Upright LX31 Service Manual Download

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4-12 LX31/41 Electric Work Platform

R O U B L E S H O O T I N G

Section

4.8

11 Flashes

- Tachometer signal out of
range

- Drive inhibited

- Flashes until fault cleared

Check tachometer wires for shorts to frame or a

voltage source

Rectify

Check output voltage from tachometer using

voltmeter

Replace

Replace MOS90 Controller

12 Flashes

- Severe tilt condition with
platform raised above
2 meters

- Vehicle goes into emergency
stop (forced neutral state) and
plug brakes to a stop

- Recycle nuetral to clear fault

Use calabrator test mode and check platform up

switch and severe tilt switch inputs and wiring

Rectify

Replace MOS90 Controller

Summary of Contents for LX31

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Page 3: ...e equipment name plate Should the nameplate be missing the SERIAL NUMBER is also stamped on top of the chassis above the front axle pivot 067448 001 12 99 K Stamped Serial Number Call Toll Free in U S A 1 800 926 LIFT PARTS 1 888 UR PARTS PARTS FAX 559 896 9244 UpRight Inc 1775 Park Street Selma California 93662 TEL 559 891 5200 FAX 559 891 9012 PARTS 1 888 UR PARTS PARTS FAX 559 896 9244 ...

Page 4: ......

Page 5: ...eivable 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 per sonal safety nor machine safety will be jeopardized 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 change...

Page 6: ...ii LX31 41 Electric Work Platform FORWARD NOTES ...

Page 7: ...ols 2 7 From the Chassis Controls 2 7 Emergency Lowering 2 7 2 8 Design Features 2 7 2 9 Controls and Indicators 2 8 2 10 Fold Down Guardrails 2 10 Erection Procedure 2 10 Double Deck Fold Down Procedure 2 11 Erection Procedure 2 11 SECTION 3 Maintenance 3 1 3 1 Introduction 3 1 Terminology 3 1 General Procedures 3 1 3 2 Date Code Identification on Hoses 3 1 3 3 Special Tools 3 1 3 4 Deutsch Conne...

Page 8: ...in Assembly 3 20 3 17 Cylinder Repair 3 22 Removal 3 22 Disassembly 3 22 Assembly 3 22 Installation 3 22 3 18 Steering Cylinder 3 23 Removal 3 23 Installation 3 23 3 19 Lift Cylinder 3 24 Removal 3 24 Installation 3 24 3 20 Torque Specifications 3 26 Fasteners 3 26 Hydraulic Components 3 26 SECTION 4 Troubleshooting 4 1 4 1 Introduction 4 1 General Procedure 4 1 4 2 Troubleshooting Electrical Sche...

Page 9: ...anifold 3 9 Figure 3 11 Rotary Control Adjustment Upper Control Box 3 10 Figure 3 12 Platform Down Limit Switch 3 11 Figure 3 13 Tilt Sensor 3 11 Figure 3 14 Hydraulic Manifold Exploded View 3 13 Figure 3 15 Hydraulic Power Unit 3 14 Figure 3 16 Rear Axle Assembly 3 14 Figure 3 17 Brake Assembly 3 15 Figure 3 18 Replacing Drive Motor Brushes 3 16 Figure 3 19 Torque Hub Assembly 3 17 Figure 3 20 Me...

Page 10: ...klist 3 5 Table 3 2 Torque Specifications for Fasteners 3 26 Table 3 3 Torque Specifications for Hydraulic Components 3 26 SECTION 4 Troubleshooting Table 4 1 Trouble Shooting Guide Electrical Schematics 4 2 Table 1 Troubleshooting Guide Hydraulic Schematics 4 6 Table 4 2 Calibrator Settings 4 8 Table 4 3 Calibrator Display 4 8 SECTION 5 Schematics Table 5 1 Electrical Schematic 067447 001 5 2 Tab...

Page 11: ...e elevating assembly a three LX31 or four LX41 section scis sor assembly powered by a single stage lift cylinder The hydraulic pump driven by the batteries powers the cylinder Solenoid operated valves control raising and lowering Power Module The power module contains the batteries hydraulic pump and hydraulic reservoir Control Module The control module contains the hydraulic valve man ifold horn ...

Page 12: ...olt DC Hydraulic Tank Capacity 28 3 Gallons 107 13 l 28 3 Gallons 107 13 l Maximum Hydraulic System Pressure 3000 psi 206 8 bar 3000 psi 206 8 bar Hydraulic Fluid Normal use 32 oF 0 oC ISO 46 ISO 46 Low Temp use 10 to 32 oF 23 to 0 oC ISO 32 ISO 32 Lift System One Single Stage Lift Cylinder One Single Stage Lift Cylinder Lift Speed Raise 50 sec Lower 48 sec Raise 50 sec Lower 48 sec Drive Control ...

Page 13: ...olts NEVER climb down elevating assembly with the platform elevated NEVER perform service on machine while platform is elevated without blocking elevating assembly NEVER recharge battery near sparks or open flame batteries that are being charged emit highly explosive hydrogen gas AFTER USE secure the work platform against unauthorized use by turning key switch off and removing key NEVER replace an...

Page 14: ...k the hydraulic oil level sight gauge on the hydraulic tank Add ISO 46 hydraulic oil if necessary 4 Check that fluid level in all batteries is correct See Battery Maintenance in Section 3 5 Check that all guardrails are in place Insure that gate operates freely and latches securely 6 Check tires for damage Check tire pressure 75 psi 5 2 bar if equipped with pneumatic tires 7 Carefully inspect the ...

Page 15: ...should only partially elevate and the tilt alarm should sound If the platform continues to elevate and or there is no alarm STOP and remove the machine from service until it is repaired 9 Release the tilt sensor and fully elevate platform 10 Visually inspect the elevating assembly lift cylin der cables and hoses for damage or erratic oper ation Check for missing or loose parts 11 Lower the platfor...

Page 16: ...travel 8 While moving push the drive lift speed range switch to HIGH SPEED for travel on level sur faces or to LOW SPEED for climbing grades or traveling in confined areas Steering 1 Push the steering switch RIGHT or LEFT to turn the wheels Observe the tires while maneuvering to insure proper direction NOTE Steering is not self centering Wheels must be returned to the straight ahead position by op...

Page 17: ...switch to OFF and remove the key to prevent unauthorized operation Parking Brake Release Perform the following only when the machine will not operate under its own power and it is necessary to move the machine or when winching onto a trailer to transport Never release brakes if machine is on a slope Hook machine to towing vehicle before releas ing brakes 1 Turn Platform Chassis Brake Release switc...

Page 18: ...preservative BATTERIES 1 Disconnect the batteries negative cables and secure to the chassis 2 Disconnect the remaining battery leads and secure to the chassis 3 Remove the batteries and place in alternate ser vice 2 6 RAISING THE PLATFORM From the Platform Controls 1 Select platform at the Chassis Platform Switch 2 Select lift at the Drive Lift Switch 3 Push the Control Handle forward a This will ...

Page 19: ...This will allow oil to flow out of the Lift Cylinder through the Down Orifice regulating the descent speed through the Down Valve through the Lift Valve and out to the Hydraulic Reservoir 2 8 DESIGN FEATURES The LX31 41 has the following features to insure safe operation 1 The Lift Valve will not energize unless the chassis is level 2 A warning alarm sounds and Drive Valves are de energized if the...

Page 20: ... chassis controls 4 Steering Switch Moving the momentary rocker switch RIGHT or LEFT steers the work platform in that direction Although the Steering Switch is self centering the steering system is not The wheels must be steered back to straight 13 Brake release Button Press button to release the Parking Brake 14 Down Alarm Sounds an audible signal while platform is lowering during normal operatio...

Page 21: ...7 4 2 3 5 8 6 1 10 16 17 9 10 11 12 13 14 15 LX13 41 Electric Work Platform 2 9 MACHINE PREPARATION OPERATION Section 2 9 Figure 2 6 Controls and Indicators ...

Page 22: ...ardrail Fold the rear guardrail down onto the platform being careful to keep gate latched at all times 5 Remove nuts bolts and washers from the top of the side guardrails Lift up and fold one side guardrail in so it rests on the deck Repeat with other side guardrails Erection Procedure 1 Raise side guardrails making sure each is pushed down to secure the guardrail in the verti cal position 2 Insta...

Page 23: ...d washers opposite the gate latch on the right side guardrail so it too can be separated into two pieces 5 Lift up and fold side guardrails in so they rest on the deck 6 Lift up and fold front guardrail in so it rests on the deck Repeat for rear guardrail Erection Procedure 1 Raise front guardrail making sure it is pushed down to secure the guardrail in the vertical posi tion Repeat for rear guard...

Page 24: ...2 12 LX13 41 Electric Work Platform MACHINE PREPARATION OPERATION Section 2 10 NOTES ...

Page 25: ... by yellow arrows on chassis AFT Rear of machine indicated by orange arrows on machine General Procedures CONTACT BLOCKS Removed by inserting a flat screwdriver into the slot at either end of block and prying outward Installed by pressing into an empty slot SWITCH MOUNT BASE Assembled to back of switch actuator Removed by rotating the small black lever counterclockwise and lifting off base TERMINA...

Page 26: ...ECTORS Deutsch connectors are designed so that connector parts contacts or electrical cables may be replaced without replacing the entire connector Figure 3 1 Deutsch Connector Kit Small Figure 3 2 Deutsch Connector Kit Large Figure 3 3 Plugs and Receptacles Deutsch Connectors ...

Page 27: ...eutsch Connector 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 Crimping NOTE Complete crimping instructions are included in each Field Kit 1 Strip 1 4 ...

Page 28: ...ion and maintenance shall be per formed by personnel who are trained and familiar with mechanical and electrical procedures Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to enter the scissor assembly to perform maintenance while the platform is ele vated The preventative maintenance tab...

Page 29: ... fasteners for proper torque Daily Check welds for cracks Daily Check condition of deck Daily Tires Check for damage Daily Check lug nuts torque to 150 ft lbs 203 Nm 30d Check air pressure 75 psi 5 2 bar Daily Hydraulic Pump Wipe clean 30d Check for leaks at mating surfaces 30d Check for hose fitting leaks Daily Check mounting bolts for proper torque 30d Drive Motors Check for operation Daily Torq...

Page 30: ...m until the scissors brace can be rotated to the vertical posi tion 5 From the left side of the machine disengage the locking pin securing the brace Rotate the scissor brace counterclockwise until it is vertical and between the two scissor center pivots 6 Push lower button and gradually lower platform until brace is supporting the platform Brace Removal 1 Using chassis controls gradually raise pla...

Page 31: ...ater Clean batteries and cables contact surfaces to a bright metal finish whenever a cable is removed 3 8 LUBRICATION Refer to Table 3 1 for the lubrication intervals and Figure 3 7 for location of items that require lubrica tion service Refer to the appropriate sections for lubrication information on the Steering Linkage Torque hubs and Hydraulic Oil and Filter Grease Fittings Wipe each grease fi...

Page 32: ...e a suitable container to catch the drained oil The hydraulic tank has a capacity of 28 3 US gallons 107 l 3 Remove the drain plug and allow all oil to drain into the container be sure to dispose of oil prop erly 4 Reinstall the drain plug 5 Remove the three screws from the filter body cover and open the filter body 6 Lift the filter element from the filter body 7 Fill the hydraulic oil tank to th...

Page 33: ... Turn the Lift Relief Valve adjustment screw coun terclockwise two full turns 4 Place rated load on the platform Refer to specifi cations Section 1 5 Depress the Throttle Button and the Raise But ton to lift the platform 6 Slowly turn the Lift Relief Valve adjustment screw clockwise until the platform begins to rise 7 Replace the cap or tighten the locknut on the Lift Relief Valve and remove the l...

Page 34: ...If they have not been pre viously set preset to about mid range and start from there Turn pot clockwise CW to increase settings Turn pot counterclockwise CCW to decrease set tings Adjust pots only in sequence as outlined in this pro cedure Proportional Drive Control IMPORTANT Back out ramp trimpot 10 turns counter clockwise before making any adjustments Adjusting one pot affects the setting of oth...

Page 35: ...the capscrews and nuts holding the bracket in place and moving the bracket until the switches align with the magnets Lower the Plat form and retest When switches are aligned alarm will not sound while platform is lowered 4 With platform elevated repeat step 2 When switches are properly adjusted alarm will sound Tilt Sensor The Tilt Sensor has three wires red power 48v in black ground white output ...

Page 36: ...g solvent to remove built up contaminants and then blow out all pas sages 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 Assembly NOTE Lubricate all O r...

Page 37: ...LX31 41 Electric Work Platform 3 13 MAINTENANCE Section 3 11 Figure 3 15 Hydraulic Manifold Exploded View ...

Page 38: ...usly removed 2 Unplug and reconnect the hydraulic hoses 3 Reconnect the electric cables 4 Fill the tank with clean hydraulic fluid 5 Check the oil level in the hydraulic tank before operating the work platform 6 Operate the pump and check for leaks and proper operation 7 Replenish hydraulic fluid if necessary Brake Valve Block Pump Motors Figure 3 16 Hydraulic Power Unit 3 13 HYDRAULIC BRAKES Remo...

Page 39: ...s critical The brake will not hold if it is exceeded 8 Install gasket 2 9 Install power plate piston assembly 14 19 to housing 1 using capscrews 21 and washers 20 Tighten sequentially one turn at a time to press the two assemblies together Torque cap screws 50 60 ft lbs 68 81 N m Installation 1 Coat output shafts of brake and drive motor with high pressure molybdenum grease and install gasket 22 a...

Page 40: ...s on electric model 2 Tag and disconnect electric cables from motor 3 Remove and save hardware which secures pump motor to pump assembly Installation NOTE Unless otherwise specified torque all fit tings according to Table 3 2 on page 3 26 and Table 3 3 on page 3 26 1 Install motor using original hardware 2 Connect electric cables to motor 3 Connect Anderson connectors or negative termi nals on bat...

Page 41: ...0 nuts and washers from torque hub 14 Remove torque hub IMPORTANT Note position of 90 fitting on torque hub body Hub must be installed with fitting in same position Installation IMPORTANT Hub must be installed with 90 fit ting in same position as when it was removed NOTE Unless otherwise specified torque all fit tings according to Table 3 2 on page 3 26 and Table 3 3 on page 3 26 1 Install torque ...

Page 42: ...g Remove thrust washer from counterbore in cover 4 Remove input gear from planet gears 5 Using a punch remove retaining ring from groove around inside of input gear 6 Lift carrier sub assembly from hub Lift ring gear from hub Remove O ring from counterbore in hub 7 Remove pipe plugs from side of hub body 8 Apply a preload to output shaft to remove retain ing ring Follow steps a b a Place bearing c...

Page 43: ...ssing when hub starts to resist rotating 7 Place spacer onto output shaft so it rests on top of bearing cone Using retaining ring pliers place retaining ring to make sure it is seated 8 Hit the end of output shaft once or twice with a soft face hammer Turn the shaft in both clock wise and counter clockwise directions while hit ting This will seat the bearing cone against the spacer and retaining r...

Page 44: ...g into groove inside input gear Use a soft punch to press the remain ing half of the retaining ring into the groove 8 Insert input gear with large diameter end down into mesh with planet gears 9 Place large thrust washer over input gear so it rests on carrier housing Oil all exposed surfaces inside hub 10 Grease O ring and place into counterbore of cover NOTE O rings may be stretched or squeezed t...

Page 45: ... J Bolt K Stud L Stud M Pipe Plug N Pipe Plug 1 Lip Seal 2 Bearing Cone 3 Bearing Cup 4 Thrust Washer 5 Retaining Ring 6 O ring 2 7 Washer 2 8 Thrust Washer SK91 068570 011 9 Bearing Cup 10 Bearing Cone Repair Kit 068570 010 contains LX31 41 Electric Work Platform 3 21 MAINTENANCE Section 3 16 Figure 3 22 Torque Hub ...

Page 46: ...ylinder Pol ishing is a sign of uneven loading when this occurs the surface should be checked for round ness Cylinders not round within 007 0 18 mm should be replaced Assembly NOTE Unless otherwise specified torque all fit tings according to Table 3 2 on page 3 26 and Table 3 3 on page 3 26 1 Lubricate all components with clean hydraulic fluid NOTE To avoid cutting the seals do not use sharp edged...

Page 47: ...on 1 Align the ends of the cylinder with the mounts on the chassis 2 Install the clevis pins 3 Install the hair pin retainers into the clevis pins at each end of the cylinder 4 Install the hoses noting their orientation mark ings from disassembly 1 Rod Wiper 2 Rod Seal 3 Wear Ring 2 required 4 Retaining Ring 5 Head 6 Backup Ring 7 O ring 8 Locknut 9 O ring 10 Rod Weldment 11 Tube Weldment 12 Pisto...

Page 48: ...E Before installing the cylinder check the pins and bearings for excessive wear Replace if necessary 1 Using a suitable lifting device lower the cylinder into the elevating assembly from the front DO NOT sling the cylinder by the rod end pivot this will cause the cylinder to extend when hoisted 2 Align the pivots and install the pivot pins lower one first then the upper one 3 Install the retaining...

Page 49: ...LX31 41 Electric Work Platform 3 25 MAINTENANCE Section 3 19 NOTES ...

Page 50: ... 5 61 55 60 74 5 81 M18 x 2 50 172 210 233 284 240 294 325 398 7 16 20 51 55 69 74 5 68 75 92 102 M20 x 2 50 247 301 335 408 343 426 465 577 1 2 13 65 72 88 97 5 86 96 116 130 M22 x 2 50 332 404 450 547 472 576 639 780 1 2 20 76 84 103 114 102 112 138 152 M24 x 3 00 423 517 573 700 599 732 812 992 9 16 12 95 105 129 142 127 140 172 190 M27 x 3 00 637 779 863 1055 898 1098 1217 1488 9 16 18 111 123...

Page 51: ... and chassis controls and note all functions that are not operating correctly 2 Narrow the possible causes of the malfunction a Use the troubleshooting guide to determine which components are common to all circuits that are not functioning correctly 3 Identify the problem component a Test components that are common to all cir cuits that are not functioning correctly Remem ber to check wires and te...

Page 52: ... X X X X X X X X Main Fuse F1 X X X Main Fuse F2 X X X Circuit Breaker CB1 X X Circuit Breaker CB2 X X Bi Energy Circuit Breaker CB3 X X Tilt Alarm Diode D1 X X X Lift Diode D2 X X X Down Diode D3 X X X X Down Alarm Diode D4 X Steer Right Diode D5 X Steer Left Diode D6 X Pump Start Diode D7 X X Brake Relay Diode D8 X X X Brake Solenoid Diode D9 X X X Drive Lift Diode D10 X X X Brake Release Relay ...

Page 53: ... Bi Energy Glow Plug Relay R19 Bi Energy Oil Pressure Relay R20 Resistor Pack RES1 X X X X Drive Enable Light Resistor RES2 Joystck Interlock Switch S1 X X X X X Reverse Micro Switch S2 X Forward Micro Switch S3 X Lower Emergency Stop Switch S4 X X X X X X Lift Switch S5 X X Brake Release Switch S6 X X X Drive Switch S7 X X Lift Switch S8 X X X High Low Switch S9 X Platform Down Switches S10 S13 X...

Page 54: ...teer Right Solenoid SOL5 X Steer Left Solenoid SOL6 X Brake Solenoid SOL8 X X X Forward Solenoid SOL9 X Reverse Solenoid SOL10 X Brake Release Solenoid SOL11 X X X Bi Energy Stop Run Solenoid SOL12 Tachometer Generator TG1 TG2 Table 4 1 Trouble Shooting Guide Electrical Schematics Continued COMPONENT F UNCTION L OWER C ONTROLS U PPER C ONTROLS D RIVE F ORWARD D RIVE R EVERSE R AISE P LATFORM L OWE...

Page 55: ... CV2 X Left Brake Cylinder CYL1 X Right Brake Cylinder CYL2 X Lift Cylinder CYL3 X Steering Cylinder CYL4 X X Return Filter F1 X X X X X X Suction Strainer F2 X X X X X X Flow Divider FD1 X X Brake Orifice ORF2 X X Lift Orifice ORF3 X X Hydraulic Pump P1 X X X X X X Hydraulic Pump P2 X X X X X X Main Relief Valve RV1 X X X X Steering Relief Valve RV2 X X Pressure Switch S1 X X Brake Apply Valve V1...

Page 56: ...ats go to step Two 2 If the green L E D lights up and stays on continuously operate machine Note which functions are being used when problem repeats itself Step 2 Disconnect the 17 pin connector from the MOS90 Connect pin Six 6 to a fused battery supply 14 0 VDC minimum and observe the green L E D If flash error stays replace MOS90 If green L E D lights up and remains on continuously check wiring ...

Page 57: ...ation Delay Seconds 1 0 Adjustable from 1 0 sec to 3 0 sec 3 Deceleration Delay Seconds 0 5 Adjustable from 0 5 sec to 3 0 sec 4 Traction Creep 0 Adjustable from 0 to 10 5 Max allowed Speed 65 Adjustable from 5 to 100 6 Cutback Speed 1 20 Adjustable from 5 to 25 7 Cutback Speed 2 75 Adjustable from 20 to 75 8 Pump Current limit Amps 270 Adjustable from 50 amps to 600 amps 9 Cutback1 Plug Current A...

Page 58: ...l or less than 7V for 15mS in drive or contactor coil short circuit Drive inhibited Recycle to neutral to clear NOTE If recycling to neutral does not clear the fault then the fail safe is due to a S C contactor coil and the keyswitch must be recycled and the coil replaced Check power and control wiring for shorts Rectify Replace Controller 1 Flash Power up Fail safe Fault EEPROM data corrupted on ...

Page 59: ... field shorts or leakage Rectify Check for shorts to frame and battery leakage Rectify Replace MOS90 Controller 5 Flashes Direction contactors or line contactor did not close Motor armature or field open circuit Point A not within 6V of B ve within one second of selecting direction Drive inhibited Flashes until fault is cleared when contactor closes Check contactor tips Repair replace Check contac...

Page 60: ...s until fault cleared Check operation of accelerator with test se quence Rectify replace Check pot operation with voltmeter for voltage at minimum setting Adjust as necessary or replace Replace MOS90 Controller 7 Flashes Battery voltage dipped below 14 volts Drive inhibited Turn key switch off and on to clear flash Check battery voltage under load with a voltme ter or calibrator Change charge batt...

Page 61: ...rent limit setting Re set Check mounting and heatsink of controller Rectify Check application is correct Use larger controller Replace MOS90 Controller 10 Flashes Tachometer fault Drive inhibited Recycle key to clear fault Check tachometer wires for opens or shorts Rectify Check output voltage from tachometer using voltmeter Replace Check output voltage from tachometer board using voltmeter Replac...

Page 62: ...source Rectify Check output voltage from tachometer using voltmeter Replace Replace MOS90 Controller 12 Flashes Severe tilt condition with platform raised above 2 meters Vehicle goes into emergency stop forced neutral state and plug brakes to a stop Recycle nuetral to clear fault Use calabrator test mode and check platform up switch and severe tilt switch inputs and wiring Rectify Replace MOS90 Co...

Page 63: ...rection is first selected after power up Recycle keyswitch b Contactor drive S C LED resets itself if short circuit clears c Mosfets did not turn on Recycle direction to neutral to clear fault indication Replace controller 14 Flashes Battery voltage has fallen out of range Traction and pump mode will not be allowed Requires key recycle to clear fualt Check battery voltage under load with a voltme ...

Page 64: ...dband zone Figure 4 2 MOS90 17 Way Connector Pinout Designation MOS90 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Pump Traction Tachometer direction input from tach board 18 Volts rev 0 Volts FWD No connection Height Limit Battery side of direction brake contactors for coil suppression 48 Volts 48 Volt supply to power up controller Tilt 48 Volts when forward is selected 0 Volts in neutral No connect...

Page 65: ...9 10 11 12 13 14 15 16 Battery Negative Supply Tach speed signal to pin 12 of MOS90 Input from tach generator Tach direction signal to pin 2 of MOS90 Input from tach generator Tach generator No connection 48 Volts no over speed condition 0 Volts over speed condition 2 Tach speed signal from tach board 7 5 Volts to 15 volts 0 100 speed in FWD 7 5 Volts to 0 volts 0 100 speed in REV 4 Tach direction...

Page 66: ...4 16 LX31 41 Electric Work Platform TROUBLESHOOTING Section 4 9 ...

Page 67: ...oting Truth Tables in Section 4 They allow understanding of the makeup and functions of the systems for checking tracing and faultfinding during troubleshooting analysis The components that comprise the electrical and hydraulic systems are given a reference designation and are explained as to function and location in the following tables Schematic 5 1 Electrical Schematic 5 2 Hydraulic Schematic 5...

Page 68: ... S19 R17 S21 S18 S7 S8 S9 S17 S5 S6 S16 S10 S11 SEN1 S12 S13 S14 S15 R3 R4 R5 R6 R7 R8 R9 R10 R12 R1 R2 C1 R11 C5 C4 R16 R15 C2 C3 SOL5 ALM2 ALM1 SOL3 SOL2 SOL1 SOL8 SOL6 M1 CB1 CB2 TG2 TG1 MOT1 MOT2 CONT MOT3 MOT4 F1 F2 BAT1 CH1 RES1 D1 D2 D3 D4 D5 D6 D7 D12 D8 D9 D10 D11 D15 SOL11 ...

Page 69: ...tch Power to SOL6 Lower Control Box R9 Pump Start Relay Provide Power to S1 Lower Control Box R10 Brake Relay Switch Power to SOL8 Lower Control Box R11 Brake Release Relay Switch Power to SOL11 Lower Control Box R12 Power Relay Switch Power to All Relays Lower Control Box R15 Brake Release Relay Provide Power to Brake Relay R10 Relay Panel R16 Platform Power Relay Power to Upper Controls Upper Co...

Page 70: ...ake Allow Brakes to Release Quickly and Apply Slowly Brake Valve Block ORF3 Orifice Lift Limit Hydraulic Oil Flow to Lift Cylinder Lift Cylinder P1 P2 Hydraulic Pump Provide Fluid Power for Hydraulic System Chassis RV1 Valve Main Relief Provide Over Pressure Protection for the Main Hydraulic Line Main Valve Block RV2 Valve Steering Relief Provide Over Pressure Protection for the Steering Component...

Page 71: ...LX31 41 Electric Work Platform 5 5 SCHEMATICS Section 5 2 Figure 5 3 Hydraulic Schematic 067446 000 CYL1 CYL2 V1 V2 ORF2 ACC S1 F2 P1 P2 F1 RV1 V5 FD1 RV2 V3 CYL4 CYL3 ORF3 V6 CV2 V4 CV1 ...

Page 72: ...Circuit Breaker 10 AMP 9 Glow Plug Button Bi Energy 10 Start Button Bi Energy 11 Ignition Key Switch Bi Energy 12 Hour Meter 13 Down Alarm 14 Tilt Alarm 15 Panel Assembly 16 Plug Electric a End Bracket b Terminal Block Blue c Terminal Block d Relay DPDT e Relay SPDT f Terminal Block Ground Retainer Catch to be Positioned to the Inside Typical Retainer Installation 3 6 7 10 R16 R17 4 11 1 9 2 8 5 U...

Page 73: ...5 10 Brake Valve Manifold Exploded View DRIVE LIFT 8METER CUTOUT CHARGE TILT UP DOWN DOWNALARM STEERRIGHT STEERLEFT PUMPSTART BRAKE BRAKERELEASE POWER START Relay Numbers R5 RES C5 C4 C C3 C2 F F2 TG TG2 CONT 1 R18 Start Relay 2 R19 Glow Plug Relay 3 R20 Oil Pressure 3 2 1 V3 RV2 RV V4 V5 FD Guage Port Plug Poppet Vale N C 4VDC Poppet Vale N O 4VDC Pressure Switch Pipe Nipple S V2 rake Release V r...

Page 74: ...5 8 LX31 41 Electric Work Platform SCHEMATICS Section 5 4 ...

Page 75: ... 001 6 16 Control Module Assembly LX31 41 067360 001 6 18 Lower Control Box Assembly LX31 41 067362 001 6 22 Controller Assembly 48V LX31 41 067384 001 6 24 Tire Wheel Assembly Front LX31 41 067665 004 6 26 Tire Wheel Assembly Rear LX31 41 068327 000 6 27 Valve Block Assembly LX31 41 067389 000 6 30 Brake Valve Block Assembly LX31 41 068324 002 6 31 Hose Kit Installation LX31 41 067383 000 6 32 Sl...

Page 76: ...29447 099 CABLE 3 COND 16 GA 10 FT 22 029620 002 CONN BUTT 16 14 GA 8 23 063497 001 MERCURY SWITCH 2 24 013919 013 CLAMP 2 25 014996 004 WASHER 1 4 SAE FLAT 4 30 067473 000 SWITCH MOUNT 1 33 015963 099 STRAP MATL 9 201 068776 048 CABLE ASSY X 48 3 8 X 3 8 LUG 2 202 068776 014 CABLE ASSY X 165 3 8 X 3 8 LUG 2 204 068776 012 CABLE ASSY X 150 3 8 X 3 8 LUG 2 206 010154 001 BATTERY TERM COVER 10 210 0...

Page 77: ...Final Assembly 067430 000 Drawing 2 of 2 LX31 41 Electric Work Platform 6 3 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 78: ... ELEC SCHM REF 12 067692 000 CLIP CABLE RETAINER 8 13 020032 001 TEE 4MJ 4MJ 4MJ 1 15 011252 006 SCRW 1 4 20 X 3 4 2 16 011248 004 LOCKNUT 1 4 20 UNC 3 17 065373 006 MAGNET 2 18 065373 005 SWITCH 2 19 067913 000 ALUM SW PAD 1 20 026551 005 RIVET 1 8 X 1 4 GRIP 8 21 029447 099 CABLE 3 COND 16 GA 10 FT 22 029620 002 CONN BUTT 16 14 GA 8 23 063497 001 MERCURY SWITCH 2 24 013919 013 CLAMP 2 25 014996 ...

Page 79: ...Final Assembly 067431 001 Drawing 2 of 2 LX31 41 Electric Work Platform 6 5 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 80: ...ENT 1 4 067879 001 MOTOR COVER 2 5 011253 008 SCR H H C 5 16 X 1 8 6 067935 001 LADDER WELDMENT 1 7 067738 000 SLIDE BLOCK 6 8 067852 000 PIN 4 9 067853 000 PIN 2 10 014996 005 WASHER 5 16 DIA 8 11 066189 000 SPACER 1 4 4 12 067853 001 PIN 2 13 066189 004 SPACER 1 8 8 15 011256 012 SCREW HHC 1 2 13 X 1 1 2 4 16 011256 028 SCREW HHC 1 2 13 X 3 1 2 8 17 014033 032 SCREW HHC 1 2 13 X 4 GR8 8 20 01124...

Page 81: ...Basic Assembly 067354 000 Drawing 1 of 1 LX31 41 Electric Work Platform 6 7 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 82: ...LDMENT 1 4 067879 001 MOTOR COVER 2 5 011253 008 SCR HHC 5 16 X 1 8 6 067935 000 LADDER WELDMENT 1 7 067738 000 SLIDE BLOCK 6 8 067852 000 PIN 4 9 067853 000 PIN 2 10 014996 005 WASHER 5 16 DIA 8 11 066189 000 SPACER 1 4 4 12 067853 001 PIN 2 13 066189 004 SPACER 1 8 8 15 011256 012 SCREW HHC 1 2 13 X 1 1 2 4 16 011256 028 SCREW HHC 1 2 13 X 3 1 2 8 17 014033 032 SCREW HHC 1 2 13 X 4 8 20 011248 0...

Page 83: ...Basic Assembly 067355 000 Drawing 1 of 1 LX31 41 Electric Work Platform 6 9 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 84: ...16 31 011257 028 SCREW HHC 5 8 11 X 3 1 2 2 32 011247 008 NUT 1 2 20UNF HEX ESNA THIN 28 33 011256 024 SCREW HHC 1 2 13 X 3 8 34 011848 050 PIN CLEVIS 1 X 2 3 4 1 35 067746 001 PIN STEERING LINK 2 36 011256 020 SCREW HHC 1 2 13 X 2 1 2 2 37 013315 011 RETAINING E RING 2 38 062889 012 HAIRPIN COTTER 2 39 003495 000 FITTING ELBOW STREET 6MB 6FJ 2 40 011469 005 LUG NUT 9 16 18 10 41 011936 001 FITTIN...

Page 85: ...150 DTE 26 Chassis Assembly 067358 000 Drawing 1 of 1 LX31 41 Electric Work Platform 6 11 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 86: ...20 BEARING 2 ID X 1 1 2 LG 12 11 067606 030 BEARING 3 ID X 1 1 2 LG 16 12 067583 000 PIN WELDMENT 5 13 067580 000 PIN WELDMENT 8 14 067585 000 PIN WELDMENT 1 15 067586 000 PIN CYLINDER 2 16 067635 000 LIFT CYLINDER 1 067635 010 SEAL KIT 17 014033 048 H H C S 1 2 13UNC X 6 GR 8 8 18 014033 032 H H C S 1 2 13UNC X 4 GR 8 6 19 011248 008 HEX LOCK NUT 1 2 13UNC 14 20 067591 000 SUPPORT WELDMENT 1 21 0...

Page 87: ...Scissor Linkage Assembly 067422 001 Drawing 1 of 1 LX31 41 Electric Work Platform 6 13 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 88: ...LG 16 12 067583 000 PIN WELDMENT 11 13 067580 000 PIN WELDMENT 8 14 067585 000 PIN WELDMENT 1 15 067586 000 PIN CYLINDER 2 16 067635 000 LIFT CYLINDER 1 067635 010 SEAL KIT 17 014033 048 H H C S 1 2 13UNC X 7 1 2 GR 8 8 18 014033 032 H H C S 1 2 13UNC X 4 1 2 GR 8 12 19 011248 008 HEX LOCK NUT 1 2 13UNC 20 20 067591 000 SUPPORT WELDMENT 1 21 013336 001 GREASE FITTING 20 22 011941 005 STRAIGHT ADAP...

Page 89: ...Scissor Linkage Assembly 067423 001 Drawing 1 of 1 LX31 41 Electric Work Platform 6 15 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 90: ... 33 011939 024 FITTING 16MP 16MJ 1 34 015959 004 FITTING 12FJX 8MB 2 35 011939 022 FITTING STR 12MJ 16MP 1 36 011982 004 FITTING TEE 12MP 12FP 12FP 1 37 063930 001 BREATHER FILLER CAP 1 38 021305 007 PLUG MAGNETIC 1 40 068712 002 BRACKET 1 41 066516 004 PLUG 4 1 42 010150 005 FITTING BULKHEAD 1 43 011979 008 O RING 1 44 068565 000 ACCUMULATOR 1 45 011252 006 SCREW HHC 1 4 20 X 3 4 2 47 020733 002 ...

Page 91: ...Power Module Assembly 067359 001 Drawing 1 of 1 LX31 41 Electric Work Platform 6 17 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 92: ... 47 068334 010 BATTERY CABLE ASSY X 10 5 48 068332 004 BATTERY CABLE ASSY 1 49 068574 000 CHARGER 1 50 068332 003 BATTERY CABLE ASSY 1 51 067366 000 BATTERY CHARGER BRACKET 1 52 067368 000 RELAY COVER 1 53 011252 012 SCREW HHC 1 4 20UNC X 1 1 2 4 55 029902 002 CONNECTOR HANDLE 1 57 067338 000 RELAY COVER 1 58 062786 004 SCREW SELF TAP 10 3 59 068334 014 CABLE ASSY X 14 2 100 067387 000 PANEL ASSY ...

Page 93: ...Control Module Assembly 067360 001 Drawing 2 of 3 LX31 41 Electric Work Platform 6 19 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 94: ...Control Module Assembly 067360 001 Drawing 3 of 3 6 20 LX31 41 Electric Work Platform ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 95: ... 16 6 18 12 MULTICONDUCTOR FT 62 4 029601 013 CONN RING TERM 16 14 GA 10 2 5 063956 002 PIN CONTACT MALE 20 14 GA 8 6 029610 002 CONN FORK TERM 16 14 GA 8 6 7 029457 099 WIRE 16GA GRN X 12 IN 1 8 029620 002 CONN BUTT 16 14GA 2 9 029616 001 CONN FEMALE PUSH 16 14GA X 188 2 10 029483 099 WIRE 16 GA RD WHT X 14 IN 1 Control Cable Assembly 067536 000 Drawing 1 of 1 ...

Page 96: ...066807 001 ALARM 2 22 014996 004 WASHER 1 4 SAE 2 23 066516 000 PLUG HOLE 2 09 DIA 1 24 064462 029 PLUG 15 16 DIA FLUSH 3 25 064462 002 PLUG 1 2 DIA FLUSH 1 101 029825 002 DIODE 3 AMP 25 102 029610 002 TERMINAL 8 FORK 35 103 029610 003 TERMINAL 6 FORK 31 104 060214 099 WIRE 16 AWG 15 COND FT 2 105 029496 099 CABLE 2 COND 16GA FT 22 106 029447 099 CABLE 3 COND 16GA FT 14 107 005491 099 WIRE 16GA GR...

Page 97: ...Lower Control Box Assembly 067362 001 Drawing 2 of 2 LX31 41 Electric Work Platform 6 23 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 98: ...ING 1 14 063951 003 RELAY 2 15 064443 001 CONTACT BLOCK N O 1 16 064443 002 CONTACT BLOCK N C 1 18 067483 000 CONTROLLER SUPPORT 1 19 067486 000 COVER PLATE CONTROLLER BOX 1 20 068889 099 WEATHERSTRIP 1 2 X 3 16 FOAM 3 FT 21 064462 002 CAPLUG 1 2 DIA 4 22 010952 004 SCREW BUTT HD TORX 10 24UNC X 1 2 6 23 011715 004 SCREW 6 32 X 1 2 4 24 011248 047 LOCKNUT 6 32 4 25 066805 011 CONTACT BLOCK N C 2 2...

Page 99: ...Controller Assembly 48V 067384 001 Drawing 2 of 2 LX31 41 Electric Work Platform 6 25 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 100: ...REAKDOWN Section 6 1 Tire Wheel Assembly Front LX31 41 067665 004 ITEM PART DESCRIPTION QTY 1 067609 001 WHEEL 16 5 X 8 25 8 HOLE 8 BC 1 2 068555 000 TIRE 9 5 X 16 5 NHS 10 PLY 1 3 012282 001 VALVE STEM 1 Tire Wheel Assembly Front 067665 004 Drawing 1 of 1 ...

Page 101: ...BREAKDOWN Section 6 1 Tire Wheel Assembly Rear LX31 41 068327 000 ITEM PART DESCRIPTION QTY 1 068555 000 TIRE 16 5 X 9 50 10 PLY 1 2 067609 000 WHEEL 16 5 X 8 25 6 HOLE ON 6 B C 1 3 012282 001 VALVE STEM 1 Tire Wheel Assembly Rear 067327 000 Drawing 1 of 1 ...

Page 102: ...ABEL MAINT BRACE 1 39 060086 000 SAFETY WALK 20 X 32 12 40 066558 000 LABEL EMERG LOWERING 2 41 068641 003 LABEL PARKING BRAKE 1 Not Shown Label Kit Installation LX41 067361 010 ITEM PART DESCRIPTION QTY 1 010076 000 MANUAL CASE 1 2 010076 001 LABEL ATTENTION 1 3 067449 000 USER MANUAL LX SERIES 1 4 060197 000 LABEL HYDRAULIC FLUID 1 5 061205 000 NAME PLATE 1 6 061220 001 LABEL ANSI 1 7 060577 000...

Page 103: ...Label Kit Installation 067361 009 010 Drawing 1 of 1 LX31 41 Electric Work Platform 6 29 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 104: ...ssembly LX31 41 067389 000 ITEM PART DESCRIPTION QTY 1 067389 005 STEERING SOLENOID 2 2 067389 006 STEERING RELIEF VALVE 1 3 067389 007 LIFT RELIEF VALVE 1 4 067389 008 FLOW CONTROL VALVE 1 5 067389 009 DUMP VALVE 1 6 067389 010 LIFT SOLENOID 1 Valve Block Assembly 067389 000 Drawing 1 of 1 ...

Page 105: ...IFICE CESSNA 815 1 6 063921 010 PRESSURE SWITCH 1 7 011934 003 STR ADAPTER 6MB 6MJ 1 8 011934 026 ELBOW 90ø 4MB 4MJ 1 9 012004 006 PLUG 6 2 10 005135 000 STEEL BALL 5 16 DIA 1 11 013987 009 SPRING 1 4 DIA X 19 32 LG 1 12 012004 004 PLUG 4 SAE 1 13 014021 005 PIPE NIPPLE 1 2 SCH 40 X 2 1 2 LG 1 14 011920 002 PLUG PIPE SOC HD 1 4 18 NPTF 1 15 068798 001 SPRING 3 8 OD 035WIRE X 1 1 4 LG 1 16 011934 0...

Page 106: ... 3 8 HOSE ASSY X 334 6FJX 6FJX 1 4 068745 062 3 8 HOSE ASSY X 62 6FJX 6FJX 1 7 068745 035 3 8 HOSE ASSY X 35 6FJX 6FJX 1 8 068745 023 3 8 HOSE ASSY X 23 1 2 6FJX 6FJX 2 15 067683 109 3 8 HOSE ASSY X 109 6FJX 6FJX45ø 1 16 067683 118 3 8 HOSE ASSY X 118 6FJX 6FJX45ø 1 19 067684 236 3 8 HOSE ASSY X 236 6FJX 6FJX 1 21 065234 093 1 4 HOSE ASSY X 93 4FJX 4FJX 1 22 065234 062 1 4 HOSE ASSY X 62 4FJX 4FJX...

Page 107: ...NC ESNA 34 20 012865 099 LOOM WIRE 3 4 1FT 21 011254 008 SCREW HHC 3 8 16UNC X 1 10 22 011254 014 SCREW HHC 3 8 16UNC X 1 3 4 4 23 011254 006 SCREW HHC 3 8 16UNC X 3 4 8 24 015936 014 SCREW SHOU 3 8 16UNC X 1 3 4 12 25 011254 032 SCREW HHC 3 8 16UNC X 4 4 26 067920 000 SPACER GUARDRAIL 2 27 060086 000 SAFETY WALK 20 X 32 4 28 066557 001 LABEL PLATFORM CAPY 1 29 067867 001 ROLLER BRACKET REAR WELDM...

Page 108: ...Slide Out Deck Installation 067866 001 Drawing 1 of 1 6 34 LX31 41 Electric Work Platform ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 109: ...GHT 12 24 VOLT 2 2 063193 000 LIGHT BRACKET 2 3 029702 000 FUSE HOLDER 1 4 029704 002 FUSE 2 AMP 1 5 029610 002 CONN FORK 16 14 8 1 6 029601 013 CONN RING 16 14 10 1 7 029620 002 CONN BUTT 16 14 4 8 029496 099 WIRE 16 AWG 2 COND 18FT 9 011249 003 NUT HEX ESNA 10 32 4 10 011826 004 SCREW MACH RD HD 10 32 X 1 2 4 Amber Beacon Option 067947 000 Drawing 1 of 1 ...

Page 110: ...1 2 2 011248 004 NUT HEX 1 4 20 2 3 029452 099 WIRE 16 GA BLACK 75FT 4 067902 000 BRACKET GAS SPRING 1 5 029610 002 CONNECTOR FORK 3 6 029601 014 CONNECTOR RING 1 7 029615 002 CONNECTOR PUSH 2 8 029958 001 HORN 24VDC 1 9 063917 000 SWITCH PUSHBUTTON 1 11 011248 005 NUT HEX ESNA 5 16 18 1 12 011253 008 SCREW HHC 5 16 18UNC X 1 1 Horn Option 067908 000 Drawing 1 of 1 ...

Page 111: ...RE WHEEL ASSY FRONT 2 2 068327 003 POLY FILL TIRE WHEEL ASSY REAR 2 067665 005 ITEM PART DESCRIPTION QTY 1 067609 001 WHEEL 16 5 X 8 25 8 HOLE 8 BC 1 2 068555 000 TIRE 9 5 X 16 5 NHS 10 PLY 1 3 012282 001 VALVE STEM 1 068327 003 ITEM PART DESCRIPTION QTY 1 068555 000 TIRE 9 5 X 16 5 10 PLY 1 2 067609 000 WHEEL 16 5 X 8 25 6 HOLE ON 6 8 B C 1 3 012282 001 VALVE STEM 1 ...

Page 112: ...NTACT FEMALE 15 8 030719 001 110 VAC BRACKET 1 10 011254 020 SCREW HHC GRD5 3 8 16UNC X 2 1 2 2 11 011240 006 WASHER 3 8 STD FLAT 4 12 011248 006 NUT HEX ESNA 3 8 16 2 13 068761 000 LOCKING WEDGE CONN 1 14 068760 001 CONNECTOR RECEPTACLE 1 15 068762 000 PIN CONTACT 9 16 068761 001 LOCKING WEDGE CONN 1 17 068760 000 PLUG CONNECTOR 1 18 068762 001 SOCKET CONTACT 9 19 068764 000 PLUG CONNECTOR 6 20 0...

Page 113: ...Removable Controller Option 067898 002 Drawing 2 of 2 LX31 41 Electric Work Platform 6 39 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 114: ...1 003 LABEL DANGER TIPPING 1 17 062562 002 LABEL BATTERY 120 LBS 1 19 066554 000 LABEL READ 1 20 066555 000 LABEL DO NOT ASJUST 2 21 063423 000 LABEL BRAKE RELEASE 1 22 066562 001 LABEL TIRE PSI 75 1 23 061515 000 LABEL LIFT HERE 1 24 066568 000 LABEL WARNING 1 26 101250 008 LABEL MAX LOAD 2000 LBS 2 28 061683 005 LABEL UPRIGHT 4 1 2 3 29 061683 007 LABEL UPRIGHT 5 1 2 4 30 067644 002 LABEL LX31 2...

Page 115: ...LX31 41 Electric Work Platform 6 41 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 116: ...51 003 LABEL DANGER TIPPING 1 17 062562 002 LABEL BATTERY 120 LBS 1 19 066554 000 LABEL READ 1 20 066555 000 LABEL DO NOT ASJUST 2 21 063423 000 LABEL BRAKE RELEASE 1 22 066562 001 LABEL TIRE PSI 75 1 23 061515 000 LABEL LIFT HERE 1 24 066568 000 LABEL WARNING 1 26 101250 008 LABEL MAX LOAD 2000 LBS 2 28 061683 005 LABEL UPRIGHT 4 1 2 3 29 061683 007 LABEL UPRIGHT 5 1 2 4 30 067644 002 LABEL LX31 ...

Page 117: ...LX31 41 Electric Work Platform 6 43 ILLUSTRATED PARTS BREAKDOWN Section 6 1 ...

Page 118: ...6 44 LX31 41 Electric Work Platform ILLUSTRATED PARTS BREAKDOWN Section 6 1 NOTES ...

Page 119: ......

Page 120: ...Call Toll Free in U S A 1 800 926 LIFT 1775 Park Street Selma California 93662 TEL 559 891 5200 FAX 559 891 9012 PARTS 1 888 UR PARTS PARTS FAX 559 896 9244 067448 001 12 99 K ...

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