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Upright TM12, Service Manual

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Upright TM12 Service Manual Download Page 55

Section 2 - Service and Repair

Cylinders

107099-002 TM12 Work Platform

Page 2-17

L

I F T

  C

Y L I N D E R

R

EMOVAL

Refer to Figure 2-16: “Elevating Assembly,” on page 2-19 for details.

Figure 2-14: 

Lift Cylinder Seal Kit

1. Fully lower platform.

2. Provide a suitable container to catch the hydraulic 

fluid, then disconnect the hydraulic hose. Immedi-
ately plug hoses to prevent foreign material from 
entering.

3. Remove the adapter from the base of the cylinder, 

inside the chassis.

4. Remove the Emergency Lowering Valve Knob from 

the valve at the base of the cylinder, then remove 
the Emergency Lowering Valve out the access hole 
in the bottom of the chassis.

5. Remove the snap ring at the bottom of the cylinder 

under the chassis.

6. Detach the 6,35 mm (

0.25 in.

) vent line tubing from 

the top of the hydraulic tank, and cut any plastic ties 
that secure the tubing. Plug the end of the tubing to 
prevent contamination.

7. Remove the platform mast cover.

8. Remove the capscrew and locknut securing the cyl-

inder rod to the upper cylinder mount.

9. Attach a suitable hoisting device and sling to the 

cylinder. Carefully lift the cylinder approximately 
0,5 m (

18 in.

) until you can see the vent line tubing 

attached near the top of the cylinder barrel. Detach 
the tubing by depressing the green ring on the fitting 
at the same time you pull firmly on the tube. Plug 
the end of the tube and the fitting to prevent con-
tamination.

10. Raise the cylinder the rest of the way through the top of the mast.

R

EPAIR

Refer to Cylinder Repair in Section 1 - General Information.

I

NSTALLATION

1. Attach a suitable hoisting device and sling to the cylinder. Carefully lower the cylinder through the top of 

the mast until you can reattach the vent line tubing. Simply push the tubing into the fitting until it goes no 
further. Pull firmly to ensure that it is installed correctly. 

2. Lower the cylinder the rest of the way, and secure the cylinder to the chassis with the snap ring.

3. Install capscrew, washers and locknut securing cylinder rod to the upper cylinder mount.

4. Install platform mast cover.

5. Install the Emergency Lowering Valve, Knob and adapter to the base of the lift cylinder.

6. Remove the plug from the hydraulic hose and attach it to the adapter.

7. Attach the vent line to the hydraulic tank.

8. Test with weight at rated platform load to check system operation. Check for leaks

8

11

12

10

9

2

C

A

7

6

5

B

3

4

E

1

D

1. Rod
2. Cylinder Barrel
3. Headcap
4. Piston
5. Ball Bearing, 3/8”
6. Spring
7. Set Screw, Allen Head
8. 90° Fitting
9. Emergency Lowering 

Valve

10. Orifice Spring
11. Orifice, 0.063”
12. Spacer

Seal Kit Includes:

A. Piston Seal
B. Piston Seal

C. Static Seal
D. Rod Seal

E. Rod Wiper

Summary of Contents for TM12

Page 1: ...TM12 Work Platform Serial Numbers 7352 Current Publication Number 107099 002 ...

Page 2: ...t Industrial Park Friel Avenue Nangor Road Dublin 12 Ireland TEL 353 1 620 9300 FAX 353 1 620 9301 When contacting UpRight for service or parts information be sure to include the MODEL and SERIAL NUMBERS from the equipment nameplate Should the nameplate be missing the SERIAL NUMBER is also stamped on top of the chassis near the front axle pivot TM12 Serial Number 7352 to current Stamped Serial Num...

Page 3: ...n may be reproduced stored in retrieval system or transmitted in any form by any means electronic mechani cal photocopying recording or otherwise without the prior written permission of the publisher This includes text figures and tables This manual consists of five 5 parts OPERATOR MANUAL A copy of the Operator Manual that is stored on every UpRight Aerial Work Platform SECTION 1 GENERAL INFORMAT...

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

Page 5: ...le the platform is elevated STOP carefully lower the platform Move the machine to a firm level surface IN CASE OF EMERGENCY push the Emergency Stop Switch to cut power to all machine functions NEVER perform service on the machine while the platform is elevated without blocking the elevating assembly NEVER recharge batteries near sparks or open flame batteries that are being charged emit explosive ...

Page 6: ...el With The Platform Elevated 6 Lowering The Platform 6 Emergency Lowering 7 Parking Brake Release 7 After Use Each Day 7 Transporting the Machine 8 By Crane 8 By Forklift 8 By Truck 8 Maintenance 9 Blocking the Elevating Assembly 9 Installation 9 Removal 9 Hydraulic Fluid 9 Check Hydraulic Fluid 9 Battery Maintenance 10 Battery Charging 11 Daily Inspection and Maintenance Schedule 12 Daily Preven...

Page 7: ...ons before attempting to operate the machine GENERAL DESCRIPTION Figure 1 TM12 Series W A R N I N G DO NOT use the machine if all guardrails are not properly in place and secured with all fasteners properly torqued 1 Platform 2 Entry Chain 3 Elevating Mast 4 Platform Controls 5 Manual Case 6 Electrical Box 7 Hydraulic Reservoir 8 Battery Tray 9 Emergency Down Valve Knob 10 Battery Charger 11 Charg...

Page 8: ...n the chassis door and remove the reservoir cap fluid should be visible on the dipstick Add recommended hydraulic fluid if necessary See Specifications on page 16 3 Check that the fluid level in the batteries is correct See Battery Maintenance on page 10 4 Verify that the batteries are charged 5 Check that the A C extension cord has been disconnected from the chassis outlet 6 Check that all guardr...

Page 9: ...ower the platform by pushing the Chassis Up Down Switch to DOWN and check the operation of the audible lowering alarm 8 Check the Emergency Down Valve for proper operation see Figure 4 a Open the valve by pulling the knob out b Once the platform is fully lowered close the valve by releasing the knob 9 Push the Chassis Emergency Stop Switch in to the OFF position All machine functions should be dis...

Page 10: ... the Interlock Switch push the Steering Switch to RIGHT or LEFT to turn the wheels in the desired direction Observe the tires while maneuvering the machine to ensure proper direction ELEVATING THE PLATFORM 1 Position the Lift Drive Switch to LIFT 2 While depressing the Interlock Switch push Control Handle forward to UP the farther you push the Control Handle the faster the Platform will elevate 3 ...

Page 11: ...ng onto a trailer to transport Figure 5 Parking Brake Release 1 Remove the spring compression nut so the spring is loose and the brake bars are away from the tires 2 The machine will now roll when pushed or pulled After moving the machine and before normal oper ation 1 Replace the spring compression nut and tighten until the spring measures 22 2 cm 22 9 cm 8 in 9 in in length verify that the brake...

Page 12: ... weight of machine and be certain that forklift is of adequate capacity to lift the machine Figure 6 Transporting the Machine Forklift from the side by lifting under the chassis BY TRUCK 1 Maneuver the machine into transport position and chock wheels 2 Secure the machine to the transport vehicle with chains or straps of adequate load capacity attached to the chassis lifting tie down points C A U T...

Page 13: ... one mast 6 Move the Chassis Lift Switch to the DOWN position and gradually lower the work platform until the num ber two mast is supported by the block REMOVAL 1 Push the Chassis Up Down Switch to the UP posi tion and gradually raise platform until the wood block can be removed 2 Remove the block 3 Push the Chassis Up Down Switch to the DOWN position and completely lower the platform HYDRAULIC FL...

Page 14: ...ghing 26 3 kg 58 lbs each Check the battery fluid level daily especially if the machine is being used in a warm dry climate If electrolyte level is lower than 10 mm 3 8 in above the plates add distilled water only DO NOT use tap water with high mineral content as it will shorten battery life Inspect the battery regularly for signs of cracks in the case electrolyte leakage and corrosion of the term...

Page 15: ...n extension cord 1 5 mm 12 gauge minimum conductor diameter 15 m 50 ft maximum length to the charger plug located through a cutout at the left side of the chassis 3 The charger turns on automatically after a short delay There are three LED s to indicate the state of charge cycle The first LED will blink until the batteries reach 50 state of charge and then it will stop blinking and stay ON The sec...

Page 16: ...ance items daily Inspection and maintenance shall be performed by personnel who are trained and familiar with mechanical and electrical procedures W A R N I N G Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to perform maintenance while the platform is elevated The daily preventative mai...

Page 17: ...or pinch or rubbing points Check welds for cracks Control Cable Check the exterior of the cable for pinching binding or wear Controller Check switch operation Drive Motors Check for operation and leaks Elevating Assembly Inspect for external damage dents loose rivets or cracks EmergencyHydraulic System Operate the emergency down valve and check for serviceability Entire Unit Perform pre operation ...

Page 18: ...ERSE CUTOUT CUTOUT EMERGENCY STOP UP DOWN DECK OFF CHASSIS BREAKER CIRCUIT TIP OVER HAZARD DANGER BATTERIES ACT AS COUNTERWEIGHT 60 LBS OR MORE EACH REPLACEMENT BATTERY SHALL WEIGH TIP OVER HAZARDS ELECTROCUTION HAZARD FALL HAZARD slopes or soft ground DO NOT elevate or drive elevated on drop offs DO NOT drive into holes or over lines THIS MACHINE IS NOT INSULATED DO NOT operate within ten feet of...

Page 19: ...Labels 107098 002 TM12 Operator Manual Page 15 Figure 11 Safety Labels Locations ...

Page 20: ...imensions Weight 776 kg 1710 lbs Overall Width 76 cm 30 in Overall Height Lowered 165 cm 65 in Overall Length 1 36 m 53 5 in Drive Speed Platform Lowered 3 65 km h 2 27 mph Platform Raised 0 87 km h 0 54 mph Energy Source 24V battery pack Four 220 ampere hour 6 Volt batteries min wt 26 3 kg 58 lbs each 4 HP DC electric motor System Voltage 24 VDC Battery Charger 20 AMP 220 VAC 50Hz Battery Duty Cy...

Page 21: ...ng 1 16 1 12 Hydraulic Fluid 1 17 1 13 Long Term Storage 1 18 LIST OF FIGURES Figure 1 1 UpRight Connector Kits 1 6 Figure 1 2 UpRight Male Connector 1 6 Figure 1 3 UpRight Female Connector 1 6 Figure 1 4 Locking Finger UpRight Connector 1 7 Figure 1 5 Heavy Duty UpRight Connector 1 7 Figure 1 6 Electric Motor Service 1 10 Figure 1 7 Electric Motor Brushes 1 11 Figure 1 8 Contact Area 1 16 Figure ...

Page 22: ...d damage a machine or make it unsafe Please under stand that these warnings cannot cover all conceivable ways in which service whether or not recom mended by UpRight Inc might be done or of the possible hazardous consequences of each conceivable way nor could UpRight Inc investigate all such ways Anyone using service procedures or tools whether or not recommended by UpRight Inc must satisfy themse...

Page 23: ...5 122 85 90 115 122 950 1050 107 119 16 130 140 176 190 130 140 176 190 1300 1368 147 155 SAE J429 Grade 5 SAE J429 Grade 8 SAE J429 Grade 5 SAE J429 Grade 8 Nominal Thread Size Clamp Load Tightening Torque Clamp Load Tightening Torque Nominal Thread Size Clamp Load Tightening Torque Clamp Load Tightening Torque K 15 K 20 K 15 K 20 K 15 K 20 K 15 K 20 lbs in lbs in lbs lbs in lbs in lbs lbs in lbs...

Page 24: ... 0 49 400 583 4 778 1 57 733 682 2 909 4 27 46 435 617 3 84 8 64 235 853 4 1138 1 75 069 997 2 1329 8 30 56 753 837 9 1117 4 78 509 1159 4 1545 2 91 751 1354 9 1807 0 33 70 208 1140 3 1520 1 97 121 1576 9 2102 8 113 503 1843 9 2457 5 36 82 651 1464 1 1952 3 114 334 2025 3 2700 9 133 620 2367 6 3156 0 8 8 10 9 12 9 Grade 8 8 Grade 10 9 Grade 12 9 Nominal Thread Size Clamp Load Tightening Torque Cla...

Page 25: ...hine 0 69 bar 0 1000 psi Hydraulic Pressure Gauge with Adapter Fittings 0 207 bar 0 3000 psi Hydraulic Pressure Gauge with Adapter Fittings 0 414 bar 0 6000 psi Hydraulic Pressure Gauge with Adapter Fittings Small UpRight Connector Field Kit UpRight P N 030899 000 Large UpRight Connector Field Kit UpRight P N 030898 000 Inclinometer UpRight P N 010199 000 00 MOS90 Calibrator UpRight P N 057128 000...

Page 26: ...cking Wedge from the Male Connector Care should be taken that the Sealing Gasket is not dam aged during this procedure 3 Check all parts for damage Replace all parts which are damaged or worn 4 Replace or re crimp the wires and contacts Refer to Crimping proce dure FEMALE CONNECTOR RECEPTACLE Figure 1 3 UpRight Female Connector 1 Disconnect the male connector plug from the female connector recepta...

Page 27: ... are included in each Field Kit 2 Insert the contact into the crimping tool 3 Insert the stripped wire into the contact Copper strands should be visible in the bleed hole of the contact and no copper strands should be loose outside of the contact barrel 4 Completely close the handles of the crimping tool Release the handles of the crimping tool and remove the crimped contact 5 Inspect the crimped ...

Page 28: ...s seal against internal and external surfaces 3 Wash and dry each component and check for thread damage torn or cracked O rings and proper oper ation 4 Replace parts and O rings found unserviceable ASSEMBLY Refer to the Service and Repair section for assembly drawings and the Parts Manual for illustrated parts breakdowns NOTE Lubricate all O rings before installation to prevent damage to O rings S...

Page 29: ... occurs the surface should be checked for roundness Cylinders not round within 0 18 mm 007 in should be replaced ASSEMBLY Refer to the Service and Repair section for seal kit assembly drawings and the Parts Manual for illustrated parts breakdowns NOTE To avoid cutting the seals do not use sharp edged tools during seal replacement After installing seals allow at least one hour for the seals to elas...

Page 30: ...otor sounds normal go to Step 3 d If the motor sounds noisy it should be taken apart as described in the disassem bly section 3 If the motor turned freely connect an amme ter in the circuit as shown in Figure 1 6A With rated voltage applied and the shaft run ning free the ammeter should read less than 20 of the nameplate full load current If the motor meets the above conditions then it can be assu...

Page 31: ...rmature assembly including bearings and insert the commutator end bearing into the bearing bore NOTE Do not re use bearings which have been removed from the armature shaft Keep the assembly in a vertical position Use extreme care not to damage the armature with bearing pullers New bearings should be installed by pressing the inner race of the bearing onto proper position on the armature shaft 5 Se...

Page 32: ...gen gas or fuel vapors are present Check battery fluid level daily If electrolyte level is lower than 10 mm 3 8 in above plates add distilled water only DO NOT use tap water with high mineral content It will shorten battery life DO NOT overfill Battery acid expands during charging and can overflow Keep terminals and tops of batteries clean The battery and cables should be inspected regularly for s...

Page 33: ...he specific gravity of all cells with a hydrometer The temperature corrected specific gravity of a fully charged battery should be 1 260 If any corrected readings are below 1 230 the batteries containing such cells should be replaced Do not check the specific gravity in a cell to which water has just been added If there is not enough elec trolyte in a fully charged cell to obtain a sample for the ...

Page 34: ... match the AC power source 3 Connect an extension cord that meets or exceeds the charger AC current onto the charger plug 4 Connect the other end of the extension cord to a grounded AC outlet of proper current voltage and fre quency rating 5 The charger turns on automatically after a short delay Table 1 6 illustrates charging indicators Table 1 6 Battery Charging UpRight Electric and BiEnergy Mach...

Page 35: ...m from charger No green Light No hum from charger Not Applicable Charger automatically adjusts to the incoming AC current 063944 001 ONLY Check the fuse inside the switch box replace if bad If the fuse is good the charger has failed All Others Check the AC main circuit breaker and reset if necessary Set the voltage selector switch to the proper voltage Fuse visible on front of charger has failed A...

Page 36: ...the direction of extension and decreased localized pressure at the opposite end MEASURE THE CONTACT AREA Measure the contact area of the contacting sur face tire or outrigger The tire contact area can be determined by placing the loaded tire on a clean surface The tire will leave an imprint from which an area can be determined Figure 1 9 Occupied Surface Area CALCULATE THE LOCALIZED PRESSURE Find ...

Page 37: ...ons Above 10 C 15 F MOBIL DTE 13 M Viscosity Grade ISO 32 High V I similar to SAE 5W 20 Viscosity index 140 Operating Range 18 C to 80 C 4 F to 176 F Reservoir Temperature Ambient Conditions 18 C to 30 C 4 F to 86 F MOBIL DTE 11 M Viscosity Grade ISO 15 Viscosity index 140 Operating Range 35 C to 45 C 30 F to 115 F Reservoir Temperature Ambient Conditions 35 C to 20 C 30 F to 70 F MOBIL EAL ENVIRO...

Page 38: ...s damaged repaint 2 Fill the hydraulic reservoir to operating level IMPORTANT Do not fill the hydraulic reservoir while the platform is elevated 3 Coat exposed portions of cylinder rods with a preservative such as multipurpose grease and wrap with a barrier material 4 Coat all exposed unpainted metal surfaces with preservative 5 Internal Combustion Models Service the engine according to the manufa...

Page 39: ...Right Aerial Work Platform D A N G E R Never perform service on the machine in the elevating assembly area while platform is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing brace TABLE OF CONTENTS 2 1 Supporting Elevating Assembly 2 3 Installation 2 3 Removal 2 3 2 2 Preventative Maintenance 2 4 Preventative Maintenance Chec...

Page 40: ...brication Points 2 7 Figure 2 4 Battery Cables 2 8 Figure 2 5 Hydraulic Tank and Filter 2 9 Figure 2 6 Hydraulic Pump 2 10 Figure 2 7 Cylinder Valve 2 10 Figure 2 8 Hydraulic Manifold Exploded View 2 11 Figure 2 9 Hydraulic Manifold 2 12 Figure 2 10 Depression Cylinder Remove Replace 2 14 Figure 2 11 Brake Cylinder Remove Replace 2 15 Figure 2 12 Steering Cylinder Remove Replace 2 16 Figure 2 13 B...

Page 41: ... Turn the Chassis Key Switch to CHASSIS 4 Move the Chassis Lift Lower Switch to UP and ele vate work platform approximately 1 2 m 4 ft 5 Place a solid 2 x 4 wood block approximately 50 cm 18 in long between the number two mast and chassis just behind the mast assembly and against the number one mast 6 Move the Chassis Lift Switch to the DOWN position and gradually lower the work platform until the...

Page 42: ...egular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechani cal and electrical procedures W A R N I N G Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to enter the scissor assembly to perform maintenance while the platform is elev...

Page 43: ...eck chain tension 1yr Remove and inspect chains 5yr 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...

Page 44: ... Electrical Box Assembly Controller Assembly Hydraulic Reservoir Assembly Batteries 6 Volt Tilt Sensor Assembly Battery Charger Control Valve Assembly Power Unit Control Cable Assembly Motor Control Proximity Switch Dip Switch Settings Dip Switch Settings Fuse Circuit Board Relay Flow Control Valve Assembly Hydraulic Oil Filter ...

Page 45: ...099 002 TM12 Work Platform Page 2 7 2 4 GENERAL LUBRICATION Figure 2 3 Lubrication Points Apply grease to each grease fitting 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 46: ...handling Battery fluid is highly corrosive Thoroughly rinse away any spilled fluid with clean water Always replace batteries with UpRight batteries or manufacturer approved replacements weighing 26 3 kg 58 lbs each Before disconnecting the battery negative lead ensure that all switches are OFF If ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel va...

Page 47: ...install the drain plug 7 Un thread the suction screen from the tank 8 Wash the suction screen in cleaning solvent and then blow it out with clean compressed air 9 Apply a thin film of clean hydraulic fluid ISO 46 to the threads and re install the suction screen 10 Un thread the filter from the filter head 11 Apply a thin film of clean hydraulic fluid ISO 46 to the gasket of the replacement filter ...

Page 48: ...crisscross pattern torque each capscrew a little at a time until all capscrews are torqued to 27 N m 20 ft lbs 3 Unplug and reconnect the hydraulic hoses 4 Check the fluid level in the hydraulic tank before operating the machine LIFT CYLINDER VALVE ASSEMBLY EMERGENCY DOWN VALVE The Emergency Down Valve Knob is located at the front of the machine The valve is a 24 Volt DC sole noid mounted on the b...

Page 49: ...aight 6MB 6MJ 5 Fitting Straight 4MB 6MJ 6 Fitting 6 Plug 7 Plug Cavity 8 2 way 8 Fitting 8MB 6MJ 9 Relief Valve Steering 103 4 bar 1500 psi 10 Relief Valve Main 206 8 bar 3000 psi 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 Fitting 4MB 4MJ with orifice 0 079 mm 0 031 in 17 P...

Page 50: ...Hydraulic Manifold 1 Operate the hydraulic system 10 to 15 min utes to warm the fluid 2 Remove the cap or loosen the locknut on the main relief valve 3 Install a 0 207 bar 0 3000 psi pressure gauge to the gauge port 4 Turn the Chassis Keyswitch to CHASSIS and elevate the machine fully 5 While holding the Chassis Lift Switch to the UP position adjust the Main relief valve until the pressure gauge r...

Page 51: ...rbalance valve by turning the adjustment screw until the pressure gauge indi cates 83 bar 1200 psi 10 Check the settings by slowly moving the Control Handle to FORWARD then to REVERSE checking the gauge to ensure pressures are properly set Re adjust as needed 11 Tighten the locknuts on the valves to 8 N m 6 ft lbs Remove the blocks and lower the machine to the surface 12 Remove the gauge from the ...

Page 52: ...gs and immediately cap the openings to prevent foreign material from entering 2 Place a support under the depres sion guard 3 Remove the cotter pins from the pivot pins 4 Remove the pivot pins while sup porting the cylinder 5 Remove the cylinder REPAIR Refer to Cylinder Repair in Section 1 General Information INSTALLATION Installation is reverse of removal 1 2 3 4 4 2 1 Depression Cylinder 2 Pivot...

Page 53: ...ssemblies and cap the openings to prevent foreign material from entering 9 Remove the cylinder from the chassis REPAIR Refer to Cylinder Repair in Section 1 General Information 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 ...

Page 54: ... and secure with new cotter pins 2 Connect the hose assemblies to the fittings 3 Operate the steering circuit several times throughout its entire range of travel to expel trapped air and check for leaks Figure 2 13 Brake and Steering Cylinder Seal Kit 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 Steering...

Page 55: ...etach the tubing by depressing the green ring on the fitting at the same time you pull firmly on the tube Plug the end of the tube and the fitting to prevent con tamination 10 Raise the cylinder the rest of the way through the top of the mast REPAIR Refer to Cylinder Repair in Section 1 General Information INSTALLATION 1 Attach a suitable hoisting device and sling to the cylinder Carefully lower t...

Page 56: ... yoke pivot Remove the drive motor wheel assembly from the machine 7 Remove the locknuts flat washers capscrews and drive motor from the wheel yoke Figure 2 15 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 the pivot bearing along with the lower thrust washer thrus...

Page 57: ...om the assembly Figure 2 16 Elevating Assembly Front 12 Rear 11 Mast Bearings 4 12 12 18 18 18 16 16 5 6 3 2 1 22 23 20 3 15 14 13 17 10b 2 1 7 8 11 11 19 16 16 10b 9 9 9 10a 10b 9 21 10a 1 Base Mast 2 First Inner Mast 3 Second Inner Mast 4 Platform Mast 5 Platform Mast Cover 6 Controller Cover 7 Controller 8 Chain Inspection Cover 9 Inner Chain Anchor 10a Outer Chain Anchor 10b Outer Chain Inner ...

Page 58: ...fer to Figure 2 16 Elevating Assembly on page 2 19 At the same time as the chain lubrication task inspect all elevating assembly components for wear With the platform in the stowed position inspect the system through the platform mast cover 5 to look for worn pulleys 13 15 or damaged components Inspect the chain anchors 10a 10b and visible portions of lift chain as you lubricate it Look for cracks...

Page 59: ... in the inner set should be within 20 of each other IMPORTANT If the readings are not within 20 then a problem exists that is causing unequal chain tension Investigate the problem and repair or replace the worn components CHAIN ELONGATION INSPECTION Figure 2 17 Chain Elongation Inspection At five year intervals the chains should be removed from the mast and the entire length of the chain inspected...

Page 60: ...ring 10 The upper chain set may now be removed by detaching the upper chain inner pulley mounts from the first inner mast section 2 Carefully set the chain set aside on a clean surface 11 Remove the single bolt that attaches the cylinder to the upper cylinder mount 17 12 Using a suitable hoisting device carefully raise the first inner mast section 2 up several inches 13 Lay the remaining chain set...

Page 61: ...working properly there is one red LED under the sensor If the LED is on the sensor is off level Figure 2 18 Tilt Sensor ADJUSTMENT 1 Place machine on a firm level surface 2 Use an inclinometer to ensure that the chas sis is level front to rear and side to side 3 Adjust the three leveling screws until the bub ble is centered in the circle on the attached bubble level TEST 1 Raise the platform appro...

Page 62: ...multimeter should read no continuity 5 Remove the elevating assembly support and fully lower the work platform The switch should be CLOSED and the multimeter should read continuity If the multimeter reads no continuity replace the switch 6 Support the elevating assembly see Supporting Elevating Assembly on page 2 3 7 Install the top cover to the chassis 8 Remove the elevating assembly support and ...

Page 63: ...efective switches See the Parts Manual for replacement part numbers Figure 2 20 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 64: ...or to the 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 Indicator 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 65: ... in diagnosing and repair of the machine W A R N I N G When troubleshooting ensure that the work platform is resting on a firm level surface When performing any service which requires the platform to be raised the Elevating Assembly must be blocked Disconnect the battery when replacing or testing the continuity of any electrical component TABLE OF CONTENTS 3 1 Technical Support 2 3 3 2 General Pro...

Page 66: ...3 3 I O Board 2 5 Figure 3 4 Motor Controller 2 6 Figure 3 5 I O Board 2 7 LIST OF TABLES Table 3 1 LED Fault Codes 2 6 Table 3 2 Connector J1 2 8 Table 3 3 Connector J2 2 9 Table 3 4 Connector J3 2 9 Table 3 5 Connector J4 2 10 Table 3 6 Connector J5 2 10 Table 3 7 Electrical Troubleshooting Table 2 11 Table 3 8 Hydraulic Troubleshooting Table 2 12 ...

Page 67: ...is controls and note all functions that are not operating correctly 2 Narrow the possible causes of the malfunction Use the troubleshooting guide to determine which com ponents are common to all circuits that are not functioning correctly To aid in troubleshooting the letters following the component on the table are the same as the component s designation on the schematics 3 Identify the problem c...

Page 68: ...d creep speed If the machine does not operate at the specified speed at the default settings use the following table to adjust the dip switch settings DECELERATION TIME Switches 5 6 determine the deceleration time Switch 5 is for the deceleration rate while the platform is lowered Switch 6 is for the elevated rate 1 2 3 4 5 6 7 8 MX15 19 OFF ON OFF ON OFF ON OFF ON SL20 ON OFF OFF ON OFF ON OFF ON...

Page 69: ...onal alarm settings 1 2 3 4 MX15 19 OFF OFF OFF OFF SL20 OFF OFF OFF OFF TM12 OFF OFF OFF OFF X20N OFF OFF OFF OFF X20W OFF OFF OFF OFF X26 32 OFF OFF OFF OFF 1 2 3 4 RESULT ON Two Speed Mode not used OFF Proportional Control ON not used OFF Depression Mechanism extends when platform is raised OFF OFF Down alarm only ON OFF Down and Reverse alarm OFF ON Drive and Down alarm ON ON All Motion alarm ...

Page 70: ...e motor M2 cable in contact with B cable Short circuit within controller Check cable routing 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 termin...

Page 71: ...o the OFF position then to either Platform or Chassis 3 Pull both E Stop switches to the ON position The Green LED should be ON The Red LED should be OFF 4 Perform all machine functions until the Red LED is ON Determine which function activated the Red LED and check all components that are active for that function Figure 3 5 I O Board 1 2 3 4 8 7 6 5 1 2 3 4 8 7 6 5 1 2 3 4 12 11 10 9 5 6 8 7 1 2 ...

Page 72: ...or J1 PIN PIN DESCRIPTION CONDITION VOLTAGE CONTINUOUS TO PIN J1 1 Lift input from Lift Drive selector switch Lift selected BV Lift not selected 0V J1 2 Not Used J1 3 Drive input from Lift Drive selector switch Drive selected BV Drive not selected 0V J1 4 Lower E Stop activation output from I O board when lower E Stop is closed Lower E Stop closed BV J4 9 Lower E Stop open 0V J1 5 Upper E Stop act...

Page 73: ...uested 0V Steer Right not requested BV PIN PIN DESCRIPTION CONDITION VOLTAGE CONTINUOUS TO PIN J3 1 Alarm activation Alarm sounding out of level unit lowering etc If the alarm is sounding because the unit is out of level BV will drop to 0V as long as the alarm is sounding If the alarm is sounding because the unit is lowering there will be alternating high and low voltages the voltages will vary J3...

Page 74: ...d BV J1 4 Lower E Stop open 0V J4 10 Power output to Platform Controls Platform selected at Keyswitch BV J1 6 Platform not selected at Keyswitch 0V J4 11 Battery negative supply to I O Board B J4 12 24 Volt supply to Hourmeter and Line Contactor coil Upper Lower E Stops closed and Platform Controls or Chassis Controls selected BV PIN PIN DESCRIPTION CONDITION VOLTAGE CONTINUOUS TO PIN J5 1 24 Volt...

Page 75: ... X X X X X Motor Control MC X X X X X X X X X X X X Motor MOT X X X X X X X X X X Motor Relay R1 X X X X X X X X X X Chassis Emergency Stop Switch S1 X X X X X X X X X X X X X X Chassis Lift Switch S2 X X Chassis Key Switch S3 X X X X X X X X X X X X X X Lift Drive Selector Switch S4 X X X X X Platform Down Switch S5 X Platform Emergency Stop Switch S6 X X X X X X X X X X X X X X Interlock Switch ...

Page 76: ...X Depression Mechanism Cylinder CYL3 X X Brake Cylinder CYL5 X Priority Flow Divider DVDR X X X X X X X X X Suction Strainer FL1 X X X X X X X X Return Filter FL2 X X X X X X X X Drive Motors 2 MOT X X Pump PMP X X X X X X X X Main Relief Valve RV3 X X X X X X X Steering Relief Valve RV1 X X Lift Relief Valve RV2 X Orofice OR X X Tank TNK Steering Right Left Valve V1 X X Lift Valve V2A X Down Emer...

Page 77: ...the Troubleshooting Truth Tables in Section 3 They allow under standing 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 TABLE OF CONTENTS 4 1 Electric Schematic 4 2 ...

Page 78: ...gh speed cutout Chassis 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 le...

Page 79: ...Section 4 Schematics Electric Schematic 107099 002 TM12 Work Platform Page 4 3 HM S1 S2 S3 ALM MOT BAT CHG SNSR SOL7 SOL8 SOL9 SOL1 SOL2 SOL3 SOL4 SOL5 SOL6 S4 S9 S8 S7 S6 S5 MC I O F1 R1 F2 ...

Page 80: ...t Motor Mounts ORF Down Orifice Control descent rate Lift Cylinder PMP Pump Provides hydraulic pressure for all functions On Electric motor left side behind charger RV1 Main Relief Valve Provides pressure protection to pump Hydraulic Manifold RV2 Steering Relief Valve Provides pressure protection to pump and steering components when steering Hydraulic Manifold TNK Tank Holds hydraulic oil Right Si...

Page 81: ...Section 4 Schematics Hydraulic Schematic 107099 002 TM12 Work Platform Page 4 5 CYL4 CYL3 MOT MOT V7 V7 V6 V4 V4 CYL3 V5 CV V2 CYL2 V3 ORF FC CYL1 V1 RV2 FD RV1 FL2 FL1 TNK PMP ...

Page 82: ...Section 4 Schematics Page 4 6 107099 002 TM12 Work Platform NOTES ...

Page 83: ...Call Toll Free in U S A 1 800 926 LIFT ...

Page 84: ...h Pine Street Madera California 93637 TEL 559 662 3900 FAX 559 673 6184 PARTS 1 888 UR PARTS PARTS FAX 1 800 669 9884 UpRight Unit S1 Park West Industrial Park Friel Avenue Nangor Road Dublin 12 Ireland TEL 353 1 620 9300 FAX 353 1 620 9301 P N 107099 002 07 02 ...

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