LX31 / LX41
Electric Models
Serial Numbers 4022 - Current
P/N 067448-003
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
F
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.
O
PERATOR
A copy of the Operator Manual that is stored on every UpRight Aerial Work Platform.
S
ECTION
Contains generic information relevant to all UpRight Aerial Work Platforms.
S
ECTION
Detailed information specific to this UpRight Aerial Work Platform.
M
1 - G
2 - S
ANUAL
ENERAL
ERVICE AND
I
NFORMATION
R
EPAIR
S
ECTION
Causes and solutions to typical problems.
S
ECTION
Electric and Hydraulic schematics.
3 - T
4 - S
ROUBLESHOOTING
CHEMATICS
Service Manual Page i
Foreword
N
OTES
:
Page ii Service Manual
PERATOR
O
M
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 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
C
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
I
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.
G
ENERAL
D
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
3
4
2
9
7
1
9
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)
2
5
8
9
9
6
067449-002 LX Electric Work Platform - Operator Manual Page 3
Controls and Indicators
C
ONTROLS
4*
6
10
1. Steering Switch
2. Interlock Lever
3. Control Handle
4. Outrigger Switches
5. Outrigger Indicator
Lights
AND
Platform Controls Chassis Controls
I
NDICATORS
1
2
2
1
5*
3
5*
4*
9
8
10. Horn Button (option)
7**
6. Emergency Stop Switch
7. Lift/Drive Switch
8. Drive Speed/Torque
Selector Switch
9. Drive Enable Indicator
3
5
1. Emergency Stop
2. Platform/Chassis Key Switch
3. Raise Button
4
4. Brake Release Button
5. Lower Button
6. Hour Meter (option)
Figure 2:
Controls and Indicators
6
Outrigger Options
* Outrigger Switches and Outrigger Lights are installed on outrigger equipped machines only.
** Outrigger selection is available on outrigger equipped machines only.
P
RE
-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
I
NSPECTION
Page 4 067449-002 LX Electric Work Platform - Operator Manual
System Function Inspection
S
YSTEM
F
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
I
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
Operation
O
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.
T
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
P
LATFORM
!
L
OWERED
T
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.
S
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
W
ORK
P
LATFORM
E
LEVATED
Operation
R
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.
L
EVELING
UTRIGGER EQUIPPED MACHINES ONLY
(O
THE
L
OWERING
P
LATFORM
THE
P
LATFORM
)
!
WARNING
When using outriggers, all four (4) outriggers must be in firm contact with the supporting surface.
O
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.
P
LATFORM
!
L
IGHTS
(E
XTEND
THE
O
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.
Towing or Winching
E
MERGENCY
L
OWERING
T
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.
W
OR
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.
P
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.
B
RAKE
R
ELEASE
Figure 5:
Platform/Chassis/Brake Release Switch
!
Brake Release Button
Parking Brake Release
A
FTER
Page 8 067449-002 LX Electric Work Platform - Operator Manual
U
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.
E
SE
rized operation.
ACH
D
AY
Fold Down Guardrails
F
OLD
D
OWN
This procedure is only for passing through doorways. Guardrails must be returned to proper position
before using the machine.
F
OLD
ROCEDURE
P
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.
G
UARDRAILS
Figure 6:
D
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).
A
B
C
F
Fold Down Guardrails
D
E
E
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
P
ROCEDURE
!
Transporting the Work Platform
T
RANSPORTING
P
L
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
W
FOR
RANE
ORK
S
P
LATFORM
HIPMENT
Figure 7:
Tie-Down / Lifting Lugs
Transporting Work Platform
Front ViewRear View
D
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.
W
INCHING
the machine onto the transport vehicle:
the machine onto the transport vehicle:
(1 ft/s)
ONTO A
.
T
RUCK OR
T
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
M
AINTENANCE
B
LOCKING
THE
E
LEVATING
A
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.
B
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
B
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.
H
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.
R
EMOVAL
ter pivots.
F
LUID
Never add fluid if the platform is elevated.
Figure 9:
2
Hydraulic Fluid Reservoir
1
1. Fluid Sight Gauge
2. Filler Cap
067449-002 LX Electric Work Platform - Operator Manual Page 11
Maintenance
B
ATTERY
The batteries are located in the Control Module.
M
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
3
(
/
in.) above plates, add distilled water ONLY. Do not use tap
8
B
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.
C
HARGING
!
3
/
in.) above the plates add
8
[12 gauge] minimum conductor diameter; 15 m (50 ft.) maximum
²
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
Preventative Maintenance Schedule
P
REVENTATIVE
D
M
AINTENANCE
M
AINTENANCE
S
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
P
REVENTATIVE
T
ABLEKEY
M
AINTENANCE
M
AINTENANCE
C
HECK
R
EPORT
L
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
Labels
L
ABELS
1
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
8
066562-001
DANGER
066562-001
14
061205-005
TIP-OVER HAZARD
MAXIMUM DISTRIBUTED LOAD
500 LBS. OR 2 OCCUPANTS
ON EXTENDED DECK
MAXIMUM SIDE LOAD 100 LBS.
19
101251-001
2
066554-000
3
066555-000
4
066551-002
5
066556-000
9
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.
10
068641-003
068641-003
WARNING
Explosive gas is
generated when
charging batteries.
Do not expose to
sparks or flames.
11
066552-000
WARNING
MAXIMUM DISTRIBUTED
PLATFORM LOAD 2000 LBS.
OR 5 OCCUPANTS
MAXIMUM SIDE LOAD 300 LBS.
12
LX31: 101250-008
101250-009
LX41: 101250-009
WARNING
CRUSHING HAZARD
KEEP CLEAR OF
PLATFORM
LOWER PLATFORM
COMPLETELY BEFORE
SERVICING MACHINE
13
066568-000
15
066558-000
16
061515-000
17
068639-000
18
061220-002
25
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
20
066550-009
21
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.
22
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.
23
066561-001
24
061197-000
LH FRT
EXTEND
DANGER
FALL HAZARD
RH FRT
EXTEND
6
067365-000
MAXIMUM WHEEL
AND/OR OUTRIGGER
LOAD 3900 LBS.
7
LX31: 101252-013
LX41: 101252-014
101252-013
EMERGENCY
STOP
RAISE FWD
LOWER REV.
26
067642-012
HIGH
LOW
SPEED
SPEED
LIFT DRIVE
RETRACT
LH AFT
EXTEND
RETRACT
RAISE FWD
EMERGENCY
STOP
26
LOWER REV.
067642-010 Outrigger Option
HIGH
LOW
SPEED
SPEED
OUTRIGGER
LIFT DRIVE
Page 14 067449-002 LX Electric Work Platform - Operator Manual
RETRACT
RH AFT
EXTEND
RETRACT
Labels
2
26
CONTROLLER
12
16
Figure 11:
1
Safety Labels Locations
21
21
20
Outrigger
Option
19
24
3
22
POWER
MODULE
11
3
9
8
REAR
12
8
7
4
CONTROL
MODULE
25
10
6
Inside
on Door
FRONT
15
5
23
13
14
18
17
067449-002 LX Electric Work Platform - Operator Manual Page 15
Specifications
S
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
Section 1
T
ABLE
G
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.
C
OF
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
I
NFORMATION
L
IST OF
L
IST OF
F
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
T
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
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.
I
NDICATORS
DANGER
WARNING
CAUTION
!
!
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.
P
ROCEDURES
!
!
Page 1-2 Service Manual
Section 1 - General Information Torque Specifications
1-3 T
Table 1 - 1 :
ORQUE
H
YDRAULIC
NOTE:
S
PECIFICATIONS
C
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
F
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 :
T
HREAD
C
ONDITION
• For lubricated or zinc plated fasteners use K =,15
• For dry unplated fasteners use K =,20
T
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
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
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.
C
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)
T
I
DENTIFICATION
OOLS
ON
H
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
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.
M
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.
C
C
ONNECTOR
ONNECTORS
(P
LUG
Figure 1-1:
UpRight Connector Kits
Large KitSmall Kit
)
Figure 1-2:
UpRight Male Connector
F
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
C
ONNECTOR
(R
ECEPTACLE
)
Figure 1-3:
UpRight Female Connector
Section 1 - General Information UpRight Connectors
R
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.
C
RIMPING
1. Strip 6 mm (¼in.)fromthewire.
NOTE:
Complete crimping instructions are included in each Field Kit.
L
OCKING
F
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.
R
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.
C
ONTACT
FROM
H
EAVY
D
UTY
P
LUG
Figure 1-5:
Heavy Duty UpRight Connector
Service Manual Page 1-7
Hydraulic Manifold Repair Section 1 - General Information
1-7 H
YDRAULIC
R
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.
D
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.
C
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.
M
ANIFOLD
Service and Repair
AND
I
NSPECTION
R
EPAIR
section for model specific information.
A
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.
I
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
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
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.
R
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
D
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.
R
EPAIR
Service and Repair
!
section for the location of cylinders, and the
Service and Repair
Parts Manual
section.
for a list of parts
A
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.
I
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
Electric Motors Section 1 - General Information
1-9 E
LECTRIC
T
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.
M
OTORS
DC
Power
Supply
A
Brushes raised with
the springs in locked
position on the side
B
of the brush
Keep fingers
clear of this
space.
Figure 1-6:
A
V
Voltage Meter
Brushes and
springs in their
final position
Electric Motor Service
Ammeter
DC
Motor
C
D
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
Loading...