Snorkel UL25, UL32, UL40-01-060200 Parts And Service Manual

PARTS & SERVICES
Serial Number UL25-01-060166 and after
Serial Number UL25-01-060167 and after
Serial Number UL32-01-060036 and after
Serial Number UL32-01-060037 and after
Serial Number UL40-01-060200 and after
Serial Number UL40-01-060201 and after
MANUAL
Part Number 515066-200
July 2017
UL25, UL32 & UL40
ENGLISH
When contacting Snorkel for service or parts information, be sure to include the model and serial
numbers from the equipment name plate. Should the name plate be missing, the serial number
is also stamped on top of the chassis above the front axle pivot.
The serial number is available on
nameplate
Stamped Serial
Number on Rear Axle
MODEL
NUMBER
SERIAL
NUMBER
MONTH / YEAR
OF MANUFACTURE
SLOPE SENSOR ALARM SETTING
NON-LOADED
MACHINE
WEIGHT
lbs
kg
ENGINE
POWERED
MODELS
hp
kW
MAXIMUM
OUTRIGGER
LOAD
lbs
kg
MAXIMUM
GRADEABILITY
Outdoors
lbs
N
MAXIMUM
PLATFORM
HEIGHT
ft
m
Indoors
Outdoors
deg
SIDE
TO SIDE
deg
MAXIMUM
WHEEL
LOAD
lbs
kg
BATTERY
POWERED
MODELS
DRIVE
MOTORS
V
V
Ah
BATTERIES
CHARGER
INPUT
%
Indoors
MAXIMUM
ALLOWABLE
MANUAL FORCE
(SIDE PULL)
RATED NUMBER
OF OCCUPANTS
FRONT
TO BACK
V
MAXIMUM
ALLOWABLE
WIND SPEED
mph
m/s
MAXIMUM
PLATFORM
REACH
ft
m
MAXIMUM
DRIVE
HEIGHT
ft
m
MAXIMUM
PLATFORM
LOAD
ASSEMBLED IN
CAUTION
ONLY trained and authorised personnel may operate this machine.Consult the Operation Manual before using this machine.
DO NOT make any changes to this machine, any changes made will invalidate the manufactures warranty and
may contravene legislation.
Axle weights with machine in the stowed position.
lbs
STEER AXLE
kg
DRIVE AXLE
lbs
kg
USA
Europe
TEL: +1 (559)443 6600
FAX: +1 (559)268 2433
TEL: +44 (0) 1952 200
FAX: +44 (0) 1952 229
www.snorkellifts.com
UL25, UL32 & UL40 SERVICE AND PARTS MANUAL
FOREWORD
This manual is divided into six sections namely;
SECTION 1: INTRODUCTION
General description and machine specifications.
SECTION 2: OPERATION AND SPECIFICATION
Information on how to operate the work platform
and how to prepare it for operation.
SECTION 3: SERVICE AND REPAIR
Preventative maintenance and service information.
SECTION 4: TROUBLESHOOTING
Causes and solutions to typical problems.
SECTION 5: SCHEMATICS
Schematics and valve block diagrams with
description and location of components.
SECTION 6: ILLUSTRATED PARTS BREAKDOWN
Complete parts list with illustrations.
SPECIAL INFORMATION
! D A N G E R !
Indicates an imminently hazardous situation which if not avoided, will result in
death or serious injury.
! W A R N I N G !
Indicates a potentially hazardous situation which if not avoided, could
result in death or serious injury.
! C A U T I O N !
Indicates a potentially hazardous situation which if not avoided,
may result in minor or moderate injury.
NOTE: Provides helpful information.
WORKSHOP PROCEDURES
All information contained in this manual is based on the latest product information available at the
time of printing. We reserve the right to make changes at any time without notice.
No part of this publication may be reproduced, stored in retrieval system or transmitted in any
form by any means whether electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher. This also includes text, figures and tables.
! C A U T I O N !
Detailed prescriptions of standard workshop procedures, safety
principles and service operations are not included.
Please note that this manual contains warnings and cautions
against some specific service methods which could cause personal
injury or could damage a machine or make it unsafe.
Please understand that these warnings cannot cover all conceivable
ways in which service, whether or not recommended by Snorkel,
might be carried out, or of the possible hazardous consequences of
each conceivable way, nor could snorkel investigate all such ways.
Anyone using service procedures or tools whether or not recommended by Snorkel must satisfy themselves thoroughly that neither
personal saftey nor machine safety will be jeopardized.
INTRODUCTION
INTRODUCTION
PURPOSE
The purpose of this service and parts manual is to provide instructions and illustrations for
the operation and maintenance of this work platform manufactured by Snorkel.
SCOPE
The manual includes procedures for proper operation, maintenance, adjustment and repair
of this product as well as recommended maintenance schedules and troubleshooting.
GENERAL DESCRIPTION
The work platform consists of the platform, controller, elevating assembly, power module,
control module and chassis.
! W A R N I N G !
DO NOT use the work platform without
guardrails properly assembled and in place
PLATFORM
The platform has a reinforced steel floor, 1.1 m (43.75 inches) high guardrails with a mid rail,
152 mm (6 inches) toe boards and an entry gate at the rear of the platform.
Features of the UL25/UL32/UL40 is shown in Figure 1-1.
1.
2.
3.
4.
5.
6.
Platform
Mast
Chassis
Outriggers
Drop bar
Lower Guardrail
2
5
6
1
4
3
Figure 1-1: Work platform
UL25/UL32/UL40
Page 1 - 1
INTRODUCTION
PLATFORM CONTROLLER
The platform controller contains the controls to operate the machine. It is located at the front
of the platform. A complete explanation of control functions can be found in section 2.
ELEVATING ASSEMBLY
The platform is raised and lowered by the elevating assembly. The hydraulic pump driven
by the engine, powers the cylinders. Solenoid operated valves control raising and lowering.
CHASSIS
The chassis is a structural frame that supports all the components of the SL26/30SL work
platform.
PURPOSE OF EQUIPMENT
The objective of the work platform is to provide a quickly deployable, self propelled, variable
height work platform to elevate personnel and materials to overhead work areas.
! D A N G E R
!
The elevating function shall ONLY be used when the work
platform is level and on a firm surface.
Page 1 - 2
UL25/UL32/UL40
OPERATION AND SPECIFICATION
UL25/UL32/UL40
Page 2 - 1
SAFETY RULES
WARNING
All personnel shall carefully read, understand and follow all safety rules and operating instructions before operating or
performing maintenance on any SNORKEL aerial work platform.
ELECTROCUTION
HAZARD
TIP OVER
HAZARD
THIS MACHINE IS
NOT INSULATED
NEVER ELEVATE THE
PLATFORM OR DRIVE
THE MACHINE WHILE
ELEVATED UNLESS
THE MACHINE IS ON A
FIRM LEVEL SURFACE
COLLISION
HAZARD
NEVER POSITION
THE PLATFORM
WITHOUT FIRST
CHECKING FOR
OVERHEAD OBSTRUCTIONS OR
OTHER HAZARDS
FALL
HAZARD
TRAPPING/CRUSHING
HAZARD
NEVER CLIMB,
STAND OR SIT
ON PLATFORM
GUARDRAILS OR
MIDRAIL
BEWARE OF CRUSHING HAZARD WHEN
HOLDING HANDRAILS
WHILE THE PLATFORM
IS MOVING IN CLOSE
PROXIMITY TO OTHER
OBJECTS
STABILITY
HAZARD
PUSH
HAZARD
NEVER ELEVATE THE NEVER ATTEMPT TO
PLATFORM UNLESS PUSH THE SNORKEL
LIFT WITH PEOPLE
ALL 4 OUTRIGGERS
OR MATERIALS ON
HAVE BEEN PROPTHE PLATFORM OR
ERLY INSTALLED
WITH THE PLATFORM
ELEVATED.
USE OF THE AERIAL WORK PLATFORM: This aerial work platform is intended to lift a person or persons and their tools including material needed for a job. The work platform is designed to be used for repair and assembly jobs ONLY at overhead work
places (ceilings, cranes, roof structures, buildings, etc.).
The use and operation of the aerial work platform as a lifting tool or a crane is prohibited!
Climbing up the railing of the platform, standing on or stepping from the platform unto buildings, steel or prefab concrete structures
etc is prohibited!
NEVER use the machine if damaged, not functioning properly, has damaged or missing decals.
NEVER attach notice boards etc. to the platform as this will increase the wind loading.
INSULATION: The aerial work platform is not insulated. It is imperative to keep a safe distance from live parts or electrical
equipment. DO NOT get closer than the minimum distance recommended by the “National Regulations”.
PLATFORM CAPACITY: Exceeding the specified permissible maximum load is prohibited! Refer to platform capacity on page 24
for details.
MANUAL FORCE: NEVER exceed the manual force allowed for this machine. Refer to special limitations on page 9 for details.
LOAD DISTRIBUTION: Ensure that all loads are distributed evenly on the platform.
SURVEILLANCE: NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs,
bumps, curbs or debris and avoiding them.
WHEEL LOAD: OPERATE the machine only on surfaces capable of supporting wheel load.
WIND SPEED: NEVER operate the machine when the wind speed exceeds the machine’s wind speed rating. Refer to the Beaufort
scale for details.
EMERGENCY STOP: In case of an emergency, push the EMERGENCY STOP switch to de-activate all powered functions.
ALARM: If the alarm sounds while the platform is elevated, STOP operation immediately and carefully lower the platform. Move the
machine to a firm, level surface.
SWING GATE: Dismantling the entry gate or other railing components is prohibited! Always make certain that the entry gate is
closed and securely locked.
It is prohibited to keep the entry gate in an open position when the platform is raised.
Extending the height of the platform by placing ladders, scaffolds or similar devices on the platform is prohibited!
SERVICING: NEVER perform service on machine while platform is elevated without blocking the elevating assembly. Refer to
“maintenance” for details.
INSPECT: the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire connections and
damaged cables or hoses before usage.
DECALS: VERIFY that all labels are in place and legible before using the machine.
BATTERIES: NEVER charge batteries near sparks or open flame. Charging batteries emit explosive hydrogen gas.
STORAGE: AFTER USE, secure the work platform from unauthorised use by turning the key switch off and removing the key.
HARNESS: Harness attachment points are provided on the platform and the manufacturer recommends the usage of a fall restraint
harness especially where required by national safety regulations.
Modifications to the aerial work platform are prohibited or permissible only at the approval of the manufacturer.
ENVIRONMENTAL TEMPERATURE LIMITATION: The machine is primarily for use in normal ambient temperatures and conditions
ranging between 50°C to -20°C
INDOOR USE: This machine is for indoor use only. Do not use outdoors.
Page 2 - 2
UL25/UL32/UL40
SAFETY NOTICE
Harness attachment points are provided in the platform and the manufacturer recommends the usage of a fall
restraint harness, especially where required by national safety regulations.
All harness attachment points on SNORKEL vehicles have been tested with a force of 3,650 lbs (16.3 KN)
per person.
See below examples of harness attachment points used on SNORKEL vehicles with their corrosponding rating;
Harness attachment point Type 1. is rated for one lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating (see operators manual & decals).
Type 1.
Type 1.
Top View
Top View
Top View
2 lanyard
attachments
1 lanyard
attachment
1 lanyard
attachment
Harness attachment point Type 2. is rated for two
lanyard attachments per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
Type 2.
Top View
Top View
2 lanyard
attachments
1 lanyard
attachment
Harness attachment point Type 3. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
Front View
1 lanyard
attachment
Type 3.
Harness attachment point Type 4. is rated for one
lanyard attachment per loop as shown in the
illustrations depending upon platform occupancy rating
(see operators manual & decals).
1 lanyard
attachment
Type 4.
NOTE: There can be more harness attachment points per machine than the
maximum number of occupants allowed in a platform. Refer to
the platform decal & specifications table listed in the operators
manual for the correct occupancy rating before use.
UL25/UL32/UL40
Page 2 - 3
SAFETY NOTICE
NOTE:
1. To bypass any safety equipment is prohibited and presents a danger for the person/persons on
the aerial work platform and in its working range.
2. Modification to the aerial work platform is prohibited or permissible only at the approval of Snorkel.
3. The driving of MEWP’S on the public highway is subject to national traffic regulations.
4. It is important to ensure that the machine meets the requirements of stability during use, transportation, assembly, dismantling when out of service, testing or foreseeable breakdowns.
5. Never use a machine that is damaged or not functioning properly. Verify that all labels are in
place and legible before using.
Page 2 - 4
UL25/UL32/UL40
UL25/UL32/UL40
Page 2 - 5
Serienummer
Numero de serie
Matricola
Serial number
Matricola
ajanumero
QUA 217 Iss1 EC Declaration UL
Manufacturing Quality Manager
Signed for Snorkel
Inhaber des technischen Dossiers
Titulaire du dossier technique
Titular del expediente técnico
Houder van een technisch dossier
Innehavaren av technichal fil
Voer tekst in om hier te vertalen
Haltija technichal tiedosto
Titolare del fascicolo technichal
Innehaveren av technichal fil
Holder of Technical File
Modello
Verticaal model
Malli
Model
Modell
Modele
Modelo
Datum
Fecha
Data
Dato
Paivamaara
Date
Jan-15
Snorkel
Vigo centre
Washington
Tyne and Wear
NE38 9DA
England
UL32-01-060004
UL32DC
Description .................................... Aerial Work Platform
Bezeichnung ................................... Arbeitsbühne
Description ...................................... Plate-forme elevatrice de personnel Descripcion
........................................................ Platforma aerea de trabajo con motor
Descrizione ..................................... Piattaforma di sollevamento motorizzata
Beschrijving..................................... Mechanisch aangedreven werkplatform
Beskrivning ..................................... Höj-och sänkbar arbetsplattform
Beskrivelse...................................... Selvgående arbetsplattform
Beskrivelse...................................... Motordrevet lofteplatform
Kuvaus ............................................ Konevoimalla toimiva nostolava
Selvgående personarbetslift
Snorkel Europe
Vigo Centre, Washington
Tyne and Wear, England
Tel: +44 (0) 845 1557 755
FAX: +44 (0) 845 1557 756
Snorkel
Vigo Centre, Washington
Tyne and Wear, England , NE38 9DA
TEL:+44(0)845 1557 755
FAX:+44(0)845 1557 756
Authorized Representative
Autorisierte Vertretung
Representant autorise
Representante autorizado
Mandatario
Erkend vertegenwoordiger
Auktoriserad representant
Autorisert representant
Represenentant
Valtuutettu edustaja
Manufacturer
Hersteller
Fabrikant
Produsent
Tillverkare
Valmistaja
Fabbricante
Fabricante
Fabricant
EC Declaration of Conformity of Machinery 2006/42/EC
EC-Konformitätserklärung für Maschinen 2006/42/EC
Declaration De Conformite CE pour les Machines 2006/42/EC
Declaracion De Conformidad CE Para Maquinaria 2006/42/EC
Dichiarazione Di Conformità CE Per Le Macchine 2006/42/EC
CE Conformiteitsverklaring voor Machinerie 2006/42/EC
EU Deklaration Avseende Överensstammelse För Maskinutrustning 2006/42/EC
EF-Samsvarserklaering For Maskiner 2006/42/EC
EF-Overensstemmelseserklaering for Maskiner 2006/42/EC
EU Vaatimustenmukaisuusvakuutus 2006/42/EC
CONTENTS
INTRODUCTION
GENERAL DESCRIPTION
2-7
2-7
SPECIAL LIMITATIONS
PLATFORM CAPACITY
MANUAL FORCE
LIFT LEVEL SENSOR INTERLOCK
2-8
2-8
2-8
2-8
CONTROLS/PRE-OPERATION
PLATFORM CONTROLS AND INDICATORS DC
CHASSIS CONTROLS AND INDICATORS DC
PLATFORM CONTROLS AND INDICATORS AC
CHASSIS CONTROLS AND INDICATORS AC
PRE-OPERATION SAFETY INSPECTION
OUTRIGGER INTERLOCK TEST
LEVEL SENSOR INTERLOCK TEST
2-9
2-9
2-9
2-10
2-10
2-11
2-12
2-12
SYSTEM FUNCTION INSPECTION
OPERATION
OUTRIGGER INSTALLATION
PLATFORM ELEVATION
PLATFORM LOWER
BATTERY CONTROLLED LED
2-13
2-14
2-14
2-14
2-14
2-14
EMERGENCY PROCEDURE
EMERGENCY LOWERING
2-15
2-15
TRANSPORTATION
AFTER USE EACH DAY
TRANSPORTING THE WORK PLATFORM
FORKLIFT
TRUCK
DC MODELS
LOADING
UN-LOADING
PASSAGE THROUGH A DOORWAY
LOWERING
RAISING
2-16
2-16
2-16
2-16
2-16
2-16
2-19
2-18
2-18
2-19
2-19
MAINTENANCE
BATTERY MAINTENANCE
BATTERY CHARGER
HYDRAULIC FLUID
HYDRAULIC FLUID CHECK
2-21
2-21
2-21
2-22
2-22
INSPECTION AND MAINTENANCE
DAILY PREVENTATIVE MAINTENANCE SCHEDULE
SPECIFICATIONS
WASTE REMOVAL AND DISPOSAL
2-23
2-24
2-25
2-26
Page 2 - 6
UL25/UL32/UL40
INTRODUCTION
INTRODUCTION
This manual covers the operation of the UL25, UL32 and UL40 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.
GENERAL DESCRIPTION
! W A R N I N G !
DO NOT use the maintenance platform without guardrails properly
assembled and in place.
1. Platform
2. Mast
3. Chassis
4. Outriggers
5. Guardrail
6. Entry drop bar
7. Chassis controls
8. Power unit
• Motor
• Hydraulic reservoir
9. Battery box (DC units)
• Battery
• Battery charger
10. Casters
11. Rear wheels
12. Screw jacks
13. Loader assembly
14. Emergency lowering valve
2
5
7
8
13
6
9
12
11 14
1
4
3
10
Figure 2-1: UL25/UL32/UL40 work platform.
UL25/UL32/UL40
Page 2 - 7
SPECIAL LIMITATIONS
SPECIAL LIMITATIONS
Elevating the work platform is limited to firm, level surfaces only. This machine is rated for indoor
use only. All four outriggers must be properly installed before operating the machine.
!
! DANGER
The elevating function shall ONLY be used when the work platform
is levelled and on a firm surface. DO NOT attempt to move this
machine with the mast in an elevated position. The machine weighs
in excess of 760 lb (345 kg) and must only be manoeuvered on firm,
level ground.
PLATFORM CAPACITY
The platform capacity for the machine including occupants is determined by model and options.
This is listed under “specifications”.
! D A N G E R
!
DO NOT exceed the maximum platform
occupancy limits for this machine
MANUAL FORCE
Manual force is the force applied by the occupants to objects such as walls or other structures outside the work platform. The maximum allowable manual force is limited to 200N (45 lbs.) of force.
! D A N G E R
!
DO NOT exceed the maximum amount of
manual force for this machine.
LIFT LEVEL SENSOR INTERLOCK
The platform lift function is interlocked through a level sensor system. If the chassis is tilted more
than 1.5 degrees in either direction, an alarm will sound when the power is turned on and the lift
function will not operate. When the alarm sounds, only the platform lower function will operate.
Page 2 - 8
UL25/UL32/UL40
CONTROLS/PRE-OPERATION
PLATFORM CONTROLS AND INDICATORS DC MODELS
1.
2.
3.
4.
5.
Emergency stop button
Platform raise button
Enable button
Platform lower button
Battery condition indicator
1
2
3

4
5
514826-000
Figure 2-2: Platform controls and indicator locations
CHASSIS CONTROLS AND INDICATORS DC MODELS
1.
2.
3.
4.
5.
6.
7.
Emergency stop button
Diagnostics port
Enable button
Platform raise button
Platform lower button
Power indicator
Control selector switch
6
4
3
1
0
7
2
514441-001
5
Figure 2-3: Chassis controls and indicator locations
UL25/UL32/UL40
Page 2 - 9
CONTROLS/PRE-OPERATION
PLATFORM CONTROLS AND INDICATORS AC MODELS
1.
2.
3.
4.
5.
1
Emergency stop button
Platform raise button
Enable button
Platform lower button
Emergency lower switch
NB: Use emergency lower switch in
conjunction with the enable button (3)
and the platform lower button (4) to lower
the platform in the event of a mains
power failure only.
2
3

4
5
514825-000
Figure 2-4: Platform controls and indicator locations
CHASSIS CONTROLS AND INDICATORS AC MODELS
1.
2.
3.
4.
5.
6.
7.
Emergency stop button
Diagnostic port
Circuit breaker (MCB)
Enable button
Platform raise button
Platform lower button
Control selector switch
3
4
5
1
0
7
2
514442-001
6
Figure 2-5: Chassis controls and indicator locations
Page 2 - 10
UL25/UL32/UL40
CONTROLS/PRE-OPERATION
PRE-OPERATION SAFETY INSPECTION
NOTE: Carefully read, understand and follow all safety rules, operating instructions, labels
and National Safety Instructions/Requirements. Perform the following steps each day before use.
1.
2.
3.
4.
5.
6.
7.
Check that all 4 outriggers are properly installed.
Check that the base is level.
AC units: Connect the power unit plug to an approved extension cord.
DC units: Verify that the batteries are charged.
Perform the safety interlock tests.
Check for external damage to the mast.
Check the level of the hydraulic fluid with the platform fully lowered using the following procedures;
• Remove the reservoir cap and check the fluid level on the dipstick.
• Add hydraulic fluid if necessary. Oil should be visible on the end of the dipstick.
8. Check that the fluid level in the batteries is correct. Refer to “Battery maintenance”.
9. Check that all guardrails are in place and all fasteners are properly tightened.
10. Inspect the machine thoroughly for cracked welds and structural damage, loose or missing
hardware, hydraulic leaks, damaged control cable and loose wire connections.
UL25/UL32/UL40
Page 2 - 11
CONTROLS/PRE-OPERATION
OUTRIGGERS INTERLOCK TEST
! D A N G E R
!
Never perform this test from the platform.
1. Properly install all 4 outriggers and level the base.
2. Release the tension on 1 outrigger by turning the screw jack counter clockwise until the indicator light is no longer lit.
3. While standing on the ground, activate the control panel to elevate the platform. The platform
should not elevate.
4. Re-level the base.
5. Repeat steps 2, 3 and 4 until all 4 outriggers have been tested.
6. Repeat steps 1 to 5 using the platform controls.
! D A N G E R
!
DO NOT use a machine that elevates when the
tension has been released on an outrigger. The
machine must be repaired before using.
! D A N G E R
!
DO NOT use a machine if any outrigger indicator light remains illuminated when the related outrigger screw jack foot is clear of the ground.
The machine must be repaired before use.
LEVEL SENSOR INTERLOCK TEST
1. Properly install all 4 outriggers and ensure they all have tension applied. All 4 outrigger lights
should be on.
2. Adjust the outriggers so that the platform is tilted by more than 1.5 degrees.
3. Verify that the tilt alarm sounds and using the ground control panel, the platform should not
elevate.
4. Repeat steps 1 to 3 using the platform controls.
Page 2 - 12
UL25/UL32/UL40
SYSTEM FUNCTION INSPECTION
Refer to “Controls and indicators” for the locations of various controls and indicators.
! W A R N I N G !
Stand Clear of the work platform while performing the
following checks. Check above the work platforms for obstructions and electrical conductors.
NOTE: The platform will not elevate unless all four outriggers are properly installed with
screw jack pads firmly in contact with the floor and each outrigger indicator lamp lit. The
chassis is level to 1.0 degree or less in all directions.
Perform all tests prior to operating the machine.
1.
2.
3.
4.
Pull the chassis emergency stop switch to the ON position.
Turn the key to “ground controls”.
Pull the platform emergency stop switch to the ON position.
Push both the middle and the top buttons (enable and up) on the ground control box at the
same time to elevate the platform. Release the buttons to stop.
5. Push both the middle and the bottom buttons (enable and down) at the same time to lower the
platform. Release the buttons to stop.
6. Open the emergency lowering valve to verify proper operation.
7. Push the chassis emergency stop switch to verify proper operation. All machine functions
should be disabled. Pull out the chassis emergency stop switch to resume.
8. Turn the key to platform controls and enter the platform ensuring the drop bar gate is correctly
closed.
9. Repeat tests 4 & 5 from the platform controls.
10. Push the platform emergency stop switch to verify proper operation. All machine functions
should be disabled. Pull out the platform emergency stop switch to resume.
UL25/UL32/UL40
Page 2 - 13
OPERATION
Before operating the work platform, ensure that the pre-operation safety inspection has been completed and that any deficiencies have been corrected. Never operate a damaged or malfunctioning
machine. The operator must be thoroughly trained on this machine.
NOTE: The platform will not elevate unless all 4 outriggers are properly installed with screw
jack pads firmly in contact with the floor and each outrigger indicator lamp lit. The chassis
is level to 1.0 degrees or less in all directions.
1.
2.
3.
4.
5.
6.
AC units: Connect the power unit plug to an approved extension cord.
DC units: Verify that the battery charger is turned off and that the extension cord is removed.
Pull the chassis emergency stop switch to the ON position.
Turn the key to platform.
Enter the platform by raising the drop bar.
Ensure the drop bar falls freely to its lowered position.
OUTRIGGER INSTALLATION
Bubble level
Indicator lights
1. Remove the outriggers from the storage locations
on the sides of the mast.
2. Insert the outriggers into the outrigger socket at the
base.
3. Ensure the locking pin engages with the hole at the
Locking pin
end of the outrigger. Pull the outrigger outwards to
ensure it is engaged.
4. Repeat step 3 for the rest of the outriggers. Make
Screw jack
sure all 4 locking pins are engaged.
5. Level the base, centring the bubble in the orbit
level on the base by adjusting the screw jacks (turn
clockwise) at the end of each outrigger. Do not
release the tension (turn counterclockwise) on an Figure 2-6: Outrigger installation
outrigger to level the base.
6. All 4 screw jack pads must be in solid contact with components
a firm surface and each outrigger indicator light must be lit before the platform is elevated.
PLATFORM ELEVATION
1. Check that the area above the platform is clear before elevating the platform.
2. Pull the platform emergency stop switch to the ON position.
3. Push both the middle and the top buttons (enable and up) on the control box at the same time
to elevate the platform. Release the buttons to stop.
• In the event of an emergency, push the emergency stop button.
4. Visually inspect the mast assembly for cracked welds and structural damage, loose hardware,
hydraulic leaks, loose wire connections and erratic operation. Check for missing or loose parts
PLATFORM LOWER
1. Check that the area below the platform is clear before lowering the platform.
2. Push both the middle and bottom buttons (enable and down) at the same time to lower the
platform. Release the buttons to stop.
BATTERY CONDITION LED
The battery condition LED illuminates to give an approximate indication of the amount of charge
left to be used as follows:
Not illuminated
100% to 40%
Slow flash
40% to 20%
Fast flash
20% to 10%
Steady on less than
10%
Table 2-1: Battery condition indicators.
NOTE: To maximise battery life, always re-charge the battery after use and never store the
machine for extended periods without first fully re-charging the battery.
Page 2 - 14
UL25/UL32/UL40
EMERGENCY PROCEDURE
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.
The emergency lowering valve can be reached only
from the ground. When needed to be open to lower
the platform, ask for assistance from the ground. The
valve is located at the rear of the machine as shown in
Figure 9.
1. Pull the knob to open the valve.
2. To close the valve, release the knob.
NOTE: The platform will not elevate if the emergency lowering valve is open.
AC UNITS ONLY
Emergency
lowering valve
In the event of a mains power failure, the platform can Figure 2-7: Emergency lowering valve
be lowered from the platform controls by operating the location
emergency lower switch, the enable button and the
platform lower button at the same time.
NOTE: This procedure should only be used in the event of an emergency.
UL25/UL32/UL40
Page 2 - 15
TRANSPORTATION
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.
TRANSPORTING THE WORK PLATFORM
FORKLIFT
!
C A U T I O N !
Forklifting is for transportation only. Refer to specifications for weight of the machine and be certain that the
forklift is of adequate capacity to lift the machine.
Forklift the aerial platform from the rear by lifting from the fork pockets shown in Figure 2-10
Centre of gravity
Battery
Forklift pockets
Charger
Figure 2-8: Centre of gravity.
Figure 2-9: Fork pockets
location.
Figure 2-10: Battery box (DC
model).
TRUCK
1. Manoeuvre the machine into the transport position and chock the wheels.
2. Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis lifting/tie down points.
DC MODELS
For DC models, prior to transportation, disconnect the plug from the battery box and remove the
battery box from the rear of the machine.
!
C A U T I O N !
The battery box is heavy (23.6kg/52 lbs). Lift
properly to avoid back injury.
Page 2 - 16
UL25/UL32/UL40
TRANSPORTATION
Loader channel
Gravity hook
Loader support
bracket
Loader
Retaining pin
Figure 2-11: Loader in load position.
Retaining pin
Handle
Handle bar
Figure 2-12: handle positioning.
UL25/UL32/UL40
Page 2 - 17
TRANSPORTATION
LOADING
! W A R N I N G !
Ensure that the loader fully engages the
tailgate or vehicle bed.
1. Raise the loader support brackets and engage the retaining pin in the top hole of the loader
channel.
2. Secure the loader to the loader support bracket with the gravity hook.
3. Position the unit so that the back of the machine comes into contact with the tailgate or vehicle
bed.
4. Release the gravity hook and slide the loader down until it comes into contact with the tailgate
or vehicle bed. Then, re-position the loader support bracket so that the retaining pin is in the
first available hole above the loader.
5. Release the locking pin and pull the T-handle out until the locking pin engages the hole in the
end of the T-handle.
6. Lift up on the T-handle using the loader as a pivot until the unit rotates to a horizontal position
in the vehicle bed.
7. Push the base of the unit towards the front of the vehicle bed. The machine will slide on the
loader until the rear wheels are on the bed. The unit may then be rolled on the rear wheels and
upper casters.
8. Re-turn the T-handle to the stored position making sure that the locking pin engages the Thandle.
9. Secure the unit with suitable tie straps using the forklift pockets located under the base of the
tilt back frame.
!
C A U T I O N !
To prevent damage to the mast assembly, do not place
rope or tie straps across the mast assembly when securing the unit for transportation.
DO NOT overtighten the rope or tie straps otherwise
damage to the machine will result.
UNLOADING
1. Unsecure the unit.
2. Release the locking pin and pull the T-handle out until the locking pin engages the hole at the
end of the T-handle.
3. Roll the unit back until the rear wheels are off the edge of the tailgate or vehicle bed.
4. Pull downward on the T-handle allowing the unit to slide on the loader.
• As the unit stops sliding on the loader, it will pivot on the loader to an upright position.
• Gradually counterbalance the unit’s weight by applying an upward force on the T-handle.
This allows the unit to settle gently on the wheels avoiding undue impact on the unit.
5. Return the T-handle to the stored position making sure that the locking pin engages the T-handle.
Page 2 - 18
UL25/UL32/UL40
TRANSPORTATION
PASSAGE THROUGH A DOORWAY
The UL machine is equipped with a castered rear tilt back assembly. When the unit is tilted back
onto this support frame, the overall height is reduced to allow the unit to pass through a standard
doorway.
LOWERING
! C A U T I O N !
Before tilting the machine unto the rear tilt back assembly, be sure that the retaining pin is fully inserted
with the hair pin retainer and the cylinder assembly is
fully extended.
DO NOT drop the tilt back frame. Keep out from under
the tilt back frame and machine when tilting.
1. Ensure that the area is clear of personnel and obstructions.
2. While holding the tilt back frame, remove the hair pin retainer and the retaining pin.
3. Lower the tilt back frame until the hole in the cylinder assembly align with the upper mounting
bracket pin hole. Secure the cylinder assembly to the upper mounting bracket using the retaining pin and hair pin retainer.
4. Extend the tilt back handle to the tilt/lift position by releasing the locking pin and pulling the
handle out of the tilt back assembly until the locking pin engages.
5. Push down on the tilt back handle until the unit comes to rest on the tilt back frame.
• As the mast tilts back, counterbalance the machine’s weight by increasing upward force
on the end of the tilt back handle. This allows the machine to gently come to rest on the tilt
back casters.
6. Pull down on the handle on the back of the mast to compress the cylinder assembly.
7. Return the tilt back handle to the storage position, making sure that the locking pin engages
the handle.
RAISING
1. Lift up on the mast handle to extend the cylinder assembly.
2. Fully engage the tilt back handle until the locking pin engages.
3. Lift up on the tilt back handle.
• As the mast approaches vertical, counterbalance the machine’s weight by increasing
downward force on the end of the tilt back handle. This allows the machine to settle gently
on the front casters.
4. Return the tilt back handle to the storage position, making sure that the locking pin engages
the handle.
5. While holding the tilt back frame, remove the retaining pin and raise the tilt back assembly to
the stowed position.
6. Secure with the retaining pin, making sure that the retaining pin is fully inserted and that the
hair pin retainer is installed.
UL25/UL32/UL40
Page 2 - 19
TRANSPORTATION
Retaining pin
Hair pin retainer
Cylinder
assembly
Figure 2-13: Cylinder secured with retaining pin.
Tilt back handle
Retaining pin
Figure 2-14: Lowering and raising with the tilt back handle.
Page 2 - 20
UL25/UL32/UL40
MAINTENANCE
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 the batteries with Snorkel batteries or manufacturer approved replacements weighing 22 kg (48 lbs.) each.
Use the following procedure to ensure battery maintenance.
1. Check the battery fluid level daily especially if the work platform is being used in a warm, dry
climate.
2. If the electrolyte level is lower than 10 mm (3/8") above the plates, add distilled water only. Do
not use tap water due to its high mineral content since it will shorten battery life.
3. Keep the terminals and tops of the batteries clean.
4. Refer to the service manual to extend battery life and for complete service instructions.
BATTERY CHARGING
! W A R N I N G !
Charge the batteries in a well ventilated area. Do not charge the batteries when
the work platform is near a source of spark or flames.
Permanent damage to the batteries will result if the batteries are not
immediately recharged after discharging. Never disconnect the cables from the
batteries when the charger is operating. Keep the charger dry.
Use the following procedure to charge the batteries after use.
1. Check the battery fluid level. If the battery fluid level is lower than 10 mm (3/8") above the
plates, add distilled water only.
2. Verify the charger voltage switch is set to 12 volts.
3. Connect an appropriate extension cord to the charger plug. Plug the extension cord into a
properly grounded outlet of proper voltage and frequency.
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.
UL25/UL32/UL40
Page 2 - 21
MAINTENANCE
HYDRAULIC FLUID
The hydraulic fluid reservoir is located under the power unit cover.
NOTE: Never add fluid if the platform is elevated.
HYDRAULIC FLUID CHECK
1.
2.
3.
4.
5.
Make sure that the platform is fully lowered.
Open the chassis door.
Check the fluid level using the gauge on the dipstick.
To add hydraulic fluid, remove the filler cap.
Add the appropriate hydraulic fluid to raise the level to the end of the dipstick.
Page 2 - 22
UL25/UL32/UL40
INSPECTION AND MAINTENANCE
The complete inspection consists of periodic visual and operational checks along with periodic minor adjustments that assure proper performance. Daily inspection will prevent abnormal wear and
prolong the life of all systems. The inspection and maintenance schedule should be performed 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. Photocopy the checklist page and use the checklist when inspecting the machine.
UL25/UL32/UL40
Page 2 - 23
INSPECTION AND MAINTENANCE
DAILY PREVENTATIVE MAINTENANCE SCHEDULE
MAINTENANCE TABLE KEY
PREVENTATIVE MAINTENANCE REPORT
Y = Yes/Acceptable
N = No/Not Acceptable
R = Repaired/Acceptable
Date: ______________________________
Owner: _____________________________
Model #: ____________________________
Serial #: ____________________________
Serviced by: _________________________
COMPONENT
INSPECTION OR SERVICES
Y
N
R
COMPONENT
Operator’s
Manual
Check that the operators manual is in
the manual holder and all pages are
intact and readable
Labels &
Decals
Check that labels and decals are in
place, intact and readable
Control
Cable
Check the exterior of the cable for
pinching, binding or wear.
Mast
Assembly
Inspect for bends, cracks or loose
rivets.
Battery
System
Check electrolyte level
Lift Cylinders
Check for leaks
Check battery cable condition
Harness
anchor point
Check fasteners are secure
System function inspection
Conduct system function inspection (see
system function inspection pocedure)
Emergency
stops
Check that the emergency stop button on
the basket panels opertates correctly
Check terminals are clean and connectors are tight
Check charger condition and operation
Charge batteries
Hydraulic
fluid
Check oil level
Hydraulic
system
Check all fittings are tight and there are
no leaks
Drive motors
Check for operation and leaks
Hydraulic
pump
Check fittings are secure and there are
no leaks
Emergency
lowering
Operate the emergency lowering valve
and check for serviceability.
Controller
Check switch operation
Platform
deck and
rails
Check fasteners are in place, correctly
tightened and not damaged
Elevating
assembly
INSPECTION OR SERVICES
Y N
R
Inspect for external damage, dents, loose
rivets or cracks.
Check the structure and welds for damage, deformation, corrosion and cracks
Chassis
Check operation of outrigger interlocks
Check castors for damage
Check hoses for pinch or rubbing points
Check welds for cracks
Check for damage, deformation, corrosion
and cracks
Check that the emergency stop button
on the ground control panel operates
correctly
Alarm
Check that the alarm sounds when
activated
* NOTE: Use ISO #46 during summer
and ISO #32 during winter
Check the structure and welds for damage, deformation, corrosion and cracks
Check condition of deck (no damage,
deformation, corrosion or cracks
Check entry gate closure functions
correcly
Table 2-2: Daily preventative maintenance
checklist
Page 2 - 24
UL25/UL32/UL40
SPECIFICATIONS
ITEM
UL25
UL32
UL40
Platform capacity
159 kg (350 lbs.)
136 kg (300 lbs.)
136 kg (300 lbs.)
Occupants
1 PERSON
1 PERSON
1 PERSON
Working height
9.62 m (31.6 ft.)
11.75 m (38.5 ft.)
14.19 m (46.6 ft.)
Maximum platform height
7.62 m (25 ft.)
9.75 m (32 ft.)
12.19 m (40 ft.)
Minimum platform height
38 cm (15")
38 cm (15")
38 cm (15")
Height
Dimensions
Overall weight
390 kg (860 lbs)
435 kg (960 lbs)
470 kg (1040 lbs)
DC option weight
29 kg (64 lbs.)
29 kg (64 lbs.)
29 kg (64 lbs.)
Overall width (outriggers extended)
2.06 m (81")
2.06 m (81")
2.95 m (116")
Overall length (outriggers extended)
1.98 m (78")
1.98 m (78")
2.84 m (112")
Vertical height
1.98 m (78")
2.53 m (100")
2.90 m (114")
Width
74 cm (29")
74 cm (29”)
74 cm (29”)
Stowed dimensions
Depth
1.24 m (49")
1.32 m (52")
1.32 m (52")
Diagonal storage height
1.94 m (76")
1.94 m (76")
2 m (79")
Diagonal storage length
2.59 m (102")
2.72 m (107")
3.05 m (120")
System voltage
AC electric motor
120 VAC 60 Hz or 220 VAC 50/60 Hz
DC electric power source
1-12 volt battery, group 27 105 Amp/hrs. minimum weight 22 kg (48 lbs.)
Battery charger
Automatic, 120 VAC 60 Hz or 220 VAC 50 Hz
Output: 10 Amp, 12 volts DC
Hydraulic tank capacity
5.7 litres (1.5 gal)
Maximum hydraulic
pressure
165 bar (2400 PSI)
Hydraulic Fluid
Normal temperature: above 0° C
[32 F]
ISO #46
Low temperature: below 0° C [32 F]
ISO #32
Extreme temperature: below -17° C
[ 0 F]
ISO #15
Control system
Push button lift and lower, red mushroom emergency stop switch
Guardrails
1.1 m (43.5") high
Toeboard
152 mm (6") high
Maximum chassis inclination
1.0 degrees in all directions
Outrigger loading
170 kg (374 lbs.)
Vibration
Whole body vibration < 0.5 m/s2, Handarm vibration < 2.5 m/s2
Sound pressure
68 dB (A) at control station
Operating temperature range
-20° C to +50° C
Table 3: UL25/32/40 Specification
NOTE: Specifications are subject to change without notice. Hot weather or heavy use may affect
performance. Refer to the service manual for complete parts and service information. This machine meets or exceeds all applicable OSHA and ANSI A92.6 - 1999.
UL25/UL32/UL40
Page 2 - 25
Page 2 - 26
Is the waste: a Polymer, Tyre or Hose ?
Is the waste: an electrical component
or wiring ?
Is the waste: an
IIs the waste: A used
Is the waste: A solid metal ?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Is the metal:
Aluminum,
Copper,
Iron,
Lead,
Steel, or Zinc?
Your waste can't be recycled as scrap metal.
Is your waste:
Polymer wear pads
Tyres
Hydraulic hoses
* Armer cable
* Electrical Components
* Electrical circuit boards
Is your waste:
* Power Steering Fluid
* Diesel Fuel
* Gear Oil
* Hydraulic Oil
* Kerosene (#3,#4, & #6)
Oils can NOT be disposed down the drain
(even if they are not hazardous waste).
Is your waste:
* Motor Oil
Is your waste (not Leaking / damaged)?
End of Life Waste Advice Chart :
No
Yes
No
Yes
Yes
No
disposal of HAZARDOUS WASTE
been depoluted
Your End of life waste is a HAZARDOUS WASTE
HAZARDOUS WASTE
Your waste is a HAZARDOUS WASTE Follow your
* Coolant from chillers/HAVC systems
Is your waste?
Your waste should be RECYCLED following your
Is your waste (Leaking / damaged)?
RECYCLED according to
should be RECYCLED according to the universal
No
Yes
No
Yes
* Naptha
* Transformer oil
* Brake Fluid
* Radiator Flush
* Deicers
* Oily Water
* Degreasing solvents
Is your waste?
*Any type of oil contaminated with a hazardous chemical
HAZARDOUS WASTE
Your waste is a HAZARDOUS WASTE Follow your
Yes
Yes
WASTE
HAZARDOUS
Your waste is a HAZARDOUS WASTE
RECYCLING purposes.
friendly you may chouse to collect
These are non-hazardous and can be
placed in regular trash, however, in an
WASTE DISPOSAL AND REMOVAL
UL25/UL32/UL40
SERVICE AND REPAIR
CONTENTS
INTRODUCTION
3-2
SPECIAL TOOLS
3-2
PREVENTATIVE MAINTENANCE
3-2
PREVENTATIVE MAINTENANCE TABLE
3-3
LUBRICATION
3-4
BATTERY MAINTENANCE
BATTERY INSPECTION AND CLEANING
BATTERY CHARGING
BATTERY CELL EQUALIZATION
3-5
3-5
3-5
3-6
SETTING SYSTEM RELIEF VALVE
3-6
CASTERS
CHAINS
SCREW JACKS
HYDRAULIC OIL RESERVOIR
3-4
3-4
3-4
3-4
MAST ASSEMBLY/DISASSEMBLY
PLATFORM ASSEMBLY REMOVAL
PLATFORM ASSEMBLY
PLATFORM SUPPORT ASSEMBLY
SEQUENCING STRAP INSTALLATION
3-7
3-7
3-12
3-13
3-13
CYLINDER ASSEMBLY
SEAL REPLACEMENT
ORIFICE VALVE CLEANING
CYLINDER REMOVAL
CYLINDER INSTALLATION
3-13
3-13
3-15
3-17
3-17
TORQUE SPECIFICATIONS
3-18
HYDRAULIC COMPONENTS
FASTENERS
UL25/UL32/UL40
3-18
3-19
Page 3 - 1
SERVICE AND REPAIR
INTRODUCTION
This section contains instructions for the maintenance of the work platform. Refer to the general
information section for information relevant to all Snorkel work platform and help in diagnosing and
repair of the machine.
The preventative maintenance table should be used at intervals specified by Snorkel or that of Local/National regulations to ensure the aerial platform is in good condition for use.
! W A R N I N G !
Be sure to read, understand and follow all information
stated in the operation section of this manual before
attempting to operate or perform service on any work
platform.
! D A N G E R
!
Never perform service on the work platform in the elevating
assembly area 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.
SPECIAL TOOLS
The following is a list of special tools that are required to perform certain maintenance procedures.
These tools may be purchased from local dealers.
Description
Spanner Wrench for UL 25/32/40
Strap Wrench
Tie Rod Tensioner ( 2 required)
Tensioner Bracket (2 required)
EZCal Caliberation & Diagnostic Tool
Table 3-1: List of special maintenance tools.
Part Number
062521-010
062482-000
062738-000
062739-000
3072123
PREVENTATIVE MAINTENANCE
The complete inspection consists of periodic visual and operational checks together with all necessary adjustments to assure proper performance. Daily inspection will prevent abnormal wear and
pro-long 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. Complete descriptions of the procedures
are stated in the table 3-2.
! W A R N I N G !
Before performing preventative maintenance, it is important
to get familiar with the operation of the machine.
Never enter the area below the platform when the platform
is elevated.
The preventative maintenance table has been designed to be used for machine service and maintenance repair.
Page 3 - 2
UL25/UL32/UL40
SERVICE AND REPAIR
PREVENTATIVE MAINTENANCE TABLE
INTERVAL
PREVENTATIVE MAINTENANCE REPORT
Daily = each shift or everyday
30 d = every 30 days
3 m = every 3 months
1 y = every 1 year
Y = Yes/Acceptable
N = No/Not Acceptable
R = Repaired/Acceptable
Date:
Owner:
Model #:
Serial #:
Serviced By:
Service Interval:
DO NOT fit replacement parts other than genuine components without express written approval
from the manufacturer.
COMPO- INSPECTION OR SERVICES INTERNENT
VAL
Check electrolyte level
Battery
System
(DC units
only)
Hydraulic
Oil
Hydraulic
system
Emergency
hydraulic
System
Daily
C O M P O - INSPECTION OR SER- INTERNENT
VICES
VAL
Elevating
Assembly
Inspect for external damage, dents loose rivets or
cracks
Daily
30d
Daily
Check charger condition &
operation
Daily
Check chains and
sheaves for wear
3m
Clean exterior
3m
30d
Check battery cable condition
Daily
Inspect and adjust sequence straps
Clean terminals
3m
Check cables for pinch
or rubbing points
Daily
Chassis
Check oil level
Daily
1y
Check component
mounting for proper
torque
6m
Drain and replace oil (ISO
#46)
Check for leaks
Daily
Check welds for cracks
Daily
Check line connections
30d
Daily
Check hoses for exterior wear
30d
Check casters for damage
Check procedure for emergency down batteries
3m
A.C. Only: Replace emergency down batteries in upper
control box
1y
Controls
Check condition and operation
Daily
Control
Cable
Check the exterior of the
cable for pinching, binding or
wear
Daily
Check fasteners for proper
torque
Daily
Hydraulic
Pump
R
Charge batteries
3m
Platform
deck and
rails
N
Check specific gravity
Open the emergency lowering valve and check for
serviceability
Emergency
Down
Y
Check welds for cracks
Daily
Check condition of deck
Daily
Check entry way closure
Daily
Check for fitting leaks
Daily
Wipe clean
30d
Check for leaks at mating
surfaces
30d
Check mounting bolts for
proper torque
30d
Lift Cylinder
Entire Unit
Labels
Check for leaks
Daily
Check for proper torque
30d
Perform pre-operation
inspection
Daily
Check for and repair collision damage
Daily
Lubricate
3m
Check fasteners for
proper torque
3m
Check for corrosion;
remove and repaint
3m
Check for peeling, missing or unreadable labels
& replace
Daily
Check for and repair collision damage
Daily
Check fasteners for
proper torque
3m
Check for corrosionremove and paint
6m
Lubricate
30d
Entire
unit
Y
N
R
Table 3-2: Preventative maintenance checklist
A thorough investigation should be carried out every 6 months.
NOTE: Frequency and extent of periodic examinations may depend on national regulations.
UL25/UL32/UL40
Page 3 - 3
SERVICE AND REPAIR
LUBRICATION
Refer to figure 3-1 for the location of items that require lubrication service. Use an aerosol chain
lubricant for all components to be lubricated.
CASTERS
Using a grease gun, apply 1 or 2 shots of multi-purpose bearing grease to each zerk fitting. Swivel
casters have two zerk fittings, one at the wheel bearing and one at the swivel.
CHAINS
1. Ensure that the platform is fully lowered.
2. Apply enough aerosol chain lubricant to exposed section of chain to allow lubricant to run down
chain.
SCREW JACKS
Apply a moderate amount of aerosol chain lubricant to each screw jack assembly.
1
2
4
5&6
3
Figure 3-1: Locations for lubrication.
1
2
3
4
Chains
Casters
Rear Wheels
Screw Jacks
Figure 3-2: Hydraulic Power Unit.
1
2
3
4
5
6
Motor
Pump
Reservoir
Breather/Dipstick
Capscrew (under pump)
Grip Plate (under pump)
HYDRAULIC OIL RESERVOIR
To change oil in the reservoir, firstly verify that the platform is fully lowered.
1. Remove the hydraulic reservoir from the pump by removing four screws and four grip plates.
2. Provide a suitable container as an ideal reservoir for a 5.7 litres (1.5 U.S. gallon) capacity and
dispose of hydraulic fluid properly. Contact local oil recyclers for more information.
NOTE: Ensure the o-ring is in place on the pump when installing the hydraulic reservoir.
3. Reinstall hydraulic reservoir to pump assembly with grip plates and screws.
Page 3 - 4
UL25/UL32/UL40
SERVICE AND REPAIR
4. Fill hydraulic reservoir through the dipstick hole with ISO #46 hydraulic fluid. The hydraulic reservoir has a 5.7 litres (1.5 U.S. gallon capacity. Ensure that the oil is visible on the end of the
dipstick.
BATTERY MAINTENANCE - DC UNITS ONLY
Electrical energy for the motor is supplied by a 12 volt battery. Proper care and maintenance of the
battery and motor will ensure maximum performance from the lift.
! W A R N I N G !
Hazard of explosive gas mixture. Keep sparks, flames and smoking materials away
from batteries.
Always wear safety glasses when working with batteries.
Battery fluid is highly corrosive. Rinse away any spilled fluid thoroughly with clear
water.
BATTERY INSPECTION AND CLEANING
Check the battery fluid level daily, especially if the work platform is being used in a warm, dry
climate. If required, add distilled water only. Use of tap water with high mineral content will shorten
battery life.
! W A R N I N G !
If the battery water level is not maintained, a full charge cannot be achieved. This
will create a low discharge rate which will damage the motor/pump unit and void the
warranty.
The battery should be inspected periodically for signs of cracks and in some cases, electrolyte
leakage and corrosion of the terminals. Inspect cables for worn spots or breaks in the insulation
and for broken cable terminals.
Clean battery that shows signs of corrosion at the terminals or onto which the electrolyte has overflowed during charging. Use a baking soda solution to clean the battery, taking care not to get the
solution inside the cells. Rinse thoroughly with clear water. Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed.
BATTERY CHARGING
Charge the battery at the end of each work shift or when the battery has been discharged; whichever occurs first.
! C A U T I O N !
Charge the battery in a well ventilated area. DO NOT charge the battery
when the lift is in an area containing sparks or flames.
Permanent damage to the battery will result if not immediately recharged
after discharging.
NEVER leave the charger operating unattended for more than two days.
NEVER disconnect cables from the battery when the charger is operating.
Keep the charger dry.
UL25/UL32/UL40
Page 3 - 5
SERVICE AND REPAIR
When night air temperatures fall below 18°C (65°F), a battery charged in an unheated area should
be placed on charge as soon as possible after use. Under such conditions, a 4 hour charge once a
week in the early afternoon will improve the battery life. Use the following procedure to charge the
battery.
1. Check battery fluid level. If the electrolyte level is lower than 10mm (3/8 inches) above the plates,
add distilled water only.
2. Verify charger voltage switch is set to 12 volts.
3. The battery charger is located at the rear of the mast. Connect an extension cord (a minimum
of 1.5mm2 [12 gauge] conductor and a maximum length of 15m [50 feet]) to the charger plug.
Connect the other end of the extension plug to a properly grounded outlet of proper voltage and
frequency.
4. Set charger control to “conventional” setting. Charger ammeter should indicate charger rate.
5. When battery is fully charged, charger automatically turns itself off. Disconnect the extension
cord.
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.
• After the initial charge, check the electrolyte level in all cells and add distilled water as necessary.
• Turn the charger on for an additional 8 hours. During this charge, the charging current will be
low (four amps) as cells are equalizing.
• After equalization, the specific gravity of all cells should be checked with a hydrometer. The
temperature corrected specific gravity in this state should be 1.260. If any corrected readings
are below 1.230, the battery should be replaced.
Do not check the specific gravity in a cell to which water has just been added. If there is not enough
electrolyte in a fully charged cell to obtain a sample for the hydrometer, add water and continue
charging for 1 to 2 hours to adequately mix the water with the electrolyte.
Battery
Charger
Figure 3-3: Battery Charger.
SETTING SYSTEM RELIEF VALVE
Check the hydraulic system pressure whenever the pump or relief valve has been serviced or replaced.
Page 3 - 6
UL25/UL32/UL40
SERVICE AND REPAIR
! W A R N I N G !
The hydraulic oil may be of sufficient temperature to
cause burns. Wear safety gloves and safety glasses
when handling hot oil.
1. Install the outriggers and level the unit as normal (refer to the operators manual for operating
instructions). Operate the hydraulic system for 5-10 minutes to warm up the hydraulic oil.
2. Remove the cover from the power unit assembly.
3. Place the rated safe working load for the machine (as stated under specifications in the operation
section) on the platform. Do not use personnel as safe working load for this procedure.
4. Install a pressure gauge on the gauge port.
5. Remove the cap from the system relief valve (refer to figure 3-4) and turn the adjustment screw
counterclockwise, 2 full turns.
6. Operate controls to elevate the machine. Note that the machine will not raise until the relief valve
is properly adjusted.
7. Turn the system relief valve clockwise (refer to figure 3-4) until the machine begins to rise.
8. Elevate the platform fully and verify that the pressure does not exceed 165 bar (2400 PSI) at any
time during the lift cycle.
9. Replace cap on the system relief valve and reassemble cover.
Relief Valve
Gauge Port
Figure 3-4: System Relief Valve.
MAST ASSEMBLY/DISASSEMBLY
Using a suitable lifting device, lower the work platform into a horizontal position (refer to figure 3-5).
If possible, place the machine unto a sturdy work table using a forklift.
! W A R N I N G !
Never attempt to lower the lift into a horizontal position
without the use of a suitable lifting device; bodily injury
or damage to the machine may result.
NOTE: Mark all components as they are removed to ease with re-installation in the correct
location and sequence.
PLATFORM ASSEMBLY REMOVAL
1. Extend elevating assembly far enough to expose the eight screws attaching the cage support
assembly to stage 6 by opening the emergency lowering valve and pulling on the cage guardrail.
2. Remove cover from the front of the platform assembly.
UL25/UL32/UL40
Page 3 - 7
SERVICE AND REPAIR
Forklift
Figure 3-5: Lifting/Lowering Procedure.
3. Remove the cotter pins and chain retaining pins from the top front of stage 5.
4. Loosen screws from the strap retainer on the top casting of stage 5. Pull the strap free of the
retainer.
5. Remove the cage support screws, slide the cage support out of the sixth stage mast and set
aside. It should not be necessary to remove the pinch shield. Be careful not to damage the control cable.
NOTE: To remove the platform assembly from the cage support assembly, follow the steps
6-10 below.
6. Remove cable sheaves from the cage support weldment and strain reliefs from the top casting
of stage 5.
7. Loosen screws from the strap retainer on the platform assembly weldment and free strap from
the retainer.
8. Remove the 2 screws and washers holding the stop bracket located on the top of platform assembly weldment. Remove the stop bracket.
9. Slide the cage support weldment out of the top of the platform assembly weldment.
10. The slide bearings in platform assembly may now be inspected or replaced if necessary.
Use the following procedure in the sequence provided to disassemble the masts.
#6 MAST
1. Remove sequence strap retainer on the top of #4 mast.
2. Remove the allen head screws holding the top mast bearings between the #5 and #6 mast. Remove the top mast bearings.
3. Slide #6 mast out of #5 mast. As mast is removed, the bottom four mast bearings will fall out. Its
important to note their orientation for re-assembly.
4. Disconnect the chain from the top of #4 mast.
#5 MAST
1. Remove the sequence strap retainer on the top of #3 mast.
2. Remove the allen head screws holding the top mast bearings between the #4 and #5 mast. Remove the top mast bearings.
3. Slide #5 mast out of #4 mast. As the mast is removed, the bottom four mast bearings will fall out.
Its important to note their orientation for re-assembly.
4. Disconnect the chain from the top of #3 mast.
#4 MAST
1. Remove sequence strap retainer on the top of #2 mast.
2. Remove the Allen head screws holding the top mast bearings between the #3 and #4 mast. Remove the top mast bearings.
Page 3 - 8
UL25/UL32/UL40
SERVICE AND REPAIR
3. Slide #4 mast out of #3 mast. As mast is removed, the bottom four mast bearings will fall out;
note their orientation for re-assembly.
4. Disconnect the chain from the top of the #2 mast.
5. Remove the cylinder by following instructions provided under the section named “CYLINDER
ASSEMBLY”.
#3 MAST
1. Remove the sequence strap retainer on the top of #1 mast.
2. Remove the Allen head screws holding the top mast bearings between the #2 and #3 mast. Remove the top mast bearings.
3. Slide #3 mast out of #2 mast. As mast is removed, the bottom four mast bearings will fall out. Its
important to note their orientation for re-assembly.
#2 MAST
1. Remove the Allen head screws holding the top mast bearings between the #1 and #2 mast. Remove the top mast bearings.
2. Slide the #2 mast out of the #1 mast. As mast is removed, the bottom four mast bearings will fall
out. Its important to note their orientation for re-assembly.
UL25/UL32/UL40
Page 3 - 9
SERVICE AND REPAIR
Figure 3-6: Mast Assembly, Strap and Chain Detail.
Page 3 - 10
UL25/UL32/UL40
SERVICE AND REPAIR
Figure 3-7: Mast Assembly, Bearing Detail.
UL25/UL32/UL40
Page 3 - 11
SERVICE AND REPAIR
PLATFORM ASSEMBLY
NOTE: Use WD-40 lubricant as necessary to aid with re-assembly.
#2 MAST
1.
2.
3.
4.
5.
Set #2 mast in place.
Install bottom lower bearings.
Install bottom upper bearings.
Slide #2 mast in all the way except 30-38 cm (12-15 inches).
Install top bearings and secure with retaining screws using loctite 242 or equivalent on the
threads.
6. Slide #2 mast in completely.
#3 MAST
1.
2.
3.
4.
5.
Set #3 mast in place with the sequencing strap inside.
Install bottom lower bearings.
Install bottom upper bearings.
Slide #3 mast in all the way except 30-38 cm (12-15 inches).
Install top bearings and secure with retaining screws using loctite 242 or equivalent on the
threads.
6. Place a 25 cm (10 inches) long wood block between #3 and #2 masts, slide #3 mast down tight
against block. Pull sequencing strap completely out of the bottom assembly.
7. Install cylinder assembly by following instructions under “CYLINDER ASSEMBLY” section.
#4 MAST
1.
2.
3.
4.
5.
Set #4 mast in place with the sequencing strap inside and the chains on the bottom.
Install bottom lower bearings.
Install bottom upper bearings.
Slide mast #4 in, making sure chains are not twisted.
Install top bearings and secure with retaining screws using loctite 242 or equivalent on the
threads.
6. Install chains around #3 sheave and down through #3 casting. Secure to #2 casting with new roll
pins.
7. Use a centre punch to dimple pin hole after roll pins are installed.
#5 MAST
1.
2.
3.
4.
5.
6.
Set #5 mast in place with the sequencing strap inside.
Install bottom lower bearings.
Install bottom upper bearings.
Slide #5 mast in, making sure chains are not twisted.
Install top bearings and secure with retaining screw using loctite 242 or equivalent on the threads.
Install chains around #4 sheaves and down through the casting. Secure to #3 casting with new
roll pins.
7. Use a center punch to dimple pin holes after all roll pins are installed.
8. Slide mast in, leaving 25 cm (10 inches) exposed.
#6 MAST
1. Set #6 mast in place with the sequencing strap inside.
2. Run the remaining sequencing strap from the platform to the assembly through the slot in the
bottom of stage #6 and up through the inside. Leave just enough slack on the outside to reach
the attachment point at the top of stage #5.
3. Install the bottom lower bearings.
4. Install the bottom upper bearings.
5. Slide #6 mast in, making sure the chains are not twisted.
6. Install the top bearings and secure with retaining screws using loctite 242 or equivalent on the
threads.
7. Install the #6 chain around the #5 sheave and through the casting secured to the #4 casting with
Page 3 - 12
UL25/UL32/UL40
SERVICE AND REPAIR
new roll pins.
8. Use a centre punch to dimple pin holes after all roll pins are installed.
9. Pull the sequencing strap attached to the bottom of mast #6 out through the bottom of the mast
assembly. Be sure not to pull the strap that is attached to the top of mast #5.
PLATFORM SUPPORT ASSEMBLY
1.
2.
3.
4.
5.
Slide the cage support weldment into the top of the platform assembly weldment.
Install the stop bracket and retaining screws/washers.
Feed chains over sheave.
Install cable sheaves with cables to the top of the cage support weldment.
Feed sequencing strap from inside mast #6 over sheave and out through the slot in the top of
the cage support weldment.
6. Install cage support weldment to mast #6 using 8 screws and tighten.
7. Attach chains to #5 casting front using new cotter pins.
SEQUENCING STRAP INSTALLATION
NOTE: When installing straps, make sure they are not twisted.
1. Feed fish tape up through the bottom slot in the cage support weldment and out through the top
slot.
2. Attach strap to the fish tape and pull out through bottom slot.
3. Feed fish tape down through the opening in the front of the platform support weldment and out
through the bottom of the platform support weldment.
4. Attach strap to the fish tape and pull out through the opening. Attach the strap to the platform
support weldment, pull tightly and secure with strap clamp and screws using loctite 242 or equivalent on the threads.
5. Feed #6 strap up through the mast between fourth and fifth stages with a fish tape.
6. Feed #5 strap up through the mast between third and fourth stages with a fish tape.
7. Feed #4 strap up through the mast between third and second stages with a fish tape.
8. Feed #3 strap up through the mast between first and second stages with a fish tape.
9. Install strap #6 to #4 top casting.
10. Install strap #5 to #3 top casting.
11. Install strap #4 to #2 top casting.
12. Install strap #3 to the top of #1 mast weldment.
13. Install the strap clamps and retaining screws using loctite 242 or equivalent on the threads. Pull
straps tight while tightening retaining screws.
CYLINDER ASSEMBLY
SEAL REPLACEMENT
NOTE: The lift cylinder seal can be accessed from the bottom of the lift without removing the
cylinder assembly.
Using a suitable lifting device, lower the work platform into a horizontal position (refer to Figure 3-5).
If possible, place the machine on a sturdy work table using a forklift.
! W A R N I N G !
Never attempt to lower lift into a horizontal position without the
use of a suitable lifting device as this can lead to bodily injury
or damage to the machine .
1. Remove cylinder mounting plate fasteners and retaining ring.
2. Remove tie rod nuts and count the number of turns required to bring the nut flush with the tie
rod end and record for reference during installation. The tension on the tie rods maintain the left/
right positioning of the cylinder within the mast assembly. Re-installing the nuts with the proper
tension will speed up adjustment later.
3. Remove the cylinder mounting plate. Be careful not to allow the tie rods to suck back inside the
UL25/UL32/UL40
Page 3 - 13
SERVICE AND REPAIR
mast assembly. Replace the nuts on the tie rod ends temporarily to prevent this.
4. Remove the hydraulic line from the cylinder fitting and cap the cylinder fitting to prevent contaminants from entering the cylinder.
C A U T I O N !
!
Marring the surface of the cylinder rod will damage cylinder seals and cause leakages. Use a strap
wrench to prevent rod damage.
5. Extend the cylinder rod at least 12 inches by hand. Apply heat to rod near end cap to loosen
loctite.
! W A R N I N G !
Wear safety glasses and heat resistant gloves when operating torch. Do not touch hot surfaces without proper
protection.
6. Using a strap wrench - 062482-000 to secure the cylinder rod, unscrew the cylinder rod end. If
necessary, thread a 9/16 x 18 bolt into end cap port to use as a lever. Remove rod end cap and
orifice/bleeder tube assembly.
7. Remove the seal retainer, using the spanner wrench - 062521-010.
8. Clean all sealing surfaces with a solvent. Inspect the cylinder rod for excessive wear. Replace if
necessary.
9. Remove all seals from seal retainer, rod end cap and discard.
NOTE: Apply clean hydraulic fluid to new cylinder seal, threads and all sliding surfaces prior
to assembly. If necessary, soften new seals with warm water 82°C (180° F) to aid in installation.
10. Twist the pressure seal into a ‘C’ shape and snap into a seal groove in seal retainer making sure
the lip of the seal is facing inward.
11. Using the same method, install the rod wiper into the seal retainer outer groove, making sure that
the blade of the seal is facing outward from the seal retainer.
12. Replace static seals in rod end cap and seal retainer by stretching them into place. Be careful
not to cut the seal during installation.
13. Install the seal retainer unto the rod using a sharp blow from a hard rubber mallet to overcome
seal squeeze. Slide the seal retainer into place and tighten using the spanner wrench.
1
2
3
4
A
B
Seal Profiles
C
D
1
2
3
4
Seal Kit
Rod end cap
A
Seal retainer
B
Cylinder rod
C
Cylinder body
D
Static seal #1
Rod wiper
Pressure seal
Static seal #2
Figure 3-8: Lift Cylinder.
Page 3 - 14
UL25/UL32/UL40
SERVICE AND REPAIR
14. The rod and rod end threads must be absolutely clean. Spray threads with loctite primer #7471
and allow to dry for 5 minutes. Coat threads liberally with loctite #242. Thread rod end cap unto
rod and tighten using strap wrench to hold rod.
15. Push rod back into cylinder for re-assembly.
16. Reconnect hydraulic line.
17. Remove nuts from tie rod ends and set the cylinder mounting plate in place. Secure the mounting
plate with fasteners.
18. Install tie rod nuts flush with tie rod ends and torque each nut the exact number of turns used to
remove it.
19. Re-install the retaining ring.
20. Using a suitable lifting device, raise the lift to its normal vertical position.
21. Bleed air from the cylinder by cycling the mast to full extension several times. The cylinder is self
bleeding; air will be forced out of the cylinder during the lowering cycle.
22. If necessary, remove pinch shield and check the alignment of the cylinder within the mast assembly by looking down the mast with a flashlight. The cylinder may be moved left or right by
tightening one or the other of the tie rod nuts.
!
C A U T I O N !
If the cylinder is not centred, the mast may
“hang” when lowering.
! W A R N I N G !
Keep hands clear of the mast assembly when the pinch shield is
removed for inspection purposes; pinching injury to hands may result.
Never operate a machine with the pinch shield removed except for inspection.
ORIFICE VALVE CLEANING
Using a suitable lifting device, lower the work platform into a horizontal position (refer to Figure 3-5).
If possible, place the machine on a sturdy work table using a forklift.
! W A R N I N G !
Never attempt to lower lift into a horizontal position without the
use of a suitable lifting device as this can lead to bodily injury
or damage to the machine .
1. Remove the cylinder mounting plate fasteners and retaining ring.
2. Remove tie rod nuts and count the number of turns required to bring the nut flush with the tie
rod end and record for reference during installation. The tension on the tie rods maintain the left/
right positioning of the cylinder within the mast assembly. Re-installing the nuts with the proper
tension will speed up adjustment later.
3. Remove the cylinder mounting plate. Be careful not to allow the tie rods to suck back into the
mast assembly. Replace the nuts on the tie rod ends temporarily to prevent this.
4. Remove the hydraulic line from the cylinder fitting and cap the cylinder fitting to prevent contaminants from entering the cylinder.
UL25/UL32/UL40
Page 3 - 15
SERVICE AND REPAIR
C A U T I O N !
!
Marring the surface of the cylinder rod will damage cylinder
seals and cause leakages. Use a strap wrench to prevent
rod damage.
5. Extend cylinder rod at least twelve inches by hand. Apply heat to the rod near the end cap to
loosen Loc-tite.
! W A R N I N G !
Wear safety glasses and heat resistant gloves when
operating torch. Do not touch hot surfaces without
proper protection.
6. Using a strap wrench 062482-000 to secure the cylinder rod, unscrew the cylinder rod end. If
necessary, thread a 9/16 x 18 bolt into an end cap port to use as a lever. Remove the rod end
cap and orifice/bleeder tube assembly.
7. Remove snap ring to release orifice/bleeder tube from the rod end cap.
8. Clean the orifice valve hole with a straight pin. Flush with solvent to remove any contamination
that may remain in the bleeder tube.
9. Re-install the orifice/bleeder tube into the rod end cap and secure with a snap ring.
10. Replace the static seal on the rod end. The existing seal may have been damaged by the heating rod end.
11. Rod and rod end threads must be absolutely clean. Spray threads with loctite primer #7471 and
allow to dry for 5 minutes. Coat threads liberally with loctite #242. Thread the rod end cap unto
the rod and tighten using a strap wrench to hold the rod.
12. Push the rod back into the assembly for re-assembly.
13. Re-connect the hydraulic line.
14. Remove nuts from the tie rod ends and set the cylinder mounting plate into place. Secure the
mounting plates with fasteners.
15. Install the tie rod nuts flush with the tie rod ends and torque each nut the exact number of turns
used to remove it.
16. Re-install the retaining ring.
17. Using a suitable lifting device, raise the lift to its normal vertical position.
18. Bleed air from the cylinder by cycling the mast to full extension several times. The cylinder is self
bleeding; air will be forced out of the cylinder during the lowering cycle.
19. If necessary, remove the pinch shield and check alignment of the cylinder within the mast assembly by looking down the mast with a flashlight. The cylinder guide bearings must not be touching
the inside surface of the #6 mast. The cylinder may be moved left or right by tightening the left or
right tie rod nuts respectively.
!
C A U T I O N !
If the cylinder is not centred, the mast may
“hang” when lowering.
! W A R N I N G !
Keep hands clear of the mast assembly when the pinch shield is
removed for inspection purposes; pinching injury to hands may result.
Never operate a machine with the pinch shield removed except for inspection.
Page 3 - 16
UL25/UL32/UL40
SERVICE AND REPAIR
2
3
1
1
2
6
5
4
3
4
Cylinder Assembly Installation
Tension bracket 5 Bottom casting,
(062739-000)
Mast #3
Tie rod
6
Cylinder
tensioners
(062738-000)
Tie rods
Bottom casting,
Mast #2
Figure 3-9: Cylinder Assembly Installation.
CYLINDER REMOVAL
Using a suitable lifting device, lower the work platform into a horizontal position (refer to Figure 3-5).
If possible, place the machine on a sturdy work table using a forklift.
! W A R N I N G !
Never attempt to lower lift into a horizontal position without the
use of a suitable lifting device as this can lead to bodily injury
or damage to the machine .
1. Remove the cylinder mounting plate fasteners and retaining ring.
2. Remove the tie rod nuts and count the number of turns required to bring the nut flush with the
tie rod end and record for reference during installation. The tension on the tie rods maintains the
left and right positioning of the cylinder within the mast assembly. Re-installing the nuts with the
proper tension will speed up adjustment later.
3. Remove the cylinder mounting plate. Be careful not to allow the tie rods to suck back into the
mast assembly. Replace the nuts on the tie rod ends temporarily to prevent this.
4. Remove the hydraulic line from the cylinder fitting and cap the cylinder fitting to prevent contaminants from entering the cylinder.
5. Remove sequence strap retainers on the top of the #3 and #2 masts.
6. Remove the front and rear mast access plates from the bottom of the #1 mast.
7. Remove the screws and washers, attaching the #2 and #3 bottom castings to the #2 and #3 mast
assemblies.
8. While keeping tension on the tie rods, slide the cylinder, the #2 and #3 bottom castings out of the
bottom of the UL lift far enough to expose both castings.
9. Install the cylinder tensioner brackets 062739-000 on #2 and #3 boom castings. Remove the tie
rod nuts and install the tie rod tensioners, 062738-000. Remove all slack from the chains with
the tie rod tensioners.
10. Remove the cylinder assembly from the mast assembly.
CYLINDER INSTALLATION
NOTE: The cylinder assembly must have tension brackets, a tension spacer and tie rod tensioners installed to remove slack from the chain.
1. Slide the cylinder assembly into the mast assembly until #3 bottom casting is at the bottom of
the mast assembly.
2. Install the screws and washers attaching the #3 bottom casting to the #3 mast assembly.
3. Remove the cylinder tensioner brackets from the #2 and #3 bottom castings and tie rod tensioners from the tie rods. Install the tie rod nuts finger tight.
4. While maintaining tension on the tie rods to keep slack out of the chains, slide the cylinder assembly completely into the mast assembly.
5. Install the screws and washers attaching the #2 bottom casting to the #2 mast assembly.
6. Install the front and rear mast cover plates on the bottom of the #1 mast.
7. Feed the #4 strap between the #3 and the #2 mast with a fish tape.
8. Slide the #4 strap through the #2 casting.
9. Feed the #3 strap between the #2 and the #1 mast with a fish tape.
UL25/UL32/UL40
Page 3 - 17
SERVICE AND REPAIR
10. Install strap #4 to the #2 top casting.
11. Install strap #3 to the #1 top casting.
12. While maintaining tension on the sequencing straps, install strap retainers using loctite 242 or
equivalent on the threads of the retainer screws.
13. Reconnect the hydraulic line.
14. Remove nuts from the tie rod ends and set the cylinder mounting plate into place. Secure the
mounting plate with fasteners.
15. Install the tie rod nuts flush with the tie rod ends and torque each nut the exact number of turns
used to remove it.
16. Re-install the retaining ring.
17. Using a suitable lifting device, raise the lift to its normal vertical position.
18. Bleed air from the cylinder by cycling the mast to full extension several times. The cylinder is self
bleeding; air would be forced out of the cylinder during the lowering cycle.
19. If necessary, remove the pinch shield and check the alignment of the cylinder within the mast
assembly by looking down the mast with a flashlight. The cylinder guide bearings must not be
touching the inside surface of the #6 mast. The cylinder may be moved left or right by tightening
the left or right tie rod nuts respectively.
! W A R N I N G !
Keep hands clear of the mast assembly when the pinch shield is
removed for inspection purposes; pinching injury to hands may result.
Never operate a machine with the pinch shield removed except for inspection.
TORQUE SPECIFICATIONS
HYDRAULIC COMPONENTS
Use the following values to torque the hydraulic components used on Snorkel work platforms.
NOTE: Always lubricate threads with clean hydraulic oil prior to installation.
Coil nuts: 3 Nm (30 In/lbs)
Type: SAE part series
Cartridge poppet
Ft/Lbs
Nm
#4
N/A
N/A
#6
N/A
N/A
#8
25-30
34-41
#10
35-40
47-54
#12
85-90
115-122
#16
130-140
176-190
Table 3-4: Hydraulic Component Torque.
Page 3 - 18
Fittings
Ft/Lbs
Nm
N/A
N/A
10-20
14-27
25-30
34-41
35-40
47-54
85-90
115-122
130-140
176-190
Hoses
In/Lbs
Nm
135-145
15-16
215-245
24-28
430-470
49-53
680-750
77-85
950-1050 107-131
1300-1368 147-155
UL25/UL32/UL40
SERVICE AND REPAIR
FASTENERS
Use the following values to torque fasteners used on Snorkel work platforms unless a specific torque
value is called out for the part being installed.
Thread size (American National
Standard-UNF (fine))
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1
Table 3-5: Bolt Torque.
UL25/UL32/UL40
Width across flats
7/16
1/2
9/16
5/8
3/4
15/16
1(1/8)
1(5/16)
1(1/2)
Torque value
Imperial
Metric
110 IN/Lbs
12
Nm
190 IN/Lbs
22
Nm
30
Ft/Lbs
41
Nm
50
Ft/Lbs
68
Nm
75
Ft/Lbs 102
Nm
150 Ft/Lbs 203
Nm
250 Ft/Lbs 339
Nm
400 Ft/Lbs 542
Nm
600 Ft/Lbs 813
Nm
Page 3 - 19
Page 3 - 20
UL25/UL32/UL40
TROUBLESHOOTING
CONTENTS
INTRODUCTION
4-2
GENERAL PROCEDURE
4-2
TILT SENSOR
4-4
TILT SENSOR SWITCH
3-4
SETTING THE TILT SENSOR TO ZERO
3-4
DIAGNOSTICS USING EZCAL CALIBERATOR
4-4
REPLACING THE EZ120 CONTROL MODULE
4-6
UL25/UL32/UL40
Page 4 - 1
TROUBLESHOOTING
INTRODUCTION
Table 4-1 provides a logical sequence of tests that are designed to isolate problems with the Snorkel
lift. This table includes a list of probable causes and remedies.
! W A R N I N G !
When troubleshooting, ensure that the work platform is resting on a firm, level
surface.
When performing any service which requires the platform to be raised, ensure that
all four outriggers are properly installed. Unplug the machine or disconnect the battery when replacing or testing the continuity of any electrical component.
GENERAL PROCEDURE
Troubleshooting should be carried out in two steps. First, thoroughly study both hydraulic and electrical schematics to determine possible causes. Loose terminal connections and short circuits are
always a potential cause when troubleshooting. Secondly, check suspect components electrically,
hydraulically and mechanically to determine if they are at fault. Refer to the section “SCHEMATICS”
for further information to be used together with information from Table 4-1.
ISSUE
PROBABLE CAUSE
1. Extension cord too long or
insufficient capacity.
2. Not plugged in or faulty connection (AC only)
3. No power at wall outlet (AC
only)
4. Faulty battery charger (DC
only)
5. Faulty battery (BAT)
Lift function inoperable, electric 6. Key switch (S2), Emergenmotor does not start.
cy stop switch (S1, S3) or
push button switch (S4, S5)
failed to open.
7. Outrigger interlock switch
(S7, S8, S9 &S10)
8. Open circuit in cable to motor control box.
9. Faulty electric motor (MI)
Lift turns on and off repeatedly. 1. Low line voltage or battery
charge.
Page 4 - 2
REMEDY
Use minimum 1.5 mm2 (12 ga.)
cord of 16m (50 feet) or less in
length.
Check that all AC plugs and
cords are used.
Check power output at wall
outlet.
Check the voltage output of the
battery charger. If less than 12
V DC, repair or replace
After completely charging the
battery, test the battery.
Replace if faulty.
With the switch in the “on”
position, check for continuity
across the contacts. If none,
replace.
Make sure all four outrigggers
are in firm contact with the
ground. Check continuity of
interlock switches.
Test for continuity through cable
assembly and repair or replace.
While operating the lift function,
check the voltage to the electric
motor. If voltage is present (12
V DC or 120/240 V AC),
replace the motor. In case of
low AC voltage, refer to #1.
Use minimum 11.5 mm2 (12
ga.) cord of 16 m (50 feet) or
less in length.
UL25/UL32/UL40
TROUBLESHOOTING
ISSUE
PROBABLE CAUSE
REMEDY
1. Indicator light damaged or
Replace indicator light.
faulty
One or more, but not all
2. Outrigger limit switch damReplace switch.
indicator lights fail to operate.
aged or faulty.
3. Chassis harness damaged Repair damage and ensure
or improperly connected.
proper connection.
1. Emergency lowering valve
Close valve.
(V2) open.
2. Hydraulic reservoir low.
Check hydraulic fluid level and
top off as required.
3. Down valve (V2) stuck
Check or replace down valve
Lift function inoperable. Electric
(V2).
motor starts when control is
4. Relief valve (RV) out of ad- Adjust the relief valve (RV). If
activated.
justment or faulty.
not adjustable, replace.
5. Lift valve (V1) faulty.
Check or replace lift valve (V1).
6. Faulty hydraulic pump (P) Check pressure and delivery of
the hydraulic pump. Replace
pump if required.
Platform does not lower using 1. Down valve solenoid (SOL1)
Test for continuity across
electrical switches. (Will
faulty.
solenoid. Repair or replace.
lower using emergency
lowering valve.)
2. Electrical malfunction.
Check all AC plugs and cords
used (AC only). Check power
output at wall outlet (AC only).
With each switch (S1, S2, S3,
S4 &S6) in the “on” position,
check continuity across the
contacts. If none, replace.
Platform does not lower or low- 1. Down orifice (ORF) plugged. Remove and clean the down
ers very slowly.
orifice check valve.
2. Down valve (V2) blocked or Check function/clear blockage
stuck closed.
of down valve.
3. Mechanical interference
Inspect mast assembly, correct
interference.
Platform continues to lower 1. Down valve (V1) stuck open. Clean or replace down valve.
when controls are released.
Table 4-1: Troubleshooting table.
UL25/UL32/UL40
Page 4 - 3
TROUBLESHOOTING
TILT SENSOR
TILT SENSOR SWITCH
The tilt sensor is incorporated in the EZ120 control module. The switch is activated if the machine
inclination is greater than 1.0° side to side or front to back. This results in a continuous audible alarm
and lift disabled. The only way to stop the alarm from sounding is to return the machine to an inclination level below 1.0° side to side and front to back. The settings of this limit is preset at the factory
and should on no account be adjusted.
SETTING THE TILT SENSOR TO ZERO
! W A R N I N G !
If the EZ120 control module is replaced and/or moved within the
machine for any reason, the tilt sensor must be reset for 0° using the
procedure provided. Failure to do so could result in serious injury or
death.
To follow the procedure, first connect an EZcal calibrator into the diagnostic port in the lower control
box.
1. Place the machine on a firm level surface ≤ 0.25°.
2. Use a gauge to confirm that the front and rear of the chassis are level to within +/- 0.25° in both
directions.
3. Switch the machine on and the EZcal menu should appear.
4. Scroll to access level and hit “Enter”.
5. Enter code 2222 for access level 2 and hit “Enter”.
6. Scroll to setups and hit “Enter”.
7. Scroll to tilt setups and hit “Enter”.
8. Choose calibrate level and hit “Enter”.
9. Hit “Enter” for yes for the machine tilt setup should be complete.
To confirm the calibration has worked, switch the machine off and then on again.
10. Scroll to diagnostics and hit “Enter”.
11. Search for system and hit “Enter”.
12. Scroll to tilt and both readings should be below 0.2°. If not, repeat from #3.
Display
Change Entry
Up / Down
Esc to leave
Sub-Menu
without saving.
ESC
ENTER
Enter to Save
Entry
Scroll
Left/Right
Figure 4-1: EZcal calibrator.
Page 4 - 4
UL25/UL32/UL40
TROUBLESHOOTING
DIAGNOSTICS USING EZCAL CALIBRATOR
The EZcal calibrator can be used as a diagnostic tool. Plug it into the diagnostic port in the lower
control box. Switch the machine on until the “EZlift menu” is displayed then select diagnostics. The
following menu becomes available:
1. SYSTEM
• SUPPLY: Displays battery voltage.
• TILT: Displays tilt angle of the machine in X and Y direction. Both should be below 1.0°.
• TILTED: YES or NO. (Should be yes when the machine is tilted.)
• OUTRIGGERS: YES or NO. (Should be yes when the outriggers are correctly deployed.
The remaining submenu’s under “SYSTEM” are not applicable to this machine.
2. INPUTS
• Displays the condition of all inputs to the EZ120. Refer to the I/O list for further information.
3. OUTPUTS
• Displays the condition of all outputs from the EZ120.
4. LOG
• SOFTWARE REV:
• MAX BAT VOLTS:
• Function time: Displays total machine run time.
• Motor time: Displays total pump motor run time.
I/O PORT
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P1-10
P1-11
P1-12
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
P2-9
Table 4-2: EZlift 120 I/O allocations.
UL25/UL32/UL40
DESCRIPTION
Platform mode supply.
Ground mode supply.
Input from platform enable switch.
Input from platform lower switch.
Input from ground enable switch.
Input from ground lower switch
Spare.
Input from outrigger limit switch #1
Input from outrigger limit switch #2
Input from outrigger limit switch #3
Input from outrigger limit switch #4
Input from outrigger limit switches #1,2,3,4 &
platform raise switch in series.
Output to alarm.
Output to BDI lamp (DC only).
Spare.
Output to power on lamp (DC only)
Output to platform raise valve.
Output to platform lower valve.
Output to line contactor.
Spare.
Output to outrigger switches & alarm supply.
Page 4 - 5
TROUBLESHOOTING
REPLACING THE EZ120 CONTROL MODULE
If for any reason the EZ120 control module has to be replaced, it is important that the procedure
listed below is followed.
! W A R N I N G !
If the EZ120 control module is replaced and/or moved within the
machine for any reason, the tilt sensor must be reset for 0° using the
procedure provided. Failure to do so could result in serious injury or
death.
To follow the procedure, first connect an EZcal calibrator into the diagnostic port in the lower control
box.
1. Place the machine on a firm level surface ≤ 0.25°.
2. Use a gauge to confirm that the front and rear of the chassis are level to within +/- 0.25° in both
directions.
3. Switch the machine on and the EZcal menu should appear.
4. Scroll to access level and hit “Enter”.
5. Enter code 2222 for access level 2 and hit “Enter”.
6. Scroll to setups and hit “Enter”.
7. Scroll to Change defaults and hit “Enter”.
8. Scroll to Vehicle and select (2) = UL D.C. or (11) = UL A.C. and then hit “Esc”.
9. Scroll to tilt setups and then hit “Enter”.
10. Choose calibrate level and hit “Enter”.
11. Choose “Enter” again for yes to enable the machine to be calibrated.
To confirm the calibration has worked, switch the machine off and then back on again.
12. Scroll to diagnostics and hit “Enter”.
13. Search for system and hit “Enter”.
14. Scroll to tilt and both readings should be below 0.2°. If not, repeat from #5.
Page 4 - 6
UL25/UL32/UL40
SCHEMATICS
INTRODUCTION
This section contains electrical and hydraulic power schematics and associated information for
maintenance purposes.
The diagrams are to be used in conjunction with the information in section 4. The schematics provide an understanding to the makeup and functions of the systems for checking, tracing and faultfinding during troubleshooting analysis.
CONTENTS
INTRODUCTION
5-1
ELECTRICAL SCHEMATIC A.C. - 514446-000
5-2
ELECTRICAL SCHEMATIC D.C. - 514445-000
5-3
HYDRAULIC SCHEMATIC
5-4
UL25/UL32/UL40
Page 5 - 1
SCHEMATICS
ELECTRICAL SCHEMATIC A.C. - 514446-000
Page 5 - 2
UL25/UL32/UL40
SCHEMATICS
ELECTRICAL SCHEMATIC D.C. - 514445-000
UL25/UL32/UL40
Page 5 - 3
SCHEMATICS
HYDRAULIC SCHEMATIC
REFERENCE
DESIGNATION
CV
CYL
NAME
FUNCTION
Check valve
Cylinder
Filter
Allows flow in one direction
Operates lift
Separates matter held in susFLT
pension from fluid.
ORF
Orifice
Controls flow out of cylinder
Pump
Supplies hydraulic pressure
P
to system
Relief valve
Limits maximum pressure by
RV
releasing oil
Valve, 2-way norm. Stops flow when energized.
V1
Open
Valve, 2-way norm. Allows flow when energized.
V2
Closed
Table 5-1: Hydraulic schematic legend.
LOCATION
Valve block assembly
On lift assembly
Inline with pump.
Inline with cylinder
Lower power module
Valve assembly
Lower power module
Valve block assembly
Lift cylinder assembly.
CYL
CV
ORF
P
V2
RV
V1
FLT
Figure 5-1: Hydraulic schematic.
Page 5 - 4
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
INTRODUCTION
This section lists and illustrates the replaceable assemblies and parts of this product as manufactured by Snorkel.
Each part list contains the component parts for that assembly.
CONTENTS
GENERAL ASSEMBLY
6-2
GENERAL ASSEMBLY BREAKDOWN
6-3
A.C. POWER OPTION
6-8
D.C. POWER OPTION
6-10
A.C. LOWER CONTROL BOX
6-12
D.C. LOWER CONTROL BOX
6-14
LIFT CYLINDER
6-16
2nd STAGE MAST ASSY
6-18
3rd STAGE MAST ASSY
6-19
4th STAGE MAST ASSY
6-20
5th STAGE MAST ASSY
6-22
6th STAGE MAST ASSY
6-24
PLATFORM SUPPORT ASSY
6-26
PLATFORM ASSY UL25
6-28
PLATFORM ASSY UL32/40
6-30
A.C. PLATFORM CONTROL BOX
6-32
D.C. PLATFORM CONTROL BOX
6-33
TILT BACK ASSY
6-34
LOADER STOP BRACKET ASSY
6-38
LOADER BAR ASSY
6-39
OUTRIGGER ASSY UL25/32
6-40
OUTRIGGER ASSY UL40
6-41
UL DC BATTERY BOX
6-43
DECAL KIT UL25
6-44
DECAL KIT UL32
6-46
DECAL KIT UL40
6-48
UL25/UL32/UL40
Page 6 - 1
ILLUSTRATED PARTS LIST
GENERAL ASSEMBLY
ITEM
SUB ITEM
Power option AC
Decal kit
UL25 AC
514856-800
Operator’s manual
Parts & services manual
Power option DC
Decal kit
UL25 DC
514857-800
Operator’s manual
Parts & services manual
Power option AC
Decal kit
UL32 AC
514858-800
Operator’s manual
Parts & services manual
Power option DC
Decal kit
UL32 DC
514859-800
Operator’s manual
Parts & services manual
Power option AC
Decal kit
UL40 AC
514860-800
Operator’s manual
Parts & services manual
Power option DC
Decal kit
UL40 DC
514861-800
Operator’s manual
Parts & services manual
Table 6-1: Overall UL25/32/40 assembly and part numbers.
Page 6 - 2
PART NUMBER
PART NUMBER
068008-011
508783-002
515066-000
515066-200
068009-011
508783-000
515066-000
515066-200
068008-011
508783-003
515066-000
515066-200
068009-011
508783-001
515066-000
515066-200
068008-011
508783-003
515066-000
515066-200
068009-011
508783-001
515066-000
515066-200
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
GENERAL ASSEMBLY BREAKDOWN
UL25 - 514856-800 (AC)
514857-800 (DC)
UL32 - 514858-800 (AC)
514860-800 (DC)
UL40 - 514860-800 (AC)
514861-800 (DC)
ITEM
PART NUMBER
DESCRIPTION
512805-100
Lift cylinder assembly
1
512789-100
Lift cylinder assembly
512806-100
Lift cylinder assembly
nd
068050-001
2 stage mast assembly
2
068050-002
2nd stage mast assembly
068050-003
2nd stage mast assembly
068056-001
3rd stage mast assembly
3
068056-002
3rd stage mast assembly
068056-003
3rd stage mast assembly
068061-001
4th stage mast assembly
4
068061-002
4th stage mast assembly
068061-003
4th stage mast assembly
068066-001
5th stage mast assembly
5
068066-002
5th stage mast assembly
068066-003
5th stage mast assembly
514600-001
6th stage mast assembly
6
514600-002
6th stage mast assembly
514600-003
6th stage mast assembly
068160-009
Cage support assembly
7
068160-010
Cage support assembly
068160-011
Cage support assembly
8
068218-000
Mast bearing
9
068217-000
Mast bearing
10
068216-000
Mast bearing
11
068122-000
Mast bearing
12
068121-000
Mast bearing
13
068120-000
Mast bearing
14
068119-000
Mast bearing
18
012553-005
Screw SOC HD 1/4 - 20 UNC x 5/8
19
012553-006
Screw SOC HD 1/4 - 20 UNC x 3/4
20
501258-020
Screw butt HD 3/8 - 16 x 5/8
21
062129-000
Strap retainer
22
011735-020
Roll pin
23
068143-000
Pin Leaf chain
UL25/UL32/UL40
UL25
1
UL32
UL40
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
12
4
4
4
4
4
21
22
8
5
4
2
8
12
4
4
4
4
4
21
22
8
5
4
2
1
8
12
4
4
4
4
4
21
22
8
5
4
2
Page 6 - 3
ILLUSTRATED PARTS LIST
ITEM
24
25
27
28
29
30
31
32
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
Page 6 - 4
PART NUMBER
DESCRIPTION
068141-000
Pin chain
510146-001
Cable connector gland
510147-001
Cable connector nut
056065-045
Bolt hexhd .500-13 1.75 GR5
056069-012
Washer, SteelFlatWasher M12
984519
Nut hex LKG .500-13
063926-007
Plug
011735-020
Roll pin
068140-000
Pin
068187-000
Loader assembly
068200-003
Tilt back assembly
068200-000
Tilt back assembly
068200-001
Tilt back assembly
062945-001
Retractile cord
062945-003
Retractile cord
062945-004
Retractile cord
062226-002
Cable storage tube
062226-003
Cable storage tube
062226-004
Cable storage tube
068157-001
Outrigger assembly
068157-001
Outrigger assembly
030838-007
Outrigger assembly
514735-000
Chassis weldment
514736-000
Chassis weldment
514737-000
Chassis weldment
514432-000
Motor cover
067995-000
Lifting alarm assembly
514817-000
Caster
068645-000
Axle shaft
514383-000
Wheel UL 10 x 2-1/2
068158-000
#1 Section slide
003570-000
Retaining pin
514471-000
Switch
514728-000
Stainless steel washer flat 3/4" x 2"
068646-000
Roll pin
020398-024
Clamp
011868-032
Grommet strain relief
011868-019
Grommet snap 7/8 DIA
011252-010
Screw HHC 1/4 - 20 UNC x 1(1/4)
056060-030
Screw HHC 3/8 - 16 x 3/4
056058-020
Screw MRH 1/4 - 20
011240-004
Washer 1/4 STD flat
UL25
2
2
2
4
4
4
2
2
2
1
1
UL32
2
2
2
4
4
4
2
2
2
UL40
2
2
2
4
4
4
2
2
2
1
1
1
1
1
2
2
2
4
4
4
1
1
1
1
2
1
2
1
5
4
2
2
4
1
2
4
8
3
20
1
1
2
1
2
1
5
4
2
2
4
1
2
4
8
3
20
1
1
1
2
1
2
1
5
4
2
2
4
1
2
4
8
3
20
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
63
64
65
66
68
69
79
90
91
92
056069-010
505050-010
056058-040
011868-019
514738-000
005503-003
014066-004
514457-000
514454-000
514455-000
514456-000
515182-000
Washer 3/8 STD flat
Nutzert 3/8 - 16 UNC
Bolt, HexBolt DIN931 M6
Grommet snap 7/8 DIA
Chassis cover
Screw, #6 self tapping
Screw HWH SLFTP 1/4 x 1/2
Wire harness
Retractile Cord
Retractile Cord
Retractile Cord
Fork Pocket
16
8
2
1
2
4
4
1
1
16
8
2
1
2
4
4
1
16
8
2
1
2
4
4
1
1
2
2
1
2
Table 6-2: UL25/32/40 general assembly components and part numbers.
UL25/UL32/UL40
Page 6 - 5
ILLUSTRATED PARTS LIST
GENERAL ASSEMBLY BREAKDOWN
Figure 6-1: General assembly illustration, DWG 1.
Page 6 - 6
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
GENERAL ASSEMBLY BREAKDOWN
Figure 6-2: General assembly illustration, DWG 2.
UL25/UL32/UL40
Page 6 - 7
ILLUSTRATED PARTS LIST
AC POWER OPTION - 068008-011
ITEM
PART NUMBER
068115-001
068115-011
068115-012
068115-013
068115-015
514458-000
514444-000
020809-001
DESCRIPTION
Power unit
Valve, load
1
Pump
Seal kit
Motor
2
Chassis harness, A.C.
3
Control box
5
Fitting, Tee
6MJ-6MB-6FJX
6
063965-003
Gage port
8
056069-008
Washer 8mm flat
9
011240-004
Washer 1/4 flat
10
011252-004
Screw HHC
1/4 - 20 (1/2)
11
056064-008
8 mm nut
13
013540-001
Wire nut 12-10
14
011868-019
Connection cable
Table 6-3: AC power option components and part numbers.
QTY
Page 6 - 8
UL25/UL32/UL40
1
1
1
1
1
4
4
4
4
2
1
UL25/UL32/UL40
Figure 6-3: AC power option illustration.
0
Cable marker #4
Cable marker #4
Cable marker #0
2
Cable
marker #3
To mains
Green Cable
Brown Cable
White/Red Cable
A.C. 110v connection type
Blue Cable
Blue/Black
Cable
Green Cable
Brown Cable
White Cable
To mains
Blue/Red
Cable
Blue Cable
A.C. 220v connection type
Black Cable
ILLUSTRATED PARTS LIST
AC POWER OPTION - 068008-011
Page 6 - 9
ILLUSTRATED PARTS LIST
DC POWER OPTION - 068009-011
ITEM
1
2
3
4a
4b
6
7
9
12
15
16
20
26
27
28
29
30
PART NUMBER
068214-000
3050002
514015-000
068116-001
515280-000
513896-001
513895-000
029902-000
011941-005
011252-008
056058-040
056069-006
068007-023
011240-004
011252-004
010154-000
514459-000
DESCRIPTION
Battery box
Battery
UL - China charger
Power unit (SN before 059999), See identification below
Power unit (SN after 060000), See identification below
Black cable 25mm CSA - see note 1
Ring crimp M10
Conn 175 amp
Fitting, straight 6MB - 6MJ
Screw HHC 1/4 - 20 x 1
M6 x 40 Hexhead UL
M6 flat washer UL
Control box w/electric down
Washer 1/4 flat
Screw HHC 1/4 - 20 x 1/2
Terminal cover
D.C. power harness
QTY
1
1
1
1
1
2
2
2
1
2
8
8
1
4
4
2
1
Table 6-4: DC power option components and part numbers.
DC power unit identification
Page 6 - 10
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
(+)
(-)
30
DETAIL B
22
22
B
DC POWER OPTION - 068009-011
Figure 6-4: DC power option illustration.
UL25/UL32/UL40
Page 6 - 11
ILLUSTRATED PARTS LIST
AC LOWER CONTROL BOX - 514444-000
ITEM
PART NUMBER
DESCRIPTION
1
0120804
Push button; Schneider XB2BA3351C
2
0120803
Push button; Schneider XB2BA3341C
3
510542-000
Push button; Schneider XB2BA21C
4
510524-000
SW Twist release E/stop
5
512543-000
Keyswitch
6
513949-000
9 way chassis socket
7
514433-000
7 way chassis socket
8
514435-000
5 way chassis socket
9
502588-000
Alarm, ECCO beeping 6-28 VDC
10
510156-000
9 way panel plug
11
510157-000
12 way panel plug
12
505082-014
M5 x 14 skt button cap screw DIN9427
13
514442-001
Overlay
14
514439-000
UL AC lower control box weldment
15
514467-000
AC120 controller
16
514440-000
UL AC control box panel
17
514005-000
PSU 230 V AC to 12 V DC 7.5 A
18
029868-007
Circuit breaker 15 A
19
056064-006
M6 nylock nut
20
058502-025
M6 x 25 S.H.C.S.
21
501253-012
M6 x 12 Button HD. screw - 12.9
22
512368-000
Din rail (62mm)
23
514470-000
AC contactor
24
067155-001
Battery holder
25
026551-004
Pop-rivet 1/8”
26
510147-000
Cable gland M20
27
510146-000
Cable gland nut M20
28
056066-004
M4 nylock nut - 8
29
058500-012
M4 x 12 socket HD cap screw - 12.9
30
508077-000
3 - core cable 2.5mmCSA H07RN - F
31
510167-000
8 A Diode
32
514642-000
Socket 4-way panel mount
33
512366-000
4-way panel plug
34
509755-000
Mate - n - lock SCKT contact
35
510145-000
Mate - n - lock pin contact
Table 6-5: AC Lower control box components.
Page 6 - 12
QTY
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
4
2
2
1
1
3
6
2
2
2
2
2.5m
1
1
1
22
4
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
AC LOWER CONTROL BOX - 514444-000
24
24
SECTION B-B
ENTRY FOR PUMP MOTOR
CABLE, 0.5meters OF ITEM 30
ENTRY FOR LINE IN CABLE,
2.0meters OF ITEM 30
16
27
26
25
6
7
B
B
8
4
32
18
35
1
3
0
2
1
9
2
5
12
22
17
23
11
A
A
29
19
14
SECTION A-A
28
21
20
15
10
34
33
Page 6 - 13
UL25/UL32/UL40
USE SINGLE SIDED ADHESIVE
SEAL TAPE TO SEAL FRONT PANEL.
GROUND STUD
Figure 6-5: AC Lower control box illustration.
ILLUSTRATED PARTS LIST
DC LOWER CONTROL BOX - 514443-000
ITEM
PART NUMBER
DESCRIPTION
1
514437-000
UL DC Lower control box weldment
2
514895-000
EZ120 controller
3
514438-000
UL DC lower control box panel
4
0120804
Push button; Schneider XB2BA3351C
5
0120803
Push button; Schneider XB2BA3341C
6
510542-000
Pushbutton; Schneider XB2BA21C
7
510524-000
SW twist release E/stop
8
512543-000
Keyswitch 3 position stayput
9
513949-000
9 way chassis socket
10
514433-000
7 way chassis socket
11
514435-000
5 way chassis socket
12
502588-000
Alarm, ECCO beeping 6-28 VDC
13
446086
Fuse holder
14
513876-000
FSHCS M5 x 0.8 x 25 class 8.8 DIN7991
15
056067-008
M8 nut - 8
16
510156-000
9 way panel plug
17
510157-000
12 way panel plug
18
505082-014
M5 x 14 skt button cap screw DIN9427
19
509755-000
Mate - n - lock SCKT contact
20
514441-001
Overlay
21
446076
Fuse 250 A
22
510561-008
M8 washer - ST/ST
23
056064-006
M6 nylock nut
24
058502-035
M6 x 35 S.H.C.S. - GR 8.8
25
509741-000
Blade fuse holder
26
509740-005
Blade fuse 7.5 A
27
514642-000
Socket 4-way panel mount
28
512935-000
LED green 12 V
29
510145-000
Mate - n - lock pin contact
30
512366-000
4 way panel plug
Table 6-6: DC Lower control box components.
Page 6 - 14
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
1
4
22
1
1
2
2
2
1
1
1
1
4
1
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
DC LOWER CONTROL BOX - 514443-000
98
REF
29
3
27
9
22
7
15
?
21
1
0
2
5
13
14
28
8
4
18
1
23
24
USE SINGLE SIDED ADHESIVE SEAL TAPE
TO SEAL FRONT PANEL.
A
A
16
30
WIRE TO CCT DIAG 514445-000
USING BLACK CABLE 1.0mm CSA 510671-000
AND CABLE MARKERS 510644-000 THRU -009
2
12
SECTION A-A
Page 6 - 15
UL25/UL32/UL40
10
11
17
Figure 6-6: DC Lower control box illustration.
ILLUSTRATED PARTS LIST
LIFT CYLINDER
UL25 - 068074-020
UL32 - 068074-021
UL40 - 068074-022
ITEM PART NUMBER
DESCRIPTION
rd
1
068129-000
3 stage bottom casting
2
068128-000
2nd stage bottom casting
3
068113-006
Lift cylinder
068113-007
Lift cylinder
068113-008
Lift cylinder
068113-010
Seal kit
4
068076-000
Cylinder sheave
062164-000
Chain
5
062164-123
Chain
062164-149
Chain
6
068089-000
Cylinder mount
068080-001
Tie rods
7
068080-002
Tie rods
068080-003
Tie rods
8
011248-010
Locknut 5/8 -11 UNC
9
068079-000
Cylinder guide bearing
10
011737-010
Roll pin
11
068081-000
Pin cylinder
12
011764-023
Retaining ring
13
062642-022
Bearing 16DU16
14
062169-004
Master link
15
062655-001
Chain guard
16
011941-005
Fitting ST O-ring 6MB - 6MJ
17
011828-006
Screw Flat HD socket 1/4 - 20 x 3/4
18
068143-000
Chain pin
19
011240-002
Washer #8 flat
20
026553-008
Rivet 3/16
060861-115
Hydraulic hose
21
060861-011
Hydraulic hose
060861-011
Hydraulic hose
22
011737-010
Roll pin 1/4 x 1 - 1/4
23
063988-006
Shim
24
066179-001
Valve, Lowering
25
069040-000
Threaded stud 1/4 - 28 x 1
26
069041-000
Knob - Red
Table 6-7: Lift cylinder components.
Page 6 - 16
UL25 UL32 UL40
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
2
1
2
1
2
2
2
1
1
1
2
2
2
1
2
2
4
4
1
2
2
1
1
1
2
2
2
1
2
2
4
4
2
2
2
1
1
1
2
2
2
1
2
2
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
LIFT CYLINDER
UL25 - 068074-020
UL32 - 068074-021
UL40 - 068074-022
Figure 6-7: Lift cylinder illustration.
UL25/UL32/UL40
Page 6 - 17
ILLUSTRATED PARTS LIST
2nd STAGE MAST ASSEMBLY
UL25 - 068050-001
UL32 - 068050-002
UL40 - 068050-003
ITEM
PART NUMBER
DESCRIPTION
nd
068055-001
2 Stage mast assy UL25
1
068055-002
2nd Stage mast assy UL32
068055-003
2nd Stage mast assy UL40
2
068053-000
#2 Section slide
3
011703-016
Screw socket hex set 1/4 - 20 UNC x 1
nd
Table 6-8: 2 stage mast assembly components.
QTY
1
1
1
1
2
Figure 6-8: 2nd stage mast assembly illustration.
Page 6 - 18
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
3rd STAGE MAST ASSEMBLY
UL25 - 068056-001
UL32 - 068056-002
UL40 - 068056-003
ITEM
1
3
4
6
8
9
10
PART NUMBER
068060-001
068060-002
068060-003
068139-000
011735-012
062753-000
068137-000
062642-010
011786-005
DESCRIPTION
3 stage mast assy UL25
3rd stage mast assy UL32
3rd stage mast assy UL40
Shaft
Pin
Strap assy
Sheave
Bearing
MAC. Bushing
rd
QTY
1
1
1
1
1
1
1
3
2
Table 6-9: 3rd stage mast assembly components.
Figure 6-9: 3rd stage mast assembly illustration.
UL25/UL32/UL40
Page 6 - 19
ILLUSTRATED PARTS LIST
4th STAGE MAST ASSEMBLY
UL25 - 068061-001
UL32 - 068061-002
UL40 - 068061-003
ITEM
1
2
3
4
5
6
8
9
10
11
PART NUMBER
068064-001
068064-002
068064-003
062168-111
062168-137
062168-163
068138-000
011753-020
068146-000
062753-000
068065-000
012553-008
062642-016
068136-000
DESCRIPTION
4 stage mast assy UL25
4th stage mast assy UL32
4th stage mast assy UL40
Chain
Chain
Chain
Shaft
Shaft
Pin
Strap assy
#4 section slide
Screw socket HD cap 1/4 - 20 UNC x 1
Bearing
Sheave
th
QTY
1
1
1
2
2
2
2
2
2
1
1
2
2
2
Table 6-10: 4th stage mast assembly components.
Page 6 - 20
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
4th STAGE MAST ASSEMBLY
UL25 - 068061-001
UL32 - 068061-002
UL40 - 068061-003
Figure 6-10: 4th stage mast assembly illustration.
UL25/UL32/UL40
Page 6 - 21
ILLUSTRATED PARTS LIST
5th STAGE MAST ASSEMBLY
UL25 - 068066-001
UL32 - 068066-002
UL40 - 068066-003
ITEM
1
2
3
4
5
6
8
9
10
11
12
PART NUMBER
068069-001
068069-002
068069-003
062167-141
062167-173
062167-205
068138-001
068135-000
068140-000
062753-000
011751-004
011252-016
011240-004
011248-004
068097-000
DESCRIPTION
5 stage mast assy UL25
5th stage mast assy UL32
5th stage mast assy UL40
Chain
Chain
Chain
Shaft
Sheave, 5 stage top
Pin
Strap assy
Pin, cotter 1/16 x 1/2
Screw HHC 1/4 - 20 x 2
Washer 1/4 STD flat
Nut 1/4 - 20 UNC ESNA
5th stage guide
th
QTY
1
1
1
2
2
2
1
1
2
1
4
2
4
2
1
Table 6-11: 5th stage mast assembly components.
Page 6 - 22
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
5th STAGE MAST ASSEMBLY
UL25 - 068066-001
UL32 - 068066-002
UL40 - 068066-003
Figure 6-11: 5th stage mast assembly illustration.
UL25/UL32/UL40
Page 6 - 23
ILLUSTRATED PARTS LIST
6th STAGE MAST ASSEMBLY
UL25 - 514600-001
UL32 - 514600-002
UL40 - 514600-003
ITEM
1
2
3
5
6
7
8
9
PART NUMBER
514601-001
514601-002
514601-003
062166-139
062166-171
062166-203
062753-000
068073-000
011821-005
068144 - 000
011735-005
068219-099
DESCRIPTION
6 stage weldment UL25
6th stage weldment UL32
6th stage weldment UL40
Chain
Chain
Chain
Strap assy
Chain block
Screw Butt HD 1/4 - 20 UNC
Clevis pin 6B
Roll pin 1/8 DIA x 5/8 LG
UHMW wear strip x 1(1/2)
th
QTY
1
1
1
2
2
2
1
1
4
2
2
.25 ft
Table 6-12: 6th stage mast assembly components.
Page 6 - 24
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
6th STAGE MAST ASSEMBLY
UL25 - 514600-001
UL32 - 514600-002
UL40 - 514600-003
Figure 6-12: 6th stage mast assembly illustration.
UL25/UL32/UL40
Page 6 - 25
ILLUSTRATED PARTS LIST
PLATFORM SUPPORT ASSEMBLY
UL25 - 514599-000
UL32 - 514599-010
UL40 - 514599-011
ITEM
1
2
4
5
6
7
8
9
10
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PART NUMBER
514599-001
514599-002
514599-003
062165-133
062165-169
062165-201
017301-005
068092-000
068093-000
068094-0041
068162-000
062753-001
068049-000
011254-010
011240-006
011250-006
068142-000
011253-006
011240-005
011250-005
011252-008
011240-004
011248-004
014099-044
011248-012
068231-000
011240-012
011252-003
062129-000
012553-005
063926-007
DESCRIPTION
Platform support weldment
Platform support weldment
Platform support weldment
Chain
Chain
Chain
Tube 1/2 OD x 18 GA wall x 7/8
Sleave spanner tube
Roller chain
Control cable sheave
Control cable sheave bracket
Strap assy
Control bracket
Screw HHC 3/8 - 16 UNC x 1(1/4)
Washer 3/8 STD flat
Nut hex ESNA 3/8 - 16 UNC
Chain pin
Screw HHC 5/16 - 18 UNC x 3/4
Washer 5/16 STD flat
Nut hex ESNA 5/16 - 18 UNC
Screw HHC 1/4 - 20 UNC x 1
Washer 1/4 STD flat
Nut hex ESNA 1/4 - 20 UNC
Screw HHC 3/4 - 10 UNC x 5(1/2)
Nut hex ESNA 3/4 - 10 UNC
Top cover
Washer STD flat 3/4
Screw HHC 1/4 - 20 UNC x 3/8
Strap retainer
Screw SOC HD 1/4 - 20 UNC x 5/8
50 x 50 insert
UL25
1
UL32 UL40
1
1
2
2
2
1
1
2
2
1
1
2
2
2
2
2
2
2
4
11
6
1
1
1
2
3
1
2
2
2
1
1
2
2
1
1
2
2
2
2
2
2
2
4
11
6
1
1
1
2
3
1
2
2
2
2
1
1
2
2
1
1
2
2
2
2
2
2
2
4
11
6
1
1
1
2
3
1
2
2
Table 6-13: Platform support assembly components.
Page 6 - 26
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
PLATFORM SUPPORT ASSEMBLY
UL25 - 514599-000
UL32 - 514599-010
UL40 - 514599-011
30
Figure 6-13: Platform support assembly illustration.
UL25/UL32/UL40
Page 6 - 27
ILLUSTRATED PARTS LIST
PLATFORM ASSEMBLY - UL25
068179-003
ITEM
PART NUMBER
DESCRIPTION
1
068082-001
Platform support weldment
2
068123-000
Slide angle
3
506275-001
Rail weldment (ANSI Lower rail 068150-002)
4
068149-002
Cage pan
5
068276-000
Shear guard
6
068096-000
Rail bearing top
7
068147-000
Front cover
8
057524-001
Drop bar assy
9
026525-003
Screw SLFTP #8 HWH x 3/8
10
970109
Screw HHC 1/4 - 20 UNC 2 x 3/4
11
011240-004
Washer 1/4 STD
12
011248-004
Nut hex ESNA 1/4 - 20 UNC
13
011264-022
Screw HHC 5/16 - 18 UNC x 2(3/4)
14
011240-005
Washer 5/16 STD
15
011246-010
Nut ESNA 5/16 - 18 UNC
16
510524-000
Switch, push pull
17
510525-000
Contact block
18
062799-011
Enclosure box & cover
19
0120803
Push button up
20
510527
Contact block N.O.
21
0120804
Push button down
22
510542
Push enable
23
029925-000
Connector
24
029939-002
Locknut 1/2 NPT
25
014252-004
Nut sert 1/4 - 20 UNC
26
011825-006
Screw RND HO 1/4 - 20 UNC x 3/4
27
011708-003
Screw RD HO mach #8-32 x 1/2
28
011252-014
Screw HHC 1/4 - 20 UN x 1 3/4
29
014924-008
U-bolt
30
068630-000
Extension spring Ø 0.055 wire
31
013919-009
Clamp, 5/8 DIA.
32
026551-007
Rivet 1/8 .251-.312 grip
33
057094-002
Harness hardpoint bracket
34
514696-000
Backing plate
35
514697-000
Backing plate
36
058508-030
Bolt - M10 x 30
37
056064-010
Nyloc nut - M10
38
505087-010
Flatwasher - M10
39
970129
Screw HHC 1/4 - 20 UNC x 3
Table 6-14: Platform assembly components UL25.
Page 6 - 28
QTY
1
4
1
1
1
4
1
1
16
2
15
12
4
4
4
1
1
1
1
3
1
1
1
1
3
5
2
4
2
2
4
4
1
1
2
1
1
2
2
UL25/UL32/UL40
12
UL25/UL32/UL40
2
11
9
31
A
25
30
25
5
DETAIL A
SCALE 1 : 2
1
34
29
6
32
11
12
39
11
12
37
38
27
10
4
3
15
36
14
35
8
13
33
6
12
28
18
21
22
19
16
17
POWER TO
PLATFORM
20
7
11
26
26
11
(BLUE) LOWER
POWER ON
(ORANGE) LIFT
(RED) E-STOP
24
COIL CORD
23
CONTROLLER
WIRING
ILLUSTRATED PARTS LIST
PLATFORM ASSEMBLY - UL25
068179-003
Figure 6-14: Platform assembly illustration UL25.
Page 6 - 29
ILLUSTRATED PARTS LIST
PLATFORM ASSEMBLY - UL32/UL40
068179-004
ITEM
PART NUMBER
DESCRIPTION
1
068082-001
Platform support weldment
2
068123-000
Slide angle
3
506275-001
Rail weldment (ANSI Lower rail 068150-002)
4
068149-002
Cage pan
5
068096-000
Rail bearing top
6
068147-000
Front cover
7
057524-001
Drop bar assy (ANSI upper rail 068171-002)
8
026525-003
Screw SLFTP #8 HWH x 3/8
9
970109
Screw HHC 1/4 - 20 UNC x 2(3/4)
10
011240-004
Washer 1/4 STD
11
011248-004
Nut Hex ESNA 1/4 - 20 UNC (ANSI rail only)
12
011264-022
Screw HHC 5/16 - 18 - UNC x 2 3/4
13
011240-005
Washer 5/16 STD
14
011246-010
Nut ESNA 5/16 - 18 UNC
15
510524-000
Switch, push pull
16
510525-000
Contact block
17
062799-011
Enclosure box & cover
18
0120803
Push button up
19
510527
Contact block N.O.
20
0120804
Push button down
21
510542
Push enable
22
029925-000
Connector
23
029939-002
Locknut 1/2 NPT
24
014252-004
Nut sert 1/4 - 20 UNC
25
011825-006
Screw RND HO 1/4 - 20 UNC x 3/4
26
011708-003
Screw RD HO mach #8 - 32 x 1/2
27
011252-014
Screw HHC 1 14 - 20 UNC x 1 3/4
28
014924-008
U - bolt
29
068630-000
Extension spring Ø 0.055 wire
30
013919-009
Clamp, 5/8 diameter
31
057094-002
Harness hardpoint bracket
32
514696-000
Backing plate
33
514697-000
Backing plate
34
058508-030
Bolt - M10 x 30
35
056064-010
Nyloc nut - M10
36
505087-010
Flat washer - M10
37
970129
Screw HHC 1/4 - 20 UNC x 3
Table 6-15: Platform assembly components UL32/UL40.
Page 6 - 30
QTY
1
4
1
1
4
1
1
16
2
15
12
4
4
4
1
1
1
1
3
1
1
1
1
3
5
2
4
2
2
4
1
1
2
1
1
2
2
UL25/UL32/UL40
11
UL25/UL32/UL40
2
10
8
30
A
24
29
24
1
32
28
5
33
37
10
11
34
35
36
7
13
31
12
11
10
9
3
14
26
4
11
27
20
21
18
17
16
POWER TO
PLATFORM
15
19
25
6
25
10
10
(RED) E-STOP
(BLUE) LOWER
POWER ON
(ORANGE) LIFT
23
COIL CORD
22
CONTROLLER
WIRING
ILLUSTRATED PARTS LIST
PLATFORM ASSEMBLY - UL32/UL40
068179-004
Figure 6-15: Platform assembly illustration UL32/UL40.
Page 6 - 31
ILLUSTRATED PARTS LIST
A.C. PLATFORM CONTROL BOX - 514795-000
ITEM
PART NUMBER
DESCRIPTION
1
514788-000
UL upper control box weldment
2
514789-000
UL A.C. upper control box panel
3
514433-000
7 way chassis socket
4
510524-000
SW twist release E/stop
5
0120803
Raise push button
6
510542-000
Pushbutton
7
0120804
Lower push button
8
514822-000
Switch 2-way spring to off
9
505082-010
10
514825-000
Overlay
Table 6-16: A.C. platform control box components.
9
QTY
1
1
1
1
1
1
1
1
4
1
1
2
3
4
5
6
7
8
Figure 6-16: A.C. platform control box illustration.
Page 6 - 32
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
D.C. PLATFORM CONTROL BOX - 514796-000
ITEM
1
2
3
4
5
6
7
8
9
10
PART NUMBER
514788-000
514790-000
514433-000
510524-000
0120803
510542-000
0120804
505082-010
514826-000
512934-000
DESCRIPTION
UL upper control box weldment
UL D.C. upper control box panel
7 way chassis socket
SW twist release E/stop
Raise push button
Pushbutton
Lower push button
QTY
1
1
1
1
1
1
1
4
1
1
Overlay
LED red 12V
Table 6-17: D.C. platform control box components.
8
1
2
3
4
5
6
7
10
Figure 6-17: D.C. platform control box illustration.
UL25/UL32/UL40
Page 6 - 33
ILLUSTRATED PARTS LIST
TILT BACK ASSEMBLY
UL32 - 068200-000
UL40 - 068200-001
ITEM
PART NUMBER
DESCRIPTION
1
068180-000
Loader bar assembly
2
068190-000
Loader stop bracket assembly
3
068201-000
Tilt back weldment 32-40
4
062844-000
Tiltbar weldment
5
062846-001
Tube cylinder mount
6
068196-000
Inner tube 32
7
062884-002
Tube cylinder outer
8
062885-001
Fitting cylinder end
9
062886-000
Fitting cylinder end
10
062887-001
Pin cylinder mount
11
062891-001
Lanyard assembly
12
003570-000
Pin retaining
13
063650-003
Cylinder gas spring
14
062843-001
Grip
15
063926-004
Caplug
16
062888-003
Pin 3/4 x 2(1/2)
17
016590-001
Pipe .3/4 SCHD40ALUM 3/8 LG
18
514816-000
Caster
19
5592006
Ring retaining
21
504145-000
Split pin 3.2mm X 32 DIN 94 zinc plated
22
011256-008
1/2”- 13 UNC x 1” H.T. HEX Set
23
970269
Screw HHC 5/16 - 18 x 1
24
011256-022
Screw HHC 1/2 - 13 2(3/4)
25
986269
Flat washer .313
26
011248-008
Nut HEX ESNA 1/2-13 UNC
27
5560031
HEX lock nut .3125-18 UNC
28
016590-001
Pipe.3/4 SCHD40ALUMX3/8LG
Table 6-18a: UL32/40 tilt back assembly components.
Page 6 - 34
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
8
2
16
4
8
2
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
TILT BACK ASSEMBLY UL32 - 068200-000
UL40 - 068200-001
060545-022
Figure 6-18a: UL32/40 tilt back assembly illustration.
UL25/UL32/UL40
ULII Series Parts Manual
Page 6 - 35
Page 33
TILT BACK ASSEMBLY UL25 - 068200-003
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART NUMBER
068201-002
068180-000
068190-000
514816-000
068265-000
062846-001
063926-004
062844-000
062843-001
003570-005
011256-022
011248-008
986269
970269
5560031
062891-001
5592006
068190-000
062891-001
011248-008
011256-022
DESCRIPTION
TILTBACK WELDMENT(UL25)
LOADER BAR ASSEMBLY
LOADER STOP BRKT. ASSY.
CASTOR, SWIVEL LOCK (4 x 2)
LIFT TUBE
TUBE - CYL. MOUNT
CAP PLUG
LIFTBAR WELDMENT
GRIP SLEEVE
RETAINING PIN ASSY.
HEX HD BOLT - 1/2" UNC x 2.75
NUT - 1/2-13 UNC
FLAT WASHER - 5/16"
HEX. HD. BOLT - 5/16"-18 x 1.25"
NYLOCK NUT - 5/16"-18
LANYARD ASSEMBLY
EXTERNAL CIRCLIP - 19mm
LOADER STOP BRACKET ASSY
LANYARD ASSEMBLY
Nut HEX ESNA 1/2-13 UNC
SCREW HHC 1/2 - 13 2(3/4)
QTY
1
1
1
2
1
1
1
1
1
1
2
2
16
8
8
1
2
1
1
4
2
Table 6-18b: UL25 tilt back assembly components.
Page 6 - 36
UL25/UL32/UL40
TILT BACK ASSEMBLY UL25 - 068200-003
19
7
18
6
17
5
9
14
13
8
15
20
4
1
2
10
16
21
3
11
12
Table 6-18b: UL25 tilt back assembly components.
UL25/UL32/UL40
Page 6 - 37
ILLUSTRATED PARTS LIST
LOADER STOP BRACKET ASSEMBLY - 068190-000
ITEM
PART NUMBER
DESCRIPTION
1
068191-000
Loader stop bracket weldment
2
068193-000
Slide pad - loader stop
3
03570-000
Retaining pin assy
4
014066-006
Screw 1/4 self tapping x 3/4
Table 6-19: UL25/32/40 loader stop bracket assembly components
QTY
1
2
1
4
Figure 6-19: UL25/32/40 loader stop bracket assembly illustration.
Page 6 - 38
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
LOADER BAR ASSEMBLY - 068168-000
ITEM
PART NUMBER
DESCRIPTION
1
068187-000
Loader bar weldment
2
068188-000
Slide pad
3
061694-005
Hose 2 5/8 OD x 2 ID x 5
4
062923-000
Loader hanger
5
015936-004
Bolt shoulder 3/8 x 1/2
6
011248-005
Nut hex ESNA 5/16 - 18 UNC
7
014066-006
Screw HWH SLFTP 1/4 - AB x 3/4
Table 6-20: UL25/32/40 loader bar assembly components
QTY
1
2
2
1
2
2
6
Figure 6-20: UL25/32/40 loader bar assembly illustration.
UL25/UL32/UL40
Page 6 - 39
ILLUSTRATED PARTS LIST
OUTRIGGER ASSEMBLY
UL25/UL32 - 068157-001
ITEM
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
18
19
PART NUMBER
003471-000
003508-000
003532-000
026553-005
056059-045
056066-006
056066-008
056069-010
056069-016
058491-050
062636-000
068102-001
068148-000
508247-008
056060-075
970369
056066-010
5569922
DESCRIPTION
Handle alarm
Knob UL - Outrigger
Pad assembly
3/16” x 3/8” pop rivet
Bolt, hexbolt DIN931 M8 x 45mm
Nut nylock DIN985 M6 8.0 Zi
Nut nylock DIN985 M8 8.0 Zi
Washer, steelflat washer DIN125
Washer, steelflat washer Din125A M16 Zinc
Bolt, hexsetscrew DIN933 M6
Jack screw
Outrigger tube x 44
Screw casting
Washer, pennywasher, DIN9021, M8
Bolt, hexbolt Din931 M10 x 75mm
Bolt hexhead .313-18 1.00 GR5-5/1
Nut, nylocknut Din985 M10 8.0
M8 spring washer
QTY
1
1
1
4
4
4
4
8
1
4
1
1
1
8
4
4
4
1
Table 6-21: UL25/32 outrigger assembly components
Page 6 - 40
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
OUTRIGGER ASSEMBLY
UL40 - 030838-007
ITEM
PART NUMBER
DESCRIPTION
1
003471-000
Handle alarm
2
003508-000
Knob UL - Outrigger
3
003532-000
Pad assembly
4
026553-005
3/16” x 3/8” pop rivet
5
056059-045
Bolt, hexbolt DIN931 M8 x 45mm
6
056066-006
Nut nylock DIN985 M6 8.0 Zi
7
056066-008
Nut nylock DIN985 M8 8.0 Zi
8
030838-200
Outrigger tube strap
9
056069-010
Washer, steelflat washer DIN125
10
056069-016
Washer, steelflat washer Din125A M16 Zinc
11
058491-050
Bolt, hexsetscrew DIN933 M6
12
062636-000
Jack screw
13
030838-005
Outrigger tube UL40 CSA
14
068148-000
Screw casting
15
508247-008
Washer, pennywasher, DIN9021, M8
16
056060-075
Bolt, hexbolt Din931 M10 x 75mm
17
970369
Bolt hexhead .313-18 1.00 GR5-5/1
18
056066-010
Nut, nylocknut Din985 M10 8.0
19
5569922
M8 spring washer
20
011741-004
Screw flat HD SOC 3/8 - 16 UNC 1
Table 6-22: UL40 outrigger assembly components
UL25/UL32/UL40
QTY
1
1
1
4
4
4
4
2
8
1
4
1
1
1
8
4
4
4
1
18
Page 6 - 41
ILLUSTRATED PARTS LIST
OUTRIGGER ASSEMBLY
UL25/UL32 - 068157-001
UL40 - 030838-007
11
2
9
6
1
5
12
7
15
20
8
14
13
16 18 9
10
3
4
17 15
7
19
Figure 6-21: UL25/32/40 outrigger assembly illustration.
Page 6 - 42
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
UL DC BATTERY BOX - 068214-000
ITEM
PART NUMBER
DESCRIPTION
1
068214-002
Battery box
2
068214-003
Battery box cover
3
011703-016
Socket HD cap 1/4” UNC x1”
4
514015-020
Battery charger mount
Table 6-23: UL DC battery box components
QTY
1
1
2
1
4
2
3
1
Figure 6-22: UL25/32/40 outrigger assembly illustration.
UL25/UL32/UL40
Page 6 - 43
ILLUSTRATED PARTS LIST
DECAL KIT - UL25
AC - 068013-012
DC - 068013-013
ITEM
1
2
3
4
5
6
8
9
10
12
13
14
15
16
18
19
20
21
23
25
26
27
PART NUMBER
010076-901
067195-003
067195-203
067195-303
005223-903
101210-000
064444-000
026551-004
062218-901
061683-008
068212-001
061205-003
066550-015
066557-971
101208-002
066551-905
069338-900
064936-009
062840-900
066550-215
066550-315
062466-902
DESCRIPTION
Label, operating instructions
Label, warning use
Label, warning use
Label, warning use
Label, emergency down
Label, warning hydrogen gas
Label, USA
Rivet, pop 1/8 .126 - .187 grip
Label, insert outrigger
Label, upright
Label, UL25
Nameplate
Label, warning before using
Label, warning max load 159 kg
Label, warning pinch point
Label, warning centre bubble
Label, control switch
Tape reflective
Label, controls
Label, warning before using
Label, Warning before using
Label, Tiltback warning
QTY
1
1
1
1
1
1 DC only
1
18
2
2
1
1
1
1
2
1
1
FT 12
1
1
1
1
Table 6-24: UL25 decal kit breakdown
Page 6 - 44
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
DECAL KIT - UL25
AC - 068013-012
DC - 068013-013
ILLUSTRATION SHOWS
U.S. CAGE
Figure 6-23: UL25 decal kit illustration.
UL25/UL32/UL40
Page 6 - 45
ILLUSTRATED PARTS LIST
DECAL KIT - UL32
AC - 068014-012
DC - 068014-013
ITEM
PART NUMBER
1
010076-901
2
067195-003
3
067195-203
4
067195-303
5
005223-903
6
101210-000
8
064444-000
9
026551-004
10
062218-901
12
061683-008
13
068212-002
14
061205-003
15
066550-015
16
066557-959
18
101208-002
19
066551-905
20
069338-900
21
064936-009
23
062840-900
25
066550-215
26
066550-315
27
062466-902
Table 6-25: UL32 decal kit breakdown
Page 6 - 46
DESCRIPTION
Label, operating instructions
Label, warning use
Label, warning use
Label, warning use
Label, emergency down
Label, warning hydrogen gas
Label, USA
Rivet, pop 1/8 .126 - .187 grip
Label, insert outrigger
Label, upright
Label, UL32
Nameplate
Label, warning before using
Label, warning max load 135 kg
Label, warning pinch point
Label, warning centre bubble
Label, control switch
Tape reflective
Label, controls
Label, warning before using
Label, Warning before using
Label, Tiltback warning
QTY
1
1
1
1
1
1 DC only
1
18
2
2
1
1
1
1
2
1
1
FT 22
1
1
1
1
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
DECAL KIT - UL32
AC - 068014-012
DC - 068014-013
ILLUSTRATION SHOWS
U.S. CAGE
Figure 6-24: UL32 decal kit illustration.
UL25/UL32/UL40
Page 6 - 47
ILLUSTRATED PARTS LIST
DECAL KIT - UL40
AC - 068015-012
DC - 068015-013
ITEM
1
2
3
4
5
6
8
9
10
12
13
14
15
16
18
19
20
21
23
25
26
27
PART NUMBER
010076-901
067195-003
067195-203
067195-303
005223-903
101210-000
064444-000
026551-004
062218-901
061683-008
068212-003
061205-003
066550-015
066557-959
101208-002
066551-905
069338-900
064936-009
062840-900
066550-215
066550-315
062466-902
DESCRIPTION
Label, operating instructions
Label, warning use
Label, warning use
Label, warning use
Label, emergency down
Label, warning hydrogen gas
Label, USA
Rivet, pop 1/8 .126 - .187 grip
Label, insert outrigger
Label, upright
Label, UL40
Nameplate
Label, warning before using
Label, warning max load 135 kg
Label, warning pinch point
Label, warning centre bubble
Label, control switch
Tape reflective
Label, controls
Label, warning before using
Label, Warning before using
Label, Tiltback warning
QTY
1
1
1
1
1
1 DC only
1
18
2
2
1
1
1
1
2
1
1
FT 28.7
1
1
1
1
Table 6-26: UL40 decal kit breakdown
Page 6 - 48
UL25/UL32/UL40
ILLUSTRATED PARTS LIST
DECAL KIT - UL40
AC - 068015-012
DC - 068015-013
ILLUSTRATION SHOWS
U.S. CAGE
Figure 6-25: UL40 decal kit illustration.
UL25/UL32/UL40
Page 6 - 49
Local Distributor / Lokaler Vertiebshändler / Distributeur local
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EUROPE, MIDDLE EAST
AFRICA & ASIA
PHONE: +44 (0) 845 1550 057
FAX: +44 (0) 845 1557 756
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