Upright TM12 Service & Parts Manual Download Page 102

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107099-020
02/00 K

Call Toll Free in U.S.A.

1-800-926-LIFT

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

UpRight International

Support Centre

Innsbruckweg 114

3047 AH Rotterdam

Netherlands

TEL: +31-10-238-0000

FAX: +31-10-238-0001

Parts Tel: +31-10-490-8090

Parts Fax: +31-10-490-8099

Summary of Contents for TM12

Page 1: ...TM12 ...

Page 2: ...e missing the SERIAL NUMBER is also stamped on top of the chassis above the front axle pivot Stamped Serial Number Call Toll Free in U S A 1 800 926 LIFT 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 UpRight International Support Centre Innsbruckweg 114 3047 AH Rotterdam Netherlands TEL 31 10 238 0000 FAX 31 10 238...

Page 3: ...valve block diagram with description and location of components Large sche matic drawings may be located in the back of the manual SECTION 6 ILLUSTRATED PARTS BREAKDOWN Complete parts lists with illustrations Large parts drawings may be located in the back of the manual SPECIAL INFORMATION NOTE Gives helpful information D A N G E R Indicates an imminently hazardous situation which if not avoided w...

Page 4: ...led 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 recommend...

Page 5: ...Steering 2 4 Elevating Platform 2 4 Travel With Platform Elevated 2 5 Lowering Platform 2 5 Emergency Lowering 2 5 Parking Brake Release 2 6 After Use Each Day 2 6 2 4 Transporting Work Platform 2 7 By Forklift 2 7 By Crane 2 7 By Truck 2 7 2 5 Maintenance 2 8 Blocking The Elevating Assembly 2 8 Block Removal 2 8 Battery Maintenance 2 9 Battery Charging 2 9 2 6 Labels 2 10 Label Installation 2 10 ...

Page 6: ...l Equalization 3 8 3 9 Lubrication 3 9 3 10 Hydraulics 3 10 Hydraulic Oil Tank And Filter 3 10 Oil and Filter Replacement 3 10 Hydraulic Pump 3 11 Hydraulic Valve Assemblies 3 12 Cylinder valve Assembly 3 13 Drive Relief Valve Assembly 3 14 Main Hydraulic Manifold 3 15 Setting Hydraulic Manifold Pressures 3 16 3 11 Cylinder Repair 3 18 Removal 3 18 Disassembly 3 18 Assembly 3 18 Installation 3 18 ...

Page 7: ...ents 3 31 Fasteners 3 31 Section 4 Troubleshooting 4 1 Introduction 4 1 General Procedure 4 1 4 2 Cause and Remedy 4 2 Special Tools 4 2 Adjustment Procedures 4 2 Checking Pump Pressures 4 2 4 3 UpRight Motor Controller Diagnostics 4 5 4 4 Measured Voltage at I O Board 4 6 4 5 Electric 4 7 4 6 Hydraulic 4 8 Section 5 Schematics 5 1 Introduction 5 1 Section 6 Illustrated Parts Breakdown 6 1 Introdu...

Page 8: ...s Location 3 5 Figure 3 6 Supporting the Elevating Assembly 3 6 Figure 3 7 Battery Tray 3 7 Figure 3 8 Battery Charger Outlet 3 8 Figure 3 9 Lubrication Points 3 9 Figure 3 10 Hydraulic Oil Tank and Filter 3 10 Figure 3 11 Hydraulic Pump 3 11 Figure 3 12 Cylinder Valve 3 13 Figure 3 13 Drive Relief Valve 3 14 Figure 3 14 Hydraulic Manifold Exploded View 3 15 Figure 3 15 Hydraulic Manifold 3 16 Fig...

Page 9: ...ifications for SAE Fasteners 3 31 Table 3 3 Torque Specifications for Metric Fasteners U S Customary Units 3 32 Table 3 4 Torque Specifications for Metric Fasteners SI Units 3 32 Section 4 Troubleshooting Table 4 1 Cause and Remedy 4 3 Table 4 2 Motor Controller Diagnostics 4 5 Table 4 3 I O Board Voltage 4 6 Table 4 4 Electrical Truth Table 4 7 Table 4 5 Hydraulic Truth Table Model 4 8 ...

Page 10: ...Page VI Table of Contents List of Tables TM12 Work Platform European NOTES ...

Page 11: ...rk platform designed to be used as a means of elevating personnel and equipment and to provide a mobile work platform Mobility with the platform elevated is automatically limited to the low speed range 1 3 PURPOSE AND LIMITATIONS The objective of the Work Platform is to provide a quickly deployable self propelled variable height work platform The elevating function shall only be used when the work...

Page 12: ...roduction 1 4 Specifications TM12 Work Platform European 1 4 SPECIFICATIONS The Specifications Table is located at the end of Section 2 Figure 1 1 TM12 Work Platform 1 Platform 2 Controller 3 Mast 4 Chassis 2 1 3 4 ...

Page 13: ...nts is prohibited After entering the platform always make certain that the midrail is down IT IS PROHIBITED to keep the middrail in an open position held open with tie straps when the platform is raised To extend the height or the range by placing of ladders scaffolds or similar devices on the platform is prohibited NEVER perform service on the machine while the platform is elevated without suppor...

Page 14: ...rd has been disconnected from chassis outlet 6 Check that all guardrails are in place with fasteners properly tightened 7 Inspect the machine thoroughly for cracked welds loose hardware hydraulic leaks dam aged control cable loose wire connections and wheel bolts 8 Move machine if necessary to unobstructed area to allow for full elevation 9 Pull Chassis Emergency Stop Switch to the ON position 10 ...

Page 15: ... Platform Controls 20 PLATFORM CONTROLS Turn the Drive Lift Switch to DRIVE While engaging the Interlock Switch move the Control Handle to FORWARD then REVERSE to check for speed control 21 Push the Steering Switch RIGHT then LEFT to check for steering control 22 Turn the Drive Lift Switch to LIFT Grasp the Con trol Handle engage the Interlock Switch and push it forward to check platform lift cont...

Page 16: ...Engage the Interlock Switch and move the Control Handle to FORWARD or REVERSE to travel in the desired direction The speed of the machine will vary depending on how far from center the Control Handle is moved STEERING 1 Turn the Drive Lift Switch to DRIVE 2 While engaging the Interlock Switch push the Steering Switch to RIGHT or LEFT to turn wheels in the desired direction Observe the tires while ...

Page 17: ... sounds the platform must be lowered and the machine moved to a firm level surface before attempting to re elevate the Platform LOWERING PLATFORM 1 Turn the Drive Lift Switch to LIFT 2 Check around the base of the platform to ensure that no one is in contact with the machine Engage the Interlock Switch and pull back on the Control Handle to lower the platform EMERGENCY LOWERING Figure 2 4 Emergenc...

Page 18: ...chine and before normal operation 1 Tighten the spring compression nut until the spring measures 22 2 cm 22 8 cm 8 9 in length verify that the brake bars have fully engaged the tires before the machine is oper ated AFTER USE EACH DAY 1 Ensure that the platform is fully lowered 2 Park the machine on a firm level surface preferably under cover secure against vandals children and unauthorized operati...

Page 19: ...ecure the work platform to the trans port vehicle with chains or straps of adequate load capacity to the chassis lifting tie down points 3 Open the Emergency Lowering Valve The platform must be in the fully low ered position for transport F o r k l i f t S i d e Lift TieDownPoints Controller Assembly D A N G E R Forklifting is for transporting only See specifications for weight of work platform an...

Page 20: ...section and Chassis just behind the mast assembly 6 Push Chassis Lift Switch to DOWN position and grad ually lower the platform until the second mast section is supported by the block BLOCK REMOVAL 1 Turn and hold the Chassis Key Switch to Chassis Push the Lift Lower Switch to UP and gradually raise the platform until the wood block can be removed 2 Remove the wood block 3 Turn and hold the Chassi...

Page 21: ...um length to charger plug located through cutout at the left side of the chassis 4 Connect an extension cord to properly grounded outlet of proper voltage and frequency 5 The battery charger turns on automatically after a short delay the LED charge indicator will illuminate 6 The battery charger turns off automatically when batteries are fully charged the LED charge indicator will blink indicating...

Page 22: ...00 9 UpRight 2 061683 003 061683 003 061683 003 061683 003 10 WARNING Maximum Load 3 066557 051 066557 301 064910 003 066557 401 11 TM12 2 061684 014 061684 014 061684 014 061684 014 13 ATTENTION Safety Operating Instructions Enclosed 1 010076 001 010076 301 064913 000 010076 401 15 Lower Controls 1 065568 001 065568 301 065568 201 065568 401 17 Reflective Tape XX mm 5 ft 2 Not Used Not Used 06493...

Page 23: ...cifications 2 6 Labels TM12 Work Platform European English French Spanish German 11 10 9 18 1 3 25 23 15 24 21 28 8 18 7 20 13 10 9 11 18 26 25 2 21 6 29 5 25 19 9 17 18 11 7 9 18 17 10 Label descriptions are on the previous page ...

Page 24: ...to be per formed at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures The preventative maintenance table has been designed to be used primarily for machine service and maintenance repair Please photocopy and use the table as a checklist when inspecting the machine for service W A R N I N G Before perf...

Page 25: ...ck chains and sheaves for wear 6m Chassis Check cables for pinch or rubbing points Daily Check welds for cracks Daily Check component mounting for proper torque 6m Lift Cylinder Check for leaks Daily Check for proper torque 6m Entire Unit Perform pre operation inspection Daily Check for and repair collision damage Daily Lubricate 30d Check fasteners for proper torque 6m Check for corrosion remove ...

Page 26: ...ve Speed Platform Lowered 3 65 km h 2 27 mph Platform Raised 0 99 km h 62 mph Energy Source 24V battery pack Four 220 ampere hour 6 Volt batteries min wt 28 12 kg 62 lbs each 4 HP DC electric motor System Voltage 24 VDC Battery Charger 20 AMP 110 220 VAC Hydraulic Tank Capacity 7 2 L 1 9 gal Maximum Hydraulic System Pressure 207 bar 3000 psi Hydraulic Fluid Above 0 C 32 F Below 0 C 32 F Below 17 C...

Page 27: ...dicated 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 TERMINAL BLOCKS Remove wires by inserting a small flat bla...

Page 28: ...Pressure Gauge with Adapter Fittings 0 414 bar 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 3 4 UPRIGHT CONNECTORS UpRight connectors are designed so that connector parts contacts or electrical cables may be replaced without replacing the entire connector Figure 3 1 UpRi...

Page 29: ... Finger UpRight 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 Fin gers aside This will release the grip on the contact 3 Pull the wire and contact out of the connector CRIMPING 1 Strip 6 mm from the wire NOTE Complete crimping instructions are in...

Page 30: ...ction will prevent abnor mal wear and prolong the life of all systems The inspection and maintenance schedule is to be performed at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures The preventative maintenance table in Section 2 has been designed to be used primarily for machine service and maintenan...

Page 31: ...007 000 Batteries 6 Volt 015796 000 Tilt Sensor Assembly 029945 021 Battery Charger 063948 003 Control Valve Assembly 101120 021 Power Unit 101230 000 Control Cable Assembly 107009 000 Drive Relief Valve Assembly 107006 000 Motor Control 065708 001 Dip Switch Settings Dip Switch Settings Fuse 010148 000 Circuit Board 065709 001 Relay 010122 000 Cylinder Valve Assembly 107005 000 Hydraulic Oil Filt...

Page 32: ...ween the 2 Mast and Chassis just behind the Mast Assembly 6 Push Chassis Lift Switch to DOWN position and gradually lower Platform until the 2 Mast is sup ported by the block REMOVAL 1 Push Chassis Lift Switch to UP position and grad ually raise Platform until wood block can be removed 2 Remove block 3 Push Chassis Lift Switch to DOWN position and completely lower Platform W A R N I N G Never perf...

Page 33: ... for broken cable termi nals Clean the batteries when it shows signs of corrosion at the terminals or when electrolyte has overflowed dur ing charging Use a baking soda solu tion to clean the battery taking care not to get the solution inside the cells Rinse thoroughly with clean water Clean battery and cable contact surfaces to a bright metal fin ish whenever a cable is removed W A R N I N G Haza...

Page 34: ...utomatically when bat teries are fully charged the LED charge indicator will blink BATTERY CELL EQUALIZATION The specific gravity of the electrolyte in the bat tery cells should be equalized monthly To do this charge batteries as outlined in Battery Charging After this initial charge check the electrolyte level in all cells and add distilled water as necessary Then turn the charger on for an addit...

Page 35: ...tion TM12 Work Platform European 3 9 LUBRICATION Figure 3 9 Lubrication Points Apply grease to each zerk Apply one or two drops of motor oil to each bearing 1 King Pin Bearings 2 Steering Linkage 3 Wheel Bearings G Grease Oil G 3 1 2 ...

Page 36: ...the drain plug 7 Un thread the suction screen from the tank 8 Wash the suction screen in cleaning solvent and then blow out with clean compressed air 9 Apply a thin film of clean hydraulic oil ISO 46 to the threads and re install the suction screen 10 Un thread the filter from the Control Valve Block 11 Apply a thin film of clean hydraulic oil ISO 46 to the gasket of the replace ment filter 12 Thr...

Page 37: ...e assemblies 2 Loosen the capscrews and remove the pump assembly from the motor INSTALLATION Figure 3 11 Hydraulic Pump 1 Lubricate the pump shaft with gen eral purpose grease and attach the pump to the motor with the cap screws 2 Using a crisscross pattern torque each capscrew a little at a time until all capscrews are torqued to 27 Nm 20 Ft Lbs 3 Unplug and reconnect the hydraulic hoses 4 Check ...

Page 38: ...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 rings before installation to prevent damage to O rings Seat all balls in valve block by lightly tapping on the ball with a b...

Page 39: ...e valve is a 24 Volt DC solenoid mounted on the Cylinder Valve Block CYLINDER VALVE BLOCK The Cylinder Valve Block is located behind the panel on the left side of the machine toward the rear 6 7 8 2 5 4 3 1 1 Valve Block 2 Flow Control Valve 1GPM 3 Solenoid Valve 24 VDC 4 Plug 1 4 18 NPTF 5 Fitting 90 6MB 6MJ 6 Fitting 90 6JX 6MJ 7 Fitting Straight 6MB 6MJ 8 Fitting 90 6MB 4MJ Emergency Down Valve...

Page 40: ...ov able object 3 Install gauge in the gauge port of the hydraulic manifold see Figure 3 15 4 Loosen locknut or remove cover on the Drive Relief Valve and turn adjusting screw counter clockwise two full turns 5 While one person drives the machine forward against the wall slowly turn the Drive Relief Valve adjusting screw clockwise to increase the pressure until the gauge reads 207 bar 3000 psi 6 Ti...

Page 41: ...ol Valve Block 2 Fitting 2 Plug 3 Fitting 4 Plug 4 Fitting Straight 6MB 6MJ 5 Fitting Straight 4MBH 6MJ 6 Fitting 6 Plug 7 Plug Cavity 8 2 way 8 Fitting 8MB 6MJX 9 Relief Valve Steering 103 4 bar 10 Relief Valve Main 206 8 bar 11 Lift Valve 2 Position 4 Way Solenoid with Coil 12 Coil 13 Steering Valve 3 Position 4 Way Solenoid with Coils 14 Counterbalance Valve 15 Fitting Straight 8MB 4MJ 16 17 Pr...

Page 42: ...P position and hold it there 6 Loosen locknut or remove cover on the Lift Relief Valve and slowly turn the adjustment screw clockwise until the plat form begins to rise 7 Release the Chassis Lift Switch 8 Replace the cap or tighten the locknut on the Lift Relief Valve and torque to 8 Nm 6 Ft Lbs 9 Remove the load from the platform W A R N I N G The hydraulic oil may be of sufficient temperature to...

Page 43: ...s sure gauge indicates 83 bar 1200 psi 10 Check the settings by slowly moving the Control Lever FORWARD then REVERSE check ing the gauge to ensure pressures are properly set Re adjust as needed 11 Tighten locknuts on valves to 8 Nm 6 Ft Lbs Remove blocks and lower work platform to ground 12 Reconnect the red Control Cable wire to terminal 9 13 Remove the gauge from the gauge port and re install ca...

Page 44: ...uld be replaced ASSEMBLY NOTE To avoid cutting the seals do not use sharp edged tools during seal replacement After installing seals allow at least one hour for the seals to elastically restore to their original shape before assembling cylinder Torque all hardware to torques according to Table 3 1 Torque Specifications for Hydraulic Components on Page 3 32 unless otherwise specified 1 Lubricate al...

Page 45: ...nings to pre vent foreign material from entering 2 Place a support under the depression guard 3 Remove the cotter pins from the pivot pins 4 Remove the pivot pins while supporting the cyl inder 5 Remove the cylinder REPAIR Reference 3 11 Cylinder Repair on Page 3 18 Depression Cylinder Seal Kit Part Number 065970 011 INSTALLATION Installation is reverse of removal 1 2 3 4 4 2 1 Depression Cylinder...

Page 46: ...der to be lowered 8 Disconnect the hose assem blies and cap the openings to prevent foreign material from entering 9 Remove the cylinder from the chassis INSTALLATION 1 Connect the hose assemblies 2 Install the tension bar pivot through the cylinder clevis and brake actuator and secure with a new cotter pin 3 Install the pivot pin through the cylinder mounting tabs and rear cylinder mount and secu...

Page 47: ...the fittings 3 Operate the steering circuit several times throughout its entire range of travel to expel trapped air and check for leaks Figure 3 19 Brake and Steering Cylinder Seal Kit Part Number 065397 011 REPAIR Reference 3 11 Cylinder Repair on Page 3 18 1 2 3 4 5 10 8 8 9 10 10 10 11 11 11 12 12 14 14 15 13 13 13 15 12 7 6 5 1 Steering Link Right 2 Steering Link Left 3 Bell Crank Weldment 4 ...

Page 48: ...er by lifting up through the top of the mast REPAIR Reference 3 11 Cylinder Repair on Page 3 18 INSTALLATION 1 Attach a suitable hoisting device and sling to the cylinder Carefully lower cylinder through the top of the Mast The flat in the cylinder rod and fitting port at the base of the cylinder face to the rear of the machine 2 Secure the base of the cylinder to the Chassis with the retaining ri...

Page 49: ...mbly and remove the retaining ring at the top of the wheel yoke pivot Remove the drive motor wheel assembly from the machine 8 Remove the locknuts flat washers capscrews and drive motor from the wheel yoke Figure 3 21 Drive Motor Assembly INSTALLATION 1 Position the drive motor in the wheel yoke and secure with capscrews flat washers and locknuts 2 Install the drive motor wheel yoke assembly into ...

Page 50: ...gs 6 Remove the can with the hoisting device 7 Support the inner can with the sling and hoisting device 8 Remove locknuts washers and carriage bolts securing the can to the Chassis 9 Remove the can with the hoisting device Front 12 Rear 11 11 Mast Bearings 2 12 10 14 1 9 3 16 8 5 7 6 8 3 4 13 17 15 1 Inner Can 2 Platform Assy Can 3 Lift Cylinder 4 Upper Cylinder Mount 5 Retaining Ring 6 Velocity F...

Page 51: ...s washers and locknut securing cylinder rod to the upper cylinder mount 6 Pull the inner chains attached to the inner can up and over the inner pulley 7 Using the hoisting device and sling carefully lower the third can over the first two 8 Install the lower mast bearings and chain mount 9 Using the hoisting device and sling carefully lower the Platform Assembly over the three cans 10 Install the l...

Page 52: ...is is level 3 Adjust the three leveling screws until the bubble is centered in the circle on the attached bubble level TEST 1 Raise the platform approxi mately 7 feet 2 meters 2 Support the elevating assembly see 3 7 Supporting Elevating Assembly on Page 3 6 3 Push the level sensor to the side The red LED should turn on and the tilt alarm should sound W A R N I N G Never perform service on the wor...

Page 53: ...tive switches See Section 6 for replacement part numbers Figure 3 24 Upper Controls 12 Pin Connector Lift Drive Selector Switch Lift Drive Selector Switch Emergency Stop Switch Emergency Stop Switch Lever Interlock Boot Steering Rocker Rocker Pin Rocker Steering Right Handle Half Switch Steering Switch Interlock Left Handle Half Boot Handle Hall Effect Device ...

Page 54: ...e left of the Hydraulic tank It is secured to the door with Four carriage bolts 1 4 20UNC x 3 4 Right Side Door 1 2 6 2b 3 7 8 3 1 4 2 4 4b 5 5 1 Hour Meter Voltage Indi cator 2 Mushroom Emergency Stop Switch 2b E Stop Switch Contact 3 Key Chassis Platform Selector Switch 4 Up Down Toggle Switch 4b Boot Switch Cover 5 Circuit Breaker 6 Alarm Dual Tone 7 Connector Cable 3 4 8 Box Weldment ...

Page 55: ...UIT BOARD Figure 3 27 I O Board The above table shows the default dip switch settings on the I O board when the machine leaves the factory Switches three and four work together to determine the optional alarm settings 1 2 3 4 5 6 7 8 TM12 off off off on off off off on MX15 19 off on off on off on off on X 20N on off off on off off off on X20W on on off on off off off on X26 31 on on off on off off...

Page 56: ...onditions then it can be assumed the original problem is external to the motor DISASSEMBLY 1 Remove throw bolts 2 Remove pulley end cover 3 Pull the armature out of the assembly in one swift motion 4 Remove commutator end cover 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 INSPECTION ...

Page 57: ...oper position on armature shaft 5 Set the brushes to final position as shown in Figure 3 28B 6 Place the complete stator down over the vertical armature and into position on the commutator cover 7 The stator assembly must be placed in a definite relationship with the commutator covers in order to obtain a neutral brush setting There is a match mark on both items These two marks must line up exactl...

Page 58: ...2 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 in ...

Page 59: ...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 Clamp Load Tightening Torque...

Page 60: ...Page 3 34 Maintenance 3 18 Torque Specifications TM12 Work Platform European NOTES ...

Page 61: ... vari ous components and systems of the Work Platform 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 which is listed under each machine function which does not operate properly Use the charts on the following pag...

Page 62: ...m and chassis controls to verify that all functions are operating correctly and 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 UpRight Work Platform Flow Meter with Pressure Gauge UpRight P N 067040 000 0 1000 PSI Hydraulic Pressure Gauge with Adapter Fittings UpRight P N 014124 010 0 3000 ...

Page 63: ... continuity Replace if defective 2 Mechanical damage Inspect all steering components Replace damaged parts 3 Steering Valve stuck Inspect Steering Valve If spool is sticking replace 4 Steering Cylinder piston seal leaking Check Steering Cylinder for leakage from one port to another Repair as required 5 Steering Relief Adjust the relief valve if not adjustable replace Work Platform will not steer r...

Page 64: ...t Relay replace if faulty 9 Faulty Controller Check operation of Controller Replace if required 10 Faulty Lift Flow Control Replace Flow Control Platform drifts down after being elevated 1 Emergency Lowering Down Valve partly open or faulty Ensure that the Emergency Lowering Valve is completely closed Replace the valve Platform will not lower Drive function operable 1 Faulty Down Valve Coil Test D...

Page 65: ... and connections Test terminals for source of B Replace the controller 4 Flash Controller senses B at the M2 terminal before engaging the motor start relay B cable routed incorrectly M2 cable making contact with B cable Motor start relay contacts welded closed Check cable routing and connections Test terminals for source of B Replace the motor start relay 5 Flash Controller senses open circuit at ...

Page 66: ...ts Tilt Inactive 0 Volts Tilt Active 3 24 Volt Supply for Alarm Tilt Sensor Lift Down and Depression Mechanism Retract Solenoids 4 24 Volts Below Height Limit 0 Volts Above Height Limit 5 Goes to 0 Volts to Activate Lift Down Solenoid 24 Volts Solenoid OFF 6 Goes to 0 Volts to Activate Depression Mechanism Solenoid 24 Volts Solenoid OFF 7 24 Volts High Speed Active 0 Volts Low Speed Active 8 Batte...

Page 67: ... X X X X X MC Motor Control X X X X X X X X X X X X X MOT Motor X X X X X X X X X X X X X R1 Motor Relay X X X X X X X X X X X X X S1 Chassis Emergency Stop Switch X X X X X X X X X X X X X X X S2 Chassis Lift Switch X X S3 Chassis Key Switch X X X X X X X X X X X X X X X S4 Proximity Switch X X S5 Lift Drive Selector Switch X X X X X S6 Platform Emergency Stop Switch X X X X X X X X X X X X X X X...

Page 68: ... Lift Cylinder X CYL3 Depression Mechanism Cylinders 2 X X CYL4 Break Cylinder X FD Priority Flow Divider X X X X X X X X X FL1 Suction Strainer X X X X X X X X FL2 Return Filter X X X X X X X X MOT Drive Motors 2 X X PMP Pump X X X X X X X X RV1 Main Relief Valve X X X X X X X RV2 Steering Relief Valve X X TNK Tank V1 Steering Right Left Valve X X V2 Lift Valve X V3 Down Emergency Lowering Valve ...

Page 69: ...uth Tables in Section 4 They allow understanding of the makeup and functions of the systems for check ing 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 CONTENTS 5 2 Electric 5 2 Electric Schematic 107016 001 5 2 5 3 Hyd...

Page 70: ...utout Control Module S5 Lift Drive Selector Switch Activates lift or drive functions Platform Controls S6 Platform Emergency Stop Switch Shuts down all machine functions Platform Controls S7 Interlock Switch Safety mechanism for PQ Control Handle Platform Controls S8 PQ Control Handle Proportionally controls the drive and lift functions Platform Controls S9 Platform Steering Switch 2 Control left ...

Page 71: ...Page 5 3 Schematics 5 2 Electric Tm12 Work Platform European S9 S8 S7 S6 S5 S4 SNSR I O MC F2 CHG MOT R1 ALM F1 S3 S2 S1 HM SOL6 SOL5 SOL4 SOL3 SOL2 SOL1 SOL9 SOL8 SOL7 BAT ...

Page 72: ...tric motor left side behind charger RV1 Main Relief Valve Provides pressure protection to pump limits platform load capacity Hydraulic Manifold RV2 Steering Relief Valve Provides pressure protection to pump and steering components when steering Hydraulic Manifold RV3 Drive Relief Valve Provides pressure protection to Pump and Drive components Left side forward of Charger TNK Tank Holds hydraulic o...

Page 73: ...Page 5 5 Schematics 5 3 Hydraulic Tm12 Work Platform European CYL4 CYL3 MOT MOT RV3 V7 V7 V6 V4 V4 CYL3 V5 CV V2 CYL2 V8 V3 ORF ORF CYL1 V1 RV2 FD RV1 FL2 FL1 TNK PMP ...

Page 74: ...Page 5 6 Schematics 5 3 Hydraulic Tm12 Work Platform European NOTES ...

Page 75: ...ssis Assembly 2 of 4 107002 000 6 9 Chassis Assembly 3 of 4 107002 000 6 10 Chassis Assembly 4 of 4 107002 000 6 11 Hose Kit 107011 000 6 12 Control Valve Assembly 101120 021 6 14 Controller Assembly 107010 000 6 15 PQ Controller 065512 000 6 16 Electrical Box Assembly 107008 001 6 17 Level Sensor Wire Assembly 029945 021 6 18 Cylinder Valve Assembly 107005 000 6 19 Drive Relief Valve Assembly 107...

Page 76: ... HHC X 3 4 2 24 026616 008 NIPPLE 1 CHASE 1 25 029939 004 LOCKNUT 1 NPT 1 26 013923 004 SCREW 10 SLFTP X 1 2 4 27 011252 006 SCREW 1 4 20UNC HHC X 3 4 9 28 011829 006 BOLT 1 4 20UNC CARRIAGE X 3 4 8 29 011248 004 LOCKNUT 1 4 20UNC HEX 7 30 011240 004 WASHER 1 4 DIA STD FLAT 6 31 064195 050 BATTERY CABLE ASSY 5 16 5 16 X 50 1 32 062125 016 BATTERY CABLE ASSY 5 16 3 8 X 16 2 33 064195 008 BATTERY CA...

Page 77: ...Page 6 3 Illustrated Parts Breakdown Final Assembly TM12 Work Platform European Drawing 1 of 2 ...

Page 78: ...Page 6 4 Illustrated Parts Breakdown Final Assembly TM12 Work Platform European Drawing 2 0f 2 ...

Page 79: ...Page 6 5 Illustrated Parts Breakdown TM12 Work Platform European NOTES ...

Page 80: ...PLATFORM WELDMENT REF 25 065366 020 SWITCH PROXIMITY ASSY 1 26 013336 011 GREASE ZERK 4 28 011828 010 SCREW 1 4 20 X 1 1 4 FH 2 29 011821 006 SCREW 1 4 20 X 3 4 BH 6 30 012553 012 SCREW 1 4 20UNC SOC HD x 1 1 2 2 31 011979 006 O RING 1 32 011253 004 SCREW 5 16 18UNC HHC X 1 2 6 33 013315 009 RING RETAINING 1 34 011941 009 FITTING STR 8MB 6MJ 2 35 011248 006 LOCKNUT 3 8 16UNC HEX 2 36 011248 008 LO...

Page 81: ...Page 6 7 Illustrated Parts Breakdown Basic Assembly TM12 Work Platform European ...

Page 82: ... 1 33 25 065656 000 WEAR PAD 2 27 065368 000 TACK 2 28 026553 004 RIVET 3 16 X 250 375 GRIP 2 29 014996 010 WASHER 5 8 SAE 2 30 011252 006 SCREW HHC 1 4 20UNC x 3 4 1 31 064397 003 NUT ACORN 10 24 NC 4 32 011709 004 SCREW MRDHD 10 24UNC x 1 2 4 33 026553 008 RIVET 3 16 X 501 625 GRIP 2 34 011256 012 SCREW HHC 1 2 13UNC x 1 1 2 2 35 014066 006 SCREW 1 4 AB x 3 4 6 36 011248 004 NUT HEX 1 4 20 UNC 1...

Page 83: ...4 001 FITTING 90 4MBH 4MJ 2 108 011848 041 PIN 3 4 PIVOT 2 109 011757 010 COTTER PIN RUE RING 3 4 2 110 011753 012 PIN COTTER 1 8 x 1 1 2 2 111 065518 000 STEER LINK LH 1 112 011256 026 SCREW HHC GR5 1 2 13 UNC x 3 1 4 8 113 011248 008 NUT HEX 1 2 13 UNC 8 114 010092 011 WASHER THRUST 1 1 2 3 115 027931 068 BEARING 1 1 2 3 116 065534 000 STEER PIN 4 117 011736 012 ROLL PIN 3 16 DIA x 1 1 2 4 118 0...

Page 84: ...SY 1 211 101230 000 POWER UNIT 1 101230 010 PUMP REF 015797 011 MOTOR ELECTRIC REF 212 107152 000 BRACKET CONTROL VALVE MOUNT 1 213 065395 000 LATCH 1 214 107150 000 PANEL WELDMENT RH 1 216 011252 016 SCREW HHC 1 4 20 X 2 2 217 011934 004 FITTING 90 6MBH 6MJ 1 218 015959 004 FITTING 8MBH 12FJX 1 219 013919 010 CLAMP HOSE 1 220 011829 006 CARRIAGE BOLT 1 4 20 x 3 4 7 221 011240 004 WASHER FLAT STD ...

Page 85: ...Page 6 11 Illustrated Parts Breakdown Chassis Assembly 3 of 4 TM12 Work Platform European Drawing 3 of 4 ...

Page 86: ...1 CIRCUIT BOARD 1 316 065708 001 MOTOR CONTROL 1 317 011252 012 BOLT 1 4 20 UNC X 1 1 2 2 318 011248 004 LOCKNUT 1 4 20 HEX 6 319 011240 004 WASHER 1 4 DIA STD FLAT 8 320 011252 010 SCREW HHC 1 4 20 X 1 1 4 2 321 011252 006 SCREW HHC 1 4 20 X 3 4 4 322 011238 004 WASHER SPLIT LOCK 1 4 2 323 107005 000 CYLINDER VALVE ASSY 1 326 010122 001 RELAY 1 327 011248 005 NUT HEX 5 16 18 2 328 011240 005 WASH...

Page 87: ...1 6FJX 6FJX 1 8 107091 047 HOSE ASSY 3 16 X 47 4FJX 4FJX X 90 1 9 107092 020 HOSE ASSY 1 4 X 20 6FJX 6FJX X 90 2 10 107090 035 HOSE ASSY 1 4 X 35 4FJX 4FJX X 90 1 11 107090 029 HOSE ASSY 1 4 X 29 4FJX 4FJX X 90 1 12 107091 024 HOSE ASSY 3 16 X 24 4FJX 4FJX X 90 1 13 061351 053 HOSE ASSY 1 8 X 27 4FJX 4FJX 1 14 061789 026 HOSE ASSY 3 4 X 26 12FJX 12MP 1 15 068965 018 HOSE ASSY 3 8 x 18 6FJX 6FJX X ...

Page 88: ...Page 6 14 Illustrated Parts Breakdown Hose Kit TM12 Work Platform European ...

Page 89: ...41 009 FITTING 8MB 6MJX 1 9 060390 013 RELIEF VALVE STEERING 1500 PSI 1 10 060390 025 RELIEF VALVE MAIN 3000 PSI 1 11 063923 006 2 POS 4 WAY SOLENOID W COIL 1 12 101120 033 COIL 2 13 064845 000 3 POS 4 WAY SOLENOID W COILS 1 14 101120 035 COUNTERBALANCE VALVE 2 15 011941 008 FITTING STR 8MB 4MJ 1 17 064843 000 FLOW DIVIDER VALVE 1 0 GPM 1 18 063973 001 2 POS POPPET VALVE W COIL 1 19 101120 033 COI...

Page 90: ...000 CONTROLLER WELDMENT 1 3 066805 002 SWITCH SELECTOR 2 POSITION 1 068807 010 KEY NOT SHOWN 1 4 066805 012 CONTACT BLOCK NO NC 1 5 065512 000 CONTROLLER PQ 1 6 066805 011 CONTACT BLOCK 1 7 066805 006 PUSHBUTTON 1 8 063956 003 CONN 12 PIN MATE N LOC 1 9 064462 029 HOLE PLUG 1 14 011826 004 SCREW 10 32 SLFTP X 1 2 6 15 026525 008 SCREW 8 SLFTP ABHWH X 1 4 ITEM PART NO DESCRIPTION QTY ...

Page 91: ...ean PQ Controller 065512 000 ITEM PART NO DESCRIPTION QTY 1 063953 001 CAP RUBBER 1 2 065512 013 ROCKER PIN 1 3 063953 007 SWITCH INTERLOCK 1 4 065512 015 SWITCH STEERING 1 5 065512 016 HANDLE HALF RIGHT 1 6 065512 017 HANDLE HALF LEFT 1 7 065512 018 BOOT HANDLE 1 1 2 4 3 6 7 5 ...

Page 92: ...8582 005 CIRCUIT BREAKER 5 AMP 1 5 012798 000 SWITCH TOGGLE 1 6 029925 001 CONNECTOR CABLE 3 4 1 7 011725 006 SCREW 1 4 20 UNC PAN HD x3 4 1 8 066805 011 SWITCH CONTACT 1 9 011811 004 SCREW 10 32 SELF TAP x 1 2 3 10 066805 006 SWITCH HEAD MUSHROOM 1 11 066807 001 ALARM DUAL TONE 1 12 029959 000 LOW VOLTAGE HOUR METER 1 13 029872 000 BOOT SWITCH COVER 1 14 066805 010 CONTACT BLOCK 2 15 029939 003 L...

Page 93: ... TM12 Work Platform European Level Sensor Wire Assembly 029945 021 ITEM PART NO DESCRIPTION QTY 1 029945 013 LEVEL SENSOR PQ M40000 00005 1 2 067456 000 PLUG 3 CONTACT DT 06 3S 1 3 067456 002 WEDGE W3S PO12 1 4 068762 001 CONTACT SOCKET 3 5 067456 005 BOOT DT3S BT 1 ...

Page 94: ... 2 065545 000 VALVE BLOCK 1 3 063925 002 VALVE SOL 24 VDC 1 4 063924 005 VALVE FLOW CONTROL 1 GPM 1 5 011920 002 PLUG SOC HD 1 4 18 NPTF 1 6 063977 001 PLUG 9mm 1 7 011934 004 FITTING 90 6MB 6MJ 1 11 015919 000 ORIFICE 2 12 011941 005 FITTING STR 6MB 6MJ 1 13 011937 003 FITTING 90 6JX 6MJ 1 14 011934 003 FITTING 90 6MB 4MJ 1 ITEM PART NO DESCRIPTION QTY ...

Page 95: ...k Platform European Drive Relief Valve Assembly 107006 000 ITEM PART NO DESCRIPTION QTY 1 107006 001 VALVE BLOCK 1 2 107006 002 VALVE DRIVE RELIEF 1 3 011934 004 FITTING 90 6MB 6MJ 1 4 011935 003 FITTING 45 6MB 6MJ 1 1 2 3 4 TORQUE DRIVE RELIEF VALVE TO 35 40 FT LBS 47 54 Nm ...

Page 96: ... Work Platform European Hydraulic Tank Assembly 107007 000 ITEM PART NO DESCRIPTION QTY 1 107127 000 TANK WELDMENT 1 3 011939 015 FITTING 8MP 8MJ 1 4 061818 000 SUCTION SCREEN FITTING 1 5 021305 006 PLUG MAGNETIC 1 6 005963 001 FILLER BREATHER 1 7 005963 010 Gasket 1 ...

Page 97: ...ROLLER 1 9 061683 003 LABEL UPRIGHT 2 10 066557 051 LABEL MAX LOAD 225 KG 3 11 061684 014 LABEL TM12 2 12 010076 000 MANUAL CASE 1 13 010076 001 LABEL ATTENTION 1 14 011248 004 NUT ESNA 1 4 20 UNC 4 15 065568 001 LABEL CONTROLS 1 16 060574 020 USER MANUAL 1 18 064444 000 LABEL USA 3 19 062562 001 LABEL BATTERIES 1 20 066550 001 LABEL DANGER 1 21 14222 003 99 LABEL FORK LIFT 2 23 066555 000 LABEL R...

Page 98: ...OLLER 1 9 061683 003 LABEL UPRIGHT 2 10 064910 003 LABEL MAX LOAD 225 KG 3 11 061684 014 LABEL TM12 2 12 010076 000 MANUAL CASE 1 13 064913 000 LABEL ATTENTION 1 14 011248 004 NUT ESNA 1 4 20 UNC 4 15 065568 201 LABEL CONTROLS 1 16 060574 020 USER MANUAL 1 18 064444 000 LABEL USA 3 19 062562 102 LABEL BATTERIES 1 20 066550 200 LABEL DANGER 1 21 064948 000 LABEL FORK LIFT 2 23 066555 200 LABEL RELI...

Page 99: ...OLLER 1 9 061683 003 LABEL UPRIGHT 2 10 066557 301 LABEL MAX LOAD 225 KG 3 11 061684 014 LABEL TM12 2 12 010076 000 MANUAL CASE 1 13 010076 301 LABEL ATTENTION 1 14 011248 004 NUT ESNA 1 4 20 UNC 4 15 065568 301 LABEL CONTROLS 1 16 060574 020 USER MANUAL 1 18 064444 000 LABEL USA 3 19 062562 301 LABEL BATTERIES 1 20 066550 301 LABEL DANGER 1 21 014222 303 LABEL FORK LIFT 2 23 066555 300 LABEL RELI...

Page 100: ...ROLLER 1 9 061683 003 LABEL UPRIGHT 2 10 066557 401 LABEL MAX LOAD 225 KG 3 11 061684 014 LABEL TM12 2 12 010076 000 MANUAL CASE 1 13 010076 401 LABEL ATTENTION 1 14 011248 004 NUT ESNA 1 4 20 UNC 4 15 065568 401 LABEL CONTROLS 1 16 107098 000 USER MANUAL 1 18 064444 000 LABEL USA 3 19 062562 401 LABEL BATTERIES 1 20 066550 401 LABEL DANGER 1 21 014222 403 LABEL FORK LIFT 2 23 066555 400 LABEL REL...

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Page 102: ... Street Selma California 93662 TEL 559 891 5200 FAX 559 891 9012 PARTS 1 888 UR PARTS PARTS FAX 559 896 9244 UpRight International Support Centre Innsbruckweg 114 3047 AH Rotterdam Netherlands TEL 31 10 238 0000 FAX 31 10 238 0001 Parts Tel 31 10 490 8090 Parts Fax 31 10 490 8099 ...

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