Snorkel UL25 Parts & Service Manual Download Page 1

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Ansi Part Number:

511128- 1

MAY 2013

Serial Number 21691 - 060000

PARTS & SERVICE

MANUAL

Summary of Contents for UL25

Page 1: ...Ansi Part Number 511128 1 0 2 MAY 2013 Serial Number 21691 060000 PARTS SERVICE MANUAL...

Page 2: ......

Page 3: ...EED mph m s MAXIMUM PLATFORM REACH ft m 512582 000 MAXIMUM ALLOWABLE MANUAL FORCE SIDE PULL lbs N Indoors Outdoors SLOPE SENSOR ALARM SETTING FRONT TO BACK deg SIDE TO SIDE deg MAXIMUM OUTRIGGER LOAD...

Page 4: ...10 Seal Replacement Figure 2 8 4 10 2 6 Cylinder Assembly Cont 4 12 Orifice Valve Cleaning 4 12 Cylinder Removal Figure 2 9 4 13 Installation 4 13 2 6 Cylinder Assembly Cont 4 14 Installation Cont 4...

Page 5: ...ption and location of components Large sche matic drawings may be located in the back of the manual SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations Large parts drawings m...

Page 6: ...shop procedures safety principles and service operations are not included Note that this manual does contain warnings and cautions against some specific service methods that could cause personal injur...

Page 7: ...FORM The platform has a reinforced steel floor 1 11m 43 75 inch high guardrails with midrail 6 inch 152 mm toeboards and an entrance gate at the rear of the platform PLATFORM CONTROLLER The platform c...

Page 8: ...platform standing on or stepping from the platform onto buildings steel or prefab concrete structures etc is prohibited Dismantling the entry gate or other railing components is prohibited Always mak...

Page 9: ...tion Inspection 7 Perform all tests from the ground 7 Operation 8 Elevating the Platform 8 Lowering the Platform 8 Emergency Lowering 8 Transporting the Work Platform 9 DC Models 9 Loading 9 Unloading...

Page 10: ...5 Guardrail 6 Entry Drop Bar 7 Chassis Controls 8 Power Unit Motor Hydraulic Reservoir 9 Battery Box DC Units Battery Battery Charger 10 Casters 11 Rear Wheels 12 Screw Jacks 13 Loader Assembly 2 7 5...

Page 11: ...This machine weighs in excess of 760lb 345kg and MUST only be manoeuvred on firm level ground DO NOT attempt to move this machine with the mast in an elevated position...

Page 12: ...Indicators 1 1 Emergency Stop Switch 2 Power On Button 3 Up Button 4 Down Button 1 Power Indicator 2 Emergency Stop Switch 3 Key Switch 4 Emergency Lowering Valve 5 Orbit Level 6 Outrigger Indicator...

Page 13: ...ckwise on an outrigger to level the base 6 All four 4 screwjack pads must be in solid contact with a firm surface and each outrigger indicator light must be lit before the platform is elevated NEVER p...

Page 14: ...atform for obstructions and electrical conductors PERFORM ALL TESTS FROM THE GROUND 1 Pull the Chassis Emergency Stop Switch to the ON position 2 Turn the Key to ON 3 Pull the Platform Emergency Stop...

Page 15: ...the mast assembly for cracked welds and structural damage loose hardware hydraulic leaks loose wire connections and erratic operation Check for missing or loose parts LOWERING THE PLATFORM 12 Check th...

Page 16: ...loader as a pivot until the unit rotates to a horizontal position in the vehicle bed 7 Push the base of the unit towards the front of the vehicle bed The machine will slide on the loader until the re...

Page 17: ...o an upright position Gradually counterbalance the unit s weight by applying an upward force on the T handle This allows the unit to settle gently on the wheels avoiding undue impact on the unit 5 Ret...

Page 18: ...pulling the handle out of the Tilt Back assembly until the locking pin engages 5 Push down on the Tilt Back Handle until the unit comes to rest on the Tilt Back frame As the mast tilts back counterbal...

Page 19: ...ugh a Doorway Passing Through Doorways Hair Pin Retainer Retaining Pin Cylinder Assembly Tilt Back Handle Retaining Pin Cylinder Secured with Retaining Pin Lowering and Raising with the Tilt Back Hand...

Page 20: ...tructions Figure 8 Battery Charger Charge the batteries at the end of each work shift or sooner if the batteries have been discharged Charge the batteries in a well ventilated area Do not charge the b...

Page 21: ...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 main...

Page 22: ...Daily Preventative Maintenance Checklist Operation Manual Page 15 NOTES...

Page 23: ...n good condition before operating the work platform Be sure to read understand and follow these labels when operating the work platform e t a l P e m a N UL25D C 512581 001 UL25A C 512582 001 UL32D C...

Page 24: ...2 84m 112 in 2 53m 100 in 2 90m 114 in 1 32m 52 in 1 32m 52in 1 94m 76 in 1 94m 76 in 3 05m 120 in Vibration 2 5m sec2 Sound Pressure 68dB A at Control Station OperatingTemperature Range 20 C to 50 C...

Page 25: ...N G E R Never perform service on the work platform in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area whil...

Page 26: ...Mast Assembly 2 9 2 Mast Assembly 2 9 Pla orm Support Assembly 2 10 Sequencing Installa on 2 10 2 6 Cylinder Assembly 2 10 Seal Replacement 2 10 Ori ce Valve Cleaning 2 12 Cylinder Removal 2 13 Instal...

Page 27: ...Maintenance Section 2 0 4 1 Electrical Schematics 4 2 Electrical Schematic Legend AC 4 2 Electrical Schematic Legend DC 4 2 4 2 Hydraulic Schematics 4 4 Hydraulic Schematic Legend 4 4 5 0 Illustrated...

Page 28: ...eq d 062739 000 2 1 Preventative Maintenance Table 2 1 The complete inspection consists of periodic visual and operational checks together with all necessary adjustments to assure proper performance D...

Page 29: ...for System serviceability Daily Emergency Check procedure for Emergency Down Down batteries 3m Hydraulic Check for fitting leaks Daily Pump Wipe clean 30d Check for leaks at mating surfaces 30d Check...

Page 30: ...raulic reservoir through the dipstick hole with ISO 46 hydraulic fluid Hydraulic reservoir has a 5 7 liter 1 5 U S gal capacity Ensure that oil is visible on the end of the dipstick 2 2 Lubrication Re...

Page 31: ...inside the cells Rinse thoroughly with clear water Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed BATTERY CHARGING Figure 2 3 Charge battery at end of ea...

Page 32: ...electrolyte 2 3 Figure 2 3 Battery Charger Check the hydraulic system pressure whenever the pump or relief valve has been serviced or replaced The hydraulic oil may be of sufficient temperature to cau...

Page 33: ...e support weldment and strain reliefs from stage 5 top casting 7 Loosen screws from strap retainer on platform assem bly weldment and free strap from retainer 8 Remove two screws and washers holding s...

Page 34: ...UL 25 32 40 Portable Personnel Lifts 2 7 Maintenance Section Figure 2 6 Mast Assembly Strap and Chain Detail 2 5...

Page 35: ...2 8 Maintenance Section UL 25 32 40 Portable Personnel Lifts 2 5 Figure 2 7 Mast Assembly Bearing Detail 2 5...

Page 36: ...ith new roll pins 8 Use a center punch to dimple pin holes after all roll pins are installed 9 Pull the sequencing strap attached to the bottom of mast 6 out through the bottom of the mast assembly Be...

Page 37: ...s and retaining screws using Loctite 242 or equivalent on the threads Pull straps tight while tightening retaining screws 2 6 Cylinder Assembly SEAL REPLACEMENT Figure 2 8 Note The Lift Cylinder Seal...

Page 38: ...w to dry for five minutes Coat threads liberally with Loctite 242 Thread rod end cap onto rod tighten using strap wrench to hold rod 15 Push rod back into cylinder for reassembly 16 Reconnect hydrauli...

Page 39: ...cap port to use as a lever Remove rod end cap and orifice bleeder tube assembly 7 Remove snap ring to release orifice bleeder tube from rod end cap 8 Clean orifice valve hole with a straight pin Flus...

Page 40: ...castings Remove tie rod nuts and install the Tie Rod Tensioners 062738 000 Remove all slack from the chains with the Tie Rod Tensioners 10 Remove cylinder assembly from mast assembly INSTALLATION NOT...

Page 41: ...ns HYDRAULIC COMPONENTS Use the following values to torque hydraulic components used on Snorkel Work Platforms Note Always lubricate threads with clean hydraulic oil prior to installation CARTRIDGE PO...

Page 42: ...sure that all four 4 outriggers are properly installed Unplug the machine or disconnect the bat tery when replacing or testing the continuity of any electrical component GENERAL PROCEDURE Troubleshoot...

Page 43: ...unction check the voltage to the Electric Motor If voltage is present 12VDC or 120 240VAC replace the motor In case of low AC voltage see 1 Use minimum 11 5 mm2 12 ga cord of 16m 50 feet or less in le...

Page 44: ...N b Circuit board is damaged Replace circuit board a Indicator light is damaged b Chassis harness damaged or incorrectly connected c Outrigger limit switch defective or improperly connected a Continue...

Page 45: ...and 12 VDC 4b Voltage at ground pin 1 is not zero 4 Plug in Chassis harness Turn on ignition key turn off E Stop switch Check voltages at pin 1 and pin 6 of the chassis harness This may require the us...

Page 46: ...aged down solenoid a Continue to step 2 2a Lift turns off and restarts in five seconds 2b Lift will not lower 2 Check circuit board for correct output Open lid on the lower box Using a voltmeter check...

Page 47: ...3 6 UL 25 32 40 Portable Personnel Lifts Troubleshooting Section 3 1 NOTES...

Page 48: ...g Guide They allow understanding of the makeup and functions of the systems for checking tracing and faultfinding during troubleshooting analysis The components that comprise the electrical and hydrau...

Page 49: ...it left coil hand side T1 Transformer Steps down AC Inside electrical voltage Control Box 4 1 Electrical Schematics REFERENCE DESIGNATION NAME FUNCTION LOCATION BAT Battery Supplies current to In Powe...

Page 50: ...4 3 Schematics UL 25 32 40 Portable Personnel Lifts Section Figure 4 1 Electrical Schematic AC Models Figure 4 2 Electrical Schematic DC Models 4 1 M1 SOL1 SOL2 R5 BR S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 T1...

Page 51: ...uid ORF Orifice Controls flow out Inline with CYL of CYL P Pump Supplies hydraulic Lower Power Module pressure to system RV Relief Valve Limits maximum Valve Assembly pressure by releasing Lower Power...

Page 52: ...8066 003 5 21 6th Stage Mast Assembly UL25 068070 001 5 22 UL32 068070 002 5 22 UL40 068070 003 5 22 Cage Support Assembly UL25 068160 009 5 24 UL32 068160 010 5 24 UL40 068160 011 5 24 Platform Assem...

Page 53: ...4 068006 025 068006 026 068008 011 068009 011 068013 013 068013 012 068014 012 068014 013 068015 012 068015 013 511128 000 EN 511128 200 BASIC ASSY BASIC ASSY BASIC ASSY POWER OPTION AC EUR POWER OPTI...

Page 54: ...5 3 ULII Series Parts Manual...

Page 55: ...5 4 ULII Series Parts Manual Basic Assembly UL25 068006 024 UL32 068006 025 UL40 068006 026 512805 000 512789 000 512806 000...

Page 56: ...5 5 ULII Series Parts Manual Drawing 1 of 2...

Page 57: ...5 6 ULII Series Parts Manual Drawing 2 of 2...

Page 58: ...5 7 ULII Series Parts Manual AC Power Option 068008 011 020809 001 FITTING TEE 6MJ 6MB 6FJX...

Page 59: ...5 8 ULII Series Parts Manual...

Page 60: ...5 9 ULII Series Parts Manual DC Power Option 068009 011...

Page 61: ...ULII Series Parts Manual 5 10...

Page 62: ...5 11 ULII Series Parts Manual AC Control Box 068007 021...

Page 63: ...5 12 ULII Series Parts Manual...

Page 64: ...5 13 ULII Series Parts Manual DC Control Box 068007 023...

Page 65: ...Page 15 ULII Series Parts Manual...

Page 66: ...Page 16 ULII Series Parts Manual Lift Cylinder UL25 068074 020 UL32 068074 021 UL40 068074 022...

Page 67: ...Page 17 ULII Series Parts Manual...

Page 68: ...Page 18 ULII Series Parts Manual 2nd Stage Mast Assembly UL25 068050 001 UL32 068050 002 UL40 068050 003...

Page 69: ...Page 19 ULII Series Parts Manual 3rd Stage Mast Assembly UL25 068056 001 UL32 068056 002 UL40 068056 003...

Page 70: ...Page 20 ULII Series Parts Manual 4th Stage Mast Assembly UL25 068061 001 UL32 068061 002 UL40 068061 003...

Page 71: ...Page 21 ULII Series Parts Manual 5th Stage Mast Assembly UL25 068066 001 UL32 068066 002 UL40 068066 003...

Page 72: ...Page 22 ULII Series Parts Manual 6th Stage Mast Assembly UL25 068070 001 UL32 068070 002 UL40 068070 003...

Page 73: ...Page 23 ULII Series Parts Manual NOTES...

Page 74: ...Page 24 ULII Series Parts Manual Cage Support Assembly UL25 068160 009 UL32 068160 010 UL40 068160 011...

Page 75: ...Page 25 ULII Series Parts Manual...

Page 76: ...Page 26 ULII Series Parts Manual Platform Assembly UL25 068179 003 506275 001 057524 001 DROP BAR ASSY 510524 000 0120804 PUSH BUTTON DOWN 510542 000 PUSH BUTTON ENABLE 0120803 PUSH BUTTON UP...

Page 77: ...Page 27 ULII Series Parts Manual...

Page 78: ...Page 28 ULII Series Parts Manual Platform Assembly UL32 UL40 068179 004 506275 001 057524 001 DROP BAR ASSY 026551 007 RIVET 1 8 251 312 GRIP...

Page 79: ...Page 29 ULII Series Parts Manual ILLUSTRATION OF CE CAGE...

Page 80: ...Page 30 ULII Series Parts Manual Loader Assembly UL25 068194 000...

Page 81: ...Page 31 ULII Series Parts Manual NOTES...

Page 82: ...Page 32 ULII Series Parts Manual Tilt Back Assembly UL32 068200 000...

Page 83: ...Page 33 ULII Series Parts Manual...

Page 84: ...Page 34 ULII Series Parts Manual Tilt Back Assembly UL40 068200 001...

Page 85: ...Page 35 ULII Series Parts Manual...

Page 86: ...Page 36 ULII Series Parts Manual Loader Stop Bracket Assembly 068190 000 Drawing...

Page 87: ...Page 37 ULII Series Parts Manual Loader Bar Assembly 068186 000...

Page 88: ...Page 38 ULII Series Parts Manual Outrigger Assembly UL25 068157 000 UL32 068157 001 UL40 068157 002...

Page 89: ...Page 39 ULII Series Parts Manual...

Page 90: ...Page 40 ULII Series Parts Manual Power Pack Option 068100 001...

Page 91: ...Page 41 ULII Series Parts Manual Electrical Schematic AC 068010 000...

Page 92: ...Page 42 ULII Series Parts Manual Electrical Schematic DC 068010 001...

Page 93: ...Page 43 ULII Series Parts Manual Hydraulic Schematic 068011 002...

Page 94: ...l Distributore locale EUROPE MIDDLE EAST AFRICA ASIA PHONE 44 0 845 1550 057 FAX 44 0 845 1557 756 NORTH SOUTH AMERICA PHONE 1 785 989 3000 TOLL FREE 1 800 225 0317 FAX 1 785 989 3070 AUSTRALIA PHONE...

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