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Cylinder Repair

Section 1 - General Information

Service Manual

Page 1-9

1-8 C

YLINDER

R

EPAIR

W A R N I N G

!

!

Cylinders may be very heavy. Support heavy cylinders before removing pins which secure the cylinder
to the machine.

R

E M O V A L

NOTE:

Refer to the

Service and Repair

section for the location of cylinders, and the

Parts Manual

for a list of parts

which secure the cylinders.

1. Mark and disconnect hoses and IMMEDIATELY cap the openings to prevent contamination.

2. Remove the cylinder from the machine as described in the

Service and Repair

section.

D

I S A S S E M B L Y

1. Remove the head from the cylinder body.

2. Carefully slide the rod assembly out of the cylinder.

3. Remove the seal kit components (wipers, rod seals, o-rings and backup rings) from the head and piston.

4. Inspect parts for scratches, pits or polishing. Check seal grooves and sealing surfaces. Scratches or pits

deep enough to catch the fingernail are unacceptable; replace the cylinder. Polishing is a sign of uneven
loading. When this occurs, the surface should be checked for roundness. Cylinders not round within
0,18 mm (

.007 in.

) should be replaced.

A

S S E M B L Y

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 elastically restore to their original shape before assembling the cylinder.
•Torque all hardware to torques according to Table 1-1, “Torque Specifications for Hydraulic Components,” on
Page 1-3 unless otherwise specified.

1. Lubricate all components with clean hydraulic fluid.

2. Install new seal kit components.

3. Lubricate the rod wiper and seal with hydraulic fluid and slide the head onto the rod.

4. Lubricate the seals on the piston and head.

5. Carefully slide the rod assembly into the cylinder.

6. Secure the head into the cylinder.

I

N S T A L L A T I O N

1. Installation is reverse of removal.

2. Carefully remove the elevating assembly support.

3. Slowly cycle the cylinder several times to remove air from the hydraulic system.

4. Check for proper cylinder operation. Check hydraulic connections for leaks.

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Содержание X20N

Страница 1: ...X26 Ultra Narrow Serial Numbers 20000 Current Publication Number 114101 000 ...

Страница 2: ...l Park Friel Avenue Nangor Road Dublin 12 Ireland TEL 353 1 620 9300 FAX 353 1 620 9301 FRONT REAR When contacting UpRight for service or parts information be sure to include the MODEL and SERIAL NUMBERS from the equipment nameplate Should the nameplate be missing the SERIAL NUMBER is also stamped on top of the chassis above the front axle pivot X26 Ultra Narrow Serial Number 20000 Current Stamped...

Страница 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...

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

Страница 5: ... 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 hydrogen gas NEVER...

Страница 6: ...wering Procedure 8 Raising Procedure 8 Parking Brake Release 9 Release the Parking Brake 9 Engage the Parking Brake 9 After Use Each Day 9 Transporting the Machine 10 Lifting By Crane 10 Moving By Forklift 10 Driving or Winching onto a Truck or Trailer 11 Maintenance 12 Blocking The Elevating Assembly 12 Scissor Brace Installation 12 Scissor Brace Storage 12 Level Sensor 13 Testing the Level Senso...

Страница 7: ...ructions before attempting to operate the machine GENERAL DESCRIPTION Figure 1 X 26 Ultra Narrow W A R N I N G DO NOT use the machine if all guardrails are not properly in place and secured 1 Platform Controls 2 Manual Case 3 Platform Extension 4 Platform 5 Elevating Assembly 6 Chassis 7 Batteries 8 Charger Outlet Plug 9 Chassis Controls 10 Emergency Lowering Valve Knob 11 Hydraulic Fluid Reservoi...

Страница 8: ... lowered See Hydraulic Fluid on page 14 Add recommended hydraulic fluid if necessary See Specifications on page 20 3 Check that fluid level in the batteries is correct See Battery Maintenance on page 14 4 Verify that the batteries are charged 5 Check that the A C extension cord has been disconnected from the charger plug 6 Check that all guardrails are properly in place and secured 7 Inspect the m...

Страница 9: ...si tion and fully elevate the platform Check for erratic operation 10 Partially lower the platform by pushing Chassis Lift Lower Switch to LOWER and check for proper oper ation of the audible lowering alarm 11 Check the Emergency Lowering Valve for proper operation see Emergency Lowering on page 7 12 Lower the platform 13 Push the Chassis Emergency Stop Switch to check for proper operation All mac...

Страница 10: ...capable of supporting the wheel loads 3 Verify that the Chassis Key Switch is turned to DECK and the Chassis Emergency Stop Switch is ON pulled out 4 Mount the platform and properly close and secure the entrance 5 Check clearances above below and to the sides of machine 6 Pull the Platform Emergency Stop Switch out to the ON position 7 Turn the Lift Drive Switch to DRIVE NOTE Turn Lift Drive Switc...

Страница 11: ... DRIVE 5 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 Han dle is moved 6 If the machine is not level the level sensor alarm will sound and the machine will not lift or drive If the level sensor alarm sounds the platform must be lowered and the machine ...

Страница 12: ...l could drop suddenly when the final retaining pin is retracted Keep hands away from the slide tubes to prevent injury c Push down on the platform extension guardrail to lower it completely The retaining pins will remain in the retracted position 4 Lower the side guardrails and rear guardrail as a single unit Repeat steps 3a through 3c 5 Lower the rear top rail Pull the two retaining pins and lowe...

Страница 13: ...n turn increments to insure uniform adjustment and prevent binding 1 Chock the rear wheels to prevent the machine from rolling 2 Using a 13 mm socket wrench turn the brake release nuts clockwise until they contact the motor body 3 Alternately turn each nut clockwise in turn increments until resistance is felt approximately two turns 4 The brake is released ENGAGE THE PARKING BRAKE 1 Chock the rear...

Страница 14: ...lift the machine Secure straps to chassis tie down lifting points only see Figure 7 MOVING BY FORKLIFT D A N G E R Forklifting is for transport only See specifications for the weight of the machine and be certain that the forklift is of adequate capacity to lift the machine Forklift from the rear of the machine using the forklift pockets provided If necessary the machine may be forklifted from the...

Страница 15: ...into transport position b Set the wheels straight and turn off the machine c Chock the wheels B To Winch the machine onto the transport vehicle a Drive the machine up to the ramp b Attach the winch cable to the tie down lifting points c Release the parking brakes refer to Parking Brake Release on page 9 d Winch the machine into transport position e Chock the wheels f Re engage the parking brakes 2...

Страница 16: ...m until the scissor brace can be rotated to the vertical position 6 From the rear of the machine lift the scissor brace from its stowed position Rotate upward and outward then down until it is hanging ver tically below its attachment point 7 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER and gradually lower the platform until the scissor brace is supporting the platform SCISS...

Страница 17: ...tes the sensor is ON has power red indicates the sensor is LEVEL TESTING THE LEVEL SENSOR Figure 10 Level Sensor 1 Place machine on firm level surface 2 Use the Chassis Controls to raise the platform to approximately 2 1 m 7 ft 3 Install the scissor brace see Blocking The Elevating Assembly on page 12 4 Remove the Level Sensor electrical box cover near the front of machine 5 Push the Level Sensor ...

Страница 18: ... Always wear safety glasses when working near batteries 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 30 kg 66 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...

Страница 19: ... gauge minimum conductor diameter 15 m 50 ft maximum length to the charger plug located at the left side of the chassis Figure 13 Charge Indicator Lights 3 The charger turns on automatically after a short delay Look through the charge indicator cutout to check the state of charge 0 50 charge First Light BLINKING Second and Third Light OFF 50 75 Charge First Light ON Second Light BLINKING Third Lig...

Страница 20: ...maintenance 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 preventat...

Страница 21: ...cable condition Chassis Check hoses for 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 structural cracks Emergency Hydraulic System Operate the emergency lowering valve and check for serviceability Entire Unit Check f...

Страница 22: ...UID AT RECOMMENDED LEVEL 3 005221 000 4 066552 000 5 101251 000 MAXIMUM DISTRIBUTED PLATFORM LOAD 500 LBS OR TWO OCCUPANTS MAXIMUM SIDE LOAD 100 LBS 6 101250 000 7 014222 003 99 9 066553 000 8 066555 000 10 060197 000 11 061205 005 12 061220 002 13 066550 000 15 066554 000 16 066561 000 17 066558 000 20 010076 001 25 066556 000 26 066559 000 29 062562 001 31 101222 005 CHARGER BATTERY 32 066522 00...

Страница 23: ...Labels 114100 000R1 X26 Ultra Narrow Operator Manual Page 19 Figure 14 Safety Labels Locations REAR FRONT POWER MOUDLE CONTROL MODULE ...

Страница 24: ...ivable Height 7 9 m 26 ft Drive Speed Platform Lowered 0 to 3 2 km h 0 to 2 0 mph Platform Raised 0 to 0 8 km h 0 to 0 50 mph Energy Source 24 Volt Battery Pack 4 235 A Hour 6 Volt Batteries min wt 30 kg 66 lbs each Motor 24 Volt 4 Horse Power DC Electric Motor System Voltage 24 Volt DC Battery Charger 25 A 110 220 VAC Hydraulic Reservoir Capacity 15 L 4 US Gallons Maximum Hydraulic Pressure 207 b...

Страница 25: ...ng 1 16 1 12 Hydraulic Fluid 1 17 1 13 Long Term Storage 1 18 LIST OF FIGURES Figure 1 1 UpRight Connector Kits 1 6 Figure 1 2 UpRight Male Connector 1 6 Figure 1 3 UpRight Female Connector 1 6 Figure 1 4 Locking Finger UpRight Connector 1 7 Figure 1 5 Heavy Duty UpRight Connector 1 7 Figure 1 6 Electric Motor Service 1 10 Figure 1 7 Electric Motor Brushes 1 11 Figure 1 8 Contact Area 1 16 Figure ...

Страница 26: ...d damage a machine or make it unsafe Please under stand that these warnings cannot cover all conceivable ways in which service whether or not recom mended by UpRight Inc might be done or of the possible hazardous consequences of each conceivable way nor could UpRight Inc investigate all such ways Anyone using service procedures or tools whether or not recommended by UpRight Inc must satisfy themse...

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

Страница 28: ... 0 49 400 583 4 778 1 57 733 682 2 909 4 27 46 435 617 3 84 8 64 235 853 4 1138 1 75 069 997 2 1329 8 30 56 753 837 9 1117 4 78 509 1159 4 1545 2 91 751 1354 9 1807 0 33 70 208 1140 3 1520 1 97 121 1576 9 2102 8 113 503 1843 9 2457 5 36 82 651 1464 1 1952 3 114 334 2025 3 2700 9 133 620 2367 6 3156 0 8 8 10 9 12 9 Grade 8 8 Grade 10 9 Grade 12 9 Nominal Thread Size Clamp Load Tightening Torque Cla...

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

Страница 30: ...cking Wedge from the Male Connector Care should be taken that the Sealing Gasket is not dam aged during this procedure 3 Check all parts for damage Replace all parts which are damaged or worn 4 Replace or re crimp the wires and contacts Refer to Crimping proce dure FEMALE CONNECTOR RECEPTACLE Figure 1 3 UpRight Female Connector 1 Disconnect the male connector plug from the female connector recepta...

Страница 31: ... are included in each Field Kit 2 Insert the contact into the crimping tool 3 Insert the stripped wire into the contact Copper strands should be visible in the bleed hole of the contact and no copper strands should be loose outside of the contact barrel 4 Completely close the handles of the crimping tool Release the handles of the crimping tool and remove the crimped contact 5 Inspect the crimped ...

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

Страница 33: ... occurs the surface should be checked for roundness Cylinders not round within 0 18 mm 007 in should be replaced ASSEMBLY Refer to the Service and Repair section for seal kit assembly drawings and the Parts Manual for illustrated parts breakdowns NOTE To avoid cutting the seals do not use sharp edged tools during seal replacement After installing seals allow at least one hour for the seals to elas...

Страница 34: ...otor sounds normal go to Step 3 d If the motor sounds noisy it should be taken apart as described in the disassem bly section 3 If the motor turned freely connect an amme ter in the circuit as shown in Figure 1 6A With rated voltage applied and the shaft run ning free the ammeter should read less than 20 of the nameplate full load current If the motor meets the above conditions then it can be assu...

Страница 35: ...rmature assembly including bearings and insert the commutator end bearing into the bearing bore NOTE Do not re use bearings which have been removed from the armature shaft Keep the assembly in a vertical position Use extreme care not to damage the armature with bearing pullers New bearings should be installed by pressing the inner race of the bearing onto proper position on the armature shaft 5 Se...

Страница 36: ...gen gas or fuel vapors are present Check battery fluid level daily If electrolyte level is lower than 10 mm 3 8 in above plates add distilled water only DO NOT use tap water with high mineral content It will shorten battery life DO NOT overfill Battery acid expands during charging and can overflow Keep terminals and tops of batteries clean The battery and cables should be inspected regularly for s...

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

Страница 38: ... match the AC power source 3 Connect an extension cord that meets or exceeds the charger AC current onto the charger plug 4 Connect the other end of the extension cord to a grounded AC outlet of proper current voltage and fre quency rating 5 The charger turns on automatically after a short delay Table 1 6 illustrates charging indicators Table 1 6 Battery Charging UpRight Electric and BiEnergy Mach...

Страница 39: ...m from charger No green Light No hum from charger Not Applicable Charger automatically adjusts to the incoming AC current 063944 001 ONLY Check the fuse inside the switch box replace if bad If the fuse is good the charger has failed All Others Check the AC main circuit breaker and reset if necessary Set the voltage selector switch to the proper voltage Fuse visible on front of charger has failed A...

Страница 40: ...the direction of extension and decreased localized pressure at the opposite end MEASURE THE CONTACT AREA Measure the contact area of the contacting sur face tire or outrigger The tire contact area can be determined by placing the loaded tire on a clean surface The tire will leave an imprint from which an area can be determined Figure 1 9 Occupied Surface Area CALCULATE THE LOCALIZED PRESSURE Find ...

Страница 41: ...ons Above 10 C 15 F MOBIL DTE 13 M Viscosity Grade ISO 32 High V I similar to SAE 5W 20 Viscosity index 140 Operating Range 18 C to 80 C 4 F to 176 F Reservoir Temperature Ambient Conditions 18 C to 30 C 4 F to 86 F MOBIL DTE 11 M Viscosity Grade ISO 15 Viscosity index 140 Operating Range 35 C to 45 C 30 F to 115 F Reservoir Temperature Ambient Conditions 35 C to 20 C 30 F to 70 F MOBIL EAL ENVIRO...

Страница 42: ...s damaged repaint 2 Fill the hydraulic reservoir to operating level IMPORTANT Do not fill the hydraulic reservoir while the platform is elevated 3 Coat exposed portions of cylinder rods with a preservative such as multipurpose grease and wrap with a barrier material 4 Coat all exposed unpainted metal surfaces with preservative 5 Internal Combustion Models Service the engine according to the manufa...

Страница 43: ...orm is elevated without first blocking the elevating assembly DO NOT stand in elevating assembly area while deploying or storing maintenance brace TABLE OF CONTENTS 2 1 General Description 2 4 Component Locations 2 4 2 2 Preventative Maintenance 2 6 Preventative Maintenance Check List 2 7 2 3 Blocking the Elevating Assembly 2 8 Installation 2 8 Storage 2 8 2 4 Lubrication 2 8 2 5 Controls 2 9 Plat...

Страница 44: ...raulic Manifold Pressures 2 23 Main Relief Valve 2 23 Steering Relief Valve 2 24 Lift Relief Valve 2 24 Counterbalance Valves 2 24 Series Parallel Manifold 2 25 Removal and Installation 2 25 Emergency Lowering Valve 2 26 Repair 2 26 2 8 Cylinders 2 27 Steering Cylinder 2 27 Removal 2 27 Repair 2 27 Installation 2 27 Depression Mechanism Cylinder 2 28 Removal 2 28 Repair 2 29 Installation 2 29 Lift...

Страница 45: ...e 2 13 Fluid Filter 2 18 Figure 2 14 Hydraulic Pump 2 20 Figure 2 15 Hydraulic Manifold Location 2 21 Figure 2 16 Hydraulic Manifold Exploded View 2 22 Figure 2 17 Hydraulic Manifold Adjustment 2 23 Figure 2 18 Series Parallel Manifold Location 2 25 Figure 2 19 Series Parallel Valve Manifold 2 25 Figure 2 20 Emergency Lowering Valve 2 26 Figure 2 21 Steering Cylinder Location 2 27 Figure 2 22 Stee...

Страница 46: ... Platform 1 Entry Way 2 Deck Lock Assembly 3 Work Platform 4 Guardrails 5 Platform Extension 6 Platform Controls 7 Rear Guardrail Retaining Pin 8 Guardrail Retaining Pin 9 Elevating Assembly 10 Control Module 11 Chassis Controls 12 Circuit Board 13 Motor Controller 14 Hydraulic Fluid Reservoir 15 Hydraulic Fluid Filter 16 Hydraulic Pump and Motor 17 Main Valve Manifold 18 175 AMP Fuse Overload Pro...

Страница 47: ...ral Description 114101 000 X26 Ultra Narrow Service Manual Page 2 5 Figure 2 1 X26 Ultra Narrow Component Locations 17 18 21 37 31 32 33 34 23 27 26 28 10 35 11 7 3 9 8 4 6 FRONT FRONT REAR 5 12 13 14 29 30 36 24 25 1 2 22 15 16 20 19 ...

Страница 48: ... at regular intervals Inspection and maintenance shall be performed by personnel who are trained and familiar with mechani cal and electrical procedures W A R N I N G Before performing preventative maintenance familiarize yourself with the operation of the machine Always block the elevating assembly whenever it is necessary to enter the elevating assembly to perform maintenance while the platform ...

Страница 49: ...Check condition of platform Daily Check condition of anchorage points Daily Check condition of operators manual Daily Tires Check for damage Daily Check lug nuts torque to 123 N m 90 ft lbs 30d Hydraulic Drive System Check hydraulic drive motor operation Daily Check hoses fittings and valve manifold for leaks Daily Hydraulic Pump Check for leaks at mating surfaces 30d Check for hose fitting leaks ...

Страница 50: ...ard then down until it is hanging vertically below its attachment point 7 Lower the platform by pushing the Chassis Lift Lower Switch to LOWER and gradually lower the plat form until the maintenance brace is supporting the platform STORAGE 1 Using the Chassis Controls gradually elevate the platform until the maintenance brace is clear 2 Rotate the maintenance brace outward and upward over its atta...

Страница 51: ... necessary from Platform Control box a Remove the control panel b Unplug the control handle wir ing harness c Remove the four screws from the control handle mounting plate d Lower the control handle through the control panel 2 Remove and replace defective parts Refer to the Parts Manual for repair parts numbers 3 2 4 1 5 7 9 8 8 6 1 Platform Control Box 2 Platform Control Panel 3 Control Handle 4 ...

Страница 52: ...ts the cir cuit board and the motor control 3 Place the control cover top side down MOTOR CONTROLLER AND CIRCUIT BOARD Refer to Section 3 Trouble shooting for motor controller and circuit board dip switch settings To access the Motor Controller Dip Switches open the control module as described in Chassis Controls The circuit board is mounted inside the control box cover 3 4 1 8 10 12 2 13 7 5 6 9 ...

Страница 53: ...cking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing the maintenance brace LEVEL SENSOR ADJUSTMENT Figure 2 7 Level Sensor and Proximity Switch 1 Place machine on firm level surface 2 Use the Inclinometer P N 10119 000 00 to ensure that the Chassis is level from front to rear and side to side 3 Deploy the maintenance brace see Blocking the Elevating A...

Страница 54: ...re should un roll as the platform elevates 4 Measure the distance from the platform deck to the surface The height should be 7 86 m 25 ft 10 in If the distance is more the switch is out of adjustment or not functioning If the distance is less the switch is out of adjustment Figure 2 9 Height Limit Test the Mercury Switch W A R N I N G Never perform service while the platform is elevated without fi...

Страница 55: ... the Height Limit Switch 1 Place the machine on a firm level surface 2 Use adhesive tape to attach the tab of a tape measure to the front edge of the platform see Figure 2 8 Ensure that the locking device on the tape measure is disengaged and extend the tape measure to the surface 3 Deploy the maintenance brace see Blocking the Elevating Assembly on page 2 8 4 Place a reference mark alongside the ...

Страница 56: ...hanism is enabled Power to the High Speed Circuit is cut preventing the machine from travel faster than 0 8 km h 0 5 mph When Completely Lowered Power is supplied to the High Speed Circuit allowing the machine to travel up to 3 2 km h 2 0 mph when the Platform Controls Lift Drive Switch is set to DRIVE HI TEST HIGH SPEED CIRCUIT 1 Elevate the platform 30 cm 12 in 2 Turn the Lift Drive Switch to DR...

Страница 57: ...ploy the maintenance brace see Blocking the Elevating Assembly on page 2 8 2 Use a clamp to attach a straight guide to the elevating assembly tube 3 Measure the distance from the face of the Proximity Switch to the side of the guide that faces the elevating assembly tube 4 Turn the adjusting nuts to adjust to within 4 76 mm to 6 35 mm 3 16 in to 1 4 in 5 Remove the clamp and guide and repeat the t...

Страница 58: ...on a 24 volt system the charger will not recharge the batteries If this extreme voltage drop occurs disconnect and recharge each battery separately using a 6 volt charger to bring the voltage in each up to at least 4 1 2 volts C A U T I O N If battery water level is not maintained batteries will not fully charge creating a low discharge rate W A R N I N G Hazard of explosive gas mixture Keep spark...

Страница 59: ...battery negative lead IMPORTANT Disconnect the battery negative lead first 5 Disconnect the remaining battery leads 6 Lift the batteries out of the module INSTALLATION Battery cables must be installed as shown in Figure 2 11 IMPORTANT Connect the battery negative lead last 1 Verify that the Chassis Key Switch and the Chas sis and Platform Emergency Stop Switches are in the OFF position 2 Place the...

Страница 60: ...safety glasses when handling hot fluid RESERVOIR BREATHER CAP Figure 2 12 Hydraulic Reservoir Clean the breather cap at the same time that the fluid filter is replaced Use cleaning solvent and blow dry with clean dry com pressed air FILTER REPLACEMENT Figure 2 13 Fluid Filter Replace the filter every 250 hours or six months 1 Unscrew the filter from the filter assembly 2 Apply a thin film of clean...

Страница 61: ...operly contact your local fluid recycler 5 Install the drain plug 6 Fill the hydraulic reservoir with the appropriate hydraulic fluid until the fluid is up to the full mark on the dipstick Refer to Specifications at the end of the Operator Manual included in this Service Manual to identify the proper fluid for your conditions FLUID OUTLET SCREEN Clean or replace the outlet screen at the same time ...

Страница 62: ...om the vibration mounts and lift the motor and pump assembly from the control module 6 Loosen the capscrews and remove the pump assembly from the motor INSTALLATION Pump to Motor 1 Lubricate the pump shaft with general purpose grease and attach the motor with the capscrews 2 Using a crisscross pattern torque each capscrew a little at a time until all capscrews are torqued to 27 N m 20 ft lbs Pump ...

Страница 63: ... lead make sure all switches are OFF If ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present Figure 2 15 Hydraulic Manifold Location 1 Disconnect the battery pack connector and the battery negative lead 2 Tag and disconnect the solenoid valve leads 3 Tag disconnect and plug hydraulic hoses 4 Remove the bolts that hold the manifold t...

Страница 64: ...ydraulic Manifold 2 Fitting 2 Plug 3 Fitting 4 Plug 4 Fitting Straight 6MB 6MJ 5 Fitting Straight 4MBH 4MJ 6 Fitting Plug 6 7 Fitting Plug 8 8 Fitting 8MB 8MJX 9 Steering Relief Valve 10 Main Relief Valve 11 2 Pos 4 Way Solenoid W Coil Lift 12 3 Pos 4 Way Solenoid W Coils Steer 13 Counterbalance Valve 14 Lift Relief Valve 15 Flow Divider Valve 16 2 Pos Poppet Valve W Coil Depression Mechanism 17 P...

Страница 65: ...es to warm the fluid 2 Slowly drive the machine to within 8 cm 3 in of a solid immovable brick wall Ease the machine for ward until the front of the chassis is in solid contact with the wall 3 Insert a 0 207 bar 0 3000 psi pressure gauge into the test port 4 Loosen the locknut or remove the cover on the Main Relief Valve and turn the adjusting screw counter clockwise two full turns 5 Unhook the Pl...

Страница 66: ...n and hold it there 5 Slowly turn the Lift Relief Valve adjusting screw clockwise to increase the pressure until the platform just begins to rise 6 Release the Chassis Lift Switch Tighten locknut or replace the Lift Relief Valve cover and torque to 8 N m 6 ft lbs COUNTERBALANCE VALVES 1 Operate the machine for 10 15 minutes to bring the hydraulic fluid up to normal operating temperature 2 Remove t...

Страница 67: ...switches are OFF If ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present 2 Disconnect the battery pack connec tor and the battery negative lead 3 From the control module side tag and disconnect wires tag disconnect and plug the side hoses 4 From the front tag disconnect and plug the front hoses 5 Remove the three capscrews and nuts ...

Страница 68: ...lve along the elevating assembly tube to the front of the machine through the cable access hole to the rear of the machine REPAIR 1 Deploy the maintenance brace see Blocking the Elevating Assembly on page 2 8 2 Inspect the cable Replace if damaged 3 Inspect the valve Replace if damaged 4 Check for and clear any blockage in the orifice Install the orifice with the beveled side toward the cylinder b...

Страница 69: ...ng assembly 7 Remove the cylinder 8 Remove the bearing from the steering assembly end of the cylinder REPAIR Figure 2 22 Steering Cylinder Assembly Refer to Section 1 General Information for disassem bly cleaning and inspection and assembly instruc tions INSTALLATION 1 Apply Neverseize or equivalent to the clevis pins 2 Insert the bearing into the cylinder rod eye 3 Position the cylinder into the ...

Страница 70: ... negative lead make sure all switches are OFF If ON a spark will occur at the ground terminal which could cause an explosion if hydrogen gas or fuel vapors are present 3 Disconnect the battery pack connector and the battery negative lead 4 Tag and disconnect the electrical connections from the solenoid 5 Tag and disconnect the hoses from the cylinder fittings and immediately cap the openings to pr...

Страница 71: ...he clevis pins 4 Place a second washer on the lower clevis pin located on the depression tube 5 Install a retaining ring on each clevis pin 6 Unplug and connect the hoses to the fittings 7 Connect the electrical connections to the solenoid 8 Connect the negative battery lead 9 Connect the battery pack connector 10 Check the fluid level in the hydraulic reservoir before operating the machine 11 Lif...

Страница 72: ...gs to prevent foreign material from entering 4 Remove the cable and electrical con nections from the Emergency Lowering Valve 5 Remove the retaining rings securing the lift cylinder pins 6 Remove lower lift cylinder pin by driving the pin towards the shaft locking pin side Lower the cylinder to rest on the chassis 7 Attach a suitable hoisting device and sling to the cylinder and remove the upper l...

Страница 73: ...n der pin Make sure the locking pin is properly installed then install the retaining ring 4 Connect the Emergency Lowering Valve cable and electrical connec tions 5 Unplug and attach the hydraulic hoses to the cylinder 6 Connect the negative battery lead 7 Connect the battery pack connector 8 Check the fluid level in the hydraulic reservoir before operating the machine 9 Test with weight at rated ...

Страница 74: ...sition the drive motor into the wheel yoke and secure it with capscrews and locknuts 2 Torque the locknuts to 95 N m 70 ft lbs 3 Install the shaft key hub and slotted nut Torque the slotted nut to 190 217 N m 140 160 ft lbs 4 Install a new cotter pin DO NOT back off the nut to install the cotter pin 5 Remove the plugs from the hose assemblies and reconnect them to the drive motor 6 Install the whe...

Страница 75: ...Motor Exploded View 23 20 21 21 22 24 25 26 27 28 29 30 31 33 34 18 19 32 12 13 15 16 15 17 14 10 11 7 8 9 6 4 5 4 3 2 1 Non Servicable Parts 1 Rotor Bolts 2 Washer 3 Endcap 5 Rotor 6 Cardan Shaft 7 Channel Plate 8 Bearing Race 9 Needle Bearing 10 Commutation Valve 11 Output Shaft 12 Balance Plate 13 Spring Washer 15 Washer 16 Needle Bearing 18 Brake Release Nut 20 Bearing Housing 21 Brake Spring ...

Страница 76: ...ment so that the bearing sur faces face each other Use the old bearing cone as a drift to work the replacement into position by tapping evenly around the circumference 2 Apply a liberal coating of multipurpose grease to the bearing surface of each cup 3 Pack the inner bearing with multipurpose grease and position it into the inner bearing cup 4 Press a new grease seal into the hub assembly 5 Apply...

Страница 77: ...the machine and help in diagnosing and repair of the machine W A R N I N G When troubleshooting ensure that the machine 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...

Страница 78: ...O Board Dip Switch 2 5 Figure 3 4 Motor Controller Connections 2 6 Figure 3 5 I O Board Connections 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 ...

Страница 79: ...ions 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 component Test components that ...

Страница 80: ...ep 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 TM12...

Страница 81: ...ional 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 X26UN 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 ...

Страница 82: ...ircuit at the 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...

Страница 83: ...to 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 Connections 1 2 3 4 8 7 6 5 1 2 3 4 8 7 6 5 1 2 3 4 12 11 10 9...

Страница 84: ...e 3 2 Connector 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 Upp...

Страница 85: ...t requested 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 va...

Страница 86: ... closed 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 2...

Страница 87: ...X X X X X X X X X MOT Motor X X X X X X X X X X R1 Motor Relay X X X X X X X X X X R2 Series Parallel Relay X X X S1 Chassis Emergency Stop Switch 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 S4 Proximity Switch X S5 Height Limit Switch X X S6 Platform Emergency Stop Switch X X X X X X X X X X X X X X S7 Lift Drive Selector Switch X X X X...

Страница 88: ...r 2 X X DVR1 Priority Flow Divider X X X X X X X X X DVR2 Series Parallel Flow Divider 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 X OR Orifice X X PMP Pump X X X X X X X X RES Reservoir X X X X X X X X X X RV1 Steering Relief Valve X X RV2 Lift Relief Valve X RV3 Main Relief Valve X X X X X X X V1 Steering Right Left Valve X X V2A Lift Valve...

Страница 89: ...nce designation and are explained as to function and location in the following tables TABLE OF CONTENTS 4 1 Electric 4 2 066769 020 Electric Schematic 4 2 4 2 Hydraulics 4 8 066781 020 Hydraulic Schematic 4 8 LIST OF FIGURES Figure 4 1 Electric Components Locations 4 2 Figure 4 2 Electric Schematic 4 3 Figure 4 3 Wire Routing 4 4 Figure 4 4 Chassis Controls Components 4 5 Figure 4 5 Platform Contr...

Страница 90: ...it Switch Stops lift assembly at upper limit Elevating Assembly Front S7 Platform Emergency Stop Switch Shuts down all machine functions Platform Controls S8 Interlock Switch Trigger Safety mechanism for control handle Platform Controls S9 Control Handle Proportionally controls the drive and lift functions Platform Controls S10 Platform Steering Switch Control left and right steering solenoids Pla...

Страница 91: ...14101 000 X26 Ultra Narrow Service Manual Page 4 3 Figure 4 2 Electric Schematic R2 HM S1 S2 S3 F1 SOL1A SOL1B SOL4A SOL4B SOL5 SOL5 SOL3A SOL2A S5 I O MC MOT R1 CHG BAT F2 ALM SNSR S4 SOL2B SOL3B SOL3B S7 S6 S8 S10 CONTROL HANDLE S9 ...

Страница 92: ...ion 4 Schematics Page 4 4 114101 000 X26 Ultra Narrow Service Manual Figure 4 3 Wire Routing R2 SOL2A SOL3A SOL4B SOL4A SOL1A SOL1B SOL5 SOL5 SOL2B ALM SNSR BAT CHG SOL3B S6 SOL3B S5 I O MC MOT F2 R1 F1 S3 S2 S1 HM ...

Страница 93: ... 5 Figure 4 4 Chassis Controls Components Circuit Board I O HM S1 S2 S3 F1 R2 MC Cover Hour Meter Contact Block Normally Closed Toggle Switch Contact Switch Normally Open Control Box Motor Control Emergency Stop Switch Lift Lower Switch Cover Key Switch Circuit Breaker Relay 24 V ...

Страница 94: ...onents Controller Box 3 Position Selector Switch Lift Drive Red Mushroom Switch Emergency Stop Interlock Switch S6 S10 S8 S9 S7 Control Panel Contact Block Normally Closed Contact Block Normally Open Normally Closed Contact Block Normally Open Control Handle Rocker Switch Steering Amp Connector Hall Effect Connector ...

Страница 95: ...Section 4 Schematics Electric 114101 000 X26 Ultra Narrow Service Manual Page 4 7 Figure 4 6 Platform Controls Wiring S8 S7 S6 S10 ...

Страница 96: ...lic pressure for all functions Control Module RV1 Steering Relief Provides pressure protection to pump and steering components when steering Hydraulic Manifold RV2 Lift Relief Valve Provides pressure protection to lift system Hydraulic Manifold RV3 Main Relief Valve Provides pressure protection to hydraulic system Hydraulic Manifold RES Reservoir Holds hydraulic fluid Control Module SP Series Para...

Страница 97: ...cs Hydraulics 114101 000 X26 Ultra Narrow Service Manual Page 4 9 Figure 4 8 Hydraulic Schematic PMP FL2 FL1 RES MAN SP RV3 DVR1 RV1 V1 CYL1 V2B CYL2 OR2 CYL3 V3B CYL3 V3B V3A V2A RV2 CV V4 V6 V6 V5 V5 DVR2 MOT MOT PB PB ...

Страница 98: ...Hydraulics Section 4 Schematics Page 4 10 114101 000 X26 Ultra Narrow Service Manual Figure 4 9 Hose Routing MOT MOT PB PB SP MAN PMP CYL3 CYL3 CYL1 CYL2 FL1 FL2 RES ...

Страница 99: ...terbalance Valve V6 Drive Solenoid and Valve SOL4A SOL4B V4 Depression Mechanism Solenoid and Valve SOL3A V3A Main Relief Valve RV3 Check Valve CV Lift Solenoid and Valve Sol2A V2A Steering Solenoid and Valve Sol1A Sol1B V1 Fitting Flow Divider Valve DVR1 Steering Relief Valve RV1 Fitting High Pressure Test Port Lift Relief Valve RV2 TOP VIEW BOTTOM VIEW ...

Страница 100: ...14101 000 X26 Ultra Narrow Service Manual Figure 4 11 Depression Mechanism Cylinder Figure 4 12 Series Parallel Drive Manifold Depression Mechanism Retract Solenoid and Valve SOL3B V3B 3 Way 2 Position Valve SOL5 V5 2 Flow Divider Combiner DVR2 ...

Страница 101: ...Call Toll Free in U S A 1 800 926 LIFT ...

Страница 102: ... UpRight Inc 801 South 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 ...

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