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Section 3 - Troubleshooting

Hydraulic Troubleshooting

104045-021 - AB62 Work Platform - European Model

Page 3-13

3-9 H

YDRAULIC

T

ROUBLESHOOTING

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

High flow and low flow system pressures can be verified by connecting a 207 bar (3000 PSI) gauge to the
upper port on the valve block. Operate Riser down to test high flow system or Jib up to test the low flow
system. Operate function until it stops and system bypasses.

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

• High flow pressure, 186 bar (2700 PSI).

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

• Low flow pressure, 97 bar (1400 PSI).

W A R N I N G

!

!

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

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Summary of Contents for ab62

Page 1: ...AB62 Work Platform European Specifications Serial Numbers 1266 Current Publication Number 104045 021 ...

Page 2: ...st Industrial Park Friel Avenue Nangor Road Dublin 12 Ireland TEL 353 1 620 9300 FAX 353 1 620 9301 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 AB62 Aerial Work Platform Serial Numbers 1266 Curre...

Page 3: ...n may be reproduced stored in retrieval system or transmitted in any form by any means electronic mechani cal 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 OPERATOR MANUAL A copy of the Operator Manual that is stored on every UpRight Aerial Work Platform SECTION 1 GENERAL INFORMAT...

Page 4: ...Foreword Page ii Service Manual NOTES ...

Page 5: ... carefully lower platform Move machine to a firm level surface Climbing up the railing of the platform standing on or stepping from the platform onto buildings steel or prefab concrete structures etc is prohibited Dismantling the swing gate or other railing components is prohibited Always make certain that the swing gate is closed and securely locked It is prohibited to keep the swing gate in an o...

Page 6: ...ne 8 Driving 9 Steering 10 Positioning the Platform 10 Multifunction Controls 10 Lower Control Operation 10 Upper Control Operation 11 Leveling the Platform 11 Rotating the Turret 11 Elevating the Riser 11 Elevating the Upper Boom 11 Extending the Upper Boom 12 Elevating the Jib 12 Rotating the Platform 12 Emergency Operation 13 After Use Each Day 13 Towing 13 Transportation 14 By Crane 14 By Truc...

Page 7: ... the front of the platform cage The foot switch must be depressed to operate any function from the platform 3 Riser Used to raise the platform 4 Boom Used to extend the platform 5 Jib Used to level and rotate the platform and to raise or lower the platform at the end of the boom 6 Power Module The Power Module contains the engine and the hydraulic pump 7 Control Module The Control Module contains ...

Page 8: ... lbs for two or more occupants D A N G E R DO NOT exceed the maximum amount of manual force for this machine BEAUFORT SCALE Never operate the machine when wind speeds exceed 45 km h 28 mph Beaufort scale 6 LIFT OVERLOAD ALARM All models include a feature that alerts the operator when the platform load is exceeded If the alarm sounds during the lift function lower the platform and reduce the platfo...

Page 9: ...form Level 17 Function Speed HI LOW 18 Auxiliary Power 19 Riser 20 Boom Raise 21 Boom Extend 22 Jib Raise 23 Emergency Stop 24 YELLOW Tilt 25 RED Oil Pressure Warning 26 Torque Speed 27 Diesel Glow Plug Light 28 Auxiliary Power 29 Turret Rotate 30 Cage Rotate 31 Cage Level 32 Auxiliary Light option 33 Horn 34 Generator option 35 Function Speed 36 Drive Control Handle 37 Steering Rocker Switch 38 K...

Page 10: ...ect the elevating assembly for damage deformation buckled paint loose or missing hardware and cracked welds 7 Inspect the platform and guardrails for damage deformation buckled paint loose or missing hardware and cracked welds Ensure that the gate operates freely and latches securely 8 Check the hydraulic fluid level with the platform fully lowered 9 Check the battery fluid level 10 Check the fuel...

Page 11: ...p the engine 11 Turn chassis key switch to the right PLATFORM 12 Mount the platform lower the bar and attach an approved fall restraint to the designated platform anchorage point Attach only one fall restraint to each point 13 Start the engine 14 Without depressing the foot switch move the Drive Control handle the machine should not function 15 Depress the foot switch and move the Drive Control ha...

Page 12: ... anchorage point CONTROLLER FUNCTIONS Refer to Figure 2 on page 5 for control locations EMERGENCY STOP At any time during operation press the Emergency Stop button to stop all functions in an emergency SER VICE HORN At any time during operation press the Service Horn button to sound an audible warning if necessary STARTING THE ENGINE FROM THE LOWER CONTROLS 1 Turn platform controls key to the ON p...

Page 13: ...at the surface is capable of supporting wheel loads 6 Depress the foot switch and move the drive control handle forward to travel forward and reverse to travel in the reverse direction Figure 5 Direction Arrows on Chassis NOTE When the boom is rotated to the front of the chassis steering wheels aft directions of travel and steering will be reversed Observe the color coded arrows on the control pan...

Page 14: ...he instructions on the following pages to position the platform as close to the work area as possible Always before operating any function check the area around and overhead for any obstructions or electri cal conductors W A R N I N G NEVER exit the platform while the boom is elevated Keep both feet on the platform floor at all times MULTIFUNCTION CONTROLS The UpRight AB62 employs the use of multi...

Page 15: ...ockwise to decrease If you are not sure what speed to use start out slow the speed can be varied while operating the function 2 While depressing the footswitch push the Turret Rotation control lever right to rotate counterclockwise left to rotate clockwise Release the switch to stop rotation Observe the area around the boom when rotating the turret to avoid any obstructions ELEVATING THE RISER 1 S...

Page 16: ...oom Release the control lever to stop extending retracting ELEVATING THE JIB 1 Set the Function Speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease If you are not sure what speed to use start out slow the speed can be varied while operating the function 2 While depressing the foot switch push the Jib control lever forward to elevate th...

Page 17: ...r when winching onto a trailer for transportation Figure 6 Disengaging Drive Hub C A U T I O N DO NOT move the machine faster than 5 km h 3 mph Faster speeds will damage drive components and void warranty W A R N I N G Never disengage the hubs unless the wheels are properly chocked and the machine is on a level surface 1 Chock the wheels 2 Ensure that the platform is fully lowered and that the tur...

Page 18: ...HICLE 1 When winching follow instructions for Towing on page 13 Attach the winch cable to the front tie down lugs C A U T I O N Do not winch the machine faster than 5 km h 3 mph Faster speeds will damage drive components and void warranty 2 After winching ensure that the wheels are chocked SECURE TO TRANSPORT VEHICLE Figure 7 Securing the Machine for Transportation 1 Secure the machine to the tran...

Page 19: ... 3 Install the cap HYDRAULIC FLUID Figure 9 Hydraulic Fluid Tank 1 Open the turret cover and check the fluid level at the sight gauge with the boom stowed and retracted engine running or stopped NOTE Never add hydraulic fluid if the boom is elevated or extended 2 If necessary fill to capacity with clean ISO compatible hydraulic fluid Normal Temperature above 0 C 32 F ISO 46 Low Temperature below 0...

Page 20: ...dry climate If the electrolyte level is lower than 10 mm 3 8 in above plates add distilled water ONLY Do not use tap water with high mineral content it will shorten battery life The battery and cables should be inspected regularly for signs of cracks in the case electrolyte leakage and corrosion of the terminals Inspect the cables for worn spots or breaks in the insulation and for broken cable ter...

Page 21: ...R SERVICES Y N R Battery Check electrolyte level Engine Oil and Filter Check level and condition Check for leaks Engine Fuel System Check fuel level Check for leaks Check air cleaner Engine Coolant Check coolant level with engine cold Hydraulic Fluid Check fluid level Hydraulic System Check for leaks Emergency Hydraulic System Operate the emergency lowering valve and check for serviceability Contr...

Page 22: ...00 53 100102 000 54 100103 000 55 030768 002 56 100105 000 57 100101 000 33 068633 001 Model______________ Serial number ___________ Machine weight _______kg Mfg date _________ Maximum wheel load ________ Maximum allowable incline of machine when elevated _____deg Occupants and equipment must not exceed the rated maximum load _____kg Maximum platform occupants _____ Maximum allowable sIde force on...

Page 23: ...44 021 AB62 Work Platform European Model Operator Manual Page 19 Figure 11 Safety Labels Locations 19 49 26 54 53 52 51 56 9 49 40 24 30 49 35 36 32 13 33 49 9 57 35 32 36 9 23 22 11 9 57 10 23 29 7 6 40 9 23 32 1 24 30 ...

Page 24: ...Speed boom stowed and lowered HIGH 6 8 km h 4 25 mph LOW 2 6 km h 1 6 mph Drive Speed Elevated 0 96 km h 0 6 mph Maximum Gradeability 22 40 Dimensions boom stowed Platform Size Standard 1 8 m 6 ft 1 m x 1 8 m 39 in x 72 in Platform Size Optional 2 4 m 8 ft 1 m x 2 4 m 39 in x 96 in Guardrails 1 4 m 45 in Toeboard 152 mm 6 in Platform Capacity Maximum 227 kg 500 lbs Occupants Maximum 2 Weight 10 61...

Page 25: ...ng 1 16 1 12 Hydraulic Fluid 1 17 1 13 Long Term Storage 1 18 LIST OF FIGURES 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 ...

Page 26: ...d damage a machine or make it unsafe Please under stand that these warnings cannot cover all conceivable ways in which service whether or not recom mended 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 themse...

Page 27: ...5 122 85 90 115 122 950 1050 107 119 16 130 140 176 190 130 140 176 190 1300 1368 147 155 SAE J429 Grade 5 SAE J429 Grade 8 SAE J429 Grade 5 SAE J429 Grade 8 Nominal Thread Size Clamp Load Tightening Torque Clamp Load Tightening Torque Nominal Thread Size Clamp Load Tightening Torque Clamp Load Tightening Torque K 15 K 20 K 15 K 20 K 15 K 20 K 15 K 20 lbs in lbs in lbs lbs in lbs in lbs lbs in lbs...

Page 28: ... 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 8 8 10 9 12 9 Grade 8 8 Grade 10 9 Grade 12 9 Nominal Thread Size Clamp Load Tightening Torque Cla...

Page 29: ...hine 0 69 bar 0 1000 psi Hydraulic Pressure Gauge with Adapter Fittings 0 207 bar 0 3000 psi Hydraulic Pressure Gauge with Adapter Fittings 0 414 bar 0 6000 psi Hydraulic Pressure Gauge with Adapter Fittings Small UpRight Connector Field Kit UpRight P N 030899 000 Large UpRight Connector Field Kit UpRight P N 030898 000 Inclinometer UpRight P N 010199 000 00 MOS90 Calibrator UpRight P N 057128 000...

Page 30: ...cking Wedge from the Male Connector Care should be taken that the Sealing Gasket is not dam aged 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 proce dure FEMALE CONNECTOR RECEPTACLE Figure 1 3 UpRight Female Connector 1 Disconnect the male connector plug from the female connector recepta...

Page 31: ... are included in each Field Kit 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 ...

Page 32: ...s seal against internal and external surfaces 3 Wash and dry each component and check for thread damage torn or cracked O rings and proper oper ation 4 Replace parts and O rings found unserviceable ASSEMBLY Refer to the Service and Repair section for assembly drawings and the Parts Manual for illustrated parts breakdowns NOTE Lubricate all O rings before installation to prevent damage to O rings S...

Page 33: ... occurs the surface should be checked for roundness Cylinders not round within 0 18 mm 007 in should be replaced ASSEMBLY Refer to the Service and Repair section for seal kit assembly drawings and the Parts Manual for illustrated 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 elas...

Page 34: ...otor sounds normal go to Step 3 d If the motor sounds noisy it should be taken apart as described in the disassem bly section 3 If the motor turned freely connect an amme ter in the circuit as shown in Figure 1 6A With rated voltage applied and the shaft run ning 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 assu...

Page 35: ...rmature assembly including bearings and insert the commutator end bearing into the bearing bore NOTE 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 Se...

Page 36: ...gen gas or fuel vapors are present Check battery fluid level daily If electrolyte level is lower than 10 mm 3 8 in above plates add distilled water only 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 s...

Page 37: ...he specific gravity of all cells with a hydrometer The temperature corrected specific gravity of a fully charged battery should be 1 260 If any corrected readings are below 1 230 the batteries containing such cells should be replaced Do not check the specific gravity in a cell to which water has just been added If there is not enough elec trolyte in a fully charged cell to obtain a sample for the ...

Page 38: ... 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 fre quency 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 Mach...

Page 39: ...m from charger No green Light No hum from charger Not Applicable Charger automatically adjusts to the incoming AC current 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 Fuse visible on front of charger has failed A...

Page 40: ...the direction of extension and decreased localized pressure at the opposite end MEASURE THE CONTACT AREA Measure the contact area of the contacting sur face 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 Figure 1 9 Occupied Surface Area CALCULATE THE LOCALIZED PRESSURE Find ...

Page 41: ...ons Above 10 C 15 F MOBIL 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 MOBIL 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 MOBIL EAL ENVIRO...

Page 42: ...s 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 a barrier material 4 Coat all exposed unpainted metal surfaces with preservative 5 Internal Combustion Models Service the engine according to the manufa...

Page 43: ...locking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing the brace TABLE OF CONTENTS 2 1 Supporting the Elevating Assembly 2 3 Installation of Elevating Assembly Brace 2 3 Removal of Elevating Assembly Brace 2 3 2 2 Preventative Maintenance 2 4 Preventative Maintenance Check List 2 5 2 3 Lubrication 2 6 Turret Bearing 2 6 Lubricating Turret Gears 2 6 Hy...

Page 44: ... 5 Figure 2 6 Switch Locations 2 6 Figure 2 7 Proximity Switch Adjustment 2 6 Figure 2 8 Linkage Limit Switch Adjustment 2 7 Figure 2 9 Level Sensor Adjustment 2 7 Figure 2 10 Hydraulic Manifold 2 9 Figure 2 11 Torque Hub Assembly Remove and Replace 2 11 Figure 2 12 Torque Hub Assembly Seal kit Installation 2 15 Figure 2 13 Master Cylinder 2 16 Figure 2 14 Riser Cylinder 2 16 Figure 2 15 Boom Cyli...

Page 45: ...ON OF ELEVATING ASSEMBLY BRACE Figure 2 2 Elevating Assembly Brace 1 Park the work platform on a firm level surface 2 Fully retract and lower the upper boom 3 Verify that the platform emergency stop switch is ON 4 Turn platform chassis switch to CHASSIS 5 Using the Riser Raise Lower Switch elevate the elevating assembly 6 Use a brace with a minimum capacity of two tons to support the ele vating as...

Page 46: ... maintenance schedule is to be performed at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechani cal and electrical procedures W A R N I N G Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to enter the lifting assembly to p...

Page 47: ...s Check fasteners for proper torque Daily Check welds for cracks Daily Check condition of platform Daily Check condition of anchorage points Daily Check condition of operator manual Daily Tires Check for damage Daily Check lug nuts torque to 190 ft lbs 257Nm 30d Check air pressure 80 psi 5 5 bar Daily Hydraulic Pump Wipe clean 30d Check for leaks at mating surfaces 30d Check for hose fitting leaks...

Page 48: ...rease fitting for the turret bearing is located at the front of the turret assembly Figure 2 3 Turret Bearing Grease Fitting 1 Wipe the fitting before and after greasing 2 Using multipurpose grease in a grease gun pump the grease into the fitting until grease just begins to appear at the edges of the pivot 3 Wipe off any excess grease LUBRICATING TURRET GEARS Figure 2 4 Turret Gear Using a brush a...

Page 49: ...oves and safety glasses when handling hot fluid 2 Provide a suitable container to catch the drained fluid 3 Remove the drain plug and allow all fluid to drain into the container Be sure to dispose of fluid properly 4 Reinstall the drain plug 5 Remove filter element from filter head 6 Apply a thin film of clean hydraulic fluid ISO No 46 to the gasket of the replacement filter 7 Thread replacement f...

Page 50: ... whether the boom is extended or retracted When the boom is retracted and the platform fully lowered the Proximity switch bypasses the Level Sensor and closes the circuit to the receiver This allows high speed travel cage trim function and axle float Figure 2 7 Proximity Switch Adjustment TEST AND ADJUST 1 Lower the platform completely 2 With the Platform Chassis switch on CHASSIS push the Level S...

Page 51: ...ning the arm c lower the platform and re test the level sensor When the switch is properly adjusted the alarm will not sound 4 With the platform elevated repeat step 2 When the switch is properly adjusted the alarm will sound LEVEL SENSOR The Level Sensor also known as the Tilt Sensor has three wires red power 12v in black ground and white output 12v out To verify that the sensor is working proper...

Page 52: ...manifold block REPAIR Refer to the General Information section for instructions on Disassembly Cleaning and Inspection and Assembly NOTE Mark all components as they are removed so as not to confuse their location during assembly Refer to Figure 2 10 on page 2 11 often to aid in disassembly and assembly INSTALLATION 1 Attach manifold assembly to mounting plate with bolts 2 Connect solenoid leads to...

Page 53: ...alve 2 High Flow Proportional Valve 3 Gage Port Plug High Pressure 4 Steering Valve 5 High Pressure Relief Valve 6 Riser Valve 7 Boom Extend Retract Valve 8 Low Flow Proportional Valve 9 Low Pressure Relief Valve 10 Boom Raise Valve 11 Platform Level Valve 12 Platform Rotate Flow Control Valve 13 Jib Valve 14 Turret Rotate Valve 15 Gage Port Plug Low Pressure 16 Platform Rotate Valve ...

Page 54: ...justing screw Turning the adjusting screw clockwise increases pressure counterclock wise decreases pressure 5 Remove the pressure gauge and reinstall all plugs LOW PRESSURE RELIEF VALVE 1 Operate the hydraulic system 10 15 minutes to warm the fluid 2 Install a 0 207 bar 0 3000 PSI pressure gauge to the pressure test port 3 Completely extend jib function 4 Continue activating function and set the p...

Page 55: ...the front plug opening the torque hub must be full 8 Replace the plugs 9 Install the wheel and lower the machine to the surface TORQUE HUB REMOVAL Figure 2 11 Torque Hub Assembly Remove and Replace 1 Park the work platform on a firm level surface and block the wheels to prevent the work plat form from rolling 2 Disconnect the battery negative terminal 3 Loosen the wheel lug nuts on the torque hub ...

Page 56: ... and O ring 27 from the large cover 28 5 Remove the primary sun gear 24 from the end of the input shaft 2 6 Remove the primary carrier assembly 22 7 Remove the secondary carrier assembly 21 8 Remove the input shaft 2 from the spindle 3 Remove the retaining rings 17 washers 18 and dis engage spring 19 from the input shaft 2 only if replacement is required 9 One tab of the lock washer 15 will be eng...

Page 57: ...a Nm in lbs torque wrench arm or dial type on the center nut of the Spindle Drive Tool and turning the hub 11 slowly and steadily with the torque wrench Note the mean torque An initial bearing torque of greater than 81 Nm 52 in lbs with the boot seal installed or 4 3 5 2 Nm 38 46 in lbs without the boot seal means that the cone 13 was pressed on to tightly in step 4 In this case back off the beari...

Page 58: ...t lbs 21 Assemble the disengage cover 31 with the dimpled center protruding out if the wheel is to be used to drive the vehicle 22 Assemble and torque the two 5 16 18 x 1 2 inch bolts 32 Torque the bolts to 13 27 Nm 10 20 ft lbs 23 Invert the torque hub assembly and assemble the coupling 1 with counterbore out to the input shaft 2 24 After the motor is assembled to the drive or the drive is sealed...

Page 59: ...her 27 O Ring 1 Coupling 2 Input Shaft 3 Spindle 4 Boot Seal 5 Oil Seal 6 Bearing Cone 7 Bearing Cup 8 Wheel Bolt 9 Hex Head Bolt Grade 8 10 Flat Washer 11 Hub 12 Bearing Cup 13 Bearing Cone 14 Thrust Washer 15 Lock Washer 16 Bearing Nut 17 Retaining Ring 18 Washer 19 Disengage Spring 20 Ring Gear 21 Secondary Carrier Assembly 22 Primary Carrier Assembly 23 Retaining Ring 24 Primary Sun Gear 25 Th...

Page 60: ...cludes Item Description 1 O ring 2 Rod Wiper 3 Seal 4 Wear Ring 5 O Ring 6 Back up Ring 7 O Ring 8 Seal 9 Wear Ring A Rod B Head C Piston D Nut E Cylinder F Counterbalance Valve NOTE Torque Locknut D to 339 407 Nm 250 300 ft lbs Service Kit includes Item Description 1 Rod Wiper 2 Seal 3 Wear Ring 4 O Ring 5 Back up Ring 6 O Ring 7 Seal 8 O ring 9 Wear Ring A Rod B Head C Piston D Nut E Cylinder F ...

Page 61: ...n E Set Screw F Cylinder G Counterbalance Valve Service Kit includes Item Description 1 Rod Wiper 2 Seal 3 Wear Ring 4 O Ring 5 Back up Ring 6 O Ring 7 Wear Ring 8 Seal Service Kit includes Item Description 1 Rod Wiper 2 Seal 3 Seal 4 O Ring 5 Back up Ring 6 O Ring 7 Wear Ring 8 Wear Ring 9 Seal A Rod Wiper B Head C Spacer D Set Screw E Piston F Cylinder G Counterbalance Valve ...

Page 62: ...ion 1 O Ring 2 Rod Wiper 3 Seal 4 Wear Ring 5 O Ring 6 Back up Ring 7 O Ring 8 Seal 9 Wear Ring A Rod B Head C Piston D Nut E Cylinder F Counterbalance Valve G Washer Seal H Bleeder Plug NOTE Torque Locknut D to 237 271 Nm 175 200 ft lbs Service Kit includes Item Description 1 O Ring 2 Rod Wiper 3 Seal 4 Wear Ring 5 Back up Ring 6 O Ring 7 Wear Ring 8 Seal A Rod B Head C Spacer D Cylinder ...

Page 63: ...ng screws five turns Do not move the gearbox 4 Place the magnetic indicator base on the bottom of the turret assembly Set the dial indicator probe on the gearbox pinion straight across from the bearing and adjust the dial to ZERO 5 Move the gearbox away from the bearing until the indicator shows the correct amount of backlash 0 178mm 0 229mm 007 009 6 Carefully torque the gearbox mounting bolts wh...

Page 64: ... allow to drain A high pressure rinse and wipe with a lint free rag is preferable 5 Inspect the body and housing for scratches pits or polishing Check seal grooves and sealing surfaces Scratches or pits deep enough to catch the fingernail are unacceptable replace the manifold ASSEMBLY NOTE Torque all hardware and fittings to torques listed in the General Information section unless otherwise specif...

Page 65: ...in diagnosing and repair of the machine W A R N I N G When troubleshooting ensure that the work platform is resting on a firm level surface When performing any service which requires the platform to be raised the Elevating Assembly must be blocked Disconnect the battery when replacing or testing the continuity of any electrical component TABLE OF CONTENTS 3 1 Technical Support 3 2 3 2 General Proc...

Page 66: ...controls and chassis controls and note all functions that are not operating correctly 2 Narrow the possible causes of the malfunction Use the troubleshooting guide to determine which components are common to all circuits that are not functioning correctly 3 Identify the problem component Test components that are common to all circuits that are not functioning correctly Remember to check wires and ...

Page 67: ... Figure 3 2 and Figure 3 1 a signal or series of signals can be followed from switch to actuator to help in determining the cause of a problem Four blinking diagnostic LEDs located at the bottom center of the DMR 30 are labeled as to their function and are also used for diagnostic purposes A CPU LED DMR 30 is powered up operating properly Solid light indicates internal failure Not lit when no powe...

Page 68: ...itch The hour meter should flash BT4 08 oil pressure input will illuminate while engine is running NOTE If no oil pressure is detected ignition signal is deactivated The engine will not continue to run GLOW PLUG BT1 08 on DMR 30 is illuminated Glow plugs are automatic BOOM Speed control knob in UPPER control box must be turned past 5 to operate BOOM UP Function enable is pushed LEDs on DMR 30 are ...

Page 69: ...d LEDs on DMR 30 illuminated BT2 07 boom retract input BT6 08 boom retract output to valve BT6 10 high flow output BT 06 throttle output TURRET ROTATE SWING RIGHT Function enabled LEDs on DMR 30 illuminated BT2 09 swing right input BT7 09 turret valve output BT5 06 throttle output BT6 12 low flow valve output SWING LEFT Function enabled LEDs on DMR 30 illuminated BT2 08 swing left input BT7 08 tur...

Page 70: ... valve BT6 12 low flow valve output BT5 06 throttle output CAGE TRIM UP Function enabled LEDs on DMR 30 illuminated BT2 12 cage trim up input BT6 05 cage trim up output to valve BT6 12 low flow valve output BT5 07 throttle output CAGE TRIM DOWN Function enabled LEDs on DMR 30 illuminated BT4 01 cage trim down input BT6 06 cage trim down output to valve BT6 12 low flow valve output BT5 07 throttle ...

Page 71: ...08 glow plug output diesel only BT4 04 oil pressure BOOM LIFT FUNCTION RISER UP Function enabled foot switch depressed LEDs on DMR 30 Illuminated BT5 12 riser up output BT5 06 throttle output BT6 10 high flow valve output LEDs on DMT 30 illuminated BT4 03 foot switch BT 3 09 riser up RISER DOWN Function enabled foot switch depressed LED s on DMR 30 illuminated BT6 01 riser down output BT5 06 throt...

Page 72: ...1 boom extended BOOM RETRACT Function enabled foot switch depressed LEDs on DMR 30 illuminated BT6 08 boom retract output BT5 06 throttle output BT6 10 high flow valve output LEDs on DMT 30 illuminated BT4 03 foot pedal BT3 06 boom retract TURRET ROTATE FUNCTIONS SWING RIGHT Function enabled foot switch depressed LEDs on DMR 30 illuminated BT7 09 turret rotate right output BT5 06 throttle output B...

Page 73: ...al BT4 02 jib down CAGE ROTATE CAGE RIGHT Function enabled foot switch depressed LEDs on DMR 30 Illuminated BT7 03 cage rotate right output BT5 06 throttle output BT6 12 low flow valve output LEDs on DMT 30 illuminated BT4 03 foot pedal BT4 01 cage rotate right CAGE LEFT Function enabled foot pedal depressed LEDs on DMR 30 Illuminated BT7 04 cage rotate left output BT5 06 throttle output BT6 12 lo...

Page 74: ...commands are relayed from the joystick controller to the DMT 30 on BT3 08 JSA Joystick actuator DRIVE FORWARD Function enabled foot switch depressed LEDs on DMR 30 Illuminated BT5 06 throttle output BT5 04 brake release LEDs on DMT 30 Illuminated BT3 02 JSA joystick actuator DRIVE REVERSE Function enabled foot switch depressed LEDs on DMR 30 Illuminated BT5 06 throttle output BT5 04 brake release ...

Page 75: ...gnal is sent to the brake solenoid by BT5 04 on DMR 30 TILT A 12 volt signal is at BT1 05 tilt signal input when the machine is level If the machine is out of level or the level sensor fails the machine will stop Red wire on level sensor is power in and white wire is signal out INTERLOCKS There are two interlocks on the machine 1 Lift Interlock A12 Volt signal is sent to BT2 01 on DMR 30 allows hi...

Page 76: ...yed Max Out or MX pertains to the extension of the cylinders in the group Low Range or LR pertains to the retraction of the cylinders in the group SEQUENCE Emergency stop switches must be pulled and ignition switches on It is not necessary to have the engine running when retrieving the initial settings or resetting the DMR 30 Plug the Optimizer in at either location and it should read Run mode nor...

Page 77: ...operates Boom up down Jib up down Swing right left Cage rotate and Cage level High flow and low flow system pressures can be verified by connecting a 207 bar 3000 PSI gauge to the upper port on the valve block Operate Riser down to test high flow system or Jib up to test the low flow system Operate function until it stops and system bypasses The high flow relief valve is located just below the gau...

Page 78: ...ircuit Breaker 20 AMP X X X X X X X X X X X X X X X X X X X X X X X CB2 Circuit Breaker 10 AMP X X X X X X X X X CB3 Circuit Breaker 10 AMP X X X X X X X CONT1 Controller DMR 30 X X X X X X X X X X X X X X X X X X X X CONT2 Controller Glow Plug X X D1 Diode Auxiliary Power X D3 Diode Power to Platform X X X X X X X D4 Diode X D5 Diode Auxiliary Pump Relay X D6 Diode X D7 Diode Alternator X D8 Diod...

Page 79: ... SW24 Enable Switch Lower X SW26 Boom Hi Lo Speed Lower X X X X X X X X SW28 Engine start Switch Lower X SW29 Turret Rotate Switch Lower X X SW30 Boom Up Down Switch Lower X X SW31 Cage Level Switch Lower X X SW32 Cage Rotate Switch Lower X X SW33 Jib Up Down Switch Lower X X SW34 Rise Up Down Switch Lower X X SW35 Boom Extend Retract Lower X X SNSR1 Tilt Sensor X X SNSR2 Engine Temperature Sensor...

Page 80: ...r Valve X SOL20 Brake X SOL21 Torque X SOL22 Axle Lock X SOL23 Fuel X X TMR Timing Module X X TRANS Transmitter DMT 30 X X X X COMPONENT F UNCTION E NGINE S TART R UN U PPER CONTROLS E NGINE S TART R UN L OWER CONTROLS U PPER C ONTROL F UNCTIONS L OWER C ONTROL F UNCTIONS R ISER R AISE L OWER B OOM U P D OWN B OOM E XTEND R ETRACT D RIVE F ORWARD R EVERSE S PEED H IGH C REEP S TEER L EFT R IGHT J ...

Page 81: ... Cylinder X CV1 2 High Pressure Test Port Check Valve CV3 7 Low Pressure Test Port Check Valve X X X X X CV8 Boom Extend Cylinder Check Valve X CV9 Turret Rotate Check Valve X CYL1 Steer Cylinder X CYL2 Riser Cylinder X CYL 3 Boom Extend Cylinder X CYL4 Boom Raise Cylinder X CYL5 Jib Cylinder X CYL6 Master Cylinder X CYL7 Slave Cylinder X CYL8 Turret Rotate Brake Cylinder X CYL11 Left Axle Lock Cy...

Page 82: ...V10 High Flow Valve X X X V11 Diverter Valve V12 Brake Valve X V13 Axle Float Valve X V14 High Speed Valve X V15 Rear Drive Torque Speed Valve X V16 Front Drive Torque Speed Valve X COMPONENT F UNCTION S TEER R ISER E LEVATE D ESCEND B OOM E XTEND R ETRACT B OOM R AISE L OWER J IB U P D OWN C AGE L EVEL U P D OWN C AGE R OTATE CW C C W T URRET R OTATE CW CCW D RIVE F ORWARD R EVERSE F RONT A XLE L...

Page 83: ...ing 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 TABLE OF CONTENTS 4 1 Electrical Schematic Diesel 4 2 104049 000 Electrical Schematic Diesel 4 2 4 2 Hydraulic Schematic 4 5 104048 011 Hydraulic Schematic 4 5 104525 000 Valve Manifold Assembly 4 5 4 3 Platform Contr...

Page 84: ...dule SW1 Switch Emergency Stop Platform Control Box SW2 Switch Ignition Start Engine Platform Control Box SW3 Not Used SW4 Switch Auxiliary Power Platform Control Box SW5 Switch Generator Platform Control Box SW6 Switch Drive Hi Low Speed Platform Control Box SW7 Switch Level the Platform Platform Control Box SW8 Switch Boom Up Down Platform Control Box SW9 Switch Turret Rotate Platform Control Bo...

Page 85: ...Page 4 3 SOL1 SOL2 SOL3 SOL4 SOL5 SOL6 SOL7 SOL8 SOL9 SOL10 SOL11 SOL12 SOL13 SOL14 SOL15 SOL16 SOL17 SOL18 SOL19 SNSR1 LS1 LS2 HORN BAT2 BAT1 MOT1 FU1 R15 SOL20 SOL21 SOL22 PMP1 ALT D7 ISO MOT2 SNSR2 SNSR3 SW17 D9 R1 D8 SOL23 ACT1 CONT2 TMR 104049 000 Electrical Schematic Diesel Drawing 1 of 2 ...

Page 86: ...MP1 LAMP2 ALM1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 SW9 SW10 SW11 SW12 SW13 SW14 LAMP3 LAMP4 SW21 SW22 SW23 D3 CB1 CB2 CB3 D4 D5 D2 D6 D1 SW24 MTR1 MTR2 MTR3 SW28 SW26 SW29 SW30 SW31 SW32 SW33 SW34 SW35 R5 R6 R7 R8 R9 R10 SW18 DRIVE CONTROLLER R12 R11 R13 R14 TRANS CONT1 104049 000 Electrical Schematic Diesel Drawing 2 of 2 ...

Page 87: ...w Divider Flow Divider Drive Valve Block FL1 Filter Suction Filter Tank FL2 Filter Suction Filter Tank FL3 Filter Return Filter Tank MOT1 Drive Motor Left Rear Drive Motor Left Rear Axle MOT2 Drive Motor Right Front Drive Motor Right Front Axle MOT3 Drive Motor Right Rear Drive Motor Right Rear Axle MOT4 Drive Motor Left Front Drive Motor Left Front Axle ORF1 Orifice Limit Turret Rotate Speed Main...

Page 88: ... CYL1 CYL12 CYL11 CB9 CB10 V12 V13 V14 FL1 PMP2 PMP1 FL3 FL2 ORF3 ORF4 FD1 FD2 V15 V16 CYL2 CYL3 CYL4 CYL5 CB1 ORF2 CB2 CV10 CB3 CB4 RV3 CYL6 CB5 CYL7 CB6 CYL8 CB8 CV11 ROT CB7 V8 V7 ORF1 CV6 CV7 RV1 RV3 V6 V5 CV5 V4 CV4 CV9 V3 V2 V1 CV3 CV8 V10 V9 V11 RV2 CV2 CV1 PMP3 104048 011 Hydraulic Schematic Drawing 2 of 2 ...

Page 89: ...25 1 Riser 2 Boom Raise 3 Boom Extend 4 Jib Raise 5 Emergency Stop 6 Engine Temperature 7 Tilt Indicator 8 Hi Lo Speed 9 Glow Plug Light 10 Auxiliary Power 11 Turret Rotate 12 Cage Rotate 13 Cage Level 14 Horn 15 Boom Speed 16 Proportional Drive Controller 17 Steering 18 Multiplex Transmitter 19 Terminal Strip 20 Connector 31 Socket 21 Cable Connector 22 Connector 4 Socket 23 Lever Switch 24 Alarm...

Page 90: ...Platform Controls Section 4 Schematics Page 4 8 104045 021 AB62 Work Platform European Model 104531 000 PLATFORM CONTROLS WIRING DIAGRAM DIESEL ...

Page 91: ...1 19 22 4 7 8 5 12 14 18 3 2 1 5 9 13 17 11 16 10 15 1 Hour Meter 2 Water Temp 3 Oil Pressure 4 Circuit Breaker 5 Key Switch 6 Engine Start 7 Enable 8 Diesel Glow Plug Light 9 Emergency Stop 10 Riser 11 Boom Raise 12 Boom Speed HI LOW 13 Boom Extend 14 Jib 15 Turret 16 Platform Rotate 17 Platform Level 18 Auxiliary Power 19 Relay 12 Volt 20 Terminal Strip 21 Relay Card Assembly 22 Multiflex Receiv...

Page 92: ...Chassis Controls Section 4 Schematics Page 4 10 104045 021 AB62 Work Platform European Model 104019 000 CHASSIS CONTROL BOX WIRING DIAGRAM DIESEL ...

Page 93: ...Call Toll Free in U S A 1 800 926 LIFT ...

Page 94: ...h Pine Street Madera California 93637 TEL 559 662 3900 FAX 559 673 6184 PARTS 1 888 UR PARTS PARTS FAX 1 800 669 9884 UpRight Unit S1 Park West Industrial Park Friel Avenue Nangor Road Dublin 12 Ireland TEL 353 1 620 9300 FAX 353 1 620 9301 P N 104045 021 06 02 ...

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