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Maintenance

3.17 - Torque Specifications

TL38 Service & Parts

Maintenance

Preventative Maintenance Table Key

Interval

Daily

each shift or every day

50h/30d

every 50 hours or 30 days

250h/6m

every 250 hours or 6 months

500h/1y

every 500 hours or 1 year

1000h/2y

every 1000 hours or 2 years

=Yes/Acceptable

=No/Not Acceptable

=Repaired/Acceptable

Preventative Maintenance Report

Date : _______________________________
Owner : ______________________________
Model No : ____________________________
V.I.N No : _____________________________
Serial No :____________________________
Serviced By :__________________________
Service Interval :________________________

Battery

Check electrolyte level

Daily

System

Check battery cable condition.

Daily

Charge batteries.

Daily

Check specific gravity.

50h/30d

Clean exterior.

250h/6m

Clean terminals.

250h/6m

Hydraulic

Check oil level.

Daily

Oil

Drain and replace oil.

500h/1y

(ISO No.46)

Hydraulic

Wipe clean.

50h/30d

Pump

Check for hose fitting leaks

50h/30d

Check for leaks at mating surfaces. 50h/30d

Check mounting bolts for proper

50h/30d

torque.

Hydraulic

Check for leaks.

Daily

System

Check hose connections.

50h/30d

Check for exterior wear.

50h/30d

Change filter.

250h/6m

Emer.

Open the emergency lowering

Daily

Hydraulic

valves and check for proper

System

operation.

Control

Check switch operation.

Daily

Cable

Check the exterior of cable for

Daily

pinching, binding or cable wear.

Tyres /

Check tyre press. 4.45bar (65psi)

Daily

Wheels

Check for damage.

Daily

Check thread depth.

Daily

Check/torque nuts 100 Nm-74 ft lbs Daily

Platform

Check welds for cracks.

Daily

Deck and

Check condition of floor.

Daily

Guardrails

Check that securing bolts are

Daily

tightened.

Check drop bar on cage entrance. Daily

COMPONENT

INSPECTION OR SERVICES

INTERVAL

Signature of Service Engineer

_____________________________

Slew

Grease slew gear.

50h/30d

System

Check slew motor for leaks and

50h/30d

mounting bolts for proper torque.

Check hardware and fittings for

250h/6m

proper torque.

Slew

Check torque on all bolts, 15 outer 50h/30d

System/

ring and 20 inner ring.

First Post

Retorque to 120 Nm (88 ft lbs).

Elevating

Inspect for structural cracks.

Daily

Assembly

Check hoses for pinch or rubbing

Daily

points.

Check pivot pins for damage.

50h/30d

Check pivot pin retaining rings.

50h/30d

Check elevating assembly for

250h/6m

bending.

Check component mounting for

250h/6m

proper torque.

Check fasteners for proper torque. 250h/6m

Lift

Check cylinder rod for wear.

50h/30d

Cylinders

Check pivot pin retaining rings.

50h/30d

Grease all fittings as section 3.4.

50h/30d

Chassis

Inspect for structural cracks.

Daily

Assembly

Check hoses for pinch or rubbing

Daily

points.

Entire Unit

Function check Emergency stop

Daily

switches at control boxes.

Perform pre-operation inspection.

Daily

Check for and repair collision

Daily

damage.

Lubricate.

50h/30d

Grease all fittings.

50h/30d

Check for corrosion - Remove and 250h/6m

repaint.

Outriggers

Check outrigger cylinders for

Daily

damage.

Check interlock switch function.

Daily

Lubricate.

50h/30d

Grease all fittings.

50h/30d

Tow Hitch

Check coupling for function and

Daily

wear.

Inspect breakaway cable for

Daily

proper attachment.

Grease all fittings as section 3.4.

50h/30d

Road

Check all trailer lights and

Daily

Lights

connecting plug.

Brake

Apply handbrake and check

Daily

function.

Check brake shoes for wear.

50h/30d

Test auto reverse function.

50h/30d

Adjust brake shoes.

50h/30d

Check handbrake and adjust.

250h/6m

Axle/ Hubs

Repack wheel bearings.

1000h/ 2y

COMPONENT

INSPECTION OR SERVICES

INTERVAL

Summary of Contents for TL38

Page 1: ...ERVICE PARTS MANUAL POWERED ACCESS WORK PLATFORM TL38 ...

Page 2: ......

Page 3: ...the MODEL and SERIAL NUMBERS from the equipment nameplate Should the nameplate be missing the SERIAL NUMBER is also stamped on top of the left hand axle mount TL 38 Serial Numbers 1800 Current www upright com The Vigo Centre Washington Tyne Wear NE38 9DA UK Service Parts Manual ...

Page 4: ......

Page 5: ...SECTION 5 SCHEMATICS Schematics and valve block diagram with description and location of components SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations SPECIAL INFORMATION NOTE Gives helpful information D A N G E R Indicates an imminently hazardous situation which if not avoided will result in death or serious injury W A R N I N G Indicates a potentially hazardous situati...

Page 6: ...iled descriptions of standard workshop procedures safety principles and service operations are not included Please note that this manual does contain warnings and cautions against some specific service methods which could cause personal injury or could damage a machine or make it unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommen...

Page 7: ...l floor 1 1m 43 5 inch high guardrails with midrail 152 mm 6 inch toe boards and an entry gravity drop bar at the side of the platform PLATFORM CONTROLLER The platform controller contains the controls to operate the machine It is located at the front of the platform cage A complete explanation of control func tions can be found in Section 2 ELEVATING ASSEMBLY The platform is raised and lowered by ...

Page 8: ... materials to overhead work areas SPECIAL LIMITATIONS Elevating of the work platform is limited to firm level surfaces only Any degree of slope greater than 3 will sound a warning alarm when the machine is elevated D A N G E R The elevating function shall ONLY be used when the work platform is level and on a firm surface The work platform is NOT intended to be used on uneven rough or soft terrain ...

Page 9: ...eck all outriggers are secure and the chassis is levelbefore resuming operation 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 gravity drop bar or other railing components is prohibited Always make certain that the gravity drop bar is closed and securely locked It is prohibited t...

Page 10: ... 4 Controls and Indicators 5 Pre Operation Safety Inspection 6 System Function Inspection 7 Operation 7 Boom Elevate 7 Boom Lower 8 Rotate 8 Telescopic Boom 8 Cage Rotate 9 Emergency Lowering 9 Transporting the Work Platform 10 Hour Meter 10 Maintenance 12 Inspection and Maintenance Schedule 13 Daily Preventative Maintenance Checklist 13 Labels 16 Specifications 17 ...

Page 11: ...achine at all times GENERAL DESCRIPTION Figure 1 TL 38 1 Platform W A R N I N G DO NOT use the maintenance platform without guardrails properly assembled and in place 2 Elevating Assembly 3 Chassis 4 Power Module 5 Control Module 6 Platform Controls 7 Manual Case 8 Chassis Controls 9 Hydraulic Fluid Reservoir 10 Batteries 1 2 3 4 5 6 7 8 9 10 ...

Page 12: ...with the requirements os BS EN 280 2001 If a load equivelent to 90 of safe working load is lifted a fault code 03 will be displayed on the digital display on the platform control box If a load which is greater than the safe working load is present in the basket all machine functions will cease to operate and an acoustic warning will sound In order to return to normal operation a load equal to or l...

Page 13: ...CATORS Figure 2 Controls and Indicators Platform Controls Chassis Controls 1 2 3 4 5 6 7 1 2 3 4 5 1 Emergency stop 2 Telescope 3 Upper Boom 4 Lower Boom 5 Rotate 6 Display 7 Joystick 1 Emergency stop 2 Machine Controls 3 Outrigger Controls 4 Analog Rocker 5 Key Switch ...

Page 14: ...platform fully lowered The hydraulic reservoir is located in the Control Module The fluid level must be between the MIN and MAX lines Add hydraulic fluid if nec essary 3 Check that fluid level in the batteries is correct 4 Verify that batteries are charged 5 Check that A C extension cord has been disconnected from the charger plug 6 Check that all guardrails are in place and all fasteners are prop...

Page 15: ... the Analog Rocker to the Up or Down position ref chassis controls illustration on page 5 7 Open the Emergency Lowering Valve see Figure 3 by pulling the knob out to check for proper opera tion When the platform is lowered release the knob 8 Push the Chassis Emergency Stop Switch to check for proper operation All machine functions should be disabled Twist the Chassis Emergency Stop Switch to resum...

Page 16: ...and the machine will not rotate OPERATING THE JIB 1 Ensure the outriggers are deployed and the machine is level 2 Select jib function button the button will illuminate to confirm selection 3 While engaging the Interlock Switch move the Control Handle forwards or backwards to jib out or jib in 4 If the machine is not level the tilt alarm will sound and the machine will not telescope EMERGENCY LOWER...

Page 17: ...8 Two securing lines Positions 3 4 should also be used when lifting the TL38 Work Platform These are used to maintain the balance of the TL38 but are NOT to be considered as lifting points Position 3 shows the securing line around the Tow Bar where the Cycle Guard Frames meet Position 4 shows the securing line around the First Post This line should be secured below the Boom Rest however care shoul...

Page 18: ...Jockey Wheel 10 The tailboard harness is connected to the vehicle s braking system by means of a 7 Pin Plug 11 Attach the Breakaway Safety Cable to the towing vehicle The TL38 may then be towed If the TL38 is to be transported by other means then it must be securely tied down to the transporting unit at several points Recommended securing points are the four outrigger support members on the Chassi...

Page 19: ...harge the batteries in a well ventilated area Do not charge the batteries when the work platform is near a source of sparks or flames Permanent damage to the batteries will result if the batteries are not immediately recharged after discharging Never leave the battery charger operating for more than two days Never disconnect the cables from the batteries when the charger is operating Keep the char...

Page 20: ...TENANCE TABLE KEY Y Yes Acceptable N No Not Acceptable R Repaired Acceptable PREVENTATIVE MAINTENANCE REPORT Date _______________________________________ Owner _____________________________________ Model No ___________________________________ Serial No ___________________________________ Serviced By _________________________________ COMPONENT INSPECTION OR SERVICES Y N R Battery Check electrolyte ...

Page 21: ...3 6 057385 000 HAZARD TAPE 900mm LONG 8 7 058609 000 DECAL UpRight LOGO 2 8 057339 001 PLASTIC PUSH RIVET 2 9 058838 000 E U NAME PLATE 1 10 058836 000 V I N PLATE 1 11 057416 000 DECAL BEFORE TOWING 1 12 057418 000 DECAL LOCK OUTRIGGER TOWING 2 13 058607 000 DECAL UPPER CONTROL BOX 1 14 058186 000 DECAL ON OFF UPPER CONTROL 1 15 058016 000 DECAL MACHINE GENERAL INSTR 1 16 057392 000 DECAL S W L L...

Page 22: ...ND HAZARD 6 057385 000 HAZARD TAPE 900mm LONG 7 058609 000 DECAL UpRight LOGO 8 057339 001 PLASTIC PUSH RIVET 9 058838 000 E U NAME PLATE 10 058836 000 V I N PLATE 11 057416 000 DECAL BEFORE TOWING 12 057418 000 DECAL LOCK OUTRIGGER TOWING 13 058607 000 DECAL UPPER CONTROL BOX 14 058186 000 DECAL ON OFF UPPER CONTROL 15 058016 000 DECAL MACHINE GENERAL INSTR 16 057392 000 DECAL S W L LARGE CE 17 0...

Page 23: ... x 3 22m 10 4ft x 10 6ft 3 24m x 3 33m 10 6ft x 10 9ft Rotation 370 degrees non continuous 370 degrees non continuous Gross Weight 1468kg 3 237lbs 1468kg 3 237lbs Maximum Towable Speed 83km h 50mph 83km h 50mph Power Source 24V DC 4HP 4 X 6V 220Ah Batteries 24V DC 4HP 4 X 6V 220Ah Batteries System Voltage 24V DC 24V DC Battery Charger 24V 25A 220 110VAC 50 60 Hz 24V 25A 220 110VAC 50 60 Hz Hydraul...

Page 24: ...RE COLOR Indicated by color color First color refers to insulation color and second color indicates stripe If sec ond color is not given there is no stripe 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 rotatin...

Page 25: ...r i e 04 03 2004 4th of March 2004 SPECIAL TOOLS The following is a list of special tools which may be required to perform certain maintenance pro cedures on the work platform 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 Inclinometer ...

Page 26: ...Boss_______________________ 1 1 per Jib Boom Pivot Boss _________________________ 1 2 per Slew Ring______________________________ 2 2 per Jib Cylinder ____________________________ 2 2 per Lower Lift Cylinder ___________________________ 2 2 per Upper Lift Cylinder ___________________________ 2 1 per Towhitch coupling____________________________ 2 Total__________________________________________ 26 G...

Page 27: ...als Clean the battery when it shows signs of corrosion at the terminals or when electrolyte has over flowed during charging Use a baking soda solution to clean the batteries taking care not to get the solution inside the cells Rinse thoroughly with clean water Clean the battery and cable con tact surfaces to a bright metal finish whenever a cable is removed BATTERY CHARGING Figure 3 1 Battery Char...

Page 28: ...ng current will be low four amps as cells are equalizing After equalization the specific gravity of all cells should be checked with a hydrometer The tem perature corrected specific gravity in this state 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 t...

Page 29: ...e on the attached bubble level SLEW CUT OUT LIMIT SWITCH Function The purpose of this limit switch is to prevent the operator from slewing while the lower boom and second post are on or near the towbar thus preventing accidental damage to it It does this by breaking the slew signal from the upper or lower controls while the second post is less than approximately 1 m above the ground Location The s...

Page 30: ...rated Location Between the outrigger pivot plates Adjustment The lever is non adjustable and should be depressed by the outrigger cylinder head when the outriggers are deployed It should be checked for freedom of movement and kept clean from dirt or other contaminants Function This limit switch is activated when the booms are fully stowed and the lower boom is sitting in the boom rest The outrigge...

Page 31: ...ff and the display reads OF If OF is dis played pressing the joystick enable switch turns on the option and On is displayed The options that can be adjusted each individually are AL Motion alarm option Ad Descent alarm option OL Overload option 2H two handed operation option dA Drive assist option LI Lift type option 50 or 38 is displayed Cr Cage Rotate option ECU FAULT CODES The following codes w...

Page 32: ...pper Boom Up Coil fault 54 Upper Boom Down Coil fault 55 Telescope Boom Out Coil fault 56 Telescope Boom In Coil fault 57 Slew Lift CW Coil fault 58 Slew Lift CCW Coil fault 59 Steer Right Coil fault 61 Steer Left Coil fault 62 Level Platform Cage Up Coil fault 63 Level Platform Cage Down Coil fault 66 Drive Forward Coil fault 67 Drive Reverse Coil fault 68 Low Battery fault 71 Rotate Platform Cag...

Page 33: ... Dispose of hydraulic fluid properly contact your local oil recycler 5 Reinstall the drain plug 6 Unscrew the filter from the filter assembly 7 Apply a thin film of clean hydraulic oil ISO 46 to the gasket of the replacement filter 8 Screw the replacement filter onto the filter head until the gasket makes contact then turn the filter 3 4 of a turn further 9 Fill the hydraulic reservoir with ISO 46...

Page 34: ...lockwise two full turns 5 Operate telescope in function switch at lower controls and keep it activated 6 Slowly turn the main relief valve adjusting screw clockwise until the pressure gauge reads 155 Bar pressure 7 Release Telescope in switch 8 Tighten locknut on main relief valve while holding the adjusting screw in position Figure 3 4 Hydraulic Manifold W A R N I N G The hydraulic oil may be of ...

Page 35: ...s 5 Operate slew function from lower controls and rotate elevating assembly through approx 180 degrees until the slew stop prevents further rotation 6 Slowly turn the cross line relief valve adjusting screw clockwise until the pressure gauge reads 50 Bar pressure 7 Now operate the slew function in the opposite direction through approx 360 degrees until the slew stop prevents further rotation 8 Slo...

Page 36: ...compressed air 2 Inspect the manifold for cracks thread damage and scoring where the 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 of each component 4 Replace all parts and O rings found unserviceable ASSEMBLY NOTE Lubricate all O rings before installation to prevent damage to the O rings R...

Page 37: ...ALE 8 FITTING 3 8 1 4 MALE MALE 9 FITTING 3 8 1 4 MALE MALE 10 Blanking Cap 11 Blanking Cap 12 FITTING 3 8 1 4 MALE MALE 13 FITTING 3 8 1 4 MALE MALE 14 Test Port 15 CROSS LINE RELIEF VALVE SLEW 16 CROSS LINE RELIEF VALVE SLEW 17 FITTING 1 2 1 2 MALE MALE 18 FITTING 3 8 3 8 MALE MALE 19 Main Relief Valve 20 Solenoid Valve Slew 21 Solenoid Valve Level 22 Solenoid Valve Telescope 23 Solenoid Valve L...

Page 38: ...ith clean compressed air 2 Inspect the manifold for cracks thread damage and scoring where the 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 of each component 4 Replace all parts and O rings found unserviceable ASSEMBLY NOTE Lubricate all O rings before installation to prevent damage to the...

Page 39: ...3 FITTING 1 4 1 4 MALE MALE BULKHEAD 4 FITTING 1 4 1 4 MALE MALE BULKHEAD 5 FITTING 1 4 1 4 MALE MALE 6 FITTING 1 4 1 4 MALE MALE 7 FITTING 1 4 1 4 MALE MALE 8 FITTING 1 4 1 4 MALE MALE 9 FITTING 1 2 1 2 MALE MALE 10 FITTING 3 8 3 8 MALE MALE 11 SOLENOID VALVE REAR RHS O R 12 SOLENOID VALVE REAR LHS O R 13 SOLENOID VALVE FRONT RHS O R 14 SOLENOID VALVE FRONT LHS O R 15 SOLENOID VALVE ...

Page 40: ... by suitable sup port slings REMOVAL 1 Disconnect both hoses and plug ends to avoid excessive oil spillage Note which hose goes to which port 2 Remove lock plate securing bolt and spring washer from both the rod end pin and body end pin 3 Remove lock plates 4 Hold cage assembly in position and knock out rod end pin and body end pin 5 Remove cylinder INSTALLATION 1 Lift the cylinder into place and ...

Page 41: ...ttach a sling to the second post and to an overhead crane 3 Disconnect the two hoses from the cylinder body and plug Note which hose goes to which port 4 Remove lock plate securing bolt and spring washer from both the rod end pin and body end pin 5 Remove the lock plates 6 Take up the slack on the sling to remove the weight of the booms on the rod end pin 7 Knock the rod end pin out pin out 8 Knoc...

Page 42: ...shed in by hand If the pin and holes are not properly aligned and the pin is forced in the bushings will be damaged 2 Line the Lower Boom Anchor holes up with the cylinder rod hole and insert the rod end pin Note To align the holes use an overhead crane and sling of suitable capacity firmly secured to the second post This should be used to raise and lower the Lower Boom 3 Slide both locking plates...

Page 43: ...latform end and to an overhead crane 3 Disconnect the two hoses from the cylinder body and plug Note which hose goes to which port 4 Remove lock plate securing bolt and spring washer from both the rod end pin and body end pin 5 Remove the lock plates 6 Take up the slack on the sling to remove the weight of the booms on the rod end pin 7 Knock the rod end pin out pin out 8 Knock the body end pin ou...

Page 44: ...end This should be used to raise and lower the Upper Boom 3 Slide both locking plates into the groves on the pins and secure with the bolts and washers 4 Reconnect the hoses to their correct ports 5 Test with weight at rated platform load to check system operation 3 14 HYDRAULIC CYLINDER OUTRIGGER REMOVAL 1 With the booms in the stowed position raise all 4 outriggers 2 Disconnect the hoses from th...

Page 45: ... valve cartridges and overcentre valve cartridges from the cylinder blocks 2 Bend up tab on tab washer if applicable 3 Unscrew end cap and remove from cylinder body with rod and piston 4 Unscrew the piston locknut from the rod and remove the piston head and the end cap Note Some piston locknuts are fitted with a roll pin and grub screw which must be removed before unscrewing the locknut 5 Remove a...

Page 46: ...n and grub screw where applicable 4 Lubricate the entire assembly s seals and slide the piston into the cylinder body 5 Screw end cap onto end of cylinder body 6 Bend down tab on tab washer 7 Insert all cartridge valves and fittings into the cylinder valve block 1 CYLINDER BODY 2 VALVE BODY 3 CARTRIDGE 4 END CAP 5 ROD AND END PIVOT 6 ROD SEAL 7 O RING 8 WIPER 9 PISTON O RING 10 GREASE NIPPLE 11 PI...

Page 47: ...e shaft running free the ammeter should read less than 20 of the nameplate full load current If the motor meets the above conditions then it can be assumed the original problem is external to the motor Figure 3 7 Electric Motor DISASSEMBLY NOTE Do not place the stator ring in any mechanical holding device during the disassembly or assembly operation Permanent distortion or other damage will result...

Page 48: ...0 115 122 950 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 in lbs lb...

Page 49: ...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 Clamp Load Tightening Torque Cla...

Page 50: ...are Daily tightened Check drop bar on cage entrance Daily COMPONENT INSPECTION OR SERVICES INTERVAL Y N R Signature of Service Engineer _____________________________ Slew Grease slew gear 50h 30d System Check slew motor for leaks and 50h 30d mounting bolts for proper torque Check hardware and fittings for 250h 6m proper torque Slew Check torque on all bolts 15 outer 50h 30d System ring and 20 inne...

Page 51: ...Page 3 28 Maintenance 3 17 Torque Specifications TL38 Service Parts NOTES ...

Page 52: ...omponents and systems and help in diagnosing and repair of the machine GENERAL PROCEDURE Thoroughly study hydraulic and electronic schematics in Section 5 Check for loose connections and short circuits Check repair replace each component in the Truth Table that is listed under each machine function that does not operate properly Use the charts on the following pages to help determine the cause of ...

Page 53: ...tion test from both the platform and chassis controls to verify that all functions are operating correctly and that the machine is performing to specified values SPECIAL TOOLS Following is a list of tools which may be required to perform certain maintenance procedures on the TL38 work platforms Flow Meter with Pressure Gauge 0 69 bar 0 1000 psi Hydraulic Pressure Gauge with Adapter Fittings 0 207 ...

Page 54: ...unctionality of controller R eplace if faulty upper controls 4 Blown control fuse Check 7A circuit contrrol fuse R eplace if blown 5 Battery level low Check Battery Voltage Charge if necessary Check for fault code 68 6 Outrigger limit E nsure all four outriggers are deployed and the switches not activated limit switch contacts are closed R eplace switch 1 E mergency E nsure that emergency lowering...

Page 55: ...cy stop button If the fault code is still displayed you may have a faulty upper or lower control box consult the error code list to identify the problem component and replace if necessary For fault codes 51 84 the following procedure should be followed 1 Check the fault code list to identify the problem component 2 Ensure that the wiring harness is connected secure in good condition and fully inta...

Page 56: ...orm Telescope Switch ON at power up 27 Platform Lower Boom Switch ON at power up 28 Platform Upper Boom Switch ON at power up 29 Platform Joystick Enable Switch ON at power up 31 Platform Joystick not in neutral at power up 32 Lower Control Analog Rocker not in neutral at power up 34 Lower Control Rotate Lift Switch ON at power up 36 Lower Control Telescope Switch ON at power up 37 Lower Control L...

Page 57: ...oil fault 63 Level Platform Cage Down Coil fault 66 Drive Forward Coil fault 67 Drive Reverse Coil fault 68 Low Battery fault 71 Rotate Platform Cage Left Coil fault 72 Rotate Platform Cage Right Coil fault 73 Outrigger Enable Coil fault 74 Right Rear Outrigger Up Coil fault 75 Left Rear Outrigger Up Coil fault 76 Right Front Outrigger Up Coil fault 77 Left Front Outrigger Up Coil fault 78 Right F...

Page 58: ...ATICS 5 1 INTRODUCTION This section contains electrical and hydraulic power schematics and associated information for maintenance purposes CONTENTS Schematic J1 Harness 5 2 Schematic J2 Harness 5 3 Electrical Assembly 5 4 Hydraulic Schematic 5 5 ...

Page 59: ...Page 5 2 Schematics 5 1 Introduction TL38 Service Parts ...

Page 60: ...Page 5 3 Schematics 5 1 Introduction TL38 Service Parts ...

Page 61: ...Page 5 4 Schematics 5 1 Introduction TL38 Service Parts ...

Page 62: ...Page 5 5 Schematics 5 1 Introduction TL38 Service Parts ...

Page 63: ...Page 5 6 Schematics 5 1 Introduction TL38 Service Parts Notes ...

Page 64: ...osts Assembly 6 6 Playform Assembly Standard 6 8 Axle Brake Hub Assembly 6 10 Hub Assembly 6 11 Hydraulic Manifold Assembly Main 6 12 Hydraulic Manifold Assembly Outrigger 6 13 Tow Hitch Assembly 6 14 Platform Controls Assembly 6 15 Ground Controls Assembly 6 16 Hydraulic Cylinder Assembly Lower Lift 6 17 Hydraulic Cylinder Assembly Upper Lift 6 18 Hydraulic Cylinder Assembly Jib 6 19 Hydraulic Cy...

Page 65: ...00050 003 4 BRAKE ASSEMBLY 057190 000 1 TAILBOARD ASSEMBLY 058241 000 TOWHITCH ASSEMBLY 058266 000 SLEW GEARBOX ASSEMBLY 500055 000 MAIN MANIFOLD ASSEMBLY 500058 000 OUTRIGGER MANIFOLD BLOCK ASSEMBLY 057104 000 LOWER LIFT CYL ASSEMBLY 500056 000 UPPER LIFT CYL ASSEMBLY 500059 000 JIB CYLINDER ASSEMBLY 500058 000 OUTRIGGER CYLINDER ASSEMBLY 500084 000 MOTOR CONTROL UNIT 500086 001 LOWER CONTROLS 50...

Page 66: ...Page 6 3 Illustrated Parts Breakdown General Assembly TL38 Service Parts ...

Page 67: ... BRAKE CABLE ASSY 2 10 5000505 000 AXLE BRAKE HUB ASSY 1 11 500051 000 WHEEL ASSY 2 500312 000 TYRE 2 500313 000 WHEEL ONLY 2 12 057474 000 WHEEL NUT M12 8 13 500031 000 BATTERY BOX COVER 1 14 057107 000 FILTER ASSY HOUSING 1 15 057375 000 FILTER 1 16 504536 000 PUMP MOTOR 1 17 500032 000 OUTRIGGER WELDMENT 4 18 500033 000 OUTRIGGER FOOTPAD 4 19 500361 000 LIMIT SWITCH O R 4 20 057199 000 PIVOT PI...

Page 68: ...Page 6 5 Illustrated Parts Breakdown Chassis Assembly TL38 Service Parts Chassis Assembly 500001 001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 21 ...

Page 69: ...000 SLEW RING BEARING 1 14 500076 000 FIRST POST COVER 1 15 058056 000 PIN LOCK PLATE 19 056060 020 BOLT M10 X 20mm 19 056021 010 WASHER 10mm 19 16 500055 000 MANIFOLD BLOCK 1 17 500086 000 LOWER CONTROL BOX 1 18 058266 000 SLEW GEAR BOX 1 19 058268 000 SLEW MOTOR 1 20 057034 000 CIRCLIP 5 21 057047 000 BUSHING PLAIN 25mm 8 22 057054 000 BUSHING FLANGED 30mm 16 23 057046 000 BUSHING FLANGED 35mm 6...

Page 70: ...Page 6 7 Illustrated Parts Breakdown Booms Posts Assembly TL38 Service Parts ...

Page 71: ...3 057523 000 MOUNTING BRACKET CONTROLLER 1 4 502543 000 PLATFORM CONTROLLER 1 5 010076 000 DOCUMENT BOX 1 6 501950 000 CAGE BASE 1 7 057190 000 TAILBOARD ASSEMBLY EURO 1 057190 001 TAILBOARD ASSEMBLY USA 1 057190 002 TAILBOARD ASSEMBLY UK IRELAND 1 8 057347 000 LADDER 1 9 058251 000 LATCH LADDER 1 10 501886 000 OVERLOAD DEVICE 1 11 056069 016 M16 WASHER 16 12 503101 040 M16 X 40 HEW SCREW 8 ...

Page 72: ...Page 6 9 Illustrated Parts Breakdown Platform Assembly TL38 Service Parts ...

Page 73: ...00 Item Part Description QTY 1 057077 000 BRAKE CABLE ASSY 2 2 500050 001 WHEEL HUB ASSEMBLY 2 3 500050 004 BRAKE ASSEMBLY RIGHT HAND 1 4 500050 003 BRAKE ASSEMBLY LEFT HAND 1 500050 006 BRAKE SHOE STANDARD 1 500050 005 BRAKE SHOE REVERSING 1 5 057474 000 WHEEL NUT M12 8 6 057471 000 WHEEL STUD M12 8 1 3 2 5 6 2 4 ...

Page 74: ...scription QTY 1 500050 003 LEFT HAND BRAKE ASSEMBLY 1 500050 004 RIGHT HAND BRAKE ASSEMBLY 1 2 058571 000 GREASE SEAL 1 3 057083 000 INNER BEARING 1 4 057084 000 OUTER BEARING 1 5 SPLIT PIN 1 6 AXLE NUT 1 7 057471 000 WHEEL STUD M12 4 8 057474 000 WHEEL NUT M12 4 9 500050 002 DRUM 1 10 057089 000 HUB CAP 1 ...

Page 75: ...E MALE FITTING 1 2 X 1 2 1 2 058722 000 RELIEF VALVE 3 3 057122 000 MALE MALE FITTING 3 8 X 3 8 3 4 057121 000 MALE MALE FITTING 3 8 X 1 4 8 5 500261 002 HANDPUMP 1 6 503351 000 SOLENOID VALVE SLEW 1 7 503352 000 SOLENOID VALVE LEVEL 1 8 503535 000 SOLENOID VALVE TELE 1 9 503354 000 SOLENOID VALVE LIFT 2 1 2 3 4 5 6 7 8 9 9 3 4 4 4 4 4 4 4 3 ...

Page 76: ...Parts Hydraulic Block Outrigger 058180 010 Item Part Description QTY 1 058723 000 SOLENOID VALVE COILS 4 2 058180 001 SOLENOID VALVE COIL 1 3 057123 000 FITTING MALE MALE 3 8 X 1 2 1 4 057122 000 FITTING MALE MALE 3 8 X 3 8 1 5 057358 000 FITTING MALE MALE 1 4 X 1 4 8 1 2 3 4 5 ...

Page 77: ...000 Item Part Description QTY 1 058348 000 COUPLING HEAD EUROPE 1 058349 000 COUPLING HEAD USA 1 2 058790 000 GAITER 1 3 058242 000 JOCKEY WHEEL NOT PART OF TOW HITCH ASSEMBLY 1 4 058787 000 HANDBRAKE ASSEMBLY 1 5 058794 000 SPRING PACK ASSEMBLY 1 6 058746 000 BREAKAWAY SAFETY CABLE 1 1 1 2 1 2 3 4 5 6 ...

Page 78: ...form Controls Assembly Item Part Description QTY 1 502453 000 CIRCUIT BOARD 1 2 501866 000 KEY SWITCH 1 3 501867 000 EMERGENCY STOP BUTTON 1 4 000 DECAL 1 5 501881 000 ENCLOSURE 1 6 501882 000 JOYSTICK 1 7 501882 002 JOYSTICK BOOT 1 8 501882 001 JOYSTICK STEERING BOOT 1 9 501866 001 KEY 1 ...

Page 79: ...BUTTON 1 508033 000 CONTACT BLOCK EM STOP 1 2 502560 000 SOCKET 1 3 503288 000 DECAL 1 4 501866 000 KEY SWITCH 501866 001 FOR THE KEY ALONE 1 5 502539 000 ANALOG ROCKER 1 6 502451 000 ECU 1 7 502561 000 ALARM 1 8 502492 000 MOTOR CONTROLLER 1 9 502489 000 LINE CONTACTOR 1 10 501878 000 FUSE 1 11 501877 000 FUSE BLOCK 1 12 502562 000 SOCKET 1 13 502457 000 CIRCUIT BOARD 1 ...

Page 80: ...wer Lift Cylinder Assembly TL38 Service Parts Lower Lift Cylinder Assembly 057104 000 Item Part Description QTY 1 058887 000 EMERGENCY DOWN VALVE 1 2 058728 000 OVERCENTRE VALVE 1 3 057360 000 SEAL KIT 1 4 058819 000 GREASE NIUPPLE 1 1 2 3 4 ...

Page 81: ...pper Lift Cylinder Assembly TL38 Service Parts Upper Lift Cylinder Assembly 500056 000 Item Part Description QTY 1 058887 000 EMERGENCY DOWN VALVE 1 2 058728 000 OVERCENTRE VALVE 1 3 500056 001 SEAL KIT 1 4 058819 000 GREASE NIPPLE 2 1 2 3 4 ...

Page 82: ...reakdown Jib Cylinder Assembly TL38 Service Parts Jib Cylinder Assembly 500059 000 Item Part Description QTY 1 058925 000 OVERCENTRE VALVE 1 2 058728 000 SINGLE PO CHECK VALVE 1 3 500059 001 SEAL KIT 1 4 058819 000 GREASE NIPPLE 2 ...

Page 83: ... Outrigger Cylinder Assembly TL38 Service Parts Outrigger Cylinder Assembly 500058 000 Item Part Description QTY 1 058925 000 SINGLE PO CHECK VALVE 1 2 058728 000 OVERCENTRE VALVE 1 500058 001 SEAL KIT 1 058819 000 GREASE NIPPLE 2 1 2 3 4 ...

Page 84: ...Page 6 21 Illustrated Parts Breakdown Outrigger Cylinder Assembly TL38 Service Parts NOTES ...

Page 85: ...ECT 1 14 502552 000 HARNESS CHARGER DISCONNECT LINE CON4 1 15 502553 000 HARNESS CHARGER DISCONNECT BATT 1 16 502554 000 HARNESS CHARGER DISCONNECT LINE CON2 1 17 502555 000 LINE CONTACTOR 3 FUSE 1 18 502556 000 LINE CONTACTOR 5 LINE CONTACTOR 3 1 19 502489 000 LINE CONTACTOR 1 20 502557 000 LINE CONTACTOR 2 MOTOR CONT B 1 21 502558 000 LINE CONTACTOR 1 MOTOR CONT ENABLE 1 22 502559 000 LINE CONTA...

Page 86: ...Page 6 23 Illustrated Parts Breakdown Electrical Assembly TL38 Service Parts ...

Page 87: ...E ASSY 1 4 M1T 11350mm B90 BANJO MAIN MANIFOLD TO JIB CYLINDER 2 8 500111 000 HOSE ASSY 1 4 M1T 5350mm B90 B90 MAIN MANIFOLD TO BOOM 2 2 9 500112 000 HOSE ASSY 1 4 M1T 900mm B90 B90 MAIN MANIFOLD TO BOOM 1 2 10 500121 000 HOSE ASSY 1 4 M1T 1040mm B90 1 8 BF SLEW MOTOR DRAIN TO TANK 1 11 500114 000 HOSE ASSY 1 2 M1T 1200mm BF BF RETURN LINE FROM MAIN MANIFOLD TO T JUNCTION 1 12 500115 000 HOSE ASSY...

Page 88: ...Page 6 25 Illustrated Parts Breakdown Hydraulic Assembly TL38 Service Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ...

Page 89: ...SSY COMPLETE 1 4 058261 000 BRAKE INDICATOR LENS 2 5 057327 000 FOG LIGHT LENS 1 6 057334 000 7 PIN PLUG 1 057335 000 7 PIN SOCKET 1 7 058262 000 NUMBER PLATE LIGHT ASSY 2 Tailboard Assembly 057190 001 ANSI Version Item Part Description QTY 1 058260 000 BRAKE INDICATOR ASSY COMPLETE 2 2 058739 000 REFLECTOR 2 3 4 058261 000 BRAKE INDICATOR LENS 5 6 057334 000 7 PIN PLUG 1 057335 000 7 PIN SOCKET 1...

Page 90: ...mbly TL38 Service Parts R H FLASHER FOG LIGHT EARTH L H FLASHER L H TAIL LIGHT STOP LIGHTS L H TAIL LIGHTS NUMBER PLATE L H FLASHER FOG LIGHT EARTH R H FLASHER R H TAIL LIGHT STOP LIGHTS L H TAIL LIGHTS NUMBER PLATE Y BL W GN BN R BLK Y BL W GN BN R BLK ...

Page 91: ...RY 1 29 057426 000 DECAL SAFETY HARNESS 1 30 31 057428 000 DECAL ANSI A92 2 1990 1 32 058538 001 DECAL U S SAFETY HAZARD 1 33 057432 000 DECAL STRUCTURAL DAMAGE 2 34 057424 000 DECAL CRUSH HAZARD 4 35 058761 000 DECAL S W L LARGE ANSI 1 36 057434 000 DECAL GENUINE REPLACEMENTS 1 37 057435 000 DECAL FALL HAZARD 1 38 057422 000 DECAL COLLISION HAZARD BOOM 2 Decal Assembly English CE 500391 003 Item ...

Page 92: ...Page 6 29 Illustrated Parts Breakdown Decal Assembly TL38 Service Parts ...

Page 93: ...VEL 2 34 057417 012 DECAL OUTRIGGER LOWERED 4 35 058992 002 DECAL BOOM LOCK PIN 1 36 057507 001 DECAL EMERGENCY STOP 2 37 057507 007 DECAL MAX SIDE LOAD 1 38 057507 021 DECAL BUBBLE LEVEL 1 39 057507 022 DECAL BEFORE MAINTENANCE 1 40 057507 023 DECAL HYDRAULIC OIL 1 Decal Assembly French CE 500391 001 Item Part Description QTY 1 057507 016 DECAL MACHINE NOT INSULATED 2 2 057507 018 DECAL ACTION ON...

Page 94: ...Page 6 31 Illustrated Parts Breakdown Decal Assembly TL38 Service Parts ...

Page 95: ...Page 6 32 Illustrated Parts Breakdown Decal Assembly TL38 Service Parts NOTES ...

Page 96: ... 443 6600 FAX 1 559 268 2433 www upright com PN 500314 002 Europe TEL 44 0 845 1550 058 FAX 44 0 195 2299 948 Local Distributor Lokaler Vertiebshändler Distributeur local El Distribuidor local Il Distributore locale ...

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