 1. Lubricate the pump shaft with general purpose grease and attach the motor with the capscrews. 2. Using a crisscross pattern, torque each capscrew a little at a time until all capscrews are torqued to 27 N-m (20 ft./lbs.). Pump and Motor Assembly to Chassis 3. Position the motor and vibration mounts into the chassis. 4. Put a drop of Loctite® 242 thread lock on each capscrew as you install the capscrew and lock washer. 5. Tighten the motor mount nuts to 24 N-m (18 ft./lbs.). 6. Unplug and connect the hydraulic hoses. 7. Connect the power supply to the motor. 8. Connect the battery negative (–) lead. 9. Connect the battery pack connector. 10. Check the fluid level in the hydraulic reservoir before operating the machine. 113101-000 MX15 / MX19 | Service Manual Page 2-19 Hydraulic Drive Motors Section 2 - Service and Repair 2-10 H YDRAULIC D RIVE M OTORS DRIVE MOTORS Figure 2-14: Drive Motor REMOVAL 1. Chock the rear wheels to prevent the machine from rolling. • Use a 1000 Kg (1 ton) capacity jack to raise the front of the machine. • Place two 1000 Kg (1 ton) jackstands beneath the machine for support. • Remove the jack. 1 2. Remove the cotter pin and slotted nut. 3. Remove the wheel. 3 4 NOTE: It may be necessary to use a wheel puller to remove the wheel. 4. Remove the shaft key. IMPORTANT: Before disconnecting any hoses, thoroughly clean off all the outside dirt around the fittings. IMMEDIATELY plug the holes after disconnecting the hoses and before removing the motor from the machine. 5. Tag, disconnect and plug the hose assemblies to prevent foreign material from entering. 5 6 2 7 8 6 1. 2. 3. 4. Chassis Cotter Pin and Slotted Nut Wheel Shaft Key 5. Hydraulic Hoses 6. Locknuts, Washers and Capscrews 7. Drive Motor 8. Wheel Yoke 6. Remove the locknuts, washers and capscrews. 7. Remove the drive motor. INSTALLATION 1. Position the drive motor into the wheel yoke and secure it with capscrews and locknuts. 2. Torque the locknuts to 95 N-m (70 ft./lbs.). 3. Remove the plugs from the hose assemblies and connect them to the drive motor. 4. Clean the motor shaft and hub bore and lubricate the slotted nut face and threads. 5. Install the shaft key, wheel, and slotted nut. Torque the slotted nut to 95-108 N-m (70-80 ft./lbs.). 6. Install a new cotter pin. DO NOT back-off the nut to install the cotter pin. 7. Remove the jackstands and lower the machine to the ground. 8. Check the fluid level in the hydraulic reservoir before operating the machine. 9. Operate the drive system and check for leaks. Page 2-20 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Hydraulic Drive Motors BRAKE SERVICE If brake service or repair is required, replace all serviceable parts. Refer to the Parts Manual for the brake service kit part number. Refer to Figure 2-15 when assembling the motor. Torque the rotor bolts [1] and the front flange bolts [34] to 54 N-m (40 ft.lbs.). Brake Adjustment 1. Using a 13 mm socket wrench, alternately turn the brake release nuts counter-clockwise in ½ turn increments. Repeat until there is approximately 3.2 mm (1/8 in.) between the brake release nuts and the drive motor body. 2. After installing the motors, verify that the brakes have fully engaged before operating the machine. Refer to the Operator Manual. Figure 2-15: Drive Motor Exploded View 17 Non-Serviceable Parts 1 Rotor Bolts 2 Washer 3 End-cap 5 Rotor 6 Cardan Shaft 7 Channel Plate 8 Bearing Race 9 Needle Bearing 10 Commutation Valve 11 Output Shaft 12 Balance Plate 13 Spring Washer 15 Washer 16 Needle Bearing 18 Brake Release Nut 20 Bearing Housing 21 Brake Spring 22 Brake Piston 24 Brake Release Bolt 29 Bushing 30 Needle Bearing 33 Front Flange 34 Front Flange Bolts 15 16 15 14 13 12 11 10 9 34 8 7 33 6 32 31 4 30 5 29 4 28 3 27 26 2 25 1 24 23 22 21 21 20 19 18 113101-000 MX15 / MX19 | Service Manual Brake Service Kit 4 O-ring 14 Balance Plate P-ring 17 High Pressure Shaft Seal 19 O-ring 23 O-ring 25 O-ring 26 O-ring 27 O-ring 28 Brake Disc Set 31 Standard Shaft Seal 32 O-ring Page 2-21 Hydraulic Drive Motors Section 2 - Service and Repair REAR WHEELS Figure 2-16: Rear Wheel REMOVAL 1. Chock the front wheels to prevent the machine from rolling. • Use a 1000 Kg (1 U.S. ton) capacity jack to raise the rear of the machine. • Place two 1000 Kg (1 U.S. ton) jackstands beneath the machine for support. • Remove the jack. 1. 2. 3. 4. 5. Wheel Axle Shaft Washer Slotted Nut Cotter Key 1 2. Remove the cotter pin and slotted nut. 3. Remove the wheel. INSTALLATION 5 3 4 2 NOTE: If you are installing a new wheel, it may be necessary to ream the hub bore. 1. Clean the axle shaft and hub bore. 2. Lubricate the slotted nut face and threads. 3. Position the wheel onto the axle shaft. 4. Tighten slotted nut until it is snug, then back-off until the wheel turns freely and install a new cotter pin. 5. Remove the jackstands and lower the machine to the ground. Page 2-22 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Steering Cylinder 2-11 S TEERING C YLINDER REMOVAL Figure 2-17: Steering Cylinder Installation 1. Turn the wheels to the straight position. 2 IMPORTANT: Before disconnecting any hoses, thoroughly clean off all the outside dirt around the fittings. IMMEDIATELY plug the holes after disconnecting the hoses and before removing the cylinder from the machine. 9 10 2. Elevate the platform and block the elevating assembly with the brace (see “Blocking the Elevating Assembly” on page 2-6). 6 3. Tag and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering. 5 7 4. Remove the retaining rings from the pivot pins. 5. While supporting the cylinder, remove the locknuts, washers, and capscrews. 6. Remove the cylinder. 3 8 REPAIR 1. 2. 3. 4. 5. Refer to Section 1 - General Information for disassembly, cleaning and inspection, and assembly instructions. 4 1 6. Steer Guide/Cylinder Mount 7. Bearing 8. Capscrew 9. Locknut and Washer 10. Wheel Yolk Steering Cylinder Steering Link Pivot Pin Retaining Ring Bearing INSTALLATION Figure 2-18: Steering Cylinder Assembly 1. Position the cylinder assembly in the chassis. 4 2. Insert the capscrews into the steer guide/ cylinder mounts, up through the chassis, and secure with washers and locknuts. 3 B 2 1 IMPORTANT: If capscrews are inserted down through the chassis the ends of the capscrews will protrude through the bottom of the steer guide/ cylinder mount and may rub and cut the hydraulic hoses. A 3. Insert pivot pins and secure with retaining rings. A. Tube Assembly B. Head C. Rod and Piston C 4. Connect the hose assemblies to the fittings. 5. Operate the steering circuit several times throughout its entire range of travel to expel trapped air, then check for leaks. 6 5 1 2 B Seal Kit Includes: Description Qty 1. Back-up 2 2. O-Ring 2 3. Seal 2 4. Wiper 2 5. Wear Ring 1 6. Seal 1 3 4 113101-000 MX15 / MX19 | Service Manual Page 2-23 Depression Mechanism Cylinder Section 2 - Service and Repair 2-12 D EPRESSION M ECHANISM C YLINDER REMOVAL Figure 2-19: Depression Mechanism Cylinder 1. Open the module door to access the cylinder. 2. Tag and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering. 3. Remove the cotter rue ring from the upper pivot pin. 1 4 5 2 4. Remove the cotter pin from the lower pivot pin. 5. While supporting the cylinder, remove pivot pins and lift the cylinder out. REPAIR Refer to Section 1 - General Information for disassembly, cleaning and inspection, and assembly instructions. 7 6 7 1. 2. 3. 4. 3 9 8 5. 6. 7. 8. 9. Depression Cylinder Mount Depression Cylinder Depression Rail Upper Pivot Pin Cotter Rue Ring Lower Pivot Pin Cotter Pin Bearing Flat Washers INSTALLATION Figure 2-20: Depression Mechanism Cylinder 1. Position the cylinder assembly in the chassis. Insert the pivot pins and secure with new cotter pins. A A. B. C. D. 2. Connect the hose assemblies to the fittings. 3. Operate the steering circuit several times throughout its entire range of travel to expel trapped air, then check for leaks. Rod Head Piston Tube 1 Seal Kit Includes: Description Qty 1. Seal 1 2. O-Ring 1 3. Seal 1 4. Wiper 1 B 2 C 3 4 D Page 2-24 113101-000 MX15 / MX19 | Service Manual Section 2 - Service and Repair Lift Cylinder 2-13 L IFT C YLINDER REMOVAL Refer to Figure 2-21. 1. Elevate the platform and deploy the maintenance brace (see “Blocking the Elevating Assembly” on page 2-6). 2. Provide a suitable container to catch the hydraulic fluid, then disconnect the hydraulic hoses. Immediately plug hoses to prevent foreign material from entering. 3. Remove emergency lowering valve cable and down valve wires from the emergency lowering (down) valve. 4. Remove the cable bracket from the lift cylinder. 5. Remove capscrews and locknuts securing lift cylinder pivot pins. 6. Remove lower pivot pin and lower cylinder to rest on chassis. 7. Attach a suitable hoisting device and sling to the cylinder, and remove upper pivot pin. 8. Carefully remove cylinder. Figure 2-21: Lift Cylinder Location 1. Lift Cylinder 2. Pivot Pin 3. Capscrew and Locknut 3 1 2 113101-000 MX15 / MX19 | Service Manual Page 2-25 Lift Cylinder Section 2 - Service and Repair REPAIR Refer to Section 1 - General Information for disassembly, cleaning and inspection, and assembly instructions. Figure 2-22: Lift Cylinder Assembly INSTALLATION 1. Coat both pivot pins with anti-seize compound. 2. Attach a suitable hoisting device and sling to the cylinder. Carefully position cylinder in the elevating assembly, and install the upper pivot pin. 3. Install the capscrew and locknut securing the upper pivot pin. 4. Carefully lift the cylinder and align the lower mount, and install the pivot pin. B C A. B. C. D. Rod Piston Cylinder Barrel Seal Retainer (Head) Seal Kit Includes: Description 1. Static Seal 2. Wear Ring 3. Rod Seal 4. Rod Wiper D 4 1 2 Qty 1 1 1 1 3 A 5. Install the capscrew and locknut securing the lower pivot pin. 6. Connect the emergency lowering valve cable and down valve wires. 7. Unplug hydraulic hoses and attach to the cylinder. 8. Replace hydraulic fluid removed from lift cylinder. 9. Test with weight at rated platform load to check system operation. 10. Check for leaks 11. Check level of hydraulic fluid. Page 2-26 113101-000 MX15 / MX19 | Service Manual Section 3 TROUBLESHOOTING This section contains troubleshooting Truth Tables. 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 toll free number for service assistance. Referring to the Operator Manual and the Schematics section will aid in understanding the operation and function of the various components and systems of the machine and help in diagnosing and repair of the machine. ! W A R N I N G ! When troubleshooting, ensure that the machine is resting on a firm, level surface. When performing any service which requires the platform to be raised, the Elevating Assembly must be blocked. Disconnect the battery when replacing or testing the continuity of any electrical component. TABLE OF C ONTENTS 3-1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-2 General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-3 Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-4 Motor Controller Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Default Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Adjusted Dip Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-5 I/O Board Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Optional Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-6 LED Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-7 LEDs at I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-8 I/O Board Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-9 Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3-10 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 113101-000 MX15 / MX19 | Service Manual Page 3-1 Section 3 - Troubleshooting L IST OF F IGURES Figure 3-1: Hydraulic Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-2: Controller Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-3: I/O Board Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4: Motor Controller Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-5: I/O Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-4 3-5 3-6 3-7 L IST OF TABLES Table 3-1: LED Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Table 3-2: Connector J1 – Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Table 3-3: Connector J2 – Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Table 3-4: Connector J3 – Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Table 3-5: Connector J4 – Chassis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Table 3-6: Connector J5 - Motor Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Table 3-7: Electrical Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Table 3-8: Hydraulic Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Page 3-2 113101-000 MX15 / MX19 | Service Manual Section 3 - Troubleshooting Technical Support 3-1 TECHNICAL S UPPORT Technical Support is available by telephone or FAX. U P R IGHT USA Tel: 1-800-926-5438 FAX: 1-559-662-4785 U P R IGHT E UROPE Tel: +353-1-620-9300 FAX: +353-1-620-9301 3-2 G ENERAL P ROCEDURE Thoroughly study hydraulic and electric schematics in Section 3 - Schematics. Check for loose connections and short circuits. Check/repair/replace each component in the Truth Table which is listed under each machine function which does not operate properly. Determine whether the problem is mechanical (interference), electrical or hydraulic. Some functions require power at more than one solenoid. Use the charts on the following pages to help determine the cause of a fault in your UpRight Aerial Work Platform. NOTE: Spike protection diodes at components have been left out of the charts to eliminate confusion. 3-3 TROUBLESHOOTING P ROCEDURES 1. Verify your problem. Do a full function test from both platform controls 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. To aid in troubleshooting, the letters following the component on the table are the same as the component’s designation on the schematics. 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 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 according to specifications. ADJUSTMENT PROCEDURES Figure 3-1: Hydraulic Test Port • 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. NOTE: Correct pressure settings are listed in the hydraulic schematic. Test Port 113101-000 MX15 / MX19 | Service Manual Page 3-3 Motor Controller Dip Switch Settings Section 3 - Troubleshooting 3-4 M OTOR C ONTROLLER D IP S WITCH S ETTINGS Figure 3-2: Controller Dip Switch The Dip Switch is located behind a snap-out cover on the side of the Motor Controller. Slide your fingernail or a small screw driver under the edge of the cover at the middle and pry it off. DEFAULT DIP SWITCH SETTINGS The table shows the default dip switch settings on the controller box when the machine leaves the factory. MX15/19 1 2 3 4 5 6 7 8 OFF OFF OFF ON OFF ON OFF ON SL20 ON OFF OFF ON OFF ON OFF ON TM12 OFF OFF OFF ON OFF ON OFF ON ON X20N ON OFF OFF ON OFF ON OFF X20W ON OFF OFF ON OFF ON OFF ON X26UN ON ON OFF OFF OFF ON OFF ON X26/32 ON ON OFF ON OFF OFF OFF ON ADJUSTED DIP SWITCH SETTINGS The following adjustments may be made to the dip switch settings. CREEP SPEED Switches 3 & 4 determine the elevated “creep” speed. If the machine does not operate at the specified speed at the default settings, use the following table to adjust the dip switch settings. Creep Speed 3 4 1 (slowest) OFF OFF OFF 2 (slow) ON 3 (default) OFF ON 4 (fastest) ON ON DECELERATION TIME Switches 5 & 6 determine the deceleration time. • Switch 5 determines the deceleration rate while the platform is lowered. • Switch 6 determines the deceleration rate while the platform is elevated. Page 3-4 DECEL 5 6 0.24 sec. OFF OFF 1.27 sec. ON ON 113101-000 MX15 / MX19 | Service Manual Section 3 - Troubleshooting I/O Board Dip Switch Settings 3-5 I/O B OARD D IP S WITCH S ETTINGS Figure 3-3: I/O Board Dip Switch 1 2 3 4 DEFAULT SETTINGS The table shows the default dip switch settings on the I/O board when the machine leaves the factory. 4 OFF OFF SL20 OFF OFF OFF OFF TM12 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF X26UN OFF OFF OFF OFF X26/32 OFF OFF OFF OFF 2 7 1 8 3 4 X20N X20W 1 2 3 4 1 2 3 4 5 6 8 7 6 5 12 11 10 9 8 7 5 3 OFF 6 2 OFF 1 2 3 4 1 MX15/19 OPTIONAL SETTINGS 1 2 3 4 5 6 1 2 3 4 12 11 10 9 8 7 8 7 6 5 The table shows the result of each switch setting on the I/O board Dip Switch. Switches 3 & 4 work together to determine the optional alarm settings. 1 2 3 4 RESULT ON — — — Two Speed Mode (not used) Proportional Control OFF — — — — ON — — not used — Depression Mechanism extends when platform is raised — OFF — — — OFF OFF Down alarm only — — ON OFF Down and Reverse alarm — — OFF ON Drive and Down alarm — — ON ON All Motion alarm 113101-000 MX15 / MX19 | Service Manual Page 3-5 LED Fault Codes Section 3 - Troubleshooting 3-6 LED F AULT C ODES Batteries must be fully charged before troubleshooting. Check/Repair all connections before replacing any components Figure 3-4: Motor Controller Connections M2 Terminal B– Terminal B+ Terminal LED Indicator NOTE: Before dip switch settings will take effect, power must be disconnected or Emergency Stop switches must be depressed. Table 3-1: LED Fault Codes Flash Code Meaning Status Corrective Action LED on Power to the controller and • System is functional the controller is operational. • None. LED off No power to the controller, or • Battery cables not connected properly internal fault in the controller. • Failed controller • Check battery cable connections. • Replace the controller. 2 Flash Procedural fault. • Lift, drive, or steer switch is engaged at start-up • Drive/Lift switch rotated while operating • Cycle the Control Handle through neutral to clear fault. 3 Flash Controller senses B– at the M2 terminal. • Short circuit at the motor • M2 cable in contact with B– cable • Short circuit within controller • Check cable routing and connections. • Test terminals for source of B–. • Replace the controller 4 Flash Controller senses B+ at the • B+ cable routed incorrectly M2 terminal before engaging • M2 cable making contact with B+ cable the Motor Start relay. • Motor Start relay contacts welded closed. • Check cable routing and connections. • Test terminals for source of B+. • Replace the Motor Start relay. 5 Flash Controller senses open circuit • Cables loose or not connected at M2 after engaging the • Faulty Motor Start relay Motor Start terminal. • Check the cable routing and connections. • Check the signal from Motor Controller to relay. • Check/replace the Motor Start relay. 6 Flash Faulty signal from Control Handle or I/O board. • If Platform Controls are affected, check/replace the Control Handle. • If Chassis Controls are affected, check/replace the I/O board. 7 Flash Battery voltage below 12V or • Dead batteries above 45V. • Bad cable connections 8 Flash Thermal cut-off. Page 3-6 • Faulty Control Handle • Wiring error • Check batteries and cable connections. • Controller is overheated due to overuse or other failure • Allow system to cool. • Locate and repair other source of overheat. 113101-000 MX15 / MX19 | Service Manual Section 3 - Troubleshooting LEDs at I/O Board 3-7 LED S AT I/O B OARD GREEN LED ON The Green LED indicates that power is present at the board. RED LED ON The Red LED indicates a short in the system. To locate the problem; 1. Push both E-Stop switches to the OFF position. 2. Turn the Keyswitch to the OFF position, then to either Platform or Chassis. 3. Pull both E-Stop switches to the ON position. • The Green LED should be ON. • The Red LED should be OFF. 4. Perform all machine functions until the Red LED is ON. Determine which function activated the Red LED and check all components that are active for that function. Figure 3-5: I/O Board Connections Grey J2 Green LED 1 2 3 4 1 2 3 4 5 6 8 7 6 5 12 11 10 9 8 7 1 2 3 4 5 6 1 2 3 4 12 11 10 9 8 7 8 7 6 5 7 8 6 2 1 J5 3 4 Dip Switch 5 1 2 3 4 Red LED J1 Black J4 113101-000 MX15 / MX19 | Service Manual J3 Green Page 3-7 I/O Board Inputs and Outputs Section 3 - Troubleshooting 3-8 I/O B OARD I NPUTS AND O UTPUTS Refer to Figure Figure 3-5: “I/O Board Connections,” on page 3-7. PERFORM TESTS WITH FULLY CHARGED BATTERIES Battery state of charge will affect readings. BV = BATTERY VOLTAGE Readings within a few volts of current battery state of charge will be called BV. ØV ØV is generally Ø up to 1 volt. VOLTAGE READINGS FOR ELECTRONICS ARE RARELY EXACT Many factors can affect readings, such as state of charge, voltage drops through switches (mechanical or electrical), and wires. Be sure that both the Platform and Chassis Emergency Stop Switches are pulled out to the ON position. All voltages are measured between the component and the B– terminal on the Motor Controller. NOTE: For the I/O board to be powered up (Green LED illuminated), both E-Stops must be closed and either Platform Controls or Chassis Controls selected by the Keyswitch. Table 3-2: Connector J1 – Platform Controls Page 3-8 PIN PIN DESCRIPTION J1-1 Lift input from Lift/Drive selector switch J1-2 Not Used CONDITION VOLTAGE Lift selected BV Lift not selected ØV — — Drive selected BV Drive not selected ØV J1-3 Drive input from Lift/Drive selector switch J1-4 Lower E-Stop activation (output from I/O board when lower E-Stop is closed) Lower E-Stop closed BV Lower E-Stop open ØV J1-5 Upper E-Stop activation (output to I/O board when upper E-Stop is closed) Upper E-Stop closed BV Upper E-Stop open ØV J1-6 Power to Platform Controls when selected by Keyswitch J1-7 CONTINUOUS TO PIN — — — J4-9 J4-2 Platform Controls selected BV Platform Controls not selected ØV Not Used — — — J1-8 Controller direction “A” (up/forward) Control Handle pushed forward 20-22V — J1-9 Controller direction “B” (down/reverse) Control Handle pushed forward 20-22V — J1-10 Speed signal from Control Handle Signal starts high and drops proportionally as Control Handle is moved in either direction 4.3V dropping to 0.2V — J1-11 Steer Left input from Steering switch J1-12 Steer Right input from Steering switch Steer Left selected 23V Steer Left not selected ØV Steer Right selected 23V Steer Right not selected ØV J4-10 — — 113101-000 MX15 / MX19 | Service Manual Section 3 - Troubleshooting I/O Board Inputs and Outputs Table 3-3: Connector J2 – Valve Manifold PIN PIN DESCRIPTION J2-1 Depression mechanism activation (extend) J2-2 Not Used J2-3 24 Volt supply for solenoids J2-4 Forward solenoid activation J2-5 Reverse solenoid activation J2-6 Up solenoid activation J2-7 Steer Left solenoid activation J2-8 Steer Right solenoid activation CONDITION VOLTAGE Lift Up requested ØV Lift Up not requested BV — — Upper & Lower E-Stops closed BV Upper or Lower E-Stop open ØV Forward requested ØV Forward not requested BV Reverse requested ØV Reverse not requested BV Up requested ØV Up not requested BV Steer Left requested ØV Steer Left not requested BV Steer Right requested ØV Steer Right not requested BV CONTINUOUS TO PIN — — J4-5 & J3-3 — — — — — Table 3-4: Connector J3 – Chassis PIN PIN DESCRIPTION CONDITION J3-1 Alarm activation Alarm sounding (out of level unit lowering, etc.) VOLTAGE CONTINUOUS TO PIN † — † If the alarm is sounding because the unit is out of level, BV will drop to ØV as long as the alarm is sounding. If the alarm is sounding because the unit is lowering, there will be alternating high and low voltages (the voltages will vary). Unit within Level Sensor angle BV Unit outside Level Sensor angle ØV J3-2 Level Sensor output signal J3-3 24 Volt supply for Alarm, Level Sensor and solenoids, J3-4 Input from platform down Proximity Switch J3-5 Down solenoid activation J3-6 Depression mechanism activation (retract) J3-7 Not Used — — — J3-8 Battery negative supply for Level sensor and Proximity switch — B– J4-11 113101-000 MX15 / MX19 | Service Manual Upper & Lower E-Stops closed BV Upper or Lower E-Stop open ØV Above Proximity switch ØV Below Proximity switch BV Down requested ØV Down not requested BV Drive requested ØV Drive not requested BV — J2-3 & J4-5 — — — Page 3-9 I/O Board Inputs and Outputs Section 3 - Troubleshooting Table 3-5: Connector J4 – Chassis Controls PIN PIN DESCRIPTION J4-1 Motor Start relay and Hourmeter activation J4-2 24 Volt supply to Keyswitch J4-3 Chassis Controls selected from Keyswitch J4-4 24 Volt supply to chassis Up/Down switch CONDITION VOLTAGE Drive, Lift or Steer requested ØV Drive, Lift or Steer not requested BV Upper & Lower E-Stops closed BV Upper or Lower E-Stop open ØV Chassis Controls selected BV Chassis Controls not selected ØV — ‡ CONTINUOUS TO PIN — — — — ‡ Keyswitch must be held to Chassis Controls position to measure BV J4-5 24 Volt supply to Keyswitch J4-6 Not Used J4-7 Up signal from Chassis Controls J4-8 Down signal from Chassis Controls J4-9 Lower E-Stop activation (input to I/O board when E-Stop is closed) J4-10 Power output to Platform Controls J4-11 J4-12 Upper & Lower E-Stops closed BV Upper or Lower E-Stop open ØV — — Up requested from Chassis Controls BV Up not requested from Chassis Controls ØV Down requested from Chassis Controls BV Down not requested from Chassis Controls ØV Lower E-Stop closed BV Lower E-Stop open ØV J2-3 & J3-3 — — — J1-4 Platform selected at Keyswitch BV Platform not selected at Keyswitch ØV Battery negative supply to I/O Board — B– — 24 Volt supply to Hourmeter and Line Contactor coil Upper & Lower E-Stops closed and Platform Controls or Chassis Controls selected BV — VOLTAGE CONTINUOUS TO PIN — J1-6 Table 3-6: Connector J5 - Motor Controller Page 3-10 PIN PIN DESCRIPTION CONDITION J5-1 24 Volt supply to EMC motor controller Upper & Lower E-Stops closed and Platform Controls or Chassis Controls selected BV J5-2 Drive signal to EMC motor controller Forward/Reverse requested 15V Forward/Reverse not requested ØV J5-3 Steer signal to EMC motor controller Steer Right/Steer Left requested 15V Steer Right/Steer Left not requested ØV J5-4 Up signal to EMC motor controller Up requested 15V Up not requested ØV J5-5 Speed Reduction signal to EMC motor controller J5-6 Line Contactor activation signal J5-7 Direction enable J5-8 Speed signal to EMC motor controller Below Proximity switch 15V - 17V Above Proximity switch ØV Drive, Lift or Steer requested ØV Drive, Lift or Steer not requested BV Forward/Reverse requested ØV Forward/Reverse not requested 4.0V - 4.3V Signal starts high and drops proportionally as Control Handle is moved in either direction 4.3V dropping to 0.2V — — — — — — — 113101-000 MX15 / MX19 | Service Manual Section 3 - Troubleshooting Electric 3-9 E LECTRIC Drive Reverse High Speed/Creep Raise Platform Lower Platform Steer Left Steer Right Depression Mechanism Extend Depression Mechanism Retract Brakes Level Alarm Down Alarm X X X X X X X X X X X X X X X X X X X X Alarm BAT Batteries CHG Battery Charger X F1 5 AMP Circuit Breaker X X X X X X X X X X X X X X X X X X X X X X X X F2 175 AMP Fuse HM Hour Meter/low Voltage Indicator I/O I/O Board X X X X X X X X X X X X MC Motor Control X X X X X X X X X X X X MOT Motor X X X X X X X X X X R1 Motor Relay X X X X X X X X X X S1 Chassis Emergency Stop Switch X X X X X X X X X X X X S2 Chassis Lift Switch X X X X X X X X X X X X X X X X X X X X X X X S3 Chassis Key Switch S4 Lift/Drive Selector Switch S5 Proximity Switch X X X X X X X X X X X S7 Platform Emergency Stop Switch X X X X X X X X S8 Interlock Switch X X X X X X X X S9 Control Handle X X X X X S10 Platform Steering Switch X X X X X X X X X SNSR Level Sensor SOL1A Steering Solenoid (right) SOL1B Steering Solenoid (left) SOL2A Platform Lift Solenoid SOL2B Down Solenoid (Emergency Lowering) SOL3A Depression Mechanism Extension Solenoid SOL3B Depression Mechanism Retraction Solenoid (2) SOL4A Reverse Solenoid SOL4B Forward Solenoid 113101-000 MX15 / MX19 | Service Manual Battery Charge Drive Forward ALM1 Upper Controls Component Lower Controls Function Table 3-7: Electrical Troubleshooting Table X X X X X X X X X X X Page 3-11 Hydraulic Section 3 - Troubleshooting 3-10 H YDRAULIC Table 3-8: Hydraulic Troubleshooting Table Page 3-12 Steering Cylinder CYL2 Lift Cylinder CYL3 Depression Mechanism Cylinder (2) DVDR Priority Flow Divider DVR2 Series Parallel Flow Divider X X X X X X X X X X X X X X FL1 Suction Strainer X X X X X X X X FL2 Return Filter X X X X X X X X MOT Drive Motors (2) X X OR1 Lift Cylinder Orifice OR2 Depression Mechanism Orifice (2) X OR3 Brake Orifice PMP Pump X RES Reservoir X RV1 Steering Relief Valve RV2 Lift Relief Valve X RV3 Main Relief Valve X V1 Steering Right/Left Valve V2A Lift Valve Brakes Depression Mechanism Retract X Check Valve CYL1 Depression Mechanism Extend X Creep X Drive Reverse Steer Left X Drive Forward Steer Right CV Lower Platform Component Lift Platform Function .\ X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X V2B Down/Emergency Lowering Valve V3A Depression Mechanism Extend Valve X V3B Depression Mechanism Retract Valve (2) V4 Forward/Reverse Valve X X V5 Series Parallel Valve (2) X X X V6 Counterbalance Valve (2) X X X X X X 113101-000 MX15 / MX19 | Service Manual Section 4 S CHEMATICS This section contains electrical and hydraulic power schematics and associated information for maintenance purposes. The diagrams are to be used in conjunction with the Troubleshooting Truth Tables in Section 3. They allow understanding of the makeup and functions of the systems for checking, tracing, and faultfinding during troubleshooting analysis. The components that comprise the electrical and hydraulic systems are given a reference designation and are explained as to function and location in the following tables. TABLE OF C ONTENTS 4-1 Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-2 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 L IST OF F IGURES Figure 4-1: Electric Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4-2: Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-3: Electrical Wire Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Figure 4-4: Lower Controls Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Figure 4-5: Upper Controls Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Figure 4-6: Upper Controls Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Figure 4-7: Hydraulic Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Figure 4-8: Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Figure 4-9: Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Figure 4-10: Valve Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Figure 4-11: Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 113101-000 MX15 / MX19 | Service Manual Page 4-1 Electric Section 4 - Schematics 4-1 E LECTRIC Legend: Electrical Schematic 065616-027 Reference Name Number ALM1 ALM2 BAT CHG F1 F2 HM I/O MC MOT R1 S1 S2 S3 S4 S5 S7 S8 S9 S10 S12 SNSR SOL1A SOL1B SOL2A SOL2B SOL3A SOL3B SOL4A SOL4B Function Location Alarm Horn (option) Battery Pack Battery Charger 5 AMP Circuit Breaker 175 AMP Fuse Hour Meter I/O Board (Circuit Board) Motor Control Motor Motor Relay Chassis Emergency Stop Switch Chassis Lift Switch Chassis Key Switch Lift/Drive Selector Switch Provides warning sound Provides warning sound Power source for the machine Charges the battery pack Electrical overload protection Overload protection for the electric motor Shows how many hours the machine has been in use Connection point for machine function wiring Controls the speed of the electric motor Provides power to the hydraulic pump Controls the speed of the electric motor Shuts down all machine functions Elevates platform Allows some machine functions to be initiated from ground level Activates lift or drive functions, and high and low speed drive Stops lift assembly at lower limit, cuts out high speed drive when Proximity Switch (Limit Switch) platform is elevated Platform Emergency Stop Switch Shuts down all machine functions Interlock Switch (Trigger) Safety mechanism for control handle Control Handle Proportionally controls the drive and lift functions Platform Steering Switch Control left and right steering solenoids Horn Button (option) Provides power to horn Activates level sensor alarm and disables all machine functions except Level Sensor platform lower when the machine is more than 2° out of level Steering Solenoid (right) Shifts steering valve to the left Steering Solenoid (left) Shifts steering valve to the right Platform Lift Solenoid Elevates platform Down Solenoid (Emergency Lower) Lowers platform Depression Mechanism Extension Solenoid Extends depression mechanism bars Depression Mechanism Retraction Solenoid (2) Retracts depression mechanism bars Reverse Solenoid Shifts forward/reverse valve to reverse Forward Solenoid Shifts forward/reverse valve to forward Control Module Power Module Power Module Power Module Chassis Controls Control Module Chassis Controls Control Module Control Module Control Module Control Module Chassis Controls Chassis Controls Chassis Controls Platform Controls Chassis, Front Platform Controls Platform Controls Platform Controls Platform Controls Platform Controls Chassis, Front Hydraulic Manifold Hydraulic Manifold Hydraulic Manifold Lift Cylinder Hydraulic Manifold Depression Mechanism cylinders Hydraulic Manifold Hyraulic Manifold Figure 4-1: Electric Components Location Chassis Controls F1 HM S1 S2 S3 Lift Cylinder ALM1 MC Cable R1 Motor Connector Alarm Motor Relay Controller I/O Circuit Board Hydraulic Manifold SOL1A SOL1B SOL2A SOL3A SOL4A SOL4B Right Door SOL2B Emergency Lowering Solenoid BAT Battery Pack F2 175 AMP Fuse FRONT MOT Pump Motor SNSR Level Sensor REAR BAT Battery Pack Left Door Page 4-2 ALM2 Horn SOL3B Depression Mechanism Retract Solenoid CHG Battery Charger S5 Proximity Switch Emergency Lowering Control Platform Controls S4 S9 S7 S10 S8 S12 113101-000 MX15 / MX19 | Service Manual Section 4 - Schematics Electric Figure 4-2: Electrical Schematic HM S1 S2 S3 HORN OPTION F1 PLATFORM CONTROLS SOL1A S7 SOL1B SOL2A S12 SOL4A SOL4B SOL3A R1 MOT ALM2 MC CHG I/O F2 BAT RIGHT DOOR CONTROL HANDLE S4 ALM1 S7 SNSR SOL2B SOL3B SOL3B S8 S9 S5 S10 113101-000 MX15 / MX19 | Service Manual Page 4-3 Electric Section 4 - Schematics Page 4-4 RIGHT DOOR LEFT DOOR CHASSIS CHASSIS CONTROLS Figure 4-3: Electrical Wire Routing 113101-000 MX15 / MX19 | Service Manual Section 4 - Schematics Electric Figure 4-4: Lower Controls Components HM Hourmeter S1 Emergency Stop S2 Lift / Lower Switch S3 Key Switch F1 Circuit Breaker 113101-000 MX15 / MX19 | Service Manual Page 4-5 Electric Section 4 - Schematics Figure 4-5: Upper Controls Components S7 Red Mushroom Switch Emergency Stop S8 Interlock Switch Control Panel S10 Rocker Switch Steering S9 Control Handle S4 3-Position Selector Switch Lift/Drive Contact Block Normally Closed Amp Connector (male) Hall Effect Connector Contact Block Normally Open - Normally Closed Amp Connector (female) HORN OPTION Controller Box Contact Block Normally Closed S12 Push Button Page 4-6 113101-000 MX15 / MX19 | Service Manual Section 4 - Schematics Electric Figure 4-6: Upper Controls Wiring S4 S7 S8 S12 S10 113101-000 MX15 / MX19 | Service Manual Page 4-7 Hydraulic Section 4 - Schematics 4-2 H YDRAULIC Legend: Hydraulic Schematic 065615-023 Reference Name number CV CYL1 CYL2 CYL3 DVDR FL1 FL2 MOT OR1 OR2 OR3 PMP RV1 RV2 RV3 RES V1 V2A V2B V3A V3B V4 V5 Check Valve Steering Cylinder Lift Cylinder Depression Mechanism Cylinder (2) Priority Flow Divider Suction Strainer Return Filter Drive Motors (2) Orifice Orifice Orifice Pump Steering Relief Lift Relief Valve Main Relief Valve Reservoir Steering Right/Left Valve Lift Valve Down/Emergency Lowering Valve Depression Mechanism Extend Valve Depression Mechanism Retract Valve (2) Forward/Reverse Valve Counterbalance Valve (2) Function Location Allows depression mechanism to retract in drive mode Provides force to turn front wheels Provides force to lift platform Extends or retracts depression mechanism bar Provides priority fluid flow to steering Traps particles in hydraulic reservoir Filters fluid returning to reservoir Provides tractive effort to move platform Controls the fluid flow rate of the lift cylinder Controls the fluid flow rate of the depression mechanism cylinders Controls the fluid flow rate of the brakes Provides hydraulic pressure for all functions Provides pressure protection to pump and steering components when steering Provides pressure protection to lift system Provides pressure protection to hydraulic system Holds hydraulic fluid Provides directional control for steering Provides fluid control for drive or lift functions Allows fluid to return to reservoir; manually operated for emergency lowering Provides fluid control for depression mechanism bar Provides fluid control for Depression Mechanism bar Provides fluid control for drive or lift functions Provides dynamic braking Hydraulic Manifold Front of Chassis above drive motors Elevating Assembly Front of hydraulic reservoir Hydraulic Manifold Inside hydraulic reservoir at outlet Back of hydraulic reservoir Front motor mounts Lift Cylinder Hydraulic Manifold Hydraulic Manifold On Electric Motor between Battery Modules Hydraulic Manifold Hydraulic Manifold Hydraulic Manifold Rear end of Chassis Hydraulic Manifold Hydraulic Manifold Lift Cylinder Hydraulic Manifold Depression Mechanism Cylinder Hydraulic Manifold Hydraulic Manifold Figure 4-7: Hydraulic Components Location Hydraulic CV Manifold DVR1 RV1 RV2 RV3 CYL2 Lift Cylinder FL2 Return Filter Right Door CYL1 Steering Cylinder V2B - OR Emergency Lowering Solenoid and Orifice FRONT REAR Emergency Lowering Control Left Door RES Hydraulic Reservoir Page 4-8 V1 V2A V3A V4 V6 CYL3 - V3B Depression Mechanism Cylinder and Retract Valve PMP Pump MOT Hydraulic Motors with Parking Brakes FL1 Suction Strainer Filter (Output of Reservoir) 113101-000 MX15 / MX19 | Service Manual Section 4 - Schematics Hydraulic V3A CV OR2 RV2 OR2 FL1 RES PMP FL2 RV3 RV1 V1 CYL1 DVDR V2A OR1 V2B CYL2 V3B CYL3 V3B CYL3 OR3 V4 V5 V5 MOT MOT Figure 4-8: Hydraulic Schematic 113101-000 MX15 / MX19 | Service Manual Page 4-9 Hydraulic Section 4 - Schematics CYL3 RES FL1 CYL3 FL2 PMP CYL2 MOT MOT CYL1 Figure 4-9: Hose Routing Page 4-10 113101-000 MX15 / MX19 | Service Manual Section 4 - Schematics Hydraulic Figure 4-10: Valve Diagram yl on C i ress g p e i D Fitt n der ylin 2 -C n OR Orifice ssio pre ing .031 e D Fitt 2 -OR Orifice .031 tu Re ort eP ur ess Pr Lef Re rake g -- B Fittin 3 OR rifice O .031 e) Top urfac gS ntin t ar u o (M r inde ort rn P g Top untin o (M DR DV V1 -R ve l a e er V f Valv ivid lie D Re w g Flo n i er Ste Rig S t ht Bott om ce) a urf n Fro lve d Va 1 n a ,V id eno , Sol1B l lve o Va A g S ol1A d n i r n e S a , V2 rt Ste oid Sol2A Po n t e l s V Te So -- C t e f r i e u L lv ss V3 Va Pre -R ck lve e h d Va A lve Ch Hig n a a fV oid V3 elie olen 3A, lve R S m OL in Va 4 s i a d n S M ha an , V 5 Mec oid L4B n --V n o i e e s l v l 5 s O o a re S S -- V ce V Dep e ve 4A, n i v a l r l 2 a a D OL ce V terb RV n n S a u l ba Co alve nter ief V l e Cou R Lift Coil oriented with spades away from work ports ce) rfa u gS Top untin o (M #2 #4 #6 #8 Plug #2 Plug #4 Plug #6 Plug #8 113101-000 MX15 / MX19 | Service Manual Rig ) Lef t Re ar e Top urfac S g ntin Bott om ht t n Fro u Mo ( Page 4-11 Hydraulic Section 4 - Schematics Figure 4-11: Cylinders Steering Cylinder Depression Mechanism Cylinder SOL3B & V3B Depression Mechanism Retract Solenoid and Valve Lift Cylinder V2B Manual Emergency Lowering Valve OR1 Orifice (beveled side toward cylinder block) Page 4-12 113101-000 MX15 / MX19 | Service Manual Call Toll Free in U.S.A. 1-800-926-LIFT UpRight, Inc. 801 South Pine Street Madera, California 93637 TEL: 559-662-3900 FAX: 559-673-6184 PARTS: 1-888-UR-PARTS PARTS FAX: 1-800-669-9884 Call Toll Free in U.S.A. 1-800-926-LIFT P/N 113101-000 01-03 UpRight Unit S1, Park West Industrial Park Friel Avenue Nangor Road Dublin 12, Ireland TEL: +353 1 620 9300 FAX: +353 1 620 9301 ">

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Key features
- Telescopic platform
- Extension for greater height
- Compact design
- Robust construction
- Emergency lowering valve
- Level sensor
- Drive or winch for transport
Frequently asked questions
You can release the parking brakes by turning the brake release nuts on each drive motor clockwise, but only when the machine is not operating under its own power.
If the level sensor alarm sounds, the platform must be lowered and the machine moved to a firm, level surface before attempting to elevate or drive.
Check the battery fluid level daily, especially if the machine is being used in a warm, dry climate.