Snorkel LX41 User Manual

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Page 1

LX31 / LX41

Electric Models

Serial Numbers 4022 - Current

P/N 067448-003

Page 2

LX31 / LX41

Electric Models

When contacting UpRight for service or parts information, be sure to include the MODEL and SERIAL NUMBERS from the equipment nameplate. Should the nameplate be missing, the SERIAL NUMBER is also stamped on top of the chassis above the left front axle pivot.

UpRight, Inc.

801 South Pine Street Madera, California 93637

TEL: 559-662-3900 FAX: 559-673-6184 PARTS: 1-888-UR-PARTS PARTS FAX: 1-800-669-9884

Call Toll Free in U.S.A.

1-800-926-LIFT

UpRight

Unit S1, Park West Industrial Park

Friel Avenue

Nangor Road

Dublin 12, Ireland TEL: +353 1 620 9300 FAX: +353 1 620 9301

Page 3

OREWORD

This manual contains instructions for the maintenance of the machine. Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the machine, and help in diagnosing and repair of the machine.

All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables.

This manual consists of five (5) parts.

PERATOR

A copy of the Operator Manual that is stored on every UpRight Aerial Work Platform.

ECTION

Contains generic information relevant to all UpRight Aerial Work Platforms.

ECTION

Detailed information specific to this UpRight Aerial Work Platform.

1 - G

2 - S

ANUAL

ENERAL

ERVICE AND

NFORMATION

EPAIR

ECTION

Causes and solutions to typical problems.

ECTION

Electric and Hydraulic schematics.

3 - T

4 - S

ROUBLESHOOTING

CHEMATICS

Service Manual Page i

Page 4

Foreword

OTES

Page ii Service Manual

Page 5

PERATOR

ANUAL

WARNING

All personnel shall carefully read, understand and follow all safety rules and operating instructions

before operating or performing maintenance on any UpRight aerial work platform.

Safety Rules

Safety RulesSafety Rules

Electrocution Hazard

Electrocution Hazard Tip Over Hazard

Electrocution HazardElectrocution Hazard

Tip Over Hazard Collision Hazard

Tip Over HazardTip Over Hazard

Collision Hazard Fall Hazard

Collision HazardCollision Hazard

Fall Hazard

Fall HazardFall Hazard

NEVER operate the machine within ten

(10) feet of power lines.

THIS MACHINE IS NOT INSULATED.

• NEVER exceed the maximum platform load. See “Specifications” on page 16.

• NEVER operate the machine if all guardrails are not properly in place and secured with all fasteners properly torqued.

• NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs, bumps, curbs, or debris.

• ALWAYS close and secure the entrance after entering the platform.

• NEVER use ladders or scaffolding on the platform.

• NEVER attach overhanging loads or increase platform size.

• LOOK up, down and around for overhead obstructions and electrical conductors.

• DISTRIBUTE all platform loads evenly on the platform.

• NEVER use damaged equipment. (Contact UpRight for instructions. See toll free phone number on inside back cover.)

• NEVER change operating or safety systems.

• INSPECT the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, damaged cables or hoses, loose wire connections, and wheel bolts.

• NEVER climb down elevating assembly when the platform is elevated.

• IF ALARM SOUNDS while the platform is elevated, STOP, carefully lower the platform. Move the machine to a firm, level surface.

• IN CASE OF EMERGENCY push the Emergency Stop Button to cut power to all machine functions.

• NEVER perform service on the machine while the platform is elevated without blocking the elevating assembly.

• NEVER recharge batteries near sparks or open flame; batteries that are being charged emit explosive hydrogen gas.

• NEVER replace any component or part with anything other than original UpRight replacement parts without the manufacturer’s written consent.

• VERIFY that all labels are in place and legible before using.

• NEVER tow the machine. Transport by truck or trailer only.

• AFTER USE, secure the machine against unauthorized use by turning the Key Switch off and removing the key.

NEVER operate or drive with the

platform elevated unless on firm, level

surface.

NEVER position the platform without

first checking for overhead obstructions

or other hazards.

NEVER climb, stand or sit on the

platform guardrails or midrail.

California Proposition 65 Warning

Battery Posts, terminals and related accessories contain lead compounds, chemicals known to the State of

California to cause cancer and reproductive harm. Wash hands after handling.

067449-002 LX Electric Work Platform - Operator Manual Page 1

Page 6

ONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

GeneralDescription...................................................................3

ControlsandIndicators................................................................4

Pre-Operation&SafetyInspection.......................................................4

SystemFunctionInspection ............................................................5

Operation............................................................................6

TravelwithPlatformLowered.................................................................. 6

TravelwithWorkPlatformElevated ............................................................. 6

Steering................................................................................... 6

RaisingandLoweringthePlatform.............................................................. 7

LevelingthePlatform(Outriggerequippedmachinesonly) ........................................... 7

OutriggerSwitchesandIndicatorLights ...................................................... 7

ToLevelthePlatform(ExtendtheOutriggers)..................................................... 7

ToRetracttheOutriggers.................................................................. 7

EmergencyLowering......................................................................... 8

TowingorWinching...................................................................8

ParkingBrakeRelease....................................................................... 8

AfterUseEachDay....................................................................8

FoldDownGuardrails .................................................................9

FoldDownProcedure........................................................................ 9

ErectionProcedure.......................................................................... 9

TransportingtheWorkPlatform........................................................10

Preparation for Shipment . . . . . . .............................................................. 10

LiftingByCrane............................................................................ 10

DrivingorWinchingontoaTruckorTrailer....................................................... 10

Maintenance ........................................................................11

BlockingtheElevatingAssembly .............................................................. 11

BraceInstallation....................................................................... 11

BraceRemoval......................................................................... 11

HydraulicFluid............................................................................. 11

Battery Maintenance . . . ..................................................................... 12

BatteryCharging........................................................................... 12

PreventativeMaintenanceSchedule.....................................................13

DailyPreventativeMaintenanceCheckList ...................................................... 13

MaintenanceTableKey.................................................................. 13

MaintenanceReport..................................................................... 13

Labels .............................................................................14

Specifications.......................................................................16

Page 2 067449-002 LX Electric Work Platform - Operator Manual

Page 7

NTRODUCTION

Introduction

This manual covers the operation of the LX 31 and LX 41 Electric machines. This manual must be stored on the machine at all times.

ENERAL

ESCRIPTION

1. Platform

The platform has a reinforced steel floor, guardrails with midrail, toeboards and an entrance gate at the rear and both sides of theplatform.Theguardrailscanbefolded down for access through doors or for shipment.

2. Slide-out Deck

WARNING

DO NOT use the maintenance platform without guardrails properly assembled and in place

3. Platform Controls

The platform controls contain the controls to operate the machine. It should be hung on the front, left, or right guardrail.

Figure 1:

LX Electric Work Platform

4. Manual Case

5. Elevating Assembly

Theplatformisraisedandloweredbythe elevating assembly; a five section scissor assembly powered by two single-stage lift cylinders.

6. Control Module

The control module contains the horn/alarms, batteries, and chassis control panel.

7. Power Module

The power module contains the hydraulic valve manifold, hydraulic pumps, and hydraulic reservoir.

8. Chassis

The chassis is a structural frame that supports all the components of the machine.

9. Outriggers (optional)

067449-002 LX Electric Work Platform - Operator Manual Page 3

Page 8

Controls and Indicators

ONTROLS

1. Steering Switch

2. Interlock Lever

3. Control Handle

4. Outrigger Switches

5. Outrigger Indicator Lights

AND

Platform Controls Chassis Controls

NDICATORS

10. Horn Button (option)

7**

6. Emergency Stop Switch

7. Lift/Drive Switch

8. Drive Speed/Torque Selector Switch

9. Drive Enable Indicator

1. Emergency Stop

2. Platform/Chassis Key Switch

3. Raise Button

4. Brake Release Button

5. Lower Button

6. Hour Meter (option)

Figure 2:

Controls and Indicators

Outrigger Options

* Outrigger Switches and Outrigger Lights are installed on outrigger equipped machines only. ** Outrigger selection is available on outrigger equipped machines only.

-O

PERATION

NOTE:

& S

Carefully read, understand and follow all safety rules, operating instructions, labels and National Safety

Instructions/Requirements. Perform the following steps each day before use.

1. Open modules and inspect for damage, fluid leaks or missing parts.

2. Check the hydraulic fluid level sight gauge on the hydraulic reservoir with the platform fully lowered. Add fluid if necessary.

3. Check that fluid level in the batteries is correct (see “Battery Maintenance” on page 12).

4. Check that all guardrails are in place, the slide-out deck extension is secured with the pin, and all fasteners are properly tightened.

5. Check tire pressure: 5,2 bar (75 psi).

6. Carefully inspect the entire machine for damage such as cracked welds or structural members, loose or missing parts, fluid leaks, damaged cables or hoses, loose connections and tire damage.

AFETY

NSPECTION

Page 4 067449-002 LX Electric Work Platform - Operator Manual

Page 9

System Function Inspection

YSTEM

UNCTION

WARNING

STAND CLEAR

Before operating the machine, survey the work area for surface hazards such as holes, drop-offs, bumps and debris. Check in

Protect control console cable from possible damage while performing checks.

1. Move the machine, if necessary, to an unobstructed area to allow for full elevation.

2. Place chassis and platform Emergency Stop Switches in the ON position by pulling the buttons out.

3. Verify that the Platform/Chassis Switch is set to PLATFORM.

4. TurnthePlatformControlsKeySwitchclockwisetoON.

5. Position the Lift/DriveSwitchtotheDRIVE position. The drive enable light should be ON.

6. With the Speed Range Switch first in LOW SPEED and then in HIGH SPEED, depress the Interlock Lever and

7. Depress the Interlock Lever and push the Steering Switch RIGHT then LEFT to check for steering control.

8. Optional Outrigger Equipped Machines:

9. Open the control module covers to gain access to the chassis controls and Level Sensor.

10. Turn the Platform/Chassis Switch to CHASSIS.

11. Push the Raise Button to elevate platform while pushing the Level Sensor off of level. The platform should

12. Release the Level Sensor and fully elevate the platform.

13. Visually inspect the elevating assembly, lift cylinder, cables and hoses for damage or erratic operation. Check

14. Lower the platform partially by pushing in on the Lower Button, and check operation of the audible lowering

15. Open the Chassis Emergency Lowering Valve to check for proper operation (refer to “Emergency Lowering”

16. Turn the Platform/Chassis Switch to PLATFORM.

17. Close and secure the module covers.

18. Enter the platform making sure the entry-way is secured.

19. Position the Lift/DriveSwitchtoLIFT.

20. Depress the Interlock Lever and slowly push the Control Handle to UP to raise the platform; fully actuate the

21. Optional Outrigger Equipped Machines:

22. Turn the controller Key Switch to OFF, push the Emergency Stop Button, and dismount the platform.

ALL

slowly push the Control Handle to FORWARD then REVERSE positions to check for speed and directional control. The farther you push or pull the Control Handle, the faster the machine will travel.

a. With the Lift/Outrigger/Drive Switch in DRIVE, depress the Interlock Lever on the Control Handle and posi-

tion each Outrigger Switch to the EXTEND position.

• Outriggers should be disabled. If an outrigger extends during this test service until it is repaired.

b. Tur n the Drive/Outrigger/Lift Switch to OUTRIGGER. c. Depress the Interlock Lever on the Control Handle and position each Outrigger Switch to the EXTEND

position to deploy all four (4) outriggers.

• Check the outrigger indicator lights; they should be ON.

d. Depress the Interlock Lever on the Control Handle and position each Outrigger Switch to the RETRACT

position.

• Partially retract all four (4) outriggers. The outrigger indicator lights should FLASH.

• Fully retract all four (4) outriggers. The outrigger indicator lights should be OFF.

only partially elevate and the tilt alarm should sound. If the platform continues to elevate and/or there is no alarm,

for missing or loose parts.

alarm.

on page 8). Once the platform is fully lowered, close the valve by releasing the knob.

Control Handle to check proportional lift speed. Slowly pull the Control Handle to the DOWN position to lower the platform. Check that the lowering alarm sounds.

a. With the Lift/Outrigger/Drive Switch in LIFT, depress the Interlock Lever on the Control Handle and position

any Outrigger Switch to the EXTEND position.

• Outriggers should be disabled. If an outrigger extends during this test, remove the machine from service until it is repaired.

of the work platform while performing the following checks.

directions, including above the work platform, for obstructions and electrical conductors.

STOP

NSPECTION

and remove the machine from service until it is repaired.

. Remove the machine from

STOP

. Lower the platform and

STOP

067449-002 LX Electric Work Platform - Operator Manual Page 5

Page 10

Operation

PERATION

NOTE:

Before operating the machine, ensure that the pre-operation and safety inspection has been completed, any

deficiencies have been corrected, and the operator has been thoroughly trained on this machine.

WARNING

Never operate the machine with the parking brakes released. Serious injury or damage could result.

RAVEL

1. Verify the following:

• the chassis Emergency Stop Button is in the ON position (pull out).

• the Drive Enable indicator is ON.

•thePlatform/Chassis Switch is on PLATFORM.

NOTE:

If the drive enable indicator is OFF, verify that the platform is fully lowered and (if so equipped) the outriggers

are fully retracted.

2. After mounting the platform, close and latch the gate. Check that the guardrails are in position and properly assembled, with the fasteners properly torqued.

3. Check that the route is clear of persons, obstructions, holes and drop-offs, and is capable of supporting the wheel loads.

4. Check clearances above, below and to the sides of the platform.

5. Pull the controller Emergency Stop Button out to the ON position.

6. Turn the Platform Controls Key Switch clockwise to ON.

7. Set the Lift/Drive Switch to DRIVE.

8. Set the Speed Range Switch to LOW SPEED.

9. Grasp the Control Handle so that the Interlock Lever is depressed (releasing the Interlock Lever cuts power to controller). Slowly push or pull the Control Handle to FORWARD or REVERSE to travel in the desired direction. The farther you push or pull the Control Handle from center, the faster the machine will travel.

10. While moving, push the Speed Range Switch to HIGH SPEED for travel on level surfaces or to LOW SPEED for climbing grades or traveling in confined areas.

WITH

LATFORM

OWERED

RAVEL

Travel with the platform elevated ONLY on firm and level surfaces.

NOTE:

The machine will travel at reduced speed when in the elevated position.

1. Check that the route is clear of persons, obstructions, holes and drop-offs, is level and capable of supporting the wheel loads.

2. Check clearances above, below and to the sides of the platform.

3. Position the Lift/Drive Switch to the DRIVE position.

4. Push the Control Handle to FORWARD or REVERSE for the desired direction of travel.

5. If the machine quits driving and the tilt alarm sounds, immediately lower the platform and move the machine to a level location before re-elevating the platform.

TEERING

Push the Steering Switch RIGHT or LEFT to turn the wheels. Observe the tires while maneuvering to insure proper direction.

NOTE:

Steering is not self-centering. Wheels must be returned to the straight ahead position by operating the Steering

Switch.

Page 6 067449-002 LX Electric Work Platform - Operator Manual

WITH

ORK

LATFORM

LEVATED

Page 11

Operation

AISING AND

The machine must be on a firm, level surface, capable of supporting the weight of the machine. On machines equipped with optional outriggers, use the outriggers to level the machine. Refer to “Leveling the Platform (Outrigger equipped machines only)” on page 7.

1. Position the Lift/Drive Switch to LIFT.

2. While holding the Control Handle so the Interlock Lever is depressed, push the Control Handle slowly to UP to raise the platform. Pushing the Control Handle farther increases the lift speed.

3. When the work task is completed, position the Lift/Drive Switch to LIFT, and lower the platform by pulling back on the Control Handle until the platform is fully lowered.

EVELING

UTRIGGER EQUIPPED MACHINES ONLY

THE

OWERING

LATFORM

THE

LATFORM

)

WARNING

When using outriggers, all four (4) outriggers must be in firm contact with the supporting surface.

UTRIGGERSWITCHES ANDINDICATOR

For each outrigger, there is an Outrigger Switch and an outrigger indicator light (refer to Figure 2).

Each Outrigger Switch will raise and lower one outrigger.

Each outrigger indicator light will indicate the position of one outrigger.

• When the indicator light is OFF - the outrigger is fully retracted.

• When the indicator light is FLASHING - the outrigger is partially extended.

• When the indicator light is ON - the outrigger is in firm contact with the supporting surface.

TO L

EVEL THE

1. Make sure that the extension deck is retracted before operating the outriggers.

2. Look around the machine; make sure that there is nothing obstructing the outriggers, and that the surface beneath them is suitable to support the weight of the machine.

3. Position the Lift/Outrigger/Drive Switch set to OUTRIGGER.

4. Depress the Interlock Lever on the Control Handle, and operate the Outrigger Switches to extend each outrigger until it is making firm contact with the supporting surface.

5. While observing the bubble level on the guardrail, extend the outrigger opposite the position of the bubble until the platform is level. For example: if the bubble is to the front and left in the orbit, extend the rear right outrigger. Continue to adjust until the bubble is centered in the small circle indicating that the platform is level.

6. Confirm that all four (4) outriggers are in firm contact with the supporting surface. The outriggers are in contact with the supporting surface when the indicator lights are ON.

LATFORM

IGHTS

XTEND

THE

UTRIGGERS

Figure 3:

)

Platform Orbit Bubble Level

TOR

067449-002 LX Electric Work Platform - Operator Manual Page 7

ETRACT THEOUTRIGGERS

1. Fully lower the platform.

2. Position the Lift/Outrigger/Drive Switch set to OUTRIGGER.

3. Depress the Interlock Lever on the Control Handle, and position each Outrigger Switch to RETRACT.

• The outrigger indicator lights will be OFF when the outriggers are fully retracted.

• The drive enable indicator light will not come on until all four outriggers are fully retracted.

Page 12

Towing or Winching

MERGENCY

OWERING

OWING

Figure 4:

The Emergency Lowering Control Knob is located at the rear of the machine at the base of the scissor assembly.

1. Open the emergency lowering valve by pulling on the knob and holding it.

2. Once the platform is fully lowered, release the knob to close the valve.

Perform the following only when the machine will not operate under its own power and it is necessary to move the machine or when winching onto a transport vehicle (see “Transporting the Work Platform” on page 10).

INCHING

Emergency Lowering Valve,

CAUTION

DO NOT tow or winch the machine faster than 0,3 m/s (1 ft./s). Faster speeds will damage drive components and void the warranty.

ARKING

WARNING

Never operate the machine with the parking brakes released. Serious injury or damage could result.

Never release the brakes if the machine is on a slope. Chock the wheels before releasing the parking brakes. Hook the machine to a towing vehicle before releasing

the parking brakes.

1. Turn the Chassis/Platform/Brake Release Switch to the Brake Release position.

• Alarm will sound

2. Momentarily push the Brake Release Button.

3. The machine will now roll when pushed or pulled.

4. For normal operation, turn the Platform/Chassis/Brake Release Switch to PLATFORM.

5. Verify that the parking brakes have engaged before the machine is operated.

RAKE

ELEASE

Figure 5:

Platform/Chassis/Brake Release Switch

Brake Release Button

Parking Brake Release

FTER

Page 8 067449-002 LX Electric Work Platform - Operator Manual

1. Ensure that the platform is fully lowered.

2. Park the machine on level ground, preferably under cover, secure against vandals, children or unautho-

3. Turn the Key Switch to OFF and remove the key to prevent unauthorized operation.

rized operation.

ACH

Page 13

Fold Down Guardrails

OLD

OWN

This procedure is only for passing through doorways. Guardrails must be returned to proper position before using the machine.

OLD

ROCEDURE

NOTE:

procedures, retain all fasteners.

1. Place the controller on the platform.

2. Starting at the slide-out deck:

3. Go to the rear of the platform:

4. Unlatch the side gate so the left side guardrails can be folded down in two separate pieces. Also remove

5. Fold the rear half of the side guardrails onto the deck:

6. Fold the front half of the side guardrails onto the deck:

7. Lift up and fold down the front slide-out deck guardrail.

UARDRAILS

Figure 6:

OWN

When performing the following

• remove nuts, bolts and washers from the top front corners of guardrails (A)

• remove the nuts, bolts and washers from the slide-out deck side guardrail mid-rails (B)

• remove nuts, bolts and washers located at the top of the sockets that hold the slide-out deck side guardrails to the deck (C)

• fold the side guardrails down onto the slide-out deck platform

• leave the end rail up and slide the deck all the way in.

• close and latch the rear gate

• remove the nuts, bolts, washers, and corner brackets from the top of the rear guardrail

• fold the rear guardrail down onto the platform, being careful to keep the gate latched.

the nuts, bolts and washers opposite the gate latch on the right side guardrail so it too can be separated into two pieces (E).

• lift up and fold down so the guardrails rest on the deck, on top of the rear guardrail.

• lift up and fold down so the guardrails rest on the slide-out deck, with the guardrail posts resting in the cutouts on the slide-out deck toeboard (F).

Fold Down Guardrails

RECTION

1. Raise the front guardrail, making sure it is pushed down to secure the guardrail in the vertical position.

2. Raise the side guardrails, making sure each is pushed down to secure the guardrail in the vertical position; align holes and install bolts, washers and nuts. Tighten securely.

3. Raise one of the slide-out deck side guardrail assemblies; align holes and install bolts, washers and nuts. Tighten securely. Repeat this procedure for the other slide-out deck side guardrails.

4. Raise the rear guardrail, and install the corner brackets, nuts, bolts and washers.

5. Hang the controller from the front guardrail.

6. Before operating machine check that all fasteners are in place and properly torqued.

WARNING

Before operating machine, guardrails must be securely fastened in their proper position.

067449-002 LX Electric Work Platform - Operator Manual Page 9

ROCEDURE

Page 14

Transporting the Work Platform

RANSPORTING

THE

REPARATION

1. Fully lower the platform.

2. Disconnect the battery negative (–) lead from the battery terminal.

3. Band the controller to the front guardrail.

4. Band the elevating linkage to the frame.

IFTING

1. Secure straps to chassis tie down/lifting lugs only.

2. Place the platform onto the transport vehicle in transport position.

3. Chock the wheels.

4. Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down/lifting lugs.

BY C

FOR

RANE

ORK

LATFORM

HIPMENT

Figure 7:

Tie-Down / Lifting Lugs

Transporting Work Platform

Front ViewRear View

RIVING OR

NOTE:

Do not winch faster than 0,3 m/s

1. Move the machine onto the truck or trailer;

A. To

B. To

2. Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to

Drive

a. Move the machine up the ramp and into transport position. b. Set the wheels straight and turn off the machine.

c. Chock the wheels.

Winch

a. Move the machine up to the ramp. b. Attachthewinchcabletothetiedown/lifting lugs.

c. Release the parking brakes (refer to “Towing or Winching” on page 8). d. Winch the platform into transport position e. Chock the wheels.

thechassistiedown/lifting lugs.

INCHING

the machine onto the transport vehicle:

(1 ft/s)

ONTO A

RUCK OR

RAILER

CAUTION

Overtightening of chains or straps through tie down/lifting lugs may result in damage to the machine.

Page 10 067449-002 LX Electric Work Platform - Operator Manual

Page 15

AINTENANCE

LOCKING

THE

LEVATING

SSEMBLY

Maintenance

Figure 8:

WARNING

Never perform service on the machine in the elevating assembly area while the platform is elevated without first blocking the elevating assembly.

DO NOT stand in elevating assembly area while deploying or storing brace.

RACEINSTALLATION

1. Park the machine on firm, level ground.

2. Verify that the platform Emergency Stop Button is ON.

3. Turn the Platform/Chassis Switch to CHASSIS.

4. Using the Raise Button, elevate the platform until the scissor brace can be rotated to the vertical position.

5. From the left side of the machine, disengage the locking pin securing the brace. Rotate the scissor brace counterclockwise until it is vertical and between the two scissor center pivots.

6. Push the Lower Button and gradually lower the platform until the brace is supporting the platform.

Upper Scissor

Center Pivot

Brace

Locking Pin

Blocking Elevating Assembly

Lower Scissor

Center Pivot

RACE

1. Using the chassis controls, gradually raise the platform until the scissor brace clears the two scissor cen-

2. Rotate the scissor brace clockwise until the locking pin engages.

3. Push the Lower Button to completely lower the platform.

YDRAULIC

The hydraulic fluid reservoir is located in the Power Module.

NOTE:

1. Make sure that the platform is fully lowered.

2. Check fluid level by observing the fluid sight gauge

3. Remove the filler cap to fill with the appropriate fluid.

EMOVAL

ter pivots.

LUID

Never add fluid if the platform is elevated.

Figure 9:

Hydraulic Fluid Reservoir

1. Fluid Sight Gauge

2. Filler Cap

067449-002 LX Electric Work Platform - Operator Manual Page 11

Page 16

Maintenance

ATTERY

The batteries are located in the Control Module.

AINTENANCE

Figure 10:

Battery Location

WARNING

Hazard of explosive gas mixture. Keep sparks, flame, and smoking material away from battery.

Always wear safety glasses when working with batteries. Battery fluid is highly corrosive. Thoroughly rinse away any

spilled fluid with clean water. Always replace batteries with UpRight batteries or

manufacturer approved replacements weighing 48 kg (106 lbs.) each.

Check battery fluid level daily, especially if the machine is beingusedinawarm,dryclimate.

If the electrolyte level is lower than 10 mm water with high mineral content; it will shorten battery life.

When night temperatures fall below 18°C (65°F), batteries charged in unheated areas should be charged as soon after use as possible. Under such conditions a four hour charge cycle once a week in the early afternoon will improve the state of charge and battery life.

The battery and cables should be inspected regularly for signs of cracks in the case, electrolyte leakage and corrosion of the terminals. Inspect the cables for worn spots or breaks in the insulation and for broken cable terminals.

Refer to the Service Manual to extend battery life and for complete service instructions.

Battery Charger

located behind

ladder

Eight 6 Volt Batteries

(

in.) above plates, add distilled water ONLY. Do not use tap

ATTERY

Charge the batteries at the end of each work shift or sooner if the batteries have been discharged. Discharging a deep cycle battery to less than 1.75 Volts per cell can cause permanent damage.

WARNING

Charge batteries only in a well ventilated area. Do not charge the batteries when the machine is near a source of sparks or flames. Permanent damage to the batteries will result if the batteries are not immediately recharged after

discharging. Never leave the battery charger operating for more than two days. Never disconnect the cables from the batteries when the charger is operating. Keep the charger dry.

1. Check the battery fluid level. If the battery fluid level is lower than 10 mm ( distilled water only.

2. Connect an extension cord (1,5 mm length) to the charger plug located in the control module behind the ladder.

3. The charger turns on automatically after a short delay.

• The charging current is displayed on the ammeter.

• The charging current drops off as the batteries charge.

• When fully charged, the ammeter shows “0” current.

4. The charger shuts off automatically.

HARGING

in.) above the plates add

[12 gauge] minimum conductor diameter; 15 m (50 ft.) maximum

NOTE:

The battery charger circuit must be used with a GFI (Ground Fault Interrupt) outlet.

NOTE:

DO NOT operate the machine while the charger is plugged in.

Page 12 067449-002 LX Electric Work Platform - Operator Manual

Page 17

Preventative Maintenance Schedule

REVENTATIVE

AINTENANCE

CHEDULE

The complete inspection consists of periodic visual and operational checks, along with periodic minor adjustments to assure proper performance. Daily inspection will prevent abnormal wear and prolong the life of all systems. The inspection and maintenance schedule is to be performed at regular intervals. Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures.

WARNING

Before performing preventative maintenance, familiarize yourself with the operation of the machine. Always block the elevating assembly whenever it is necessary to enter the scissor assembly to perform

maintenance while the platform is elevated (see page 11).

The daily preventative maintenance table has been designed for machine service and maintenance repair. Please photocopy the Daily Preventative Maintenance Check List and use the table as a checklist when inspecting the machine for service.

AILY

REVENTATIVE

ABLEKEY

AINTENANCE

HECK

EPORT

IST

Y=Yes/Acceptable

N = No/Not Acceptable

R = Repaired/Acceptable

COMPONENT INSPECTION OR SERVICES Y N R

Batteries Check electrolyte level

Chassis

Control Cable

Controller Check switch operation

Drive Motors Check for operation

Elevating Assembly Inspect for structural cracks

Emergency Lowering

System

Check hoses for pinch or rubbing points

Check welds for cracks Check the exterior of the cable for pinching,

binding or wear

Operate the emergency lowering valve and check for serviceability

Date: _______________________________________

Owner: _____________________________________

Model No: ___________________________________

Serial No: ___________________________________

Serviced By: _________________________________

COMPONENT INSPECTION OR SERVICES Y N R

Entire Unit Check for and repair collision damage

Hydraulic fluid Check fluid level

Hydraulic Pump Check for hose fitting leaks

Hydraulic System Check for leaks

Labels

Platform Deck and

Rails

Tires and Wheels Check for damage

Check for peeling, missing, or unreadable labels & replace

Check welds for cracks

Check condition of deck

067449-002 LX Electric Work Platform - Operator Manual Page 13

Page 18

Labels

ABELS

These labels shall be present and in good condition before operating the machine. Be sure to read, understand and follow these labels when operating the machine.

010076-001

WARNING

TIPPING HAZARD Check tire pressure daily. Pressure must be maintained at 65 P.S.I.(4,4 Bar) lug tire at 75 P.S.I.(5,2 Bar) highway

066562-001

DANGER

066562-001

061205-005

TIP-OVER HAZARD

MAXIMUM DISTRIBUTED LOAD

500 LBS. OR 2 OCCUPANTS

ON EXTENDED DECK

MAXIMUM SIDE LOAD 100 LBS.

101251-001

066554-000

066555-000

066551-002

066556-000

066556-001

Outrigger Option

WARNING

Do not turn chassis control switch to the brake release position and press the brake release button to disengage the brakes without restraining the machine from rolling.

068641-003

WARNING

Explosive gas is generated when charging batteries.

Do not expose to sparks or flames.

066552-000

WARNING

MAXIMUM DISTRIBUTED

PLATFORM LOAD 2000 LBS.

OR 5 OCCUPANTS

MAXIMUM SIDE LOAD 300 LBS.

LX31: 101250-008

101250-009

LX41: 101250-009

WARNING

CRUSHING HAZARD KEEP CLEAR OF PLATFORM

LOWER PLATFORM COMPLETELY BEFORE SERVICING MACHINE

066568-000

066558-000

061515-000

068639-000

061220-002

067369-001

Failure to read, understand and obey the following safetyrules

TIP-OVER HAZARD

DO NOT elevate or drive elevated on slopes or soft ground

DO NOT drive into holes or over drop offs

No more than two persons or 500 Lbs. on slide out platform

will cause death or serious injury

ELECTROCUTION HAZARD

DO NOT operate within ten feet of power lines. THIS MACHINE IS NOT INSULATED.

Look up, down and around for electrical wires

066550-009

066551-003

DO NOT climb on guardrail Make sure guardrails are fastened securely

Make sure gate is closed and secure DO NOT use ladders or scaffolding on platform DO NOT climb down scissors.

DANGER

TIP-OVER HAZARD

BATTERIES ACT AS COUNTERWEIGHT EACH REPLACEMENT BATTERY MUST WEIGH 120 LBS. (54 Kg.) OR MORE.

062562-002

MAINTENANCE BRACE

DEPLOY The work platform must be on firm level surface. Use chassis controls to elevate platform until the brace can be rotated to the vertical position. Pull the locking pin to release the brace. Rotate the brace until it is vertical and between the two scissor center pivot tubes Use chassis contols to lower platform until the brace is supporting the elevating assembly.

TO STORE Use chassis controls to elevate platform until the brace clears the two scissor center pivot tubes. Rotate brace until the locking pin engages. Lower platform.

066561-001

061197-000

LH FRT

EXTEND

DANGER

FALL HAZARD

RH FRT EXTEND

067365-000

MAXIMUM WHEEL

AND/OR OUTRIGGER

LOAD 3900 LBS.

LX31: 101252-013 LX41: 101252-014

101252-013

EMERGENCY

STOP

RAISE FWD

LOWER REV.

067642-012

HIGH

LOW

SPEED

LIFT DRIVE

RETRACT

LH AFT

EXTEND

RETRACT

RAISE FWD

EMERGENCY

STOP

LOWER REV.

067642-010 Outrigger Option

HIGH

LOW

SPEED

OUTRIGGER

LIFT DRIVE

Page 14 067449-002 LX Electric Work Platform - Operator Manual

RETRACT

RH AFT EXTEND

RETRACT

Page 19

Labels

CONTROLLER

Figure 11:

Safety Labels Locations

Outrigger Option

POWER

MODULE

REAR

CONTROL

MODULE

Inside on Door

FRONT

067449-002 LX Electric Work Platform - Operator Manual Page 15

Page 20

Specifications

PECIFICATIONS

Refer to the Service Manual for service and repair information. Refer to the Parts Manual for illustrated parts breakdown.

ITEM LX31 LX41

Platform Size (Inside toeboards)

Standard 3,96 m x 1,73 m [156 in x 68 in.] 3,96 m x 1,73 m [156inx68in.]

Slide-out Deck Extended 4,83 m x 1,73 [190in.x68in.] 4,83 m x 1,73 [190 in. x 68 in.]

GVW (machine + Rated Load)

Standard 5493 kg [12,110 lbs.] 5978kg[13,180 lbs.]

Rear Deck Option 5711 kg [12,590 lbs.] 6196kg[13,660 lbs.]

Maximum Wheel Load 1769 kg [3,900 lbs.] 1905 kg [4,200 lbs.] Max. Platform Capacity

Standard 907 kg [2,000 lbs.] 680 kg [1,500 lbs.]

Rear Deck Option 794 kg [1750 lbs.] 567 kg [1,250 lbs.] On Extension (one end only) 227 kg [500 lbs.] 227 kg [500 lbs.]

Max. No. of occupants

Standard 5 people 5 people Rear Deck Option 5 people 4 people

Height

Working Height 11,28 m [37 ft.]14,17m[46 ft. 6 in.] Max. Platform Height 9,45 m [31 ft.]12,34m[40 ft. 6 in.]

Min. Platform Height 1,43 m [56.3 in.]1,66m[65.3 in.]

Drivable Height 9,45 m [31 ft.]12,34m[40 ft. 6 in.]

Dimensions

Weight, Standard 4586 kg [10,110 lbs.] 5298 kg [11,680 lbs.]

Weight, Rear Deck Option 4917 kg [10,840 lbs.] 5629 kg [12,410 lbs.] Overall Width 2,29 m [90 in.] 2,29 m [90 in.]

Overall Height, guardrails up 2,53 m [99.8 in.] 2,76 m [109 in.]

Overall Height, guardrails lowered 1,64 m [64.5 in.] 1,87 m [73.5 in.] Overall Length, deck in 4,02 m [160 in.] 4,02 m [160 in.]

Overall Length, deck extended 4,89 m [192 in.] 4,89 m [192 in.]

Surface Speed

Platform Lowered 0 to 5,0 km/h [0to3.1mph] 0to5,0km/h[0to3.1mph]

PlatformRaised 0to0,48km/h[0to0.5mph] 0 to 0,48 km/h [0to0.5mph]

System Voltage 48 Volt DC 48 Volt DC Hydraulic Reservoir Capacity 107 liters [28.3USGallons] 107 liters [28.3 US Gallons]

Maximum Hydraulic System Pressure 207 bar [3000 psi] 207 bar [3000 psi]

Hydraulic Fluid

Normal Temperature: above 0° C [32° F] ISO #46 ISO #46

Low Temperature: below 0° C [32° F] ISO #32 ISO #32

Extreme Temperature: below -17° C [0° F] ISO #15 ISO #15

Lift System One Single Stage Lift Cylinder One Single Stage Lift Cylinder Lift Speed Raise: 50 sec. Lower: 52 sec. Raise: 57 sec. Lower: 60 sec.

Power Source Eight 6V 350 Ah Batteries Eight 6V 350 Ah Batteries

Drive Control Proportional Proportional Control System Smooth one-hand Controller Smooth one-hand Controller

Horizontal Drive Two Electric Wheel Motors Two Electric Wheel Motors

TiresStandard 10-16.5 NHS 8 Ply, 5,2 bar [75 psi] 10-16.5 NHS 8 Ply, 5,2 bar [75 psi] Option Poly Filled Poly Filled

Parking Brakes Dual Disc, Spring Applied, Hydraulic Release Dual Disc, Spring Applied, Hydraulic Release

Turning Radius (inside) 1,22 m [48 in.] 1,22 m [48 in.] Maximum Gradeability 17° [30%]17°[30%]

Wheel Base 2,9 m [114.5 in.] 2,9 m [114.5 in.]

Ground Clearance 0,24 m [9.5 in.]0,24m[9.5 in.] Guardrails 1.1 m [43.5 in.] high, Fold Down with gate. 1.1 m [43.5 in.] high, Fold Down with gate.

Toe Boards 15,24 m [6in.]15,24m[6in.]

Specifications subject to change without notice. Hot weather or heavy use may reduce performance. Meets or exceeds all applicable requirements of OSHA and ANSI A92.6-1999.

Page 16 067449-002 LX Electric Work Platform - Operator Manual

Page 21

Section 1

ABLE

ENERAL

This section contains generic instructions for the repair and maintenance of UpRight Aerial Work Platforms. Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the machine, and help in diagnosing and repair of the machine.

1-1 HazardIndicators ..............................................................1-2

1-2 WorkshopProcedures...........................................................1-2

1-3 TorqueSpecifications ...........................................................1-3

1-4 DateCodeIdentificationonHoses .................................................1-5

1-5 SpecialTools..................................................................1-5

1-6 UpRightConnectors ............................................................1-6

1-7 HydraulicManifoldRepair........................................................1-8

1-8 CylinderRepair................................................................1-9

1-9 ElectricMotors................................................................1-10

1-10 BatteryMaintenance...........................................................1-12

1-11 FloorLoading.................................................................1-16

1-12 HydraulicFluid................................................................1-17

1-13 LongTermStorage............................................................1-18

ONTENTS

NFORMATION

IST OF

IGURES

Figure1-1:UpRightConnectorKits.................................................... 1-6

Figure1-2:UpRightMaleConnector................................................... 1-6

Figure1-3:UpRightFemaleConnector................................................. 1-6

Figure1-4:LockingFinger,UpRightConnector .......................................... 1-7

Figure1-5:HeavyDutyUpRightConnector ............................................. 1-7

Figure1-6:ElectricMotorService.................................................... 1-10

Figure1-7:ElectricMotorBrushes ................................................... 1-11

Figure1-8:ContactArea........................................................... 1-16

Figure1-9:OccupiedSurfaceArea................................................... 1-16

ABLES

Table1-1:TorqueSpecificationsforHydraulicComponents................................. 1-3

Table1-2:TorqueSpecificationsforSAEFasteners....................................... 1-3

Table1-3:TorqueSpecificationsforMetricFasteners,U.S.CustomaryUnits................... 1-4

Table1-4:TorqueSpecificationsforMetricFasteners,SIUnits.............................. 1-4

Table 1-5: Specific Gravity and Battery Voltage ......................................... 1-13

Table1-6:BatteryCharging,UpRightElectricandBiEnergyMachines ....................... 1-14

Table1-7:BatteryChargerTroubleshooting............................................ 1-15

Service Manual Page 1-1

Page 22

Hazard Indicators Section 1 - General Information

1-1 H

AZARD

! !

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NDICATORS

DANGER

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in damage to the machine.

1-2 W

ORKSHOP

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause personal injury, or could damage a machine or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by UpRight, Inc., might be done, or of the possible hazardous consequences of each conceivable way, nor could UpRight Inc. investigate all such ways. Anyone using service procedures or tools, whether or not recommended by UpRight Inc., must satisfy themselves thoroughly that neither personal safety nor machine safety will be jeopardized.

WARNING

Be sure to read, understand and follow all safety rules, operating instructions, and the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES of ANSI A92.6-1999 before performing maintenance on or operating any UpRight Aerial Work Platform.

WARNING

Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly.

DO NOT stand in elevating assembly area while deploying or storing brace. Refer to the Operator Manual for elevating assembly blocking instructions.

ROCEDURES

Page 1-2 Service Manual

Page 23

Section 1 - General Information Torque Specifications

1-3 T

Table 1 - 1 :

ORQUE

YDRAULIC

NOTE:

PECIFICATIONS

OMPONENTS

Always lubricate threads with clean hydraulic fluid prior to installation

Use the following values to torque hydraulic components used on UpRight Aerial Work Platforms.

Torque Specifications for Hydraulic Components

Type: SAE Port Series Cartridge Poppet Fittings Hoses

Ft/Lbs Nm Ft/Lbs Nm In/Lbs Nm #4 N/A N/A N/A N/A 135-145 15-16

#6 N/A N/A 10-20 14-27 215-245 24-28

#8 25-30 34-41 25-30 34-41 430-470 49-53

#10 35-40 47-54 35-40 47-54 680-750 77-85

#12 85-90 115-122 85-90 115-122 950-1050 107-119

#16 130-140 176-190 130-140 176-190 1300-1368 147-155

ASTENERS

This standard applies to the preloading of fasteners measured by installation torque.

NOTE:

For other preloading methods or fasteners consult UpRight Engineering Department.

This general standard applies to all SAE and Metric fasteners unless otherwise specified.

Table 1 - 2 :

HREAD

ONDITION

• For lubricated or zinc plated fasteners use K =,15

• For dry unplated fasteners use K =,20

ORQUETABLES

Torque Specifications for SAE Fasteners

SAE J429 Grade 5 SAE J429 Grade 8 SAE J429 Grade 5 SAE J429 Grade 8

Nominal

Thread Size

1/4 -20 2,000 75 100 2850 107 143

5/16 - 18 3,350 157 210 4700 220 305 5/16-24 3,700 173 230 5200 245 325

3/8-16 4,950 23 31 6950 32.5 44 3/8-24 5,600 26 35 7900 37 50

7/16-14 6,800 37 50 9600 53 70 7/16-20 7,550 42 55 10700 59 78

1/2-13 9,050 57 75 12800 80 107 1/2-20 10,200 64 85 14400 90 120

9/16-12 11,600 82 109 16400 115 154 9/16-18 13,000 92 122 18300 129 172

5/8-11 14,500 113 151 20300 159 211 5/8-18 16,300 128 170 23000 180 240 3/4-10 21,300 200 266 30100 282 376 3/4-16 23,800 223 298 33600 315 420

Unified Coarse Thread Series

Clamp

7/8-9 29,435 321 430 41550 454 606 7/8-14 32,480 355 473 45855 500 668

1-8 38,600 483 640 54540 680 900 1-12 42,270 528 704 59670 745 995

Tightening

Load

lbs. in-lbs. in-lbs. lbs. in-lbs. in-lbs. lbs. in-lbs. in-lbs. lbs. in-lbs. in-lbs.

lbs. ft-lbs. ft-lbs. lbs. ft-lbs. ft-lbs. lbs. ft-lbs. ft-lbs. lbs. ft-lbs. ft-lbs.

Tor qu e

K=,15 K=,20 K=,15 K=,20 K=,15 K=,20 K=,15 K=,20

Clamp

Load

Tightening

Tor qu e

Nominal Thread

Size

1/4 -28 2,300 85 115 3250 120 163

Unified Fine Thread Series

Clamp

Load

Tightening Torque

Clamp

Load

Tightening Torque

Service Manual Page 1-3

Page 24

Torque Specifications Section 1 - General Information

Table 1 - 3 :

Torque Specifications for Metric Fasteners, U.S. Customary Units

8.8 10.9

Clamp

Load

Grade 10.9

Tightening Torque

Grade 8.8

Nominal

Thread

Size

mm lbs. in-lbs. in-lbs. lbs. in-lbs. in-lbs. lbs. in-lbs. in-lbs.

Clamp

Load

3------82314.619.5

3.5------1,10922.930.5

4------1,43633.945.2

5 1,389 41.0 54.7 1,987 58.7 78.2 2,322 68.6 91.2 6 1,966 69.7 92.9 2,813 100.0 132.8 3,287 116.8 155.8

7 2,826 116.8 155.8 4,044 167.3 223.0 4,727 195.6 260.2

8 3,579 14.1 18.8 5,122 20.1 26.9 5,986 23.6 31.4

10 11,742 27.9 37.2 8,117 39.9 53.3 9,486 46.7 62.3

12 8,244 48.7 64.9 11,797 69.7 92.2 13,787 81.1 108.4 14 11,246 77.4 103.3 16,093 110.6 147.5 18,808 129.1 172.6

16 15,883 125.4 166.7 21,971 173.3 230.9 25,677 202.1 269.2

18 19,424 171.9 229.4 26,869 238.2 317.2 31,401 278.1 371.0

20 2,304 243.4 325.3 34,286 337.8 449.9 40,070 394.6 525.9 22 30,653 331.9 442.5 42,403 458.8 612.2 49,556 536.2 715.4

24 35,711 420.4 562.0 49,400 583.4 778.1 57,733 682.2 909.4

27 46,435 617.3 84.8 64,235 853.4 1138.1 75,069 997.2 1329.8 30 56,753 837.9 1117.4 78,509 1159.4 1545.2 91,751 1354.9 1807.0

33 70,208 1140.3 1520.1 97,121 1576.9 2102.8 113,503 1843.9 2457.5

36 82,651 1464.1 1952.3 114,334 2025.3 2700.9 133,620 2367.6 3156.0

Tightening Torque

K=,15 K=,20 K=,15 K=,20 K=,15 K=,20

ft-lbs. ft-lbs. ft-lbs. ft-lbs. ft-lbs. ft-lbs.

Clamp

Load

12.9

Grade 12.9

Tightening Torque

Table 1 - 4 :

Torque Specifications for Metric Fasteners, SI Units

8.8 10.9

Grade 8.8

Nominal

Thread

Size mm N N-m N-m N N-m N-m N N-m N-m

Clamp

Load

3------36601,652,2

3,5------49322,593,45

4------63873,835,11 5 6177 4,63 6,18 8840 6,63 8,84 10330 7,75 10,3

6 8743 7,87 10,5 12512 11,3 15 14623 13,2 17,6

7 12570 13,2 17,6 17990 18,9 25,2 21025 22,1 29,4 8 15921 19,1 25,5 22784 27,3 36,5 26626 32 42,6

10 52230 37,8 50,5 36105 54,1 72,2 42195 63,3 84,4

12 36670 66 88 52475 94,5 125 61328 110 147 14 50025 105 140 71587 150 200 83663 175 234

16 70650 170 226 97732 235 313 114218 274 365

18 86400 233 311 119520 323 430 139680 377 503 20 10250 330 441 152513 458 610 178238 535 713

22 136350 450 600 188618 622 830 220433 727 970

24 158850 570 762 219743 791 1055 256808 925 1233 27 206550 837 115 285728 1157 1543 333923 1352 1803

30 252450 1136 1515 349223 1572 2095 408128 1837 2450

33 312300 1546 2061 432015 2138 2851 504885 2500 3332 36 367650 1985 2647 508582 2746 3662 594368 3210 4279

Tightening Torque

K =,15 K =,20 K =,15 K =,20 K =,15 K =,20

Clamp

Load

Grade 10.9

Tightening Torque

Clamp

Load

12.9

Grade 12.9

Tightening Torque

Page 1-4 Service Manual

Page 25

Section 1 - General Information Date Code Identification on Hoses

1-4 D

GGGG

AAAATTTTEEEESSSS

PPPP

AAAARRRRKKKKEEEERRRR

DDDD

AAAAYYYYCCCCOOOO

1-5 S

ATE

uses an eight digit code: Plant, Month, Day, Year. i.e.: XX 01 07 01 - means Plant XX January 07 2001.

uses a 4 digit code indicating Quarter and Year. i.e.: 2Q01 - means Second Quarter of 2001.

stamps month, day and year on each hose.

ODE

PECIAL

The following is a list of special tools which may be required to perform certain maintenance procedures on the machine.

•0-100bar(0-1000 psi) Hydraulic Pressure Gauge with Adapter Fittings

•0-200bar(0-3000 psi) Hydraulic Pressure Gauge with Adapter Fittings

•0-500bar(0-6000 psi) Hydraulic Pressure Gauge with Adapter Fittings

• Small UpRight Connector Field Kit (UpRight P/N 030899-000)

• Large UpRight Connector Field Kit (UpRight P/N 030898-000)

• Inclinometer (UpRight P/N 010199-000-00)

• MOS90 Calibrator (UpRight P/N 057128-000)

• Optimizer with adapter (UpRight P/N 100329-000)

• Flow Meter Kit (UpRight P/N 067040-000)

• Quadragauge with fitting (UpRight P/N 063971-000)

•0-25kg(0-50 Lbs.) Chain Tension Scale (UpRight P/N 107078-000)

DENTIFICATION

OOLS

OSES

UPR

IGHTLIFTTOOLLIST

• Gland Nut Wrench (UpRight P/N 062521-000)

• Strap Wrench (UpRight P/N 062482-000)

• Tierod Tensioner (2 required) (UpRight P/N 062738-000)

• Tensioner Bracket (2 required) (UpRight P/N 062739-000)

Service Manual Page 1-5

Page 26

UpRight Connectors Section 1 - General Information

1-6 U

PRIGHT

UpRight connectors are designed so that connector parts, contacts or electrical cables may be replaced without replacing the entire connector.

ALE

1. Disconnect the male connector (plug) from the female connector (receptacle).

2. Using the flat end of the Removal Tool (or flat blade screwdriver), pry the Locking Wedge from the Male Connector. Care should be taken that the Sealing Gasket is not damaged during this procedure.

3. Check all parts for damage. Replace all parts which are damaged or worn.

4. Replace or re-crimp the wires and contacts. Refer to “Crimping” procedure.

ONNECTOR

ONNECTORS

LUG

Figure 1-1:

UpRight Connector Kits

Large KitSmall Kit

)

Figure 1-2:

UpRight Male Connector

EMALE

1. Disconnect the male connector (plug) from the female connector (receptacle).

2. Using the notched end of the Removal Tool (or a wire hook), pull the Locking Wedge from the Female Connector.

3. Check all parts for damage. Replace all parts which are damaged or worn.

4. Replace or re-crimp the wires and contacts. Refer to “Crimping” procedure.

Page 1-6 Service Manual

ONNECTOR

ECEPTACLE

)

Figure 1-3:

UpRight Female Connector

Page 27

Section 1 - General Information UpRight Connectors

ELEASING

1. The Locking Fingers can be released following the removal of the Locking Wedge of either the male or female connector.

2. Use the removal tool (or flat bladed screwdriver) to push the Locking Fingers aside. This will release thegriponthecontact.

3. Pull the wire and contact out of the connector.

RIMPING

1. Strip 6 mm (¼in.)fromthewire.

NOTE:

Complete crimping instructions are included in each Field Kit.

OCKING

INGERS

Figure 1-4:

Locking Finger, UpRight Connector

2. Insert the contact into the crimping tool.

3. Insert the stripped wire into the contact. Copper strands should be visible in the bleed hole of the contact and no copper strands should be loose (outside) of the contact barrel.

4. Completely close the handles of the crimping tool. Release the handles of the crimping tool and remove the crimped contact.

5. Inspect the crimped contact to ensure that all strands are secure in the crimp barrel.

EMOVING

1. Slip the removal tool along the wire to be replaced.

2. Push the removal tool into the connector until the contact is released.

3. Pull the wire and contact out of the plug.

ONTACT

FROM

EAVY

UTY

LUG

Figure 1-5:

Heavy Duty UpRight Connector

Service Manual Page 1-7

Page 28

Hydraulic Manifold Repair Section 1 - General Information

1-7 H

YDRAULIC

EMOVAL

Refer to the

1. Disconnect the battery.

2. Tag and disconnect the solenoid valve leads.

3. Tag, disconnect, and plug hydraulic hoses.

4. Remove the bolts that hold the manifold to the mounting bracket.

5. Remove the manifold block.

ISASSEMBLY

NOTE:

Mark all components as they are removed so as not to confuse their location during assembly.

1. Remove coils from solenoid valves.

2. Remove valves.

3. Remove fittings, plugs, springs, balls, and orifices.

LEANING

1. Wash the manifold in cleaning solvent to remove built-up contaminants, then blow out all passages with clean compressed air.

2. Inspect the manifold for cracks, thread damage and scoring where O-rings seal against internal and external surfaces.

3. Wash and dry each component and check for thread damage, torn or cracked O-rings, and proper operation.

4. Replace parts and O-rings found unserviceable.

ANIFOLD

Service and Repair

AND

NSPECTION

EPAIR

section for model specific information.

SSEMBLY

Refer to the breakdowns.

NOTE:

Lubricate all O-rings before installation to prevent damage to O-rings. Seat all balls in manifold block by lightly

tapping on the ball with a brass drift punch.

1. Install fittings, plugs, springs, balls, and orifices. Use one drop of Locktite #242oneachscrew-inorifice.

2. Install valves.

NSTALLATION

Refer to the

1. Attach manifold assembly to mounting plate with bolts.

2. Connect solenoid leads (as previously tagged).

3. Connect hydraulic hoses. Be certain to tighten hoses to manifold.

4. Reconnect the battery.

5. Operate each hydraulic function and check for proper operation and leaks.

6. Adjust valve pressures according to the

Service and Repair

section for assembly drawings, and the

section for model specific information.

Service and Repair

section.

Parts Manual

for illustrated parts

Page 1-8 Service Manual

Page 29

Section 1 - General Information Cylinder Repair

1-8 C

YLINDER

WARNING

Cylinders may be very heavy. Support heavy cylinders before removing pins which secure the cylinder to the machine.

EMOVAL

NOTE:

Refer to the

which secure the cylinders.

1. Mark and disconnect hoses and IMMEDIATELY cap the openings to prevent contamination.

2. Remove the cylinder from the machine as described in the

ISASSEMBLY

1. Remove the head from the cylinder body.

2. Carefully slide the rod assembly out of the cylinder.

3. Remove the seal kit components (wipers, rod seals, o-rings and backup rings) from the head and piston.

4. Inspect parts for scratches, pits or polishing. Check seal grooves and sealing surfaces. Scratches or pits deep enough to catch the fingernail are unacceptable; replace the cylinder. Polishing is a sign of uneven loading. When this occurs, the surface should be checked for roundness. Cylinders not round within 0,18 mm (.007 in.) should be replaced.

EPAIR

Service and Repair

section for the location of cylinders, and the

Service and Repair

Parts Manual

section.

for a list of parts

SSEMBLY

Refer to the parts breakdowns.

NOTE:

•To avoid cutting the seals, do not use sharp edged tools during seal replacement. After installing seals allow at least one hour for the seals to elastically restore to their original shape before assembling the cylinder.

•Torque all hardware to torques according to Table 1-1, “Torque Specifications for Hydraulic Components,” on Page 1-3 unless otherwise specified.

1. Lubricate all components with clean hydraulic fluid.

2. Install new seal kit components.

3. Lubricate the rod wiper and seal with hydraulic fluid and slide the head onto the rod.

4. Lubricate the seals on the piston and head.

5. Carefully slide the rod assembly into the cylinder.

6. Secure the head into the cylinder.

NSTALLATION

1. Installation is reverse of removal.

2. Carefully remove the elevating assembly support.

3. Slowly cycle the cylinder several times to remove air from the hydraulic system.

4. Check for proper cylinder operation. Check hydraulic connections for leaks.

Service and Repair

section for seal-kit assembly drawings, and the

Parts Manual

for illustrated

Service Manual Page 1-9

Page 30

Electric Motors Section 1 - General Information

1-9 E

LECTRIC

ROUBLESHOOTING

1. Read the nameplate to become familiar with the motor, especially the rated voltage.

2. Try to turn the shaft by hand. Keep motor leads separated while doing this. If the shaft turns freely go to Step 3. If the shaft won't turn, proceed to Step A.

A. The shaft could be tight for a number of

reasons, this check is to determine if the tightness is of a temporary nature only.

a. Obtain power to produce the nameplate

voltage. Do not Make a Permanent Con- nection.

b. First touch the motor leads quickly to the

power supply just long enough to observe if the shaft turns.

c. If it does turn, then hold the motor leads

on the power supply for a longer time. If the motor sounds normal, go to Step 3..

d. If the motor sounds noisy, it should be

taken apart as described in the disassembly section.

3. If the motor turned freely, connect an ammeter in the circuit as shown in Figure 1-6A. With rated voltage applied and the shaft running free, the ammeter should read less than 20% of the nameplate full load current. If the motor meets the above conditions, then it can be assumed that the original problem is external to the motor.

OTORS

DC Power Supply

Brushes raised with the springs in locked position on the side

of the brush

Keep fingers clear of this space.

Figure 1-6:

Voltage Meter

Brushes and springs in their final position

Electric Motor Service

Ammeter

DC Motor

ISASSEMBLY

1. Remove the through bolts.

2. Remove the pulley end cover.

3. Pull the armature out of the assembly in one swift motion.

4. Remove the commutator end cover.

NOTE:

Do not place the stator ring in any mechanical holding device during the disassembly or assembly operation.

Permanent distortion or other damage will result.

Page 1-10 Service Manual

Page 31

Section 1 - General Information Electric Motors

NSPECTION

Once the motor has been disassembled, go through the following check-list steps to determine where the problem lies.

1. Bearings should spin smoothly and easily and have ample lubrication and be free of corrosion.

2. The armature should be checked for grounds and shorted turns. Re-finish the commutator surface if it is pitted or excessively worn. (This procedure should be performed by a qualified electric motor shop.)

3. Brushes should be checked for wear and to ensure that they are free in the brush holders.

NOTE:

Observe how the brushes are assembled in the brush holders, and the position of the brush lead. New brushes

must be installed in the same manner. Brushes should be removed as follows:

a. Remove the brush spring clip from its mounting on the brush assembly. b. Lift the brush assembly from the brush holder. c. Disconnect the brush assembly lead. d. Install the new brush assembly by reversing the above procedure.

4. Inspect the wire harness and all connections for signs of damage due to overheating.

5. Check the stator to see if it is securely mounted.

EASSEMBLY

Electric Motor Brushes

Brushes and springs in their final position

1. Install new brushes and be sure they are free in the holder. Install the brush with the lead wires positioned as when received. Raise all brushes to the locked position. (See

Figure 1-7:

Brushes raised with the springs in locked position on the side of the brush

Figure 1-7 and Inspection Step 3.).

2. Place the commutator cover on a work bench with the brush assembly facing upward.

3. Place the bearing spring into the bearing bore.

Brushes

4. Take a complete armature assembly, including bearings, and insert the commutator end bearing into the bearing bore.

Buss Bar

Counterclockwise

Rotation

NOTE:

Do not re-use bearings which have been removed

from the armature shaft. Keep the assembly in a

Buss Bar

vertical position. Use extreme care not to damage the armature with bearing pullers. New bearings should be installed by pressing the inner race of the bearing onto proper position on the armature shaft.

5. Set the brushes into their final position as

Typical pump motor viewed from rear.

NOTE:

This illustration is a 015797-011 pump motor. Other electric motors may rotate in either direction, and may use only two brushes.

showninFigure1-7.

6. Place the complete stator down over the vertical armature, and into position on the commutator cover.

7. The stator assembly must be placed in a definite relationship with the commutator covers in order to obtain a neutral brush setting. There is a match-mark on both items. These two marks must line up exactly. Rotate until they do.

8. Assemble the pulley end cover in the proper relationship. Insert the mounting bolts and tighten alternately to ensure a good mechanical alignment.

9. Spin the shaft by hand to see if it is free. Be sure motor leads (if used) are not touching together. If the leads are touching, a generator action will give the effect of friction in the motor. A no-load test can now be performed. At the rated voltage, observe the no-load current. It should be less than 20% of the nameplate full load current. Anything higher indicates:

• Brushes are not on neutral setting (check match-marks for exact alignment).

• Faulty armature.

Service Manual Page 1-11

Page 32

Battery Maintenance Section 1 - General Information

1-10 B

ATTERY

AINTENANCE

CAUTION

If battery water level is not maintained, batteries will not fully charge, creating a low discharge rate.

WARNING

Hazard of explosive gas mixture. Keep sparks, flame and smoking materials away from batteries. Always wear safety glasses when working with batteries. Battery fluid is highly corrosive. Thoroughly rinse away any spilled fluid with clean water. Always replace batteries with UpRight batteries or manufacturer approved replacements. Before disconnecting the battery negative (-) lead, make sure all switches are OFF. If ON, a spark will

occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present.

• Check battery fluid level daily.

• If electrolyte level is lower than 10 mm (3/8 in.) above plates, add distilled water only.

DO NOT use tap water with high mineral content. It will shorten battery life. DO NOT overfill. Battery acid expands during charging and can overflow.

• Keep terminals and tops of batteries clean.

• The battery and cables should be inspected regularly for signs of cracks in the case, electrolyte leak-

age and corrosion of the terminals. Inspect the cables for worn spots or breaks in the insulation and for broken cable terminals.

• Clean batteries whenever there are signs of corrosion at the terminals, or when electrolyte has overflowed during charging. Use a baking soda solution to clean batteries, taking care not to get the solution inside the cells. Rinse thoroughly with clean water.

• Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed.

Page 1-12 Service Manual

Page 33

Section 1 - General Information Battery Maintenance

ATTERY

Electric UpRight Aerial Work Platforms use deep cycle batteries. If poor service life is experienced, batteries should be checked for bad cells. Fully charge batteries for 14 hours minimum, ensuring that the charger has completed its cycle (see ‘Battery Charging” on page 1-14).

Deep cycle batteries do not have their full potential until they have been through 50 charge/discharge cycles. Normal 5-day weeks, charging batteries every day, equals 50 cycles in ten weeks.

If bad cells are found in any battery in a battery pack more than two years old, all batteries in the pack should be replaced for balance.

ATTERYCELLEQUALIZATION

The specific gravity of the electrolyte in the battery cells should be equalized monthly. To do this, charge batteries as outlined in ‘Battery Charging” on page 1-14. After this initial charge, recheck the electrolyte level in all cells and add distilled water as necessary. Then, turn on the charger for an additional eight hours.

PECIFICGRAVITY

Check the specific gravity of all cells with a hydrometer. The temperature corrected specific gravity of a fully charged battery should be 1.260. If any corrected readings are below 1.230, the batteries containing such cells should be replaced.

HECK

Table 1 - 5 :

Do not check the specific gravity in a cell to which water has just been added. If there is not enough electrolyte in a fully charged cell to obtain a sample for the hydrometer, add water and complete a discharge/ charge cycle before checking.

Specific Gravity and Battery Voltage

SPECIFIC GRAVITY VOLTS DC

Each Cell Per Cell 6V Battery 12V Battery 24V Battery Pack 48V Battery Pack

Fully Charged 1.270 2.10 6.30 12.60 25.20 50.40

Fully Discharged 1.130 1.75 5.25 10.50 21 42

OADTESTINGBATTERYPACKS

1. Fully charge the battery pack.

2. With the battery pack at rest and under full load, perform steps 3 and 4. a. To put the battery pack under full load,

• Activate the steering switch to turn the wheels fully in either direction.

• Continue to hold the steering switch while performing steps 3 and 4.

3. Measure the potential across each battery.

4. Measure the potential across the entire battery pack.

5. Compare the measured results

Any battery that measures 10% lower voltage than the others has a bad cell and should be replaced.

Service Manual Page 1-13

Page 34

Battery Maintenance Section 1 - General Information

ATTERY

HARGING

CAUTION

Permanent damage will result if the battery is not immediately recharged after discharging.

WARNING

Charge batteries only in a well ventilated area. DO NOT charge batteries when sparks or open flames are present. Never leave the connected charger unattended for more than two days. Never disconnect the cables from the battery when the charger is operating. Keep the charger dry.

• Charge batteries at the end of each work shift or sooner if the batteries have been discharged.

• Discharging a deep cycle battery to less than 1.75 Volts per cell can cause permanent damage.

NOTE:

Do not operate the machine when the battery charger is plugged in.

When night temperatures fall below 65°F(18°C), batteries charged in unheated areas should be charged as soon after use as possible. Under such conditions a four hour charge cycle once a week in the early afternoon will improve the state of charge and battery life.

1. Check the battery fluid level. If electrolyte level is lower than 10 mm (3/8 in.) above plates, add distilled water only.

2. Check the charger to determine the AC charging current. If equipped, set the AC voltage selector switch to match the AC power source.

3. Connect an extension cord that meets or exceeds the charger AC current onto the charger plug.

4. Connect the other end of the extension cord to a grounded AC outlet of proper current, voltage and frequency rating.

5. The charger turns on automatically after a short delay. Table 1-6 illustrates charging indicators.

Table 1 - 6 :

Battery Charging, UpRight Electric and BiEnergy Machines

Charger Display AC Charging Current Charging Indicator Charger Shutdown

068574-000 8 Amp - 115 VAC Ammeter

069112-000 4 Amp - 230 VAC

063944-001 7 Amp - 115 VAC Green Light

063948-003 4 Amp - 230 VAC

069199-000

069199-001

Dual Voltage

8Amp-115VAC 4Amp-230VAC

• Charging current is displayed on ammeter.

• Current drops off as batteries charge.

• ON during charging cycle.

• Blinking at charge completion.

Three Lights

• 0 - 50% charge:

First Light -BlinkingSecond and Third Light -OFF-

• 50% - 75% Charge:

First Light -ONSecond Light -BlinkingThird Light -OFF-

• 75% - 100% Charge:

First and Second Light -ONThird Light - Blinking-

• Charge Complete

All Lights -ON-

• Charger shuts off automatically.

• Ammeter shows “0” current.

• Charger automatically shuts down to 1 amp trickle charge.

• Green Light continues to blink.

• Charger automatically shuts down to low current after charging is complete and all Lights turn ON.

• Charger continues at low current (equalizing charge) for 3-4 hours, then charging current shuts off completely.

• Lights remain ON until the AC power supply is disconnected.

Page 1-14 Service Manual

Page 35

Section 1 - General Information Battery Maintenance

ATTERY

HARGER

ROUBLESHOOTING

CAUTION

Ensure that battery chargers with voltage selector switches are set on the correct AC line voltage before placing chargers in service to avoid charger failure.

Connect battery leads in correct polarity to avoid charger damage.

WARNING

Remove all power before working on electrical parts to avoid shock. Shock hazard can exist if AC plugs are wired incorrectly.

The battery charger troubleshooting procedure is outlined in Table 1-7. The table shows various conditions for each charger type with the problem to be investigated. Follow the table from the top down when troubleshooting. If the problem is not resolved after going through the entire table, the charger should be replaced.

NOTE:

The majority of chargers returned to UpRight as “failed” test good. Please follow the troubleshooting

procedures carefully.

Table 1 - 7 :

Battery voltage is below 18 Volts (too low to allow the charger to turn on).

The charger has been plugged into an AC outlet with different voltage than the AC switch setting on the charger.

Fuse visible on front of charger has failed.

AC power problem. • Ammeter does not move.

DC connection to batteries. • Ammeter does not move.

One or more batteries is bad.

AC input voltage too high. • Not Applicable. • Not Applicable. • All three Lights blink two times. Check and correct AC source.

Overheated charger. • Not Applicable. • Not Applicable. • All three Lights blink three times. Move the machine to a cooler area. Allow the machine

High current in DC charging output.

Battery Charger Troubleshooting

Problem

068574-000 (115V) 069112-000 (110/230V)

• Ammeter does not move.

• No hum from charger.

• Ammeter does not move.

• No hum from charger.

• Ammeter does not move.

• No hum from charger.

• Ammeter never shuts off, even after 14 hours of charging.

• Not Applicable. • Not Applicable. • All three Lights blink four times. • Check for shorted DC output wires.

063944-001 (115V) 063948-003 (110/230V)

• No green Light.

• No hum from charger.

• No green Light.

• No hum from charger.

• Not Applicable. • Not Applicable. Check for DC output short circuit and replace the fuse.

• No green Light.

• No hum from charger.

• No green Light.

• No hum from charger.

• Green Light ON but never starts blinking, even after 14 hours of charging.

069199-000 & 069199-001

(115/230V auto)

• Not Applicable.

• Charger turns on even with very low battery voltage.

• Not Applicable.

• Charger automatically adjusts to the incoming AC current.

• NoLightsON.

• No Lights blinking.

• All three Lights blink once. Connection to battery;

• Lights one and two are ON or blinking, but all three Lights ON never occurs, even after 14 hours of charging.

Charge batteries to at least 24 Volts with an external charger, then disconnect the external charger and plug in the internal charger.

063944-001 ONLY

• Check the fuse inside the switch box - replace if bad.

• If the fuse is good, the charger has failed. All Others

• Check the AC main circuit breaker and reset if necessary.

• Set the voltage selector switch to the proper voltage.

• ACoutletisbad.

• Extension cord is bad

• Plug is bad or wired wrong.

• ACwireisbroken.

Check and repair as necessary.

• missing.

• corroded.

• wrong polarity.

• DCwirebroken.

Check and repair as necessary, and check Fuse.

• Check water level.

• Check for shorted cells.

• Replace bad batteries.

to cool before connecting to AC source.

• Check for bad batteries.

Solution

Service Manual Page 1-15

Page 36

Floor Loading Section 1 - General Information

1-11 F

LOOR

Floor Loading is defined as pressure imposed onto load-bearing surfaces, and can be measured as Localized Pressure or Occupied Pressure. To calculate Floor Loading, find the Total Weight of the machine.

TOTAL WEIGHT = MACHINE WEIGHT + MAXIMUM PLATFORM CAPACITY.

Refer to the machine specifications or contact UpRight or your UpRight dealer.

OCALIZED

KG/CM²OR PSI

Localized Pressure is measured in

per square centimeter (pounds per square

inch

area (contact area). Each tire and/or outrigger imposes Localized Pressure which can cause damage to the load-bearing surface.

NOTE:

machines. Applying these formulas to machines with extending platforms will yield average pressures for machines in stowed position. Extending a platform causes increased localized pressure in the direction of extension, and decreased localized pressure at the opposite end.

OADING

RESSURE

kilograms

). It is the pressure exerted onto a small

The formulas shown here are for vertical lift

Figure 1-8:

TIRE LUG TIRE OUTRIGGER

Contact Area

EASURE THECONTACT

Measure the contact area of the contacting surface (tire or outrigger).

The tire contact area can be determined by placing the loaded tire on a clean surface. The tire will leave an imprint from which an area can be determined.

ALCULATE THELOCALIZEDPRESSURE

Find the pressure exerted at each contacting surface.

NOTE:

The wheel load can usually be found on a label on the

machine, or on the serial plate.

If you know the wheel load, use this formula:

LOCALIZED PRESSURE = WHEEL LOAD ÷ CONTACT AREA

If you do not know the wheel load, use this formula:

LOCALIZED PRESSURE = (TOTAL WEIGHT ÷ 4)÷ CONTACT AREA

CCUPIED

KPAORPSF

Occupied Pressure is measured in

pounds per square foot

onto the work surface over the area of the machine (occupied surface area). This is especially important when the work surface is supported by beams. The Occupied Pressure

RESSURE

.Itisthetotalpressureimposed

must not exceed

REA

CONTACT AREA

WIDTH

kilopascals

the maximum load that the surface can support.

Figure 1-9:

LENGTH

Occupied Surface Area

OCCUPIED PRESSURE = TOTAL WEIGHT ÷ (LENGTH X WIDTH)

Page 1-16 Service Manual

Page 37

Section 1 - General Information Hydraulic Fluid

1-12 H

EVEL

LUID

YDRAULIC

LUID

YDRAULIC

LUID

With the platform fully lowered, check the hydraulic fluid level. If the fluid is NOT in operating range, add hydraulic fluid until the fluid level is in operating range.

ECOMMENDED

• DO NOT fill above operating range.

• DO NOT add fluid when the platform is elevated.

CAUTION

Unless recommended by UpRight, do not mix hydraulic fluids of different brands or types. The required additives and fluid viscosities may vary.

If the use of hydraulic fluids other than listed below is desired please contact UpRight Product Support.

OBILFLUID

• ViscosityGrade: ................. ISO46HighV.I.(similartoSAE10W-30).

• Viscosityindex:.................. 152.

• OperatingRange: ................ -10° Cto+96° C(+15° F to +205° F) Reservoir Temperature.

• AmbientConditions*:.............. Above-10° C(+15° F).

424

OBIL

For use where a

The anti-wear quality of hydraulic fluid must meet or exceed API Service Classification GL-3. The chemical stability of the hydraulic fluid must be sufficient for mobile hydraulic system service.

DTE 13 M

• ViscosityGrade: ................. ISO32HighV.I.(similartoSAE5W-20).

• Viscosityindex:.................. 140.

• OperatingRange: ................ -18° Cto+80° C(-4° Fto+176° F) Reservoir Temperature.

• AmbientConditions*:.............. -18° Cto+30° C(-4° Fto+86° F).

DTE 11 M

• ViscosityGrade: ................. ISO15.

• Viscosityindex:.................. 140.

• OperatingRange: ................ -35° Cto+45° C(-30° Fto+115° F) Reservoir Temperature.

• AmbientConditions*:.............. -35° Cto+20° C(-30° Fto+70° F).

EAL E

• ViscosityGrade: ................. ISO46HighV.I.(similartoSAE10W-20).

• ViscosityIndex:.................. 153.

• OperatingRange: ................ -14° Cto+90° C(+6° Fto+195° F) Reservoir Temperature.

• AmbientConditions*:.............. -14° Cto+41° C(+6° Fto+105° F).

• Synthetic Ester Base.

NVIROSYN

biodegradable non-toxic hydraulic fluid is required.

46 H

*Ambient Conditions are for reference only and may vary by model. Refer to operating temperature for final determination of correct fluid.

Service Manual Page 1-17

Page 38

Long Term Storage Section 1 - General Information

1-13 L

ONG

NOTE:

1. Clean painted surfaces. If paint is damaged, repaint.

2. Fill the hydraulic reservoir to operating level.

IMPORTANT: Do not fill the hydraulic reservoir while the platform is elevated.

3. Coat exposed portions of cylinder rods with a preservative such as multipurpose grease and wrap with

4. Coat all exposed unpainted metal surfaces with preservative.

5. Internal Combustion Models: Service the engine according to the manufacturers recommendations.

6. Electric And BiEnergy Models: Remove the batteries and place them in alternative service.

ERM

Do not drain the hydraulic system prior to long term storage.

If the machine is to be placed in long term storage, follow these recommended preservation procedures.

RESERVATION

a barrier material.

TORAGE

Page 1-18 Service Manual

Page 39

Section 2

ABLE

ERVICE

This section contains instructions for the maintenance of the machine. Refer to the General Information section for information relevant to all UpRight work platforms. Referring to the Operator Manual will aid in understanding the operation and function of the various components and systems of the machine, and help in diagnosing and repair of the machine.

WARNING

Be sure to read, understand and follow all information in the Operation Section of this manual before attempting to operate or perform service on any UpRight Aerial Work Platform.

DANGER

! !

Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly.

DO NOT stand in elevating assembly area while deploying or storing brace.

ONTENTS

AND

EPAIR

2-1 GeneralDescription.............................................................2-4

Component Locations . . . . . ................................................................ 2-4

2-2 PreventativeMaintenance........................................................2-6

Preventative Maintenance Check List ......................................................... 2-7

2-3 BlockingTheElevatingAssembly .................................................2-8

Installation.............................................................................. 2-8

Removal................................................................................ 2-8

2-4 Lubrication ....................................................................2-9

GreaseFittings .......................................................................... 2-9

TorqueHubs ............................................................................ 2-9

HydraulicFluidReservoirandFilter.......................................................... 2-10

FluidLevel ........................................................................... 2-10

FluidandFilterReplacement............................................................. 2-10

2-5 SettingHydraulicPressures .....................................................2-11

LiftReliefValve......................................................................... 2-11

SteeringReliefValves.................................................................... 2-11

2-6 SwitchAdjustments............................................................2-12

ProximitySwitch-SerialNumber4022-4274 .................................................. 2-12

ProximitySwitchFunction,SerialNumber4022-4274.......................................... 2-12

TesttheProximitySwitch,SerialNumber4022-4274.......................................... 2-12

RemovalandInstallation,SerialNumber4022-4274........................................... 2-13

Proximity Switch Adjustment, Serial Number 4022-4274. . . . . ................................... 2-13

ProximitySwitch-SerialNumber4275-Current ................................................ 2-14

ProximitySwitchFunction,SerialNumber4275-Current........................................ 2-14

TesttheProximitySwitch,SerialNumber4275-Current........................................ 2-14

TestHighSpeedCircuit,SerialNumber4275-Current ......................................... 2-14

RemovalandInstallation,SerialNumber4275-Current......................................... 2-15

ProximitySwitchClearanceAdjustment-SerialNumber4275-Current ............................ 2-15

067448-003 LX31/LX41 Electric Work Platform Page 2-1

Page 40

Section 2 - Service and Repair

ProximitySwitchHeightAdjustment-SerialNumber4275-Current............................... 2-16

LevelSensor........................................................................... 2-16

2-7 HydraulicManifolds............................................................ 2-17

MainHydraulicManifold.................................................................. 2-17

BrakeHydraulicManifold ................................................................. 2-17

2-8 HydraulicPowerUnit........................................................... 2-18

Removal ............................................................................ 2-18

Installation........................................................................... 2-18

2-9 HydraulicBrakes.............................................................. 2-18

Removal ............................................................................ 2-18

BrakeSealReplacement................................................................ 2-19

Installation........................................................................... 2-19

2-10TorqueHub................................................................... 2-20

TorqueHubRemoval .................................................................... 2-20

TorqueHubInstallation................................................................... 2-21

TorqueHubSealReplacement............................................................. 2-21

Roll And Leak Testing . . . . . . ............................................................ 2-21

RollTest ............................................................................ 2-21

LeakTest............................................................................ 2-21

PressingTools........................................................................ 2-21

TorqueHubDisassembly ................................................................. 2-22

TorqueHubAssembly.................................................................... 2-23

MainAssembly ......................................................................... 2-24

2-11DriveMotors.................................................................. 2-26

Removal ............................................................................ 2-26

Installation........................................................................... 2-26

PumpMotor............................................................................ 2-26

Removal ............................................................................ 2-26

Installation........................................................................... 2-26

DriveMotorBrushes..................................................................... 2-26

2-12SteeringCylinder.............................................................. 2-27

Removal ............................................................................ 2-27

SealReplacement..................................................................... 2-27

Installation........................................................................... 2-27

2-13LiftCylinder.................................................................. 2-28

Removal ............................................................................ 2-28

SealReplacement..................................................................... 2-28

Installation........................................................................... 2-28

2-14OutriggerCylinder(Optional).................................................... 2-30

Removal ............................................................................ 2-30

SealReplacement..................................................................... 2-30

Installation........................................................................... 2-30

Page 2-2 067448-003 LX31/LX41 Electric Work Platform

Page 41

Section 2 - Service and Repair

IST OF

IGURES

Figure2-1:LXElectricComponentLocation .........................................................2-5

Figure2-2:BlockingElevatingAssembly............................................................2-8

Figure2-3:LubricationPoints.....................................................................2-9

Figure2-4:HydraulicFluidReservoir&Filter........................................................2-10

Figure2-5:ValveManifold......................................................................2-11

Figure2-6:ProximitySwitch,SerialNumber4022-4274...............................................2-12

Figure2-7:ProximitySwitchPosition..............................................................2-12

Figure 2-8: Proximity Switch Adjustment - Serial Number 4022-4274 . . ...................................2-13

Figure2-9:ProximitySwitchClearanceAdjustment ..................................................2-15

Figure2-10:ProximitySwitchAdjustment ..........................................................2-16

Figure2-11:LevelSensor ......................................................................2-16

Figure2-12:HydraulicManifold..................................................................2-17

Figure2-13:BrakeHydraulicManifold.............................................................2-17

Figure2-14:HydraulicPump ....................................................................2-18

Figure2-15:RearAxleAssembly.................................................................2-18

Figure2-16:BrakeAssembly....................................................................2-19

Figure2-17:TorqueHubAssembly...............................................................2-20

Figure2-18:MeasuringHubEndPlay.............................................................2-23

Figure2-19:TorqueHub .......................................................................2-25

Figure2-20:ReplacingDriveMotorBrushes........................................................2-26

Figure2-21:FrontAxleAssembly,4WD ...........................................................2-27

Figure2-22:SteeringCylinderCrossSection .......................................................2-27

Figure2-23:LiftCylinderCrossSection-SerialNumber4022to4129....................................2-29

Figure2-24:LiftCylinder-SerialNumber4130toCurrent .............................................2-29

Figure 2-25: Outrigger Cylinder Installation . ........................................................2-31

Figure 2-26: Outrigger Cylinder Cross Section. . . . . . .................................................2-31

067448-003 LX31/LX41 Electric Work Platform Page 2-3

Page 42

General Description Section 2 - Service and Repair

2-1 G

ENERAL

The LX 31 and LX 41 Electric Work Platforms are available with optional outriggers.

OMPONENT

Refer to Figure 2-1 to locate the components of the LX Electric Work Platforms.

1. Platform Controls

2. Document Case

3. Bubble Level (with outrigger option)

4. Platform Extension

5. Work Platform

6. Elevating Assembly

7. Outriggers (optional)

8. Hydraulic Pump

9. Hydraulic Reservoir

10. Chassis Controls

11. Hydraulic Manifold

12. Outrigger Control Manifold (optional)

13. Brake Manifold

14. Batteries

15. Level Sensor

16. Outrigger Relay Box (optional)

17. Proximity Switch

ESCRIPTION

OCATIONS

Page 2-4 067448-003 LX31/LX41 Electric Work Platform

Page 43

Section 2 - Service and Repair General Description

Figure 2-1:

LX Electric Component Location

POWER MODULE

FRONT

CONTROL MODULE

REAR

067448-003 LX31/LX41 Electric Work Platform Page 2-5

Page 44

Preventative Maintenance Section 2 - Service and Repair

2-2 P

REVENTATIVE

WARNING

Before performing preventative maintenance, familiarize yourself with the operation of the machine.

Always block the elevating assembly whenever it is necessary to enter the elevating assembly to perform maintenance while the platform is elevated.

The preventative maintenance table has been designed for machine service and maintenance repair. Please photocopy the following page and use the table as a checklist when inspecting the machine for service.

AINTENANCE

Page 2-6 067448-003 LX31/LX41 Electric Work Platform

Page 45

Section 2 - Service and Repair Preventative Maintenance

REVENTATIVE

REVENTATIVEMAINTENANCE

AINTENANCE

HECK

REVENTATIVE

IST

AINTENANCE

EPORT

Interval

Daily=each shift or every day

50h/30d=every 50 hours or 30 days

250h/6m=every 250 hours or 6 months

1000h/2y=every 1000 hours or 2 years

Y=Yes/Acceptable

N=No/Not Acceptable

R=Repaired/Acceptable

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Check electrolyte level 6m

Check specific gravity 6m

Batteries

Hydraulic

Fluid

Hydraulic

System

Emergency

Hydraulic

System

Controller Check Switch operation Daily

Control Cable

Platform

Deck and

Rails

Tires

Hydraulic

Pump

Drive Motors Check for operation and leaks Daily

Clean exterior 6m

Check battery cable condition Daily

Clean terminals 6m

Check fluid level Daily

Change filter 6m

Drain and replace fluid 2y

Check for leaks Daily

Check hose connections 30d

Check hoses for exterior wear 30d

Operate the emergency lowering valve and check for serviceability

Check the exterior of the cable for pinching, binding or wear

Check fasteners for proper torque Daily

Check welds for cracks Daily

Check condition of deck Daily

Check for damage Daily

Check lug nuts (torque to 205 Nm [150 ft. lbs.])

CheckTirePressure(5bar[75PSI]) Daily

Wipe clean 30d

Check for leaks at mating surfaces 30d

Check for hose fitting leaks Daily

Check mounting bolts for proper torque 30d

Daily

30d

Date: ______________________________________

Owner: _____________________________________

Model No: __________________________________

Serial No: ___________________________________

Serviced By:_________________________________

Service Interval: ______________________________

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Check for leaks Daily

Torque Hubs

Steering

System

Elevating

Assembly

Chassis

Lift Cylinder

Entire Unit

Labels

Check oil level 250h/6m

Change oil after break-in 50h/30d

Change oil 1000h/2y

Check hardware & fittings for proper torque 6m

Grease steering pivots 30d

Check steering cylinder for leaks 30d

Inspect for structural cracks Daily

Check pivot points for wear 30d

Check mounting pin pivot bolts for proper torque

Check elevating arms for bending 6m

Grease linkage pins 30d

Check hoses for pinch or rubbing points Daily

Check component mounting for proper torque 6m

Check welds for cracks Daily

Check the cylinder rod for wear 30d

Check mounting pin pivot bolts for proper torque

Check seals for leaks 30d

Inspect pivot points for wear 30d

Check fittings for proper torque 30d

Check for and repair collision damage Daily

Check fasteners for proper torque 3m

Check for corrosion - remove and repaint 6m

Lubricate 30d

Check for peeling, missing, or unreadable labels & replace

30d

Daily

067448-003 LX31/LX41 Electric Work Platform Page 2-7

Page 46

Blocking The Elevating Assembly Section 2 - Service and Repair

2-3 B

LOCKING

WARNING

Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly.

DO NOT stand in elevating assembly area while deploying or storing the brace.

NSTALLATION

1. Place the machine on a firm level surface.

2. Pull the Platform Emergency Stop Switch ON.

3. Turn the Chassis Key Switch to CHASSIS.

4. Press the Raise Button and elevate the work platform until the maintenance brace can be rotated to the vertical position.

5. From the left side of the machine, disengage the locking pin securing the brace. Rotate the maintenance brace counterclockwise until it is vertical and between the two elevating assembly center pivots.

6. Press the Lower Button and gradually lower the platform until the brace is supporting the platform.

LEVATING

SSEMBLY

Figure 2-2:

Maintenance

Brace

Blocking Elevating Assembly

Upper Elevating

Assembly Pivot

EMOVAL

1. Using the Chassis Controls, gradually elevate the work platform until the maintenance brace clears the two elevating assembly center pivots.

2. Rotate maintenance brace clockwise until the locking pin engages.

3. Press the Lower Button to completely lower the platform.

Locking

Lower Elevating

Assembly Pivot

Page 2-8 067448-003 LX31/LX41 Electric Work Platform

Page 47

Section 2 - Service and Repair Lubrication

2-4 L

UBRICATION

Refer to “Preventative Maintenance Check List” on page 2-7 for lubrication intervals and Figure 2-3 for location of items that require lubrication service. Refer to the appropriate sections for lubrication information on the steering linkage, torque hubs, hydraulic fluid and filter.

REASE

Grease fittings at;

• the pivot points on the elevating assembly and

• the top and bottom of the steering pivots next to the front wheels.

Wipe each grease fitting before and after applying grease. Using multipurpose grease in a grease gun. Pump the grease into the fitting until grease just begins to appear at the edges of the pivot and wipe off any excess grease.

ORQUE

ITTINGS

UBS

Figure 2-3:

Lubrication Points

NOTE:

Change oil in torque hubs after the first 50 hours of operation. Change every

1000 hours thereafter.

1. Remove the torque hub (refer to “Torque Hub Removal” on page 2-20).

2. Remove the drain plug from the underside of the torque hub.

3. Drain the oil from the unit.

4. Replace the drain plug.

5. Remove the fill plug from the top of the torque hub.

6. Using 90 weight gear lube with EP additive, fill the torque hub through the top plug hole in the rear cover until oil comes out of the 90° fitting on the side. Plug the 90° fitting.

7. Replace the fill plug.

8. Install the torque hub (refer to “Torque Hub Installation” on page 2-21).

067448-003 LX31/LX41 Electric Work Platform Page 2-9

Page 48

Lubrication Section 2 - Service and Repair

YDRAULIC

LUIDLEVEL

With the platform fully lowered, the fluid should be visible in the sight gauge. If the fluid is fluid can be seen.

•

DO NOT

•

DO NOT

LUID ANDFILTER

NOTE:

To change the filter only, follow Step 5. through Step 8.

LUID

fill above the sight gauge. fill when the platform is elevated.

NOT

visible, fill the reservoir until the

EPLACEMENT

ESERVOIR AND

ILTER

Figure 2-4:

Hydraulic Fluid Reservoir & Filter

1. Operate the machine for 10-15 minutes to bring the hydraulic fluid up to normal operating temperature.

2. Provide a suitable container to catch the drained fluid. The hydraulic reservoir has a capacity of 46,5 l (12.3 U.S. gal.).

3. Remove the drain plug and allow all fluid to drain into the container. Dispose of used fluid properly.

4. Reinstall the drain plug.

5. Remove the three screws from the filter body cover and open the filter body.

6. Lift the filter element from the filter body. Dispose of used filters properly.

7. Insert the replacement filter element into the filter body and press into position.

8. Replace the filter body cover and screws.

9. Fill the hydraulic fluid reservoir to the level of the sight gauge with the appropriate hydraulic fluid (refer to

“Specifications”

CAUTION

The hydraulic fluid may be hot enough to cause burns. Wear safety gloves and protective eye-wear when handling hot fluid.

in the

Operator Manual

1 Filter body

2. Breather/ Filler Cap

1. Sight Gauge

2. Drain plug (under reservoir)

Page 2-10 067448-003 LX31/LX41 Electric Work Platform

Page 49

Section 2 - Service and Repair Setting Hydraulic Pressures

2-5 S

YDRAULIC

ELIEF

ALVE

in the

Operator Manual

ETTING

IFT

1. Operate the hydraulic system 10-15 minutes to warm the fluid.

2. Remove the cap on the Lift Relief Valve.

3. Turn the Lift Relief Valve adjustment screw counterclockwise two full turns.

4. Place the rated load on the platform (refer to

“Specifications”

5. Press the Raise Button to elevate the work platform.

6. Slowly turn the Lift Relief Valve adjustment screw clockwise until the platform begins to elevate.

7. Replace the cap, on the Lift Relief Valve, and remove the load from the platform

RESSURES

1. Steering Relief Valve

2. Flow Control Valve

3. Lift Solenoid

4. Dump Solenoid

Figure 2-5:

5. Lift Relief Valve

6. High Pressure Test Port

7. Steering Solenoids

8. Lift Test Port

Valve Manifold

TEERING

1. Operate the hydraulic system 10-15 minutes to warm the fluid.

2. Install a 0-200 bar (0-3000 PSI) gauge at the Main Pressure Test Port.

3. Remove the cap on the Left Steer Relief Valve.

4. Turn the adjustment screw two full turns counterclockwise.

5. Press the Steering Switch to the left and hold until the system bypasses.

6. Turn the Steering Relief Valve adjustment screw clockwise until the gauge reads 105 bar (1500 PSI).

7. Replace the cap on the Steering Relief Valve.

ELIEF

ALVES

067448-003 LX31/LX41 Electric Work Platform Page 2-11

Page 50

Switch Adjustments Section 2 - Service and Repair

2-6 S

WITCH

ROXIMITY

The Proximity Switch is located near the front right corner of the chassis under the elevating assembly. Its function is determined by the location of the lower elevating assembly tube.

ROXIMITYSWITCHFUNCTION ERIALNUMBER

The Proximity Switch controls the machine operation.

Platform Elevated:

• The switch is open.

• The Level Sensor is enabled.

• Power to the High Speed Circuit is cut, pre-

DJUSTMENTS

WITCH

- S

4022-4274

ventingthemachinefromtravelfasterthan0,8km/h(0.5 mph).

ERIAL

UMBER

Figure 2-6:

4022-4274

Proximity Switch, Serial Number 4022-4274

Figure 2-7:

Proximity Switch Position

Platform Lowered:

• The switch is closed.

• Power is supplied to the High Speed Circuit,

allowing the machine to travel up to 3,2 km/h (2.0 mph) when the Platform Controls Drive Speed Switch is set to HI SPEED.

EST THEPROXIMITYSWITCH

ERIALNUMBER

1. Place the machine on a firm, level surface.

2. Use an inclinometer to ensure that the chassis is level from front to rear and side to side.

3. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

4. Disconnect the switch leads and connect a multimeter to the switch.

• TheswitchcontactsshouldbeOPEN(nocontinuity).

• Push the lever down to close the switch contacts. If there is no continuity, the switch is defective.

5. Connect the switch leads, store the maintenance brace and lower the work platform.

6. Elevate the work platform not more than 1 m (3ft.).

7. With the Platform/Chassis switch on CHASSIS, push the Tilt Sensor base to test the alarm circuit.

• If the alarm does not sound, the switch is out of adjustment.

8. Turn the Drive Speed Switch to HI SPEED and attempt to drive the machine.

• If the machine will drive faster than 0,8 km/h (0.5 mph), the switch is out of adjustment.

9. Lower the work platform completely.

4022-4274

FRONT

1. Proximity Switch in OPEN position

2. Proximity Switch in CLOSED position

3. Chassis

4. Inner Elevating Assembly Tube

Page 2-12 067448-003 LX31/LX41 Electric Work Platform

Page 51

Section 2 - Service and Repair Switch Adjustments

EMOVAL ANDINSTALLATION

ERIALNUMBER

4022-4274

WARNING

Never perform service while the platform is elevated without first blocking the elevating assembly. DO NOT stand in the elevating assembly area while deploying or storing the maintenance brace.

1. Place the machine on a firm, level surface.

2. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

3. Disconnect the switch leads.

4. Remove the defective switch and install a new one.

5. Connect the switch leads.

6. Store the maintenance brace and lower the platform.

7. Adjust the Proximity Switch.

ROXIMITYSWITCHADJUSTMENT

WARNING

Never perform service while the platform is elevated without first blocking the elevating assembly.

DO NOT stand in the elevating assembly area while deploying or storing the maintenance

ERIAL

Figure 2-8:

UMBER

Proximity Switch Adjustment - Serial Number 4022-4274

4022-4274

1. Proximity Switch

2. Bracket

3. Inner Elevating

4. Chassis

brace.

Adjustment Screws

Assembly Tube

1. Place the machine on a firm, level surface.

2. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

3. Disconnect the switch leads and connect a multimeter or continuity tester to the switch.

4. Place a reference mark on the switch bracket to establish its position.

5. Store the maintenance brace and fully lower the platform.

6. Measure and record the distance from the top of the chassis to the base of the work platform.

7. Elevate the work platform until the Proximity Switch is OPEN (no continuity).

8. Measure the distance from the top of the chassis to the base of the work platform and compare with Step 6..

• If the platform elevated 50 - 60 cm (1.75 - 2 ft.), no adjustment is necessary. Otherwise, continue.

9. Deploy the maintenance brace. Loosen the bracket adjustment screws and move the switch up to increase or down to decrease the platform height. Tighten the adjustment screws.

10. Repeat Step 5. through Step 8..

067448-003 LX31/LX41 Electric Work Platform Page 2-13

Page 52

Switch Adjustments Section 2 - Service and Repair

ROXIMITY

Refer to Figure 2-9.

The Proximity Switch is located near the front right corner of the chassis under the elevating assembly. Its function is determined by the location of the lower elevating assembly tube.

ROXIMITYSWITCHFUNCTION

A red LED at the rear of the switch should be ON when the elevating assembly tube is next to the switch (the platform is lowered). The Proximity Switch controls the machine operation based upon the proximity of the lower elevating assembly tube to the Proximity Switch.

When Elevating:

• The Level Sensor is enabled.

• Power to the High Speed Circuit is cut, preventing the machine from travel faster than 0,8 km/h

(0.5 mph).

When Completely Lowered:

• Power is supplied to the High Speed Circuit, allowing the machine to travel up to 5 km/h (3.0 mph) when the Platform Controls Drive Speed Switch is set to HI SPEED.

WITCH

- S

ERIAL

ERIALNUMBER

UMBER

4275-C

URRENT

EST THEPROXIMITYSWITCH

WARNING

Never perform service while the platform is elevated without first blocking the elevating assembly. DO NOT stand in the elevating assembly area while deploying or storing the maintenance brace.

1. Place the machine on a firm, level surface.

2. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

3. Disconnect the switch leads and connect a multimeter to the switch.

• TheswitchcontactsshouldbeOPEN(nocontinuity).

• Place a piece of metal near the face of the switch. This should close the switch contacts. If there is no

continuity, the switch is defective.

4. Connect the switch leads, store the maintenance brace and lower the work platform.

5. With the work platform fully lowered, look at the Proximity Switch.

• When the Platform Controls key Switch is ON, the red LED at the rear of the Proximity Switch is ON.

• If the red LED is OFF, the Proximity Switch is out of adjustment.

6. Elevate the work platform not more than 1 m (3ft.).

• The red LED should turn OFF when the machine reaches 50 - 60 cm (1.75 - 2 ft.). If it remains ON, the switch is out of adjustment.

ERIAL

UMBER

4275-C

URRENT

ESTHIGHSPEED

1. Elevate the work platform 0,75 m (2.5 ft.).

2. Turn the Drive Speed Switch to HI SPEED and attempt to drive the machine.

• If the machine will drive faster than 0,8 km/h (0.5 mph), the switch is out of adjustment or defective.

Page 2-14 067448-003 LX31/LX41 Electric Work Platform

IRCUIT

ERIAL

UMBER

4275-C

URRENT

Page 53

Section 2 - Service and Repair Switch Adjustments

EMOVAL ANDINSTALLATION

ERIAL

UMBER

4275-C

URRENT

WARNING

Never perform service while the platform is elevated without first blocking the elevating assembly. DO NOT stand in the elevating assembly area while deploying or storing the maintenance brace.

1. Place the machine on a firm, level surface.

2. Use an inclinometer to ensure that the chassis is level from front to rear and side to side.

3. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

4. Disconnect the switch leads.

5. Remove the defective switch and install a new one.

6. Adjust the switch to elevating assembly tube clearance (see “Proximity Switch Clearance Adjustment Serial Number 4275-Current” on page 2-15).

7. Connect the switch leads.

8. Store the maintenance brace and lower the platform.

9. Adjust the Proximity Switch height (see “Proximity Switch Height Adjustment - Serial Number 4275-Current” on page 2-16).

ROXIMITYSWITCHCLEARANCE

ERIALNUMBER

4275-C

URRENT

DJUSTMENT

Figure 2-9:

Proximity Switch Clearance Adjustment

WARNING

Never perform service while the platform is elevated without first blocking the elevating assembly.

DO NOT stand in the elevating assembly area while deploying or storing the maintenance brace.

1. Place the machine on a firm, level surface.

2. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

3. Use an Inclinometer to ensure that the chassis is level from front to rear and side to side.

4. Useaclamptoattachastraightguidetothe elevating assembly tube.

5. Measure the distance from the face of the Proximity Switch to the side of the guide that faces the elevating assembly tube.

6. Turn the adjusting nuts to set the clearance to 9,5 mm (0.375 in.) maximum.

7. Remove the clamp and guide and repeat Step 5. and Step 6. of “Test the Proximity Switch, Serial Number 4275-Current” on page 2-14).

1. Proximity Switch

2. Clearance

9,5 mm (3/8 in.)

maximum

Adjustment Nuts

3. Clamp

4. Guide

5. Inner Elevating Assembly Tube

6. Chassis

067448-003 LX31/LX41 Electric Work Platform Page 2-15

Page 54

Switch Adjustments Section 2 - Service and Repair

ROXIMITYSWITCHHEIGHT

DJUSTMENT

-S

ERIALNUMBER

Figure 2-10:

4275-C

Proximity Switch Adjustment

URRENT

WARNING

Never perform service while the platform is elevated without first blocking the elevating assembly.

DO NOT stand in the elevating assembly area while deploying or storing the maintenance brace.

1. Place the machine on a firm, level surface.

2. Use an Inclinometer to ensure that the chassis is level from front to rear and side to side.

3. Measure and record the distance from the top of the chassis to the base of the work platform.

4. Elevate the work platform until the red LED at the rear of the Proximity Switch turns OFF.

5. Measure the distance from the top of the chassis to the base of the work platform and compare with Step 3..

• If the platform elevated 50 - 60 cm (1.75 - 2 ft.) no adjustment is necessary. Otherwise, continue.

6. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

7. Place a reference mark on the bracket to establish its position.

8. Loosen the bracket adjustment screws and move the switch up to increase or down to decrease platform height. Tighten the adjustment screws.

9. Store the maintenance brace and fully lower the platform.

10. Repeat Step 4. and Step 5..

1. Proximity Switch

2. Bracket Adjustment Screws

3. Inner Assembly Arm Tube

4. Chassis

EVEL

The Level Sensor has three wires;

To verify the sensor is working properly there is one red LED under the sensor. When the LED is ON, the sensor is out of level, turning OFF the power to the white wire.

1. Check tires for proper pressure.

2. Place the machine on a firm level surface.

3. Use an inclinometer to ensure that the front and rear of

4. Open the control module door to gain access to the

5. Adjust the three leveling locknuts until the bubble is

6. Deploy the maintenance brace (see “Blocking The Elevating Assembly” on page 2-8).

7. Push the Level Sensor base to test the alarm circuit. The red LED under the Level Sensor should turn

ENSOR

• red-power in (12v),

• black-ground,

• white-power out (12v).

the Chassis are level.

Level Sensor.

centered in the circle on the attached bubble level.

ON and the alarm should sound.

Bubble Level

Adjustment

Screws

Figure 2-11:

Level Sensor

Page 2-16 067448-003 LX31/LX41 Electric Work Platform

Page 55

Section 2 - Service and Repair Hydraulic Manifolds

2-7 H

YDRAULIC

ANIFOLDS

Though it is not necessary to remove the manifold to perform all maintenance procedures, a determination should be made prior to beginning as to whether or not the manifold should be removed before maintenance procedures begin. Refer to the General Information Section for remove and replace instructions.

AIN

YDRAULIC

ANIFOLD

Refer to “Setting Hydraulic Pressures” on page 2-11 for adjustment instructions.

Figure 2-12:

Hydraulic Manifold

RAKE

1 Valve Manifold

2. Gage Port

3. Valve, Normally Open

4. Valve, Normally Closed

5. Pressure Switch

6. Steel Ball

7. Spring, 6,4 mm

8. Plug

9. Orifice

10. Spring, 9,5 mm

11. 90° Fitting, 6MB-6MJ

12. 90° Fitting, 4MB-6MJ

13. 90° Fitting, 4MB-4MJ

(0.25 in.) Diameter

(0.375 in.) Diameter

1 Valve Manifold

2. High Pressure Test Port

3. Lift Test Port

4. Flow Control Valve

5. Lift Relief Valve

6. Steering Relief Valve

7. Steering Solenoids

8. Lift Solenoid

9. Dump Valve

YDRAULIC

ANIFOLD

Figure 2-13:

Brake Hydraulic Manifold

067448-003 LX31/LX41 Electric Work Platform Page 2-17

Page 56

Hydraulic Power Unit Section 2 - Service and Repair

2-8 H

YDRAULIC

EMOVAL

1. Mark, disconnect and plug the hose assemblies.

2. Mark and disconnect the electric cables.

3. Remove hardware which secures power unit andremovefromchassis.

NSTALLATION

1. Install power unit using hardware previously removed.

2. Unplug and reconnect the hydraulic hoses.

3. Reconnect the electric cables.

4. Fill the tank with clean hydraulic fluid.

5. Check the oil level in the hydraulic tank before operating the work platform.

6. Operate the pump and check for leaks and proper operation.

7. Replenish hydraulic fluid if necessary.

OWER

NIT

Hydraulic Manifold

Brake

Manifold

Figure 2-14:

Hydraulic Pump

Pump Motors

2-9 H

YDRAULIC

EMOVAL

1. Park the work platform on firm level ground and block the wheels to prevent the work platform from rolling.

2. Disconnect and plug the hydraulic brake lines.

3. Tag and disconnect electric cables from drive motors.

CAUTION

Clean all fittings before disconnecting the hose assemblies.

Plug all port holes and hose assemblies IMMEDIATELY to prevent contamination from dust and debris.

4. Remove capscrews and washers holding the motor and brake to torque hub.

5. Remove the motor.

6. Remove the brake.

RAKES

Torque

Hub

Brake

Figure 2-15:

Rear Axle Assembly

Drive Motor

Page 2-18 067448-003 LX31/LX41 Electric Work Platform

Page 57

Section 2 - Service and Repair Hydraulic Brakes

RAKE

EALREPLACEMENT

Figure 2-16:

Brake Assembly

1. With shaft protrusion downward, remove capscrews (21) and washers (20) from brake assembly.

2. Remove power plate (19) from housing (1). Remove gasket (2).

3. Remove piston (14) from power plate (19) by introducing low pressure air [1,0 bar (15 PSI)] into the hydraulic inlet. Make sure piston is not pointed at anyone.

4. Remove o-rings (16 & 18) and backup rings (15 & 17) from inner and outer diameter grooves of piston.

5. Clean piston (14) and power plate (19) assemblies with solvent. Inspect the sealing surfaces of the piston (14) and power plate (19). Inspect seal grooves in the piston. Replace brake assembly if they are damaged or scratched deeply. Lubricate piston (14), power plate (19), and seals (15, 16, 17, & 18) with clean hydraulic oil prior to assembly.

6. Install the backup rings (15 & 17) and orings (16 & 18) into the seal grooves in the piston.

7. Install piston into power plate using a shop press. Be careful not to damage the seals during assembly. Center cutouts in piston with torque pin holes in the power plate. Press piston to a depth no less than flush, but not exceeding [3 mm (0.120 in.)] below the surface of the power plate at cutouts in piston. This depth is critical. The brake will not hold if it is exceeded.

8. Install gasket (2).

9. Install power plate/piston assembly (14 &

1 Housing

2. Gasket

3. Ball Bearing

4. Retaining Ring

5. Oil Seal

6. Spring Retainer

7. Spring, Compression

8. Shaft

9. Pin, Torque

10. Primary Disk

11. Spring, Compression

Seal Kit Includes:

Item Description Quantity

2Gasket 1 15 Backup Ring 1 16 O-ring 1 17 Backup Ring 1 18 O-ring 1 22 Gaskets 2

12. Rotating Disk

13. Stationary Disk

14. Piston

15. Backup Ring

16. O-ring

17. Backup Ring

18. O-ring

19. Power Plate

20. Washer

21. Capscrews

22. Gaskets

19) to housing (1) using capscrews (21) and washers (20). Tighten sequentially, one turn at a time, to press the two assemblies together. Torque capscrews 65 - 80 N-m (50 - 60 ft.-lbs.).

NSTALLATION

1. Coat output shafts of brake and drive motor with high pressure molybdenum grease and install gasket (22) and brake onto torque hub.

2. Install gasket (22) and drive motor. Align holes and install the two cap screws and lock washers.

3. Reinstall cables to drive motor and hoses to the brake.

4. Install the wheel. Torque the wheel nuts to 205 N-m (150 ft. lbs.).

5. Remove the jack stands and lower chassis to the ground.

6. Position chassis switch to parking brake release position. Alarm will sound.

7. Depress the electric motor start switch to energize brake hydraulic system.

8. Check for leaks and bleed air out of brake hydraulic system using bleed valve located on brake housing.

067448-003 LX31/LX41 Electric Work Platform Page 2-19

Page 58

Torque Hub Section 2 - Service and Repair

2-10 T

ORQUE

CAUTION

Clean all fittings before disconnecting the hose assemblies. Plug all port holes and hose assemblies IMMEDIATELY to prevent contamination from dust and debris.

Torque Hub Assembly

4. Torque Hub

5. 90° Fitting

ORQUE

1. Park the work platform on firm level ground and block the wheels to prevent the work platform from rolling.

2. Disconnect battery negative terminals or Anderson connectors (both sides on electric model).

3. Loosen the wheel lug nuts on the torque hub to be removed.

4. Raise the rear of the work platform usinga2-tonjack.

5. Position two 2-ton jack stands under the rear axle to prevent the work platform from falling if the jack fails.

6. Remove the wheel nuts and wheel.

7. Disconnect hydraulic brake line from brake.

8. Remove 90° fitting from side of torque hub.

9. Tag and remove electric cables from drive motors.

10. Remove mounting bolts from electric motor.

11. Separate electric motor from brake. Discard gasket.

12. Separate brake from torque hub. Discard gasket.

13. Remove ½-20 nuts and washers from torque hub.

14. Remove torque hub.

EMOVAL

Figure 2-17:

1 Motor

2. Gasket

3. Brake

IMPORTANT: Note position of 90° fitting on torque hub body. Hub must be installed with fitting in same position.

Page 2-20 067448-003 LX31/LX41 Electric Work Platform

Page 59

Section 2 - Service and Repair Torque Hub

ORQUE

IMPORTANT: Hub must be installed with 90° fitting in same position as when it was removed.

NOTE:

Unless otherwise specified, torque all fittings according to

“Section 1 - General Information”.

1. Install torque hub using ½-20 nuts and ½ washers.

2. Remove plug from 90° fitting and install fitting in side of torque hub. Point fitting towards rear of hub.

3. Using 90 weight gear lube with EP additive, fill torque hub through top plug hole in rear cover until oil comes out of 90° fitting in side. Plug 90° fitting and top of rear cover.

4. Install new gasket and brake.

5. Install new gasket and electric motor.

6. Secure assembly using washers and bolts.

7. Connect hydraulic brake lines.

8. Connect electric cables.

9. Install wheels. Torque lug nuts to 205 Nm (150 ft. lbs.).

10. Bleed brake lines if necessary.

11. Remove jack stands and lower rear end.

12. Connect battery terminals or Anderson connectors.

13. Check function of brake.

UB INSTALLATION

Torque Specifications

ORQUE

OLL

IMPORTANT: Torque hubs should always be roll and leak tested before disassembly and after assembly to make sure

gears and sealants are working properly.

OLLTEST

Gears should be able to rotate by applying a constant force to the axle. Some gear packages roll with more difficulty than others.

Do not be concerned if gears seem to roll hard as long as they roll with consistency. If you feel more drag only at certain points the gears are not rolling freely and should be checked for improper installation or defects.

EAKTEST

The purpose of a leak test is to make sure the unit is air tight. Pressurize hub to 0,35 bar (5 PSI). Torque hub has a leak if the air pressure starts to fall after hub has been pressurized.

Use soap and water on hub to detect location of leaks. If a leak is detected, seal or O-ring must be replaced.

RESSINGTOOLS

Use pressing tools to remove the seal, cup and cone.

EAL

NDLEAKTESTING

EPLACEMENT

067448-003 LX31/LX41 Electric Work Platform Page 2-21

Page 60

Torque Hub Section 2 - Service and Repair

ORQUE

ISASSEMBLY

CAUTION

Safety glasses should be used during disassembly of hub.

1. Remove two pipe plugs in cover and drain the oil from the unit.

2. Loosen and remove shoulder bolts and cap screws from cover. Remove cover from hub.

3. Remove O-ring. Remove thrust washer from counterbore in cover.

4. Remove input gear from planet gears.

5. Using a punch, remove retaining ring from groove around inside of input gear.

6. Lift carrier sub-assembly from hub. Lift ring gear from hub. Remove O-ring from counterbore in hub.

7. Remove pipe plugs from side of hub body.

8. Apply a preload to output shaft to remove retaining ring. Follow steps a & b. a. Place bearing cone pressing tool on retaining ring.

b. Apply pressure to fixture using a hydraulic ram or by striking the fixture with a soft face hammer. Pres-

sure should be applied until hub rotates with difficulty.

9. Using retaining ring pliers remove retaining ring. Remove spacer from output shaft.

10. Place spacer under hub so output shaft will fall through bottom when pressed out.

11. Press output shaft out of hub. Output shaft may come out with bearing cone and seal attached. Remove seal and discard. Use a punch and hammer to remove bearing cone. Be careful not to strike shaft with punch.

12. If seal and cone remain in hub, press them out using a pressing tool.

13. Lift bearing cone out of hub.

14. Stand hub on its small end. Using a punch and hammer, remove bearing cup from counterbore of hub. Be careful not to strike counterbore with punch.

15. Turn hub over on larger end. Using a punch and hammer, remove bearing cup from counterbore of hub. Be careful not to strike counterbore.

NOTE:

Carrier sub-assembly does not need to be disassembled to replace seals.

Page 2-22 067448-003 LX31/LX41 Electric Work Platform

Page 61

Section 2 - Service and Repair Torque Hub

ORQUE

NOTE:

Unless otherwise specified, torque all fittings according to General Information”.

1. Oil output shaft and bearing cone. Using cone press, press bearing cone onto end of output shaft with retaining ring groove.

2. Stand hub on its small end. Using bearing cup pressing tool press bearing cup down into hub.

NOTE:

Make sure cup sits square with counterbore.

3. Turn hub over so it sit on large end. Using bearing cup pressing tool press bearing cup into small end of hub.

NOTE:

Make sure cup sits square with counterbore.

4. Place output shaft into hub so end of shaft with retaining ring groove points down.

5. Oil output shaft. Using seal pressing tool press seal into counterbore in small end of hub. The closed face of the seal should be up.

6. Turn hub over so small end points down. Using bearing cone pressing tool, press bearing cone onto output shaft. Rotate hub while pressing bearing. Stop pressing when hub starts to resist rotating.

7. Place spacer onto output shaft so it rests on top of bearing cone. Using retaining ring pliers, place retainingringtomakesureitisseated.

8. Hit the end of output shaft once or twice with a soft face hammer. Turn the shaft in both clockwise and counter clockwise directions while hitting. This will seat the bearing cone against the spacer and retaining ring allowing necessary endplay in the hub-shaft sub-assembly.

9. Turn hub over so it rests on large end. Measure endplay in hub-shaft sub-assembly. Follow steps a-c.

a. Mount a dial indicator on hub. Locate the dial rod on top of output shaft. b. Lift up on output shaft until the needle on the dial stops moving. c. Read the dial. Reading should be no greater than 0,203 mm (.008 in.).

d. Remove spacer and replace it with thicker spacer (SK91 068570-011). e. Repeat steps 6.-9. and remeasure end play (Figure ).

10. Apply a light coat of “Never Seize” to the pipe plugs and install into pipe plug holes in hub.

SSEMBLY

Figure 2-18:

Torque Specifications

- If dial reads less than 0,203 mm (.008 in.), continue on to step 10.

- If dial reads more than.0,203 mm (.008 in.), repeat steps 8.-15. of “Torque Hub Assembly” on page 2-23.

in “Section 1 -

Measuring Hub End Play

NOTE:

Leave hole for 90° fitting open.

067448-003 LX31/LX41 Electric Work Platform Page 2-23

Page 62

Torque Hub Section 2 - Service and Repair

AIN

SSEMBLY

1. Position hub on its output shaft so that hubs small diameter end points down.

2. Using a marker, mark the four shoulder bolt holes in hub.

3. Grease O-ring and place in counterbore in hub.

NOTE:

O-rings may be stretched or squeezed together in order to fit exactly in counterbore.

4. Oil all exposed surfaces inside hub. Oil carrier sub-assembly.

5. Place carrier sub-assembly, with spline connections down, into mesh with output shaft.

6. Place ring gear, with squared shoulder down, into mesh with the planet gears of the carrier sub-assembly. Make sure that marked shoulder bolt hole on ring gear aligns with any of the marked shoulder bolt holes on the hub. “X” mark should be on the cover side of ring gear.

7. Start one half of retaining ring into groove inside input gear. Use a soft punch to press the remaining half of the retaining ring into the groove.

8. Insert input gear, with large diameter end down, into mesh with planet gears.

9. Place large thrust washer over input gear so it rests on carrier housing. Oil all exposed surfaces inside hub.

10. Grease O-ring and place into counterbore of cover.

NOTE:

O-rings may be stretched or squeezed together in order to fit exactly in counterbore.

11. Place cover on top of ring gear so the fill hole will be at top of hub when it is installed.

12. Install four shoulder bolts into shoulder bolt holes and tighten.

13. Install eight cap screws in remaining holes and tighten.

14. Apply 30-35 N-m (23-27 ft. lbs) of torque to all bolts.

15. Apply a light coat of “Never Seize” to both pipe plugs and install into the two holes in cover.

16. Roll test the unit in both clockwise and counterclockwise directions. Turn hub nine full revolutions in each direction.

17. Leak test the hub at 0,35 bar (5PSI)fortwotothreeminutes.

Page 2-24 067448-003 LX31/LX41 Electric Work Platform

Page 63

Section 2 - Service and Repair Torque Hub

Figure 2-19:

Torque Hub

1Spindle

2. Housing

3. Carrier Assembly

4. Gear ring

5. Spaces, Input

6. sun Gear

7. Gear, Internal

8. Cover

9. Shoulder Bolt

10. Bolt

11. Stud

12. Stud

13. Pipe Plug

14. Pipe Plug

Repair Kit contains:

1 Lip Seal

2. Bearing, Cone

3. Bearing, Cup

4. Thrust Washer

5. Retaining Ring

6. O-ring (2)

7. Washer (2)

8. Thrust Washer - SK91 (068570-011)

9. Bearing, Cup

10. Bearing, Cone

067448-003 LX31/LX41 Electric Work Platform Page 2-25

Page 64

Drive Motors Section 2 - Service and Repair

2-11 D

RIVE

EMOVAL

1. Disconnect battery negative terminals or Anderson connectors (both sides on electric model).

2. Tag and disconnect electric cables from motor.

3. Remove and save hardware which secures drive motor to torque hub.

NSTALLATION

NOTE:

“Section 1 - General Information”.

1. Install drive motor to torque hub using original hardware.

2. Connect electric cables to motor.

3. Connect Anderson connectors or negative terminals on batteries.

UMP

EMOVAL

1. Disconnect battery negative terminals or Anderson connectors (both sides on electric model).

2. Tag and disconnect electric cables from motor.

3. Remove and save hardware which secures pump motor to pump assembly.

OTORS

Unless otherwise specified, torque all fittings according to

OTOR

Torque Specifications

NSTALLATION

NOTE:

Unless otherwise specified, torque all fittings according to

“Section 1 - General Information”.

1. Install motor using original hardware.

2. Connect electric cables to motor.

3. Connect Anderson connectors or negative terminals on batteries.

RIVE

1. If necessary, remove electric motor (Refer to

2. Release latch and remove headband.

3. Pull back brush spring and latch on hook.

4. Remove screw and set aside.

IMPORTANT: Be sure screw does not fall inside motor.

5. Remove old brush and replace with new

6. Replace screw, unhook brush spring and

7. Install and relatch headband.

OTOR

previous section).

brush.

return to original position.

RUSHES

Torque Specifications

Brush

Hook

Figure 2-20:

Hook

Replacing Drive Motor Brushes

Screw

Page 2-26 067448-003 LX31/LX41 Electric Work Platform

Page 65

Section 2 - Service and Repair Steering Cylinder

2-12 S

TEERING

EMOVAL

YLINDER

1. Remove and cap the hoses. Mark them for reference.

2. Remove the hair pin retainers from the clevis pins at each end of the cylinder.

3. Remove the clevis pins.

4. Remove the cylinder from the chassis.

EALREPLACEMENT

Refer to “Cylinder Repair” in the General Information section, and Figure 2-22.

NSTALLATION

1. Align the ends of the cylinder with the mounts on the chassis.

2. Install the clevis pins.

3. Install the hair pin retainers into the

1 Steer Cylinder

2. Clevis Pin

3. Hair Pin Retainer

4. Steering Clamp

clevis pins at each end of the cylinder.

4. Install the hoses, noting their orientation markings from disassembly.

Figure 2-21:

Front Axle Assembly, 4WD

1 Rod Wiper

2. Rod Seal

3. Wear Ring (2 required)

4. Retaining Ring

5. Head

6. Backup Ring

7. O-ring

8. Locknut

9. O-ring

10. Rod Weldment

11. Tube Weldment

12. Piston Seal

Figure 2-22:

13. Piston

14. Wear Ring

Steering Cylinder Cross Section

067448-003 LX31/LX41 Electric Work Platform Page 2-27

Page 66

Lift Cylinder Section 2 - Service and Repair

2-13 L

IFT

EMOVAL

1. Elevate and block the elevating assembly (See Figure 2-2).

2. Open emergency lowering valve to be sure all pressure is out of the lift cylinder.

3. Remove and cap both hoses and fittings.

4. Remove the down valve and cable assembly.

5. Support the lift cylinder with a suitable lifting device to prevent falling.

6. Remove the retaining bolts from the upper and lower pivot pins.

7. Drive out the pivot pins, upper one first, then the lower one.

8. Hoist the cylinder out of the elevating assembly from the front. DO NOT sling the cylinder by the rod

end pivot, this will cause the cylinder to extend when hoisted.

EALREPLACEMENT

Refer to “Cylinder Repair” in the General Information section, and Figure 2-23 or Figure 2-24.

NSTALLATION

YLINDER

NOTE:

Before installing the cylinder, check the pins and bearings for excessive wear. Replace if necessary.

1. Using a suitable lifting device, lower the cylinder into the elevating assembly from the front. DO NOT sling the cylinder by the rod end pivot, this will cause the cylinder to extend when hoisted.

2. Align the pivots and install the pivot pins, lower one first, then the upper one.

3. Install the retaining bolts into the pivot pins.

4. Install the down valve and cable assembly. Adjust the cable to stop on the collar of the cable jacket, before the down valve reaches the full extent of its pull. The down valve may leak if the cable is allowed to pull the spool of the valve beyond its limit.

5. Install the hoses.

6. Lift and lower the machine for several cycles to work out the air. Check for leaks, repair as necessary.

Page 2-28 067448-003 LX31/LX41 Electric Work Platform

Page 67

Section 2 - Service and Repair Lift Cylinder

1 Rod Wiper

2. Rod Seal

3. Wear Ring (3 required)

4. O-ring

5. Head

6. Backup Ring

7. O-ring

8. Rod Weldment

9. Tube Weldment

10. Spacer

Figure 2-23:

11. O-ring

12. Locknut

13. Bushing

14. Orifice

15. Cast Iron Ring

Lift Cylinder Cross Section - Serial Number 4022 to 4129

16. Wear Ring

17. Piston

18. Piston Seal

A. Rod B. Head C. Piston D. Cylinder E. Set Screw

Figure 2-24:

Lift Cylinder - Serial Number 4130 to Current

Seal Kit Includes:

1 Rod Wiper

2. Rod Seal

3. Wear Ring

4. Static Seal

5. Wear Ring

6. Piston Seal

7. Piston Seal

067448-003 LX31/LX41 Electric Work Platform Page 2-29

Page 68

Outrigger Cylinder (Optional) Section 2 - Service and Repair

2-14 O

UTRIGGER

EMOVAL

Refer to Figure 2-25.

1. Remove the plug from the top of the outrigger cylinder.

2. Disconnect the wires from the pressure Switch and the ball Switch. Tag them for identification during reassembly.

3. Unscrew the strain relief and pull the wires out of the top of the cylinder.

4. Remove and cap the hoses. Tag them for identification during reassembly.

5. Remove the four capscrews, nuts, and washers holding the outrigger cylinder to the outrigger support weldment.

6. Remove the outrigger cylinder.

EALREPLACEMENT

Refer to “Cylinder Repair” in the General Information section, and Figure 2-26.

NSTALLATION

1. Install the outrigger cylinder to the outrigger support weldment using the four capscrews, nuts, and washers; tighten.

2. Install the hoses exactly as disassembled.

3. Thread the wires for the pressure Switch and the ball Switch through the strain relief.

4. Reattach the wires to the Switches exactly as disassembled.

5. Tighten strain relief.

6. Install plug to top of outrigger cylinder.

YLINDER

PTIONAL

)

Page 2-30 067448-003 LX31/LX41 Electric Work Platform

Page 69

Section 2 - Service and Repair Outrigger Cylinder (Optional)

1Plug

2. Pressure Switch (Outrigger Down Sensor)

3. Ball Switch (Outrigger Up Sensor

4. Cap Plug

5. Fitting 90°

6. Chassis Weldment

7. Capscrew

8. Outrigger Support Weldment

9. Outrigger Cylinder

10. Hex Nut

11. Washer

12. Counterbalance Valve

13. Fitting

Figure 2-25:

Outrigger Cylinder Installation

1 Barrel Assembly

2. Rod

3. Piston

4. Seal Retainer

5. Head Cap

Figure 2-26:

6. Sensor Assembly

7. Foot Pad

8. Counterbalance Valve

9. Foot Pad Bolt

10. Rod Wiper

11. Rod Seal

12. Static Seal #1

13. Piston Seal

Outrigger Cylinder Cross Section

067448-003 LX31/LX41 Electric Work Platform Page 2-31

Page 70

OTES

Section 2 - Service and Repair

Page 2-32 067448-003 LX31/LX41 Electric Work Platform

Page 71

ROUBLESHOOTING

Section 3

3-1 I

ABLE

NTRODUCTION

This section contains troubleshooting Truth Tables for the LX 31 and LX41 Electric Work Platforms.

Careful inspection and accurate analysis of the symptoms listed in the Troubleshooting Guide will localize the trouble more quickly than any other method. This manual cannot cover all possible problems that may occur. If a specific problem is not covered in this manual, call our toll free number for service assistance.

Referring to the Operator Manual and the Schematics section will aid in understanding the operation and function of the various components and systems of the Work Platform and help in diagnosing and repair of the machine.

WARNING

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, the Elevating Assembly must be

blocked. Disconnect the battery when replacing or testing the continuity of any electrical component.

3-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-3 GeneralProcedure..............................................................3-2

3-4 Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-5 AdjustmentProcedures..........................................................3-2

3-6 CheckingPumpPressures .......................................................3-2

3-7 ElectricTruthTables ............................................................3-3

3-8 HydraulicTruth Table...........................................................3-6

3-9 Troubleshooting the MOS90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-10UsingtheCalibrator.............................................................3-7

3-11MOS90FaultFindingFlowCharts .................................................3-9

3-12Activating"TEST"..............................................................3-15

ONTENTS

ElectricalSchematics...................................................................... 3-3

OutriggerOption ......................................................................... 3-5

WhenaFlashErroroccurs ................................................................. 3-7

CalibratorSettings........................................................................ 3-8

UprightTractionControllerdisplay ........................................................... 3-8

067448-003 LX31/LX41 Electric Work Platform Page 3-1

Page 72

Technical Support Section 3 - Troubleshooting

3-2 T

UUUU

RRRR

PPPP

UUUU

RRRR

PPPP

EEEE

UUUURRRROOOOPPPPEEEE

3-3 G

3-4 T

ECHNICAL

Technical Support is available by telephone of FAX.

IIIIGGGGHHHHTTTT

USA

USAUSA

IIIIGGGGHHHHTTTT

Tel: 1-800-926-5438 FAX: 1-559-662-4785

Tel: +353-1-620-9300 FAX: +353-1-620-9301

ENERAL

Thoroughly study hydraulic and electronic schematics in the Schematics section. Check for loose connections and short circuits. Check/repair/replace each component in the Truth Table which is listed under each machine function which does not operate properly.

Determine whether the problem is mechanical (interference), electrical or hydraulic. Some functions require power at more than one solenoid.

Use the charts on the following pages to help determine the cause of a fault in your UpRight work platform

NOTE:

Spike protection diodes at components have been left out of the charts to eliminate confusion.

ROUBLESHOOTING

1. Verify your problem.

• Do a full function test from both platform controls and chassis controls and note all functions that

2. Narrow the possible causes of the malfunction.

• Use the troubleshooting guide to determine which components are common to all circuits that are

3. Identify the problem component.

• Test components that are common to all circuits that are not functioning correctly. Remember to

4. Repair or replace component found to be faulty.

5. Verify that repair is complete.

• Do a full function test from both platform and chassis controls to verify that all functions are oper-

UPPORT

ROCEDURE

ROCEDURES

are not operating correctly.

not functioning correctly.

check wires and terminals between suspect components. Be sure to check connections to battery negative.

ating correctly and machine is performing to specified values

3-5 A

3-6 C

Page 3-2 067448-003 LX31/LX41 Electric Work Platform

DJUSTMENT

• Hydraulic settings must be checked whenever a component is repaired or replaced.

• Connect a pressure meter of appropriate range to the test port located on the hydraulic manifold.

• Correct pressure settings are listed in the hydraulic schematic.

HECKING

• Remove hose from pump port, and connect pressure tester.

ROCEDURES

UMP

RESSURES

Page 73

Section 3 - Troubleshooting Electric Truth Tables

3-7 E

LECTRIC

LECTRICAL

ALM1 Level Sensor Alarm X

ALM2 Down Alarm X

BAT1 Battery X XXX X

C1 Main Power Contactor X XXX

C2 Forward Contactor X

C3 Reverse Contactor X

C4 Pump Override Contactor X XX X X

C5 Pump/Traction Contactor X X

CB1 Circuit Breaker X X

CB2 Circuit Breaker X X

CH1 Battery Charger X

CONT Controller X XXXX X X XXX

F1 Main Fuse X X X

F2 Main Fuse X X X

MOT1 Power Unit Motor X XXXX XX

MOT2 Power Unit Motor X XXXX XX

MOT3 Left Traction Motor X X X

MOT4 Right Traction Motor X X X

R1 Drive/Lift Relay X XXXX

R3 Level Sensor Alarm Relay X

R4 Up Relay X

R5 Down Relay X X X X

R6 Down Alarm Relay X

R7 Steer Right Relay X

R8 Steer Left Relay X

R9 Pump Start Relay X X

R10 Brake Relay X X X

R11 Brake Release Relay X X X

R12 Power Relay X XXX

R15 Serial #4022-4274 | Brake Release Relay X

R16 Platform Power Relay X XXXX

R17 Prevent Pump Start Relay X XXX

RES1 Resistor Pack X XXX

S1 Control Handle Interlock Switch XXX X X

S2 Forward Micro Switch X

S3 Reverse Micro Switch X

S4 Lower Controls Emergency Stop Switch X X XX X X

S5 Lift Button X X

S6 Lower Button X X

S7 Brake Release Button X X X

S8 Lift/Drive Switch X XXX

S9 High/Low Switch X

RUTH

OMPONENT

8 Meter Cutout Relay X X X

Platform Stowed Relay X XXX X

ABLES

CHEMATICS

UNCTIONLOWER

ONTROLS

PPER

ORWARD

RIVE

EVERSE

RIVE

LATFORM

AISE

LATFORM

IGHT

OWER

EFT

TEER

RAKES

TEER

LARM

ENSOR

EVEL

LARM

OWN

PEED

IGH

HARGER

ATTERY

067448-003 LX31/LX41 Electric Work Platform Page 3-3

Page 74

Electric Truth Tables Section 3 - Troubleshooting

LARM

OMPONENT

UNCTIONLOWER

ONTROLS

PPER

ORWARD

RIVE

EVERSE

RIVE

LATFORM

AISE

LATFORM

IGHT

TEER

EFT

TEER

OWER

ENSOR

RAKES

EVEL

S10 – S13 Serial #4022-4275 | Platform Down Switches X X X

S10 Serial #4275–Up | Proximity Switch X XXX

S14 Serial #4022-4275 | 8 Meter Cutout Switch X X X

S15 Serial #4022-4275 | Up Limit Switch X XX

S16 Pump Start Switch X XXXX

S17 Chassis/Platform/Brake Release Switch X X X

S18 Platform Controls Emergency Stop Switch XXXX X X

S19 Steering Rocker Switch X X

S20 Proportional Speed Control Switch X XXXXX

S21 Keyswitch X

SEN1 Level Sensor X XXXX

SOL1 & SOL2 Up Solenoids X

SOL3 Down Solenoid X

SOL5 Steer Right Solenoid X

SOL6 Steer Left Solenoid X

SOL8 Brake Solenoid X X X

SOL11 Brake Release Solenoid X X X

TG1 & TG2 Tachometer-Generator X X X

PEED

LARM

OWN

IGH

HARGER

ATTERY

Page 3-4 067448-003 LX31/LX41 Electric Work Platform

Page 75

Section 3 - Troubleshooting Electric Truth Tables

UTRIGGER

PTION

IGHTS

NDICATOR

OMPONENT

UNCTION

UTRIGGER

UTRIGGERS

EPLOY

ETRACT

ORWARD

RIVE

EVERSE

RIVE

OR-LB Outrigger Light Board X XX

OR-L1 LED, Outrigger Indicator, Left Front X XX

OR-L2 LED, Outrigger Indicator, Left Rear X XX

OR-L3 LED, Outrigger Indicator, Right Rear X XX

OR-L4 LED, Outrigger Indicator, Right Front X XX

OR-R1 Relay, Outrigger Extend, Left Front X

OR-R2 Relay, Outrigger Retract, Left Front X

OR-R3 Relay, Outrigger Extend, Left Rear X

OR-R4 Relay, Outrigger Retract, Left Rear X

OR-R5 Relay, Outrigger Extend, Right Front X

OR-R6 Relay, Outrigger Retract, Right Front X

OR-R7 Relay, Outrigger Extend, Right Rear X

OR-R8 Relay, Outrigger Retract, Right Rear X

OR-R9 Relay, Drive Override XX

OR-R16 Relay, Drive Cutout XX

OR-R18 Relay, Outrigger Power X XXXXXX

OR-S1 Switch, Outrigger Extend/Retract, Left-Front X XX

OR-S2 Switch, Outrigger Extend/Retract, Left-Rear X XX

OR-S3 Switch, Outrigger Extend/Retract, Right-Rear X XX

OR-S4 Switch, Outrigger Extend/Retract, Right-Front X XX

OR-S5 Outrigger Switch X XXXXXX

OR-S6 – OR-S9 Ball Switch, Outrigger X

OR-S10 – OR-S13 Pressure Switches, Outrigger X

OR-SOL1 Solenoid, Outrigger Extend, Left-Front X XXXX

OR-SOL2 Solenoid, Outrigger Retract, Left-Front X XXXX

OR-SOL3 Solenoid, Outrigger Extend, Left-Rear X XXXX

OR-SOL4 Solenoid, Outrigger Retract, Left-Rear X XXXX

OR-SOL5 Solenoid, Outrigger Extend, Right-Front X XXXX

OR-SOL6 Solenoid, Outrigger Retract, Right-Front X XXXX

OR-SOL7 Solenoid, Outrigger Extend, Right-Rear X XXXX

OR-SOL8 Solenoid, Outrigger Retract, Right-Rear X XXXX

IFTLOWER

067448-003 LX31/LX41 Electric Work Platform Page 3-5

Page 76

Hydraulic Truth Table Section 3 - Troubleshooting

3-8 H

YDRAULIC

RUTH

ABLE

LATFORM

IGHT

EFT

LATFORM

OMPONENT

ACC Accumulator X X

CV1 Check Valve X X

BK1 Left Brake Cylinder X

BK2 Right Brake Cylinder X

CYL1 Lift Cylinder X X

CYL2 Steering Cylinder X X

CYL3-6 Cylinder, Outrigger X

F1 Return Filter X XXXXXX

F2 Suction Strainer X XXXXXX

FD1 Flow Divider X XXX

LV1-4 Load Holding Valve, Outrigger X

ORF1 Brake Orifice X X

ORF2 Lift Orifice X X

P1 Hydraulic Pump X XXXXXX

P2 Hydraulic Pump X XXXXXX

PS1 Pressure Switch X X

RV1 Main Relief Valve X XXX

RV2 Steering Relief Valve X X

V1 Brake Apply Valve X X

V2 Brake Release Valve X X

V3 Steering Valve X X

V4 Lift Valve X X

V5 Dump Valve X XXX

V6 Down Valve X X

V7–V10 Outrigger Valve X

AISE

UNCTION

TEER

OWER

TEER

RAKE

IGHT

RAKE

EFT

UTRIGGERS

EPLOY

Page 3-6 067448-003 LX31/LX41 Electric Work Platform

Page 77

Section 3 - Troubleshooting Troubleshooting the MOS90

3-9 T

ROUBLESHOOTING

Important basics applicable to the motor control unit.

• The MOS90 has a green diagnostics L.E.D. in the front panel.

• The green L.E.D. will turn on and shine continuously when the MOS90 is powered up and working cor-

rectly.

• The green L.E.D. will be off if no power is supplied to the MOS90.

• The green L.E.D. will flash a sequence of flashes if the MOS90 is damaged or is receiving an improper

signal. An explanation of the flash sequences "flash faults" is shown on the following pages.

• The MOS90 is high temperature protected by "thermal cutback". The cutback operates between 80°C (176°F) and 90°C(194°F). Powered functions will gradually operate slower and slower until 90°C (194°F). The MOS90 will shut down at 90°C(194°F). Continued operation at high temperature will damage the MOS90.

• The MOS90 is low voltage protected by "low voltage cutout". The MOS90 shuts down at 14.0 VDC. Powered functions suddenly stop. When input voltage goes above 14.0 VDC turns back on.

HEN A

1. Disconnect the 17 pin connector from the MOS90. Wait Five (5) seconds and plug it back in again. If

TEP

the flash error repeats go to step Two (2). If the green L.E.D. lights up and stays on continuously - operate machine. Note which functions are being used when problem repeats itself.

2. Disconnect the 17 pin connector from the MOS90. Connect pin Six (6) to a fused battery supply (14.0

TEP

VDC minimum) and observe the green L.E.D. If flash error stays, replace MOS90. If green L.E.D. lights up and remains on continuously, check wiring.

NOTE:

NOTE: Troubleshoot the possible cause of the flash error before replacing the MOS90, for example an Eight (8)

flash error will cure itself when the MOS90 cools down.

LASH

THE

RROR OCCURS

MOS90

3-10 U

SING THE

The calibrator has 20 L.E.D. segments marked as shown.

The values which should be expected when checking the machine are shown on the following page.

Therearethreebuttonsonthecalibrator:

increment, marked + decrement, marked select

When select is pressed, each L.E.D. will light in sequence until the select button is released. Each setting can be incremented or decremented using the + or - buttons when the adjacent L.E.D. is lit.

When "Test" L.E.D. is lit, the state of the MOS90 inputs is displayed. The first input displayed is the accelerator which can vary from 0100%. When the + button is pressed once the switch Input 1 is displayed. This will be seen as "1.0P" until the switch Input voltage changes. "1.CL" will then be displayed. This is repeated for all the switch inputs.

When BATTV, MOTORV, MOTORA and TEMPC are selected, the controller shows their values. When BATTV is selected and the "+" button is held in, the highest voltage that the MOS90 has recorded will be displayed. When TEMPC is selected and the "+" button is held in, the highest temperature that the MOS90 has recorded will be displayed. The "-" button will display the lowest values.

ALIBRATOR

Figure 3-1:

MOS90 Calibrator LED Segments

When the MOS90 is first powered up, the recorded minutes of run time is displayed. The "+" button displays thousands of hours and the "-" button displays hundreds of hours. When the MOS90 is pulsing (being used) run time is being incremented and stored. The "dot" in the time display is blinking when MOS90 is being used, steady when idle.

067448-003 LX31/LX41 Electric Work Platform Page 3-7

Page 78

Using the Calibrator Section 3 - Troubleshooting

ALIBRATOR

PRIGHT

ETTINGS

LED Function Unit Setting Comments

1 MOS90 Maximum Amp. Capacity Amps 600 Adjustable from 50 amps to 600 amps

2 Acceleration Delay Seconds 1.0 Adjustable from 1.0 sec to 3.0 sec. 3 Deceleration Delay Seconds 0.5 Adjustable from 0.5 sec. to 3.0 sec.

4 Traction Creep % 0 Adjustable from 0% to 10%

5 Max. allowed Speed % 65 Adjustable from 5% to 100% 6 Cutback Speed 1 % 20 Adjustable from 5% to 25%

7 Cutback Speed 2 % 75 Adjustable from 20% to 75%

8 Pump Current limit Amps 270 Adjustable from 50 amps to 600 amps 9 Cutback1 Plug Current Amps 400 Adjustable from 180 amps to 750 amps

10 CSC Proportional Gain 1 30 Adjustable from 1 to 100

11 CSC Integral Gain 1 20 Adjustable from 1 to 100 12 Low Voltage Cutout Volts 25 Adjustable from 25 Volts to 40 Volts

13 Pump Acceleration Delay Seconds 2.0 Adjustable from 1.0 to 3.0

14 Pump Creep % 0% Adjustable from 0% to 30%

RACTION

ONTROLLER

DISPLAY

Sequence No. Te st Display Input #

- Acc. Input 0-100% 14 1 Forward CL/OP 8

2 Reverse CL/OP 11

3 Tach Input 0-100% 12 4 Elev. Pos. CL=Clpsd. 4

5 Tilt Switch CL=Level 7

6 Pump Switch CL= Pump 16

7 Act. Direction OP=FWD 2

Tacho Output CL=REV

8 High/Low Speed CL=High 13

9 Direction Flag OP=No Dr. -

10 First Error Latch Value= 0-255

NOTE: CL = Switch Closed

OP = Switch Open

OP=Lifted

OP=Tilt

OP=Trac.

OP=Low

CL=Drv actv.

Flash Code

Page 3-8 067448-003 LX31/LX41 Electric Work Platform

Page 79

Section 3 - Troubleshooting MOS90 Fault Finding Flow Charts

3-11 MOS90 F

At battery connection, the LED should not illuminate. At key ON, the LED should illuminate steadily. If the LED illuminates and remains steady, but no drive can be selected, the calibrator can be used to test the wiring harness.

1 Flash

- Power up/Fail-safe Fault

- EEPROM data corrupted on

key

Fault appears at key switch on.

2 Flashes

- Procedure Fault

- Illegal Startup Sequence.

Two directions selected together, direction and lift selected together or lift and ground selected together

- Drive inhibited

- Flashes until fault is cleared

AULT

Replace MOS90 Controller

INDING

LOW

HARTS

Check that both directions are not selected.

Check direction switches and wiring. Use

calibrator test mode and check Fwd/Rev/Lift

switch inputs and wiring.

Rectify

Replace MOS90 Controller

3 Flashes

- Point "A" less than 7V in neutral, or less than 7V for 15mS in drive, or contactor coil short circuit.

- Drive inhibited.

- Recycle to neutral to clear.

NOTE: If recycling to neutral does not clear the fault, then the fail-safe is due to a S/C contactor coil and the keyswitch must be recycled (and the coil replaced).

Check power and control wiring for shorts

Check for correct startup sequence. Was direc-

tion or lift selected at power up?

Rectify

Retry

Replace Controller

067448-003 LX31/LX41 Electric Work Platform Page 3-9

Page 80

MOS90 Fault Finding Flow Charts Section 3 - Troubleshooting

4 Flashes

- Direction contactor welded.

(Point "A" within 6V of B+ve in neutral)

- Leakage between motor armature and field.

- Drive inhibited.

- Flashes in neutral until fault is cleared

Check direction contactor tips

Check power wiring for shorts

5 Flashes

- Direction contactors (or line contactor) did not close.

- Motor armature or field open circuit.

- Point "A" not within 6V of

B+ve within one second of

selecting direction.

- Drive inhibited.

- Flashes until fault is cleared, when contactor closes.

Check contactor tips

Free/change tips

Repair/replace

Check contactor for mechanical operation and

coil O.K.

Rectify

Check motor for armature to field shorts or

leakage

Rectify

Check for shorts to frame and battery leakage

Rectify

Replace MOS90 Controller

Repair/replace

Check power and control wiring

Rectify

Check for open circuit motor

Rectify

Replace controller

Page 3-10 067448-003 LX31/LX41 Electric Work Platform

Page 81

Section 3 - Troubleshooting MOS90 Fault Finding Flow Charts

6 Flashes

- Accelerator faults

- 3.5 Volts to 0 Volts = Min. to Max. Speed on accelerator

input (pin 14). Greater than

4.5 volts can mean an open accelerator pot. Less than 2.5

Volts on power up, indicates more than 30% demand

- Controller pulses at creep

setting

- Flashes until fault cleared

Check operation of accelerator with test se-

quence

Rectify/replace

7 Flashes

- Battery voltage dipped below 14 volts

- Drive inhibited

- Turn key switch off and on to

clear flash

Check battery voltage (under load) with a voltme-

ter or calibrator

Change/charge battery

Check power connections, fuses, etc.

Repair/replace

Check pot operation with voltmeter for voltage at

minimum setting

Adjust as necessary or replace

Replace MOS90 Controller

Check for battery leakage to frame

Rectify

Replace MOS90 Controller

067448-003 LX31/LX41 Electric Work Platform Page 3-11

Page 82

MOS90 Fault Finding Flow Charts Section 3 - Troubleshooting

8 Flashes

- Thermal cutback

- Heatsink temperature less than 80ºC (176ºF) (Current limit will be zero at 90ºC (194ºF)

- Allow unit to cool down, to clear flashing

Check current limit setting

Re-set

Check mounting and heatsink of controller

10 Flashes

- Tachometer fault

- Drive inhibited

- Recycle key to clear fault

Check tachometer wires for opens or shorts

Rectify

Check output voltage from tachometer using

voltmeter

Replace

Rectify

Check application is correct

Use larger controller

Replace MOS90 Controller

Check output voltage from tachometer board,

using voltmeter

Replace

Replace MOS90 Controller

Page 3-12 067448-003 LX31/LX41 Electric Work Platform

Page 83

Section 3 - Troubleshooting MOS90 Fault Finding Flow Charts

11 Flashes

- Tachometer signal out of range

- Drive inhibited

- Flashes until fault cleared

Check tachometer wires for shorts to frame or a

voltage source

Rectify

Check output voltage from tachometer using

voltmeter

Replace

12 Flashes

- Severe tilt condition with platform raised above 2 meters

- Vehicle goes into emergency stop (forced neutral state) and plug brakes to a stop

- Recycle nuetral to clear fault

Use calabrator test mode and check platform up

switch and severe tilt switch inputs and wiring

Rectify

Replace MOS90 Controller

067448-003 LX31/LX41 Electric Work Platform Page 3-13

Page 84

MOS90 Fault Finding Flow Charts Section 3 - Troubleshooting

14 Flashes

- Battery voltage has fallen out of range.

- Traction and pump mode will

not be allowed

- Requires key recycle to clear

fualt

Check battery voltage (under load) with a voltme-

ter or calibrator

Change/charge battery

Check power connections, fuses, etc.

LED off

- Unit not powered up or controller faulty, or LED faulty

Check battery is connected and keyswitch is on

Rectify

Check all fuses are intact

Rectify

Check supply wiring. Does calibrator unit still

function

Repair/replace

Check for battery leakage to frame

Rectify

Replace MOS90 Controller

Rectify

Controller is faulty:

a) Auto fail-safe check failed. LED turns off when

a direction is first selected after power up. Recycle keyswitch.

b) Contactor drive S/C. LED resets itself if short

circuit clears.

c) Mosfets did not turn on. Recycle direction to

neutral to clear fault indication.

Replace controller

Page 3-14 067448-003 LX31/LX41 Electric Work Platform

Page 85

Section 3 - Troubleshooting Activating "TEST"

3-12 A

CTIVATING

Position red LED at TEST. Press "+" or "-" to select the switch to be viewed.

The zero position input "-" should read zero and is set by adjusting the sensitivity threshold trim pot in the upper control box. Step on the foot switch and keeping the Control Handle centered, adjust the pot to give a readout of 1 or 2. Slowly back the pot down until the reading has just dropped to zero.

Connect voltmeter between B- and pin 14 on MOS90. Voltage at pin 14 in neutral should not be lower than +3.5 volts D.C. 3.5 VDC = 0% speed input, 0.0 VDC=100% speed input.

If set at an extremely high value MOS90 will read as fault and shut down.

Properly set the LX31/41 should start to move slowly with a small movement of the Control Handle after a very small "deadband" zone.

Battery + side of direction & brake contactors for coil suppression (48 Volts)

"TEST"

Tachometer direction input from tach board

Figure 3-2:

Pump/Traction

18 Volts = REV.

0 Volts = FWD.

No connection

MOS90 17 Way Connector Pinout Designation

Height Limit

Black

Brown

Red (spare)

Orange

Yellow

+ 48 Volt supply to power up controller

Tilt

48 Volts when forward is selected & 0 Volts in neutral

No connection

48 Volts when reverse is selected & 0 Volts in neutral

Tach signal from tach gen.

Traction accelerator signal (3.5 Volts to 0 Volts = min. to max. speed)

Forward contactor driver - goes to battery negative to energize contactor

Reverse contactor driver - goes to battery negative to energise contactor

7.5Volts to 15 Volts = FWD. 0-100%

7.5

Volts to 0 Volts = REV. 0-100%

High/Low Speed

Brake applied input

48Volts = brake on

0 Volts = brake off

Green

Blue

Purple

Grey (spare)

White (spare)

Pink

White/Purple

White/Red

White/Black

White/Yellow

White/Blue

White/Green

MOS90

067448-003 LX31/LX41 Electric Work Platform Page 3-15

Page 86

Activating "TEST" Section 3 - Troubleshooting

TAC H

RIGHT

GENERATOR

MOS90 Wiring Diargam

BATTERY POSITIVE FROM

POWER ON SWITCHES

TO CLOSE REV CONTACTOR

POSITIVE SIDE OF

ALL CONTACTOR COILS

BATTERY NEGATIVE

BATTERY POSITIVE SUPPLY

TO ALL CONTACTORS

MOS90

TRACTION MODE = 48 VOLTS

Figure 3-3:

PUMP MODE = 0 VOLTS

FORWARD = 0 VOLTS

REVERSE = 18 VOLTS

NO CONNECTION

HEIGHT LIMIT

SWITCH OPEN = 0 VOLTS

POWER ON = 48 VOLTS

NORMAL = 48 VOLTS

TILT OR OVER-SPEED = 0 VOLTS

POWER ON = 48 VOLTS

FORWARD = 48 VOLTS

NEUTRAL = 0 VOLTS

NO CONNECTION

REVERSE = 48 VOLTS

NO CONNECTION

SWITCH CLOSED = 48 VOLTS

SWITCH OPEN = 0 VOLTS

FWD 0-100% = 7.5 TO 15 VOLTS

NEUTRAL = 0 VOLTS

TRACTION ACCELERATOR SIGNAL

REV 0-100% = 7.5 TO 0 VOLTS

BRAKE ON = 48 VOLTS

48 VOLTS & GOES TO 0 VOLTS

TO CLOSE FWD CONTACTOR

BRAKE OFF = 0 VOLTS

48 VOLTS & GOES TO 0 VOLTS

3.5 TO 0 VOLTS = MIN TO MAX SPEED

CONTROLLER

Black

Brown

MOTOR

PUMP/

TRACTION

CONTACTOR

—

– OUTPUT –

Orange

Red (spare) 5Yellow6Green8Purple

HEIGHT LIMIT SWITCH

Blue 7

POWER TO TURN MOS90 ON

TILT SWITCH & OVERSPEED INPUT

FORWARD SWITCH

Grey (spare) 10White (spare) 9

Pink

REVERSE SWITCH

White/Red

White/Purple

TACH SPEED SIGNAL

14 White/Black

HIGH-LOW SPEED SWITCH

White/Yellow

TRACTION

OFF

White/Blue

White/Green

PUMP SELECT

FORWARD CONTACTOR

6K OHM POT.

REVERSE CONTACTOR

0-100% REV SPEED = 0 TO –50 VOLTS

0-100% FWD SPEED = 0 TO +50 VOLTS

PUMP

OVERIDE

CONTACTOR

NO CONNECTION

GENERATOR

LEFT

—

– OUTPUT –

TACH DIRECTION SIGNAL

INPUT FROM TACH GENERATOR

0-100% REV SPEED = 0 TO –50 VOLTS

0-100% FWD SPEED = 0 TO +50 VOLTS

MOTOR

TACH SPEED SIGNAL

BATTERY NEGATIVE SUPPLY

345

FUSE

6.3 AMP

FUSE

TAC H

20 AMP

TILT SWITCH

OVER

RELAY

SPEED

LEFT

BRAKE

– CONDITION –

OVER SPEED = 0 V

NO OVER SPEED = 48 V

RIGHT

BRAKE

NO CONNECTION

RELAY

48 VOLT

10111213141516

NO CONNECTION

INTERFACE CIRCUIT

POWER SUPPLY FOR

TAC H

CIRCUIT

MODULE

INTERFACE

Page 3-16 067448-003 LX31/LX41 Electric Work Platform

Page 87

Section 4

CHEMATICS

This section contains electrical and hydraulic power schematics and associated information for maintenance purposes.

The diagrams are to be used in conjunction with the standing of the makeup and functions of the systems for checking, tracing, and faultfinding during troubleshooting analysis.

The components that comprise the electrical and hydraulic systems are given a reference designation and are explained as to function and location in the following tables.

ABLE

4-1 ElectricalSchematic,LXElectric:Serial#4022-4274....................... 4-2

4-2 ElectricalSchematic,LXElectric:Serial#4275-4390....................... 4-4

4-3 ElectricalSchematic,LXElectric–Outriggers ............................ 4-6

4-4 WireRouting........................................................ 4-8

4-5 HydraulicSchematic ................................................ 4-12

4-6 HoseRouting ...................................................... 4-13

4-7 ComponentIdentification ............................................ 4-14

ONTENTS

LXElectric ................................................................. 4-8

ControlBox ................................................................ 4-9

UpperControls............................................................. 4-10

OutriggerOption ........................................................... 4-10

UpperControls,OutriggerOption............................................. 4-11

Troubleshooting Truth TablesinSection 3.

They allow under-

067448-003 LX31/LX41 Electric Work Platform Page 4-1

Page 88

Electrical Schematic, LX Electric: Serial # 4022-4274 Section 4 - Schematics

4-1 E

Table 4 - 1 :

REFERENCE NAME FUNCTION LOCATION

ALM1 Alarm, Level Sensor

ALM2 Alarm, Down

BAT1 48 VDC Battery Pack Electric Power Control Module

C1 Main Power Contactor

C2 Forward Contactor Switch Drive Motors to Forward Relay Panel C3 Reverse Contactor Switch Drive Motors to Reverse Relay Panel C4 Pump Override Contactor Override Pump Motors Relay Panel

C5 Pump/Traction Contactor

CB1 Circuit Breaker Protect Emergency Stop Switch Lower Control Box CB2 Circuit Breaker Protect Power Relay R9 Lower Control Box CH1 Battery Charger Charge Batteries Control Module

CONT Controller Control Logic Module Relay Panel

F1 & F2 Fuse, Main Protect Circuit Wiring Relay Panel

L1 Drive Enable Light Indicate Power to Drive Circuit Upper Controls

MOT1 & 2 Electric Motor Drive Hydraulic Pump Power Module

MOT3 Electric Motor Drive Left Rear Wheel Chassis MOT4 Electric Motor Drive Right Rear Wheel Chassis

R1 Drive/Lift Relay Start Hydraulic Pumps Lower Control Box R2 8 Meter Cutout Relay High Speed Drive Cutout Lower Control Box R3 Level Sensor Alarm Relay Switch Power to ALM1 Lower Control Box R4 Up Relay Switch Power to SOL1 & 2 Lower Control Box R5 Down Relay Switch Power to SOL3 Lower Control Box R6 Down Alarm Relay Switch Power to ALM2 Lower Control Box R7 Steer Right Relay Switch Power to SOL5 Lower Control Box R8 Steer Left Relay Switch Power to SOL6 Lower Control Box

R9 Pump Start Relay Power to S1 Lower Control Box R10 Brake Relay Switch Power to SOL8 Lower Control Box R11 Brake Release Relay Switch Power to SOL11 Lower Control Box R12 Power Relay Switch Power to All Relays Lower Control Box R15 Brake Release Relay Power to Brake Relay R10 Relay Panel R16 Platform Power Relay Power to Upper Controls Upper Controls

LECTRICAL

ERIAL

Electrical Schematic, 067447-001

# 4022-4274

CHEMATIC

Warning sound when machine is off-level

Warning sound when platform is lowering

Switch Power to All Solenoids and Motors

Switch Power Motors and Pump Motors

Between

Drive

Lower Control Box

Relay Panel

, LX E

REFERENCE NAME FUNCTION LOCATION

LECTRIC

R17 Prevent Pump Start Relay Power to Pump Start Switch Upper Controls

RES1 Resistor Pack Current Protection Relay Panel

Control Handle Interlock

Switch S2 Forward Enable Forward Upper Controls S3 Reverse Enable Reverse Upper Controls

Lower Emergency Stop S4

Switch S5 Lift Button Power to Up Relay Lower Controls S6 Lower Button Power to Down Relay Lower Controls S7 Brake Release Button Power to Brake Release Relay Lower Controls S8 Lift/Drive Switch Activate Lift or Drive Upper Controls S9 High/Low Switch Speed Control Upper Controls

S10 - S13 Platform Down Switch Close when Platform is Fully Down

S14 8 Meter Cutout Switch

S15 Up Limit Switch Stop Lift Function Chassis S16 Pump Start Switch Power to Pump Start Relay Brake Valve Block

Chassis/Platform/Brake

S17

Release Switch

Upper Emergency Stop

S18

Switch

S19 Steering Rocker Switch Power to Steering Relays

S20 Proportional Speed Control

S21 Key Switch Power to Upper Controls & Motors Upper Controls

SEN1 Level Sensor Stop Drive Function Control Module

SOL 1 & 2 Up Solenoid Control Lift Valve Valve Block

SOL3 Down Solenoid Control Down Valve Lift Cylinder SOL5 Steer Right Solenoid Control Steer Right Valve Top of Valve Block SOL6 Steer Left Solenoid Control Steer Left Valve Top of Valve Block SOL8 Brake Solenoid Control Brake Valve (powers on) Valve Block

SOL11 Brake Release Solenoid Control Brake Valve (powers off) Valve Block

TG1 & TG2 Tachometer - Generator Monitor Drive Motor Speed MOS90”D”

Enable Upper Control Functions

Stop All Functions Lower Controls

Stop Drive Function when Platform Reaches 8 Meters

Power to Upper or Lower Controls, or Brake Release Button

Stop All Functions Upper Controls

Control Speed of Motors for Drive and Lift

Front of Control

Bottom of Elevating

Lower Control Box

Top of Control

Control Handle

Handle

Assembly

Chassis

Handle

S20

R17

S19

S21

S18

R16

CB1

Continued on Next Page

R12

S17

CB2

S5 S6

Page 4-2 067448-003 LX31/LX41 Electric Work Platform

Page 89

Section 4 - Schematics Electrical Schematic, LX Electric: Serial # 4022-4274

Continued from Previous Page

S10

SEN1

ALM1

ALM2

SOL1

SOL2

SOL3

SOL5

RES1

CONT

R15

MOT3

MOT4

CH1

BAT1

SOL6

MOT1

S16

R11

R10

SOL11 SOL8

TG1

TG2

MOT2

067448-003 LX31/LX41 Electric Work Platform Page 4-3

Page 90

Electrical Schematic, LX Electric: Serial # 4275-Current Section 4 - Schematics

4-2 E

Table 4 - 2 :

REFERENCE NAME FUNCTION LOCATION

ALM1 Alarm, Level Sensor

ALM2 Alarm, Down

BAT1 48 VDC Battery Pack Electric Power Control Module

C1 Main Power Contactor

C2 Forward Contactor Switch Drive Motors to Forward Relay Panel C3 Reverse Contactor Switch Drive Motors to Reverse Relay Panel C4 Pump Override Contactor Override Pump Motors Relay Panel

C5 Pump/Traction Contactor

CB1 Circuit Breaker Protect Emergency Stop Switch Lower Control Box CB2 Circuit Breaker Protect Power Relay R9 Lower Control Box CH1 Battery Charger Charge Batteries Control Module

CONT Controller Control Logic Module Relay Panel

F1 & F2 Fuse, Main Protect Circuit Wiring Relay Panel

L1 Drive Enable Light Indicate Power to Drive Circuit Upper Controls

MOT1 & 2 Electric Motor Drive Hydraulic Pump Power Module

MOT3 Electric Motor Drive Left Rear Wheel Chassis MOT4 Electric Motor Drive Right Rear Wheel Chassis

R1 Drive/Lift Relay Start Hydraulic Pumps Lower Control Box

R2 Platform Stowed Relay

R3 Level Sensor Alarm Relay Switch Power to ALM1 Lower Control Box R4 Up Relay Switch Power to SOL1 & 2 Lower Control Box R5 Down Relay Switch Power to SOL3 Lower Control Box R6 Down Alarm Relay Switch Power to ALM2 Lower Control Box R7 Steer Right Relay Switch Power to SOL5 Lower Control Box R8 Steer Left Relay Switch Power to SOL6 Lower Control Box

LECTRICAL

ERIAL

Electrical Schematic, 067447-001

# 4275-C

CHEMATIC

URRENT

Warning sound when machine is off-level

Warning sound when platform is lowering

Switch Power to All Solenoids and Motors

Switch Power Motors and Pump Motors

Enable High Speed when Platform Lowered

Between

Drive

Lower Control Box

Relay Panel

Lower Control Box

, LX E

REFERENCE NAME FUNCTION LOCATION

LECTRIC

R14 Charge Relay Charge Battery Pack Lower Control Box R16 Platform Power Relay Power to Upper Controls Upper Controls R17 Prevent Pump Start Relay Power to Pump Start Switch Upper Controls

RES1 Resistor Pack Current Protection Relay Panel

Control Handle Interlock

Switch S2 Forward Enable Forward Upper Controls S3 Reverse Enable Reverse Upper Controls

Lower Emergency Stop S4

S10 Proximity Switch

S16 Pump Start Switch Power to Pump Start Relay Brake Valve Block

Chassis/Platform/Brake

S17

Release Switch

Upper Emergency Stop

S18

Switch

S19 Steering Rocker Switch Power to Steering Relays

S20 Proportional Speed Control

S21 Key Switch Power to Upper Controls & Motors Upper Controls

SEN1 Level Sensor Stop Drive Function Control Module

SOL 1 & 2 Up Solenoid Control Lift Valve Valve Block

SOL11 Brake Release Solenoid Control Brake Valve (powers off) Valve Block

TG1 & TG2 Tachometer - Generator Monitor Drive Motor Speed MOS90”D”

Enable Upper Control Functions

Stop All Functions Lower Controls

Disable High Speed when Platform Elevated

Power to Upper or Lower Controls, or Brake Release Button

Stop All Functions Upper Controls

Control Speed of Motors for Drive and Lift

Front of Control

Bottom of Elevating

Lower Control Box

Top of Control

Control Handle

Handle

Assembly

Handle

S20

R17

S19

S21

Continued on Next Page

R16

S18

CB1

R12

S17

CB2

S5 S6

Page 4-4 067448-003 LX31/LX41 Electric Work Platform

Page 91

Section 4 - Schematics Electrical Schematic, LX Electric: Serial # 4275-Current

Continued from Previous Page

S10

SEN1

S16

R11

R10

ALM1

ALM2

SOL1

SOL2

SOL3

SOL5

SOL6

SOL11

SOL8

RES1

CONT

MOT3

MOT1

MOT2

MOT4

CH1

BAT1

TG1

TG2

067448-003 LX31/LX41 Electric Work Platform Page 4-5

Page 92

Electrical Schematic, LX Electric – Outriggers Section 4 - Schematics

4-3 E

Table 4 - 3 :

REFERENCE NAME FUNCTION LOCATION

ALM1 Alarm, Level Sensor

ALM2 Alarm, Down

BAT1 48 VDC Battery Pack Electric Power Control Module

C1 Main Power Contactor

C2 Forward Contactor Switch Drive Motors to Forward Relay Panel C3 Reverse Contactor Switch Drive Motors to Reverse Relay Panel C4 Pump Override Contactor Override Pump Motors Relay Panel

C5 Pump/Traction Contactor

CB1 Circuit Breaker Protect Emergency Stop Switch Lower Control Box CB2 Circuit Breaker Protect Power Relay R9 Lower Control Box CB3 Circuit Breaker Protect Engine Wiring Lower Control Box CH1 Battery Charger Charge Batteries Control Module

CONT Controller Control Logic Module Relay Panel

F1 & F2 Fuse, Main Protect Circuit Wiring Relay Panel

L1 Drive Enable Light Indicate Power to Drive Circuit Upper Controls

M1 Hour Meter Record Operating Time Lower Control Box

MOT1 & 2 Electric Motor Drive Hydraulic Pump Power Module

MOT3 Electric Motor Drive Left Rear Wheel Chassis

MOT4 Electric Motor Drive Right Rear Wheel Chassis OR-LB Outrigger Light Board Power for Outrigger Indicators Upper Controls OR-L1 Outrigger Indicator LH-R Lights when Outrigger Down Upper Controls OR-L2 Outrigger Indicator LH-F Lights when Outrigger Down Upper Controls OR-L3 Outrigger Indicator RH-R Lights when Outrigger Down Upper Controls OR-L4 Outrigger Indicator RH-F Lights when Outrigger Down Upper Controls OR-R1 Outrigger Extend Relay LH-F Lower Outrigger Outrigger Control Box OR-R2 Outrigger Retract Relay LH-F Raise Outrigger Outrigger Control Box OR-R3 Outrigger Extend Relay LH-R Lower Outrigger Outrigger Control Box OR-R4 Outrigger Retract Relay LH-R Raise Outrigger Outrigger Control Box OR-R5 Outrigger Extend Relay RH-F Lower Outrigger Outrigger Control Box OR-R6 Outrigger Retract Relay RH-F Raise Outrigger Outrigger Control Box OR-R7 Outrigger Extend Relay RH-R Lower Outrigger Outrigger Control Box OR-R8 Outrigger Retract Relay RH-R Raise Outrigger Outrigger Control Box

OR-R9 Drive Override Relay

OR-R16 Drive Cutout Relay

OR-R18 Lift/Drive Cutout Relay

OR-S1 Outrigger Switch LH-F Control Outrigger Position Upper Controls OR-S2 Outrigger Switch LH-R Control Outrigger Position Upper Controls OR-S3 Outrigger Switch RH-F Control Outrigger Position Upper Controls OR-S4 Outrigger Switch RH-R Control Outrigger Position Upper Controls OR-S5 Outrigger Switch Power to OR-R18 Upper Controls OR-S6 Outrigger Ball Switch Control Outrigger Position LH-F Outrigger OR-S7 Outrigger Ball Switch Control Outrigger Position LH-R Outrigger OR-S8 Outrigger Ball Switch Control Outrigger Position RH-R Outrigger OR-S9 Outrigger Ball Switch Control Outrigger Position RH-F Outrigger

OR-S10 Outrigger Pressure Switch Control Outrigger Position LH-F Outrigger OR-S11 Outrigger Pressure Switch Control Outrigger Position LH-R Outrigger OR-S12 Outrigger Pressure Switch Control Outrigger Position RH-R Outrigger OR-S13 Outrigger Pressure Switch Control Outrigger Position RH-F Outrigger

OR-SOL1 Extend Solenoid LH-F Control Outrigger Position Outrigger Valve Block

LECTRICAL

Electrical Schematic - 067455-015

CHEMATIC

Warning sound when machine is off-level

Warning sound when platform is lowering

Switch Power to All Solenoids and Motors

Switch Power Motors and Pump Motors

Cut Drive Power when Outriggers Down

Switch Control based on Outrigger Position

Between

Drive

, LX E

Lower Control Box

Relay Panel

Outrigger Control Box

Lower Control Box

Upper Controls

LECTRIC

REFERENCE NAME FUNCTION LOCATION

OR-SOL2 Retract Solenoid LH-F Control Outrigger Position Outrigger Valve Block OR-SOL3 Extend Solenoid LH-R Control Outrigger Position Outrigger Valve Block OR-SOL4 Retract Solenoid LH-R Control Outrigger Position Outrigger Valve Block OR-SOL5 Extend Solenoid RH-F Control Outrigger Position Outrigger Valve Block OR-SOL6 Retract Solenoid RH-F Control Outrigger Position Outrigger Valve Block OR-SOL7 Extend Solenoid RH-R Control Outrigger Position Outrigger Valve Block OR-SOL8 Retract Solenoid RH-R Control Outrigger Position Outrigger Valve Block

R1 Drive/Lift Relay Start Hydraulic Pumps Lower Control Box

R2 Platform Stowed Relay

R9 Pump Start Relay Power to S1 Lower Control Box R10 Brake Relay Switch Power to SOL8 Lower Control Box R11 Brake Release Relay Switch Power to SOL11 Lower Control Box R12 Power Relay Switch Power to All Relays Lower Control Box R14 Charge Relay Charge Battery Pack Lower Control Box R16 Platform Power Relay Power to Upper Controls Upper Controls R17 Prevent Pump Start Relay Power to Pump Start Switch Upper Controls

RES1 Resistor Pack Current Protection Relay Panel

Control Handle Interlock

Switch S2 Forward Enable Forward Upper Controls S3 Reverse Enable Reverse Upper Controls

Lower Emergency Stop S4

S10 Proximity Switch

S16 Pump Start Switch Power to Pump Start Relay Brake Valve Block

Chassis/Platform/Brake

S17

Release Switch

Upper Emergency Stop

S18

Switch

S19 Steering Rocker Switch Power to Steering Relays Top of Control Handle

S20 Proportional Speed Control

S21 Key Switch

SEN1 Level Sensor Stop Drive Function Control Module

SOL 1 & 2 Up Solenoid Control Lift Valve Valve Block

SOL11 Brake Release Solenoid Control Brake Valve (powers off) Valve Block

TG1 & TG2 Tachometer - Generator Monitor Drive Motor Speed MOS90”D”

– O

UTRIGGERS

Enable High Speed when Platform Lowered

Enable Upper Control Functions

Stop All Functions Lower Controls

Disable High Speed when Platform Elevated

Power to Upper or Lower Controls, or Brake Release Button

Stop All Functions Upper Controls

Control Speed of Motors for Drive and Lift

Power to Upper Controls & Motors

Lower Control Box

Bottom of Elevating

Lower Control Box

Front of Control

Handle

Assembly

Control Handle

Upper Controls

OR-L1 OR-L2 OR-L3 OR-L4

ORS1ORS2ORS3OR

R17

S20

S19

S21

OR-LB

S18

R16

OR-R18

OR-S5

CB1

CB2

Continued on Next Page

S17

S5 S6

R12

Page 4-6 067448-003 LX31/LX41 Electric Work Platform

Page 93

Section 4 - Schematics Electrical Schematic, LX Electric – Outriggers

Continued from Previous Page

OR-S6 OR-S7 OR-S8 OR-S9 OR-S10 OR-S11 OR-S12 OR-S13

OR-R1

OR-SOL1

OR-R2

OR-SOL2

OR-R3

OR-SOL3

OR-R4

OR-SOL4

OR-R5

OR-SOL5

OR-R6

OR-SOL6

OR-R7

OR-SOL7

OR-R8

OR-SOL8

OR-R9

S10

SEN1

S16

OR-R16

R10

R11

ALM1

ALM2

SOL5

SOL6

SOL3

SOL1

SOL2

SOL11 SOL8

RES1

CONT

TG1

TG2

MOT3

MOT1

MOT2

MOT4

CH1

BAT1

067448-003 LX31/LX41 Electric Work Platform Page 4-7

Page 94

Wire Routing Section 4 - Schematics

4-4 W

LX E

IRE

LECTRIC

OUTING

Page 4-8 067448-003 LX31/LX41 Electric Work Platform

Page 95

Section 4 - Schematics Wire Routing

ONTROL

067448-003 LX31/LX41 Electric Work Platform Page 4-9

Page 96

Wire Routing Section 4 - Schematics

PPER

ONTROLS

UTRIGGER

PTION

Page 4-10 067448-003 LX31/LX41 Electric Work Platform

Page 97

Section 4 - Schematics Wire Routing

PPER

ONTROLS

, O

UTRIGGER

PTION

067448-003 LX31/LX41 Electric Work Platform Page 4-11

Page 98

Hydraulic Schematic Section 4 - Schematics

4-5 H

Table 4 - 4 :

REFERENCE NAME FUNCTION LOCATION

ACC Accumulator Accumulate Hydraulic Fluid Brake Valve Block CV1 Check Valve Slow Brake Release Brake Valve Block BK1 Left Brake Apply Left Brake Pressure Left Brake

BK2 Right Brake Apply Right Brake Pressure Right Brake CYL1 Cylinder, Lift Actuate Scissor Linkage to Lift Platform Chassis CYL2 Cylinder, Steering Actuate Steering Linkage to Steer Front Wheels Chassis

CYL3-CYL6 Outrigger Cylinder Level and Support the Machine Chassis

LV1-LV4 Load Holding Valve Outrigger

F1 Filter, Return Filter Hydraulic Line Tank

YDRAULIC

Hydraulic Schematic - 067446-000/067454-000

BK1

CHEMATIC

BK2

REFERENCE NAME FUNCTION LOCATION

F2 Filter, Tank Filter Contaminants Tank

FD1 Flow Divider Allows Lift and Steer Functions Together Main Valve Block

Orifice, One-way,

ORF1

Brake Orifice, One-way,

ORF2

Lift Cylinder

P1 & P2 Hydraulic Pump Fluid Power for Hydraulic System Chassis

PS1 Pressure Switch Disable Machine Brake Valve Block

RV1 Valve, Main Relief

Allow Brakes to Release Quickly and Apply Slowly

Limit Hydraulic Oil Flow at Lift Cylinder Lift Cylinder

Over Pressure Protection for the Main Hydraulic Line

CYL2

ORF2

RV2

Brake Valve Block

Main Valve Block

CYL1

REFERENCE NAME FUNCTION LOCATION

Valve, Steering

RV2

Relief

V1 Valve, Brake Apply Direct Hydraulic Oil to the Brake Cylinders Brake Valve Block

Valve, Brake

Release V3 Valve, Steering Control Hydraulic Oil Flow to Steering Cylinder Main Valve Block V4 Valve, Lift Control Hydraulic Oil Flow to Lift Cylinder Main Valve Block V5 Valve, Dump Divert Excess Oil Main Valve Block

Over Pressure Protection for the Steering Components

Release Hydraulic Oil Pressure from Brakes Brake Valve Block

CYL3

CYL4 CYL5 CYL6

Main Valve Block

REFERENCE NAME FUNCTION LOCATION

V6 Valve, Down

V7-V10 Valve, Outrigger Control Hydraulic Flow to Outrigger Cylinders

- Hold Oil in Lift Cylinder when Deck is Elevated.

- Release Oil from Lift Cylinder to Lower Deck

- Has Cable Actuated Manual Override for Emergency Lowering

Lift Cylinder

Outrigger Valve

Block

ACC

ORF1

PS1

CV1

FD1

RV1

LV1

LV2 LV3 LV4

V7 V8 V9 V10

OUTRIGGER OPTION

Page 4-12 067448-003 LX31/LX41 Electric Work Platform

Page 99

Section 4 - Schematics Hose Routing

4-6 H

OSE

OUTING

OUTRIGGER

OPTION

OUTRIGGER

OPTION

CONTROL

MODULE

OUTRIGGER

OPTION

POWER MODULE

OUTRIGGER

OPTION

067448-003 LX31/LX41 Electric Work Platform Page 4-13

OUTRIGGER

OPTION

Page 100

Component Identification Section 4 - Schematics

4-7 C

OMPONENT

Latch Style Retainer

Outrigger

Option

OR-R16

DENTIFICATION

Catch Style Retainer

Retainer Catch to be Positioned to the Inside

a. End Bracket b. Terminal Block

(Blue or Tan)

c. Terminal Block Ground

(Yellow or Green) d. Relay, DPDT e. Relay, SPDT

Lower Control Box

1. Emergency Stop Button

2. 3-Position Selector Switch (Platform/Chassis/Brake Release)

3. Raise Button

4. Brake Release Button

5. Lower Button

6. Circuit Breaker

7. Circuit Breaker

8. Circuit Breaker

R10

R11

Figure 4-1:

Lower Control Box Assembly

9. Glow Plug Button (Bi-Energy)

10. Start Button (Bi-Energy)

11. Run/Charge Switch (Bi-Energy)

12. Hour Meter (option)

13. Down Alarm

14. Tilt Alarm

15. Control Panel Assembly

16. Terminal Blocks

17. Relays

ALM2

ALM1

S17

CB2

CB1

Page 4-14 067448-003 LX31/LX41 Electric Work Platform

Snorkel LX41 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Controls and Indicators

System Function Inspection

Operation

Towing or Winching

Fold Down Guardrails

Transporting the Work Platform

Maintenance

Preventative Maintenance Schedule

Labels

Specifications

Hazard Indicators Section 1 - General Information

Section 1 - General Information Torque Specifications

Section 1 - General Information Date Code Identification on Hoses

UpRight Connectors Section 1 - General Information

Hydraulic Manifold Repair Section 1 - General Information

Section 1 - General Information Cylinder Repair

Electric Motors Section 1 - General Information

Battery Maintenance Section 1 - General Information

Floor Loading Section 1 - General Information

Section 1 - General Information Hydraulic Fluid

Long Term Storage Section 1 - General Information

General Description Section 2 - Service and Repair

Preventative Maintenance Section 2 - Service and Repair

Blocking The Elevating Assembly Section 2 - Service and Repair

Section 2 - Service and Repair Lubrication

Section 2 - Service and Repair Setting Hydraulic Pressures

Switch Adjustments Section 2 - Service and Repair

Section 2 - Service and Repair Hydraulic Manifolds

Hydraulic Power Unit Section 2 - Service and Repair

4. Torque Hub

Drive Motors Section 2 - Service and Repair

Section 2 - Service and Repair Steering Cylinder

Lift Cylinder Section 2 - Service and Repair

Outrigger Cylinder (Optional) Section 2 - Service and Repair

Technical Support Section 3 - Troubleshooting

Section 3 - Troubleshooting Electric Truth Tables

Hydraulic Truth Table Section 3 - Troubleshooting

Section 3 - Troubleshooting Troubleshooting the MOS90

Section 3 - Troubleshooting MOS90 Fault Finding Flow Charts

Section 3 - Troubleshooting Activating "TEST"

Electrical Schematic, LX Electric – Outriggers Section 4 - Schematics

Wire Routing Section 4 - Schematics

Hydraulic Schematic Section 4 - Schematics

Section 4 - Schematics Hose Routing

Component Identification Section 4 - Schematics