Page 1
Instant UpRight
Self-propelled Scissor Lift MX & X series
Service and Maintenance Manual
1 “Translation of the original instruction”
Page 2
Before operating, please read and understand this manual
Dear Clients:
Thank you for purchasing this quality product!
Your new access equipment is the result of an innovative
approach and the pursuit of quality. It has been designed to be
functional, safe, comfortable and durable. It has style with
excellent operational features.
When your machine requires maintenance, only the genuine
spare parts should be used as supplied by Upright in order to
ensure safety and reliability.
thoroughly!
!
Note: The Company’s products are in continuous improvement, diagrams are
not modified generally unless the product has significant changes. For any
queries or discrepancies refer to Upright or appointed agent.
2 “Translation of the original instruction”
Page 3
Essentials............................................................
......6
......7
......14
......15
......23
......23
......24
......24
......25
.....
......26
......27
......29
......30
......30
......31
......31
......32
......32
......33
......33
Brief Introduction
Safety Rules
Table of content
General Safety Rules....................................................
Specification
Hydraulic specifications........................................................
Hydraulic joint thread torque................................................
Regular maintenance procedures
Check table A program
A-1 Check the operating manual and safety manual....................................
A-2 Check the logo and label............................................
A-3 Perform pre-operation check............................................
A-4 Perform functional test..............................................
A-5 Check the hydraulic oil level............................................
A-6 Check for fuel leakage..............................................
A-7 Check the tire pressure..............................................
Check table B program
.25
B-1 Check the battery................................................
B-2 Check the electrical wiring..............................................
B-3 Check tire, wheel and groove nut torque..............................
B-4 Test emergency stop..............................................
B-5 Test the key switch..............................................
B-6 Test drive brakes............................................
B-7 Test drive speed - stowed position....................................
B-8 Test drive speed - raised position....................................
B-9 Check the electrical contactor............................................
B-10 Perform hydraulic oil analysis............................................
3 “Translation of the original instruction”
Page 4
......34
......34
......35
C-1 Test platform overload pressure sensor and platform height sensor (if
......36
......39
......39
......40
......41
......42
......43
......46
......47
......47
1-4 Method of removing the platform controller emergency stop
button..........................
......48
......49
......50
3-1 Method of removing scissor arm parts (take 80W as an
......52
......56
......58
......59
......61
......62
B-11 Check the oil level in the drive hub......................................
B-12 Replace the hydraulic tank return filter....................................
B-13 Check that the brake structure is correct..........................................
Check table C program
equipped)........
Check table D program
D-1 Check the chassis slider and the platform slider....................................
D-2 Replace the hydraulic filter............................................
D-3 Replace the wheel oil............................................
D-4 Test function pump................................................
Check table E program
E-1 Test or replace hydraulic oil..........................................
E-2 Apply grease to steering shaft and wheel bearings................................
Repair procedures
Platform controller
1-1 Method of removing the platform controller circuit board ................................
1-2 Method of removing the handle........................................
1-3 Method of removing the platform control alarm..................................
Platform components
2-1 Method of removing the platform............................................
2-2 Method of removing the platform extension board....................................
Scissor arm components
example)............................
3-1 Method of removing scissor arm parts (take 100W as an
example)...........................
3-3 Method of replacing the pad............................................
3-3 Lifting cylinder..................................................
Chassis components
4-1 Hydraulic pump....................................................
4-2 Hydraulic tank..................................................
4 “Translation of the original instruction”
Page 5
......63
......64
......64
......65
......68
Electrical schematic of electric drive A system............................................
......74
......75
......76
Schematic of electrical components of hydraulic drive A
system........................................
......77
......78
......79
Diagram of descend line, raised switch, 2m limit six core line of hydraulic drive A
system.................
......80
Connection diagram of descend line, raised switch, 2m limit six core line of hydraulic
......81
......82
Wiring diagram of valve group connection line of lower control box to controller of
hydraulic drive A system......................
......83
......84
Internal wiring diagram of base control box of hydraulic drive A
system
...................................
......85
...................................
......86
......87
Schematic of electrical components of hydraulic drive B
system........................................
......88
......89
......90
....
......92
......93
4-3 Method of removing the steering wheel seat parts....................................
4-4 Method of removing the motor............................................
4-5 Method of removing the steering cylinder........................................
4-6 Method of removing the rod............................................
Fault code
B system fault code ...................................................
Simplified diagram
Electrical diagram
Electrical schematic of electric drive B system............................................
Electrical schematic of hydraulic drive A system............................................
High current wiring diagram of hydraulic drive A system......................................
Wiring diagram of hydraulic drive A system............................................
drive A system.................
Schematic diagram of valve group connection line of lower control box to controller of
hydraulic drive A system......................
Upper control six core wire of hydraulic drive A system............................................
Internal wiring diagram of upper control box of hydraulic drive A
system
Electrical schematic of hydraulic drive B system............................................
High current wiring diagram of hydraulic drive B system......................................
Wiring diagram of hydraulic drive B system............................................
Upper control six core wire of hydraulic drive B system............................................
Wiring diagram of hydraulic drive B system..........................................
Schematic diagram hydraulic drive B system..........................................
5 “Translation of the original instruction”
..91
Page 6
Internal wiring diagram of base control box of hydraulic drive B
system......................................
......94
......95
Hydraulic diagram
Hydraulic schematic of X-W Series
.........................................
Essentials
Thank you for choosing and using our machines. We pay attention to the safety of users,
which by our endeavors we attempt to achieve it. We believe that as a user and operator
of our equipment, and you comply with the following requirements, the use of equipment
in the correct manner will ensure a greater level of safety: therefore it is essential that the
user
1. Is Compliant with user rules, workplace rules and government rules.
2. Reads, understands and complies with the instructions contained in this manual and
other manuals accompanying the machine.
3. Performs good safety practices by convention.
4. is Trained, Certified and Authorised to use the machine under the guidance of
experienced and knowledgeable supervisors.
Please contact us if there is content that is ambiguous in this manual or suggestions on
how we might improve the content to your satisfaction.
Web： www.instantupright.com
6 “Translation of the original instruction”
Page 7
1. Safety Rules
Dangerous
Failure to follow the instructions and safety rules in this manual may result in
death or serious injury.
The machine maintenance work shall not be carried out unless the following conditions are
met:
Maintenance personnel for this machine are trained and qualified.
Read, understand and observe:
- Manufacturer's instructions and safety rules
- Employer safety rules and workplace regulations
- And any applicable government regulations
the Workshop that has the correct tools and working environment to carry out the necessary repairs.
7 “Translation of the original instruction”
Page 8
1.1 Safety Rules
1.1.1Personnel Safety
Any person working on or around the
machine, beware of all known dangerous
operating safety hazards. Personnel
safety and continuous safe operation of
the machine should be the top priority.
Read each procedure carefully.
The meanings of the symbols
used in this manual and on
the machine are as follows:
Safety warning signs - used
to indicate potential
personal injury. Observe all
safety tips on the mark to
avoid possible injury or
death.
Indicates the emergency
hazard condition, if not
avoided, could result in
death or serious injury.
Indicates the potential
emergency hazard
condition, if not
avoided, could result in
death or serious injury.
Indicates the potential
emergency hazard
condition, if not
avoided, could result in minor or
moderate personal injury.
Note Indicates the potential
emergency hazard condition, if not
avoided, could result in property
damage.
If necessary, be sure to wear
protective glasses and wear
protective clothing.
When Lifting or loading the
SWL when the parts are
moving, parts that are free to
swing or are not fixed, may
cause a risk of injury. Always put on
protective shoes and clothing while
working.
8 “Translation of the original instruction”
Page 9
1.1.2 Work Place Safety
Be sure to keep flame and lit
lighted cigarettes away from
flammable substances such as
battery gas and engine fuel.
Place an approved fire extinguisher in an
easily accessible area.
Be sure to maintain all the
tools and work areas for use.
Keep the working surface clean
and prevent debris from
entering the machine parts.
Be sure that all forklifts,
cranes and other lifting or
supporting equipment have
sufficient support strength and safety
stability for the objects they lift. Use in
good condition and have enough
strength for chains and belts.
Be sure to ensure that
disposable fasteners (ie, cotter
and self-locking nuts) can not
be reused. The second use of
these components may result in failure.
Be sure to correctly handle
waste oil or other liquids. Use
approved containers. To ensure
environmental safety.
Be sure to keep the
Workshops well ventilated
and bright.
9 “Translation of the original instruction”
Page 10
Displacement
2． Hydraulic Specifications
Function Pump
Type: Gear pump
Per rotation
Velocity at 3000rpm 12L/min
Functional Manifold
System safety valve pressure
Raise safety valve pressure 190bar
Steering relief valve pressure
Steering flow regulator 3.5L/min
4cc
240bar
120bar
10 “Translation of the original instruction”
Page 11
2.3 Hydraulic Joint Thread Torque
Metric O-ring flat seal torque, 74° metric torque
11 “Translation of the original instruction”
Page 12
2.4 Hydraulic Hoses and Fittings Installation Procedures
1.Replace the "O" ring.
2.When the seal leaks, the "O" ring must be replaced. The "O" ring shall not be reused if the torque at
the joint or hose connector exceeds the tightening torque/force of the hand.
3.Apply a layer of oil to the "O" ring before installation.
4.Ensure that the cross-section seal "O" is place fitted and positioned correctly.
5.Straighten the pipe and nut joint seal and tighten the nut by hand.
6.In accordance with the above table, tighten the nut and joints according to the established size of
the corresponding torque.
7.Run all the functions of the machine and check the hose and fittings as well as the relevant parts to
ensure no leakage.
12 “Translation of the original instruction”
Page 13
2.5 Specification
SAE Fastener Torque Chart
Use this Chart only for reference unless otherwise noted in other places in this
manual. *
Dimension Screw thread Class 5 Class 8 A574 High strength black oxidation bolts
Lubricant Dry
Metric Fasteners Torq ue Chart
Use this Chart only for reference unless otherwise noted in other places in this
manual.
13 “Translation of the original instruction”
Page 14
14 “Translation of the original instruction”
Page 15
Failure to implement the procedures
The machine has been disconnected from all
After completing a series of steps, specific result
3. Regular Maintenance Procedures
Please obey:
Maintenance and inspection should be carried
out by trained maintenance and qualified
personnel for this machine.
Perform maintenance inspections daily,
quarterly, semi-annual, annual and every two years
according to the maintenance inspection report.
Caution!
specified may result in death, serious injury or
substantial damage to the machine.
Damaged or malfunctioning machines should be
marked immediately and removed from use.
Before operating the machine, repair all damage
and malfunctions of the machine.
Use only Instant UpRight approved replacement
parts.
For machines that are idle for more than 3
months, quarterly checks must be made.
Unless otherwise specified, the following
procedure shall be followed when undertaking any
and all maintenance work.
. Place the machine on a solid horizontal surface
. The platform is in the stowed position
. The key switch is in the OFF position and the key is
unplugged
. The red "emergency stop" button for the ground
and platform controllers is in the OFF position
. The wheel is in a locked state
.
external AC power sources
About this section
This section contains detailed procedures for each
periodic maintenance check. Each program includes
instructions, safety warnings and step-by-step
instructions.
Symbol legend
Safety warning signs - Used to warn of potential
danger of personal injury
Prompts an emergency hazard situation that, if not
avoided, can result in death or serious injury
Prompts an emergency hazard situation that, if not
avoided, could result in minor or moderate personal
injury
Prompts a potentially hazardous situation that, if not
avoided, could result in property damage
Tip :
may appear
Tip
After completing a series of steps, an error result
appears
15 “Translation of the original instruction”
Page 16
3.1 Regular Maintenance Procedures
personnel.
Pre-delivery preparation report
Maintenance Symbol Legend:
Note: This manual uses the following
symbols to help express the relevant
meaning in the instructions. When the
maintenance program appears in front
of one or more symbols, the meaning of
the expression is as follows.
Indicates that the tool is required to
execute this program.
Indicates that the execution of this
program requires new parts.
Indicating that the engine is
overheating and needs to be in cooled.
Indicates that the engine needs to be in
a heated state.
Indicates that this program requires the
The pre-delivery preparation report
contains a checklist of each type of
periodic inspection. Copy the
preparation report before delivery for
inspection. Save the completed form as
needed.
Maintenance schedule
According to the timetable, there are
five types of maintenance checks that
must be carried out. Daily, quarterly, six
monthly,Yearly and every two years.
Periodic maintenance procedures
section and maintenance inspection
reports are divided into five subsections,
A, B, C, D and E. Please follow the table
below to determine the program
combination for performing periodic
checks.
attention of authorised service
Check Check table
Every day or every 8 hours A
Every quarter or every 250 hours A+B
Every six months or every 500 hours A+B+C
Every year or every 1000 hours A+B+C+D
Every two years or every 2000 hours A+B+C+D+E
Maintenance Check Report
The maintenance check report contains a list of check items for each type of periodic
inspection.
Copy and maintain check reports for inspection, save the completed forms at least 4
years or save it in accordance with employers, workplaces and government regulations
and requirements.
16 “Translation of the original instruction”
Page 17
Legend
3.2 Basic principle
The implementation of "pre-delivery" is the responsibility of the dealer.
Perform "pre-delivery" inspection before each delivery. The purpose of the inspection is
to find out if there is a significant problem before the machine is put into use.
Damaged or altered machines should not be used. If any damage is found or
non-approved parts fitted from original manufacturer’s parts, the machine should be
removed from service and reported.
According to the manufacturer's regulations, only qualified service technicians can
repair the machine.
In accordance with the requirements set out in the manufacturer's specifications and
duties manual, periodic maintenance inspections should be performed by qualified
service technicians.
3.3 Specification
Use the machine's operating manual.
"Pre-delivery preparation" consists of a pre-operation check, maintenance item, and
functional test.
Use this form to record the results. After completing each part, mark the corresponding
box. Follow the instructions in the operating instructions.
If any of the checks are marked as "N", the machine is deactivated, repaired and
rechecked. After repair, mark the box marked "R".
Y = Yes, has been completed
N = No, cannot complete
R= R = has been repaired
Note
17 “Translation of the original instruction”
Page 18
All Checks before Operating are completed
The maintenance project is completed
Functional testing is completed
Model
Series Number
Date
Machine owner
Inspector (please write in block letters)
Inspector signature
Inspector duties
Inspector’s office
Prepare before delivery Y N R
18 “Translation of the original instruction”
Page 19
Model
Machine owner
Inspector (please write in block letters)
Inspector duties
Inspector's office
Every day or every 8 hours
Every quarter or every 250 hours
Check: A+B
Every six months or every 500 hours
Every year or every 1000 hours
Every two years or every 2000 hours
Legend
4. Maintenance Check Report
Serial number
Date
Inspector signature
Copy this report for use with each check.
Select the appropriate checklist according to the type of inspection.
Check: A
Check: A+B+C
Check: A+B+C+D
Check: A+B+C+D+E
After completing each inspection procedure, mark the corresponding box.
Use the step-by-step check program in this section to learn how to check.
If any of the inspections are marked as "N", the machine is marked, repaired and
rechecked and reinspected. After repair, mark the box with "R".
Y = Yes, acceptable
N = No, stop using
19 “Translation of the original instruction”
Page 20
Check table A Y N R
A-1 Check the Operating and safety manual/s
A-2 Check the logo and label
A-3 Perform pre-operation check
A-4 Perform Functional test/ check
A-5 Check the hydraulic oil level
A-6 Check for hydraulic oil leak
A-7 Check the tire pressure & nuts torqued
20 “Translation of the original instruction”
Page 21
Check Table B Y N R
B-1 Check the battery connections & fluid level
B-2 Check the electrical wiring
B-3 Check tyre, wheel and groove nut torque
B-4 Test emergency stop function
B-5 Test the key switch function
B-6 Test drive brakes
B-7 Test drive speed - stowed position
B-8 Test drive speed - raised position
B-9 Check the electrical contactor
B-10 Perform hydraulic oil analysis
B-11 Check the oil level in the drive hub
B-12 Replace the hydraulic tank return filter
B-13 Be sure the brake mechanism is correct
Check table C Y N R
C-1 Test platform overload pressure sensor and
platform height sensor (if equipped)
Check table D Y N R
D-1 Check the chassis and the platform slide blocks
D-2 Replace the hydraulic filter
D-3 Replace the wheel oil
D-4 Test hydraulic pump functions correctly
Check table E Y N R
E-1 Test or replace hydraulic oil
E-2 Apply grease to steering shaft and wheel bearings
21 “Translation of the original instruction”
Page 22
Check the operating manual and safety
4.1 Check Table A program
A-1
4.1.1 Check the Operator and Safety Manual /s
Keeping the Operator and safety Manuals in
good condition is critical to safe operation of the
machine. Each machine is equipped with
manuals, which should be kept in the box holder
provided on the platform. A blurred or
handwritten defect will not provide the
information needed for safe operation.
1.Check the holder box for storing the manual to
ensure it is fitted and is in good condition.
2.
manual to ensure that it exists, is complete and
placed in the storage holder box on the
platform.
3.Check each manual page to ensure that it is
clearly written and in good condition.
4.After using the manual, return it to the Holder
box.
If you need to change the manual, please
contact Instant UpRight or authorised dealer.
A-2
4.1.2 Check all Decals and Warning Labels
For safe operation of the machine, it is
necessary to keep all the safety and guidance
signs and labels in good condition. The
markings are used to alert the operator and
the person concerned to the many hazards
that may be present when using the
machine. They also provide users with some
operating and maintenance information. If
the writing is blurred, it will not be possible
to warn the staff of the need for a procedure
or the risk of being present and may produce
unsafe operating factors.
1. Refer to the label in the "Symbols" and
use the list and description of the label to
make sure that all Decals and labels are in
the appropriate position.
2.Check that all labels are clear and intact.
Replace any damaged or blurred decals &
Signs and labels immediately.
If you need to change the manual, please
contact Instant UpRight or authorised
dealer.
22 “Translation of the original instruction”
Page 23
requires this procedure to be
for safe operation of the machine. The
procedure. Please refer to the "Operation
procedure. Please refer to the "Operation
A-3
4.1.3Perform Pre-operation Check
Instant UpRight
carried out every 8 hours or at minimum daily.
Completing the "pre-operation check" is essential
pre-operation check is the visual inspection of the
operator before each work shift. The purpose of
the inspection is to find out if there is a significant
problem with the machine before the operator
performs the functional test. Pre-operation
checks can also be used to determine if routine
maintenance procedures are required.
The corresponding operating manual contains
complete information about the execution of this
A-4
4.1.4 Perform Functional Tests
Instant UpRight requires this procedure to be
carried out every 8 hours or at minimum daily.
Completing the functional test is critical to safe
operation of the machine. Functional tests are
used to detect faults before starting to use the
machine.. If a fault is found, the machine must
be marked and taken out of service for repair
stopped. The use of faulty machines is forbidden
The corresponding operating manual contains
complete information about the execution of this
Manual" on the machine.
Manual" on the machine.
23 “Translation of the original instruction”
Page 24
hydraulic oil leaks is critical to safe
machine. Hidden leaks can cause dangerous
conditions, reduce machine performance and
A-5
4.1.5Check the Hydraulic Oil Level
Keeping the hydraulic oil at the right oil level is
critical to the machine's work. If the hydraulic oil is
low or unsuitable, it will damage the hydraulic
system and parts. Through routine inspections,
the inspector can determine the change in the
hydraulic oil level, which can indicate a problem
with the hydraulic system.
Make sure that the arm is in the stowed position
and then visually inspect the oil level gauge on the
side of the hydraulic tank. Refuel as needed.
Result: The hydraulic oil level should be within 5
cm of the upper part of the oil level gauge.
A-6
4.1.6 Check the Hydraulic Oil Leak
Inspecting
operation and to maintain good performance of the
damage to machine parts.
The risk of physical injury.
Oil under pressure sprayed out of the hydraulic
system may penetrate and burn the skin.
1. Check whether there is any oil or oil residue on or
around the following parts:
ɑ Hydraulic tanks - filters, fittings, hoses, auxiliary
power units, filters
ɑhydraulic oil filter, fittings, hoses, pumps,
ɑ all the hydraulic cylinders
ɑ All hydraulic manifolds
ɑ scissor arms
ɑ underneath the drive chassis
ɑ ground area below the machine
24 “Translation of the original instruction”
Page 25
serious injury.
wear, it is essential to maintain the
A-7
4.1.7 Check the Tire Pressure
The risk of physical injury. Excessive tyre
pressure may explode and may result in death or
Danger of tipping. Do not use temporary leak repair
methods on tyres to repair the product.
Warning! For machines with sponge
rubber heart tyres, this check is not required.
Caution
Caution! In order to maintain maximum stability,
to optimize the operation of the machine and to
reduce tyre
proper pressure in the pneumatic tyre.
25 “Translation of the original instruction”
Page 26
cables and wiring may cause
substances. Avoid overflow or contact with acidic
and water to neutralize the overflow of the battery
Wear protective clothing and wear protective
free or sealed
battery: to ensure that the battery fixed firmly, the
battery is securely fastened and the cable is
4.2 Check Table B program
B-1
4.2.1 Check the battery
Instant UpRight specifications require this procedure to
be executed every 250 hours or quarterly, whichever
comes first.
The battery condition is good for normal mechanical
performance and safe operation. Improper electrolyte
liquid and damaged
damage to parts and hazards.
Risk of electric shock / burn. Exposure to live circuits
can result in death or serious injury. Remove all rings,
watches and other accessories.
The risk of physical injury. Batteries contain acidic
substances in the battery. With hydrogenated sodium
acid.
glasses.
corroded.
Note: Adding a terminal protector and anti-corrosion
sealant will help eliminate corrosion of the battery
terminals and cables.
cable wiring fastening. Proceed to step 4. Model with
maintenance-free or sealed battery: Make sure the
1.
2.Ensure that the wiring of the battery cable is not
3.Models without maintenance-
tightened. Proceed to step 12.
4.Allow the battery to fully charge and leave for at
least 6 hours.
5.Remove the battery vent cover and check the
specific gravity of each battery unit with a liquid
hydrometer. Write down the results.
6.Check the ambient air temperature and adjust
the specific gravity of each unit according to the
following:
a. Increase the reading of each unit by 0.004 for
each additional 5.5 ° C above 26.7 ° C.
b. Reduce the reading of each unit by 0.004 for
each reduction of 5.5 ° C below 26.7 ° C.
Result: All battery cells show an adjusted specific
gravity of 1.277 or higher. The battery is full. Proceed
to step 11.
Result: One or more battery cells show a specific
gravity of 1.217 or less. Proceed to step 8.
7.Make sure that the battery is balanced or fully
charged and allowed to stand for at least 6 hours.
8.Remove the battery vent cover and check the
specific gravity of each battery unit with a liquid
hydrometer. Write down the results.
26 “Translation of the original instruction”
Page 27
15. Connect the battery charger to a properly
phase AC power
Result: After a brief delay, the transformer will be
9. Check the ambient air temperature and adjust the
Result: All battery cells show an adjusted specific
The difference between the different units in the
d level. If necessary, add
Install the ventilation cover and neutralize any
specific gravity of each unit according to the following:
a. Increase the reading of each unit by 0.004 for
each additional 5.5 ° C above 26.7 ° C.
b. Reduce the reading of each unit by 0.004 for
each reduction of 5.5 ° C below 26.7 ° C.
gravity of 1.277 or higher. The battery is full. Proceed to
step 13.
specific gravity reading is greater than 0.1, or the
specific gravity of one or more units is less than 1.177.
Replace the battery.
10.Check the battery aci
distilled water to 3mm below the bottom of the battery
fill tube. Do not add too much.
11.
electrolyte that may overflow.
All models:
12.Check each battery pack and make sure the battery
wiring is correct. Please refer to the battery wiring
diagram on the machine.
13.Check the battery charger socket and lead wire
insulation is damaged or excessive wear. Replace as
needed.
14. Thoroughly clean the outer surface of the battery
charger. If necessary, check and tighten all wiring on
the charger.
grounded 115V or 230V single-
supply.
humming, indicating that the charger has begun to
charge the battery.
Note: For best results, be sure to use a 14 AWG /
1.5mm three-phase heavy-duty wire with a ground
extension cord that is as short as possible. Please
refer to the battery charger operating instructions.
Note: If you have additional questions about the
operation of the battery charger, please contact the
Instant UpRight service department.
27 “Translation of the original instruction”
Page 28
Maintaining the electrical wiring is critical to safe
Check the following areas for wiring, burned,
Harness connection
3.Check that all of the harness connectors are coated
B-2
4.2.2 Check the Electrical Wiring
Instant UpRight specifications require this procedure to
be executed every 250 hours or quarterly, whichever
comes first.
operation and good machine performance. Failure to
detect and replace burned, worn, corroded, or crushed
wiring may result in unsafe operating conditions and
damage to the parts.
Risk of electric shock / burn. Exposure to live circuits
can result in death or serious injury. Remove all rings,
watches and other accessories.
1.Check the ground bus below the chassis for damage
or loss.
2.
corroded, and loose.
3. Rear axle:
Drive motor
Hydraulic box:
Battery box:
Machine:
Limit switch
Ground control inside
End connection
电 Motor Controller
Battery charger
Battery
Fuse box
Center of drive chassis
Connecting rod assembly
Platform
Platform control
with an adequate insulating grease layer:
Ground controller
Platform controller
Functional manifold
Motor controller
Limit switch
Level sensor
Steering sensor
28 “Translation of the original instruction”
Page 29
Check Tire, Wheel and Groove Nut
be executed every 250 hours or quarterly, whichever
them in good
critical for safe operation and good machine
cause the machine to tipping over. Failure to detect
Check the tire surface and sidewall for incisions,
Remove the slotted nut opening pin and check
to be executed every 250 hours or quarterly,
A functioning emergency stop system is very
important for the safe operation of the machine.
cut off the power and stop all functions of the
NOTE: In the case of safety considerations, in
controller and platform controller to the ON
Push the red "emergency stop" button on the
controller and platform controller to the ON
"emergency stop" button on the
Note: Even if the key switch is turned to the
platform controller, the ground controller's
B-3
4.2.3
Torq ue
Instant UpRight specifications require this procedure to
comes first.
Maintain tires and wheels to keep
condition, as well as suitable wheel fastener torque, is
performance. Damage to tires and / or wheels may
problems and repair in time may also cause damage to
machine parts.
1.
cracks, perforations and abnormal wear.
2.Check the wheels for damage, bending and cracks.
3.
whether the torque of each groove nut is suitable.
CAUTION: When removing the groove nut or checking
the groove nut torque, be sure to replace the cotter
pin.
4.Check whether each lug bolt torque is appropriate.
5.Install a new cot and secure it.
29 “Translation of the original instruction”
B-4
4.2.4 Test Emergency Stop
Instant UpRight specifications require this procedure
whichever comes first.
Incorrect operation "Emergency stop" button can not
machine, which will lead to dangerous situations.
addition to the red "emergency stop" button on the
platform, you can also choose to operate the ground
controller instead of the platform controller.
1.Turn the key switch to the ground controller and
pull the red "emergency stop" button on the ground
position.
2.
ground controller to the OFF position.
Result: All functions of the machine should not
operate.
3.Turn the key switch to the platform controller and
pull the red "emergency stop" button on the ground
position.
4.Push the red
platform controller to the OFF position.
Result: All functions of the machine should not
operate.
"emergency stop" button can also stop all machine
work.
Page 30
are critical to safe operation of the machine. The
to be executed every 250 hours or quarterly,
abnormal noise. When a
not be fully operated, they seem to be working
speed drive. When the reference point on the
B-5
4.2.5 Test the Key Switch
B-6
4.2.6 Tes t Drive Brakes
Instant UpRight specifications require this procedure to
be executed every 250 hours or quarterly, whichever
comes first.
The key switch is working properly and function properly
machine can be operated from the ground controller or
the platform controller.The key switch is used to
determine from which controller to activate. When the
key switch can not activate the corresponding control
panel, it will lead to dangerous operating conditions.
Note: Perform this test on the ground with a platform
controller. Do not stand on the platform.
1.Pull the red "emergency stop" button on the ground
controller and platform controller to the ON position.
2.Turn the key switch to the platform controller.
3.Use the ground controller to check the platform's up /
down function.
Result: The machine function should not run.
4.Turn the key switch to the ground controller.
5.Check the function of the machine by the platform
controller.
6.Turn the key switch to the OFF position.
Result: All functions will not run.
Instant UpRight specifications require this procedure
whichever comes first.
The brake function is vital to safe operation of the
machine. The drive brakes should run smoothly and
without hysteresis and
single wheel brake that is released by electricity can
properly.
Note: This procedure is executed when the machine
on the platform controller is on the ramp and the
button is in the OFF position (the LED should be off)
and the platform extension table is fully indented.
1.Mark the test line on the ground as a reference.
2.Turn the key switch to the platform controller and
pull the red "emergency stop" button on the ground
controller and platform controller to the ON position.
3.Press the drive function selection button.
4.Press and hold the function enable button on the
joystick.
5.Select a point on the machine that is the point of
contact between the tire and the ground as a visual
reference point when the machine passes the test
leads.
6.Before the test line reaches the machine in full
machine passes through the test leads, release the
function to enable the switch or joystick.
7.Measure the distance between the test leads and
the machine reference points.
Note: On any slope where the machine can climb,
the brakes must be able to stabilize it.
30 “Translation of the original instruction”
Page 31
to be executed every 250 hours or quarterly,
entire controllable range of the corresponding
controller and platform controller to the ON
specifications require this
procedure to be executed every 250 hours or
entire controllable range of the corresponding
B-7
4.2.7 Test Drive Speed - Stowed
Position
Instant UpRight specifications require this procedure
whichever comes first.
The correct drive function is critical to safe operation
of the machine. The drive function should respond
quickly and smoothly under operator control. In the
speed, the drive performance should also have no
hysteresis and abnormal noise.
1.Mark two lines at a distance from the ground as
the start and stop lines.
2.Turn the key switch to the platform controller and
pull the red "emergency stop" button on the ground
position.
3.Press the drive function selection button.
4.Select a point on the machine, the point of contact
between the tire and the ground, use as a visual
reference point when the machine passes through
the start and stop lines.
5.The machine is fully driven at the start line. When
the reference point on the machine passes through
the start line, start timing.
6.Continue to maintain the full speed state, when
the reference point on the machine passes through
the stop line, write down the time.
B-8
4.2.8 Tes t Drive Speed - Raised
Position
Instant UpRight
quarterly, whichever comes first.
The intact drive function is critical to safe operation
of the machine. The drive function should respond
quickly and smoothly under operator control. In the
speed, the drive performance should also have no
hysteresis and abnormal noise.
1. Mark two lines at a distance from the ground as
the start and stop lines.
2. Turn the key switch to the platform controller
and pull the red "emergency stop" button on
the ground controller and platform controller
to the ON position.
3.Press the drive function selection button.
4. Elevate the platform to about 2 meters height.
5.Select a point on the machine, the point of
contact between the tire and the ground, as a visual
reference point when the machine passes the start
line and stop line.
6.The machine is fully driven at the start line. When
the reference point on the machine passes through
the start line, start timing.
7.Continue to keep the full speed state, until the
reference point on the machine passes through the
stop line, write down the time.
31 “Translation of the original instruction”
Page 32
to be executed every 250 hours or quarterly,
in good
Visual inspect the following aspects of each
CAUTION: If any damage is found, replace the
to be executed every 250 hours or quarterly,
such as continued use will cause damage to
replace the
B-9
4.2.9 Check the Electrical Contactor
Instant UpRight specifications require this procedure
whichever comes first.
Maintaining the electrical contactor
condition is critical to safe operation of the machine.
Failure to detect worn or damaged contactors in
time may endanger working conditions and cause
damage to parts.
1.Open the battery compartment cover.
2.Remove the contactor housing mounted on the
top of the battery compartment cover.
3.
contactor contact point:
Excessive burning
Excessive bending
Excessive pitting
Risk of electric shock / burn. Exposure to live circuits
can result in death or serious injury. Remove all
rings, watches and other accessories.
contactor.
B-10
4.2.10 Perform Hydraulic Oil Analysis
Instant UpRight specifications require this procedure
whichever comes first.
Replacement or testing of hydraulic oil is essential to
maintaining good performance and service life of the
machine. Dirty hydraulic oil and blocked inlet filters
are likely to cause machine performance degradation,
components. In a particularly dirty environment, the
need for frequent replacement of hydraulic oil.
CAUTION: Before replacing the hydraulic oil, allow the
hydraulic oil dealer to test the specific contamination
of the oil to confirm the need for replacement.
During the two-year inspection, if the hydraulic oil is
still not replaced, the hydraulic oil should be tested
quarterly. When the oil test fails
hydraulic oil.
32 “Translation of the original instruction”
Page 33
Check the oil level in the
Replacing the hydraulic tank oil return filter is
to cause damage to the component. In a
icularly dirty environment, the need to
When the engine is turned off, execute the
B-11
4.2.11
drive hub
If you do not maintain the appropriate drive wheel
oil level may lead to poor machine performance,
continued use can lead to damage to parts.
1.Select the drive hub to change the oil. Drive the
machine to one of the two stoppers at the highest
point.
B-12
4.2.12 Replace the Hydraulic Tank
Return Filter
critical to maintaining the good performance and
service life of the machine. A dirty or blocked filter
may cause the machine to degrade and continue
part
constantly replace the filter.
The risk of physical injury. Be careful of hot oil.
Exposure to hot water can cause severe burns.
2.Remove the plug at 90 ° position and check the oil
level.
Result: The oil level should be flat with the bottom
of the hole.
3.If necessary, unplug the top stopper and refuel
until the oil level is flat with the bottom of the hole.
4.Apply a sealant to the pipe thread of the plug and
install the stopper.
5.Repeat steps 1 and 4 for the other drive hub.
6.Check the torque of the drive hub mounting bolts.
program.
1. Place a suitable container under the hydraulic
tank return filter.
2. Remove the filter with the oil filter wrench.
3. Apply a thin layer of new oil to the gasket of the
new hydraulic filter.
4. Install the new filter and tighten it by hand.
Remove any traces of spilled during installation.
33 “Translation of the original instruction”
Page 34
The brake should hold the machine when
B-13
4.2.13 Make Sure the Brake
Assembly Mechanism is Correct
The brake mechansim is critical to safe operation
and to maintain good machine performance.
stopped and allow movement when a drive
function is activated. If the brakes cannot
function adequately to allow movement they
can be adjusted to release the brake and allow
the machine be moved for maintenance.
1.Check the separation cap of each drive hub to
ensure that it is in use.
2.Make sure the free wheel is closed
(homeopathic).
The free wheel is located on the drive pump.
The free wheel should always remain closed.
34 “Translation of the original instruction”
Page 35
executed every 500 hours or every six months, whichever
sensors and
firmly into the cable rubber sleeve of the pressure
4.3 Check the Table C Program
C-1
4.3.1 Test platform overload pressure
sensor and platform height sensor (if
equipped)
Instant UpRight specification requires this procedure to be
comes first, or when the machine can not lift the maximum
rated load.
Periodic Test Platforms overload pressure
platform height sensors are critical to the safe operation of
the machine. Continuing to use a platform that does not
work properly about overload pressure sensor or platform
height sensor may cause the system to fail to detect the
overload of the platform. The stability of the machine will
be affected, which led to the machine overturned.
Note: Perform this procedure on a solid level without
obstacle on the surface.
4.Turn the key switch to the ground controller and pull the
red "emergency stop" button on the ground and platform
controller to the ON position.
5.Raise the platform by about 4 meters.
6.Raise the safety arm and move it to the center of the
shearing arm and rotate it down to the vertical position.
7.Lower the platform to the safety arm.
The risk of injury. When you lower the platform, keep your
hands away from the safety arm.
8. Turn the key switch on the ground controller to the OFF
position and push the red "emergency stop" button to the
OFF position.
4.3.2 Overload Sensor
1.At the end of the lift cylinder, follow the pressure
sensor cable down to find the end of the shear clip on
the chassis table.
2.Insert the positive pole of the multimeter probe
sensor pin A. See the illustration below.
3.Insert the negative pole of the multimeter probe
firmly into the rubber sleeve of the pressure sensor pin
B. See below for illustrations.
Result: The pressure sensor has a voltage reading
of 24V. The input voltage of the pressure sensor is
normal. Proceed to step 9.
Result: The pressure sensor has a voltage reading
of 0V. The input voltage of the pressure sensor is
not normal. Check if there is wiring harness in the
power supply or ground circuit. Check the GC V
sensor at V + output.
35 “Translation of the original instruction”
Page 36
9.Insert the positive pole of the multimeter probe firmly
eeve of the pressure
into the cable rubber sleeve of the pressure sensor pin
C. See below for illustrations.
10.Insert the negative pole of the multimeter probe
firmly into the cable rubber sl
sensor pin B. See below for illustrations.
4.3.3 Platform Height Sensor
15.In the platform height sensor assembly, locate the
end of the platform height along the platform height
sensor cable.
16.Insert the positive pole of the multimeter probe
firmly into the cable rubber sleeve of the pressure
sensor pin A. See the illustration below.
17.Insert the negative pole of the multimeter probe
firmly into the cable rubber sleeve of the pressure
sensor pin B. See the illustration below.
11.Turn the key switch to the ground controller and pull
the red "emergency stop" button to the ON position.
12.Use the multimeter to measure the voltage readings
at the pins C and B of the pressure sensor.
Result: The pressure sensor has a voltage reading
Result: The pressure sensor has a voltage reading
13.Turn the key switch on the ground controller to the
OFF position and push the red "emergency stop" button
to the OFF position.
14. Remove the probe from the rubber sleeve of the
pressure sensor cable.
between 0.2CV and 6.25V. The pressure sensor is
working properly.
between 0V and 0.2V or greater than 6.25V. The
pressure sensor does not work properly. Replace
the pressure sensor.
Result: Voltage sensor voltage reading 24V. The
height of the platform height sensor is normal.
Proceed to step 18.
Result: The pressure sensor has a voltage reading
of 0V. The height of the platform sensor is not
normal. Check if there is wiring harness open in
the power supply or ground circuit. Check the GC
V sensor at V + output.
36 “Translation of the original instruction”
Page 37
22.Turn the key switch on the ground controller
18.Insert the positive pole of the multimeter probe
firmly into the cable rubber sleeve of platform height
sensor pin C. See below for illustrations.
19. Insert the negative pole of the multimeter probe
firmly into the cable rubber sleeve of platform height
sensor pin B. See below for illustrations.
20.Turn the key switch to the ground controller and pull
the red "emergency stop" button to the ON position.
21.Use the multimeter to measure the voltage readings
at the pins C and B of the pressure sensor.
Result: The pressure sensor has a voltage reading
Result: The pressure sensor has a voltage reading
between 1V and 4V. The platform height sensor is
working properly.
of 0V or greater. The platform height sensor does
not work properly. Replace the platform height
sensor.
to the OFF position and push the red "emergency
stop" button to the OFF position.
23.Pull the probe out of the rubber sleeve of the
platform height sensor cable.
24.Turn the key switch to the ground controller
and pull the red "emergency stop" button to the
ON position.
25.Raise the platform by about 30.5cm.
26.Return the safety arm to the stowed state.
27.Lower the platform to the stowed position.
28.Turn the key switch to the OFF position.
37 “Translation of the original instruction”
Page 38
to be executed every 250 hours or quarterly,
Test the thickness of the chassis slider at the
Result: Measure 71mm or higher. Proceed to
cularly dirty
The risk of physical injury. Be careful of hot oil.
hydraulic connection to gradually reduce the oil
4.4 Check Table D program
D-1
4.4.1 Check the Chassis and
Platform Slider
Instant UpRight specifications require this procedure
whichever comes first.
Keeping the slides and slide guide blocks in good
condition is critical to safe operation of the machine.
Continued use of worn sliders can damage parts and
lead to unsafe working conditions.
1.
bottom of the machine's boom.
Result: The measurement result is 68mm or
Result: The measurement result is less than
2.Test the thickness of the platform slider at the top
of the boom of the machine.
Result: The measurement result is less than
higher. Proceed to step 2.
68mm. Replace the chassis slider.
Step 3.
71mm. Replace the platform slider.
D-2
4.4.2 Replace the Hydraulic Filter
Instant UpRight specifications require this procedure to
be executed every 250 hours or quarterly, whichever
comes first.
Replacing the hydraulic tank oil return filter is critical to
maintaining the good performance and service life of
the machine. A dirty or blocked filter may cause poor
machine performance and continued use may result in
damage to the component. In a parti
environment, you need to change the filter frequently.
Exposure to hot water can cause severe burns.
1.Remove the filter with an oil filter wrench. Clean the
contact area between the hydraulic oil filter and the
filter.
The risk of physical injury. Sprayed out of the hydraulic
oil may penetrate and burn the skin. Slowly release the
pressure. Do not spray or splash oil.
Note: The hydraulic filter is installed on the hydraulic
tank.
38 “Translation of the original instruction”
Page 39
2.Apply a thin layer of new oil to the gasket of the
number of hours displayed on the timer on the
Replacement Drive the hub oil is critical to
to degrade and damage the parts if used
new hydraulic filter.
3.Install the new filter and tighten it by hand.
4.Use the permanent ink marker to write the date and
hydraulic filter.
5.Remove any oil spills that are spilled during the
replacement process.
6.Turn the key switch to the ground controller and
pull the red "emergency stop" button on the ground
controller and platform controller to the ON position.
Start the engine.
7.Raise the platform by about 1 meter.
8.Check the filter and related parts to ensure that
there is no leakage.
D-3
4.4.3 Replace the Wheel Oil
Note: The manufacturer-driven hub specification
requires this one-time procedure to be executed
150 hours after the first use.
maintaining the machine's good performance and
service life. If the wheel oil is not replaced after
150 hours of initial use, it may cause the machine
continuously.
1.Select the drive hub to replace the oil. Drive the
machine to one of the two stoppers at the lowest
point.
2.Remove the two stoppers and drain the oil into
the appropriate container.
3.Drive the machine to one of the two stoppers at
the highest point.
4.Refuel the wheel until the oil level is flat with
the bottom of the lowest plug.
5.Install the plug in the drive hub.
6.Repeat this procedure for other drive hubs.
39 “Translation of the original instruction”
Page 40
specification requires this procedure to be executed every 1000 hours or annually, whichever
D-4
4.4.4 Tes t Function Pump
Instant UpRight
comes first.
Functional pump operation is normal for safe vibration operation and machine operation are essential.
NOTE: This procedure is executed on a rugged, horizontal surface and the platform is in stowed position,
when the platform extension table is fully indented.
1.Lower the platform to the stowed position.
2.Turn the key switch to the ground controller and pull the red "emergency stop" button on the ground and
platform controller to the ON position.
3.On the ground controller, record the time it takes to completely lift the platform.
Result: The time taken to completely raise the platform is equal to or less than the time shown in the
table below. The efficiency of the pump is good.
X2047 32s
X2647 45s
X3247 55s
X3947 61s
X4647 80s
Note: If the above time cannot be reached, the machine must be marked and the machine must be stopped
before repairing or replacing the pump.
The dangers of tipping. Failure to follow the instructions to repair or replace the pump will affect the stability
of the machine, and even lead to death or serious injury.
40 “Translation of the original instruction”
Page 41
specifications require that this
, replace the
CAUTION: When removing the hose assembly or
Remove the ground control box to locate the
The risk of physical injury. Sprayed out of the
4.5 Check Table E program
E-1
4.5.1 Test or Replace Hydraulic Oil
Instant UpRight
procedure be performed every 2,000 hours or every
two years, whichever comes first.
Replacement or testing of hydraulic oil is essential to
maintaining good performance and service life of the
machine. Dirty hydraulic oil and blocked inlet filters are
likely to cause machine performance degradation, such
as continued use will cause damage to components. In
a particularly dirty environment, the need is for
frequent replacement of hydraulic oil and filters.
CAUTION: Before replacing the hydraulic oil, allow the
hydraulic oil dealer to test the specific contamination
of the oil to confirm the need for replacement.
During the two-year inspection, if the hydraulic oil is
still not replaced, the hydraulic oil needs to be tested
quarterly. When the oil test fails
hydraulic oil.
connector, replace the O-ring (if equipped) with the
connector and / or the hose end. During installation,
the torque of all connections must be set according to
the specifications.
1.Press the red "emergency stop" button into the OFF
position.
2. Mark and disconnect the harness on the ground
control box.
3.
fastener and set it aside. Remove the ground control
box.
4.Find the fuel tank cover. Remove the fuel tank cover
to install the fasteners and remove the cover.
5.Prevent put the oil pan or other suitable container
under the hydraulic tank.
6.Remove the drain plug from the hydraulic tank and
drain the tank completely.
hydraulic oil may penetrate and burn the skin. Slowly
release the hydraulic connection to gradually reduce
the oil pressure. Do not spray or splash oil.
7.Mark, disengage and plug the suction hose on the
hydraulic tank. Cover the pipe joint.
8.Mark, disengage and plug the oil return hose on the
oil return filter. Cover the filter connector.
9.Remove the oil return filter and filter components
on the tank. Cover and plug the connector.
10.Loosen the tank in front of the tank. Place the
straps aside.
11.Remove the hydraulic tank from the machine.
12.Remove the inlet filter and clean it with a neutral
solvent or replace it.
41 “Translation of the original instruction”
Page 42
Install the inlet filter with threaded sealing
Clear all traces of overflow. Properly handle
specifications require that this
worn machine may cause unsafe operating factors,
Results: horizontal or vertical displacement.
13.Clean the inner surface of the hydraulic tank with
a neutral solvent cleaning solution.
14.Install the drain plug on the thread with a thread
sealant.
15.
material on the threads.
16.Install the hydraulic tank on the machine.
17.Tighten the tank with the tank retaining band. Do
not be too tight
18.Install the suction tubing on the tank.
19.Install the oil return filter and filter assembly.
Note: Replace the oil return filter as needed.
20.Install the return hose on the oil return filter.
21.Add hydraulic oil to the tank until the oil level is
within 5 cm of the upper part of the oil level gauge.
Do not add too much.
22.
hydraulic oil.
23.Run all the functions of the machine in a full
cycle and check for leaks.
24.Check the oil level in the tank and add the
hydraulic oil if necessary.
25.Install the fuel tank cover and install the fuel tank
cover fasteners.
E-2
4.5.2 Apply Grease to Steering Shaft
and Wheel Bearings
Instant UpRight
procedure be performed every 2,000 hours or every
two years, whichever comes first.
Maintenance of steering shafts and wheel bearings is
essential to maintaining good machine performance
and service life. Operation of wheel bearings Loose or
such as continued use will cause damage to parts.
Extremely wet or dirty conditions or regular steam
cleaning and pressure cleaning of the machine require
more frequent execution of this procedure.
1.Loosen the wheel lug nut. Do not remove them.
2.Lock the non-steering wheel and place the jack in the
center of the steering shaft.
3.Lift the machine 15cm, and then place the pad under
the drive chassis as support.
4.Remove the lug nut. Remove the tire and wheel
assembly.
5.Try the horizontal and then move the wheel vertically
to check the wear of the wheel bearings.
Result: No lateral or longitudinal displacement.
Proceed to step 10.
Proceed to step 6.
42 “Translation of the original instruction”
Page 43
9. Try the horizontal and then move the wheel
izontal or vertical displacement.
thrust washers and external bearings should be
17. Slide the hub onto the operating fork spindle.
21. Loosen the groove nut completely and
6. Remove the dust cover from the hub. Remove the
slotted nuts.
7. Tighten the groove nut with a torque of 203 Nm to
install the bearing.
8. Loosen the groove nut completely and re-tighten
with 48 Nm of torque.
vertically to check the wheel bearing wear.
Result: No lateral or longitudinal displacement.
Proceed to step 11.
Results: hor
Continue with step 11 and replace the new
wheel bearing.
Note: When replacing wheel bearings, both internal
and external bearings must be replaced, including
press-fit bearing rings.
10. Remove the dust cover from the hub. Remove the
slotted nuts.
11. Remove the groove nut.
12.Pull the hub out of the spindle. Spindle washers,
released from the hub.
13. Place the hub on a flat surface and gently pry out
the bearing seal from the hub. Remove the rear
bearing.
14. Fill the two bearings with clean new grease.
15. Place a larger internal bearing into the rear of the
hub.
16. Install the new bearing grease seal into the hub
and press evenly until it flush.
Risk of damage to parts: Do not use excessive force
as this may cause damage to the edge of the seal.
18. Place the external bearings in the hub.
19. Install the spindle washer, thrust washer and
groove nut.
20.Tighten the groove nut with a torque of 203 Nm
to mount the bearing.
re-tighten with 48 Nm of torque.
22. Install a new cotter pin. Bend the cotter pin to
lock it in place.
NOTE: Always use a new cotter pin when installing
the groove nut.
23. Install the dust cover.
43 “Translation of the original instruction”
Page 44
If it is not otherwise specified, then each repair
achine has been disconnected from all
and/or replace faulty
warn of potential danger of personal injury.
t an error result occurs after
The repair program must be carried out by personnel
trained and qualified for this machine.
Damaged or malfunctioning machines should be marked
immediately and removed from service.
Repair all the damage and trouble before operating the
machine.
Read, understand and follow the safety instructions and
operating instructions in the operating instructions.
Be sure to have all the necessary tools and required
parts for use.
Read each program in its entirety and strictly follow the
instructions. Attempts to take shortcuts may cause risk
factors.
procedure can only be performed when the machine is
in the following states:
Place the machine on a solid horizontal surface
The platform is in stowed position
The key switch is in the OFF position and the key is
unplugged
The red "emergency stop" button for the ground
and platform controllers is in the OFF position.
The wheel is in locked status.
The m
external AC power supplies.
5.1 Platform Controller
5. Repair procedures
About this section
Most of the procedures in this section should be
carried out by trained professional service
personnel in well-equipped workplaces. When
the fault is found, select the appropriate repair
program.
Perform the disassembly procedure to remove
the faulty part. Repair
part. Reassemble in the reverse order and test all
functions.
Symbol Legend
Observe all safety information after the mark to
avoid possible injury or death.
Indicates that an emergency hazard condition, if
not avoided, could result in death or serious
injury.
Warning that a potentially dangerous situation, if
not avoided, can result in death or serious injury.
Indicates a dangerous situation, if not avoided,
could result in minor or moderate personal injury.
Indicates a potentially hazardous situation that, if
not avoided, could result in property damage.
Tips:- After completing a series of steps, specific
results may appear.
Indicates tha
completing a series of steps.
Safety warning signs - used to
44 “Translation of the original instruction”
Page 45
ground and platform controller into the OFF
Disconnect the platform controller from the
Risk of damage to parts. Electrostatic discharge
(SED) can damage printed circuit board
components. When operating on printed circuit
on circuit board fasteners can cause excessive
1-1
5.1.1 Platform Removal
Controller Circuit Board Method
4.Push the red "emergency stop" button of the
position.
5.
control cable on the platform.
6.Remove the fasteners that secure the platform
control box to the platform controller bracket.
7.Remove the fasteners that secure the bottom
cover to the platform control box. Open the control
box.
8.Unlock the strap of the fixed harness.
9.Disconnect the red and black lines from the alarm.
10.Carefully remove the alarm from the platform
control box.
11.Carefully disconnect all harness connectors from
the platform controller board.
Risk of electric shock / burn. Exposure to live circuits
can result in death or serious injury. Remove all
rings, watches and other accessories.
1.Carefully remove the platform controller board
fasteners.
2.Carefully remove the platform controller board
from the platform control box.
3.Remove the transparent cap from the platform
controller board and save it.
Circuit board fasteners torque specifications
Tighten by hand until the screws are in place ﹤0.6Nm
CAUTION: Before installing the circuit board, place
the transparent cover removed in step 11 on the
board button.
CAUTION: After installing the circuit board, check
that the button is working properly. Excessive torque
torque. The circuit board fasteners do not make the
buttons fit properly.
boards, keep them in good contact with the metal
parts that are always grounded on the machine, or
use ground tapes.
45 “Translation of the original instruction”
Page 46
3.Remove the fasteners that secure the platform
Carefully remove the operating handle from the
3.Remove the fasteners that secure the platform
from the platform
1-2
5.1.2 Method to Remove the Handle
1.Press the red "emergency stop" button on the ground
and platform controller into the OFF position.
2.Disconnect the platform controller from the control
cable on the platform.
control box to the platform controller bracket.
4.Remove the fasteners that secure the bottom cover
to the platform control box. Open the control box.
5.Unlock the strap of the fixed harness.
6.Carefully disconnect the operating handle harness
from the platform controller board.
Risk of electric shock / burn. Exposure to live circuits
can result in death or serious injury. Remove all rings,
watches and other accessories.
Risk of damage to parts. Electrostatic discharge
(SED) can damage printed circuit board components.
When operating on printed circuit boards, keep them
in good contact with the metal parts that are always
grounded on the machine, or use ground tapes.
7.Carefully remove the handle fasteners.
8.
platform control box.
Torque specifications
Operating handle fasteners 1Nm
1-3
5.1.3 Method to Remove the Platform
Alarm
1.Press the red "emergency stop" button on the
ground and platform controller into the OFF position.
2.Disconnect the platform controller from the control
cable on the platform.
control box to the platform controller bracket.
4.Remove the fasteners that secure the bottom cover
to the platform control box. Open the control box.
5.Disconnect the red and black lines from the alarm.
Risk of electric shock / burn. Exposure to live
circuits can result in death or serious injury. Remove
all rings, watches and other accessories.
Risk of damage to parts.
Electrostatic discharge (SED) can damage printed
circuit board components. When operating on printed
circuit boards, keep them in good contact with the
metal parts that are always grounded on the machine,
or use ground tapes.
6.Carefully remove the alarm
control box.
46 “Translation of the original instruction”
Page 47
1-4
5.1.4 Method to remove the platform controller emergency stop button
1.Push the red "emergency stop" button of the ground and platform controller into the OFF position.
2.Disconnect the platform controller from the control cable on the platform.
3.Remove the fasteners that secure the platform control box to the platform controller bracket.
4.Remove the fasteners that secure the bottom cover to the platform control box. Open the control box.
5.Disconnect the white line from the "emergency stop" button base.
Risk of electric shock / burn. Exposure to live circuits can result in death or serious injury.
Remove all rings, watches and other accessories.
Risk of damage to parts. Electrostatic discharge (SED) can damage printed circuit board
components. When operating on printed circuit boards, keep them in good contact with the metal parts
that are always grounded on the machine, or use ground tapes.
6.Carefully remove the "emergency stop" button base from the "emergency stop" button.
7.Carefully remove the retaining ring from the "emergency stop" button.
8.Carefully remove the "emergency stop" button from the platform control box.
47 “Translation of the original instruction”
Page 48
5.2 Platform Components
Note: This procedure requires the use of the
live circuits can result in death or serious injury.
the mounting position of the wear pad on the
5.Remove the platform AC power socket cover. Mark
2-1
5.2.1 Method to Remove the Platform
and disconnect the wiring on the socket.
Warning! Risk of electric shock / burn. Exposure to
Warning! The risk of physical injury. The
completion of this procedure requires special repair
skills, lifting equipment and suitable workshops.
Without these skills and tools, the execution of this
procedure may result in death or serious injury and
damage to important parts. Ask seller to repair.
Warning
corresponding load-bearing lifting equipment.
Caution! Risk of damage to parts. Make sure that
the platform power supply wiring is not cut off.
2.Remove the clip that secures the platform controller
cable to the platform.
3.Disconnect the platform controller cable from the
platform controller.
4.Remove the platform control box from the platform
and set it aside.
Caution! Risk of damage to parts. The platform
controller wiring may be damaged when it is distorted
or squeezed.
1. Unlock the strap that secures the platform
power supply to the bottom of the platform.
C
Remove all rings, watches and other accessories.
Note: If your machine has an air tube option to the
platform, you must disconnect the air tube from the
platform before removing the air tube.
6.Connect the chain from the lifting device to the four
lifting points on the platform.
Warning! The risk of crushing. If the support is not
correct, the platform will fall.
7.Remove the positioning fasteners of the platform
pins on both sides of the platform bar.
8.Slide the platform bar from the fixed end on the
other side of the platform so that the slider is moved
to the platform rail slot, where the belt of the fixed
platform bar is slowly raised to a certain height.
Carefully lift the platform away from the machine and
place it on a device that can be used as a support.
Caution! Before removing the platform, note
platform so that they can be assembled in the correct
position when assembled.
48 “Translation of the original instruction”
Page 49
2-2
5.2.2 Method to Remove the Platform Extension
1.Lower the platform to the stowed position.
2.Use the lifting strap to support the platform extension.
3.Remove the captive screws as shown.
4.Slowly lift the extension platform and place it on a device that can be used as a support.
Warning! Risk of injury.
Be Careful when Remove the platform from the machine Do not stand under it and maintain its
balance using correct lifting procedurs.
49 “Translation of the original instruction”
Page 50
iddle arm 3 welding
Scissor arm parts (MX1930 for samp le)
1.Upper arm shaft block 8.Slider
2.80W outside upper arm 9.80W inside upper arm
3.Cylinder upper seat pin 10.M
5.Middle arm pin 12.Arm seat pin
6.Middle arm 4 assembly 13.Scissor arm welding
7.Arm base pin
Steering End Non-steering End
50 “Translation of the original instruction”
4.Arm long pin 11.Side arm
Page 51
the chain, but do not apply lifting pressure.
machine, if the support is improper, the
machine, if the support is improper, the
3-1
5.2.3 Method of removing arm
parts
The risk of physical injury. The
completion of this procedure requires special repair
skills, lifting equipment and suitable workshops.
Without these skills and tools, the execution of this
procedure may result in death or serious injury and
damage to important parts. Ask seller to repair.
CAUTION: When removing the hose assembly or
connector and re-installing it, you must replace the
O-ring of the connector and / or hose and set the torque
according to the specifications.
Note: This procedure requires the use of the
corresponding load-bearing lifting equipment and
hanging chain or lifting straps.
1.Remove the platform. See Figure 2-11, Removing the
Platform.
2.Remove the positioning fasteners that connect the
ladders to the chassis. Remove the ladder and put it
aside.
3.Remove the cable from the connecting rod assembly.
Caution! Risk of component damage. The cable may
be damaged if it is twisted or squeezed.
4.Attach the lifting strap to the lifting cylinder piston rod
end with an appropriate support device. Do not apply
pressure.
5.Remove the positioning fasteners on the pivot pin of
the lift cylinder piston rod end.
6.Remove the pivot pin with a soft metal punch.
7.Lower the lift cylinder and remove the strap.
8.Connect the 4-hook chain to the end of the 80W inner
shearing arm (# 9) using the air lifting device. Tension
Warning! The risk of injury. When
removing the connecting rod assembly from the
connecting rod assembly will lose balance and
fall.
9.Remove the positioning fasteners on the arm
length pin (label # 4).
CAUTION: Do not remove the outer opening
ring.
10.Use a soft metal punch to remove the pin
and place it aside.
11.Carefully lift the connecting rod assembly
away from the machine and place it on the
device structure that can support it.
12.Use the air lifting device to connect the 4
hook chain to the end of the 3 arm (label # 10)
in the shearing arm. Tension the chain, but do
not apply lifting pressure.
Warning! The risk of injury. When
removing the connecting rod assembly from the
connecting rod assembly will lose balance and
fall.
51 “Translation of the original instruction”
Page 52
13.Remove the positioning fasteners on the arm
length pin (label # 4).
CAUTION: Do not remove the outer opening ring.
14.Use a soft metal punch to remove the pin and
place it aside.
15.Carefully lift the connecting rod assembly away
from the machine and place it on the device
structure that can support it.
16.Mark and disconnect the harness on the lifting
cylinder block.
17.Mark and disconnect the hydraulic hoses on the
lifting hydraulic cylinder. Plug the hose and cover
the joint with the cover.
18.Remove the hose clamp and hose from the trim
arm 4 (label# 6).
19.Use the aerial lifting device to connect the 4
hook chain to the end of the 4 arm in the shearing
arm. Tension the chain, but do not apply lifting
pressure.
Warning! The risk of injury. When removing the
connecting rod assembly from the machine, if the
support is improper, the connecting rod assembly
will lose balance and fall.
Wan
20.Carefully lift the connecting rod assembly away from
the machine and place it on the device structure that
can support it.
24.Remove the pin fasteners on the lower arm (label #
7).
CAUTION: Do not remove the outer opening ring.
25.Use a soft metal punch to remove the pin and place
it aside.
26.Move the link mechanism toward the non-steering
end of the machine until the chassis slider leaves the
slide.
Carefully lift the connecting rod assembly away from
the machine and place it on the device structure that
can support it.
52 “Translation of the original instruction”
Page 53
Separate Link Group:
1.Use the lift device to connect the 4 hook chain to the inner shearing arm, middle shearing arm
3, and 4 at the end of the scissors arm 4 (# 9, # 10, # 6).
Warning! The risk of injury. When removing the connecting rod assembly from the
machine, if the support is inadequate r, the connecting rod assembly may lose balance and fall.
2.Remove the positioning fasteners on the pin (# 5) of the middle shearing arm.
CAUTION: Do not remove the outer opening ring.
3.Use a soft metal punch to remove the pin and place it aside.
4.Carefully lift the connecting rod assembly and separate it, and then place it on a device structure
that can support it.
53 “Translation of the original instruction”
Page 54
Scissor arm parts (X2632 for sample)
1.Upper arm shaft block 8.slider
2.middle arm pin 9.middle arm 1 assembly
3.middle long pin 10.upper arm assembly
4.cylinder upper seat pin 11.middle arm 2 assembly
5.base arm welding 12.side arm
6.middle arm 4 assembly 13.middle arm 3 welding
7.base arm pin 14.cylinder base seat pin
15.base arm welding
54 “Translation of the original instruction”
Steering end Non-steering end
Page 55
skills, lifting equipment and suitable workshops.
CAUTION: When removing the hose assembly or
installing it, you must replace the
Note: This procedure requires the use of the
bearing lifting equipment and
Risk of component damage.The cable
connecting rod assembly from the machine, if the
3-2
5.2.4Method of removing arm parts
Warning! The risk of physical injury. The
W
completion of this procedure requires special repair
Without these skills and tools, the execution of this
procedure may result in death or serious injury and
damage to important parts. Ask seller to repair.
connector and re-
O-ring of the connector and / or hose and set the torque
according to the specifications.
corresponding load-
hanging chain.
1.Remove the platform. See Figure 2-11, Removing the
Platform.
2.Remove the positioning fasteners that connect the
ladders to the chassis. Remove the ladder and put it
aside.
3.Remove the cable from the connecting rod assembly.
Caution!
may be damaged if it is twisted or squeezed.
4..Use the lifting device to connect the 4 hook chain to
the end of the trim arm 1 assembly (# 9). Tension the
chain, but do not apply lifting pressure.
Warning! The risk of injury. When removing the
WWar
support is improper, the connecting rod assembly will
lose balance and fall.
5.Remove the positioning fasteners on the arm
length pin (label # 3).
CAUTION: Do not remove the outer opening
ring.
6.Use a soft metal punch to remove the pin and
place it aside.
7.Carefully lift the connecting rod assembly
away from the machine and place it on the
device structure that can support it.
8.Attach the belt to the lifting cylinder piston
rod end with an appropriate support device. Do
not apply pressure.
9.Remove the positioning fasteners on the lift
cylinder piston rod end cylinder (label # 4).
10.Remove the cylinder catch pin (label# 4) with
a soft metal punch.
11.Lift the hydraulic cylinder down and then
remove the belt.
12.Use the aerial lift device to connect the 4
hook chain to the end of the 2 arm (label # 11)
in the shearing arm. Tension the chain, but do
not apply lifting pressure.
Warning! The risk of injury. When removing
the connecting rod assembly from the machine,
if the support is improper, the connecting rod
assembly will lose balance and fall.
55 “Translation of the original instruction”
Page 56
the support is improper, the connecting rod
13. Remove the positioning fasteners on the
arm length pin (label # 3).
CAUTION: Do not remove the outer opening
ring.
14.Use a soft metal punch to remove the pin
and place it aside.
15.Carefully lift the connecting rod assembly
away from the machine and place it on the
device structure that can support it.
16.Use the air lifting device to connect the 4
hook chain to the end of the (# 13) middle
shearing arm 3. Tension the chain, but do not
apply lifting pressure.
WaWa
Warning! The risk of injury. When removing the
connecting rod assembly from the machine, if
20.Mark and disconnect the harness on the lifting
cylinder block.
21.Mark and disconnect the hydraulic hoses on the
lifting hydraulic cylinder. Plug the hose and cover the
joint with the cover.
Warning! The risk of injury. When removing
the connecting rod assembly from the machine, if the
support is improper, the connecting rod assembly will
lose balance and fall.
22.Remove the hose clamp and hose from the trim arm
4.
23.Connect the 4 hook chain to the end of the middle
arm 4 (# 6) using an air lift device. Tension the chain,
but do not apply lifting pressure.
Warning! The risk of injury. When removing the
connecting rod assembly from the machine, if the
support is improper, the connecting rod assembly will
lose balance and fall.
assembly will lose balance and fall.
17.Remove the positioning fasteners on the arm
length pin (label # 3).
CAUTION: Do not remove the outer opening
ring.
18.Use a soft metal punch to remove the pin
and place it aside.
19.Carefully lift the connecting rod assembly
away from the machine and place it on the
device structure that can support it.
24.Remove the positioning fasteners on the base arm
(label # 7).
CAUTION: Do not remove the outer opening ring.
25.Use a soft metal punch to remove the pin and place
it aside.
26.Move the link mechanism toward the non-steering
end of the machine until the chassis slider leaves the
slide.
27.Carefully lift the connecting rod assembly away from
the machine and place it on the device structure that
can support it.
56 “Translation of the original instruction”
Page 57
3-3
5.2.5 Method to Replace the
Platform Pad
Platform Pad
1.Remove the platform. Please refer to the method of
removing the platform.
2.Remove the platform slider and remove the pad.
3.Install the platform pad.
Note: When installing the platform, you must drill holes
at the bottom and top of the platform pad.
4.Install the platform.
57 “Translation of the original instruction”
Page 58
cting hydraulic cylinders.
important parts. It is strongly recommended to be
When removing the hose assembly or
according to the specifications. Refer to Section 2
3-4
5.2.6 Lifting cylinder
Lifting cylinders are single a
X2047, X2647 uses a lifting cylinder; and X3247, X3947
and X4647 use two lifting cylinders. Each lift cylinder is
equipped with a one-way valve to prevent the hydraulic
cylinder from moving in the event of a hydraulic pipe
failure.
Method to lift the hydraulic cylinder
X2047, X2647
Warning! The risk of physical injury. The
completion of this procedure requires special repair skills,
lifting equipment and suitable workshops. Failure to do
so may result in death or serious injury and damage to
a Platform lower solenoid valve
b Lifting Cylinder
c Pressure sensor
repaired by the original manufacturer.
CAUTION:
connector and reinstalling it, the O-ring on the connector
and / or hose must be replaced and set the torque
Hydraulic Hose and Connector Torque Specifications.
1.Remove the platform. Refer to 2-1 Method to Remove
the Platform.
2.Remove the scissor arm. Refer to 3-1 for the removal of
the scissor arm assembly.
58 “Translation of the original instruction”
Page 59
When removing the hose assembly or
n the
X3247, X3947 and X4647
Warning! Lifting cylinders are single acting hydraulic
cylinders. X2047, X2647 uses a lifting cylinder; and
X3247, X3947 and X4647 use two lifting cylinders. Each
lift cylinder is equipped with a one-way valve to prevent
the hydraulic cylinder from moving in the event of a
hydraulic pipe failure.
CAUTION:
connector and reinstalling it, the O-ring o
connector and / or hose must be replaced and set the
torque according to the specifications. Refer to Section 2
Hydraulic Hose and Connector Torque Specifications.
3.Remove the platform. Refer to 2-1 Method to Remove
the Platform.
4.Remove the scissor arm. Refer to 3-1 for the removal
of the scissor arm assembly.
a Platform lower solenoid valve
b Upper Lifting Cylinder
c Base Lifting Cylinder
d Pressure sensor
59 “Translation of the original instruction”
Page 60
5.3 Chassis Parts
4-1
5.3.1.2 Method to Remove the
Hydraulic Pump
5.3.1 Hydraulic Pump
The hydraulic pump is a single stage gear pump.
CAUTION: When removing the hose assembly or
connector and reinstalling it, you must replace the
O-ring on the connector and / or hose and set the
torque according to the specifications.
5.3.1.1 Method to Test Hydraulic Pump
1.Connect a pressure gauge with a measuring range
from 0 to 350 bar to the test port on the function
header.
2.Remove the platform controller from the platform
and place the controller near the function tank of the
machine tank side.
3.Turn the machine completely to the left or right side
and remain stable. Write down the pressure reading
on the pressure gauge.
1.Mark, disconnect and plug the hydraulic hose
on the pump. Cover the pump with the cover.
Caution! Risk of physical injury. Sprayed out
of the hydraulic oil may penetrate and burn the
skin. Slowly release the hydraulic connection to
gradually reduce the oil pressure. Do not spray or
splash oil.`
2.Remove the mounting bolts from the pump.
Carefully remove the pump.
Caution! When replacing the hydraulic pump, it
is important to adjust the lift speed and drive
speed back to the original factory settings.
60 “Translation of the original instruction”
Page 61
executed must be cleaned and there is no
cause serious damage to the component.
and set the torque according to the
rol box from the
the hydraulic tank and plug it in. Cover the
hydraulic tank and check for cracks and other
4-2
5.3.2 Hydraulic Tank
The main function of the hydraulic tank is to
cool, clean and degrade the hydraulic oil during
operation. It utilizes an internal inlet filter for
the pump supply line and is equipped with an
external return line filter.
5.3.2.1Method to Remove the
Hydraulic Tank
Note! Risk of damage to parts. The work
area and surface in which the program will be
debris that may enter the hydraulic system and
Recommended sales repairs.
CAUTION: When removing the hose assembly
or connector and reinstalling it, the O-ring on
the connector and / or hose must be replaced
specifications.
1.Open the hydraulic tank side cover.
2.Remove the drain plug from the hydraulic tank
and drain the oil from the tank thoroughly into
the appropriate container.
Warning! Risk of physical injury. Sprayed out
of the hydraulic oil may penetrate and burn the
skin. Slowly release the hydraulic connection to
gradually reduce the oil pressure. Do not spray or
splash oil.
3.Mark and disconnect the harness on the ground
control box.
4.Remove the ground cont
machine and set it aside.
5.Mark and disconnect the hydraulic hose from
terminals of the tank and return oil filter with a
lid.
6.Loosen the mounting strap on the hydraulic
tank. Pull the tank holder to the side.
CAUTION: Do not remove the fuel tank.
7.Remove the hydraulic tank from the machine.
Caution! Risk of damage to parts. Do not
tighten the hydraulic tank belt mounting fasteners
during installation.
CAUTION: Before installing, be sure to clean the
61 “Translation of the original instruction”
damage.
Page 62
center of the drive chassis of the machine's steering
4.Remove the wheel lugs. Remove the tire and wheel
4-3
5.3.3Method to Remove the
Steering Wheel Seat Assembly
1.Lock the non-steering wheel and place a jack in the
end.
2.Loosen the wheel lugs. Do not remove them.
3.Lifting machine about 5CM. Place the pad under the
chassis as support.
Warning! The risk of injury. If the support is improper,
the chassis may fall.
assembly.
5.Use a lifting device to support and secure the steering
wheel assembly.
Right Steering Seat
1.Remove the positioning fasteners on the wheel
seat arm b.
a. 140w Steering cylinder
b. Wheel seat arm
c. Steering connection plate
d. Steering seat plastic cover
e. Wheel seat right welding
f. Hydraulic motor
2.Remove the wheel seat arm.
3.Remove the right steering wheel assembly e from
the machine.
Caution! The risk of injury. When the steering
wheel assembly is removed from the machine, the
steering wheel assembly may fall out of balance if it
is not properly supported and is not secured with a
suitable lifting device.
4.Repeat the above steps to remove the left
steering wheel assembly.
62 “Translation of the original instruction”
Page 63
enter the hydraulic system and cause serious
damage to the component. Recommended sales
2.Remove the drive motor mounting fasteners.
Slowly release the hydraulic connection to
4-4
5.3.4 Method to Remove the Motor
Cati
Caution! Risk of damage to parts. Only authorized
dealers can perform motor repair operations.
Caution! Risk of damage to parts. The work area
and surface in which the program will be executed
must be cleaned and there is no debris that may
repairs.
CAUTION: When removing the hose assembly or
connector and reinstalling it, you must replace the
O-ring on the connector and / or hose and set the
torque according to the specifications.
1.Refer to Repair Agent 4-3 method of removing the
fork assembly.
Remove the motor from the operating fork.
4-5
5.3.5 Method to Remove the Steering
Cylinder
CAUTION: When removing the hose assembly or
connector and reinstalling it, you must replace the
O-ring on the connector and / or hose and set the
torque according to the specifications.
1.Mark, disengage and plug the hydraulic hose on
the steering cylinder. Cover the connector on the
hydraulic cylinder with a lid.
Warning! Risk of physical injury. Sprayed out of
the hydraulic oil may penetrate and burn the skin.
gradually reduce the oil pressure. Do not spray or
splash oil.
2.Refer to Repair Agent 4-3 method of removing
the fork assembly.
3.Remove the steering cylinder from the steering
wheel assembly.
63 “Translation of the original instruction”
Page 64
2.Remove tie rod c from the steering wheel seat
4-6
5.3.6Method to Remove the
Steering Rod
1.Refer to Repair Procedure 4-3 for removing the
steering wheel assembly.
a. 140w Steering cylinder
b. Wheel seat arm
c. Steering connection plate
d.Steering seat plastic cover
e. Wheel seat right welding
f. Hydraulic motor
assembly.
64 “Translation of the original instruction”
Page 65
emergency stop" button for the
Before troubleshooting:
and operating instructions in the operating
Make sure that all necessary tools and test
shop safety
6. Fault Code
Obey:
Read, understand and follow the safety instructions
The troubleshooting and repair process must be
performed by trained and qualified personnel who
have been trained in the machine.
Damaged or malfunctioning machines should be
marked immediately and stop operation.
Before operating the machine, it must repair all its
damage and malfunction.
Unless otherwise specified, the individual repair
procedures can only be performed if the machine is
in the following configuration:
Place the machine on a solid horizontal surface
The platform is in stowed position
The key switch is in the OFF position and the
key is pulled out
The red "
ground and platform controllers is in the OFF
position
The wheel is in locked status
The machine has been disconnected from all
external AC power supplies
instructions.
equipment are ready.
Pay attention to the following hazardous situations
and comply with the prevailing work
practices.
Danger! Risk of injury. When testing or replacing
hydraulic components, always support and fix the
components to prevent movement.
Caution! Risk of electric shock. Exposure to live
circuits can result in death or serious injury. Remove
all rings, watches and other accessories.
Caution! Risk of physical injury. Sprayed out of the
hydraulic oil may penetrate and burn the skin. Slowly
release the hydraulic connection to gradually reduce
the oil pressure. Do not spray or spray oil.
Note! Perform all troubleshooting on a solid, flat
ground.
Note! For some troubleshooting operations, two
people are required for safety reasons.
65 “Translation of the original instruction”
Page 66
Identify the
ting
Check
and test
the problem
problem
solved
About this section
After finding the fault, use the flow chart in this section to help professional service personnel
identify the cause of the malfunction. To operate in this section, you need to have basic hand
tools and some test equipment - voltmeter, ohmmeter, pressure gauge.
The terminal positions referred to in this section can be found in the corresponding electrical
and hydraulic diagrams provided in the diagram below.
Since a function may degrade in varying degrees, it may be difficult to choose a suitable flow
chart. When the machine is in good condition, the same speed or power cannot be used for
that function, please refer to the fault description in flow chart.
General Maintenance Process
The fault
has been
found
fault
phenomenon
Troubleshoo
Return to
repair
still exists
Perform
repair
66 “Translation of the original instruction”
Page 67
01
Internal ECU failure
ECU content error, EEPROM is
not programmed
Replace ECU
02
ECU / platform
communication failure
Control cable error or platform
control failure
Check the control cable
or platform control
03
The configuration code is
not defined
The machine configuration code
is set incorrectly
Set the configuration
code correctly
12
The on / off switch opens
when the switch is started
Up / down switch error
Check up / down the
toggle switch
18
Pothole protection switch
The pothole protection switch is
the connection
Check the pothole
obstacle
19
Trip switch error
Stroke switch line fault or trip
switch line is open
Check the trip switch or
check the line
31
Pressure sensor error
The pressure sensor is not
installed or the line is faulty
Check the line or
replace the sensor
32
Angle sensor error
The angle sensor is not installed
or the line is faulty
Check the line or
replace the sensor
42
Left turn switch error
Turn left micro switch fault
Check the left turn
micro switch
43
Right turn switch error
Turn Right micro switch fault
Check the Right turn
micro switch
46
Drive confirmation switch
error
Drive confirmation switch failure
Check the travel
confirmation switch
47
The platform handle is
wrong
The handle is not centered
Correct or replace the
handle
52
Forward coil error
Coil fault or coil circuit break
Check the coil or
service line
53
Backward coil error
Coil fault or coil circuit break
Check the coil or
service line
54
Platform up coil error
Coil fault or coil circuit break
Check the coil or
service line
55
Platform down coil error
Coil fault or coil circuit break
Check the coil or
service line
56
Turn right coil error
Coil fault or coil circuit break
Check the coil or
service line
57
Turn left coil error
Coil fault or coil circuit break
Check the coil or
service line
58
Brake coil error
Coil fault or coil circuit break
Check the coil or
service line
6.1 B system fault code
Code Fault Probable Reason Problem Solution
failure
wrong or there is an obstacle at
switch or remove the
67 “Translation of the original instruction”
Page 68
59
Series / parallel coil error
Coil fault or coil circuit break
Check the coil or
service line
60
ECU speed output hardware
error
ECU internal hardware error
Replace ECU
82
Right brake coil error
Coil fault or coil circuit break
Check the coil or
service line
83
Left brake coil error
Coil fault or coil circuit break
Check the coil or
service line
68
Battery voltage is low
The battery is discharged
Charge
80
Working load reaches the
calibration of 80%
Pay attention to overload, do
not add too much
Pay attention to load
90
Working load reaches the
calibration of 90%
Pay attention to overload, do
not add too much
Pay attention to load
99
Working load reaches the
calibration of 99%
Pay attention to overload, do
not add too much
Pay attention to load
LL
Machine tilted
Chassis tilt or angle switch
failure
Reduce the tilt angle of
the chassis
OL
Machine overload
Platform overload
Reduce the load
68 “Translation of the original instruction”
Page 69
Oil is too high / pump
The air in the system reduces the
efficiency of components and controls.
Excessive noise, foam and overheating
indicate that there may be air in the
Find out where the air enters
restricted and the diameter is
Cold oil
The cold oil is too viscous: the pump
Rotate the oil through the
High oil absorption vacuum will cause
Check that the piping is not
restricted and the path is
Replace the loose coupling.
Axis alignment
Eccentricity of shaft and coupler will lead
Align the axes
Abnormal noise indicates that the valve
may be viscous and there is
Clean or replace the valve,
6.2 System noise and vibration
Fault Description Method to repair
Oil tank level Low oil level causes cavitation in the tank Add proper amount of clean oil
oil vacuum
system
produces suction
Pump suction vacuum
excessive noise / produce cavitation
Coupling Loose coupling will cause abnormal noise
to abnormal noise
Oil filling / system relief
valve
contamination
the system and repair the leak.
Check that the inlet line is not
qualified
engine to the normal operating
temperature
qualified. Check the filter and its
bypass valve
Replace the pump spindle
check the pump
69 “Translation of the original instruction”
Page 70
the cooling requirements of the system
Radiator (if installed)
The radiator is not sufficient to meet the
Check the air flow and temperature
through the radiator. Clean or repair
Partially opened radiator bypass valves
will cause heat generation within the
t the bypass valve is
valve seat. If necessary, to repair or
set too low for SCR valves to generate
e sure that the SCR valve is
that the relief pressure is set
correctly. Repair or replace if
Hydraulic oil filter
Blocked filters may cause insufficient
Check the hydraulic oil filter to
properly. Replace the filter if
System load
Overload or extreme load cycles will
Make sure the machine works
parameters. Reduce the machine
6.3 System Work Overheating
Fault
Oil tank level
Radiator bypass valve
SCR (system check valve /
relief valve)
Description
The oil in the tank is insufficient to meet
cooling requirements of the system
system
Partially open SCR valves or overflows are
heat in the system
cooling of the system
Method to Repair
Add proper amount of clean oil
the radiator if necessary
Make sure tha
fully closed and fit properly with the
replace it
Mak
properly fitted to the valve seat and
necessary.
determine if it can continue to work
necessary
cause pump and / or motor speed and
pressure to exceed system design limits.
according to the designed
load if necessary
70 “Translation of the original instruction”
Page 71
Input control signal
Pump receives an error control signal .
handle is bound or have been
signal is incorrect or
damping hole control
Make sure that the input signals received in both
normally. If necessary, clean, repair or replace the
Bypass valve
A partially open bypass valve will cause the
Make sure the bypass valve is closed and set
correctly. If necessary, clean, repair or replace the
SCR (system check
SCR valve one-way or two-way valve core
Make sure the SCR valve is working properly. If
Charge pressure
Charge pump damage or charge relief
valve set pressure is low, resulting in the
Check the charge pump is damaged or not and that
the charge relief valve is set correctly or not. If
necessary, repair or replace the charge pump or oil
Charge pressure
Internal leakage causes the system to fill
Repair or replace the components that cause
h ends of the
Check the servo pressure of ports M4 and M5 to
determine that there is sufficient pressure
drain path is smooth and that the size of each
The charge pump is damaged or installed
installed correctly. If necessary, repair or replace the
6.4 System Unresponsive
Fault Description Method to repair
Oil tank level System circuit oil supply is insufficient Add proper amount of clean oil
(handle, current or
pressure)
Pump control The pump's control module or the control
valve / relief valve)
(median)
(MDC-
broken, EDC-
insufficient, HDC-
pipeline is blocked or error)
spool is damaged, will cause the control
signal not be properly transmitted to the
pump
cross port to leak
movement blocked
charge pressure is too low.
directions are correct
To ensure that the pump control operation is correct
and the control spool is not damaged or the use of
time is too long, the spool should move in the cavity
pump's control module or control spool.
bypass valve.
necessary, repair or replace the valve.
relief valve.
(variable)
Servo pressure Lackage of pressure at bot
Charge pump
the oil pressure too low
Servo piston
in the wrong direction
71 “Translation of the original instruction”
leakage
differential. Make sure that the servo oil supply or
damper hole is correct and clean, clean or repair if
necessary.
Make sure the charge pump is working properly and
charge pump.
Page 72
Fault
Description
Method to repair
Oil tank level
System circuit oil supply is insufficient
Add proper amount of clean oil
Displacement limiter
The displacement limiter is misaligned so
Make sure the displacement limiter is set correctly
Input control signal
(handle, current or
pressure)
error)
directions are correct. If necessary, adjust, clear,
Blocked filters may cause the system's oil
Check the hydraulic oil filter to determine if it can
continue to work properly. Replace the filter if
A partially open bypass valve (one or two)
Make sure the bypass valve is closed and properly
ngaged with the valve seat. If necessary, clean,
Charge pressure (median)
The charge pressure is insufficient, so that
the system circuit can not be provided
Check if the charge pump is damaged. Make sure
oil relief valve is set correctly. Repair or replace
Charge pressure
Internal leakage causes the system to fill the
Repair or replace the components that cause
Servo pressure
Lackage of pressure at both ends of the Servo
Check the servo pressure to ensure both ends of
the differential pressure. Make sure that the servo
damper is dimensioned and clean. If necessary,
The charge pump is damaged or installed in
Make sure the charge pump is working properly
and installed correctly. If necessary, repair or
Make sure the SCR valve is set correctly. If
6.5 The System will not Operate in Both Directions
that the servo piston is locked
Pump receives an error control signal . (MDC-
handle is bound or have been broken, EDC-
signal is incorrect or insufficient, HDC-
damping hole control pipeline is blocked or
Make sure that the input signals received in both
repair or replace the control module.
Hydraulic oil filter
Bypass valve
(variable)
Charge pump
SCR (system check valve /
relief valve)
supply to be insufficient
will cause the cross port to leak
enough oil
oil pressure too low
piston
the wrong direction
SCR valve failure or setting error
necessary.
e
repair or replace the bypass valve
the
the charge pump if necessary.
leakage
supply and drain lines are smooth and that each
clean up or repair.
replace the charge pump.
necessary, repair or replace the valve.
72 “Translation of the original instruction”
Page 73
Input control signal (handle,
an error control signal .
handle is bound or have been
signal is incorrect or
damping hole control
necessary, adjust, clear, repair or replace
Displacement limiter (if
The displacement limiter may be adjusted
incorrectly, causing the servo piston to
move in one direction.
Make sure the displacement limiter is
CR (system check valve /
Make sure the SCR valve is working
correctly. If necessary, repair or replace
Damaged or deviated pump control will
correct. Repair or replace the control
Servo pressure
One of the servo pistons is leaking or the
Make sure the servo oil supply or drain
damper hole is correct and clean. If
Input control signal (handle,
Pump receive an error control signal.
handle is bound or have been
signal is incorrect or
damping hole control
Make sure that the input signals received
in both directions are correct. If
djust, clear, repair or replace
PCP pressure (EDC only)
There have pressure leakage on both sides
Replace EDC
6.6 A Certain Direction of the System will not Operate
Fault Description Method to repair
current or pressure)
Pump receives
(MDC-
broken, EDC-
insufficient, HDC-
pipeline is blocked or error)
Make sure that the input signals received
in both directions are correct. If
the control module.
installed)
S
relief valve)
Pump control
SCR valve failure or setting error
make the pump work only in one direction.
oil supply line is clogged
correct
the valve.
Make sure the pump control function is
module if necessary.
path is smooth and the size of each
necessary, clean up or repair.
6.7 It’s difficult to find the Median or there is no median
Fault Description Method to repair
current or pressure)
System pressure There have pressure leakage on both side
Servo pressure There have pressure leakage on both sides
(MDC-
broken, EDC-
insufficient, HDC-
pipeline is blocked or error)
of the work circuit when there is no input
control signal.
of the servo piston when there is no input
control signal.
of the control valve spool when there is no
input control signal.
73 “Translation of the original instruction”
necessary, a
the control module.
Re-adjust the pump Median. See page 24
for adjustment procedures
Re-adjust the control Median. See page
25 to page 26 for adjustment procedures
Page 74
Measure the coil resistance, its
14.20 ohms
(24V) or 3.66 ohms (12V) at 20 degrees
Celsius (70 degrees Fahrenheit). Replace
The pump does not work
The controller is not available with electric
Restore power to the controller
Pump dose not work
bypass port pressure to determine the
appropriate flow. Determine the switch
y measuring the resistance.
6.8 Electrical Fault Diagnosis
Fault Description Method to repair
The pump works only in one
direction
normally
Filter bypass indicator switch The switch may be damaged Check / replace the switch. Measure the
Control coil failure (EDC)
resistance value should be
the coil.
power
Poor electrical contact with the pump Disconnect, check the line, reconnect the
wires
operation b
Open: resistance greater than or equal to
510ohms; closed: resistance is less than
or equal to 122ohms.
74 “Translation of the original instruction”
Page 75
and operating instructions in the appropriate
Make sure that all necessary tools and test
found
and test
problem
solved
The problem
still exists
7. Schematic Diagram
Obey:
The troubleshooting and repair process must be
performed by trained and qualified personnel who
have been trained in the machine.
Damaged or malfunctioning machines should be
marked immediately and stop operation.
Before operating the machine, repair all the damage
and trouble.
Before troubleshooting:
Read, understand and follow the safety instructions
operating instructions Manual.
equipment are ready.
The fault
has been
Identify
the fault
phenom
Return to
repair
Check
Troubleshooting
Perform
repair
75 “Translation of the original instruction”
Page 76
Pic.1 (Just reference)
7.1Electrical Schematic diagram 7.1.1Electrical Schematic of Electric drive A system
76 “Translation of the original instruction”
Page 77
Spare Parts Code
Borrow drawing register
A System Scissor Lift Explanation
Old Drawing Code
Drawing Code
Signature
Date
Joystick
Height Sensor
Overload Sensor
Mark
Design
Drawing
echnology
No.
Zone
Revised Documents
Standard
Audit
Approval
Signature
Date
Applicable models: A system scissors lift instructions
Pattern mark
Total 1 page
Version No.
Scale
Page 1
Pic. No./Name
Electric Diagram
T
77 “Translation of the original instruction”
Page 78
Pic.2
7.1.2 Electrical Schematic diagram of Electric drive B system
78 “Translation of the original instruction”
Page 79
Speed
Signal
Driving Wheel
Enable Signal
High Speed
Back
Forward
Electric Drive Motor
Right Brake
Left Brake
Ground Control
High Speed
Turn Right
Turn Left
Backward
Forward
Lower Down
Lift
Turn Right
Turn Left
Lift
Joystick
Mark
Design
CAD
Double Check
Check Special
Change Content
Change person
Date
Confirmed
Standard
Confirm and Signature
Material
Total Pages
Drawing Mark
No.
Qty.
Weight
Scale
Electric Drive Scissor Lift Wiring
79 “Translation of the original instruction”
Page 80
7.1.3 Electrical Schematic diagram of hydraulic drive A system
80 “Translation of the original instruction”
Page 81
Pic.3(Some same as Pic.1)
Power Supply
Turn Left Switch
Turn Right Switch
Enable Switch
Joystick
High Speed Switch
Horn button
Drive
Lift switch
Overload
Tilt Alarm
Shielding red
Shielding blue
Yellow Green
Height Sensor
Overload Sensor
Inside the box is the option section
Platform Mode
Height signal input
Pressure signal input
2m Stop
Lift Switch
Upper limit
Valve supply to power
Ground Control
Platform Up
Platform Down
Forward Valve
Backward Valve
High Speed
Turn Left
Turn Right
Up Valve
Down Valve
Ground Alarm
Main Contactor
Key Switch
Joystick
Green
Ground Control
Power relay
81 “Translation of the original instruction”
Page 82
Platform Emergency Stop Button
Red Color
Ground Emergency Stop Button
Charger contactor
Valve Group
Horn
Main Contactor
Totally Page 12
A System Scissor Lift Diagram
Qty.
82 “Translation of the original instruction”
Page 83
7.1.4 Illustration of electrical components of Hydraulic drive A system
83 “Translation of the original instruction”
Page 84
Pic.4(Some same as Pic.1)
Contactor
Insurance
White Line
Electric power plug
Left side door
Pothole guard limit switch
Joystick
Horn Button
Lift button
Beeper
Joystick
Low speed Button
Driving button
Battery Display
Stop button
A system controller
Flash
Up and down switch
Key switch
Emergency Stop Button
Ground control diagram
Ground Control
Charger
Hour Meter
2m stop limit switch
Page 12
The Second Page
A system Scissor Lift Electric Components Diagram
Qty.
84 “Translation of the original instruction”
Page 85
Pic.5(Some same as Pic.1)
Page 12
The Third Page
A System Scissor Lift Wiring Diagram
Qty.
7.1.5 High Current wiring diagram of Hydraulic drive A system
85 “Translation of the original instruction”
Page 86
7.1.6 Wiring diagram of Hydraulic drive A system
86 “Translation of the original instruction”
Page 87
Pic.6(Some same as Pic.1)
2m stop
Lower down Valve
Lower down wire, lift switch, 2m stop wiring
Charger
Batteries
Joystick
Ground Control
Upper 6 core wiring
Controller
The wiring connected Ground control and Controller
Pothole guard switch
Pothole guard switch
Valve Group
Totally 12 pages
The fourth Page
A System Scissor Lift Wiring Diagram
Qty.
87 “Translation of the original instruction”
Page 88
Pic.7(Some same as Pic.1)
Totally 12 pages
The fifth Page
Lower down wiring, up switch, and 2 m 6 core wiring diagram
Qty.
7.1.7Down line, raised switch, 2 m limit six core line diagram of Hydraulic drive A system
88 “Translation of the original instruction”
Page 89
7.1.8 Down line, raised switch, 2 m limit six-wire connection diagram of Hydraulic drive A system
89 “Translation of the original instruction”
Page 90
Pic.8(Some same as Pic.1)
Male Plug
Insurance
Female Plug
Charger Protection 1
Charger Protection 2
White
Black
White
Black
Yellow
Red
Blue
Brown
Orange
Insurance
Charger Protection 1
Charger Protection 2
Totally 12 Pages
The sixth Page
Lower down wiring, up switch, and 2 m 6 core wiring diagram
Qty.
90 “Translation of the original instruction”
Page 91
Pic.9(Some same as Pic.1)
16 core male plug
Totally 12 pages
The seventh Page
The wiring connected Ground control to controller
Qty.
7.1.9 Schematic diagram of valve group connection line of lower control box to controller of Hydraulic drive A system
91 “Translation of the original instruction”
Page 92
Pic.10(Some same as Pic.1)
16 core male plug
male plug
Female Plug
Charger Protection 1
Charger Protection 2
Insurance
Totally 12 pages
The Eighth Page
The Wiring Connected Ground Control and Valve of Controller
Qty.
7.1.10 Wiring diagram of the valve group connection line of the lower control box to the controller of Hydraulic drive A system
92 “Translation of the original instruction”
Page 93
7.1.11Upper control six core diagram of Hydraulic drive A system
93 “Translation of the original instruction”
Page 94
Pic.11(Some same as Pic.1)
Quick connect
Quick connect
Line No. Emergency output
Line No. Emergency input
Line No.
Orange
Red
Blue
Black
Brown
Yellow
Line No. Emergency output
Line No. Emergency input
Line No.
Quick connect
2
Quick connect 2
Totally 12 pages
The ninth Page
Upper 6 Core
Qty.
94 “Translation of the original instruction”
Page 95
7.1.12 Base control box internal wiring diagram of Hydraulic drive A system
95 “Translation of the original instruction”
Page 96
Pic.12(Some same as Pic.1)
Relay
Red Line
Red Line
Red Line
Key Switch
Red Line
Green Line
Yellow Line
Blue Line
Red Line
Black Line
16 Core Female Plug
Red Line
Fast Connect 1
Note: 1. The wiring is 0.75mm2
2. Hour meter connecting plug
Toggle Switch
Emergency Stop Button
Beeper
Hour Meter
Red Line
Red Line
Black Line
Black Line
Red Line
Totally 12 pages
The tenth page
The wiring of Ground Control
Qty.
96 “Translation of the original instruction”
Page 97
7.1.13 Upper control box internal wiring diagram of Hydraulic drive A system
97 “Translation of the original instruction”
Page 98
Pic.13(Some same as Pic.1)
Horn
Connect
Connect
Emergency Stop Button
Wiring
Fast Connect 1.2
Orange
Red
Blue
Black
Yellow
Brown
Totally 12 pages
The eleventh page
Joystick Wiring
Qty.
98 “Translation of the original instruction”
Page 99
Pic.14(Some same as Pic.1)
B System Scissor Lift
Platform Control
Ground Emergency Stop
Key Switch Wiring
Key Switch
Insurance
Ground Control
Platform UP/Down
Up
Down
Main Contactor
Batteries
Speed Signal
Enable Signal
7.1.14 Electrical schematic of Hydraulic drive B system
99 “Translation of the original instruction”
Page 100
Horn Option
Drive motor light indictor
Power Relay
Horn
Pothole Guard Switch 1
Pothole Guard Switch 1
Level switch
Level switch power
Level switch output
Data
Data
Platform Connecting to Ground
Valve Drive Power
Negative power
Positive Power
Overload Limit Switch (Option)
Down Limit Switch (Option)
Up Limit Switch (Option)
Control Power
Option
(Option)
(Option)
High Speed
Turn Right
Turn Left
Backward
Forward
Down
Up
Ground Emergency Stop
Upper Control
Enable Switch
Steering
Left
Right
Display
Beeper
X4647 can not drive above 10m
Height Limit Switch
Main Contactor Wiring
Electric
Totally 8 pages
The first page
B system Scissor Lift Diagram
Qty.
100 “Translation of the original instruction”
Loading...