Upright AB62 Service Manual

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Page 1

AB62 Work Platform

European Specifications

Serial Numbers 1266 - Current

Publication Number: 104045-021

Page 2

AB62

Aerial Work Platform

Serial Numbers 1266 - Current

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

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

NEVER operate the boom 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.

Tip Over Hazard

Tip Over HazardTip Over Hazard

Tip Over Hazard Collision Hazard

Collision HazardCollision Hazard

Collision Hazard Fall Hazard

Fall HazardFall Hazard

Fall Hazard

Electrocution Hazard

Electrocution HazardElectrocution Hazard

Electrocution Hazard

THIS MACHINE IS NOT

INSULATED!

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

USE OF THE AERIAL WORK PLATFORM

used for the job. It is designed for repair and assembly jobs and assignments at overhead workplaces (ceilings, cranes, roof structures, buildings etc.). All other uses of the aerial work platform are prohibited!

THIS AERIAL WORK PLATFORM IS NOT INSULATED!

trical equipment!

ALL OCCUPANTS

to each anchorage point. Exceeding the specified permissible maximum load The use and operation of the aerial work platform as a lifting tool or a crane (lifting of loads from below upwards or from up high on

down)

is prohibited! NEVER DISTRIBUTE NEVER

and avoiding them.

OPERATE NEVER IN CASE OF EMERGENCY IF ALARM SOUNDS

Climbing up the railing of the platform, standing on or stepping from the platform onto buildings, steel or prefab concrete structures, etc.,

is prohibited!

Dismantling the swing gate or other railing components locked!

It is prohibited

To extend the height or the range by placing of ladders, scaffolds or similar devices on the platform

NEVER INSPECT

cables or hoses before using.

VERIFY NEVER

To bypass any safety equipment range.

NEVER

Modifications to the aerial work platform

AFTER USE

exceed the manual force allowed for this machine. See “Special Limitations” on page 4 for details.

operate the machine without first surveying the work area for surface hazards such as holes, drop-offs, bumps, curbs, or debris;

machine only on surfaces capable of supporting wheel loads.

operate the machine when wind speeds exceed this machine’s wind rating. See “Beaufort Scale” on page 4 for details.

perform service on machine while platform is elevated without blocking elevating assembly.

the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire connections, and damaged

that all labels are in place and legible before using.

use a machine that is damaged, not functioning properly, or has damaged or missing labels.

charge batteries near sparks or open flame. Charging batteries emit explosive hydrogen gas.

must wear an approved fall restraint properly attached to a designated anchorage point. Attach only one fall restraint

all platform loads evenly on the platform.

push EMERGENCY STOP switch to deactivate all powered functions.

while platform is elevated, STOP, carefully lower platform. Move machine to a firm, level surface.

to keep the swing gate in an open position (held open with tie-straps) when the platform is raised!

is prohibited

, secure the work platform from unauthorized use by turning both keyswitches off and removing keys.

: This aerial work platform is intended to lift persons and his tools as well as the material

For this reason it is imperative to keep a safe distance from live parts of elec-

is prohibited!

and presents a danger for the persons on the aerial work platform and in its working

are prohibited

or permissible only at the approval by UpRight.

See “Special Limitations” on page 4 for details.

Always make certain that the swing gate is closed and securely

is prohibited!

Page 1

Page 6

104044-021 AB62 Work Platform - European Model

ONTENTS

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

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Special Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

All Models:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Platform Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Manual Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Beaufort Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lift Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Pre-Operation Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Function Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Controller Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Service Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Positioning the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Multifunction Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lower Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Upper Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Leveling the Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Rotating the Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Elevating the Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Elevating the Upper Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Extending the Upper Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Elevating the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rotating the Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

After Use Each Day. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

By Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

By Truck or Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Fueling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Inspection and Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Daily Preventative Maintenance Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Page 2 Operator Manual

Page 7

Introduction 104044-021 AB62 Work Platform - European Model

WARNING

NTRODUCTION

ENERAL

This manual covers the operation of the AB62 Articulated Boom.

machine at all times.

ESCRIPTION

1. Platform

• The platform has a non-slip aluminum floor, guardrails with midrail, toeboards, and an entrance gate at the rear of the platform.

2. Platform Controls

• The Platform Controller is located at the front of the platform cage. The foot switch must be depressed to operate any function from the platform.

3. Riser

• Used to raise the platform.

4. Boom

• Used to extend the platform.

5. Jib

• Used to level and rotate the platform, and to raise or lower the platform at the end of the boom.

6. Power Module

• The Power Module contains the engine and the hydraulic pump.

7. Control Module

• The Control Module contains the fuel tank, hydraulic fluid tank and components, the hydraulic manifold, the batteries, and the Chassis Controller.

8. Chassis Controls

9. Chassis

This manual must be stored on the

Figure 1:

AB62 Work Platform

Operator Manual Page 3

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

Page 8

104044-021 AB62 Work Platform - European Model Special Limitations

DANGER

! !

DANGER

! !

DANGER

! !

DANGER

! !

PECIAL

IMITATIONS

ODELS

Travel with the platform raised is limited to a creep speed range. Elevating of the Work Platform is limited to firm, level surfaces only.

The elevating function shall ONLY be used when the work platform is level and on a firm surface.

LATFORM

The maximum capacity for the MACHINE, including occupants is determined by model and options, and is listed in “Specifications” on page 20.

DO NOT exceed the maximum platform capacity or the platform occupancy limits for this machine.

APACITY

ANUAL

Manual force is the force applied by the occupants to objects such as walls or other structures outside the work platform.

The maximum allowable manual force is limited to 200 N ( of 400 N (

DO NOT exceed the maximum amount of manual force for this machine.

EAUFORT

Never operate the machine when wind speeds exceed 45 km/h (

BEAUFORT

RATING

3 3,4~5,4 12,25~19,4 11.5~17.75 7.5~12.0 Papers and thin branches move, flags wave. 4 5,4~8,0 19,4~28,8 17.75~26.25 12.0~18 Dust is raised, paper whirls up, and small branches sway. 5 8,0~10,8 28,8~38,9 26.25~35.5 18~24.25 Shrubs with leaves start swaying. Wave crests are apparent in ponds or swamps. 6 10,8~13,9 38,9~50,0 35.5~45.5 24.5~31 Tree branches move. Power lines whistle. It is difficult to open an umbrella. 7 13,9~17,2 50,0~61,9 45.5~56.5 31.~38.5 Whole trees sway. It is difficult to walk against the wind.

m/s km/h ft/s mph

IFT

All models include a feature that alerts the operator when the platform load is exceeded. If the alarm sounds during the lift function, lower the platform and reduce the platform load.

ORCE

90 lbs.

) for two or more occupants.

WIND SPEED

VERLOAD

CALE

LARM

GROUND CONDITIONS

45 lbs.

) of force per occupant, with a maximum

28 mph

) [Beaufort scale 6].

Never operate the machine with a platform load greater than the rated capacity.

Page 4 Operator Manual

Page 9

Controls and Indicators 104044-021 AB62 Work Platform - European Model

Foot Switch

Key Switch

Platform Controls

Chassis Controls

Diesel Model

25 26

ONTROLS

AND

NDICATORS

1. Hour Meter

2. Water Temp.

3. Oil Pressure

4. Breaker

5. Diesel - Glow Plug Light

6. Function Enable

7. Engine Start

8. Key Switch

9. Emergency Stop

10. Riser

11. Boom Extend/Retract

12. Jib Raise/Lower

13. Boom Raise/Lower

14. Turret Rotate

15. Platform Rotate

16. Platform Level

17. Function Speed HI/LOW

18. Auxiliary Power

19. Riser

20. Boom Raise

21. Boom Extend

22. Jib Raise

23. Emergency Stop

24. YELLOW-Tilt

25. RED-Oil Pressure Warning

26. Torque / Speed

27. Diesel - Glow Plug Light

28. Auxiliary Power

29. Turret Rotate

30. Cage Rotate

31. Cage Level

32. Auxiliary Light (option)

33. Horn

34. Generator (option)

35. Function Speed

36. Drive Control Handle

37. Steering Rocker Switch

38. Key Switch

39. Foot Switch

Figure 2:

Controls and Indicators

Operator Manual Page 5

Page 10

104044-021 AB62 Work Platform - European Model Pre-Operation Safety Inspection

WARNING

-O

PERATION

ISUAL

Carefully read, understand and follow all safety rules, labels, and operating instructions; then perform the

NOTE:

following steps each day before use.

Perform a complete visual inspection of the entire unit prior to operating. Check the following areas for discrepancies:

1. Open the covers and check hydraulic components and hoses for damage or leaks.

2. Check electrical components and wiring for damage or loose connections.

3. Inspect the chassis, axles, hubs, and steering linkage for damage, deformation, buckled paint, loose or missing hardware, and cracked welds.

4. Air-filled tires: check for damage, punctures, and inflation; tire pressure must be 5.5 bar (

5. Check all hoses and cables for wear.

6. Inspect the elevating assembly for damage, deformation, buckled paint, loose or missing hardware, and cracked welds.

7. Inspect the platform and guardrails for damage, deformation, buckled paint, loose or missing hardware, and cracked welds. Ensure that the gate operates freely and latches securely.

8. Check the hydraulic fluid level with the platform fully lowered.

9. Check the battery fluid level.

10. Check the fuel level; add fuel if necessary.

11. Ensure that the radiator is cold; check coolant level. Add if necessary.

AFETY

NSPECTION

80 psi

NEVER remove the cap from a hot radiator. Hot coolant can cause severe burns.

Figure 3:

12. Retract the locking pins.

• The locking pins prevent turret rotation during transport and loading or unloading from a truck or trailer. There are two pins; one on each side, at the base of the turret, at the front of the machine.

a. Lift the locking pin with the pin stop rod. b. insert the snap pin into the bottom hole.

Locking pins must be engaged for loading or unloading the machine onto

NOTE:

a truck or trailer, and during transport.

Locking Pin

Page 6 Operator Manual

Page 11

Pre-Operation Safety Inspection 104044-021 AB62 Work Platform - European Model

CAUTION

WARNING

YSTEM

1. Move the machine to a firm level surface with room to fully elevate and extend the platform.

2. Before performing the following tests, check the area around the machine and overhead for obstructions, holes, drop-offs, and debris.

3. Ensure that the locking pins are retracted (refer to Figure 3 on page 6).

Attempting to rotate the turret with locking pins engaged may cause damage to the machine.

4. Turn the chassis key switch to the left (CHASSIS).

5. Pull out the Emergency Stop switches to the ON position at the chassis control panel and at the platform control panel.

6. Turn the key switch ON.

a. Wait for Glow Plug light to go off. When the Glow Plug light goes off, start engine.

7. Push in the Chassis Emergency Stop button; the engine should stop. Return the Chassis Emergency Stop button to the ON position, and start the engine.

8. Push in the Platform Emergency Stop button; the engine should stop. Return the Platform Emergency Stop button to the ON position, and start the engine.

9. Make sure that the Function Speed Control (on the platform controls) is not at zero.

• Operate each function switch on the lower control panel to raise/lower, extend/retract, rotate left/right, each section of the elevating assembly, and observe the operation of the machine.

• All functions should operate through full cycle smoothly.

10. Stop the engine.

11. Turn chassis key switch to the right (PLATFORM).

12. Mount the platform, lower the bar, and attach an approved fall restraint to the designated platform anchorage point. Attach only one fall restraint to each point.

13. Start the engine.

14. Without depressing the foot switch, move the Drive Control handle; the machine should not function.

15. Depress the foot switch and move the Drive Control handle forward and reverse. Observe that the proportional functions operate smoothly, and that the brakes apply quickly after the control is released.

16. While depressing the foot switch, operate the steer switch to left and right. Observe that the steering wheels turn properly.

17. While depressing the foot switch, turn the Function Speed Control knob to the desired setting, and operate the boom controls.

• Observe that the boom operates smoothly, and that the upper boom, jib, turret rotation, platform level, riser, and boom extend operate proportionally in conjunction with the Function Speed Control knob.

• Observe that the platform maintains level when the boom is elevated.

18. With the upper boom elevated 0,3 m ( speed is limited to creep (0,3 m [

19. With the upper boom extended 0,3 m ( speed is limited to creep (0,3 m [

20. Press the Service Horn button. Observe that the horn is audible.

UNCTION

NSPECTION

1 ft.

), operate the Drive Control handle. Observe that the drive

1 ft.

] per second). Lower the upper boom to the stowed position.

1 ft.

] per second). Retract the upper boom to the stowed position.

), operate the Drive Control handle. Observe that the drive

DO NOT use a machine that is damaged or malfunctioning. Tag and remove the unit from service until it is repaired.

Operator Manual Page 7

Page 12

104044-021 AB62 Work Platform - European Model Operation

WARNING

PERATION

Before operating the work platform ensure that:

• Pre-operation and safety inspection has been completed, and any discrepancies have been corrected.

• The operator has been thoroughly trained on the operation of the machine.

• The work area is clear of all obstructions, holes, drop-offs, or persons in the route of travel.

• The surface is capable of supporting wheel loads.

Always wear an approved fall restraint properly attached to the designated platform anchorage point when driving or elevating the machine. Attach only one fall restraint to each anchorage point.

ONTROLLER

Refer to Figure 2 on page 5 for control locations.

UNCTIONS

Figure 4:

Typical Fall Restraint Anchorage Point

MERGENCY

At any time during operation, press the Emergency Stop button to stop all functions in an emergency.

ERVICE

At any time during operation, press the Service Horn button to sound an audible warning if necessary.

TARTING THE

ROM THE LOWER CONTROLS

1. Turn platform controls key to the ON position.

• Diesel: wait for the Glow Plug light to go off.

2. Turn the chassis controls key switch to the left (CHASSIS) position.

3. Press the Start button to crank the engine. Release when the engine starts.

ROM THE PLATFORM

1. Turn the chassis controls key switch to the right (PLATFORM) position.

2. Turn platform controls key to the ON position.

• Diesel: wait for the Glow Plug light to go off.

3. Turn the platform lever switch fully clockwise to crank the engine. Release when the engine starts.

TOP

ORN

NGINE

ONTROLS

Page 8 Operator Manual

Page 13

Operation 104044-021 AB62 Work Platform - European Model

RIVING

ITH BOOM LOWERED

1. Turn the chassis key switch to PLATFORM, and turn on (turn clockwise) the chassis Emergency Stop switch.

2. Mount the platform, close and latch the gate.

3. Attach an approved fall restraint to the designated platform anchorage point. Attach only one fall restraint to each point.

4. Start the engine.

5. Check that the area around and above the work platform is clear of obstructions, holes, drop-offs, persons in the route of travel, and that the surface is capable of supporting wheel loads.

6. Depress the foot switch and move the drive control handle forward to travel forward and reverse to travel in the reverse direction.

When the boom is rotated to the front of the

NOTE:

chassis (steering wheels aft), directions of travel and steering will be reversed. Observe the colorcoded arrows on the control panel near the drive control handle and on the chassis. They will indicate the direction of travel when the drive control handle is moved.

Figure 5:

Direction Arrows on Chassis

ITH BOOM

Travel with the boom elevated is restricted to firm, level surfaces only.

When driving with the boom elevated or extended, the machine will travel at creep speed (0,3 m [

LEVATED

1 ft.

] per second).

Operator Manual Page 9

Page 14

104044-021 AB62 Work Platform - European Model Operation

WARNING

TEERING

1. Depress the foot switch.

2. Push the steering rocker switch to the left to turn left.

3. Push the steering rocker switch to the right to turn right.

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

NOTE:

switch.

When the boom is rotated to the front of the chassis (steering wheels aft), directions of travel and steering will

NOTE:

be reversed. Observe the color-coded arrows on the control panel near the drive control handle and on the chassis. They will indicate the direction of travel when the drive control handle is moved. Refer to Figure 5 on page 9.

OSITIONING

Positioning the platform as close as possible to the work area requires some planning. First, you must survey the work site to find a suitable place to park the machine. This must be a firm, level area as close as possible to the work area. Take into consideration all obstructions on the ground and overhead, and avoid them.

Once you have moved the machine to a firm, level surface as near as possible to the work area, follow the instructions on the following pages to position the platform as close to the work area as possible.

Always, before operating any function, check the area around and overhead for any obstructions or electrical conductors.

THE

LATFORM

NEVER exit the platform while the boom is elevated. Keep both feet on the platform floor at all times.

ULTIFUNCTION

The UpRight AB62 employs the use of multifunction controls. This means that the riser or boom extension will function at full speed while simultaneously operating the upper boom, jib, turret, or rotating the platform.

If the tilt alarm sounds, lower and retract the boom, then drive the machine to a firm, level surface before elevating.

OWER

All boom functions will operate at the speed selected by the upper speed control functions.

NOTE:

1. Turn ON the platform ignition switch.

2. Turn the chassis key switch to the left (chassis).

3. With the engine running, operate the boom control switches to position the platform.

• If slower operation is desired, move the Function Speed (HI/LOW) switch to the low position (see

4. The Hi/Low switch will select between maximum speed and a lower fixed Function Speed, depending on the position of the platform Function Speed control.

ONTROL

The platform ignition switch must be turned on in order to operate the lower controls.

Figure 2 on page 5).

ONTROLS

PERATION

Page 10 Operator Manual

Page 15

Operation 104044-021 AB62 Work Platform - European Model

WARNING

PPER

1. Turn the chassis key switch to the left (platform).

2. Turn ON the platform ignition switch.

DO NOT operate the machine if the platform does not maintain level when elevated.

NOTE:

1. Set the Function Speed control dial to the desired setting. Rotate the dial clockwise to increase speed,

2. While depressing the foot switch, push the Platform Level control switch forward to swing the platform

ONTROL

EVELING

Platform leveling should be done only to calibrate the automatic leveling system.

counterclockwise to decrease. If you are not sure what speed to use, start out slow; the speed can be varied while operating the function.

upward, rearward to swing the platform downward. Release the switch to stop leveling.

THE

PERATION

LATFORM

OTATING

1. Set the Function Speed control dial to the desired setting. Rotate the dial clockwise to increase speed, counterclockwise to decrease. If you are not sure what speed to use, start out slow; the speed can be varied while operating the function.

2. While depressing the footswitch, push the Turret Rotation control lever right to rotate counterclockwise; left to rotate clockwise. Release the switch to stop rotation. Observe the area around the boom when rotating the turret to avoid any obstructions.

LEVATING

1. Set the Function Speed control dial to the desired setting. Rotate the dial clockwise to increase speed, counterclockwise to decrease.

2. While depressing the foot switch, push the Riser control lever forward to elevate the riser, rearward to lower the riser. Release the control lever to stop elevating/lowering.

LEVATING

THE

URRET

PPER

ISER

OOM

2. While depressing the foot switch, push the upper Boom control lever forward to elevate the upper boom, rearward to lower the upper boom. Release the control lever to stop elevating/lowering.

Operator Manual Page 11

Page 16

104044-021 AB62 Work Platform - European Model Operation

XTENDING

2. While depressing the foot switch, push the Boom Extend control lever rearward to extend the boom, forward to retract the boom. Release the control lever to stop extending/retracting.

LEVATING

2. While depressing the foot switch, push the Jib control lever forward to elevate the jib, rearward to lower the jib. Release the control lever to stop elevating/lowering.

THE

PPER

OOM

OTATING

1. While depressing the foot switch, push the Platform Rotate control lever right to go counterclockwise and left to go clockwise. Release the lever to stop rotation.

THE

LATFORM

Page 12 Operator Manual

Page 17

Emergency Operation 104044-021 AB62 Work Platform - European Model

WARNING

CAUTION

WARNING

Drive Hub

Center Cap

MERGENCY

FTER

OWING

In the event of a powered function failure, the elevating assembly may be lowered by using the Auxiliary Power Unit. Hold in the Auxiliary Power button and operate the Lowering Controls as normal.

NEVER climb down the elevating assembly. If controls do not respond, ask someone on the ground to lower the boom manually.

1. Ensure that the platform is fully lowered.

2. Park the machine on level ground, preferably under cover

3. Secure against vandals, children or unauthorized operation.

4. Turn the upper key switch to OFF.

5. Turn the lower key switch to the center position (OFF).

6. Remove all keys to prevent unauthorized operation.

PERATION

ACH

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 trailer for transportation

Figure 6:

DO NOT move the machine faster than 5 km/h (3 mph). Faster speeds will damage drive components and void warranty.

Never disengage the hubs unless the wheels are properly chocked and the machine is on a level surface.

1. Chock the wheels.

2. Ensure that the platform is fully lowered, and that the turret is rotated so that the platform is to the rear of the machine.

3. Attach a chain or cable of sufficient strength for towing the machine to the front or rear tie down lugs.

4. Refer to Figure 6 and disengage all four drive hubs. Remove the two screws and center cap. Re-install the center cap in the opposite direction.

When hubs are disengaged, the brakes are ineffective. The machine will roll freely.

NOTE:

Disengaging Drive Hub

Chock the wheels before disengaging the hubs. The machine may roll.

5. When ready to move the machine, remove the chocks. Tow or winch into position and replace the chocks.

6. Engage all four drive hubs by returning the center caps to their original orientation.

Operator Manual Page 13

Page 18

104044-021 AB62 Work Platform - European Model Transportation

CAUTION

WARNING

Chassis Tie Down Lifting Lug (typ.)

Wooden Block 20 cm x 10 cm x 75 cm (8 in. x 4 in. x 28 in.)

RANSPORTATION

BY C

1. Ensure that the boom is fully lowered and retracted.

2. Ensure that the locking pins are engaged (refer to Figure 3 on page 6).

3. Attach straps to the Chassis Lifting lugs only. Ensure that the straps are adjusted properly to keep the

BY T

1. Ensure that the boom is fully lowered and retracted.

2. Ensure that the locking pins are engaged (refer to Figure 3 on page 6).

RIVE ONTO TRANSPORT VEHICLE

1. Raise the jib before the machine starts up or down the ramp to avoid the platform contacting ground.

2. Maneuver the machine onto the bed of the truck/trailer.

1. When winching, follow instructions for “To w i n g ” on page 13. Attach the winch cable to the front tie down

Do not winch the machine faster than 5 km/h (3mph). Faster speeds will damage drive components and void warranty.

RANE

unit level when lifting.

RUCK

INCH ONTO TRANSPORT VEHICLE

lugs.

RAILER

2. After winching, ensure that the wheels are chocked.

ECURE TO TRANSPORT VEHICLE

1. Secure the machine to the transport vehicle using chains or straps of adequate load capacity attached to chassis tie down lugs (refer to “Specifications” on page 20).

2. Place a wooden block, 20 cm x 10 cm x 75 cm ( platform support braces as shown.

3. Attach a ratchet strap under the platform floor grating, and over the support braces. Tighten securely; do not overtighten.

NEVER elevate the machine while on a truck or trailer.

7.5 in. x 4 in. x 28 in.

), under the

Figure 7:

Securing the Machine for Transportation

Page 14 Operator Manual

Page 19

Daily Maintenance 104044-021 AB62 Work Platform - European Model

Fuel Cap

Hydraulic Fluid Filler Cap

Level Gauge

AILY

AINTENANCE

UELING

Stop the engine and turn off the key switch before re-fueling.

IESEL

1. Open the left turret cover, then open the fill cap.

2. Fill to capacity with diesel motor fuel only, grade #1-D or #2-D. Use distillate fuel only; do not use residual or blend.

• Fuel tank full capacity is 159 liters

3. Install the cap.

(42 US gallons

Figure 8:

Fuel Tank

YDRAULIC

1. Open the turret cover and check the fluid level at the sight gauge with the boom stowed and retracted; engine running or stopped.

Never add hydraulic fluid if the boom is elevated or extended.

NOTE:

2. If necessary, fill to capacity with clean ISO compatible hydraulic fluid.

• Normal Temperature, above 0° C (

• Low Temperature, below 0° C (

• Extreme Temperature, below -17° C (

3. Clean the area around the cap before opening.

4. Open the filler/breather cap to add hydraulic fluid.

5. Install the cap.

LUID

32° F

)ISO #46.

)ISO #32.

0° F

)ISO #15.

Figure 9:

Hydraulic Fluid Tank

Operator Manual Page 15

Page 20

104044-021 AB62 Work Platform - European Model Daily Maintenance

WARNING

ATTERY

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 >

kg (62 lbs.) each.

Check battery fluid level daily, especially if the work platform is being used in a warm, dry climate.

AINTENANCE

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

The battery and cables should be inspected regularly for signs of cracks in the case, electrolyte leakage and corrosion of the terminals. Inspect 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.

IRES

Tire selection can affect the stability of the machine. Use only tires supplied by the manufacturer unless approved by the UpRight in writing.

Check air filled tire pressure daily. Inflate to 5,5 bar ( Optional poly-filled tires do not require air pressure.

3/8 in.

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

80 psi

Page 16 Operator Manual

Page 21

Inspection and Maintenance schedule 104044-021 AB62 Work Platform - European Model

AINTENANCE

ABLE KEY

Y = Yes/Acceptable

N = No/Not Acceptable

R = Repaired/Acceptable

REVENTATIVE

AINTENANCE

EPORT

Date: _______________________________________

Owner: _____________________________________

Model No: ___________________________________

Serial No: ___________________________________

Serviced By: _________________________________

COMPONENT INSPECTION OR SERVICES Y N R

Battery Check electrolyte level

Engine Oil and Filter

Check level and condition

Check for leaks

Engine Fuel System

Check fuel level Check for leaks

Check air cleaner

Engine

Coolant

Check coolant level (with engine cold)

Hydraulic Fluid Check fluid level

Hydraulic System Check for leaks

Emergency Hydraulic

System

Operate the emergency lowering valve and

check for serviceability

Controller Check operation of all controls

Control Cable

Check the exterior of the cable for pinching,

binding or wear

Platform Floor and

Rails

Check fasteners for proper torque

Check welds for cracks

Check condition of platform Check condition of anchorage points Check condition of operator manual

Tires

Check for damage

Check air pressure (5,5 bar

[80 psi]

)

Hydraulic Pump Check for hose fitting leaks

Hydraulic Drive

System

Check hydraulic drive motor operation

Check hoses,fittings, and valve block for leaks

Torque Hubs Check for leaks

Steering System Check for missing/loose retainers

Elevating Assembly

Inspect for structural cracks

Check members for deformation

Chassis

Check hoses for pinch or rubbing points

Check welds for cracks

Tur r et Check ring gear for proper lubrication and wear

Entire Unit Check for and repair collision damage

Labels

Check for peeling, missing, or unreadable labels

& replace

COMPONENT INSPECTION OR SERVICES Y N R

NSPECTION

AND

AINTENANCE

SCHEDULE

The complete inspection consists of visual and operational checks, together with all necessary minor adjustments to assure proper performance. Daily inspection will prevent abnormal wear and prolong the life of all systems.

A thorough inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures at regular intervals. Refer to the Service Manual for the Preventative Maintenance Check List.

Please photocopy the Daily Preventative Maintenance Check List and use the table as a checklist when inspecting the machine for service.

AILY

REVENTATIVE

AINTENANCE

HECK

IST

Operator Manual Page 17

Page 22

104044-021 AB62 Work Platform - European Model Safety Labels

1) 061205-003

6) 101210-000

7) 066555-000

9) 101208-000

10) 101203-001

11) 027898-001

13) 010076-001

19) 062557-012

23) 066554-000

24) 068979-000

26) 104562-000

29) 104330-000

30) 066562-005

32) 068632-000

34) 068635-000

35) 068637-000

36) 068637-001

40) 062814-000

49) 100339-099

51) 100104-000

52) 100100-000

53) 100102-000

54) 100103-000

55) 030768-002

56) 100105-000

57) 100101-000

33) 068633-001

Model______________ Serial number:___________ Machine weight _______kg Mfg . date:_________ Maximum wheel load:________ Maximum allowable incline of machine when elevated:_____deg. Occupants and equipment must not exceed the rated maximum load:_____kg Maximum platform occupants: _____ Maximum allowable sIde force on platform:_____N Maximum platform height:______m Maximum platform reach:______m Maximum allowable wind speed: ______m/s=Beaufort scale_____ Maximum hydraulic system pressure:_____bar Maximum system voltage: _______Vdc This machine is manufactured to comply with Machinery directive 89-392/CEE CAUTION: CONSULT OPERATOR'S MANUAL BEFORE USE.

061205-003

THE AERIAL WORK PLATFORM IS NOT ELECTRICALLY INSULATED

STOP WHEN TILT ALARM SOUNDS

AFETY

ABELS

Proper label installation is required. All of these labels shall be present and in good condition before operating the work platform. Be sure to read, understand and follow these labels

BEFORE

operating the work

platform.

Figure 10:

Warning Labels

Page 18 Operator Manual

Page 23

Safety Labels 104044-021 AB62 Work Platform - European Model

54 53

52 51

Figure 11:

Safety Labels Locations

Operator Manual Page 19

Page 24

104044-021 AB62 Work Platform - European Model Specifications

PECIFICATIONS

Specifications are subject to change without notice. Hot weather or heavy use may affect performance.

ITEM

Height

Working Height Max. Platform Height Platform step in Height Up and Over Height Drivable Height

Horizontal Outreach 10,7 m [ Turret Rotation 360° Continuous Platform Rotation 180° Tail Swing 0 Jib Length 1,9 m [ Jib Arc 140° Inside Turning Radius 2,5 m [ Outside Turning Radius 5.5 m [ Drive Speed

(boom stowed and lowered) Drive Speed (Elevated) 0,96 km/h [ Maximum Gradeability 22° [ Dimensions (boom stowed)

Platform Size, Standard 1,8 m [ Platform Size, Optional 2,4 m [ Guardrails Toeboard

Platform Capacity (Maximum) 227 kg [ Occupants (Maximum) 2 Weight 10,614 kg [ Overall Height 2,5 m [

Overall Length

Overall Width 2,3 m [ Wheel Base 2,3 m [

Ground Clearance

Power Source

Diesel

System Voltage 12 VDC Maximum Hydraulic Pressure 345 bar [ Controls Electric Proportional Tires

Size Pressure

6 ft.

8 ft.

]

Specification Reach Envelope Diagram

68 ft.

20,7 m [ 18,9 m [

343 mm [

9,1m [

18,9 m [

HIGH

6,8 km/h [

LOW

2,6 km/h [

1 m x 1,8 m [ 1 m x 2,4 m [

1,4 m [

152 mm [

8,2 m or 7,2 m Minimum

27 ft. or 23 ft. 6 in. Minimum

[

CENTER

0,46 m [

AXLE

0,32 m [

Perkins 704-30 – 63 HP

19 x 15 NHS - 14 PLY

5,5 bar [

]

62 ft.

]

13.5 in.

30 ft.

]

62 ft.

]

35 ft.

]

6ft. 4 in.

8 ft.

]

18 ft.

]

4.25 mph

1.6 mph

0.6 mph

40%

]

39 in. x 72 in. 39 in. x 96 in.

45 in.

]

6 in.

]

500 lbs.

23,400 lbs.

8 ft. 2 in.

7 ft. 7.5 in.

8 ft. 6 in.

18 in.

12.5 in.

5000 PSI

80 PSI

]

] ]

]

Page 20 Operator Manual

Page 25

ABLE

Section 1

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.

ONTENTS

1-1 Hazard Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Workshop Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-4 Date Code Identification on Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-6 UpRight Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-7 Hydraulic Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-8 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-9 Electric Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-10 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-11 Floor Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

1-12 Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1-13 Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

NFORMATION

IST OF

IGURES

Figure 1-1: UpRight Connector Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Figure 1-2: UpRight Male Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Figure 1-3: UpRight Female Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Figure 1-4: Locking Finger, UpRight Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-5: Heavy Duty UpRight Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-6: Electric Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 1-7: Electric Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1-8: Contact Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Figure 1-9: Occupied Surface Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

ABLES

Table 1-1: Torque Specifications for Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table 1-2: Torque Specifications for SAE Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table 1-3: Torque Specifications for Metric Fasteners, U.S. Customary Units . . . . . . . . . . . . . . . . . . . 1-4

Table 1-4: Torque Specifications for Metric Fasteners, SI Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

Table 1-6: Battery Charging, UpRight Electric and BiEnergy Machines . . . . . . . . . . . . . . . . . . . . . . . 1-14

Table 1-7: Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Service Manual Page 1-1

Page 26

Section 1 - General Information Hazard Indicators

DANGER

! !

WARNING

CAUTION

WARNING

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.

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

NDICATORS

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.

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.

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 27

Torque Specifications Section 1 - General Information

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.

For other preloading methods or fasteners consult UpRight Engineering Department.

NOTE:

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

ORQUE TABLES

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.

To rq ue

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

Clamp

Load

Tightening

To rq ue

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 28

Section 1 - General Information Torque Specifications

8.8

10.9

12.9

8.8

10.9

12.9

Table 1-3:

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

Clamp

Load

Grade 10.9

Tightening Torque

Grade 8.8

Nominal

Thread

Clamp

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

3.5------1,10922.930.5

Load

3------82314.619.5

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

Grade 12.9

Tightening Torque

Table 1-4:

Torque Specifications for Metric Fasteners, SI Units

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

Grade 12.9

Tightening Torque

Page 1-4 Service Manual

Page 29

Date Code Identification on Hoses Section 1 - General Information

1-4 D

GGGG

AAAATTTTEEEESSSS

PPPP

AAAARRRRKKKKEEEERRRR

DDDD

AAAAYYYYCCCCOOOO

1-5 S

ATE

uses an eight digit code: 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.

PECIAL

ODE

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

• 0-69 bar (

• 0-207 bar (

• 0-414 bar (

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

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

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

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

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

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

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

• 0-25 kg (

OOLS

0-1000 psi

0-3000 psi 0-6000 psi

0-50 Lbs.

DENTIFICATION

Plant, Month, Day, Year

) Hydraulic Pressure Gauge with Adapter Fittings

) Hydraulic Pressure Gauge with Adapter Fittings ) Hydraulic Pressure Gauge with Adapter Fittings

) Chain Tension Scale (UpRight P/N 107078-000)

OSES

UPR

IGHT LIFT TOOL LIST

• 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 30

Section 1 - General Information UpRight Connectors

Large KitSmall Kit

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

)

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 31

UpRight Connectors Section 1 - General Information

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 the grip on the contact.

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

RIMPING

1. Strip 6 mm (

Complete crimping instructions are included in each Field Kit.

NOTE:

OCKING

¼ in.

) from the wire.

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 32

Section 1 - General Information Hydraulic Manifold Repair

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

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

NOTE:

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.

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

NOTE:

tapping on the ball with a brass drift punch.

1. Install fittings, plugs, springs, balls, and orifices. Use one drop of Locktite #242 on each screw-in orifice.

2. Install valves.

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 33

Cylinder Repair Section 1 - General Information

WARNING

1-8 C

YLINDER

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

EMOVAL

Refer to the

NOTE:

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 (

EPAIR

Service and Repair

.007 in.

) should be replaced.

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 34

Section 1 - General Information Electric Motors

DC Power Supply

Voltage Meter

Ammeter

Brushes and springs in their final position

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

Keep fingers clear of this space.

DC Motor

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.

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

Do not Make a Permanent Con-

Figure 1-6:

Electric Motor Service

Page 1-10 Service Manual

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.

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

NOTE:

Permanent distortion or other damage will result.

Page 35

Electric Motors Section 1 - General Information

Counterclockwise

Rotation

Buss Bar

Brushes

Buss Bar

Typical pump motor viewed from rear.

Brushes and springs in their final position

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

NOTE:

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

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.

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

NOTE:

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

Figure 1-7:

Electric Motor Brushes

1. Install new brushes and be sure they are free in the holder. Install the brush with the lead wires positioned as when received. Raise all brushes to the locked position. (See Figure 1-7 and

Inspection

Step 3.).

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

3. Place the bearing spring into the bearing bore.

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

Do not re-use bearings which have been removed

NOTE:

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

5. Set the brushes into their final position as shown in Figure 1-7.

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 name-

Service Manual Page 1-11

plate full load current. Anything higher indicates:

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

• Faulty armature.

Page 36

Section 1 - General Information Battery Maintenance

CAUTION

WARNING

1-10 B

ATTERY

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

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 (

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.

AINTENANCE

3/8 in.

) above plates, add distilled water only.

Page 1-12 Service Manual

Page 37

Battery Maintenance Section 1 - General Information

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 1-16).

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.

ATTERY CELL EQUALIZATION

The specific gravity of the electrolyte in the battery cells should be equalized monthly. To do this, charge batteries as outlined in ‘Battery Charging” on page 1-16. 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.

HECK

Table 1-5:

PECIFIC

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

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

Specific Gravity and Battery Voltage

SPECIFIC GRAVITY VOLTS DC

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

OAD TESTING BATTERY PACKS

1. Fully charge the battery pack.

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

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

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

3. Measure the potential across each battery.

4. Measure the potential across the entire battery pack.

5. Compare the measured results

RAVITY

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

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

Service Manual Page 1-13

Page 38

Section 1 - General Information Battery Maintenance

CAUTION

WARNING

ATTERY

HARGING

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

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.

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

NOTE:

Table 1-6:

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.

Battery Charging, UpRight Electric and BiEnergy Machines

Charger Display AC Charging Current Charging Indicator Charger Shutdown

068574-000 8 Amp - 115 VAC 069112-000 4 Amp - 230 VAC

063944-001 7 Amp - 115 VAC 063948-003 4 Amp - 230 VAC

069199-000

069199-001

Dual Voltage

8 Amp - 115 VAC 4 Amp - 230 VAC

Ammeter

• Charging current is displayed on ammeter.

• Current drops off as batteries charge.

Green Light

• ON during charging cycle.

• Blinking at charge completion.

Three Lights

• 0 - 50% charge:

• 50% - 75% Charge:

• 75% - 100% Charge:

• Charge Complete

First Light -BlinkingSecond and Third Light -OFF-

First Light -ONSecond Light -BlinkingThird Light -OFF-

First and Second Light -ONThird Light - Blinking-

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 39

Battery Maintenance Section 1 - General Information

CAUTION

WARNING

ATTERY

HARGER

ROUBLESHOOTING

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.

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.

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

NOTE:

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.

• No Lights ON.

• 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.

• AC outlet is bad.

• Extension cord is bad

• Plug is bad or wired wrong.

• AC wire is broken.

Check and repair as necessary.

• missing.

• corroded.

• wrong polarity.

• DC wire broken.

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 40

Section 1 - General Information Floor Loading

TIRE LUG TIRE OUTRIGGER

CONTACT AREA

LENGTH

WIDTH

1-11 F

LOOR

Floor Loading is defined as pressure imposed onto load-bearing surfaces, and can be measured as

Localized Pressure

machine. TOTAL WEIGHT = MACHINE WEIGHT + MAXIMUM PLATFORM CAPACITY. Refer to the machine specifications or contact UpRight or your UpRight dealer.

OCALIZED

KG/CM

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

Occupied Pressure

RESSURE

² (PSI)

kilograms

). It is the pressure exerted onto a small

The formulas shown here are for vertical lift

. To calculate Floor Loading, find the Total Weight of the

Figure 1-8:

Contact Area

EASURE THE CONTACT

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 THE LOCALIZED PRESSURE

Find the pressure exerted at each contacting surface.

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

NOTE:

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

BAR (PSF)

Occupied Pressure is measured in

. It is the total pressure imposed onto the

must not exceed

square foot)

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

REA

RESSURE

bar (pounds per

the maximum load that the surface can support.

Figure 1-9:

Occupied Surface Area

OCCUPIED PRESSURE = TOTAL WEIGHT ÷ (LENGTH X WIDTH)

Page 1-16 Service Manual

Page 41

Hydraulic Fluid Section 1 - General Information

CAUTION

1-12 H

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

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

• DO NOT fill above operating range.

• DO NOT add fluid when the platform is elevated.

• Viscosity Grade: . . . . . . . . . . . . . . . . . ISO 46 High V.I. (similar to SAE 10W-30).

• Viscosity index: . . . . . . . . . . . . . . . . . . 152.

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

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

EVEL

424

LUID

YDRAULIC

LUID

OBIL

DTE 13 M

• Viscosity Grade: . . . . . . . . . . . . . . . . . ISO 32 High V.I. (similar to SAE 5W-20).

• Viscosity index: . . . . . . . . . . . . . . . . . . 140.

• Operating Range: . . . . . . . . . . . . . . . . -18° C to +80° C (-4° F to +176° F) Reservoir Temperature.

• Ambient Conditions*: . . . . . . . . . . . . . . -18° C to +30° C (-4° F to +86° F).

OBIL

DTE 11 M

• Viscosity Grade: . . . . . . . . . . . . . . . . . ISO 15.

• Viscosity index: . . . . . . . . . . . . . . . . . . 140.

• Operating Range: . . . . . . . . . . . . . . . . -35° C to +45° C (-30° F to +115° F) Reservoir Temperature.

• Ambient Conditions*: . . . . . . . . . . . . . . -35° C to +20° C (-30° F to +70° F).

OBIL

EAL E

For use where a

• Viscosity Grade: . . . . . . . . . . . . . . . . . ISO 46 High V.I. (similar to SAE 10W-20).

• Viscosity Index: . . . . . . . . . . . . . . . . . . 153.

• Operating Range: . . . . . . . . . . . . . . . . -14° C to +90° C (+6° F to +195° F) Reservoir Temperature.

• Ambient Conditions*: . . . . . . . . . . . . . . -14° C to +41° C (+6° F to +105° F).

• Synthetic Ester Base.

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

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 42

Section 1 - General Information Long Term Storage

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.

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.

Internal Combustion Models: Electric And BiEnergy Models:

TORAGE

Service the engine according to the manufacturers recommendations.

Remove the batteries and place them in alternative service.

Page 1-18 Service Manual

Page 43

Section 2

WARNING

DANGER

! !

ERVICE

This section contains instructions for the service and repair of the Work Platform. 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 work platform, and help in diagnosing and repair of the machine.

Be sure to read, understand and follow all information in the Operator Manual before attempting to operate or perform service on any Work Platform.

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

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

AND

EPAIR

ABLE

ONTENTS

2-1 Supporting the Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Installation of Elevating Assembly Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Removal of Elevating Assembly Brace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Preventative Maintenance Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Turret Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Lubricating Turret Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hydraulic Fluid and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-4 Special Switches and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Linkage Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-5 Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-6 Setting Hydraulic Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

High Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Low Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Counterbalance Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-7 Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Changing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Torque Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Torque Hub Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Disassembly of Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Assembly of Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Carrier Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Sealing Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

104045-021 - AB62 Work Platform - European Model Page 2-1

Page 44

IST OF

Section 2 - Service and Repair

2-8 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-9 Setting the Backlash on the Rotational Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-10 Rotary Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

IGURES

Figure 2-1: Supporting the Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-2: Elevating Assembly Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-3: Turret Bearing Grease Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-4: Turret Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-5: Hydraulic Fluid Resevoiur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-6: Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-7: Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-8: Linkage Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-9: Level Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-10: Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Figure 2-11: Torque Hub Assembly, Remove and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Figure 2-12: Torque Hub Assembly, Seal kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Figure 2-13: Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-14: Riser Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-15: Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Figure 2-16: Extend Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Figure 2-17: Axle Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 2-18: Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 2-19: Jib Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Figure 2-20: Setting Rotational Gear Backlash (Viewed from bottom of turret) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Figure 2-21: Rotary Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Page 2-2 104045-021 - AB62 Work Platform - European Model

Page 45

Section 2 - Service and Repair Supporting the Elevating Assembly

WARNING

2-1 S

UPPORTING

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

Never perform service on the boom without first supporting the boom with an overhead lifting device with a minimum capacity of two tons.

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

NSTALLATION

1. Park the work platform on a firm, level surface.

2. Fully retract and lower the upper boom.

3. Verify that the platform emergency stop switch is ON.

4. Turn platform/chassis switch to CHASSIS.

5. Using the Riser Raise/Lower Switch, elevate the elevating assembly.

6. Use a brace with a minimum capacity of two tons, to support the elevating assembly.

7. Using the Riser Raise/Lower Switch gradually lower the elevating assembly until the brace is supporting the elevating assembly as shown in Figure 2-2.

THE

LEVATING

SSEMBLY

Figure 2-1:

Supporting the Elevating Assembly

RACE

Figure 2-2:

Elevating Assembly Brace

EMOVAL RACE

1. Using the Riser Raise/Lower Switch, gradually raise the elevating assembly it is free of the support.

2. Remove the support.

3. Using the Riser Raise/Lower Switch, completely lower the elevating assembly.

104045-021 - AB62 Work Platform - European Model Page 2-3

LEVATING

SSEMBLY

Page 46

Preventative Maintenance Section 2 - Service and Repair

WARNING

2-2 P

REVENTATIVE

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.

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

maintenance while the platform is elevated.

Please photocopy the Preventative Maintenance Check List and use the table as a checklist when inspecting the machine for service.

AINTENANCE

Page 2-4 104045-021 - AB62 Work Platform - European Model

Page 47

Section 2 - Service and Repair Preventative Maintenance

AINTENANCE

ABLE KEY

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

REVENTATIVE

AINTENANCE

EPORT

Date: _______________________________________

Owner: _____________________________________

Model No: ___________________________________

Serial No: ___________________________________

Serviced By: _________________________________

Service Interval _______________________________

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Battery

Check electrolyte level Daily Clean exterior 3m Clean terminals 3m

Engine Oil and

Filter

Check level and condition Daily Check for leaks Daily Change oil & filter (Diesel) 500h Change oil & filter (Gas) 200h

Engine Fuel

System

Check fuel level Daily Check for leaks Daily Replace fuel filter 6m Check air cleaner Daily

Engine

Coolant

Check coolant level (with engine cold) Daily Replace coolant 3m

Hydraulic Fluid

Check fluid level Daily Change filter 6m Drain and replace with ISO 46 compatible 2y

Hydraulic System

Check for leaks Daily Check hose connections 30d Check hoses for exterior wear 30d

Emergency

Hydraulic System

Operate the emergency lowering valve and check for serviceability

Daily

Controller Check operation of all controls Daily

Control Cable

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

Daily

Platform Floor

and Rails

Check fasteners for proper torque Daily Check welds for cracks Daily Check condition of platform Daily Check condition of anchorage points Daily Check condition of operator manual Daily

Tires

Check for damage Daily Check lug nuts

(torque to 190 ft. lbs.[257Nm])

30d

Check air pressure (80 psi [5.5 bar]) Daily

Hydraulic Pump

Wipe clean 30d Check for leaks at mating surfaces 30d Check for hose fitting leaks Daily Check mounting bolts for proper torque 30d

Hydraulic Drive

System

Check hydraulic drive motor operation Daily Check hoses,fittings, and valve block for

leaks

Daily

Torque Hubs

Check for leaks Daily Check oil level 250h/6m Change Oil after break-in period 50h/30d Change Oil (SAE 90 wt. gear oil) 2000h/2y

Steering System

Check hardware & fittings for proper torque

Check linkage for wear areas 30d Oil all pivot points 30d Check steering cylinder for leaks 30d Check for missing/loose retainers Daily

Elevating

Assembly

Inspect for structural cracks Daily Check pivot points for wear 30d Check pivot pin retaining bolts for proper

torque

30d

Check members for deformation Daily

Chassis

Check hoses for pinch or rubbing points Daily Check component mounting for proper

torque

Check welds for cracks Daily

Lift Cylinder

Check the cylinder rod for wear 30d Check pivot pin retaining bolts for proper

torque

30d

Check seals for leaks 30d Inspect pivot points for wear 30d Check fittings for proper torque 30d

Tur r et

Check ring gear for proper lubrication and wear

Daily

Lubricate ring gear (MoS2 grease)

150h/3m

Entire Unit

Check for and repair collision damage Daily Check fasteners for proper torque 3m Check for corrosion-remove and repaint 6m Lubricate 30d

Labels

Check for peeling, missing, or unreadable labels & replace

Daily

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

REVENTATIVE

AINTENANCE

HECK

IST

104045-021 - AB62 Work Platform - European Model Page 2-5

Page 48

Lubrication Section 2 - Service and Repair

Grease Fitting

Apply Open Gear Lube

2-3 L

UBRICATION

Refer to the Operator Manual for the lubrication intervals and Figure 2-3 and Figure 2-4 for location of items that require lubrication service.

URRET

The grease fitting for the turret bearing is located at the front of the turret assembly.

1. Wipe the fitting before and after greasing.

2. 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.

3. Wipe off any excess grease.

UBRICATING

Using a brush, apply open gear grease to the turret gears.

EARING

URRET

EARS

Figure 2-3:

Turret Bearing Grease Fitting

Figure 2-4:

Turret Gear

Page 2-6 104045-021 - AB62 Work Platform - European Model

Page 49

Section 2 - Service and Repair Lubrication

CAUTION

Filler/Breather Cap

Fluid Filter

Sight Gauge

Magnetic Drain Plug

YDRAULIC

LUID LEVEL

With the boom fully retracted and the platform fully lowered, check fluid level on sight gauge. If the fluid is NOT in operating range, add hydraulic fluid until fluid is visible in operating range on dipstick or visible in sight gauge. DO NOT fill above operating range or when the platform is elevated.

LUID AND

ILTER

Figure 2-5:

Hydraulic Fluid Resevoiur

LUID AND FILTER

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

The hydraulic fluid may be hot enough to cause burns. Wear safety gloves and safety glasses when handling hot fluid.

2. Provide a suitable container to catch the drained fluid.

3. Remove the drain plug and allow all fluid to drain into the container. Be sure to dispose of fluid properly.

4. Reinstall the drain plug.

5. Remove filter element from filter head.

6. Apply a thin film of clean hydraulic fluid (ISO No.46) to the gasket of the replacement filter.

7. Thread replacement filter onto the filter head until the gasket makes contact then rotate 3/4 of a turn further.

8. Fill the hydraulic fluid tank to operating level on sight gauge with clean ISO compatible hydraulic fluid.

• Normal Temperature, above 0° C (

• Low Temperature, below 0° C (

• Extreme Temperature, below -17° C (

EPLACEMENT

32° F

)ISO #46.

)ISO #32.

0° F

)ISO #15.

104045-021 - AB62 Work Platform - European Model Page 2-7

NGINE

Refer to the engine manufacturer’s documentation that came with your UpRight Work Platform.

Page 50

Special Switches and Sensors Section 2 - Service and Repair

WARNING

Linkage Limit Switch

Proximity Switch

Level Sensor

2-4 S

PECIAL

The work platform is equipped with safety switches. For operator safety, it is important that these switches be working and properly adjusted. The location of the switches is shown in Figure 2-6.

DO NOT attempt to adjust Limit Switches without first blocking the elevating assembly. Refer to “Supporting the Elevating Assembly” on page 2-3

WITCHES

AND

ENSORS

Figure 2-6:

Switch Locations

ROXIMITY

The Proximity switch (also known as the Boom Extend switch) controls machine functions based upon whether the boom is extended or retracted. When the boom is retracted and the platform fully lowered, the Proximity switch bypasses the Level Sensor and closes the circuit to the receiver. This allows high speed travel, cage trim function, and axle float.

EST AND

1. Lower the platform completely.

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

3. If the alarm sounds;

a. elevate the platform and block the elevating assembly, b. adjust the gap to 0,635 cm to 0,95 cm (

c. lower the platform and re-test the level sensor. When the switch is prop-

4. With the platform elevated, repeat step 2. When the

erly adjusted, the alarm will not sound.

DJUST

WITCH

1/4” to 3/8”

switch is properly

Figure 2-7:

Proximity Switch Adjustment

Gap

adjusted, the alarm will sound.

Page 2-8 104045-021 - AB62 Work Platform - European Model

Page 51

Section 2 - Service and Repair Special Switches and Sensors

Adjustment

Screw

Bubble Level

Adjustment

Screws

INKAGE

The Linkage Limit switch (also known as the Platform Down Limit switch) controls machine functions based upon whether the elevating assembly is elevated or lowered. When the platform fully lowered and the boom is retracted, the Linkage Limit switch bypasses the Level Sensor and closes the circuit to the Platform Down Relay. This allows high speed travel and jib function.

IMIT

WITCH

Figure 2-8:

Linkage Limit Switch Adjustment

EST AND

1. Lower the platform completely.

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

3. If the alarm sounds;

a. elevate the platform and block the elevating assembly, b. adjust the position of the switch arm by loosening the adjustment

screw and repositioning the arm,

c. lower the platform and re-test the level sensor. When the switch is properly adjusted, the alarm will not

sound.

4. With the platform elevated, repeat step 2. When the

DJUST

switch is properly adjusted, the alarm will

sound.

EVEL

The Level Sensor (also known as the Tilt Sensor) has three wires: red, power (12v in); black, ground; and white, output (12v out). To verify that the sensor is working properly, there is one red LED under the sensor that indicates the sensor is off level.

EST AND

1. Check tires for proper pressure (not required for poly filled

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

3. Use Inclinometer to ensure that the front and rear of the

4. Adjust the three leveling locknuts until the bubble is cen-

5. Elevate the platform until Linkage Limit switch opens, and

ENSOR

DJUST

tires).

chassis are level within ±1/4°.

tered in the circle on the attached bubble level.

push the Level Sensor base to test the alarm circuit. The red LED should turn on, and the alarm should sound.

Figure 2-9:

Level Sensor Adjustment

104045-021 - AB62 Work Platform - European Model Page 2-9

Page 52

Hydraulic Manifold Section 2 - Service and Repair

2-5 H

YDRAULIC

It is not necessary to remove the manifold to perform all maintenance procedures. Prior to performing maintenance, determine if the manifold needs to be removed.

EMOVAL

1. Disconnect the battery.

2. Tag and disconnect the solenoid valve leads from the terminal strip.

3. Tag, disconnect, and plug hydraulic hoses.

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

5. Remove the manifold block.

EPAIR

Refer to the Assembly.

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

NOTE:

Figure 2-10 on page 2-11 often to aid in disassembly and assembly.

ANIFOLD

General Information

section for instructions on Disassembly, Cleaning and Inspection, and

NSTALLATION

1. Attach manifold assembly to mounting plate with bolts.

2. Connect solenoid leads to terminal strip (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 lift relief and counterbalance valve pressures according to “Setting Hydraulic Pressures” on page 2-12.

Page 2-10 104045-021 - AB62 Work Platform - European Model

Page 53

Section 2 - Service and Repair Hydraulic Manifold

1. Diverter Valve

2. High Flow Proportional Valve

3. Gage Port Plug - High Pressure

4. Steering Valve

5. High Pressure Relief Valve

6. Riser Valve

7. Boom Extend/Retract Valve

8. Low Flow Proportional Valve

9. Low Pressure Relief Valve

10. Boom Raise Valve

11. Platform Level Valve

12. Platform Rotate Flow Control Valve

13. Jib Valve

14. Turret Rotate Valve

15. Gage Port Plug - Low Pressure

16. Platform Rotate Valve

Figure 2-10:

Hydraulic Manifold

104045-021 - AB62 Work Platform - European Model Page 2-11

Page 54

Setting Hydraulic Pressures Section 2 - Service and Repair

2-6 S

ETTING

Figure 2-10: “Hydraulic Manifold,” on page 2-11 shows complete hydraulic manifold assembly.

NOTE:

IGH

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

2. Install a 0-207 bar ( Quick Disconnect Adapter.

3. Retract boom completely.

4. While activating the boom retract function, set the pressure to 186 bar ( turning the adjusting screw. Turning the adjusting screw clockwise increases pressure; counterclockwise decreases pressure.

5. Remove the pressure gauge, and reinstall all plugs.

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

2. Install a 0-207 bar (

3. Completely extend jib function.

4. Continue activating function and set the pressure to 97 bar ( screw. Turning the adjusting screw clockwise increases pressure; counterclockwise decreases pressure.

5. Remove the pressure gauge, and reinstall all plugs.

YDRAULIC

Check hydraulic pressures whenever the pump, manifold, or any relief valve has been serviced or replaced.

RESSURE

0-3000 PSI

RESSURE

0-3000 PSI

RESSURES

ELIEF

) pressure gauge to the pressure test port #3-using Part # 063965-002,

ELIEF

) pressure gauge to the pressure test port.

ALVE

1400 PSI

2700 PSI

) by slowly turning the adjustment

) maximum by slowly

OUNTERBALANCE

1. If any counterbalance relief valve is faulty, completely lower the jib, and retract the boom.

2. Replace or recalibrate the counterbalance valve.

3. Slowly cycle function related to replaced counterbalance valve several times to remove air from the system.

ELIEF

ALVES

Page 2-12 104045-021 - AB62 Work Platform - European Model

Page 55

Section 2 - Service and Repair Torque Hubs

CAUTION

FRONT

REAR

1. Torque Hub (Planetary)

2. Gasket

3. Brake

4. Wheel Motor

2-7 T

ORQUE

NOTE:

HANGING

NOTE:

1. Park the work platform on a firm level, surface and block the wheels to prevent the work platform from

2. Raise the axle using an eight-ton hydraulic jack. Place one eight ton-jack stand under each end of the

3. Loosen the wheel lug nuts.

4. Remove the wheel and rotate the torque hub so the drain plug on its side is at the bottom of the hub.

5. Remove the drain plugs at the bottom of the hub and front cover, and drain the oil from the unit.

6. Rotate the hub so that the plug opening in the front cover is slightly above the half full position, and the

7. Fill the unit with 90 wt. gear oil until oil comes out of the front plug opening (the torque hub must be

8. Replace the plugs.

9. Install the wheel and lower the machine to the surface.

UBS

Change fluid in the torque hubs after the first 50 hours of operation. Change every 1000 hours thereafter.

LUID

It is not necessary to remove the torque hub to change fluid.

rolling.

axle.

side plug opening is at the top.

½ full).

ORQUE

1. Park the work platform on a firm level, surface and block the wheels to prevent the work platform from rolling.

2. Disconnect the battery negative terminal.

3. Loosen the wheel lug nuts on the torque hub to be removed.

4. Raise the axle of the work platform using an eight-ton jack.

5. Position two eight-ton jack stands under the axle.

6. Remove the wheel nuts and the wheel.

7. Disconnect the hydraulic brake line from the brake.

Clean all fittings before disconnecting the hose assemblies.

Plug all port holes and hose assemblies IMMEDIATELY to prevent contamination from dust and debris.

EMOVAL

Figure 2-11:

Torque Hub Assembly, Remove and Replace

104045-021 - AB62 Work Platform - European Model Page 2-13

8. Mark and remove the hoses from the drive motor.

9. Remove the mounting bolts from the drive motor.

10. Separate the drive motor from the brake. Discard the gasket.

11. Separate the brake from the torque hub. Discard the gasket.

12. Remove the ½-20 nuts and washers from the torque hub.

13. Remove the torque hub.

Page 56

Torque Hubs Section 2 - Service and Repair

ORQUE

Refer to Figure 2-11 on page 2-13.

Torque all hardware to torques listed in the General Information section unless otherwise specified.

NOTE:

1. Install the torque hub using hardware previously removed.

2. Using SAE 90W weight gear lube, fill the torque hub. The torque hub must be half full.

3. Using a new gasket, install the brake.

4. Using a new gasket, install the drive motor.

5. Secure the assembly using washers and bolts.

6. Connect the hydraulic brake lines.

7. Connect the hoses to the drive motor.

8. Install the wheels.Torque the lug nuts to 257Nm (

9. Bleed the brake lines if necessary.

10. Remove the jack stands and lower the rear end.

11. Connect the battery terminal.

12. Operate the machine and check for proper operation of the torque hub. Check the function of the brake.

NSTALLATION

190 ft/lbs

ISASSEMBLY

Refer to Figure 2-12 on page 2-17.

1. Slide the coupling (1) from the splines on the input shaft (2).

2. Position the assembly upright on the face of the spindle.

3. Remove the disengage cover (31) if necessary.

4. Remove the eight bolts (29) and the large cover (28) from the unit. The thrust washer (25) and the disengage plunger (26) usually remain attached to the large cover (28) when it is removed. Remove the thrust washer (25), disengage the plunger (26) and O-ring (27) from the large cover (28).

5. Remove the primary sun gear (24) from the end of the input shaft (2).

6. Remove the primary carrier assembly (22).

7. Remove the secondary carrier assembly (21).

8. Remove the input shaft (2) from the spindle (3). Remove the retaining rings (17), washers (18), and disengage spring (19) from the input shaft (2) only if replacement is required.

9. One tab of the lock washer (15) will be engaged in the slot of the bearing nut (16); bend back to release. Remove the bearing nut (16), lock washer (15), and thrust washer (14).

A special locknut wrench is required for the removal of the bearing locknut. The Bearing Locknut Tool, Bearing

NOTE:

Cone Driver and Spindle/Shaft Drive Tool are included in the Service Kit, part number 100254-020.

10. Bolt the Spindle Drive Tool (Service Kit #100254-020) to the ring gear (20). Grade 8 bolts should be used. Drive the spindle (3) from the hub by turning the center bolt of the Spindle Drive Tool. Care should be taken to avoid damaging splines and threads on spindle.

ORQUE

Bearing cone (13) has been designed with a press fit with respect to spindle (3). Considerable force will be

NOTE:

required to remove the cone from the spindle.

11. Remove the Spindle Drive Tool from the ring gear (20).

12. Remove the eighteen bolts (9) and washers (10) from the hub (11) and remove the ring gear (20). It may be necessary to strike the ring gear (20) with a rubber mallet to loosen it from the hub (11).

13. Remove the boot seal (4) and oil seal (5) and bearing cones (6 & 13) from the hub (11). Inspect the bearing cups (7 & 12) in position and remove only if replacement is required.

Page 2-14 104045-021 - AB62 Work Platform - European Model

Page 57

Section 2 - Service and Repair Torque Hubs

SSEMBLY

Refer to Figure 2-12 on page 2-17.

1. Press new bearing cups (7 & 12) into each side of the hub (11). It is recommended that bearing cups (7 & 12) and cones (6 & 13) be replaced in sets.

2. Assemble the bearing cone (6) into the cup (7) at the seal end of the hub (11) and press a new seal (5) into the hub (11). Install the boot seal (4) on the hub (11) if the unit is so equipped.

3. Position the spindle (3) upright on a work bench. Lubricate the lips of the seal (5) and lower the hub (11) onto the spindle (3). The hub (11) should be centered as it is lowered over the spindle (3) to prevent seal damage.

4. Assemble the bearing cone (13) over the spindle (3). Press the bearing cone (13) over the spindle bearing journal using a press and cylindrical Bearing Cone Driver (Service Kit 100254-020). Press the bearing cone (13) down until the rollers just touch the cup (12). Take care to avoid pressing the cone (13) too far.

If a press is not available, place the Bearing Cone Driver Tool over the spined end of the spindle (3) on the edge

NOTE:

of the bearing cone(13), and drive it into place with a hammer or mallet. If this method is used, care must be taken to avoid damage to the bearing cone and spindle.

ORQUE

5. Install the thrust washer (14) with the tab in the keyway of the spindle and bearing nut (16).

install the lock washer (15) at this time.

6. Clean the mating surfaces and apply a bead of silicone sealant to the face of the hub (11) that mates with the ring gear (20). See the instructions on the sealant package. The hub (11) is attached to the ring gear (20) with 18 3/8-24 grade 8 hex head cap screws (9) and flat washers (10). Torque the cap screws to 70-81 Nm (

7. Place the Spindle Drive Tool (Service Kit #100254-020), over the spindle (3) and bolt or pin to the ring gear (20). Make sure the center bolt of the Drive Tool is not touching the spindle and is prevented from rotating by jam nuts provided on tool.

8. Check the initial rolling torque by installing a Nm ( nut of the Spindle Drive Tool and turning the hub (11) slowly and steadily with the torque wrench. Note the mean torque. An initial bearing torque of greater than 81 Nm ( or 4,3-5,2 Nm ( step 4. In this case, back off the bearing cone (13) by pressing the spindle (3) out of the cone (13) until the initial preload is relieved. See step 10 of the disassembly procedure.

9. Torque the bearing nut (16) with the Bearing Locknut Tool (Service Kit #100254-020) until a bearing rolling torque of 4,8-5,7 Nm ( seal, is reached. This may require several trials of pressing the cone (13) by torquing the nut (16) and then checking the rolling torque. Rotate hub (11) by hand as nut is being tightened in order to seat the bearings.

10. Up to 339 Nm ( cone (13) into position.

11. Remove the bearing nut (16) and install the lock washer (15). Replace the bearing nut (16).

12. Re-torque the bearing nut (16) to 80-90 Nm (

13. Secure the bearing nut (16) by bending a lock washer (15) tab into one of the four bearing nut slots. If no tab aligns with a slot, the nut may be tightened until one of the slots aligns with a lock washer tab.

14. Assemble a washer (18), spring (19), a second washer (18), and a retaining ring (17) in the middle grooves of the input shaft (2). Install a second retaining ring (17) in the groove near the small end of the input shaft (2).

15. Assemble the splined end of the input shaft (2) down into the spindle (3).

16. Assemble the secondary carrier assembly (21) to the spindle (3) at the splines.

17. Assemble the primary carrier assembly (22) into the ring gear (20). It will be necessary to rotate the carrier to align the secondary sun gear (part of primary carrier assembly (22) with the planet gear teeth in the secondary carrier assembly (21). Assemble the primary sun gear (24) over the input shaft (2). Rotate the primary sun gear (24) to align the input shaft (2) to the gear splines and the gear teeth in the primary carrier assembly (22).

50-52 ft/lbs.

38-46 in/lbs

250 ft/lbs

in/lbs

) torque wrench (arm or dial type) on the center

52 in/lbs

) without the boot seal means that the cone (13) was pressed on to tightly in

42-50 in/lbs

) of torque may have to be applied to the bearing nut (16) in order to press the

), with a boot seal installed, or 5,2 Nm (

60-70 ft/lbs

) with the boot seal installed

46 in/lbs

DO NOT

), without a boot

104045-021 - AB62 Work Platform - European Model Page 2-15

Page 58

Torque Hubs Section 2 - Service and Repair

18. Lubricate the O-ring (27) and assemble in the groove inside the cover hole; push the disengage plunger (26) into the cover (28) with the pointed end facing inside of the unit.

19. Assemble the thrust washer (25) with the tangs engaged with the cover (28). A small amount of grease applied to the back side of the thrust washer (25) will hold the washer in place. Apply a bead of silicone sealant to the end of the face of the ring gear (20).

20. Assemble the cover (28) aligning the holes of the cover and ring gear. Assemble the eight 5/16-18 x 1 inch hex head bolts (29). Torque the bolts to 27-34 Nm (

21. Assemble the disengage cover (31) with the dimpled center protruding out if the wheel is to be used to drive the vehicle.

22. Assemble and torque the two 5/16-18 x 1/2 inch bolts (32). Torque the bolts to 13-27 Nm (

23. Invert the torque hub assembly and assemble the coupling (1), with counterbore out, to the input shaft (2).

24. After the motor is assembled to the drive, or the drive is sealed at the spindle, fill with lubricant to the proper level and replace all plugs.

ARRIER

Do not attempt to service primary or secondary carrier assemblies.

SSEMBLIES

20-25 ft/lbs

10-20 ft/lbs

EALING

Silastic RTV732 sealer and General Electric Silimate RTV No. 1473 or RTV No. 1503 are currently recommended for sealing gasket surfaces. Sealant should be applied in a continuous bead, which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole location.

OMPOUND

Page 2-16 104045-021 - AB62 Work Platform - European Model

Page 59

Section 2 - Service and Repair Torque Hubs

Service Kit includes: Item Description

4. Boot Seal

5. Oil Seal

6. Bearing, Cone

7. Bearing, Cup

8. Wheel Bolt

12. Bearing, Cup

13. Bearing, Cone

14. Thrust Washer

15. Lock Washer

27. O-Ring

1. Coupling

2. Input Shaft

3. Spindle

4. Boot Seal

5. Oil Seal

6. Bearing, Cone

7. Bearing, Cup

8. Wheel Bolt

9. Hex Head Bolt (Grade 8)

10 . Flat Washer

11. Hub

12. Bearing, Cup

13. Bearing, Cone

14. Thrust Washer

15. Lock Washer

16. Bearing Nut

17. Retaining Ring

18. Washer

19. Disengage Spring

20. Ring Gear

21. Secondary Carrier Assembly

22. Primary Carrier Assembly

23. Retaining Ring

24. Primary Sun Gear

25. Thrust Washer

26. Disengage Plunger

27. O-Ring

28. Large Cover

29. Hex Head Bolt

30. Magnetic Plug

31. Disengage Cover

32. Hex Head Bolt

33. Quick Disconnect Gasket

34. Quick Disconnect Assembly

35. Hex Head Bolt

Figure 2-12:

Torque Hub Assembly, Seal kit Installation

104045-021 - AB62 Work Platform - European Model Page 2-17

Page 60

Cylinders Section 2 - Service and Repair

2-8 C

Service Kit includes: Item Description

YLINDERS

1. O-ring

2. Rod Wiper

3. Seal

4. Wear Ring

5. O-Ring

6. Back-up Ring

7. O-Ring

8. Seal

9. Wear Ring

Refer to the General Information section for basic cylinder repair instructions.

Figure 2-13:

NOTE: Torque Locknut “D” to 339 - 407 Nm (250-300 ft/lbs)

Master Cylinder and Level Cylinder

A. Rod B. Head C. Piston D. N u t E. Cylinder F. Counterbalance Valve

Service Kit includes:

Item Description

1. Rod Wiper

2. Seal

3. Wear Ring

4. O-Ring

5. Back-up Ring

6. O-Ring

7. Seal

8. O-ring

9. Wear Ring

Figure 2-14:

NOTE: Torque Locknut “D” to 1898 - 1700 Nm (1,400-1,700 ft/lbs)

A. Rod B. Head C. Piston D. N u t E. Cylinder F. Counterbalance Valve

Riser Cylinder

Page 2-18 104045-021 - AB62 Work Platform - European Model

Page 61

Section 2 - Service and Repair Cylinders

Service Kit includes:

Item Description

1. Rod Wiper

2. Seal

3. Seal

4. O-Ring

5. Back-up Ring

6. O-Ring

7. Wear Ring

8. Wear Ring

9. Seal

A. Rod Wiper B. Head C. Spacer D. Set Screw E. Piston F. Cylinder G. Counterbalance Valve

Service Kit includes:

Item Description

1. Rod Wiper

2. Seal

3. Wear Ring

4. O-Ring

5. Back-up Ring

6. O-Ring

7. Wear Ring

8. Seal

Figure 2-15:

A. Rod B. Head C. Spacer D. P iston E. Set Screw F. Cylinder G. Counterbalance Valve

Boom Cylinder

Figure 2-16:

Extend Cylinder

104045-021 - AB62 Work Platform - European Model Page 2-19

Page 62

Cylinders Section 2 - Service and Repair

Service Kit includes: Item Description

1. O-Ring

2. Rod Wiper

3. Seal

4. Wear Ring

5. O-Ring

6. Back-up Ring

7. O-Ring

8. Seal

9. Wear Ring

Figure 2-17:

NOTE: Torque Locknut “D” to 237 - 271 Nm (175-200 ft/lbs)

A. Rod B. Head C. Piston D. N ut E. Cylinder F. Counterbalance Valve G. Washer Seal H. Bleeder Plug

Axle Lock Cylinder

Service Kit includes:

Item Description

1. O-Ring

2. Rod Wiper

3. Seal

4. Wear Ring

5. Back-up Ring

6. O-Ring

7. Wear Ring

8. Seal

Figure 2-18:

Steering Cylinder

A. Rod B. Head C. Spacer D. Cylinder

Page 2-20 104045-021 - AB62 Work Platform - European Model

Page 63

Section 2 - Service and Repair Setting the Backlash on the Rotational Gear

Service Kit includes:

Item Description

1. O-Ring

2. Rod Wiper

3. Seal

4. Wear Ring

5. Back-up Ring

6. O-Ring

7. Cast Iron Ring

8. Wear Ring

9. Seal

Figure 2-19:

NOTE: Torque Locknut “D” to 237 - 271 Nm (175-200 ft/lbs)

A. Rod B. Head C. Piston D. N ut E. Cylinder F. R el ie f Va lv e G. Counterbalance Valve

Jib Cylinder

2-9 S

ETTING

THE

ACKLASH

ON THE

OTATIONAL

EAR

Backlash is the shortest distance between tooth surfaces of adjacent teeth in mating gears.

Setting Rotational Gear Backlash (Viewed from bottom of turret)

ROTATION BEARING

1. Position boom directly over center of rear axle (standard forward driving

Figure 2-20:

DIAL INDICATOR

position).

1. Loosen the gearbox mounting bolts just enough to allow the gearbox to be adjusted in and out.

2. Turn adjusting screws in until gearbox teeth make contact with bearing teeth and adjusting screws become snug.

3. Unscrew adjusting screws five turns.

MOUNTING PLATE

GEARBOX PINION

Do not move the gearbox.

4. Place the magnetic indicator base on the bottom of the turret assembly. Set the dial indicator probe on the gearbox pinion straight across from the bearing and adjust the dial to ZERO.

5. Move the gearbox away from the bearing until the indicator shows the correct amount of backlash 0,178mm - 0,229mm (

.007”-.009”

6. Carefully torque the gearbox mounting bolts while watching the indicator to make sure the correct backlash is maintained.

7. Snug the adjusting bolts against the gearbox and tighten the jamb nuts.

104045-021 - AB62 Work Platform - European Model Page 2-21

Page 64

Rotary Manifold Removal Section 2 - Service and Repair

2-10 R

OTARY

1. Mark and tag all hoses.

2. Remove all hoses from Rotary Manifold.

3. Remove Rotary Manifold from the machine.

ANIFOLD

EMOVAL

Figure 2-21:

Rotary Manifold

Provide a clean work area for this operation, and observe clean assembly practices. Seals and O-rings are

NOTE:

highly sensitive to contamination that may not be visible to the naked eye.

ISASSEMBLY

1. Remove Retaining Rings from each end of Rotary Manifold.

2. Carefully slide body out of housing.

3. Remove seal kit components (O-rings, seals, and retaining rings).

4. Thoroughly clean all parts with solvent. Rinse the inside of the tube and allow to drain. A high pressure rinse and wipe with a lint free rag is preferable.

5. Inspect the body and housing for scratches, pits, or polishing. Check seal grooves and sealing surfaces. Scratches or pits deep enough to catch the fingernail are unacceptable, replace the manifold.

SSEMBLY

Torque all hardware and fittings to torques listed in the General Information section unless otherwise specified.

NOTE:

1. Lubricate all seals with clean hydraulic fluid prior to assembly.

2. Install new seals on body and housing.

3. Carefully slide body into housing.

4. Reinstall O-rings and retaining rings.

NSTALLATION

1. Installation is reverse of removal.

2. Replenish hydraulic fluid in tank.

3. Run hydraulic system for several minutes to remove air from hydraulic lines. Cycle cylinders for each boom function.

4. Rotate turret completely.

5. Check Rotary Manifold for leaks. Check that all boom functions are operating properly.

Page 2-22 104045-021 - AB62 Work Platform - European Model

Page 65

Section 3

WARNING

ROUBLESHOOTING

This section contains troubleshooting Truth Tables for the AB62 Work Platform. 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.

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.

ABLE

ONTENTS

3-1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-3 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-4 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-5 Checking Pump Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-6 Troubleshooting the DMR-30 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-7 Machine Operation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Lower Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Upper Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-8 Optimizer Settings and Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-9 Hydraulic Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-10 Electrical Truth Table - AB62 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-11 Hydraulic Truth Table - AB62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

104045-021 - AB62 Work Platform - European Model Page 3-1

Page 66

Technical Support Section 3 - Troubleshooting

3-1 T

UUUU

PPPP

RRRR

UUUU

PPPP

RRRR

EEEE

UUUURRRROOOOPPPPEEEE

3-2 G

3-3 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 nections 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

Spike protection diodes at components have been left out of the charts to eliminate confusion.

NOTE:

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

the Schematics section

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

. Check for loose con-

3-4 A

3-5 C

Page 3-2 104045-021 - AB62 Work Platform - European Model

DJUSTMENT

• Hydraulic settings must be checked whenever a component is repaired or replaced.

• Remove counterbalance valves and “bench test” them if they are suspect.

• Connect a pressure meter of appropriate range to the test port located on the right side of the hydrau-

lic manifold.

• Correct pressure settings are listed in the hydraulic schematic.

• Refer to DMR 30 settings listed in this section.

HECKING

RIVE PUMP

• Check charge pressure at tee added to charge filter line.

•

To check drive pressure, connect pressure tester to port “G” on the 2-speed/axle lock valve block.

ROCEDURES

UMP

RESSURES

Page 67

Section 3 - Troubleshooting Troubleshooting the DMR-30 Controller

3-6 T

ROUBLESHOOTING

There are two components to the DMR-30 system. A DMT-30 transmitter in the upper control box transmits inputs from the operator controls to the DMR-30 receiver in the lower control box. The DMR-30 receives the digital signal and commands the appropriate functions. A corresponding LED for each input and output is added to the DMR30 -DMT-30 for easier diagnosis.

These LEDs correspond to wire position in the plugs and acknowledge a signal on the wire. Using the charts in Figure 3-2 and Figure 3-1, a signal or series of signals can be followed from switch to actuator to help in determining the cause of a problem.

Four “blinking” diagnostic LEDs, located at the bottom-center of the DMR-30, are labeled as to their function and are also used for diagnostic purposes.

THE

DMR-30 C

ONTROLLER

Figure 3-1:

DMT-30 Transmitter

A. CPU LED: DMR-30 is powered up operating properly. Solid light indicates internal failure. Not lit when

no power input.

B. INPUT LED: Indicates an input from lower control panel switches, including ignition switch. This LED

should flash with CPU LED.

C. OUTPUT LED: Indicates an output to boom or drive functions. This LED flashes only when operating

boom or drive functions from either controller.

D. BUSS LED: Indicates an input from the DMT-30 (upper controller). This LED should flash with CPU

LED and INPUT LED as the upper ignition must be on to operate.

Figure 3-2:

DMR-30 Receiver

104045-021 - AB62 Work Platform - European Model Page 3-3

Page 68

Machine Operation Check List Section 3 - Troubleshooting

3-7 M

OWER

ACHINE

ONTROL

LECTRICAL POWER UP

• Both Emergency Stop Switches are pulled out.

• Lower control box key switch is in CHASSIS position.

• Upper controls key is ON.

• BT1-03 chassis selected is illuminated.

• Other LEDs on DMR-30 that may be illuminated:

• The CPU LED on the DMR-30 should be flashing ON/OFF.

• The BUSS LED on the DMR-30 should be flashing ON/OFF.

• The INPUT LED should be flashing ON/OFF.

NGINE START

• BT1-02 on DMR-30 (start) is illuminated when operating start switch.

• The hour meter should flash.

• BT4-08 (oil pressure input) will illuminate while engine is running.

If no oil pressure is detected, ignition signal is deactivated. The engine will not continue to run.

NOTE:

PERATION

• BT1-05 (tilt)

• BT2-01 (telescope interlock)

• BT1-11 (lift interlock #1)

• BT1-12 (lift interlock #2).

HECK

IST

LOW PLUG

• BT1-08 on DMR-30 is illuminated.

• Glow plugs are automatic.

OOM

Speed control knob in UPPER control box must be turned past 5 to operate.

OOM

• Function enable is pushed.

• LEDs on DMR-30 are illuminated:

OOM

• Function enable pushed.

• LEDs on DMR-30 illuminated:

• BT1-03 (chassis selected)

• BT2-04 (lift input)

• BT5-09 (lift output to valve)

• BT6-12 (low flow output)

• BT5-06 (throttle output).

OWN

• BT1-03 (chassis selected)

• BT2-05 (boom down input)

• BT6-04 (boom down output to valve)

• BT6-12 (low flow output)

• BT5-06 (mid throttle output).

OOM

• Function enable pushed.

• LEDs on DMR-30 illuminated:

Page 3-4 104045-021 - AB62 Work Platform - European Model

ISER

• BT1-03 (chassis selected)

• BT2-02 (riser up input)

• BT5-12 (riser up to valve output)

• BT6-10 (high flow output to valve)

Page 69

Section 3 - Troubleshooting Machine Operation Check List

• BT5-06 (throttle output).

ISER LOWER

• Function enable pushed.

• LEDs on DMR-30 illuminated:

• BT2-03 (riser lower input)

• BT6-01 (riser lower output)

• BT6-10 (high flow output to valve)

• BT5-06 (throttle output).

OOM EXTEND

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT2-06 (boom extend input)

• BT6-07 (boom extend output to valve)

• BT6-10 (high flow output)

• BT5-06 (throttle output)

OOM

• Function enabled.

• LEDs on DMR-30 illuminated:

URRET ROTATE

WING RIGHT

• Function enabled.

• LEDs on DMR-30 illuminated:

WING LEFT

• Function enabled.

• LEDs on DMR-30 illuminated:

ETRACT

• BT2-07 (boom retract input

• BT6-08 (boom retract output to valve)

• BT6-10 (high flow output)

• BT-06 (throttle output)

• BT2-09 (swing right input)

• BT7-09 (turret valve output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output).

• BT2-08 (swing left input)

• BT7-08 (turret valve output)

• BT5-06 (throttle output)

• BT6-12 (low flow output).

J JIB U

JIB D

104045-021 - AB62 Work Platform - European Model Page 3-5

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT2-10 (jib up input)

• BT7-06 (jib up output to valve)

• BT6-12 (low flow valve output)

• BT5-06 (throttle output).

OWN

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT2-11 (jib down input)

Page 70

Machine Operation Check List Section 3 - Troubleshooting

• BT7-07 (jib down output to valve)

• BT6-12 (low flow valve output)

• BT5-06 (throttle output).

AGE ROTATE

AGE RIGHT

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT4-03 (cage right input)

• BT7-03 (cage right output to valve)

• BT6-12 (low flow valve output)

• BT5-06 (throttle output).

AGE LEFT

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT4-02 (cage left input)

• BT7-04 (cage left output to valve)

• BT6-12 (low flow valve output)

• BT5-06 (throttle output).

AGE TRIM UP

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT2-12 (cage trim up input)

• BT6-05 (cage trim up output to valve)

• BT6-12 (low flow valve output)

• BT5-07 (throttle output).

AGE TRIM DOWN

• Function enabled.

• LEDs on DMR-30 illuminated:

• BT4-01 (cage trim down input)

• BT6-06 (cage trim down output to valve)

• BT6-12 (low flow valve output)

• BT5-07 (throttle output).

UXILIARY POWER

• Both Emergency Stops are pulled out (upper and lower).

• Auxiliary Switch enabled.

• Relay #9 activated (12 volts at relay #9, terminals #30 & #87).

If the auxiliary switch is depressed when the engine is running, the engine will stop immediately.

NOTE:

MERGENCYFUNCTIONS

)

Page 3-6 104045-021 - AB62 Work Platform - European Model

Page 71

Section 3 - Troubleshooting Machine Operation Check List

PPER

ONTROL

OWER-UP

• Both Emergency Stops are pulled out (upper and lower).

• Lower Control Box key switch in PLATFORM position. Platform key switch on.

• LEDs on DMR-30 illuminated:

• BT1-01 (platform selected)

• LEDs on DMT-30 illuminated:

• BT1-11 & BT1-12 (limit switch)

• BT1-05 (tilt)

NGINE START

• Operate start switch.

• LED’s on DMR-30 illuminated:

• BT3-03 (start input).

• LEDs on DMT-30 illuminated:

• BT5-11 (starter output)

• BT5-08 (glow plug output-diesel only)

• BT4-04 (oil pressure)

OOM LIFT FUNCTION

ISER UP

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT5-12 (riser up output)

• BT5-06 (throttle output)

• BT6-10 (high flow valve output).

• LEDs on DMT-30 illuminated:

• BT4-03 (foot switch), BT 3-09 (riser up).

ISER DOWN

• Function enabled - foot switch depressed.

• LED’s on DMR-30 illuminated:

• BT6-01 (riser down output)

• BT5-06 (throttle output)

• BT6-10 (high flow valve output)

• LED’s on DMT-30 illuminated

• BT4-03 (foot switch)

• BT 4-08 (riser down)

OOM

• Function enabled - foot switch depressed.

• LED’s on DMR-30 illuminated:

• LEDs on DMT-30 illuminated:

• BT5-09 (boom up output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output)

• BT4-03 (foot pedal)

• BT4-09 (boom up)

104045-021 - AB62 Work Platform - European Model Page 3-7

Page 72

Machine Operation Check List Section 3 - Troubleshooting

OOM

• Function enabled - foot switch depressed.

• LED’s on DMR-30 illuminated:

• LEDs on DMT-30 illuminated:

OOM

• Function enabled - foot switch depressed.

• LEDs on DMR-30 illuminated:

• LEDs on DMT-30 illuminated:

OOM

• Function enabled - foot switch depressed.

• LEDs on DMR-30 illuminated:

• LEDs on DMT-30 illuminated:

OWN

• BT5-04 (boom down output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output)

• BT4-03 (foot pedal)

• BT4-04 (boom down)

XTEND

• BT6-07 (boom extend output)

• BT5-06 (throttle output)

• BT6-10 (high flow valve output)

• BT4-03 (foot pedal)

• BT3-11 (boom extended)

ETRACT

• BT6-08 (boom retract output)

• BT5-06 (throttle output)

• BT6-10 (high flow valve output)

• BT4-03 (foot pedal)

• BT3-06 (boom retract).

URRET ROTATE

WING RIGHT

• Function enabled - foot switch depressed.

• LEDs on DMR-30 illuminated:

• BT7-09 (turret rotate right output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output).

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT3-07 (turret rotate right)

WING LEFT

• Function enabled - foot switch depressed.

• LEDs on DMR-30 illuminated:

• BT7-08 (turret rotate left output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output)

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT3-01 (turret rotate left)

UNCTIONS

Page 3-8 104045-021 - AB62 Work Platform - European Model

Page 73

Section 3 - Troubleshooting Machine Operation Check List

J JIB U

JIB D

C C

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT7-06 (jib up output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output).

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT4-07 (jib up)

OWN

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT7-07 (jib down output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output)

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT4-02 (jib down)

AGE ROTATE

AGE RIGHT

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT7-03 (cage rotate right output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output).

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT4-01 (cage rotate right)

AGE LEFT

• Function enabled - foot pedal depressed.

• LEDs on DMR-30 Illuminated:

• BT7-04 (cage rotate left output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output).

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT4-12 (cage rotate left)

AGE TRIM UP

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT6-05 (cage trim up output)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output)

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT4-11 (cage trim up)

104045-021 - AB62 Work Platform - European Model Page 3-9

Page 74

Machine Operation Check List Section 3 - Troubleshooting

AGE TRIM DOWN

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT6-06 (cage trim down valve)

• BT5-06 (throttle output)

• BT6-12 (low flow valve output)

• LEDs on DMT-30 illuminated:

• BT4-03 (foot pedal)

• BT4-06 (cage trim down)

UXILIARY POWER

• DMR-30 BT5-10 (auxiliary output)

• DMT-30 BT3-08 (auxiliary power)

If the auxiliary switch is depressed when the engine is running, the engine will stop immediately.

NOTE:

RIVE FUNCTIONS

Drive functions are relayed to the drive pump from the joystick control. All adjustments are made at the joystick controller. Brake release and throttle commands are relayed from the joystick controller to the DMT-30 on BT3-08 (JSA) Joystick actuator.

RIVE FORWARD

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT5-06 (throttle output)

• BT5-04 (brake release)

• LEDs on DMT-30 Illuminated:

• BT3-02 (JSA) joystick actuator

RIVE REVERSE

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• BT5-06 (throttle output)

• BT5-04 (brake release)

• LEDs on DMT-30 Illuminated:

• BT3-02 (JSA) joystick actuator

MERGENCYFUNCTIONS

)

TEER

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• LEDs on DMT-30 Illuminated:

TEER LEFT

• Function enabled - foot switch depressed.

• LEDs on DMR-30 Illuminated:

• LEDs on DMT-30 Illuminated:

IGH TORQUE POSITION

• No signal on DMR-30 or DMT-30.

Page 3-10 104045-021 - AB62 Work Platform - European Model

IGHT

• BT5-06 (throttle output)

• BT6-10 (high flow valve)

• BT7-02 (steer right output)

• BT4-05 on DMT-30 (steer right)

• BT5-06 (throttle output)

• BT6-10(high flow valve)

• BT7-01 (steer left output)

• BT4-10 (steer left)

Page 75

Section 3 - Troubleshooting Machine Operation Check List

RAKING

ILT

NTERLOCKS

IGH SPEED

• LEDs on DMR-30 Illuminated:

• BT3-10 (high speed)

• LEDs on DMT-30 Illuminated:

• BT5-07 (shift)

• Brakes are normally locked when the machine is not in use.

• Brakes are unlocked by a charge pressure (380 PSI) from the drive pump.

• A 12 volt signal is sent to the brake solenoid by BT5-04 on DMR-30.

• A 12 volt signal is at BT1-05 (tilt signal input) when the machine is level.

• If the machine is out of level or the level sensor fails, the machine will stop.

• Red wire on level sensor is power in, and white wire is signal out.

There are two interlocks on the machine.

1. Lift Interlock:

• A12 Volt signal is sent to BT2-01 on DMR-30;

• allows high speed travel.

2. Telescope interlock (at tail end of boom):

• A 12 volt signal is sent to BT1-11 & BT1-12 on DMR-30 when boom is fully retracted;

• allows high speed travel.

OSITION

104045-021 - AB62 Work Platform - European Model Page 3-11

Page 76

Optimizer Settings and Sequence Section 3 - Troubleshooting

3-8 O

PTIMIZER

The AB62 uses a Digital Multiplex Receiver (DMR-30) system manufactured by OEM to control the proportionality of boom functions. There is a transmitter (DMT-30) in the upper control box that takes the operator’s control inputs and relays them to the receiver, via data link (two wires). The Optimizer can be plugged into the upper control box, with the use of an adapter (part #100329-005), or directly to the DMR-30 in the lower control box on port P-8. Remove the existing plug on P-8 to access port.

The AB62 uses two groups of settings: EXTEND and STEER functions and the ROTATE, and CAGE LEVEL functions. CAGE ROTATE is also altered by adjusting the flow control valve, located on the bottom of the valve block below the cage rotate valve. All settings correspond with how all the functions in that particular group will react to the rheostat control on the upper control box. Each adjustment will affect that whole group. For example: setting high flow, will change the threshold on boom riser, extend and steer. It is important not to deviate very far from the listed settings. Before making any changes, record the current settings. This will help to diagnose an existing or potential problem with a function on the machine.

• Make all settings only in the order in which they are displayed.

• Max Out or MX pertains to the extension of the cylinders in the group.

• Low Range or LR pertains to the retraction of the cylinders in the group.

EQUENCE

• Emergency stop switches must be pulled and ignition switches on. It is not necessary to have the engine running when retrieving the initial settings or resetting the DMR-30.

• Plug the Optimizer in at either location and it should read “Run mode normal functions off.”

• If not, ensure that all switches are on and the Optimizer is plugged into P-8. If plugged into the

Low Flow:

•

• If it needs to be changed, use the + or - to raise or lower the value. Continue to MAXOUT and so

High flow:

•

ENTER. The TH, MX, RU, RD, LR icons will appear and TH will be flashing.

• Push ENTER and the display will read: CHANGE; YES = + NO = ENTER.

• Push + and the preset value will be displayed. To adjust, push + to raise value or - to lower value.

• If preset value is correct or after resetting the value, push ENTER. You will be back to Run mode,

ETTINGS

upper control box, ensure that there is a four-wire plug in P-8 port in the lower control box.

Select THRESHOLD by pushing the threshold button. The preset value will appear.

on until all low flow ranges are set, then push ENTER to save changes.

Push ENTER, then + (readout will say ERROR): push + again, high flow will appear. Push

normal functions off. To reset the other functions, repeat the procedure until TH is flashing, as it did above, then use the + or - to scroll to other functions; then continue.

AND

“High Flow,”

“Low Flow,”

EQUENCE

which pertains to the BOOM RISER, BOOM

pertaining to the BOOM RAISE, JIB, TURRET

IMPORTANT: After making changes, thoroughly test all functions for smoothness and proper operation.

ETTINGS

Low Flow System . . High Flow System

Threshold . . . 28-30% Threshold . . . . . 27-29%

High Range . . 56-58% High Range . . . . . .95%

Ramp Up. . . . .2 Sec. Ramp Up . . . . . . 2 Sec.

Ramp Down . .0 Sec. Ramp Down . . . . 0 Sec.

Low Range . .46-48% Low Range . . . . . . .95%

Page 3-12 104045-021 - AB62 Work Platform - European Model

Page 77

Section 3 - Troubleshooting Hydraulic Troubleshooting

WARNING

3-9 H

YDRAULIC

The AB62 has three independent hydraulic systems: one for drive; one for high flow lift functions; and one for low flow lift functions. The drive system uses an electrically controlled, variable displacement piston pump that powers four piston type wheel motors. The high flow system uses a gear type pump to power riser up/down, boom extend/retract, and steer functions. The low flow system, also using a gear type pump, operates Boom up/down, Jib up/down, Swing right/left, Cage rotate and Cage level.

High flow and low flow system pressures can be verified by connecting a 207 bar ( upper port on the valve block. Operate Riser down to test high flow system or Jib up to test the low flow system. Operate function until it stops and system bypasses.

The high flow relief valve is located just below the gauge port.

• High flow pressure, 186 bar (

The low flow relief valve is located below the high flow relief valve.

• Low flow pressure, 97 bar (

Counterbalance valves must never be removed if the platform is raised and hydraulic system is under pressure. Be sure the platform is completely stowed before removing counterbalance valves.

ROUBLESHOOTING

1400 PSI)

2700 PSI)

3000 PSI)

gauge to the

104045-021 - AB62 Work Platform - European Model Page 3-13

Page 78

Electrical Truth Table - AB62 Diesel Section 3 - Troubleshooting

3-10 E

LECTRICAL

OMPONENT

RUTH

CONTROLS

PPER

OWER

TART

NGINE

UNCTIONS

ONTROL

PPER

TART

NGINE

UNCTION

UNCTIONS

ONTROL

OWER

ABLE

OWN

OOM

ETRACT

XTEND

OOM

OWER

AISE

ISER

- AB62 D

EVERSE

REEP

IGHT

IGH

ORWARD

RIVE

EFT

PEED

TEER

IESEL

OWN

CW/CCW

EVEL

HARGE

OWN

ATTERY

LATFORM

OTATE

LATFORM

OCK

XLE

RONT

IGHT

ILT

OTATE

URRET

ELEASE

RAKE

ARKING

LARM

ILT

IGH

ORQUE

OWERIN G

MERGENCY

PTIONAL

- O

IGHTS

ORNDRIVING

ACT1 Throttle Actuator X X X ALM1 Alarm, Tilt X

ALT Alternator X X X BAT1 Battery, Engine Start X X BAT2 Battery, Auxiliary Power X

CB1 Circuit Breaker (20 AMP) XXXXXXXXXXXXXXXXXXXXXX X

CB2 Circuit Breaker (10 AMP) X X X X X X X X X

CB3 Circuit Breaker (10 AMP) X X X X X X X

CONT1Controller, DMR-30 XXXXXXX XXX XXXXXXXXX X CONT2 Controller, Glow Plug X X

D1 Diode, Auxiliary Power X D3 Diode, Power to Platform X X X X X X X D4 Diode X

Diode, Auxiliary Pump

Relay

D6 Diode X D7 Diode, Alternator X D8 Diode, Spike Protection D9 Diode, Spike Protection X

FU1 Fuse (175 AMP) X

HORN Horn X

ISO Charge Isolator X

Lamp1 Distress Lamp X X Lamp2 Tilt lamp XX Lamp3 Glow Plug Lamp X X

LS1 Linkage Limit Switch X X X X

LS2 Proximity Switch X X X X

MOT1 Auxiliary Pump Motor X MOT2 Engine Start Motor X X MTR1 Engine Temperature Meter X X MTR2 Oil Pressure Meter X X MTR3 Hour Meter PMP1 Drive Pump X X

R1 Engine Start Relay X X R5 Drive Motion Alarm X R8 Axle Release, Left X

R9 Axle Release, Right X R10 Axle Release Signal X R11 Power to DMR-30 XXXXXXXXXXXXXXXXXXXXX X R12 Auxiliary Pump X R13 Ignition Cutout Relay X X R14 Drive Enable Relay X X

PTIONAL

- O

ENERATOR

ONTROLLER

HROTTLE

Page 3-14 104045-021 - AB62 Work Platform - European Model

Page 79

Section 3 - Troubleshooting Electrical Truth Table - AB62 Diesel

CONTROLS

PPER

OWER

Auxiliary Pump Motor

R15

Relay

OMPONENT

UNCTION

TART

NGINE

TART

NGINE

UNCTIONS

ONTROL

PPER

OWER

OWN

AISE

ISER

OOM

ONTROL

OWER

ETRACT

XTEND

OOM

EVERSE

REEP

IGHT

EFT

TEER

OWN

IGH

ORWARD

RIVE

PEED

SW1 Emergency Stop Switch XXXXXXXXXXXXXXXXXXXXXXXX SW2Ignition Switch XX XXX XXXXX

Auxiliary Power Switch

SW4

(Upper)

X X

SW5 Generator Switch (Upper) X X SW6 Drive Hi/Lo Switch (Upper) X X SW7 Cage Level Switch (Upper) X X

Boom Up/Down Switch

SW8

(Upper)

SW9 Turret Rotate (Upper) X X SW10 Cage Rotate (Upper) X X SW11 Jib Up/Down (Upper) X X SW12 Riser Up/Down (Upper) X X

SW13

Boom Retract/Extend (Upper)

SW14 Driving Lights (Upper) X X SW17 Oil Pressure Switch X X X SW18 Horn (Upper) X X SW19 Foot Interlock (Upper) X X X SW21 Emergency Stop (Lower) XXXXXXXXXXXXXXXXXXXXXXXX SW22 Selector Switch (Lower) XXXXXXXXXXXXXXXXXXXXXXXX

SW23

Auxiliary Power Switch

(Lower) SW24 Enable Switch (Lower) X SW26 Boom Hi/Lo Speed (Lower) XXXX X XX X

SW28

SW29

SW30

Engine start Switch

(Lower)

Turret Rotate Switch

(Lower)

Boom Up/Down Switch

(Lower)

SW31 Cage Level Switch (Lower) X X

SW32

SW33

SW34

SW35

Cage Rotate Switch

(Lower)

Jib Up/Down Switch

(Lower)

Rise Up/Down Switch

(Lower)

Boom Extend/Retract

(Lower)

SNSR1 Tilt Sensor XX SNSR2 Engine Temperature Sensor X X SNSR3 Engine Oil Pressure Sensor X X

SOL1 Cage Level Solenoid X SOL2 Cage Level Solenoid X SOL3 Jib Up Solenoid X

OWN

CW/CCW

EVEL

HARGE

ATTERY

LATFORM

OTATE

LATFORM

OCK

XLE

RONT

IGHT

ILT

ELEASE

RAKE

OTATE

ARKING

URRET

LARM

ILT

IGH

ORQUE

OWERIN G

MERGENCY

ORNDRIVING

PTIONAL

- O

IGHTS

PTIONAL

- O

ENERATOR

ONTROLLER

HROTTLE

104045-021 - AB62 Work Platform - European Model Page 3-15

Page 80

Electrical Truth Table - AB62 Diesel Section 3 - Troubleshooting

CONTROLS

PPER

OWER

OMPONENT

UNCTION

TART

NGINE

TART

NGINE

UNCTIONS

ONTROL

PPER

OWER

OWN

AISE

ISER

OOM

ONTROL

OWER

ETRACT

XTEND

OOM

EVERSE

REEP

IGHT

EFT

TEER

OWN

IGH

ORWARD

RIVE

PEED

SOL4 Jib Down Solenoid X SOL5 Boom Up Solenoid X SOL6 Boom Down Solenoid X SOL7 Boom Extend Solenoid X SOL8 Boom Retract Solenoid X

SOL9 Riser Up X SOL10 Riser Down X SOL11 Cage Rotate CW X SOL12 Cage Rotate CCW X SOL13 Turret Rotate CW X SOL14 Turret Rotate CCW X SOL15 Steer Right X SOL16 Steer Left X SOL17 Low Flow X X X X X SOL18 High Flow X X X SOL19 Generator Valve X SOL20 Brake X SOL21 Torque X SOL22 Axle Lock X SOL23 Fuel X X

TMR Timing Module X X

TRANS Transmitter, DMT-30 X X X X

OWN

CW/CCW

EVEL

HARGE

ATTERY

LATFORM

OTATE

LATFORM

OCK

XLE

RONT

IGHT

ILT

ELEASE

RAKE

OTATE

ARKING

URRET

LARM

ILT

IGH

ORQUE

OWERIN G

MERGENCY

ORNDRIVING

PTIONAL

- O

IGHTS

PTIONAL

- O

ENERATOR

ONTROLLER

HROTTLE

Page 3-16 104045-021 - AB62 Work Platform - European Model

Page 81

Section 3 - Troubleshooting Hydraulic Truth Table - AB62

3-11 H

YDRAULIC

OMPONENT

RUTH

ABLE

- AB62

TEER

UNCTION

ESCEND

LEVATE

ISER

ETRACT

XTEND

OOM

OWN

OWER

AISE

OOM

CW/C

OWN

OTATE

EVEL

AGE

EVERSE

CW/CCW

OTATE

ORWARD

RIVE

URRET

OCK

XLE

RONT

CB1 Counterbalance Valve, Riser X CB2 Counterbalance Valve, Boom Extend X CB3 Counterbalance Valve, Boom Raise X CB4 Counterbalance Valve, Jib Cylinder X CB5 Counterbalance Valve, Master Cylinder X CB6 Counterbalance Valve, Slave Cylinder X CB7 Counterbalance Valve, Cage Rotate X CB8 Counterbalance Valve, Turret Rotate X CB9 Counterbalance Valve, Left Axle Cylinder X

CB10 Counterbalance Valve, Right Axle Cylinder X CV1-2 High Pressure Test Port Check Valve CV3-7Low Pressure Test Port Check Valve XXXXX

CV8 Boom Extend Cylinder Check Valve X

CV9 Turret Rotate Check Valve X CYL1 Steer Cylinder X CYL2 Riser Cylinder X

CYL 3 Boom Extend Cylinder X

CYL4 Boom Raise Cylinder X CYL5 Jib Cylinder X CYL6 Master Cylinder X CYL7 Slave Cylinder X CYL8 Turret Rotate Brake Cylinder X

CYL11 Left Axle Lock Cylinder X CYL12 Right Axle Lock Cylinder X

FD1-2 Flow Divider X

FL1 Suction Filter XXX FL2 Suction Filter XXXXXXXX X

FL3 Return Filter MOT1 Left Rear Drive Motor X MOT2 Right Front Drive Motor X MOT3 Right Rear Drive Motor X MOT4 Left Front Drive Motor X

ORF1 Turret Orifice X ORF2 Riser Orifice X

ORF3-4 Drive Orifice X

PMP12 Stage Boom Pump XXXXXXXX PMP2 Variable Drive Pump XXX PMP3 Auxiliary Pump X

ROT Cage Rotator X

RV1 Low Pressure Relief Valve XXXXX RV2 High Pressure Relief X X X RV3 Jib Cylinder Relief X

V1 Steering Valve X V2 Riser Valve X V3 Boom Extend Valve X

ELEASE

RAKE

OWER

MERGENCY

104045-021 - AB62 Work Platform - European Model Page 3-17

Page 82

Hydraulic Truth Table - AB62 Section 3 - Troubleshooting

OWN

CW/C

OWN

OTATE

EVEL

AGE

OMPONENT

UNCTION

ESCEND

ETRACT

LEVATE

ISER

TEER

XTEND

OOM

OWER

AISE

OOM

V4 Boom Raise Valve X V5 Jib Valve X V6 Cage Level Valve X V7 Turret Rotate Valve X V8 Cage Rotate X

V9 Low Flow Valve XXXXX V10 High Flow Valve X X X V11 Diverter Valve V12 Brake Valve X V13 Axle Float Valve X V14 High Speed Valve X V15 Rear Drive Torque/Speed Valve X V16 Front Drive Torque/Speed Valve X

CW/CCW

OTATE

URRET

EVERSE

ORWARD

RIVE

OCK

XLE

RONT

ELEASE

RAKE

OWER

MERGENCY

Page 3-18 104045-021 - AB62 Work Platform - European Model

Page 83

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 Troubleshooting Truth Tables in the Troubleshooting section. They allow understanding of the makeup and functions of the systems for checking, tracing, and faultfinding during troubleshooting analysis.

The components that comprise the electrical and hydraulic systems are given a reference designation and are explained as to function and location in the following tables.

ABLE

ONTENTS

4-1 Electrical Schematic - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

104049-000 Electrical Schematic - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

104048-011 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

104525-000 Valve Manifold Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-3 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

104531-000 Diesel Platform Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

104531-000 - Platform Controls Wiring Diagram - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-4 Chassis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

104019-000 Chassis Control Box - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

104019-000 - Chassis Control Box Wiring Diagram - Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

104045-021 - AB62 Work Platform - European Model Page 4-1

Page 84

Electrical Schematic - Diesel Section 4 - Schematics

4-1 E

Legend:

REFERENCE NAME FUNCTION LOCATION

ACT1 Actuator Throttle Engine Module

ALM1 Alarm, Tilt

ALT Alternator Charge Battery Engine BAT1 Battery Start Engine Under Hydraulic Block BAT2 Battery Auxiliary Power Under Hydraulic Block

CB1 Circuit Breaker Overload protection for DMR-30 Lower Control Box

CB2 Circuit Breaker

CB3 Circuit Breaker

CONT1 CONT2 Controller Glow Plug Controller Engine Module

D1 Diode Auxiliary Power from Platform Lower Control Box D2 Diode Not Used D3 Diode Power to Platform Controls Engine Module

D4 Diode D5 Diode Auxiliary Pump Relay Signal Lower Control Box D6 Diode D7 Diode Alternator exciter signal Engine, near Alternator

D8 Diode Spike Protection Diode Engine Module D9 Diode Spike Protection Diode Engine Module

FU1 Fuse Auxiliary Power Motor Control Module

HORN Horn Sound Alarm Upper Control Box

ISO Isolator Charge Isolator Engine

Lamp1 Lamp Distress, Engine Upper Control Box Lamp2 Lamp Tilt Upper Control Box Lamp3 Lamp Glow Plug Upper Control Box Lamp4 Lamp Glow Plug Lower Control Box

LS1 Limit Switch Linkage Limit Switch Lower Linkage Assy.

LS2 Limit Switch Proximity Switch

MOT1 Motor Auxiliary Pump Control Module MOT2 Motor Start Engine Engine MTR1 Meter Engine Temperature Lower Control Box MTR2 Meter Oil Pressure Lower Control Box MTR3 Meter, Hour Hours machine has operated. Lower Control Box PMP1 Pump Drive Engine Module

R1 Relay Engine Start Relay Engine Module R5 Relay Drive Motion Alarm Lower Cntrol Box Strip R6 Relay Not Used Lower Cntrol Box Strip R7 Relay Not Used Lower Cntrol Box Strip R8 Relay Left Axle Release Lower Cntrol Box Strip

R9 Relay Right Axle Release Lower Cntrol Box Strip R10 Relay Axle Release Signal Lower Cntrol Box Strip R11 Relay Power to DMR-30 Lower Control Box R12 Relay Auxiliary Pump Relay Lower Control Box

R13 Relay R14 Relay Drive Enable Platform Control Box

R15 Relay Auxiliary Pump Motor Control Module

SW1 Switch Emergency Stop Platform Control Box SW2 Switch, Ignition Start Engine Platform Control Box SW3 Not Used SW4 Switch Auxiliary Power Platform Control Box

LECTRICAL

CHEMATIC

104049-000 Electrical Schematic - Diesel

Controller, DMR-30

Provide warning sound when machine is off-level

Overload protection Platform Control Overload protection Platform Accessories

Controls machine functions Lower Control Box

Prevents Auxiliary Pump operation when ignition is on

Auxiliary Power to Lower Controls

Ignition cutout during Auxiliary Power

Lower Control Box

Right side, rear of main Boom

Lower Control Box

- D

IESEL

REFERENCE NAME FUNCTION LOCATION

SW5 Switch Generator Platform Control Box SW6 Switch Drive Hi/Low Speed Platform Control Box SW7 Switch Level the Platform Platform Control Box SW8 Switch Boom, Up/Down Platform Control Box

SW9 Switch Turret Rotate Platform Control Box SW10 Switch Cage Rotate Platform Control Box SW11 Switch Jib, Up/Down Platform Control Box SW12 Switch Riser, Up/Down Platform Control Box SW13 Switch Boom, Retract/Extend Platform Control Box SW14 Switch Driving Lights Platform Control Box SW17 Switch Oil Pressure Switch Engine Module SW18 Switch Horn Lower Control Box SW19 Switch Interlock, Foot Platform Control Box SW21 Switch Emergency Stop Lower Control Box SW22 Switch Selector Lower Control Box SW23 Switch Auxiliary Power Lower Control Box SW24 Switch Enable Lower Control Box SW26 Switch Boom, Speed Lower Control Box SW28 Switch, Ignition Engine Start Lower Control Box SW29 Switch Turret Rotate Lower Control Box SW30 Switch Boom, Up/Down Lower Control Box SW31 Switch Level the Platform Lower Control Box SW32 Switch Cage Rotate Lower Control Box SW33 Switch Jib, Up/Down Lower Control Box SW34 Switch Riser, Up/Down Lower Control Box SW35 Switch Boom, Extend/Retract Lower Control Box

SNSR1 Sensor, Tilt

SNSR2 Sensor Engine Temperature Engine SNSR3 Sensor Engine Oil Pressure Engine

SOL1 Solenoid Trim, Up Boom Valve Block SOL2 Solenoid Trim, Down Boom Valve Block SOL3 Solenoid Jib, Up Boom Valve Block SOL4 Solenoid Jib, Down Boom Valve Block SOL5 Solenoid Boom, Up Boom Valve Block SOL6 Solenoid Boom, Down Boom Valve Block SOL7 Solenoid Boom, Extend Boom Valve Block SOL8 Solenoid Boom, Retract Boom Valve Block

SOL9 Solenoid Riser, Up Boom Valve Block SOL10 Solenoid Riser, Down Boom Valve Block SOL11 Solenoid Cage Rotate, CW Boom Valve Block SOL12 Solenoid Cage Rotate, CCW Boom Valve Block SOL13 Solenoid Turret Rotate, CW Boom Valve Block SOL14 Solenoid Turret Rotate, CCW Boom Valve Block SOL15 Solenoid Steer, Right Boom Valve Block SOL16 Solenoid Steer, Left Boom Valve Block SOL17 Solenoid Low Flow Proportional Boom Valve Block SOL18 Solenoid High Flow Proportional Boom Valve Block SOL19 Solenoid Generator Valve Gen Valve Block SOL20 Solenoid Brake Engine Module SOL21 Solenoid Torque Engine Module SOL22 Solenoid Axle Lock Engine Module SOL23 Solenoid Fuel Engine Module

TMR Timing Module Fuel Solenoid Pull Circuit Engine

TRANS

Transmitter DMT-30

Activate tilt alarm. Disable all machine functions except Platform Lower when machine is more than 3° off level.

Transmit signal to controller Platform Control Box

Control module

Page 4-2 104045-021 - AB62 Work Platform - European Model

Page 85

Section 4 - Schematics Electrical Schematic - Diesel

SOL1

SOL2

SOL3

SOL4

SOL5

SOL6

SOL7

SOL8

SOL9

SOL10

SOL11

SOL12

SOL13

SOL14

SOL15

SOL16

SOL17

SOL18

SOL19

SNSR1

LS1

LS2

HORN

BAT2

BAT1

MOT1

FU1

R15

SOL20

SOL21

SOL22

PMP1

ALT

ISO

MOT2

SNSR2

SNSR3

SW17

SOL23

ACT1

CONT2

TMR

104049-000 Electrical Schematic - Diesel - Drawing 1 of 2

104045-021 - AB62 Work Platform - European Model Page 4-3

Page 86

Electrical Schematic - Diesel Section 4 - Schematics

SW1

SW19

LAMP1

LAMP2

ALM1

SW2

SW3

SW4

SW5

SW6

SW7

SW8

SW9

SW10

SW11

SW12

SW13

SW14

LAMP3

LAMP4

SW21

SW22

SW23

CB1

CB2

CB3

SW24

MTR1

MTR2

MTR3

SW28

SW26

SW29

SW30

SW31

SW32

SW33

SW34

SW35

R10

SW18

DRIVE CONTROLLER

R12

R11

R13

R14

TRANS

CONT1

104049-000 Electrical Schematic - Diesel - Drawing 2 of 2

Page 4-4 104045-021 - AB62 Work Platform - European Model

Page 87

Section 4 - Schematics Hydraulic Schematic

4-2 H

Legend:

REFERENCE NAME FUNCTION LOCATION

CB1

CB2

CB3

CB4

CB5

CB6

CB7

CB8

CB9

CB10

CV1&2 Check Valve

CV3-9 Check Valve

CV10 Check Valve

CV11 Check Valve Turret Rotate Check Valve CYL1 Cylinder Steering Cylinder Chassis

CLY2 Cylinder Riser Cylinder Riser CYL3 Cylinder Boom Extend Cylinder Inside Boom CYL4 Cylinder Boom Raise Cylinder Front of Boom CYL5 Cylinder Jib Cylinder Jib CYL6 Cylinder Master Cylinder Rear of Boom CYL7 Cylinder Slave Cylinder Front of Boom

CYL8 Cylinder Turret Rotate Brake Cylinder Turret Rotate Motor CYL11 Cylinder Left Axle Lock Cylinder Front Axle CYL12 Cylinder Right Axle Lock Cylinder Front Axle

FD1-2 Flow Divider Flow Divider Drive Valve Block

YDRAULIC

CHEMATIC

104048-011 Hydraulic Schematic

Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve Counterbalance Valve

Riser Counterbalance Riser Cylinder

Boom Extend Counterbalance Boom Extend Cylinder

Boom Raise Counterbalance Boom Raise Cylinder

Jib Counterbalance Jib Cylinder

Master Counterbalance Master Cylinder

Slave Counterbalance Slave Cylinder

Cage Rotate Counterbalance

Turret Rotate Counterbalance Turret Rotate Motor

Left Axle Counterbalance Left AXle Lock Cylinder

Right Axle Counterbalance High Pressure Test Port

Check Valve Low Pressure Test Port Check Valves Boom Extend Cylinder Check Valve

Cage Rotate Valve Block

Right Axle Lock Cylinder

Main Valve Block

Boom Extend Cylinder Turret Rotate Valve

Block

REFERENCE NAME FUNCTION LOCATION

FL1 Filter Suction Filter Tank FL2 Filter Suction Filter Tank

FL3 Filter Return Filter Tank MOT1 Drive Motor Left Rear Drive Motor Left Rear Axle MOT2 Drive Motor Right Front Drive Motor Right Front Axle MOT3 Drive Motor Right Rear Drive Motor Right Rear Axle MOT4 Drive Motor Left Front Drive Motor Left Front Axle

ORF1 Orifice Limit Turret Rotate Speed Main Valve Block ORF2 Orifice Limit Riser down speed Riser Cylinder

ORF3 & 4 Orifice

PMP1 Pump Two Stage Pump Engine Module PMP2 Pump Variable Drive Pump Engine Module PMP3 Pump Auxiliary Pump Engine Module

ROT Rotator Cage Rotator Platform RV1 Relief Valve Low Pressure Relief Main Valve Block RV2 Relief Valve High Pressure Relief Boom Valve Block RV3 Relief Valve Slew Relief Main Valve Block RV4 Relief Valve Jib Cylinder Relief Jib Cylinder

V1 Valve Steer Valve Main Valve Block V2 Valve Riser Valve Main Valve Block V3 Valve Boom Extend Valve Main Valve Block V4 Valve Boom Raise Valve Main Valve Block V5 Valve Jib Valve Main Valve Block V6 Valve Cage Level Main Valve Block V7 Valve Turret Rotate Main Valve Block V8 Valve Cage Rotate Main Valve Block

V9 Valve Low Flow Valve Main Valve Block V10 Valve High Flow Valve Main Valve Block V11 Valve Diverter Valve Main Valve Block

V12 Valve Brake Valve

V13 Valve Axle Float Valve

V14 Valve High Speed Valve V15 Valve Rear Drive Valve Drive Valve Block

V16 Valve Front Drive Valve Drive Valve Block

Limit Flow Between Front and Rear Drive Motors

Drive Valve Block

Brake, Axle Lock, 2-Speed Valve Block Brake, Axle Lock, 2-Speed Valve Block Brake, Axle Lock, 2-Speed Valve Block

104525-000 V

V10

ALVE

ANIFOLD

HIGH PRESSURE

LOW PRESSURE

SSEMBLY

V11

TEST PORT

RV2

RV1

TEST PORT

CV1

CV2

CV8

CV3

CV9

CV4

CV5

RV3

CV6

CV7

104045-021 - AB62 Work Platform - European Model Page 4-5

ORF1

Page 88

Hydraulic Schematic Section 4 - Schematics

MOT1

MOT2

MOT3

MOT4

CYL1

CYL12

CYL11

CB9

CB10

V12

V13

V14

FL1

PMP2

PMP1

FL3

FL2

ORF3

ORF4

FD1

FD2

V15

V16

CYL2 CYL3

CYL4

CYL5

CB1

ORF2

CB2

CV10

CB3

CB4

RV3

CYL6

CB5

CYL7

CB6

CYL8

CB8

CV11

ROT

CB7

ORF1

CV6

CV7

RV1

RV3

CV5

CV4CV9

CV3

CV8

V10

V11

RV2

CV2

CV1

PMP3

104048-011 Hydraulic Schematic - Drawing 2 of 2

Page 4-6 104045-021 - AB62 Work Platform - European Model

Page 89

Section 4 - Schematics Platform Controls

1. Riser

2. Boom Raise

3. Boom Extend

4. Jib Raise

5. Emergency Stop

6. Engine Temperature

7. Tilt Indicator

8. Hi/Lo Speed

9. Glow Plug Light

10. Auxiliary Power

11. Turret Rotate

12. Cage Rotate

13. Cage Level

14. Horn

15. Boom Speed

16. Proportional Drive Controller

17. Steering

18. Multiplex Transmitter

19. Terminal Strip

20. Connector, 31 Socket

21. Cable Connector

22. Connector, 4 Socket

23. Lever Switch

24. Alarm

25. Interlock Relay

4-3 P

LATFORM

104531-000 D

ONTROLS

IESEL

LATFORM

ONTROL

104045-021 - AB62 Work Platform - European Model Page 4-7

Page 90

Platform Controls Section 4 - Schematics

104531-000 - P

LATFORM

ONTROLS

IRING

IAGRAM

- D

IESEL

Page 4-8 104045-021 - AB62 Work Platform - European Model

Page 91

Section 4 - Schematics Chassis Controls

1. Hour Meter

2. Water Temp

3. Oil Pressure

4. Circuit Breaker

5. Key Switch

6. Engine Start

7. Enable

8. Diesel: Glow Plug Light

9. Emergency Stop

10. Riser

11. Boom Raise

12. Boom Speed HI/LOW

13. Boom Extend

14. Jib

15. Turret

16. Platform Rotate

17. Platform Level

18. Auxiliary Power

19. Relay 12 Volt

20. Terminal Strip

21. Relay Card Assembly

22. Multiflex Receiver

4-4 C

HASSIS

104019-000 C

ONTROLS

HASSIS

ONTROL

- D

IESEL

104045-021 - AB62 Work Platform - European Model Page 4-9

Page 92

Chassis Controls Section 4 - Schematics

104019-000 - C

HASSIS

ONTROL

IRING

IAGRAM

- D

IESEL

Page 4-10 104045-021 - AB62 Work Platform - European Model

Page 93

Call Toll Free in U.S.A.

1-800-926-LIFT

Page 94

UpRight, Inc.

801 South Pine Street Madera, California 93637

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

Call Toll Free in U.S.A.

1-800-926-LIFT

P/N 104045-021

06-02

UpRight

Unit S1, Park West Industrial Park

Friel Avenue

Nangor Road

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