Upright X26 Ultra Narrow, X20N, X26N, X26UN, X31N Service Manual

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Page 1

X26

Ultra Narrow

Serial Numbers 20000 - Current

Publication Number: 114101-000

Page 2

X26 Ultra Narrow

Serial Number 20000 – Current

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

Stamped Serial Number

UpRight, Inc.

801 South Pine Street Madera, California 93637

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

FRONT

Call Toll Free in U.S.A.

1-800-926-LIFT

REAR

UpRight

Unit S1, Park West Industrial Park

Friel Avenue

Nangor Road

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

Page 3

OREWORD

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

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

This manual consists of five (5) parts.

PERATOR

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

ECTION

Contains generic information relevant to all UpRight Aerial Work Platforms.

ECTION

Detailed information specific to this UpRight Aerial Work Platform.

1 - G

2 - S

ANUAL

ENERAL

ERVICE AND

NFORMATION

EPAIR

ECTION

Causes and solutions to typical problems.

ECTION

Electric and Hydraulic schematics.

3 - T

4 - S

ROUBLESHOOTING

CHEMATICS

Service Manual Page i

Page 4

Foreword

OTES

Page ii Service Manual

Page 5

PERATOR

ANUAL

WARNING

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

and the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES of ANSI A92.6-1999

before performing maintenance on or operating any UpRight Aerial Work Platform.

Safety Rules

Safety RulesSafety Rules

Electrocution Hazard

Electrocution Hazard Tip Over Hazard

Electrocution HazardElectrocution Hazard

Tip Over Hazard Collision Hazard

Tip Over HazardTip Over Hazard

Collision Hazard Fall Hazard

Collision HazardCollision Hazard

Fall Hazard

Fall HazardFall Hazard

NEVER operate the machine within ten

(10) feet of power lines.

THIS MACHINE IS NOT INSULATED.

NEVER

• curbs, or debris.

NEVER

•

ALWAYS

•

NEVER

•

NEVER

•

NEVER

•

LOOK

•

DISTRIBUTE

•

NEVER

•

NEVER

•

INSPECT

• hoses, loose wire connections, and wheel bolts.

NEVER

•

IF ALARM SOUNDS

• surface.

IN CASE OF EMERGENCY

•

NEVER

•

NEVER

•

NEVER

• turer’s written consent.

VERIFY

•

NEVER

•

AFTER USE

•

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

operate the machine if all guardrails are not properly in place and secured.

close and secure the entrance after entering the platform. use ladders or scaffolding on the platform. exceed the maximum platform load. See “Specifications” on page 20. attach overhanging loads or increase platform size.

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

all platform loads evenly on the platform. use damaged equipment. (Contact UpRight for instructions. See toll free phone number on inside cover.) change operating or safety systems.

the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, damaged cables or

climb down elevating assembly when the platform is elevated.

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

perform service on the machine while the platform is elevated without blocking the elevating assembly. recharge batteries near sparks or open flame; batteries that are being charged emit explosive hydrogen gas. replace any component or part with anything other than original UpRight replacement parts without the manufac-

that all labels are in place and legible before using.

tow the machine. Transport by truck or trailer only.

, secure the machine against unauthorized use by turning the Chassis Key Switch OFF and removing the key.

NEVER operate the boom or drive with

the platform elevated unless on firm,

push the Emergency Stop Switch to cut power to all machine functions.

level surface.

NEVER position the machine without

first checking for overhead obstructions

or other hazards.

NEVER climb, stand or sit on the

platform guardrails or midrail.

California Proposition 65 Warning

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

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

114100-000R1 X26 Ultra Narrow - Operator Manual Page 1

Page 6

ONTENTS

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

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

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Pre-Operation Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

System Function Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Extend the Platform Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Retract The Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Travel With the Platform Lowered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Elevating the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Travel with Work Platform Elevated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lowering the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Emergency Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Guardrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Raising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Parking Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Release the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engage the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

After Use Each Day. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Lifting By Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Moving By Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Driving or Winching onto a Truck or Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Blocking The Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Scissor Brace Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Scissor Brace Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Testing the Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Daily Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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

Maintenance Table Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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

Page 2 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 7

NTRODUCTION

ENERAL

Introduction

This manual covers the X26 Ultra Narrow Aerial Work Platform. This manual must be stored on the machine at all times.

Read, understand and follow all safety rules and operating instructions before attempting to operate the machine.

ESCRIPTION

Figure 1:

WARNING

DO NOT use the machine

not properly in place and secured

1. Platform Controls

2. Manual Case

3. Platform Extension

4. Platform

5. Elevating Assembly

6. Chassis

7. Batteries

8. Charger Outlet Plug

9. Chassis Controls

10. Emergency Lowering Valve Knob

11. Hydraulic Fluid Reservoir

if all guardrails are

Power Module

X 26 Ultra Narrow

114100-000R1 X26 Ultra Narrow - Operator Manual Page 3

Rear

Control Module

Page 8

Controls and Indicators

532 4

1. Circuit Breaker

2. Chassis Key Switch

3. Chassis Lift/Lower Switch

4. Chassis Emergency Stop Switch

5. Hour Meter/Voltage Indicator

1. Steering Switch

2. Interlock Switch (on front of Control Handle)

3. Control Handle

4. Platform Emergency Stop Switch

5. Lift/Drive Selector Switch

6. Horn Button (optional)

Platform Controls

Chassis Controls

ONTROLS

The operator shall know the location of each control and indicator and have a thorough knowledge of the function and operation of each before attempting to operate the unit.

AND

NDICATORS

Figure 2:

Controls and Indicators

-O

PERATION

NOTE:

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

2. Check the level of the hydraulic fluid with the platform fully lowered. See “Hydraulic Fluid” on page 14.

3. Check that fluid level in the batteries is correct. See “Battery Maintenance” on page 14.

4. Verify that the batteries are charged.

5. Check that the A.C. extension cord has been disconnected from the charger plug.

6. Check that all guardrails are properly in place and secured.

7. Inspect the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, dam-

AFETY

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

Industry Association’s MANUAL OF RESPONSIBILITIES of ANSI A92.6-1999

steps each day before use.

Add recommended hydraulic fluid if necessary. See “Specifications” on page 20.

aged cables or hoses, loose wire connections and wheel bolts.

NSPECTION

and the Scaffold

. Perform the following

Page 4 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 9

YSTEM

System Function Inspection

UNCTION

Refer to Figure 1 and Figure 2 for the locations of various controls and indicators.

NSPECTION

WARNING

STAND CLEAR of the machine while performing the following checks.

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

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

Protect the control cable from possible damage while performing checks.

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

2. Turn the Chassis and Platform Emergency Stop Switches ON by pulling the buttons out.

3. Turn and hold the Chassis Key Switch to CHASSIS. Push the Chassis Lift/Lower Switch to the LIFT position and elevate the platform approximately 2,1 m (

4. Install the scissor brace as described on page 12.

5. Visually inspect the elevating assembly, lift cylinder, cables, and hoses for cracked welds and structural damage, loose hardware, hydraulic leaks, and loose wire connections. Check for missing or loose parts.

6. Verify that the Depression Mechanism Supports have rotated into position under the machine.

7. Check Level Sensor operation (see “Level Sensor” on page 13).

8. Remove the scissor brace as described on page 12.

9. Turn and hold the Chassis Key Switch to CHASSIS. Push the Chassis Lift/Lower Switch to the LIFT position and fully elevate the platform.

• Check for erratic operation.

10. Partially lower the platform by pushing Chassis Lift/Lower Switch to LOWER, and check for proper operation of the audible lowering alarm.

11. Check the Emergency Lowering Valve for proper operation (see “Emergency Lowering” on page 7).

12. Lower the platform.

13. Push the Chassis Emergency Stop Switch to check for proper operation. All machine functions should be disabled. Pull out the Chassis Emergency Stop Switch to resume.

14. Turn the Chassis Key Switch to DECK.

15. Check that the route is clear of surface hazards such as holes, drop-offs, bumps, curbs, or debris, and is level and capable of supporting the wheel loads.

16. Mount the platform and properly close and secure the entrance.

17. Turn the Lift/Drive Switch to DRIVE.

18. Check for speed and directional control.

• While engaging the Interlock Switch, slowly position the Control Handle to FORWARD then REVERSE. The farther you push or pull the Control Handle from center the faster the machine will travel.

• Perform this test in both HI and LOW DRIVE.

19. Push the Steering Switch RIGHT, then LEFT, to check for steering control.

20. Turn the Lift/Drive Switch to LIFT to check platform lift controls.

• While engaging the Interlock Switch, move the Control Handle to UP to raise the platform.

• While engaging the Interlock Switch, move the Control Handle to DOWN to lower the platform. The platform should descend and the audible lowering alarm should sound.

21. Push the Platform Emergency Stop Switch to check for proper operation. All machine functions should be disabled. Pull out the Platform Emergency Stop Switch to resume.

7 ft.

114100-000R1 X26 Ultra Narrow - Operator Manual Page 5

Page 10

Operation

PERATION

Before operating the work platform, ensure that the Pre-Operation Safety Inspection and System Function Inspection have been completed and that any deficiencies have been corrected.

aged or malfunctioning machine.

LATFORM

XTENSION

The operator must be thoroughly trained on this machine.

Never operate a dam-

1. Mount the platform and properly close and secure the entrance.

2. Depress the foot lever located at the rear of the platform extension. Push the platform extension forward until the pin engages the front stop.

3. To retract the platform extension, depress the foot lever and pull the platform extension toward the rear of the machine until the pin engages the rear stop.

RAVEL

LATFORM

1. Check that the route is clear of surface hazards such as holes, drop-offs, bumps, or debris.

2. Check that the route is level, and is capable of supporting the wheel loads.

3. Verify that the Chassis Key Switch is turned to DECK and the Chassis Emergency Stop Switch is ON (pulled out).

4. Mount the platform and properly close and secure the entrance.

5. Check clearances above, below, and to the sides of machine.

6. Pull the Platform Emergency Stop Switch out to the ON position.

7. Turn the Lift/Drive Switch to DRIVE.

ITH THE

OWERED

1. Platform Extension

2. Foot Lever (deck lock assembly)

Figure 3:

Platform Extension

Turn Lift/Drive Switch to HI for traveling on level ground, or to LOW when extra torque is required for climbing

NOTE:

grades.

8. Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction. The speed of the machine will vary depending on how far from center the Control Handle is moved.

TEERING

1. Turn the Lift/Drive Switch to DRIVE.

2. While engaging the Interlock Switch, push the Steering Switch to the RIGHT or LEFT to turn the wheels in the desired direction. Observe the tires while maneuvering the machine to ensure proper direction.

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

NOTE:

Switch.

Page 6 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 11

Operation

Emergency

Lowering Valve

Knob

LEVATING

1. Locate a firm, level surface.

2. Turn the Lift/Drive Switch to LIFT.

3. While engaging the Interlock Switch, push the Control Handle FORWARD.

4. If the machine is not level the level sensor alarm will sound and the machine will not lift or drive.

level sensor alarm sounds the platform must be lowered and the machine moved to a firm, level surface before attempting to elevate the platform.

The Depression Mechanism supports will deploy automatically as the platform elevates and will retract after

NOTE:

the platform has been lowered completely and has been driven.

RAVEL

The machine will travel at reduced speed when the platform is elevated.

NOTE:

1. Check that the route is clear of surface hazards such as holes, drop-offs, bumps, curbs, or debris.

2. Check that the route is level, and is capable of supporting the wheel loads.

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

4. Turn the Lift/Drive Switch to DRIVE.

5. Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction. The speed of the machine will vary depending on how far from center the Control Handle is moved.

6. If the machine is not level the level sensor alarm will sound and the machine will not lift or drive.

level sensor alarm sounds the platform must be lowered and the machine moved to a firm, level surface before attempting to elevate the platform.

WITH

THE

LATFORM

ORK

LATFORM

LEVATED

If the

OWERING

1. Turn the Lift/Drive Switch to LIFT.

2. Check around the base of the platform to ensure that no one is in contact with the machine. Engage the Interlock Switch and pull back on the Control Handle to lower the platform.

MERGENCY

WARNING

If the platform should fail to lower, NEVER climb down the elevating assembly.

Stand clear of the elevating assembly while operating the Emergency Lowering Valve Knob.

The Emergency Lowering Valve Knob is located at the rear of the machine, behind the ladder.

1. Open the Emergency Lowering Valve by pulling and holding the knob.

2. To close, release the knob. The platform will not elevate if the Emergency Lowering Valve is open.

THE

LATFORM

OWERING

Figure 4:

Emergency Lowering Knob

114100-000R1 X26 Ultra Narrow - Operator Manual Page 7

Page 12

Operation

UARDRAILS

The guardrails may be lowered for the purpose of passing through a standard doorway.

to proper position before using the machine.

DO NOT use the machine if all guardrails are not properly in place and secured.

OWERING PROCEDURE

1. Ensure that the platform extension is fully retracted and the deck lock pin is engaged (see “Platform Extension” on page 6).

2. Place the Platform Controls on the deck of the platform extension.

3. Lower the platform extension guardrail;

a. Pull to retract the retaining pins.

b. Hold the midrail with one hand as

Guardrails must be returned

WARNING

• As the retaining pin is pulled, the rail will drop slightly and hold the pin in the retracted position.

you retract the final retaining pin.

Figure 5:

1. Platform Extension

2. Platform Controls

3. Platform Extension Retaining Pins

4. Side-rail Retaining Pins

5. Rear Top-rail Retaining Pins

Guardrails

Engaged Retracted

CAUTION

The guardrail could drop suddenly when the final retaining pin is retracted. Keep hands away from the slide tubes to prevent injury.

c. Push down on the platform extension guardrail to lower it completely.

• The retaining pins will remain in the retracted position.

4. Lower the side guardrails and rear guardrail as a single unit;

• Repeat steps 3a through 3c.

5. Lower the rear top-rail;

• Pull the two retaining pins and lower the rear top-rail completely.

AISING PROCEDURE

1. Raise the side guardrails and rear guardrail as one unit;

• Pull up on the side guardrails and raise them until all the retaining pins engage.

2. Raise the rear top-rail;

• Pull up on the rear top-rail until the retaining pins engage.

3. Raise the platform extension guardrail;

• Pull up on the platform extension guardrail and raise it until all the retaining pins engage.

4. Hang the controller on the platform extension guardrail.

Page 8 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 13

Operation

1. Motor Mount

2. Drive Motor

3. Brake Release Nut

4. Wheel

FRONT

ARKING

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

IMPORTANT: Do Not release the parking brakes if the machine is on a slope.

RAKE

ELEASE

WARNING

Never winch or move the machine faster than 0,3 m/sec. (1 ft./sec.).

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

The parking brakes are integral to the drive motors. Each drive motor has two brake release nuts. Release and engage the parking brakes one wheel at a time. Turn the brake release nuts in stages (½ turn at a time) to prevent possible binding of the brake mechanism.

ELEASE THE PARKING BRAKE

The front wheel motors each have two brake release nuts.

IMPORTANT: Turn the nuts alternately in ½ turn increments

to insure uniform adjustment and prevent binding.

1. Chock the rear wheels to prevent the machine from rolling.

2. Using a 13 mm socket wrench, turn the brake release nuts clockwise until they contact the motor body.

3. Alternately turn each nut clockwise in ½ turn increments until resistance is felt (approximately two turns).

4. The brake is released.

Figure 6:

Parking Brake Release

NGAGE THE PARKING

1. Chock the rear wheels to prevent the machine from rolling.

2. Using a 13 mm socket wrench, alternately turn the brake release nuts counter-clockwise in ½ turn increments.

• Repeat until there is approximately 3.2 mm ( motor body.

3. Verify that the brakes have fully engaged before operating the machine by testing their ability to hold the

26%

ACH

machine on a 14.5° (

FTER

1. Ensure that the platform is fully lowered.

2. Park the machine on a firm, level surface, preferably under cover, secure against vandals, children and

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

unauthorized operation.

RAKE

) grade.

1/8 in.

) between the brake release nuts and the drive

114100-000R1 X26 Ultra Narrow - Operator Manual Page 9

Page 14

Transporting the Machine

Front

Rear

RANSPORTING

Always use a transport vehicle when moving a machine to a work site. Towing the machine over long distances will damage the machine and void the warranty.

IFTING

THE

BY C

RANE

ACHINE

DANGER

! !

See specifications for the weight of the machine and be certain that the crane is of adequate capacity to lift the machine.

Secure straps to chassis tie down/lifting points only (see Figure 7).

OVING

! !

Forklifting is for transport only.

See specifications for the weight of the machine and be certain that the forklift is of adequate capacity to lift the machine.

Forklift from the rear of the machine using the forklift pockets provided. If necessary, the machine may be forklifted from the side by lifting under the Chassis Modules (refer to Figure 8).

BY F

DANGER

ORKLIFT

Figure 7:

Secure Crane Straps

FRONT

Front Tie Down/Lift

Point

Forklift Here

Rear Tie

Down/Lift Point

Figure 8:

REAR

Tie Down and Lift Points

Rear Tie

Down/Lift Point

Forklift Pockets

Page 10 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 15

RIVING OR

INCHING

ONTO

A T

RUCK

Transporting the Machine

RAILER

WARNING

Never winch faster than 0,3 m/sec. (1 ft./sec.).

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

1. Loading the machine onto the truck or trailer;

A. To

a. Turn the Lift/Drive Switch to DRIVE LOW (hi-torque mode) and drive the machine up the ramp and

into transport position. b. Set the wheels straight and turn off the machine. c. Chock the wheels.

B. To

a. Drive the machine up to the ramp. b. Attach the winch cable to the tie down/lifting points. c. Release the parking brakes (refer to “Parking Brake Release” on page 9). d. Winch the machine into transport position e. Chock the wheels.

f. Re-engage the parking brakes.

2. Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis tie down/lifting points (refer to Figure 8).

the machine onto the transport vehicle:

Drive

Winch

the machine onto the transport vehicle:

CAUTION

Overtightening chains or straps attached to the Tie Down points may result in damage to the machine

114100-000R1 X26 Ultra Narrow - Operator Manual Page 11

Page 16

Maintenance

AINTENANCE

WARNING

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

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

LOCKING

CISSOR BRACE INSTALLATION

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

2. Pull Chassis Emergency Stop Switch to the ON position.

3. Pull Platform Emergency Stop Switch to the ON position.

4. Turn and hold the Chassis Key Switch to CHASSIS.

5. Push the Chassis Lift/Lower Switch to LIFT to elevate the platform until the scissor brace can be rotated to the vertical position.

6. From the rear of the machine, lift the scissor brace from its stowed position. Rotate upward and outward, then down until it is hanging vertically below its attachment point.

7. Lower the platform by pushing the Chassis Lift/Lower Switch to LOWER and gradually lower the platform until the scissor brace is supporting the platform.

LEVATING

SSEMBLY

Figure 9:

Counterclockwise

Scissor Brace

Rotate Brace Clockwise to

Block

to Store

Brace Rests

on Weldment

CISSOR BRACE

1. Using the Chassis Controls, gradually elevate the platform until the scissor brace is clear.

2. Rotate the scissor brace outward and upward over its mounting point until it rests in the stowed position.

3. Lower the platform by pushing the Chassis Lift/Lower Switch to LOWER to completely lower the platform.

Page 12 114100-000R1 X26 Ultra Narrow - Operator Manual

TORAGE

when in

Blocking

Position

Page 17

EVEL

Maintenance

ENSOR

WARNING

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

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

The Level Sensor Is located on the chassis between the scissor sections and is covered with a protective metal box. To verify the sensor is working properly there are two LED's under the sensor; green indicates the sensor is ON (has power), red indicates the sensor is LEVEL.

ESTING THE LEVEL SENSOR

1. Place machine on firm level surface.

2. Use the Chassis Controls to raise the platform to approximately 2,1 m (

3. Install the scissor brace (see “Blocking The Elevating Assembly” on page 12).

4. Remove the Level Sensor electrical box cover near the front of machine.

5. Push the Level Sensor off of level.

6. The alarm should sound, and the red LED should turn OFF.

• If the alarm does not sound, take the machine out of service until the Level Sensor has been adjusted or repaired.

7. Replace the Level Sensor electrical box cover.

8. Store the scissor brace and lower the Platform.

7ft.

Figure 10:

Level Sensor

114100-000R1 X26 Ultra Narrow - Operator Manual Page 13

Page 18

Maintenance

YDRAULIC

The hydraulic fluid reservoir is located in the control module door.

Never add fluid if the platform is elevated.

NOTE:

HECK HYDRAULIC FLUID

1. Make sure that the platform is fully lowered.

2. Open the chassis door.

3. Remove the filler cap from the hydraulic fluid reservoir.

4. Check the fluid level on the dipstick on the filler cap.

5. Add the appropriate fluid to bring the level to the FULL mark. See “Specifications” on page 20.

ATTERY

AINTENANCE

LUID

Figure 11:

Hydraulic Fluid Reservoir and Dipstick

WARNING

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

Always wear safety glasses when working near batteries.

Battery fluid is highly corrosive. Thoroughly rinse away any spilled fluid with clean water.

Always replace batteries with UpRight batteries or manufacturer approved replacements weighing 30 kg (66 lbs.) each.

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

• If electrolyte level is lower than 10 mm

tap water with high mineral content, as it will shorten battery life.

• Inspect the battery regularly for signs of cracks in the case, electrolyte leakage and corrosion of the terminals.

• Inspect cables regularly for worn spots or breaks in the insulation and for broken cable terminals.

• Keep the terminals and tops of the batteries clean.

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

in.

) above the plates add distilled water only. DO NOT use

(

Page 14 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 19

1. Battery Charger

2. Charge Indicator

3. Charger Plug

4. Batteries

ATTERY

Maintenance

HARGING

Figure 12:

Battery Charger

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

WARNING

Charge the batteries in a well ventilated area.

Do not charge the batteries when the machine is near a source of sparks or flames.

Permanent damage to the batteries will result if the batteries are not immediately recharged after discharging.

Never leave the battery charger operating for more than two days.

Never disconnect the cables from the batteries when the charger is operating.

Keep the charger dry.

1. Check the battery fluid level. If the battery fluid level is lower than

in.

10 mm

2. Connect an extension cord (1,5 mm diameter; 15 m (

) above the plates add distilled water only.

(

12 gauge

[

50 ft.

) maximum length) to the charger plug located

] minimum conductor

at the left side of the chassis.

Figure 13:

Charge Indicator Lights

3. The charger turns on automatically after a short delay. Look through the charge indicator cutout to check the state of charge.

• 0 - 50% charge:

• First Light -BLINKING-

• Second and Third Light -OFF-

• 50% - 75% Charge:

• First Light -ON-

• Second Light -BLINKING-

• Third Light -OFF-

• 75% - 100% Charge:

• First and Second Light -ON-

• Third Light - BLINKING-

• Charge Complete

• All Lights -ON-

• The charger automatically shuts down to low current after charging is complete and all lights turn ON.

• The charger continues at low current (equalizing charge) for 3-4 hours, then charging current shuts off

completely.

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

114100-000R1 X26 Ultra Narrow - Operator Manual Page 15

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

NOTE:

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

NOTE:

Page 20

Daily Inspection and Maintenance Schedule

AILY

NSPECTION

The Complete Inspection consists of periodic visual and operational checks, along with periodic minor adjustments that assure proper performance. Daily inspection will prevent abnormal wear and prolong the life of all systems. Perform the inspection and maintenance items daily. Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures.

AND

AINTENANCE

CHEDULE

WARNING

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

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

The daily preventative maintenance checklist has been designed for machine service and maintenance. Please photocopy the Daily Preventative Maintenance Checklist and use the checklist when inspecting the machine.

Page 16 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 21

AILY

AINTENANCE

REVENTATIVE

ABLE KEY

AINTENANCE

Daily Preventative Maintenance Check List

HECK

EPORT

IST

Y = Yes/Acceptable

N = No/Not Acceptable

R = Repaired/Acceptable

COMPONENT INSPECTION OR SERVICES Y N R

Battery

Chassis

Control Cable

Controller Check switch operation

Drive Motors Check for operation and leaks

Elevating Assembly Inspect for structural cracks

Emergency Hydraulic

System

Check electrolyte level

Check battery cable condition

Check hoses for pinch or rubbing points Check welds for cracks

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

Operate the emergency lowering valve and check for serviceability

Date: _______________________________________

Owner: _____________________________________

Model No: ___________________________________

Serial No: ___________________________________

Serviced By: _________________________________

COMPONENT INSPECTION OR SERVICES Y N R

Entire Unit Check for and repair collision damage

Hydraulic fluid Check fluid level

Hydraulic Pump Check for hose fitting leaks

Hydraulic System Check for leaks

Labels

Platform Deck and

Rails

Tires and Wheels Check for damage

Check for peeling, missing, or unreadable labels & replace

Check welds for cracks

Check condition of platform

114100-000R1 X26 Ultra Narrow - Operator Manual Page 17

Page 22

Labels

ABELS

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

BATTERY

MAINTAIN BATTERY FLUID

AT RECOMMENDED LEVEL

3) 005221-000

4) 066552-000

5) 101251-000

MAXIMUM DISTRIBUTED

PLATFORM LOAD 500 LBS.

OR TWO OCCUPANTS

MAXIMUM SIDE LOAD 100 LBS.

10) 060197-000

11) 061205-005

12) 061220-002

20) 010076-001

25) 066556-000

26) 066559-000

BATTERY

CHARGER

32) 066522-000

33) 066556-001

34) 107051-000

6) 101250-000

7) 014222-003-99

8) 066555-000

9) 066553-000

13) 066550-000

15) 066554-000

16) 066561-000

17) 066558-000

29) 062562-001

35) 101252-005

36) 068639-000

31) 101222-005

Page 18 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 23

Labels

REAR

Figure 14:

Safety Labels Locations

CONTROL MODULE

POWER MOUDLE

FRONT

114100-000R1 X26 Ultra Narrow - Operator Manual Page 19

Page 24

Specifications

PECIFICATIONS

ITEM X26 ULTRA NARROW

Platform Size

Platform Extension In

Platform Extension Out

Max. Platform Capacity

Standard

on Extension

Max. No. of occupants

Standard (total)

on Extension

Height

Working Height

Max. Platform Height

Min. Platform Height

Dimensions

Weight

Overall Width

Overall Height

Overall Height, Rails Lowered

Overall Length, Extension In

Overall Length, Extension Out

Drivable Height 7,9 m [26 ft.] Drive Speed

Platform Lowered

Platform Raised

Energy Source 24 Volt Battery Pack (4-235 A Hour, 6 Volt Batteries, min. wt. 30 kg [66 lbs.] each)

Motor 24 Volt 4 Horse Power DC Electric Motor

System Voltage 24 Volt DC Battery Charger 25 A, 110/220 VAC

Hydraulic Reservoir Capacity 15 L [4 US Gallons]

Maximum Hydraulic Pressure 207 bar [3000 psi] Hydraulic Fluid

Normal Temperature (0° C [>32° F])

Low Temperature (0° C [<32° F])

Extreme Temperature (-17° C [<0° F])

Lift System

Lift Speed Lift, 42 sec./Lower 40 sec.

Control System

Drive System Dual Front Wheel Hydraulic Motors

Tires 381 mm [15 in.] Diameter Solid Rubber, non-marking Parking Brake Dual Spring Applied, Hydraulic Release

Turning Radius 203 mm [8 in.] Inside

Maximum Gradeability 14.5° [26%] Wheel Base 1,9 m [74.75 in.]

Guardrails 1,1 m [43.25 in.] High

Toe Boards 15,2 cm [6 in.] Ground Clearance 8,9 cm [3.5 in.]

0,71 m x 2,21 m [28 in. x 87 in.]

0,71 m x 3,2 m [28 in. x 126 in.]

226,8 kg [500 lbs.]

110 kg [250 lbs.]

2 people

1 person

9,8 m [32 ft.]

7,9 m [26 ft.] 1,1 m [43 in.]

2358,7 kg [5200 lbs.] 0,82 m [32.5 in.]

2,2 m [86 in.]

1,99 m [78.25 in.] 2,35 m [92.5 in.]

3,26 m [128.5 in.]

0 to 3,2 km/h [0 to 2.0 mph]

0 to 0,8 km/h [0 to 0.50 mph]

ISO #32

ISO #32 ISO #15

One Single Stage Lift Cylinder

Proportional Control Handle with Interlock Switch, Rotary Lift/Drive Switch, and Red Mushroom Emergency Stop Switch

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

Refer to the Service Manual for complete parts and service information.

Page 20 114100-000R1 X26 Ultra Narrow - Operator Manual

Page 25

ABLE

Section 1

ENERAL

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

ONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

NFORMATION

IST OF

IGURES

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

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

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

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

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

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

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

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

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

ABLES

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

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

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

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

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

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

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

Service Manual Page 1-1

Page 26

Section 1 - General Information Hazard Indicators

1-1 H

AZARD

! !

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

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

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

NDICATORS

DANGER

WARNING

CAUTION

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

1-2 W

ORKSHOP

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

WARNING

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

WARNING

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

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

Refer to the Operator Manual for elevating assembly blocking instructions.

ROCEDURES

Page 1-2 Service Manual

Page 27

Torque Specifications Section 1 - General Information

1-3 T

Table 1-1:

ORQUE

YDRAULIC

NOTE:

PECIFICATIONS

OMPONENTS

Always lubricate threads with clean hydraulic fluid prior to installation

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

Torque Specifications for Hydraulic Components

Type: SAE Port Series Cartridge Poppet Fittings Hoses

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

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

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

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

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

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

ASTENERS

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

For other preloading methods or fasteners consult UpRight Engineering Department.

NOTE:

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

Table 1-2:

HREAD

ONDITION

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

• For dry unplated fasteners use K =,20

ORQUE TABLES

Torque Specifications for SAE Fasteners

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

Nominal

Thread Size

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

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

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

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

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

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

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

Unified Coarse Thread Series

Clamp

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

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

Tightening

Load

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

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

To rq ue

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

Clamp

Load

Tightening

To rq ue

Nominal Thread

Size

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

Unified Fine Thread Series

Clamp

Load

Tightening Torque

Clamp

Load

Tightening Torque

Service Manual Page 1-3

Page 28

Section 1 - General Information Torque Specifications

10.9

Table 1-3:

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

8.8

Clamp

Load

Grade 10.9

Tightening Torque

Grade 8.8

Nominal

Thread

Clamp

Size

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

3.5------1,10922.930.5

Load

3------82314.619.5

4------1,43633.945.2

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

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

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

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

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

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

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

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

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

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

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

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

Tightening Torque

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

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

Clamp

Load

12.9

Grade 12.9

Tightening Torque

Table 1-4:

Torque Specifications for Metric Fasteners, SI Units

8.8

Grade 8.8

Nominal

Thread

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

Clamp

Load

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

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

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

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

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

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

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

16 70650 170 226 97732 235 313 114218 274 365

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

22 136350 450 600 188618 622 830 220433 727 970

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

30 252450 1136 1515 349223 1572 2095 408128 1837 2450

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

Tightening Torque

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

Clamp

Load

Grade 10.9

Tightening Torque

Clamp

Load

12.9

Grade 12.9

Tightening Torque

Page 1-4 Service Manual

Page 29

Date Code Identification on Hoses Section 1 - General Information

1-4 D

GGGG

AAAATTTTEEEESSSS

PPPP

AAAARRRRKKKKEEEERRRR

DDDD

AAAAYYYYCCCCOOOO

1-5 S

ATE

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

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

stamps month, day and year on each hose.

PECIAL

ODE

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

• 0-69 bar (

• 0-207 bar (

• 0-414 bar (

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

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

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

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

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

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

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

• 0-25 kg (

OOLS

0-1000 psi

0-3000 psi 0-6000 psi

0-50 Lbs.

DENTIFICATION

Plant, Month, Day, Year

) Hydraulic Pressure Gauge with Adapter Fittings

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

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

OSES

UPR

IGHT LIFT TOOL LIST

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

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

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

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

Service Manual Page 1-5

Page 30

Section 1 - General Information UpRight Connectors

Large KitSmall Kit

1-6 U

PRIGHT

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

ALE

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

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

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

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

ONNECTOR

ONNECTORS

LUG

Figure 1-1:

UpRight Connector Kits

)

Figure 1-2:

UpRight Male Connector

EMALE

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

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

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

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

Page 1-6 Service Manual

ONNECTOR

ECEPTACLE

)

Figure 1-3:

UpRight Female Connector

Page 31

UpRight Connectors Section 1 - General Information

ELEASING

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

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

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

RIMPING

1. Strip 6 mm (

Complete crimping instructions are included in each Field Kit.

NOTE:

OCKING

¼ in.

) from the wire.

INGERS

Figure 1-4:

Locking Finger, UpRight Connector

2. Insert the contact into the crimping tool.

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

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

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

EMOVING

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

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

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

ONTACT

FROM

EAVY

UTY

LUG

Figure 1-5:

Heavy Duty UpRight Connector

Service Manual Page 1-7

Page 32

Section 1 - General Information Hydraulic Manifold Repair

1-7 H

YDRAULIC

EMOVAL

Refer to the

1. Disconnect the battery.

2. Tag and disconnect the solenoid valve leads.

3. Tag, disconnect, and plug hydraulic hoses.

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

5. Remove the manifold block.

ISASSEMBLY

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

NOTE:

1. Remove coils from solenoid valves.

2. Remove valves.

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

LEANING

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

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

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

4. Replace parts and O-rings found unserviceable.

ANIFOLD

Service and Repair

AND

NSPECTION

EPAIR

section for model specific information.

SSEMBLY

Refer to the breakdowns.

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

NOTE:

tapping on the ball with a brass drift punch.

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

2. Install valves.

NSTALLATION

Refer to the

1. Attach manifold assembly to mounting plate with bolts.

2. Connect solenoid leads (as previously tagged).

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

4. Reconnect the battery.

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

6. Adjust valve pressures according to the

Service and Repair

section for assembly drawings, and the

section for model specific information.

Service and Repair

section.

Parts Manual

for illustrated parts

Page 1-8 Service Manual

Page 33

Cylinder Repair Section 1 - General Information

1-8 C

YLINDER

WARNING

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

EMOVAL

Refer to the Service and Repair section for the location of cylinders, and the Parts Manual for a list of parts

NOTE:

which secure the cylinders.

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

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

ISASSEMBLY

1. Remove the head from the cylinder body.

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

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

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

EPAIR

.007 in.

) should be replaced.

Service and Repair

section.

SSEMBLY

Refer to the parts breakdowns.

NOTE:

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

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

1. Lubricate all components with clean hydraulic fluid.

2. Install new seal kit components.

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

4. Lubricate the seals on the piston and head.

5. Carefully slide the rod assembly into the cylinder.

6. Secure the head into the cylinder.

NSTALLATION

1. Installation is reverse of removal.

2. Carefully remove the elevating assembly support.

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

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

Service and Repair

section for seal-kit assembly drawings, and the

Parts Manual

for illustrated

Service Manual Page 1-9

Page 34

Section 1 - General Information Electric Motors

DC Power Supply

Voltage Meter

Ammeter

Brushes and springs in their final position

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

Keep fingers clear of this space.

DC Motor

1-9 E

LECTRIC

ROUBLESHOOTING

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

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

A. The shaft could be tight for a number of

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

a. Obtain power to produce the nameplate

voltage.

nection

b. First touch the motor leads quickly to the

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

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

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

d. If the motor sounds noisy, it should be

taken apart as described in the disassembly section.

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

OTORS

Do not Make a Permanent Con-

Figure 1-6:

Electric Motor Service

Page 1-10 Service Manual

ISASSEMBLY

1. Remove the through bolts.

2. Remove the pulley end cover.

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

4. Remove the commutator end cover.

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

NOTE:

Permanent distortion or other damage will result.

Page 35

Electric Motors Section 1 - General Information

Counterclockwise

Rotation

Buss Bar

Brushes

Buss Bar

Typical pump motor viewed from rear.

Brushes and springs in their final position

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

NSPECTION

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

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

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

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

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

NOTE:

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

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

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

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

EASSEMBLY

Figure 1-7:

Electric Motor Brushes

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

Inspection

Step 3.).

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

3. Place the bearing spring into the bearing bore.

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

NOTE:

Service Manual Page 1-11

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

5. Set the brushes into their final position as

This illustration is a 015797-011 pump motor.

NOTE:

Other electric motors may rotate in either direction, and may use only two brushes.

shown in Figure 1-7.

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

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

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

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

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

• Faulty armature.

Page 36

Section 1 - General Information Battery Maintenance

1-10 B

ATTERY

AINTENANCE

CAUTION

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

WARNING

Hazard of explosive gas mixture. Keep sparks, flame and smoking materials away from batteries.

Always wear safety glasses when working with batteries.

Battery fluid is highly corrosive. Thoroughly rinse away any spilled fluid with clean water.

Always replace batteries with UpRight batteries or manufacturer approved replacements.

Before disconnecting the battery negative (-) lead, make sure all switches are OFF. If ON, a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present.

• Check battery fluid level daily.

• If electrolyte level is lower than 10 mm (

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

• Keep terminals and tops of batteries clean.

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

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

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

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

3/8 in.

) above plates, add distilled water only.

Page 1-12 Service Manual

Page 37

Battery Maintenance Section 1 - General Information

ATTERY

Electric UpRight Aerial Work Platforms use deep cycle batteries. If poor service life is experienced, batteries should be checked for bad cells. Fully charge batteries for 14 hours minimum, ensuring that the charger has completed its cycle (see ‘Battery Charging” on page 1-16).

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

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

ATTERY CELL EQUALIZATION

The specific gravity of the electrolyte in the battery cells should be equalized monthly. To do this, charge batteries as outlined in ‘Battery Charging” on page 1-16. After this initial charge, recheck the electrolyte level in all cells and add distilled water as necessary. Then, turn on the charger for an additional eight hours.

PECIFIC GRAVITY

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

HECK

Table 1-5:

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

Specific Gravity and Battery Voltage

SPECIFIC GRAVITY VOLTS DC

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

Fully Charged 1.270 2.10 6.30 12.60 25.20 50.40

Fully Discharged 1.130 1.75 5.25 10.50 21 42

OAD TESTING BATTERY PACKS

1. Fully charge the battery pack.

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

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

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

3. Measure the potential across each battery.

4. Measure the potential across the entire battery pack.

5. Compare the measured results

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

Service Manual Page 1-13

Page 38

Section 1 - General Information Battery Maintenance

ATTERY

HARGING

CAUTION

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

WARNING

Charge batteries only in a well ventilated area.

DO NOT charge batteries when sparks or open flames are present.

Never leave the connected charger unattended for more than two days.

Never disconnect the cables from the battery when the charger is operating.

Keep the charger dry.

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

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

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

NOTE:

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

1. Check the battery fluid level. If electrolyte level is lower than 10 mm (

3/8 in.

) above plates, add distilled

water only.

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

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

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

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

Table 1-6:

Battery Charging, UpRight Electric and BiEnergy Machines

Charger Display AC Charging Current Charging Indicator Charger Shutdown

068574-000 8 Amp - 115 VAC Ammeter

069112-000 4 Amp - 230 VAC

063944-001 7 Amp - 115 VAC Green Light

063948-003 4 Amp - 230 VAC

069199-000

069199-001

Dual Voltage

8 Amp - 115 VAC 4 Amp - 230 VAC

• Charging current is displayed on ammeter.

• Current drops off as batteries charge.

• ON during charging cycle.

• Blinking at charge completion.

Three Lights

• 0 - 50% charge:

First Light -BlinkingSecond and Third Light -OFF-

• 50% - 75% Charge:

First Light -ONSecond Light -BlinkingThird Light -OFF-

• 75% - 100% Charge:

First and Second Light -ONThird Light - Blinking-

• Charge Complete

All Lights -ON-

• Charger shuts off automatically.

• Ammeter shows “0” current.

• Charger automatically shuts down to 1 amp trickle charge.

• Green Light continues to blink.

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

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

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

Page 1-14 Service Manual

Page 39

Battery Maintenance Section 1 - General Information

ATTERY

HARGER

ROUBLESHOOTING

CAUTION

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

Connect battery leads in correct polarity to avoid charger damage.

WARNING

Remove all power before working on electrical parts to avoid shock.

Shock hazard can exist if AC plugs are wired incorrectly.

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

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

NOTE:

procedures carefully.

Table 1-7:

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

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

Fuse visible on front of charger has failed.

AC power problem. • Ammeter does not move.

DC connection to batteries. • Ammeter does not move.

One or more batteries is bad.

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

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

High current in DC charging output.

Battery Charger Troubleshooting

Problem

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

• Ammeter does not move.

• No hum from charger.

• Ammeter does not move.

• No hum from charger.

• Ammeter does not move.

• No hum from charger.

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

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

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

• No green Light.

• No hum from charger.

• No green Light.

• No hum from charger.

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

• No green Light.

• No hum from charger.

• No green Light.

• No hum from charger.

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

069199-000 & 069199-001

(115/230V auto)

• Not Applicable.

• Charger turns on even with very low battery voltage.

• Not Applicable.

• Charger automatically adjusts to the incoming AC current.

• No Lights ON.

• No Lights blinking.

• All three Lights blink once. Connection to battery;

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

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

063944-001 ONLY

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

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

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

• Set the voltage selector switch to the proper voltage.

• AC outlet is bad.

• Extension cord is bad

• Plug is bad or wired wrong.

• AC wire is broken.

Check and repair as necessary.

• missing.

• corroded.

• wrong polarity.

• DC wire broken.

Check and repair as necessary, and check Fuse.

• Check water level.

• Check for shorted cells.

• Replace bad batteries.

to cool before connecting to AC source.

• Check for bad batteries.

Solution

Service Manual Page 1-15

Page 40

Section 1 - General Information Floor Loading

TIRE LUG TIRE OUTRIGGER

CONTACT AREA

LENGTH

WIDTH

1-11 F

LOOR

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

Localized Pressure

machine.

TOTAL WEIGHT = MACHINE WEIGHT + MAXIMUM PLATFORM CAPACITY.

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

OCALIZED

KG/CM

Localized Pressure is measured in

per square centimeter (pounds per square inch

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

NOTE:

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

OADING

Occupied Pressure

RESSURE

² (PSI)

kilograms

). It is the pressure exerted onto a small

The formulas shown here are for vertical lift

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

Figure 1-8:

Contact Area

EASURE THE CONTACT

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

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

ALCULATE THE LOCALIZED PRESSURE

Find the pressure exerted at each contacting surface.

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

NOTE:

machine, or on the serial plate.

If you know the wheel load, use this formula:

LOCALIZED PRESSURE = WHEEL LOAD ÷ CONTACT AREA

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

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

CCUPIED

BAR (PSF)

Occupied Pressure is measured in

. It is the total pressure imposed onto the

must not exceed

square foot)

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

REA

RESSURE

bar (pounds per

the maximum load that the surface can support.

Figure 1-9:

Occupied Surface Area

OCCUPIED PRESSURE = TOTAL WEIGHT ÷ (LENGTH X WIDTH)

Page 1-16 Service Manual

Page 41

Hydraulic Fluid Section 1 - General Information

1-12 H

YDRAULIC

LUID

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

ECOMMENDED

• DO NOT fill above operating range.

• DO NOT add fluid when the platform is elevated.

EVEL

LUID

YDRAULIC

LUID

CAUTION

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

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

OBILFLUID

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

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

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

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

424

OBIL

DTE 13 M

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

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

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

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

OBIL

DTE 11 M

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

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

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

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

OBIL

EAL E

For use where a

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

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

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

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

• Synthetic Ester Base.

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

NVIROSYN

biodegradable non-toxic hydraulic fluid is required.

46 H

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

Service Manual Page 1-17

Page 42

Section 1 - General Information Long Term Storage

1-13 L

ONG

NOTE:

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

2. Fill the hydraulic reservoir to operating level.

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

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

4. Coat all exposed unpainted metal surfaces with preservative.

ERM

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

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

RESERVATION

a barrier material.

Internal Combustion Models:

Electric And BiEnergy Models:

TORAGE

Service the engine according to the manufacturers recommendations.

Remove the batteries and place them in alternative service.

Page 1-18 Service Manual

Page 43

Section 2

ERVICE

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

AND

EPAIR

ABLE

WARNING

Be sure to read, understand and follow all information in the operate or perform service on any UpRight

DANGER

! !

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

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

ONTENTS

2-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

2-2 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

2-3 Blocking the Elevating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Access to Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Chassis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Motor Controller and Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Level Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Height Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Check and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Height Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Proximity Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Test High Speed Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-6 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Aerial Work Platform

Operator Manual

before attempting to

114101-000 X26 Ultra Narrow - Service Manual Page 2-1

Page 44

Section 2 - Service and Repair

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2-7 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Hydraulic Fluid Reservoir and Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Reservoir Breather/Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Fluid Outlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Hydraulic Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Setting Hydraulic Manifold Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Lift Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Series Parallel Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-8 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

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

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

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

Depression Mechanism Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

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

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

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

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2-9 Drive Motors and Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Brake Disc Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Rear Wheels, Hubs and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Page 2-2 114101-000 X26 Ultra Narrow - Service Manual

Page 45

Section 2 - Service and Repair

IST OF

IGURES

Figure 2-1: X26 Ultra Narrow Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Figure 2-2: Maintenance Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Figure 2-3: Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Figure 2-4: Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Figure 2-5: Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Figure 2-6: Chassis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Figure 2-7: Level Sensor and Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Figure 2-8: Height Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Figure 2-9: Height Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Figure 2-10: Proximity Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Figure 2-11: Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Figure 2-12: Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Figure 2-13: Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Figure 2-14: Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Figure 2-15: Hydraulic Manifold Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Figure 2-16: Hydraulic Manifold Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Figure 2-17: Hydraulic Manifold Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Figure 2-18: Series Parallel Manifold Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Figure 2-19: Series Parallel Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Figure 2-20: Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Figure 2-21: Steering Cylinder Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Figure 2-22: Steering Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Figure 2-23: Depression Mechanism Cylinder Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Figure 2-24: Depression Mechanism Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Figure 2-25: Elevating Assembly Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Figure 2-26: Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Figure 2-27: Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Figure 2-28: Drive Motor Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Figure 2-29: Rear Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Figure 2-30: Bearing Cup Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

114101-000 X26 Ultra Narrow - Service Manual Page 2-3

Page 46

General Description Section 2 - Service and Repair

2-1 G

ENERAL

The X26 Ultra Narrow Work Platform is a self-propelled aerial work platform designed to provide mobility with the platform elevated or lowered. The elevating function shall only be used when the platform is on a firm, level surface. Travel with the platform elevated is limited to the low speed range. The machine is intended to be self-propelled only when in relatively close proximity to the work area.

OMPONENT

Refer to Figure 2-1 to locate the components of the X26 Ultra Narrow Work Platform.

1. Entry Way

2. Deck Lock Assembly

3. Work Platform

4. Guardrails

5. Platform Extension

6. Platform Controls

7. Rear Guardrail Retaining Pin

8. Guardrail Retaining Pin

9. Elevating Assembly

10. Control Module

11. Chassis Controls

12. Circuit Board

13. Motor Controller

14. Hydraulic Fluid Reservoir

15. Hydraulic Fluid Filter

16. Hydraulic Pump and Motor

17. Main Valve Manifold

18. 175 AMP Fuse, Overload Protection

19. Solenoid, Motor Relay

20. Audible Alarm

21. Depression Mechanism

22. Depression Mechanism Cylinder

23. Battery Charger Plug

24. Battery Charger

25. Battery Pack

26. Cable Connector

27. Power Module

28. Drive Motors

29. Steering Cylinder

30. Lift Cylinder

31. Maintenance Brace

32. Level Sensor

33. Proximity Switch

34. Height Limit Switch

35. Series Parallel Valve

36. Emergency Lowering Valve

37. Emergency Lowering Valve Knob

ESCRIPTION

OCATIONS

Page 2-4 114101-000 X26 Ultra Narrow - Service Manual

Page 47

Section 2 - Service and Repair General Description

Figure 2-1:

X26 Ultra Narrow Component Locations

FRONT

REAR

114101-000 X26 Ultra Narrow - Service Manual Page 2-5

Page 48

Preventative Maintenance Section 2 - Service and Repair

2-2 P

REVENTATIVE

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

WARNING

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

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

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

AINTENANCE

Page 2-6 114101-000 X26 Ultra Narrow - Service Manual

Page 49

Section 2 - Service and Repair Preventative Maintenance

AINTENANCE

REVENTATIVE

ABLE KEY

AINTENANCE

HECK

REVENTATIVE MAINTENANCE

IST

EPORT

Interval

Daily = each shift or every day 30d = every 50 hours or 30 days 3m = every 125 hours or 3 months 6m = every 250 hours or 6 months 2y = every 1000 hours or 2 years Y = Yes/Acceptable N = No/Not Acceptable R = Repaired/Acceptable

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Check electrolyte level Daily

Batteries

Hydraulic

System

Controller Check operation of all controls Daily

Control

Platform

Floor and

Hydraulic

System

Hydraulic

Clean exterior 3m

Clean terminals 3m

Check fluid level Daily

Fluid

Change filter 6m

Drain and replace hydraulic fluid 2y

Check for leaks Daily

Check hose connections 30d

Check hoses for exterior wear 30d

Check the exterior of the cable for pinching,

Cable

binding or wear

Check fasteners for proper torque Daily

Check welds for cracks Daily

Check condition of platform Daily

Rails

Check condition of anchorage points Daily

Check condition of operators manual Daily

Check for damage Daily

Tires

Check lug nuts (torque to 123 N-m [90 ft.lbs.]) 30d

Check hydraulic drive motor operation Daily

Drive

Check hoses, fittings, and valve manifold for leaks

Check for leaks at mating surfaces 30d

Check for hose fitting leaks Daily

Pump

Check mounting bolts for proper torque 30d

Wipe clean 30d

Daily

Date: ______________________________________

Owner: _____________________________________

Model No: __________________________________

Serial No: ___________________________________

Serviced By: ________________________________

Service Interval:______________________________

COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Check hardware & fittings for proper torque 6m

Steering

System

Elevating

Assembly

Chassis

Cylinders

Entire Unit

Labels

Check linkage for wear areas 30d

Check for missing/loose retainers 30d

Check steering cylinder for leaks Daily

Inspect for structural cracks Daily

Check pivot points for wear 30d

Check pivot pin retaining bolts for proper torque 30d

Check members for deformation Daily

Check hoses for pinch or rubbing points Daily

Check component mounting for proper torque 6m

Check welds for cracks Daily

Check the cylinder rods for wear 30d

Check lift cylinder pin retaining bolts for proper torque

Lift

Check seals for leaks 30d

Inspect pivot points for wear 30d

Check fittings for proper torque 30d

Check for and repair collision damage Daily

Lubricate steering pivots 30d

Check fasteners for proper torque 3m

Check for corrosion-remove and repaint 3m

Check for peeling, missing, or unreadable labels & replace

30d

Daily

114101-000 X26 Ultra Narrow - Service Manual Page 2-7

Page 50

Blocking the Elevating Assembly Section 2 - Service and Repair

2-3 B

LOCKING

WARNING

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

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

NSTALLATION

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

2. Pull Chassis Emergency Stop Switch to the ON position.

3. Pull Platform Emergency Stop Switch to the ON position.

4. Turn and hold the Chassis Key Switch to CHASSIS.

5. Push the Chassis Lift/Lower Switch to LIFT to elevate the platform until the maintenance brace can be rotated to the vertical position.

6. From the front of the machine, lift the maintenance brace from its stowed position. Rotate upward and outward, then down until it is hanging vertically below its attachment point.

7. Lower the platform by pushing the Chassis Lift/Lower Switch to LOWER and gradually lower the platform until the maintenance brace is supporting the platform.

THE

LEVATING

SSEMBLY

Figure 2-2:

Maintenance Brace

2-4 L

TORAGE

1. Using the Chassis Controls, gradually elevate the platform until the maintenance brace is clear.

2. Rotate the maintenance brace outward and upward over its attachment point until it rests in the stowed position.

3. Lower the platform by pushing the Chassis Lift/Lower Switch to LOWER to completely lower the platform.

UBRICATION

Figure 2-3:

There are four lubrication points on the machine - two on each steering pivot (see Figure 2-3).

Lubricate the steering pivots every 125 hours or three months.

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

2. Clean the grease fittings and surrounding area.

3. Using multipurpose grease in a grease gun, pump the grease into the fitting until grease just begins to appear at the edges of the pivot.

4. Wipe off any excess grease.

Lubrication Points

Page 2-8 114101-000 X26 Ultra Narrow - Service Manual

Page 51

Section 2 - Service and Repair Controls

2-5 C

ONTROLS

LATFORM

Refer to wiring diagrams.

Refer to the ment part numbers.

CCESS TO SWITCHES

1. Remove the four screws from the

2. Unplug the Control Handle wiring

Section 4 - Schematics

control panel and lift the assembly from the Platform Control box.

harness.

ONTROLS

Par ts Manual

for replace-

for

1. Platform Control Box

2. Platform Control Panel

3. Control Handle

4. Lift/Drive Switch

5. Emergency Stop Switch

Figure 2-4:

6. Horn Button (optional)

7. Contact Block - N.C.

8. Contact Block - N.O./N.C.

9. Contact Block - N.O.

Platform Controls

ONTROL HANDLE

1. Remove the Control Handle, if necessary, from Platform Control box.

a. Remove the control panel. b. Unplug the control handle wir-

ing harness.

c. Remove the four screws from

the control handle mounting plate.

d. Lower the control handle

through the control panel.

2. Remove and replace defective parts. Refer to the

Par ts Manual

for repair parts numbers.

Right Handle Half

Lever, Interlock

Figure 2-5:

Boot, Steering Rocker

Rocker Pin

Rocker, Steering

Steering Switch

Switch, Interlock

Control Handle

Left Handle Half

Boot, Handle

Hall Effect Device

114101-000 X26 Ultra Narrow - Service Manual Page 2-9

Page 52

Controls Section 2 - Service and Repair

HASSIS

Refer to for wiring diagrams.

Refer to the

ONTROLS

Section 4 - Schematics

Par ts Manual

for

Figure 2-6:

Chassis Controls

replacement part numbers.

To access the switches and components for repair or replacement;

1. Open the control module.

2. Remove the four screws from the control box cover and lift the cover.

• Be careful not to damage the cable that connects the circuit board and the motor control.

3. Place the control cover topside-down.

OTOR

ONTROLLER AND IRCUIT

Refer to

shooting

OARD

Section 3 - Trouble-

for motor controller and

circuit board dip switch settings.

To access the Motor Controller Dip Switches, open the control module as described in “Chassis Controls”.

The circuit board is mounted inside the control box cover.

1. Chassis Control Box

2. Chassis Control Box Cover

3. Circuit Board

4. Motor Control

5. Relay, 24V

6. Circuit Breaker

7. Key Switch

8. Switch Contact, N.O.

9. Lift/Lower Switch Cover

10. Toggle Switch

11. Emergency Stop Switch

12. Contact Block, N.C.

13. Hour Meter

Page 2-10 114101-000 X26 Ultra Narrow - Service Manual

Page 53

Section 2 - Service and Repair Controls

1. Level Sensor Electrical Box Cover

2. Level Sensor

3. Proximity Switch

4. Height Limit Switch

EVEL

NTRODUCTION

The Level Sensor Is located near the front of the chassis between the elevating assembly sections, and is covered with a protective metal box. It has three wires; red-power (24V in), black-ground, white-output (24V out). To verify the sensor is working properly there are two LED's under the sensor; green indicates the sensor is on (has power), red indicates the sensor is level and the white wire is 'hot' (24V out).

ENSOR

WARNING

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

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

EVEL SENSOR

1. Place machine on firm, level surface.

2. Use the Inclinometer (P/N: 10119-000-00) to ensure that the Chassis is level from front to rear and side to side.

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

4. Remove the Level Sensor electrical box cover near the front of machine.

5. Adjust the three leveling locknuts until the bubble is centered in the circle on the attached bubble level.

6. Replace the Level Sensor electrical box cover.

7. Store the maintenance brace and lower the platform.

DJUSTMENT

Figure 2-7:

Level Sensor and Proximity Switch

114101-000 X26 Ultra Narrow - Service Manual Page 2-11

Page 54

Controls Section 2 - Service and Repair

1. Platform

2. Adhesive Tape

3. Tape Measure

1. Height Limit Mercury Switch

2. Capscrew

3. Electrical Connector

FRONT

EIGHT

The Height Limit Switch is a mercury switch that prevents the lift

IMIT

WITCH

Figure 2-8:

Height Limit Switch Adjustment

cylinder from reaching the end of its stroke and results in a smooth stop at full elevation. If the Height Limit Switch is out of adjustment or not functioning, the platform will stop abruptly when it reaches full elevation (the end of the lift cylinder stroke).

CAUTION

To disable or bypass any control will void the warranty.

HECK AND TEST

A tape measure at least 8 m (

26 ft.

) in length is required to check

the operation of the Height Limit Switch.

Check Operation

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

2. Use adhesive tape to attach the tab of a tape measure to the front edge of the platform. Ensure that the locking device on the tape measure is disengaged and extend the tape measure to the surface.

3. Fully elevate the platform. The tape measure should un-roll as the platform elevates.

4. Measure the distance from the platform deck to the surface. The height should be 7,86 m (

25 ft. 10 in.

• If the distance is more, the switch is out of adjustment or not functioning.

• If the distance is less, the switch is out of adjustment.

Test the Mercury Switch

Figure 2-9:

7,86 m

25 ft. 10 in.

Height Limit

WARNING

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

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

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

2. Place a reference mark alongside the switch to establish its position.

3. Disconnect the electrical connector.

4. Install a continuity tester to the Height Limit Switch.

5. Loosen the capscrew and rotate the switch clockwise until it opens. The continuity tester light should turn OFF when the switch opens.

• If the continuity tester light remains ON, replace the switch.

• If the continuity tester light turns OFF, adjust the switch.

Page 2-12 114101-000 X26 Ultra Narrow - Service Manual

Page 55

Section 2 - Service and Repair Controls

EMOVAL AND INSTALLATION

WARNING

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

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

Refer to Figure 2-9 for the location of the Height Limit Switch.

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

2. Place a reference mark alongside the switch to establish its position.

3. Disconnect the electrical connector.

4. Remove the capscrew from the switch bracket, and remove the switch.

5. Install the new switch, align it with the reference mark and tighten the capscrew.

6. Connect the electrical connector.

7. Check the Height Limit Switch and adjust if necessary.

EIGHT LIMIT SWITCH ADJUSTMENT

Adjust the Height Limit Switch to stop elevation at 7,86 m (

26 ft.

(

) in length is required to adjust the Height Limit Switch.

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

2. Use adhesive tape to attach the tab of a tape measure to the front edge of the platform (see Figure 2-8). Ensure that the locking device on the tape measure is disengaged and extend the tape measure to the surface.

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

4. Place a reference mark alongside the Height Limit Switch to establish its position.

5. Fully elevate the platform. The tape measure should un-roll as the platform elevates.

25 ft. 10 in.

) A tape measure at least 8 m

Do not return the maintenance brace to the stowed position at this time.

NOTE:

6. Measure the distance from the platform deck to the surface (see Figure 2-8).

• If the distance is correct, store the maintenance brace and fully lower the platform.

• If the distance is not correct, proceed to Step 7.

7. Lower the platform until the maintenance brace is properly set.

8. Loosen the capscrew and adjust as follows:

• If the distance is capscrew.

• If the distance is tighten the capscrew.

9. Repeat Step 5 through Step 6.

more than

less than

7,86 m (

25 ft. 10 in.

), rotate the switch slightly clockwise and tighten the

), rotate the switch slightly counter clockwise and

114101-000 X26 Ultra Narrow - Service Manual Page 2-13

Page 56

Controls Section 2 - Service and Repair

ROXIMITY

Refer to Figure 2-7.

The Proximity Switch is located near the front of the chassis between the elevating assembly sections, and forward of the Level Sensor. Its function is determined by the location of the lower elevating assembly tube.

ROXIMITY SWITCH FUNCTION

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

When Elevating:

• The Level Sensor is enabled.

• The Depression Mechanism is enabled.

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

0.5 mph

(

When Completely Lowered:

• Power is supplied to the High Speed Circuit, allowing the machine to travel up to 3,2 km/h ( when the Platform Controls Lift/Drive Switch is set to DRIVE HI.

WITCH

2.0 mph

)

EST HIGH SPEED

1. Elevate the platform 30 cm (

2. Turn the Lift/Drive Switch to DRIVE HI and attempt to drive the machine.

• If the machine will drive faster than 3,2 km/h (

EMOVAL AND INSTALLATION

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

2. Disconnect the switch leads.

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

4. Adjust the switch-to elevating assembly tube clearance (see “Proximity Switch Adjustment” on page 2-15).

5. Connect the switch leads.

6. Store the maintenance brace and lower the platform.

IRCUIT

12 in.

0.5 mph

), adjust or replace the switch.

Page 2-14 114101-000 X26 Ultra Narrow - Service Manual

Page 57

Section 2 - Service and Repair Controls

ROXIMITY SWITCH ADJUSTMENT

Figure 2-10:

Proximity Switch Adjustment

WARNING

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

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

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

2. Use a clamp to attach a straight guide to the elevating assembly tube.

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

4. Turn the adjusting nuts to adjust to within 4,76 mm to 6,35 mm (

to 1/4 in.

3/16 in.

5. Remove the clamp and guide and repeat the test.

• If the test fails, the switch is defective and must be replaced.

4,75 mm - 6,35 mm (3/16 in. - 1/4 in.)

1. Maintenance Brace

2. Guide

3. Proximity Switch

4. Adjustment Nuts

114101-000 X26 Ultra Narrow - Service Manual Page 2-15

Page 58

Batteries Section 2 - Service and Repair

2-6 B

ATTERIES

Electrical Energy for the motor is supplied by four 6 volt batteries wired in series for 24 volts DC. Proper care and maintenance of the batteries and motor will ensure maximum performance from the machine.

ATTERY

Check the electrolyte level daily. Clean the battery exterior and terminals every 125 hours or three months.

Refer to

Refer to the instructions.

If system voltage drops below 17 volts (on a 24 volt system), the charger will not recharge the batteries. If this

NOTE:

extreme voltage drop occurs, disconnect and recharge each battery separately using a 6 volt charger to bring the voltage in each up to at least 4 1/2 volts.

AINTENANCE

Section 1: General Information

Operator Manual

included in this Service Manual for specific maintenance and charging

for complete battery maintenance instructions.

CAUTION

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

WARNING

Hazard of explosive gas mixture. Keep sparks, flame and smoking materials away from batteries.

Always wear safety glasses when working with batteries.

Battery fluid is highly corrosive. Thoroughly rinse away any spilled fluid with clean water.

Always replace batteries with UpRight batteries or manufacturer approved replacements.

Before disconnecting the battery negative (–) lead, make sure all switches are OFF. If ON, a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present.

Page 2-16 114101-000 X26 Ultra Narrow - Service Manual

Page 59

Section 2 - Service and Repair Batteries

1. Power Module

2. Negative Battery Lead

3. Positive Battery Lead

4. Battery to Battery Leads

5. Battery Pack Connector

ATTERY

EMOVAL

EPLACEMENT

Figure 2-11:

Battery Installation

1. Turn the Chassis Key Switch to the OFF position and push the Chassis and Platform Emergency Stop Switches down to the OFF position.

If switches are ON, a spark will occur at the ground

NOTE:

terminal which could cause an explosion if hydrogen gas or fuel vapors are present.

2. Open the power module.

3. Disconnect battery pack connector.

4. Disconnect the battery negative (–) lead.

IMPORTANT: Disconnect the battery negative (–) lead first.

5. Disconnect the remaining battery leads.

6. Lift the batteries out of the module.

NSTALLATION

Battery cables must be installed as shown in Figure 2-11.

IMPORTANT: Connect the battery negative (–) lead last.

1. Verify that the Chassis Key Switch and the Chassis and Platform Emergency Stop Switches are in the OFF position.

2. Place the batteries into the power module.

3. Connect the battery to battery leads.

4. Connect the battery positive (+) lead.

5. Connect the battery negative (–) lead.

6. Connect the battery pack connector.

114101-000 X26 Ultra Narrow - Service Manual Page 2-17

Page 60

Hydraulics Section 2 - Service and Repair

2-7 H

YDRAULICS

YDRAULIC

LUID LEVEL

Check the fluid level daily.

With the platform fully lowered, open the control module and remove the reservoir breather/cap. Fluid should be at the full mark.

CAUTION

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

ESERVOIR BREATHER

Clean the breather/cap at the same time that the fluid filter is replaced. Use cleaning solvent and blow dry with clean dry compressed air.

LUID

ESERVOIR AND

ILTERS

Figure 2-12:

Hydraulic Reservoir

ILTER

Replace the filter every 250 hours or six months.

1. Unscrew the filter from the filter assembly.

2. Apply a thin film of clean hydraulic fluid to the gasket of the replacement filter.

Screw the replacement filter onto the filter head until the gasket makes contact, then turn the filter ¾ of a turn further.

EPLACEMENT

1. Drain Plug

2. Filter

3. Suction Screen

Figure 2-13:

Fluid Filter

Page 2-18 114101-000 X26 Ultra Narrow - Service Manual

Page 61

Section 2 - Service and Repair Hydraulics

LUID REPLACEMENT

Replace the hydraulic fluid every 1000 hours or two years.

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

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

• Hydraulic reservoir capacity: 15 L (

3. Open the control module door.

4. Remove the drain plug and allow all the fluid to drain. Dispose of hydraulic fluid properly (contact your local fluid recycler).

5. Install the drain plug.

6. Fill the hydraulic reservoir with the appropriate hydraulic fluid until the fluid is up to the full mark on the dipstick.

• Refer to “Specifications” at the end of the the proper fluid for your conditions.

4U.S. gal

Operator Manual

included in this Service Manual to identify

LUID OUTLET

Clean or replace the outlet screen at the same time that the fluid is changed.

1. Drain the fluid (see “Fluid Replacement”).

2. Disconnect and plug the outlet hose to prevent foreign material from entering the hose.

3. Remove the suction screen. Clean or replace as necessary.

4. Install the suction screen.

5. Fill the hydraulic reservoir (see “Fluid Replacement”).

CREEN

114101-000 X26 Ultra Narrow - Service Manual Page 2-19

Page 62

Hydraulics Section 2 - Service and Repair

1. Inlet Hose

2. Outlet Hose

3. Capscrew

4. Pump Assembly

5. Electric Motor

6. Vibration Mount

7. Motor Mount Cap Screw

YDRAULIC

UMP AND

OTOR

Figure 2-14:

Hydraulic Pump

The hydraulic pump is located in the control module.

EMOVAL

If the hydraulic reservoir has not been drained,

NOTE:

suitable means for plugging hoses should be provided to prevent excessive fluid loss.

WARNING

1. Disconnect the battery pack connector and the battery negative lead.

2. Open the control module.

3. Mark, disconnect and plug the hose assemblies.

It may not be necessary to remove the motor to service or remove the pump.

NOTE:

4. Disconnect the power supply from the motor.

5. Remove the four cap screws from the vibration mounts and lift the motor and pump assembly from the control module.

6. Loosen the capscrews and remove the pump assembly from the motor.

NSTALLATION

Pump to Motor

1. Lubricate the pump shaft with general purpose grease and attach the motor with the capscrews.

2. Using a crisscross pattern, torque each capscrew a little at a time until all capscrews are torqued to 27 N-m (

20 ft./lbs.

Page 2-20 114101-000 X26 Ultra Narrow - Service Manual

Pump and Motor Assembly to Control Module

3. Position the motor and vibration mounts into the control module.

4. Put a drop of Loctite® 242 thread lock on each capscrew as you install the capscrew and lock washer through the bottom of the control module.

5. Tighten the motor mount nuts to 24 N-m (

18 ft./lbs.

6. Unplug and connect the hydraulic hoses.

7. Connect the power supply to the motor.

8. Connect the negative battery lead.

9. Connect the battery pack connector.

10. Check the fluid level in the hydraulic reservoir before operating the machine.

Page 63

Section 2 - Service and Repair Hydraulics

YDRAULIC

It is not necessary to remove the manifold to perform all maintenance procedures (i.e. replacing a single valve). Determine whether or not the manifold should be removed before maintenance begins.

ANIFOLD

Refer to

EMOVAL AND INSTALLATION

1. Disconnect the battery

2. Tag and disconnect the

3. Tag, disconnect, and plug

4. Remove the bolts that hold

5. Remove the manifold

Section 3 - Schematics

WARNING

pack connector and the battery negative lead.

solenoid valve leads.

hydraulic hoses.

the manifold to the mounting bracket.

block.

for the hydraulic schematic and hose routing diagram.

Figure 2-15:

Hydraulic Manifold Location

Installation is reverse of removal.

Torque mounting capscrews to 11 N-m (

EPAIR

Refer to

Refer to Figure 2-16: “Hydraulic Manifold Exploded View,” on page 2-22.

8 ft./lbs.

Section 1 - General Information

for repair instructions.

114101-000 X26 Ultra Narrow - Service Manual Page 2-21

Page 64

Hydraulics Section 2 - Service and Repair

Figure 2-16:

Hydraulic Manifold Exploded View

TOP VIEW

1. Hydraulic Manifold

2. Fitting #2 Plug

3. Fitting #4 Plug

4. Fitting Straight 6MB - 6MJ

5. Fitting Straight 4MBH - 4MJ

6. Fitting Plug #6

7. Fitting Plug #8

8. Fitting 8MB-8MJX

9. Steering Relief Valve

10. Main Relief Valve

11. 2 Pos - 4 Way Solenoid W/ Coil (Lift)

12. 3 Pos - 4 Way Solenoid W/ Coils (Steer)

13. Counterbalance Valve

Pressure

BOTTOM VIEW

Reservoir

14. Lift Relief Valve

15. Flow Divider Valve

16. 2 Pos Poppet Valve W/ Coil (Depression Mechanism)

17. Pressure Gauge Fitting

18. Check Valve

19. 3 Pos - 4 Way Solenoid W/ Coils (Drive)

Page 2-22 114101-000 X26 Ultra Narrow - Service Manual

Page 65

Section 2 - Service and Repair Hydraulics

Test Port

Lift Relief Valve

Counterbalance

Valves

Main Relief Valve

Steering Relief

Val ve

ETTING

Check the hydraulic pressures whenever the pump, manifold, or relief valves have been serviced or replaced.

YDRAULIC

ANIFOLD

RESSURES

WARNING

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

The fluid in the hydraulic system is under very high pressure which can easily cause severe cuts. Obtain medical assistance immediately if cut by hydraulic fluid.

Figure 2-17:

Hydraulic Manifold Adjustment

AIN RELIEF VALVE

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

2. Slowly drive the machine to within 8 cm ( ward until the front of the chassis is in solid contact with the wall.

3. Insert a 0-207 bar (

4. Loosen the locknut or remove the cover on the Main Relief Valve and turn the adjusting screw counterclockwise two full turns.

5. Unhook the Platform Controls from the guardrail so that the machine may be operated from the ground. Slowly push the Control Handle in the direction of the wall.

6. Slowly turn the Main Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 193 bar (

7. Tighten locknut or replace Main Relief Valve cover and torque to 8 N-m (

114101-000 X26 Ultra Narrow - Service Manual Page 2-23

0-3000 psi

2800 psi

) pressure gauge into the test port.

3 in.

) of a solid, immovable brick wall. Ease the machine for-

6 ft./lbs.

Page 66

Hydraulics Section 2 - Service and Repair

TEERING RELIEF

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

2. Remove the gauge port cap and install the pressure gauge assembly.

3. Loosen the locknut or remove the cover on the Steering Relief Valve and turn the adjusting screw counterclockwise two full turns.

4. While one person holds the Steering Switch to steer to the right or left, slowly turn the Steering Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 103 bar (

5. Tighten the locknut or replace the Steering Relief Valve cover and torque to 8 N-m (

6. Remove the gauge and replace the cap.

IFT RELIEF VALVE

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

2. Loosen the locknut or remove the cover on the Lift Relief Valve and turn the adjusting screw counterclockwise two full turns.

3. Place the maximum rated load on the platform (see the Specifications Table in the

4. Turn and hold the Chassis Key Switch to CHASSIS. Push the Chassis Lift Switch to the UP position and hold it there.

5. Slowly turn the Lift Relief Valve adjusting screw clockwise to increase the pressure until the platform just begins to rise.

6. Release the Chassis Lift Switch. Tighten locknut or replace the Lift Relief Valve cover and torque to 8N-m. (

6 ft./lbs.

ALVE

1500 psi

6 ft./lbs.

Operator Manual

OUNTERBALANCE

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

2. Remove the gauge port cap and install the pressure gauge assembly.

3. Lift the machine and support the chassis with jackstands so that the drive wheels are off the ground.

4. Loosen the locknuts on Counterbalance Valves.

5. With the Chassis Key Switch on DECK and the Drive/Lift Switch in DRIVE depress the Interlock Lever and slowly pull the Control Handle to REVERSE to drive the wheels.

6. Adjust the Forward Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 76 bar (

7. Slowly push the Control Handle to FORWARD to drive the wheels.

8. Adjust the Reverse Counterbalance Valve by turning the adjustment screw until the pressure gauge indicates 76 bar (

9. Check the settings by slowly moving the Control Handle FORWARD, then REVERSE, checking the gauge to ensure that the pressures are properly set. Readjust as needed.

10. Tighten the locknuts on the valves to 8 N-m ( the ground.

1100 psi

ALVES

6 ft./lbs.

). Remove the blocks and lower the machine to

Page 2-24 114101-000 X26 Ultra Narrow - Service Manual

Page 67

Section 2 - Service and Repair Hydraulics

1. Manifold Block

2. 3 Way - 2 Position Valve

3. Flow Divider/Combiner

ERIES

ARALLEL

ANIFOLD

It is not necessary to remove the manifold to perform all maintenance procedures (i.e. replacing a single valve).

Refer to

EMOVAL AND INSTALLATION

Section 3 - Schematics

for the hydraulic schematic and hose routing diagram.

1. Turn the wheels straight, then open both module doors to gain access to the manifold.

WARNING

2. Disconnect the battery pack connector and the battery negative (–) lead.

3. From the control module side;

• tag and disconnect wires.

• tag, disconnect and plug the side

hoses.

4. From the front, tag, disconnect and

1. Bracket

2. Capscrew (3 each)

3. Washer (6 each)

plug the front hoses.

5. Remove the three capscrews and nuts while supporting the manifold.

6. Remove the manifold.

Installation is reverse of removal. Torque mounting capscrews to 24 N-m (

18 ft./lbs.).

Figure 2-18:

Figure 2-19:

Series Parallel Manifold Location

4. Nut (3 each)

5. Series Parallel Manifold

Series Parallel Valve Manifold

114101-000 X26 Ultra Narrow - Service Manual Page 2-25

Page 68

Hydraulics Section 2 - Service and Repair

1. Maintenance Brace

2. Cable

3. Valve

4. Orifice

5. Cable Mount

6. Cable Access Hole

MERGENCY

OWERING

ALVE

WARNING

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

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

Figure 2-20:

Emergency Lowering Valve

The Emergency Lowering Valve is mounted on the base of the lift cylinder. The cable is routed;

• from the valve,

• along the elevating

assembly tube to the front of the machine,

• through the cable access hole to the rear of the machine.

EPAIR

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

2. Inspect the cable. Replace if damaged.

3. Inspect the valve. Replace if damaged.

4. Check for and clear any blockage in the orifice. Install the orifice with the beveled side toward the cylinder block.

5. Adjust the valve.

• At the cable mount, adjust the cable cover to stop the inner cable when the valve is fully open.

6. Store the maintenance brace and lower the platform.

Page 2-26 114101-000 X26 Ultra Narrow - Service Manual

Page 69

Section 2 - Service and Repair Cylinders

Seal Kit includes:

1. Seal

2. O-Ring

3. Seal

4. Wiper

A. Rod B. Piston C. Head D. B ar rel

2-8 C

YLINDERS

TEERING

EMOVAL

1. Turn the wheels to the straight position.

IMPORTANT: Before disconnecting any hoses,

thoroughly clean off all the outside dirt around the fittings. IMMEDIATELY plug the holes after disconnecting the hoses and before removing the cylinder from the machine.

2. Tag and disconnect the hose assemblies from the cylinder fittings and immediately cap the openings to prevent foreign material from entering.

3. Remove the retaining ring from the chassis clevis pin.

4. Remove the upper clevis pin straight down.

5. Remove the retaining ring from the steering clevis pin.

6. While supporting the cylinder, remove the lower clevis pin straight down through the steering assembly.

7. Remove the cylinder.

8. Remove the bearing from the steering assembly end of the cylinder.

YLINDER

1. Steering Assembly

2. Hydraulic Hoses

3. Retaining Ring

4. Chassis Clevis Pin

5. Retaining Ring

6. Steering Clevis Pin

7. Steering Cylinder

8. Bearing

9. Cylinder Mount

Figure 2-21:

Steering Cylinder Location

114101-000 X26 Ultra Narrow - Service Manual Page 2-27

EPAIR

Steering Cylinder Assembly

Refer to

Section 1 - General Information

Figure 2-22:

for disassembly, cleaning and inspection, and assembly instructions.

NSTALLATION

1. Apply Neverseize® or equivalent to the clevis pins.

2. Insert the bearing into the cylinder rod eye.

3. Position the cylinder into the mounting points.

4. Insert the clevis pins and secure with retaining rings.

5. Unplug and connect the hose assemblies to the cylinder fittings.

6. Check the fluid level in the hydraulic reservoir before operating the machine.

7. Operate the steering circuit several times throughout its entire range of travel to expel trapped air and check for leaks.

Page 70

Cylinders Section 2 - Service and Repair

EPRESSION

The depression mechanism cylinders are located at the end of the power module and the control module.

EMOVAL

1. Open the module door to reach the

ECHANISM

YLINDER

Figure 2-23:

Depression Mechanism Cylinder Location

1. Power Module

2. Depression Tube

3. Depression Cylinder

4. Retaining Ring

5. Clevis Pin

6. Washer

desired depression mechanism cylinder.

2. Support the depression tube from underneath.

WARNING

3. Disconnect the battery pack connector and the battery negative (–) lead.

4. Tag and disconnect the electrical connections from the solenoid.

5. Tag and disconnect the hoses from the cylinder fittings and immediately cap the openings to prevent foreign material from entering.

6. Remove the retaining rings from the depression cylinder clevis pins

7. Pull the cylinder off the pins.

Page 2-28 114101-000 X26 Ultra Narrow - Service Manual

Page 71

Section 2 - Service and Repair Cylinders

Seal Kit includes:

1. Seal

2. O-Ring

3. Seal

4. Wiper

A. Rod

B. Piston C. Head D. B ar rel

EPAIR

Depression Mechanism Cylinder Assembly

Refer to

Section 1 - General Information

Figure 2-24:

for disassembly,

cleaning and inspection, and assembly instructions.

NSTALLATION

1. Place a washer on both clevis pins.

2. Apply Neverseize® or equivalent to the clevis pins.

3. Place the cylinder, piston end down, onto the clevis pins.

4. Place a second washer on the lower clevis pin (located on the depression tube).

5. Install a retaining ring on each clevis pin.

6. Unplug and connect the hoses to the fittings.

7. Connect the electrical connections to the solenoid.

8. Connect the negative battery lead.

9. Connect the battery pack connector.

10. Check the fluid level in the hydraulic reservoir before operating the machine.

11. Lift the platform, then lower it and move the machine. Repeat this several times to check for proper operation.

114101-000 X26 Ultra Narrow - Service Manual Page 2-29

Page 72

Cylinders Section 2 - Service and Repair

IFT

EMOVAL

YLINDER

Figure 2-25:

Elevating Assembly Assembly

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

USE WASHERS AS SPACERS ON BOTH SIDES OF ROLLER TO ALLOW FREE MOVEMENT OF

WARNING

ARMS ON LIFT CYLINDER PIN

Before disconnecting the battery negative

(–) lead, make sure all switches are OFF. If ON, a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present.

2. Disconnect the battery pack connector and the battery negative (–) lead.

3. Provide a suitable container to catch the hydraulic fluid, then disconnect the hydraulic hoses from the cylinder. Immediately plug hoses and fittings to prevent foreign material from entering.

4. Remove the cable and electrical connections from the Emergency Lowering Valve.

5. Remove the retaining rings securing the lift cylinder pins.

6. Remove lower lift cylinder pin by driving the pin towards the shaft locking pin side. Lower the cylinder to rest on the

10. Flat Washer

11. Screw

12. Nut

13. Torsion Arm

1. Lift Cylinder

2. Lift Cylinder Pin

3. Retaining Ring

4. Oilite Bearing

5. Shaft Locking Pin

6. Lift Cylinder Pin

7. Washer

8. Roll Pin

9. Bearing

chassis.

7. Attach a suitable hoisting device and sling to the cylinder and remove the upper lift cylinder pin.

8. Carefully remove the cylinder.

EPAIR

Refer to

Section 1 - General Information

for disassembly, cleaning and inspection, and assembly instruc-

tions.

Page 2-30 114101-000 X26 Ultra Narrow - Service Manual

Page 73

Section 2 - Service and Repair Cylinders

Lift Cylinder Assembly

NSTALLATION

1. Attach a suitable hoisting device and sling to the cylinder. Carefully position the cylinder into the elevating assembly and install the upper lift cylinder

A. Rod B. Thread Cap Head C. Piston D. B ar rel E. Bronze Bushings F. Set Screw

Figure 2-26:

pin.

2. Install a new roll pin.

3. Carefully lift the cylinder and align the

lower mount and install the lift cylinder pin. Make sure the locking pin is properly installed, then install the retaining ring.

4. Connect the Emergency Lowering Valve cable and electrical connections.

5. Unplug and attach the hydraulic hoses to the cylinder.

Seal Kit includes:

1. Wiper

2. Seal

3. O-Ring

6. Connect the negative battery lead.

7. Connect the battery pack connector.

8. Check the fluid level in the hydraulic reservoir before operating the machine.

9. Test with weight at rated platform load to check system operation. Check for leaks and level of fluid.

114101-000 X26 Ultra Narrow - Service Manual Page 2-31

Page 74

Drive Motors and Hubs Section 2 - Service and Repair

2-9 D

RIVE

IMPORTANT: Before disconnecting any hoses,

OTORS

RIVE

EMOVAL

1. Chock the rear wheels to prevent the

2. Remove the wheel bolts and wheel.

3. Remove the cotter pin, slotted nut,

4. Remove the hub.

thoroughly clean off all the outside dirt around the fittings. IMMEDIATELY plug the holes after disconnecting the hoses and before removing the motor from the machine.

OTORS

machine from rolling.

• Use a 1000 Kg ( to raise the front of the machine.

• Place two 1000 Kg ( stands beneath the machine for support.

• Remove the jack.

hub, and shaft key.

AND

1 ton

) capacity jack

1 ton

) jack-

UBS

Figure 2-27:

Drive Motor

5. Tag, disconnect and plug the hose assemblies to prevent foreign material from entering.

6. Remove the locknuts, washers and capscrews.

7. Remove the drive motor.

NSTALLATION

1. Position the drive motor into the wheel yoke and secure it with capscrews and locknuts.

2. Torque the locknuts to 95 N-m (

3. Install the shaft key, hub, and slotted nut. Torque the slotted nut to 190-217 N-m (

4. Install a new cotter pin. DO NOT back-off the nut to install the cotter pin.

5. Remove the plugs from the hose assemblies and reconnect them to the drive motor.

6. Install the wheel and wheel bolts. Torque to 108 N-m (

7. Remove the jackstands and lower the machine to the ground.

8. Check the fluid level in the hydraulic reservoir before operating the machine.

9. Operate the drive system and check for leaks.

RAKE

If brake service or repair is required, replace all servicable parts. Refer to the service kit part number. Refer to Figure 2-28 when assembling the motor.

ERVICE

70 ft./lbs.

1. Chassis

2. Wheel Bolts and Wheel

3. Cotter Pin, Slotted Nut and Shaft Key

4. Hub

80 ft./lbs.

5. Hydraulic Hoses

6. Locknuts, Washers and Capscrews

7. Drive Motor

8. Wheel Yoke

Par ts Manual

140-160 ft./lbs.

for the brake

Torque the rotor bolts [1] and the front flange bolts [34] to 54 N-m (

Page 2-32 114101-000 X26 Ultra Narrow - Service Manual

40 ft.lbs.

Page 75

Section 2 - Service and Repair Drive Motors and Hubs

Brake Adjustment

1. Using a 13 mm socket wrench, alternately turn the brake release nuts counter-clockwise in ½ turn increments. Repeat until there is approximately 3.2 mm (

1/8 in.

) between the brake release nuts and

the drive motor body.

2. After installing the motors, verify that the brakes have fully engaged before operating the machine. Refer to the

Operator Manual

Figure 2-28:

Drive Motor Exploded View

Non-Servicable Parts

1 Rotor Bolts 2 Washer 3 Endcap 5 Rotor 6 Cardan Shaft 7 Channel Plate 8 Bearing Race

9 Needle Bearing 10 Commutation Valve 11 Output Shaft 12 Balance Plate 13 Spring Washer 15 Washer 16 Needle Bearing 18 Brake Release Nut 20 Bearing Housing 21 Brake Spring 22 Brake Piston 24 Brake Release Bolt 29 Bushing 30 Needle Bearing 33 Front Flange 34 Front Flange Bolts

Brake Service Kit

4O-ring 14 Balance Plate P-ring 17 High Preasure Shaft Seal

19 O-ring 23 O-ring 25 O-ring 26 O-ring 27 O-ring 28 Brake Disc Set 31 Standard Shaft Seal 32 O-ring

114101-000 X26 Ultra Narrow - Service Manual Page 2-33

Page 76

Drive Motors and Hubs Section 2 - Service and Repair

Old

Bearing Cup

New

Bearing Cup

REMOVE BEARING CUP

INSTALL BEARING CUP

Bearing Cup

Drift

EAR

EMOVAL

HEELS

, H

UBS AND

EARINGS

Figure 2-29:

Rear Hubs

1. Chock the front wheels to prevent the machine from rolling.

• Use a 1000 Kg (

1 ton

) capacity jack

to raise the front of the machine.

• Place two 1000 Kg (

1 ton

) jackstands

beneath the machine for support.

• Remove the jack.

2. Remove the wheel bolts and wheel.

3. Remove the dust cap, cotter pin, slotted nut, and washer.

4. Slide the entire hub assembly from the spindle.

5. Remove the outer cone bearing.

6. Remove the grease seal.

7. Remove the inner cone bearing.

8. Examine the bearing cups. If they are smooth, shiny and free of pits or any surface irregularities, them.

• If the cups need replacement, remove them by tapping around the circumference of the inside surface of the

DO NOT

remove

1. Chassis

2. Wheel Bolts and Wheel

3. Dust Cap, Cotter Pin, Slotted Nut and Washer

4. Hub Assembly

5. Outer Cone Bearing

6. Grease Seal

7. Inner Cone Bearing

8. Bearing Cup

9. Spindle

cups from the opposite side using a long drift.

NSTALLATION

1. Install the new bearing cups (refer to Figure 2-30):

• Position the replacement bearing cup over the opening in the hub assembly.

• Position the worn cup over the replacement so that the bearing surfaces face each other.

• Use the old bearing cone as a drift to work the replacement into position by tapping evenly around the circumference.

2. Apply a liberal coating of multipurpose grease to the bearing surface of each cup.

3. Pack the inner bearing with multipurpose grease and position it into the inner bearing cup.

4. Press a new grease seal into the hub assembly.

5. Apply a thin coating of multipurpose grease to the spindle to protect the grease seal, then slide the hub assembly onto the spindle.

6. Pack the outer bearing with multipurpose grease and slide it onto the spindle until it seats in the outer bearing cup.

7. Install the washer and slotted nut.

8. While rotating the hub, tighten the slotted nut until the hub drags, then back the nut to the first slot that aligns with the cotter pin hole in the spindle.

9. Install a new cotter pin and bend the end up over the nut and spindle.

10. Install the dust cap

11. Install the wheel and wheel bolts. Torque to 108 N-m (

80 ft./lbs.

Figure 2-30:

Bearing Cup Installation

Page 2-34 114101-000 X26 Ultra Narrow - Service Manual

Page 77

Section 3

ROUBLESHOOTING

This section contains troubleshooting Truth Tables.

Careful inspection and accurate analysis of the symptoms listed in the Troubleshooting Guide will localize the trouble more quickly than any other method. This manual cannot cover all possible problems that may occur. If a specific problem is not covered in this manual, call our toll free number for service assistance.

Referring to the Operator Manual and the Schematics section will aid in understanding the operation and function of the various components and systems of the machine and help in diagnosing and repair of the machine.

ABLE

WARNING

When troubleshooting, ensure that the machine is resting on a firm, level surface.

When performing any service which requires the platform to be raised, the Elevating Assembly must be blocked.

Disconnect the battery when replacing or testing the continuity of any electrical component.

ONTENTS

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

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

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

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

3-4 Motor Controller Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Default Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Adjusted Dip Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3-5 I/O Board Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Optional Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

3-6 LED Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3-7 LEDs at I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-8 I/O Board Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3-9 Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3-10 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

114101-000 X26 Ultra Narrow - Service Manual Page 3-1

Page 78

IST OF

Section 3 - Troubleshooting

IGURES

Figure 3-1: Hydraulic Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 3-2: Controller Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 3-3: I/O Board Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 3-4: Motor Controller Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 3-5: I/O Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

ABLES

Table 3-1: LED Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Table 3-2: Connector J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Table 3-3: Connector J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Table 3-4: Connector J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Table 3-5: Connector J4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Table 3-6: Connector J5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Table 3-7: Electrical Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Table 3-8: Hydraulic Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Page 3-2 114101-000 X26 Ultra Narrow - Service Manual

Page 79

Section 3 - Troubleshooting Technical Support

3-1 T

UPR

UROPE

3-2 G

3-3 T

ECHNICAL

Technical Support is available by telephone or FAX.

IGHT

USA

IGHT

Tel: 1-800-926-5438 FAX: 1-559-662-4785

Tel: +353-1-620-9300 FAX: +353-1-620-9301

ENERAL

Thoroughly study hydraulic and electric schematics in tions and short circuits. Check/repair/replace each component in the Truth Table which is listed under each machine function which does not operate properly.

Determine whether the problem is mechanical (interference), electrical or hydraulic. Some functions require power at more than one solenoid.

Use the charts on the following pages to help determine the cause of a fault in your UpRight Aerial Work Platform.

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

NOTE:

ROUBLESHOOTING

Verify your problem

functions that are not operating correctly.

Narrow the possible causes of the malfunction

ponents are common to all circuits that are not functioning correctly. To aid in troubleshooting, the letters following the component on the table are the same as the component’s designation on the schematics.

Identify the problem component

correctly. Remember to check wires and terminals between suspect components. Be sure to check connections to battery negative.

Repair or replace component found to be faulty

Verify that repair is complete

that all functions are operating correctly and that the machine is performing according to specifications.

ROCEDURE

UPPORT

Section 3 - Schematics

ROCEDURES

. Do a full function test from both platform controls and chassis controls and note all

. Use the troubleshooting guide to determine which com-

. Test components that are common to all circuits that are not functioning

. Do a full function test from both the platform and chassis controls to verify

. Check for loose connec-

DJUSTMENT

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

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

• Connect a pressure gauge of appropriate range to the test port located on the hydraulic manifold.

Correct pressure settings are

NOTE:

listed in the hydraulic schematic.

114101-000 X26 Ultra Narrow - Service Manual Page 3-3

ROCEDURES

Test Por t

Figure 3-1:

Counterbalance

Valves

Hydraulic Test Port

Page 80

Motor Controller Dip Switch Settings Section 3 - Troubleshooting

3-4 M

OTOR

EFAULT

The table shows the default dip switch settings on the controller box when the machine leaves the factory.

MX15/19 OFF ON OFF ON OFF ON OFF ON

SL20 ON OFF OFF ON OFF ON OFF ON

TM12 OFF OFF OFF ON OFF ON OFF ON

X20N ON OFF OFF ON OFF ON OFF ON

X20W ON OFF OFF ON OFF ON OFF ON

X26UN ON ON OFF OFF OFF ON OFF ON

X26/32 ON ON OFF ON OFF OFF OFF ON

DJUSTED

The following adjustments may be made to the dip switch settings.

ONTROLLER

WITCH

1 2 3 4 5 6 7 8

WITCH

ETTINGS

Figure 3-2:

Controller Dip Switch

REEP SPEED

Switches 3 & 4 determine the elevated “creep” speed. If the machine does not operate at the specified speed at the default settings, use the following table to adjust the dip switch settings

3 4

1(slowest) OFF OFF

2ONOFF

3 (default) OFF ON

4 (fastest) ON ON

ECELERATION

Switches 5 & 6 determine the deceleration time. Switch 5 is for the deceleration rate while the platform is lowered. Switch 6 is for the elevated rate.

DECEL 5 6

0.24 sec. OFF OFF

1.27 sec. ON ON

IME

Page 3-4 114101-000 X26 Ultra Narrow - Service Manual

Page 81

Section 3 - Troubleshooting I/O Board Dip Switch Settings

1234

8765

1234

8765

1234

12 11 10 9

1234

12 11 10 9

1234

8765

Part

No.

Serial

No.

4321

3-5 I/O B

EFAULT

OARD

ETTINGS

WITCH

ETTINGS

The table shows the default dip switch settings on the I/O board when the machine leaves the factory.

1 2 3 4

MX15/19

SL20 OFF OFF OFF OFF

TM12 OFF OFF OFF OFF

X20N OFF OFF OFF OFF

X20W OFF OFF OFF OFF

X26UN OFF OFF OFF OFF

X26/32 OFF OFF OFF OFF

PTIONAL

OFF OFF OFF OFF

ETTINGS

Switches 3 & 4 work together to determine the optional alarm settings

1 2 3 4 RESULT

ON Two Speed Mode (not used)

OFF Proportional Control

ON not used

OFF

OFF OFF Down alarm only

ON OFF Down and Reverse alarm

OFF ON Drive and Down alarm

ON ON All Motion alarm

Depression Mechanism extends

when platform is raised

Figure 3-3:

I/O Board Dip Switch

114101-000 X26 Ultra Narrow - Service Manual Page 3-5

Page 82

LED Fault Codes Section 3 - Troubleshooting

M2 Terminal

LED Indicator

B– Term i nal

B+ Terminal

3-6 LED F

AULT

Batteries must be fully charged before troubleshooting

ODES

Check/Repair all connections before replacing any components

Figure 3-4:

Motor Controller Connections

Before dip switch settings will take effect, power must be disconnected or Emergency Stop switches must be

NOTE:

depressed.

Table 3-1:

Flash Code Meaning Status Corrective Action

LED Fault Codes

LED on

LED off

2 Flash Procedural fault.

3 Flash

4 Flash

5 Flash

6 Flash

7 Flash

8 Flash Thermal cut-off.

Power to the controller and the controller is operational.

No power to the controller, or internal fault in the controller.

Controller senses B– at the M2 terminal.

Controller senses B+ at the M2 terminal before engaging the Motor Start relay.

Controller senses open circuit at M2 after engaging the Motor Start terminal.

Faulty signal from Control Handle or I/O board.

Battery voltage below 12V or above 45V.

System is functional None.

Battery cables not connected properly; Failed controller

Lift, drive, or steer switch is engaged at start-up; Drive/Lift switch rotated while operating

Short circuit at the motor; M2 cable in contact with B– cable; Short circuit within controller

B+ cable routed incorrectly; M2 cable making contact with B+ cable; Motor Start relay contacts welded closed.

Cables loose or not connected; Faulty Motor Start relay

Faulty Control Handle; Wiring error

Dead batteries; Bad cable connections

Controller is overheated due to overuse or other failure

Check battery cable connections. Replace the controller.

Cycle the Control Handle through neutral to clear fault.

Check cable routing and connections. Test terminals for source of B–. Replace the controller

Check cable routing and connections. Test terminals for source of B+. Replace the Motor Start relay.

Check the cable routing and connections. Check the signal from Motor Controller to relay. Check/replace the Motor Start relay.

If Platform Controls are affected, check/replace the Control Handle. If Chassis Controls are affected, check/replace the I/O board.

Check batteries and cable connections.

Allow system to cool. Locate and repair other source of overheat.

Page 3-6 114101-000 X26 Ultra Narrow - Service Manual

Page 83

Section 3 - Troubleshooting LEDs at I/O Board

J2 J1

Green LED

Red LED

Grey

Green

Black

Dip Switch

3-7 LED

S AT

REEN

I/O B

LED ON

OARD

The Green LED indicates that power is present at the board.

RED LED ON

The Red LED indicates a short in the system. To locate the problem;

1. Push both E-Stop switches to the OFF position.

2. Turn the Keyswitch to the OFF position, then to either Platform or Chassis.

3. Pull both E-Stop switches to the ON position.

• The Green LED should be ON.

• The Red LED should be OFF.

4. Perform all machine functions until the Red LED is ON. Determine which function activated the Red LED and check all components that are active for that function.

Figure 3-5:

I/O Board Connections

4321

8765

1234

8765

1234

12 11 10 9

Serial

No.

Part No.

1234

12 11 10 9

1234

8765

114101-000 X26 Ultra Narrow - Service Manual Page 3-7

Page 84

I/O Board Inputs and Outputs Section 3 - Troubleshooting

3-8 I/O B

OARD

NPUTS

AND

UTPUTS

Refer to Figure Figure 3-5: “I/O Board Connections,” on page 3-7.

ERFORM TESTS WITH FULLY CHARGED BATTERIES

Battery state of charge will affect readings.

BV = B

ATTERY VOLTAGE

Readings within a few volts of current battery state of charge will be called BV.

0V is generally 0 up to 1 volt.

OLTAGE READINGS FOR ELECTRONICS ARE

Many factors can affect readings, such as state of charge, voltage drops through switches (mechanical or electrical), and wires.

Be sure that both the Platform and Chassis Emergency Stop Switches are pulled out to the ON position.

All voltages are measured between the component and the B– terminal on the Motor Controller.

For the I/O board to be powered up (Green LED illuminated), both E-Stops must be closed and either

NOTE:

Platform Controls or Chassis Controls selected by the Keyswitch.

ARELY EXACT

Table 3-2:

Connector J1

PIN PIN DESCRIPTION CONDITION VOLTAGE

J1-1 Lift input from Lift/Drive selector switch

J1-2 Not Used ———

J1-3 Drive input from Lift/Drive selector switch

J1-4

J1-5

J1-6 Power to Platform Controls when selected by Keyswitch

J1-7 Not Used ———

J1-8

J1-9

J1-10 Speed signal from Control Handle

J1-11 Steer Left input from Steering switch

J1-12 Steer Right input from Steering switch

Lower E-Stop activation (output from I/O board when lower E-Stop is closed)

Upper E-Stop activation (output to I/O board when upper E-Stop is closed)

Controller direction “A” (up/forward)

Controller direction “B” (down/reverse)

Lift selected BV

Lift not selected 0V

Drive selected BV

Drive not selected 0V

Lower E-Stop closed BV

Lower E-Stop open 0V

Upper E-Stop closed BV

Upper E-Stop open 0V

Platform Controls selected BV

Platform Controls not selected 0V

Control Handle pushed forward 20-22V —

Signal starts high and drops proportionally as Control Handle is moved in either direction

Steer Left selected 23V

Steer Left not selected 0V

Steer Right selected 23V

Steer Right not selected 0V

4.3V

dropping to

0.2V

CONTINUOUS

TO PIN

—

J4-9

J4-2

J4-10

—

Page 3-8 114101-000 X26 Ultra Narrow - Service Manual

Page 85

Section 3 - Troubleshooting I/O Board Inputs and Outputs

Table 3-3:

Table 3-4:

Connector J2

PIN PIN DESCRIPTION CONDITION VOLTAGE

J2-1 Depression mechanism activation (extend)

J2-2 Not Used ———

J2-3 24 Volt supply for solenoids

J2-4 Forward solenoid activation

J2-5 Reverse solenoid activation

J2-6 Up solenoid activation

J2-7 Steer Left solenoid activation

J2-8 Steer Right solenoid activation

Lift Up requested 0V

Lift Up not requested BV

Upper & Lower E-Stops closed BV

Upper or Lower E-Stop open 0V

Forward requested 0V

Forward not requested BV

Reverse requested 0V

Reverse not requested BV

Up requested 0V

Up not requested BV

Steer Left requested 0V

Steer Left not requested BV

Steer Right requested 0V

Steer Right not requested BV

CONTINUOUS

TO PIN

—

J4-5 & J3-3

—

Connector J3

PIN PIN DESCRIPTION CONDITION VOLTAGE

J3-1 Alarm activation

† If the alarm is sounding because the unit is out of level, BV will drop to 0V as long as the alarm is sounding.

If the alarm is sounding because the unit is lowering, there will be alternating high and low voltages (the voltages will vary).

J3-2 Level Sensor output signal

J3-3 24 Volt supply for Alarm, Level Sensor and solenoids,

J3-4 Input from platform down Proximity Switch

J3-5 Down solenoid activation

J3-6 Depression mechanism activation (retract)

J3-7 Not Used ———

J3-8 Battery negative supply for Level sensor and Proximity switch — B– J4-11

Alarm sounding (out of level unit lowering, etc.)

Unit within Level Sensor angle BV

Unit outside Level Sensor angle 0V

Upper & Lower E-Stops closed BV

Upper or Lower E-Stop open 0V

Above Proximity switch 0V

Below Proximity switch BV

Down requested 0V

Down not requested BV

Drive requested 0V

Drive not requested BV

†—

CONTINUOUS

TO PIN

—

J2-3 & J4-5

—

114101-000 X26 Ultra Narrow - Service Manual Page 3-9

Page 86

I/O Board Inputs and Outputs Section 3 - Troubleshooting

Table 3-5:

Connector J4

PIN PIN DESCRIPTION CONDITION VOLTAGE

J4-1 Motor Start relay and Hourmeter activation

J4-2 24 Volt supply to Keyswitch

J4-3 Chassis Controls selected from Keyswitch

J4-4 24 Volt supply to chassis Up/Down switch —‡—

‡ Keyswitch must be held to Chassis Controls position to measure BV

J4-5 24 Volt supply to Keyswitch

J4-6 Not Used ———

J4-7 Up signal from Chassis Controls

J4-8 Down signal from Chassis Controls

J4-9

J4-10 Power output to Platform Controls

J4-11 Battery negative supply to I/O Board — B–—

J4-12 24 Volt supply to Hourmeter and Line Contactor coil

Lower E-Stop activation (input to I/O board when E-Stop is closed)

Drive, Lift or Steer requested 0V

Drive, Lift or Steer not requested BV

Upper & Lower E-Stops closed BV

Upper or Lower E-Stop open 0V

Chassis Controls selected BV

Chassis Controls not selected 0V

Upper & Lower E-Stops closed BV

Upper or Lower E-Stop open 0V

Up requested from Chassis Controls BV

Up not requested from Chassis Controls 0V

Down requested from Chassis Controls BV

Down not requested from Chassis Controls 0V

Lower E-Stop closed BV

Lower E-Stop open 0V

Platform selected at Keyswitch BV

Platform not selected at Keyswitch 0V

Upper & Lower E-Stops closed and Platform Controls or Chassis Controls selected

BV —

CONTINUOUS

TO PIN

—

J2-3 & J3-3

—

J1-4

J1-6

Table 3-6:

Connector J5

PIN PIN DESCRIPTION CONDITION VOLTAGE

J5-1 24 Volt supply to EMC motor controller

J5-2 Drive signal to EMC motor controller

J5-3 Steer signal to EMC motor controller

J5-4 Up signal to EMC motor controller

J5-5 Speed Reduction signal to EMC motor controller

J5-6 Line Contactor activation signal

J5-7 Direction enable

J5-8 Speed signal to EMC motor controller

Upper & Lower E-Stops closed and Platform Controls or Chassis Controls selected

Forward/Reverse requested 15V

Forward/Reverse not requested 0V

Steer Right/Steer Left requested 15V

Steer Right/Steer Left not requested 0V

Up requested 15V

Up not requested 0V

Below Proximity switch 15V - 17V

Above Proximity switch 0V

Drive, Lift or Steer requested 0V

Drive, Lift or Steer not requested BV

Forward/Reverse requested 0V

Forward/Reverse not requested 4.0V - 4.3V

Signal starts high and drops proportionally as Control Handle is moved in either direction

BV —

4.3V

dropping to

0.2V

CONTINUOUS

TO PIN

—

Page 3-10 114101-000 X26 Ultra Narrow - Service Manual

Page 87

Section 3 - Troubleshooting Electric

3-9 E

Table 3-7:

Component

ALM Alarm XX

BAT Batteries X X XXXXXXXXXXXX

CHG Battery Charger X

F1 5 AMP Circuit Breaker X X XXXXXXXXXXXX

F2 175 AMP Fuse X X XXXXXXXXXX

HM Hour Meter/low Voltage Indicator

I/O I/O Board X X XXXXXXXXXXXX

MC Motor Control X X XXXXXXXXXX

MOT Motor XXXXXXXXXX

R1 Motor Relay XXXXXXXXXX

R2 Series Parallel Relay XXX

S1 Chassis Emergency Stop Switch X X XXXXXXXXXXXX

S2 Chassis Lift Switch XX

S3 Chassis Key Switch X X XXXXXXXXXXXX

S4 Proximity Switch X

S5 Height Limit Switch XX

S6 Platform Emergency Stop Switch X X XXXXXXXXXXXX

S7 Lift/Drive Selector Switch X XX XX

S8 Interlock Switch X XXXXXXX

S9 Control Handle X XX XX

S10 Platform Steering Switch X X

SNSR Level Sensor X X XXXXXXXXXXXX

SOL1A Steering Solenoid (right) X

SOL1B Steering Solenoid (left) X

SOL2A Platform Lift Solenoid X

SOL2B Down Solenoid (Emergency Lowering) X

SOL3A Depression Mechanism Extension Solenoid X

SOL3B Depression Mechanism Retraction Solenoid (2) X

SOL4A Reverse Solenoid X

SOL4B Forward Solenoid X

SOL5 Series Parallel Solenoid (2) XXX

LECTRIC

Electrical Troubleshooting Table

Function

Lower Controls

Upper Controls

Drive Forward

Drive Reverse

High Speed/Creep

Raise Platform

Lower Platform

Steer Left

Steer Right

Depression Mechanism Extend

Depression Mechanism Retract

Brakes

Level Alarm

Down Alarm

Battery Charge

114101-000 X26 Ultra Narrow - Service Manual Page 3-11

Page 88

Hydraulic Section 3 - Troubleshooting

3-10 H

Table 3-8:

YDRAULIC

Hydraulic Troubleshooting Table

Function

Lift Platform

Lower Platform

Steer Right

Steer Left

Drive Forward

Drive Reverse

Creep

Component

CV Check Valve X X

CYL1 Steering Cylinder XX

CYL2 Lift Cylinder X

CYL3 Depression Mechanism Cylinder (2) X X

DVR1 Priority Flow Divider X XXXXXXXX

DVR2 Series Parallel Flow Divider

FL1 Suction Strainer X XXXXXXX

FL2 Return Filter X XXXXXXX

MOT Drive Motors (2) X X X

OR Orifice X X

PMP Pump X XXXXXXX

RES Reservoir X X XXXXXXXX

RV1 Steering Relief Valve XX

RV2 Lift Relief Valve X

RV3 Main Relief Valve X X XXXXX

V1 Steering Right/Left Valve XX

V2A Lift Valve X

V2B Down/Emergency Lowering Valve X

V3A Depression Mechanism Extend Valve X

V3B Depression Mechanism Retract Valve (2) X

V4 Forward/Reverse Valve X X

V5 Series Parallel Valve (2) X XX

V6 Counterbalance Valve (2) X XX X

X XX

Depression Mechanism Extend

Depression Mechanism Retract

Brakes

Page 3-12 114101-000 X26 Ultra Narrow - Service Manual

Page 89

Section 4

CHEMATICS

This section contains electrical and hydraulic power schematics and associated information for maintenance purposes.

The diagrams are to be used in conjunction with the standing of the makeup and functions of the systems for checking, tracing, and faultfinding during troubleshooting analysis.

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

ABLE

IST OF

ONTENTS

4-1 Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

066769-020 Electric Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

066781-020 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

IGURES

Figure 4-1: Electric Components Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Figure 4-2: Electric Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4-3: Wire Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Figure 4-4: Chassis Controls, Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Figure 4-5: Platform Controls Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Figure 4-6: Platform Controls Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Figure 4-7: Hydraulic Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Figure 4-8: Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Figure 4-9: Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Figure 4-10: Hydraulic Manifold Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Figure 4-11: Depression Mechanism Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Figure 4-12: Series/Parallel Drive Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Troubleshooting Truth Tables

Section 3.

They allow under-

114101-000 X26 Ultra Narrow - Service Manual Page 4-1

Page 90

Electric Section 4 - Schematics

FRONT

Control Module

Power

Module

SNSR

Level Sensor

Proximity

Switch

BAT

Battery

Pack

CHG

Battery

Charger

MOT Pump Motor

Motor

Relay

ALM

Alarm

Chassis

Control Box

175 AMP

Fuse

Depression Mechanism

Cylinder

Depression Mechanism

Cylinder

Series

Parallel

Manifold

Lift

Cylinder

Hydraulic

Manifold

Horn

Height

Limit

Switch

4-1 E

Legend:

Reference

Number

ALM Alarm Provides warning sound Control Module

BAT Battery Pack Power source for the machine Power Module

CHG Battery Charger Charges the battery pack Power Module

F1 5 AMP Circuit Breaker Electrical overload protection Chassis Controls F2 175 AMP Fuse Overload protection for the electric motor Control Module

HM Hour Meter Shows how many hours the machine has been in use Chassis Controls

I/O I/O Board (Circuit Board) Connection point for machine function wiring Control Module MC Motor Control Controls the speed of the electric motor Control Module

MOT Motor Provides power to the hydraulic pump Control Module

R1 Motor Relay Controls the speed of the electric motor Control Module R2 Series/Parallel Relay Activates Series/Parallel solenoids Chassis Controls S1 Chassis Emergency Stop Switch Shuts down all machine functions Chassis Controls S2 Chassis Lift Switch Elevates platform Chassis Controls S3 Chassis Key Switch Allows some machine functions to be initiated from ground level Chassis Controls S4 Lift/Drive Selector Switch Activates lift or drive functions, and high and low speed drive Platform Controls

S5 Proximity Switch (Limit Switch)

S6 Height Limit Switch Stops lift assembly at upper limit Elevating Assembly, Front S7 Platform Emergency Stop Switch Shuts down all machine functions Platform Controls S8 Interlock Switch (Trigger) Safety mechanism for control handle Platform Controls S9 Control Handle Proportionally controls the drive and lift functions Platform Controls

S10 Platform Steering Switch Control left and right steering solenoids Platform Controls

SNSR Level Sensor

SOL1A Steering Solenoid (right) Shifts steering valve to the left Hydraulic Manifold SOL1B Steering Solenoid (left) Shifts steering valve to the right Hydraulic Manifold SOL2A Platform Lift Solenoid Elevates platform Hydraulic Manifold SOL2B Down Solenoid (Emergency Lower) Lowers platform Lift Cylinder SOL3A Depression Mechanism Extension Solenoid Extends depression mechanism bars Hydraulic Manifold SOL3B Depression Mechanism Retraction Solenoid (2) Retracts depression mechanism bars Depression Mechanism cylinders SOL4A Reverse Solenoid Shifts forward/reverse valve to reverse Hydraulic Manifold SOL4B Forward Solenoid Shifts forward/reverse valve to forward Hyraulic Manifold

SOL5 Series/Parallel Solenoids (2) Shift between high and low speed drive Series Parallel Manifold

LECTRIC

066769-020 Electric Schematic

Name Function Location

Stops lift assembly at lower limit, cuts out high speed drive when platform is elevated

Activates level sensor alarm and disables all machine functions except platform lower when the machine is more than 2° out of level

Chassis, Front

Page 4-2 114101-000 X26 Ultra Narrow - Service Manual

Figure 4-1:

Electric Components Locations

Page 91

Section 4 - Schematics Electric

Figure 4-2:

SOL1A

SOL1B

SOL2A S5

SOL4A SOL4B

Electric Schematic

SNSR

CHG

SOL5

SOL5 SOL3A

MOT

BAT

ALM

SOL2B

SOL3B

I/O

CONTROL

HANDLE

S10

114101-000 X26 Ultra Narrow - Service Manual Page 4-3

Page 92

Electric Section 4 - Schematics

Figure 4-3:

Wire Routing

CHG

SOL4B

SOL3A

SOL2A

SOL1A

MOT

SOL4A

SOL1B

I/O

ALM

SOL3BS6SOL3B

BAT

SNSR

SOL2B

SOL5

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Section 4 - Schematics Electric

I/O

Circuit Board

Figure 4-4:

Chassis Controls, Components

Cover

Hour Meter

Emergency Stop Switch

Contact Block

Normally Closed

Toggle Switch

Contact Switch

Normally Open

Control Box

Lift/Lower Switch Cover

Key Switch

Circuit Breaker

Relay, 24 V

Motor Control

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Page 94

Electric Section 4 - Schematics

Red Mushroom Switch

Emergency Stop

Control Panel

Normally Closed

Normally Open - Normally Closed

Interlock Switch

Contact Block

S10

Rocker Switch Steering

Figure 4-5:

Platform Controls Components

Control Handle

3-Position Selector Switch Lift/Drive

Amp Connector

Hall Effect Connector

Contact Block

Normally Open

Controller Box

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Section 4 - Schematics Electric

Figure 4-6:

Platform Controls Wiring

S10

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Page 96

Hydraulics Section 4 - Schematics

FRONT

V2B

Emergency

Lowering

Valve

Series Parallel

Manifold

CYL3 Depression Mechanism

Cylinder

CYL1 Steering Cylinder

CYL2

Lift

Cylinder

MOT

Drive

Motor

PMP

Pump

RES Hydraulic Reservoir

FL2

Return

Filter

MAN

Hydraulic

Manifold

Control Module

Power

Module

4-2 H

Legend:

Reference

number

CV Check Valve Allows depression mechanism to retract in drive mode Hydraulic Manifold CYL1 Steering Cylinder Provides force to turn front wheels Front of Chassis above Drive Motors CYL2 Lift Cylinder Provides force to lift platform Elevating Assembly CYL3 Depression Mechanism Cylinder (2) Extends or retracts depression mechanism bar Control Module and Power Module DVR1 Priority Flow Divider Provides priority fluid flow to steering Hydraulic Manifold DVR2 Flow Divider Divides fluid to drive motors in parallel drive mode Series/Parallel Manifold

FL1 Suction Strainer (Filter) Traps particles in hydraulic reservoir Inside Hydraulic Reservoir at outlet

FL2 Return Filter Filters fluid returning to reservoir Control Module MAN Hydraulic Manifold Provides fluid distribution to cylinders, brakes, and series parallel reservoir Control Module MOT Drive Motors (2) Provides tractive effort to move machine Front Wheels

OR Orifice Restricts fluid return from emergency lowering valve Lift Cylinder

PB Parking Brake (2) Stops machine from moving while parked Internal to Drive Motors

PMP Pump Provides hydraulic pressure for all functions Control Module

RV1 Steering Relief Provides pressure protection to pump and steering components when steering Hydraulic Manifold RV2 Lift Relief Valve Provides pressure protection to lift system Hydraulic Manifold RV3 Main Relief Valve Provides pressure protection to hydraulic system Hydraulic Manifold RES Reservoir Holds hydraulic fluid Control Module

SP Series Parallel Valve Manifold Provides fluid distribution to drive motors Chassis, between Modules

V1 Steering Right/Left Valve Provides directional control for steering Hydraulic Manifold V2A Lift Valve Provides fluid control for drive or lift functions Hydraulic Manifold V2B Down/Emergency Lowering Valve Allows fluid to return to reservoir; manually operated for emergency lowering Lift Cylinder V3A Depression Mechanism Extend Valve Provides fluid control for depression mechanism bar Hydraulic Manifold V3B Depression Mechanism Retract Valve (2) Provides fluid control for depression mechanism bar Depression Mechanism Cylinders

V4 Forward/Reverse Valve Provides fluid control for drive or lift functions Hydraulic Manifold

V5 Series/Parallel Valve (2) Controls drive speed Series/Parallel Manifold

V6 Counterbalance Valve (2) Provides dynamic braking Hydraulic Manifold

YDRAULICS

066781-020 Hydraulic Schematic

Name Function Location

Figure 4-7:

Hydraulic Components Location

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Page 97

Section 4 - Schematics Hydraulics

PBPB

MOT

DVR2

Figure 4-8:

MOT

Hydraulic Schematic

CYL3

CYL2

V3B

OR2

V2B

CYL1

V3A

RV1

V2A

MAN

RV2

RV3

DVR1

PMP

FL2

RES

FL1

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Hydraulics Section 4 - Schematics

CYL2

FL2

RES

FL1

Figure 4-9:

CYL3

Hose Routing

CYL3

PMP

MAN

CYL1

MOT

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Section 4 - Schematics Hydraulics

Counterbalance Valve -- V6

Counterbalance Valve --V6

Drive Solenoid and Valve

SOL4A, SOL4B, V4

Depression Mechanism Solenoid and Valve

SOL3A, V3A

Main Relief Valve -- RV3

Check Valve -- CV

Lift Solenoid and Valve

Sol2A, V2A

Steering Solenoid and Valve

Sol1A, Sol1B, V1

Fitting

Flow Divider Valve -- DVR1

Steering Relief Valve -- RV1

Fitting

High Pressure Test Port

Lift Relief Valve--RV2

TOP VIEW BOTTOM VIEW

Figure 4-10:

Hydraulic Manifold Components

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Page 100

Hydraulics Section 4 - Schematics

3-Way 2-Position Valve

SOL5, V5 (2)

Flow Divider/Combiner

DVR2

Figure 4-11:

Depression Mechanism Cylinder

Depression Mechanism

Retract Solenoid and Valve

SOL3B, V3B

Figure 4-12:

Series/Parallel Drive Manifold

Page 4-12 114101-000 X26 Ultra Narrow - Service Manual