OP-FRIiGHT LmIFTs It} sing Up-Right for service or ‘the subject to change without not sure to include the MODEL and SERIAL MIMBERS ice. when contact: UL 24/30, UL 31/37, UL 38/44 SERVICE & PARTS MANUAL September 21, 1989 P.N. 62316-002-00TABLE OF CONTENTS SECTION I, INTRODUCTION Purpose of Equipment... 2... eee eee eee General Description. . . . Se eee Special Tools and Test Equipment»... 1 te SECTION II, SAFETY RULES AND OPERATING INSTRUCTIONS Safety Rules... ee ee ee ee ee Operation... .. sss Setting Up the Up-Right Lift + Alternate Configuration Set Up Using the Loader... .. Passage Through a Doorway. + Emergency Platform Lowering. Specifications... . Controls and Indicators. + SECTION III, MAINTENANCE INSTRUCTIONS Periodic Inspection and Maintenance. Lubrication, . se eee ee eee Battery Maintenance... . 1. Troubleshooting. . . cee Setting System Relief Pressure . . Disassembly/Removal, Mast Assembly Reassembly, Mast Assembly. . . . Cylinder Assembly Removal. . . . Cylinder Assembly Installation . . Lift Cylinder Seal Replacement . Cylinder Bleeding Procedure to Serial Numbers 4565, UL~31 4523, UL-38 4554 cylinder Bleeding Procedure for Self Bleeding Cylinder Serial Numbers; UL-24 4566 to Current, UL~31 4524 to Current, UL-38 4555 to Current L-24 ts; 0 SECTION IV. DIAGRAMS Content. . sone . . A.C. Electrical Diagram Legend D.C. Electrical Diagram Legend Hydraulic Diagram Legend .. . SECTION V. PARTS LIST General, «se eee eee Part List. .... sae Ordering Information ee Abbreviations. . . : Up-Right Lift, 24 Ft Model Up-Right Lift, 31 Ft Model Up-Right Lift, 38 Ft Model Base Frame and Ladder Assembly Outrigger Assembly... .. : A.C. Power Unit Assembly/Installation. D.C. Power Unit Assembly/Installation. Battery Installation, D.C. Models Seria. 4646 rans eee ee tenes Bowe cccccaee Gece ee eee eee i eretetet BEEESecwn 15 7 19 21 25 28 34 37 39 40 42 43 44 44 45 46Ir TABLE OF CONTENTS (Cont'd) Battery Installation, D.C. Models Serial # 4647 to Current Battery Charger Installation, D.C, Models Serial # thru 4646 Battery Charger Installation, D.C. Models Serial # thru Current Control Box Assembly, Serial # 4332 thru 4646. . Control Box Assembly, Serial # 4647 thru Current Pinch Shield Assembly, Serial # 4332 thru 4646 . Pinch Shield Assembly, Serial # 4647 thru Current Retractile Cable Installation. Mast Assembly... se eee ee ee ee eee Lift Cylinder Assembly >.) 7 fe Cage Assembly... 6 ee ee ee ee ee ee ee Loader 24 Ft Model ss ee ee ee ee ee eee Loader 31 and 38 Ft Models... ee eee eee Tilt Back Assembly... eee eee eee eee Decal Installation... eee eee eee eee SECTION VI. OPTIONS Introduction . . . eee ee wees Detachable Cage Kit option»). tit Fiberglass Cage Kit Option eee eee ee Narrow Cage Option . . . ae eee eee Additional Height Option, 31 Ft... 2. toe Additional Height Option, 38 Ft... 2... ee Power to Platform Option, Serial # 4332 thru 4646. Tool Tray Option... . rarer ar) Florescent Tube Caddy option > 222 2 222 t Auditorium Kit Option»... eee eee eens MAINTENANCE SCHEDULE AND RECORD LOG SHEET 4332. 4647. 70 72 74 16 78 80 82 84 86 90 93 96 98 100 102 104 105 107 110 112 114 le 118 120 122/o} UP-RIGHT INC. 1775 PARK ST. SELMA, CA 93662 MODEL NO. MAX. PLATFORM HEIGHT[____] SERIAL NO. 7 BATTERY VOLTAGE[____] MAX. DISTRIBYTED LOAD [ ] CAUTION: CONSULT OPERATOR'S MANUAL BEFORE USE. THIS PLATFORM IS NOT ELECTRICALLY INSULATED PART NUMBER Identifiction Plate and Model NumberSECTION I INTRODUCTION ‘PURPOSE OF EQUIPMENT The Up-Right Lift is a portable lift designed to elevate personnel and light equipment to work above the ground. GENERAL DESCRIPTION There are three basic Up-Right Lift models; the UL-24/30, the UL-31/37 and the UL-38/44. All models consist of a Cage, Mast, and Chassis. CAGE. The cage is an aluminum structure supported by a steel cage support attached to the mast. It has 42 inch high railings with mid rail, four (4) inch toeboards and an entrance chain at the front of the cage. DO NOT operate the Up-Right Lift without the chain properly hooked over the entrance. MAST. ‘The cage is raised and lowered by a six stage mast assembly, that is raised and lowered by a single stage lift cylinder. An AC or DC electric motor powers a hydraulic pump which in turn energizes the cylinder. A solenoid operated valve controls the raising and lowering speed. CHASSIS. The chassis is a steel structure that consists of the first stage or 'can' of the mast assembly, control box (for AC Models), Battery Charger (for DC Models), an AC or DC Motor, Hydraulic Pump and reservoir, 12v battery (for DC Models, a tilt back assembly (standard on all 31/37 and 38/44 machines; optional on 24/30 machines), and four outriggers. OPERATOR CONTROLS. There are two controls for operation located at the cage assembly level on the pinch shield; the key switch and the up/down toggle switch. An emergency lowering valve is located on the Pump/Motor Assembly on the chassis level of the mast. SPECIAL TOOLS AND TEST EOUIPMENT The following table lists special tools and test equipment for maintaining an Up-Right Lift. Use of this equipment is described in the maintenance section of this manual.{3 wyTable 1-1, Special Tools and Test Equipment ‘TOOL/EQUIPMENT FIGURE USE AND PART NUMBER NUMBER DESCRIPTION APPLICATION 20733-002-00 1-2, Tee Adapter System Relief Pres- Item 1 sure Adjustment. 14048-001-00 1-2, Adapter System Relief Pres- Item 2 sure Adjustment. 11923-003-00 1-2, Adapter System Relief Pres- Item 3 sure Adjustment. 14124-050-00 1-2, Pressure Gauge System Relief Pres- Item 4 0-5000 sure Adjustment. 62477-000-00 = 1-3 Assist Tool, Removal and Instal- Cylinder Seal lation, Lift Cylin- der Seal Replace- ment. 62479-000-00 1-4 Gland Nut Socket Removal and Instal- lation, Lift Cylin- der Seal Replace- ment. 62521-000-00 1-5 Gland Nut Wrench Removal and Instal- lation, Lift Ccylin- der Seal Replace- ment. 62480-000-00 1-7 cylinder Bleed cylinder Assembly Wrench Reassembly. 62482-000-00 1-6 Strap Wrench Removal and instal- lation Cylinder Rod end for Cylinder Seal Replacement and Orifice Clean- ing. 1-7 cylinder Removal and Instal- Insertion Tool lation of Cylinder. 62738-000-00 Tie Rod Tensioner 17415-000-00 Tensioner Spacer 62739-000-00 Tensioner Bracket1, Tee Adapter 2. Adapter 3. Adapter 4. Pressure Gauge Figure 1-2, Adapters and Pressure Gauges Figure 1-3, Assist Tool, Cylinder SealFigure 1-4, Retaining Ring Socket Figure 1-5, Gland Nut WrenchCylinder Bleed Wrench is required only on Up-Right Lifts prior to the following serial numbers; | 14 45s UL~31 4523 UL-38 4554 Figure 1-6. Cylinder Bleed Wrench Pigure 1-7. Strap WrenchSECTION II SAFETY RULES AND OPERATING INSTRUCTIONSINSTRUCTION MANUAL ‘WARNING Blea Crt sy eve Salty Wf) GUP-RIGHT Files and Operating nstutions. Make Remnecenacy soe wey he Us LIFTS a ‘SERIAL NUMBERS 4332 TO CURRENT UL-24/30, UL-31/37 & UL-38/44 SAFETY RULES & OPERATING INSTRUCTIONS NEVER Use THE up. [I fl NEVER ELevaTE THE NEVER SIT. CLIMB, OF NEVER ATTEMPT TO RIGHT. LIFT WITHIN PLATFORM UNLESS. STAND ON THE PLAT. MOVE THE. UPRIGHT TEN FEET OF ELEC: ff 9) THEGASEISLEVEL, FORM “GUARDRAILS rt Wit PEOPLE OR TRIC POWER LINES. ORMIDRAILS. MATERIALS ON. THE ‘THIS UNITS NOTINSU- PLATFORM OR. WITH tare. THE PLATFORM ELE VaTED. SAFETY RULES Before using the Up-Right Litt, thoroughly inspect it for damage such as cracked welds, loose rivets, hydraulic leaks, damaged control or power cables, and loose or missing fasteners. NEVER use damaged equipment. © NEVER elevate platform unless all four (4) outriggers have been properly installed. All outrigger screwjack pads must be in contact with a firm surface before the platform is elevated. NEVER elevate the platform ifit contains more than the rated load of 300 pounds or more than one person, NEVER attach overhanging loads to the platform or increase the platform size. NEVER use ladders, planks or other devices to increase the height of the platform. NEVER use the Up-Right Lift as a freight or personnel elevator. NEVER use the UL-24/30 outriggers with the UL-31/37 or UL-38/44 models. Check clearances above and below the platform. Latch rope across opening after entering platform. eoecccee After use, secure the unit against unauthorized use by turning off the key switch and removing key.OPERATION + Read andiully understand this opera- tor's manual. + Be sure the unit has been properly set ‘up with all four (4) outriggers installed. * Check for external damage to the mast * Plug unit into a 120 V.A.C. 60 Hz power source. (NOTE: Appites to A.C. unit only) ‘* Mount the platform using the access ladder. ‘Latch rope across entrance after ‘mounting the platform. * Check for overhead obstructions. ‘Turn on the keyswitch located on the Side of the pinch shield. * Lift up on the toggle switch to elevate the platform. Release the toggle ‘switch to stop. Push down on the tog- {le switch to lower the platform. ‘+ Always check that the area below the platform is clear before lowering the platform. * After use, secure unit against unau- thorized use by turning off key switch and removing key. SETTING UP THE UP-RIGHT LIFT A. INSTALLING THE OUTRIGGERS (1) Remove the outriggers from storage location. (Outrigger storage locations on either side of mast.) () Push in until locking pin engages hole Inend of outrigger. Pull outward on outrig- ger to ensure engagement. See insert photo 2) (2) Insert into designated outrigger socket inbase (4) Repeat the above steps for all other Outriggers. Make sure all four (4) locking pins are engaged. (At this point the unit may be moved provided the outrigger screwjacks are fully retracted.) (6) Level the base, using the screwjacks at the end of each outrigger. ll four (4) screwjack pads must be in contact with a firm surface before the platform is elevated. Center the bubble in the orbit level on the right side of the base by adjusting the screwjacks at the end of each outrigger. B. ALTERNATE CONFIGURATION SET UP When it is necessary to operate the Up- Right Lift nextto.a wall, an alternate outrig- ‘ger configuration may be used. (1) Once all four (4) outriggers have been properly installed, slide the outrigger adjacent to the wall all the way into the socket by ling the ring on the locking pin and pushing on the outrigger Note: When outrigger next to wall is aside outrigger, remove the out- rigger and install on the same side, ‘ut in the front outrigger socket tube. Lift the tube cover and slide outrigger all the way into tube. DANGER This alternate configuration should be used only when it is necessary to operate the unit next to a wall and there is insuffi- cient distance to the wall to allow full outrigger length. The platform must not be elevated higher than the wall. All four (4) outriggers must be installed. f @ Position ‘the unit next to the wall nd extend the outrigger adjacent to (4) al screwjack pads (@) Center the bubble in the Orbit level on the right side of four (4) the wall as far as possible. Level the base, using the screwjacks at the ‘end of each outrigger. the base by adjusting screw- Jacks at end of each outrigger. must be in contact with a firm surface before the platform is elevated.UP-RIGHT LIFT LOADER WARNING Ensure Loader Bar is in full contact with a clean level surface. ‘A. LOADING THE UP-RIGHT LIFT INTO A VEHICLE USING THE LOADER. : r . (1) Slide the loader bar, located on the back of the tunit, up past the top set of holes and engage the loader pin through the top set of holes below the loader bar ft. (@ Back the unit up to the Vehicle bed until the back ‘ofthe unit comes in contact, with the vehicle bed. (4) Insert an outrigger into the front outrigger socket until the locking pin ‘engages the hole in the ‘end of the outrigger. (6) Pull upward on the end of the outrigger using the loader bar as a fulcrum until the unit rotates to a horizontal position in the vehicle bed. Fa (@) Remove the loader pin and slide the loader bar down until it comes into pin retainer) in the first contact with the vehicle available set ot holes above bed. the loader bar. mull J (6) Push the base of the Unit towards the frontof the the front socket and putitin vehicle bed. The loader bar the outrigger storage loca- will slide on the unit until tion the rearwheels contact the (8) Secure the unit with vehicle bed. The unit may rope using the tie down then be rolled on the rear holes located on the base wheels and the casters of the unit and atthe top of located near the top of the the cage support member. unit (7) Remove the outrigger in WARNING To prevent serious damage to the mast assembly, do not place rope or tie downs across the mast assembly when securing the unit for transportation. B. UNLOADING THE UP-RIGHT LIFT FROM A VEHICLE USING THE LOADER. (1) Unsecure the unit (2) Insert the outrigger into the front outrigger socket until the locking pin engages the hole in the front end of the outrigger. (@) Rol! the unit back until the rear wheels are off the edge of the vehicle bed. (4) Pull downward on the outrigger, allowing the unit 10 10 slide on the loader bar. As the unit stops sliding on the loader bar the unit wll rotate upright using the loader bar {as a fulcrum. Gradually counterbalance the unis weight by applying an upward force on the outrigger. This allows the unit to settie gently on the front casters, avoiding ‘undue impact loading on the unit. (6) Remove the front outrigger and put it in the outrigger storage location.PASSAGE THROUGH A DOORWAY WITH THE UL-31/37 and UL-38/44 ‘The UL-31/97 and UL-38/44 are equipped with a castered rear Tit Back assembly. When the unitistited back onto this support frame, the overall height can be reduced tollow the tunitto pass through a standard doorway. CAUTION Before tilting the up-right Lift onto the rear Tilt Back assembly be sure the retaining pin is properiy inserted ‘and the jack is fully extended. (1) To use the Tit Back assembly, remove the retaining pin and lower the caster frame until the jack aligns with the upper ‘mounting bracket pin hole. (@) Attach the jack to the upper mounting bracket using the retaining pin. Be sure jack is fully extended by turning handle counterclockwise. (5) Remove outrigger and replace in oper storage position (4) Pull upward on end of outrigger until the unit comes to rest on the rear transport suppor frame, (8) Insert outrigger into front outrigger ‘socket until locking pin engages hole in end of outrigger. {(6) Turn handle on jack counterclockwise 10 lower the unit until the overall height is reduced tothe desired height. (8) Po stand the unit upright, fully extend the jack. Insert outrigger into front outrigger (7) Tum the handle clockwise to lift the unit, balance machin ‘Socket and push downward on end of outrigger. As mast approaches vertical, counter- ‘weight by increasing the upward force on end of outrigger. Ths allows ‘machine to settle gently on the front casters, avoiding undue impact on the machine. EMERGENCY PLATFORM LOWERING Inthe event of a power loss or electrical maltunction the platform may be manually lowered {rom the ground by means of a valve located on the power unit. (ON A.C. AND D.C. POWER UNITS: Turn valve counterclockwise to lower platform. After Platform is lowered turn valve fully clockwise to close valve. Valve must be closed for ormal operation. SOME A.C. UNITS: Tum knob counter- Clockwise and then pull out to lower plat- form. To close valve, push knob in and then turn clockwise. Valve must be closed for ‘normal operation, 11SPECIFICATIONS * Ue uu ao ava7 38/48 Platform Height (4) Maximum en sit 38h, tform Capacity 800 16s. 900 bs. 800 bs Stored Dimensions @) Vertical Height 78¥2In. 100in. 116in (©) wath ‘29in. 29in. 29 Depth ‘in Sin. 45in, (©) Horzontal Height 45in 45in.45in (©) Honzontal Length 7in. 98in. 114in, (© Diagonal Storage’ in. 73in (©) Diagonal Storage Length 10tin_116in. ‘Base Dimension with Outriggers, extended (H)Sideto Sido 110m, 146i, 148i (Frontto Back 92in.135in._195in Weight Without Outriggers &Scrowacks545Ibs. 692 Ibs. 73 Is. ‘Setof Outriggers |B Scrowiacks Stlbs. S4ibs. S4ibs. ‘Additional Weight forD.C.Option__S3ibs._S3ibs._S3ibs. Safety Raling Height ain. _42in Toe Board Height fin ain in Un System AC. Elec Motor 120 Volts, Hz D.C: Electe Power Source 1-12Vott Battery, Grp.27, 105 Amps. - Battery Charger Automatic, 120 Vot AC ‘6OHz. Output: 1Amps, 12 Votis 0. “Al apectatons subject to change witout note, MAINTENANCE AND ROUTINE SERVICE ‘Service Operation ‘Service interval TMonth | 3Month | 1 Year 1. Check oillevel ..... ceveeeeseeeee cok 2. Inspect and adjust sequence straps slack. . x 3. Check bubble level accuracy . feces pec p 4. Lubricate lift chains, chain sheaves... x 5. Change hydraulic oil (Mobile DTE-13).... 2... .eeeeceeeeeeseeeteedereeeeteeeedeneenee wx 6. Contactor malfunction check. x 7. Battery fluid level s vee For proper sence procedures S06 Up Fight Lit Sewice Manual Par No, G26 O07, a Sia aad Gpur, Richt AERIAL PLATFORMS ‘Calliol ree (800) 437-0770 California onty (800) 442-0770 ‘$775 Park St, Selma, CA 93662 Canada 68-701 108 industrial Dr, Whitby, Ontario, Gan. LINSZBCONTROLS AND INDICATORS operation of the Up-Right name and function of each The controls and indicators for Lift are shown in Figure 2-1. The control and indicator is listed in Table 2-1. The index numbers in the figure correspond to the index numbers in the table. The operator shall know the location of each control and indicator and have a thorough knowledge of the function attempting to operate the Table 2-1. Key Switch Lift/Lower Switch Emergency Lowering Valve, A.C./D.C. Power Units Emergency Lowering valve, Some A.C, Power Units Orbit Level and operation of each before unit. Controls and Indicators FUNCTION Provides Power to Lift/Lower Switch. Lifting UP on the switch elevates the Up-Right Lift. When the switch is released the lift stops. Pushing DOWN on switch lowers the Up-Right Lift. When knob is turned counterclockwise] to OPEN position platform lowers. valve is closed by turning knob clockwise. The platform cannot be taised until valve is closed. When knob is turned counterclockwise] and then pulled out platform lowers. Valve is closed by pushing knob in and then turning clockwise. The platform cannot be raised until valve is closed. When bubble is in center of level, this indicates work platform is level. Leveling is achieved by using Screwjacks at end of each outrigger.| 13a Key Switch Lift/Lower Switch Emergency Lowering Valve, DC Units Emergency Lowering Valve, AC Units Orbit Level Figure 2-1. Controls and IndicatorsSECTION III MAINTENANCE INSTRUCTIONS PERIODIC INSPECTION AND MAINTENANCE. The inspection and maintenance schedule is to be preformed at regular intervals, dependent on usage or environmental conditions, Daily inspection will prevent abnormal wear and prolong the life of all systems. Inspection and maintenance shall be performed by personnel who dre trained and familiar with mechanical and electrical procedures. The maintenance Schedule and Record log sheet provided in the back of this manual can be used to keep track of service activity. Cage Assembly Base Frame and Ladder Assembly Power Unit Assembly Control Box Assembly Outriggers Tilt Back Assembly Mast Assembly Pinch Shield Assembly Pigure 3-1. Location of Components16 Table 3-1, Periodic Inspection and Maintenance [couponer Battery system IDC Models/ chains, Sheaves, Istraps/ Mast Assy. INSPECTION or SERVICE electrolite level specific gravity exterior cable condition terminals Check Clean Check Check fasteners for tightness Check welds for cracks Check condition of deck Check for damage Check for wear Check for deformation Check for bending and weld cracks INTERVAL chassis control contro valve, laydraulic Pump chassis [Platform Check hardware switches operation Check cable for wear Check for leaks at valve base Check hose for wear Check hose connection Open emergency down valve and check for function Check pump for leaks at mating surfaces Check mounting bolts for tightness Wipe clean Drain hydraulic reservoir replace fluid Check fluid level and fill if necessary paren oe | oe oe xTable 3-1. Periodic Inspection and Maintenance - Cont'd. INSPECTION or SERVICE Check rod for gouges Check seals for leaks Check hoses for damage or cracks Inspect for external damage, dents or cracks Check exterior of the cable for pinching Check component mountings for tightness Check all fasteners for tightness Check welds for cracks Check hoses for damage, wear and cracks Check for and repair collision damage LUBRICATION, Refer to Figure 3-2 for location of items that require lubrication service. Use an aerosol chain lubricant for all components to be lubricated. a. Rear Wheel Bearings (2). (1) Apply with aerosol lubricant into bearing area. b. Chains (3). (1) Ensure that Up-Right Lift is in lowered position. (2) Apply enough aerosol chain lubricant to exposed section of chain to allow lubricant to run down chain. c. Screw Jacks (1). (1) Apply a moderate amount of aerosol chain lubricant to each screwjack assembly. ous18 1, Screw Jacks 2. Rear Wheel Bearings 3. Chains Figure 3-2. Lubrication Points HYDRAULIC OIL RESERVOIR (Figure 3-3). a. Remove hydraulic reservoir (4) from pump (1) by removing four screws (3) and four grip plates (2). b. Provide a suitable container and discard hydraulic fluid, c. Fill hydraulic reservoir (4) with Mobil DTE 13 or equivalent hydraulic fluid. Hydraulic reservoir has a 1.5 gallon capacity. NOTE Ensure o-ring is in place on pump when install- ing hydraulic reservoir. Insure that lift cylinder is fully retracted. 4, Reinstall hydraulic reservoir (4) to pump assembly (1 with grip plates (2) and screws (3).1. Pump 2. Grip Plates 3. Screws 4. Hydraulic Reservoir Figure 3-3. Hydraulic Reservoir BATTERY MAINTENANCE (DC Model). A 12 volt battery supplies power to the motor. Proper care and maintenance of the battery and motor will ensure maximum performance from the Up-Right Lift. a. Battery Inspection and Cleaning, (1) Check battery fluid level daily, especially if Up-Right Lift is being used in a warm, dry climate. CAUTION A prolonged low water level in battery will cause a low discharge. This will damage motor/pump unit, and void warranty. (2) Battery should be inspected periodically for signs of cracks in the case, electrolyte leakage and corrosion of the terminals. Inspect cables for worn spots or breaks in the insulation and for broken cable terminals. 1920 AC Cord Battery Charger Battery Charger Leads Battery Ammeter Figure 3-4. Battery Charger (3) Clean battery when signs of corrosion at the terminals exist, or when electrolyte has overflowed during charging. Use a baking soda or ammonia solution to clean the battery. Avoid getting the solution inside the cells. Rinse thoroughly with clear water. Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed. b. Battery Charging (See Figure 3-4) (1) Charge battery at end of each work shift or sooner if battery has been discharged. DO NOT charge batteries when the Up-Right Lift is in a hazardous area. CAUTION Permanent damage to battery will result if battery is not immediately recharged after discharging.(2) A battery kept in unheated areas should be placed on charge immediately after use, when night air temperatures fall below 65 degrees F. The Battery Charger Leads MUST be connected to battery before plugging in Charger in order to prevent possible bodily injury. (3) Attach battery charger leads (3) to battery (4) (Note proper polarity). (4) Connect A.C. Cord (1) to a properly grounded 115 volt, 60 Hz power supply. (5) Charge battery. A completely discharged battery will require an eight hour charge. (6) To determine approximate full charge at start of day's use, the ammeter (5) needle should indicate a charging rate of 1 amp'or less. c. Battery Cel) Equalization, (1) The specific gravity of the electrolyte in the battery cells should be equalized monthly. To do this, charge battery as outlined in Battery Charging. After this initial charge, check the electrolyte level in all cells and add water as necessary. Then, turn the charger on for additional eight hours. During this time, the charging current will be low (1 amp) as cells are equalizing. (2) After equalization, the specific gravity of all cells should be checked with a hydrometer. The temperature corrected specific gravity in this state should be 1.260. If any corrected readings are below 1.230, the battery should be replaced. The specific gravity in all cells after equalization should not vary more than .010. If a wide variation exists, this is an indication for battery replacement. (3) Do not check the specific gravity in a cell to which water has just been added. If there is not enough electrolyte in a fully charged cell to obtain a sample for the hydrometer, add water and continue charging for one to two hours to mix the water and electrolyte. ‘TROUBLESHOOTING. WARNING When troubleshooting, ensure that the lift is on a firm, level surfece. When performing any service which requires the platform to be raised ensure all four (4) outriggers are properly installed (refer to page 9). Unplug the machine (disconnect battery) before re~ placing or testing the continuity of any ical te electrical componen 2122 The following pages contain Troubleshooting Careful inspection and accurate analysis of in the Table of Troubleshooting information trouble more quickly than any other method. cover all possible problems that may occur, information. the symptoms listed will localize the This manual cannot therefore, if a specific problem is not covered herein, call for Service assistance, ‘TROUBLE 1. Ligt function inoperable, electric motor does not start. TABLE 3-2. PROBABLE CAUSE 1. Not plugged in or faulty connection (ac only). 2. No power at wall outlet (AC only). 3, Key Switch or Lift/Lower Switch faulty. 4. Open circuit in cable to motor control box. 5. Faulty motor relay or control voltage transformer (AC only). Troubleshooting REMEDY 1. Check all plugs and cords used. 2. Check power out put at wall outlet. 3. With the Rey Switch (S1) in the ON position, check con- tinuity across the contacts. If none, replace. Repeat pro- cedure for Lift/Lower Switch (S2). 4, Test for contin- uity through cable assembly (J1) and repair or replace. 5.A. While operating the Lift function, check the voltage across the Relay Coil. If no voltage present, replace faulty Transformer (Tl). If 24 VAC, check the Motor Relay by depres- sing the manual over- ride button located on the front center face of the Motor Relay (Kl). If the motor starts than replace the faulty Motor Relay (K1).TABLE 3-2, Troubleshooting - Cont'd. PROBABLE CAUSE 1, Lift function inoperable, electric motor does not start - Cont'd. 5. Faulty motor relay or control voltage transformer (Ac only) - Cont'd. NOTE: For Models with Serial Numbers 1966 to Current: 5.B. While operating the Lift function, check the voltage across the Relay Coil. If no voltage present, replace faulty Transformer (T1). While control circuit is ener- gized, NEVER come in contact with any components or the electrical mounting brackets. To do so could result in serious injury or death, If 24 VAC, check the Motor Relay by observ- ing the contacts while energizing the UP circuit. If the contacts are not activated then replace the faulty Motor Relay (K1). 6. Faulty Electric Motor (AC only). 6. Replace Motor. 7. Faulty Battery Charger (DC only). 7. Check the voltage output of the battery charger. If less than 12 voc, repair or replace. 8. Faulty Battery (Bc only). 8. After completely charging the battery, test the Battery (BT). Replace as required. 2324 TABLE 3-2. PROBABLE CAUSE Troubleshoot ing - Cont'd. REMEDY inoperable, Cont'd. 2. Lift function inoperable. starts when control is activated. 3. Inot descend Switch). 1, Lift function electric motor does not start - Electric Motor Platform does (Using Toggle 9. Faulty Motor Relay (DC only). 10. Faulty Electric Motor (DC only). 1. Emergency Lowering Valve open. 2, Hydraulic Reser- voir low. 3. Down Valve stuck. 4. Relief Valve out of adjustment or faulty. 5. Load Delay valve out of adjustment. 6. Faulty Hydraulic Pump. 1. Down Valve Solenoid faulty. 9. If 12 voc or more, check continuity| across the contact terminals of Motor Relay (K2) while still] operating the Lift function. If there is no continuity, replace. 10. While operating the Lift function, check the voltage across the Electric Motor (B) Terminals. If 12 voc or more is present, replace the Motor (B) 1. Close valve. 2. Check hydraulic fluid level, top off as required. 3. Check or replace Down Valve (V1). 4. Adjust the Relief Valve (RV1) (Para- graph 5-12). If not adjustable, replace. 5. Adjust Load Delay Valve (LDV), AC only (See Adjustments Paragraph 5-13). 6. Check pressure and delivery of the Hydraulic Pump (ASSY1) Replace if required. 1, Test for contin- uity across Solenoid. Repair or replace.TABLE 3-2. ‘Troubleshooting - Cont'd. B. Platform does not descend (Using Toggle Switch) - cont'd. 4. Platform does not come down or comes down very slowly (Using PROBABLE CAUSE 2, Down valve stuck closed. 3. Electrical malfunction. 1. Orifice Check Valve plugged with contamination. 2. Clean or replace valve, 3, See Trouble 1, Cause/Remedy 3 and 4, 1, Remove and clean Orifice (V3). Check valve. function sticks. ADJUSTMENTS , 1. Down Valve stuck open. 1. Clean or replace Down Valve (V1). SETTING SYSTEM RELIEF PRESSURE (Figure 3-5). NOTE Check the hydraulic system pressure when- ever the pump or relief valve has been serviced or replaced. a. Operate the hydraulic system for 5-10 minutes to warm fluid. Installing pressure gauge requires special adapter fitting. 1-2 through 1-6. b. Unscrew hose (10) and cap hose. See Table 1-1 and figures ¢. Install special adapter fittings (6,7,8) and 0-5000 psi pressure gauge (9). (6). a, Uncap hose (10) and screw to special tee adapter fitting Ensure that all four (4) outriggers are properly installed and the work platform leveled before elevating platform. 25AC Power Unit Tee Adapter Fitting DC Power Unit Adapter Fitting cap Adapter Fitting Locknut Pressure Gauge Adjusting Screw Hose Figure 3-5, System Relief Pressure Adjustment e. Remove the cap (3), loosen the locknut (4) on Main Pump Relief Valve and unscrew the adjusting screw (5) several turns. £, Remove the Pinch Shield (See Figure 3-7) and operate Pinch Shield controls from the ground, DO NOT elevate when standing in platform while Pinch Shield is removed. g. Turn Key Switch ON. h. Position Lift/Lower Switch to UP and elevate cage until it reaches the top and activates the Relief Valve. i. Position the Lift/Lower Switch to UP and hold there. 26j. Slowly screw the adjusting screw (5) in to increase the pressure to 1800 PSI, then tighten the locknut and replace cap. k. Turn Key Switch OFF. 1, Reinstall Pinch Shield. m, Remove special adapter fittings (6,7,8) and gauge (9) and reconnect hose (10) to remaining fitting. LOAD DELAY VALVE ADJUSTMENT, AC Models only (Figure 3-6). The Load Delay Valve (which is used on AC Models only) provides an initial bypass of flow from the pump to allow the AC motor to develop greater startup torque. a. Remove the Pinch Shield to permit control from the ground. WARNING DO NOT elevate when standing in platform while Pinch Shield is removed. b. Remove hydraulic reservoir (4) by removing the four screws (5) and four grip plates (6). Then carefully hold the reservoir up (approximately 2-3 inches from the drive plate) so that the pickup filter tube (3) is still in the hydraulic fluid and the load delay valve adjusting screw (7) on the pump (2) can be seen. c. Activate the Up Switch and observe the fluid being bypassed by the Load Delay Valve. When properly adjusted the valve should bypass fluid for 1 second and then shut off. 4. To adjust the valve, loosen the locknut (8) on the adjusting screw (7) and turn the adjusting screw clockwise to increase the duration of bypass and counterclockwise to decrease the duration of bypass. 27Motor Pump Pickup Filter Tube Reservoir Nuts Grip Plate Adjusting Screw Locknut Figure 3-6, Load Delay Valve Adjusting (AC Models Only). e. Tighten locknut (8) ensuring not to move adjusting screw (7). £, Reinstall the reservoir, ensuring grip plates (6) are in place and tighten nuts (5). g. Turn Key Switch OFF and replace Pinch Shield. REPAIR AND REPLACEMENT. DISASSEMBLY/REMOVAL, MAST ASSEMBLY (Figures 3-7 and 3-8). The following is the step by step instruction in which the mast assembly shall be disassembled. Before disassembly secure the cage to the ladder to prevent the work platform from extending when tilted to a horizontal position. Failure to secure cage to ladder before laying work platform down horizontally could result in bodily injury or damage to work platform,Using a suitable lifting device, lower the work platform into a horizontal position, preferably onto a work table. CAUTION Never attempt to lower work platform into a horizontal position without the use of a suitable lifting device. Gage Support Assembly Remova] (Figure 3-7). (1) Extend the Mast Assembly slightly to allow access to cage support mounting hardware. (2) Remove the button head capscrews (1) and flat washers (2), Set aside the Pinch Shield (3). (3) Remove capscrews (5) and flatwashers (6) to release the Cage Support Assembly (7). The disassembly procedure requires removal of one mast section at a time, beginning with the top mast assembly. Refer to Figure of 3-8 (Sheet 1 of 2 and Sheet 2 of 2) and Legend 3-8 for correct identification of parts. Fourth, Fifth and Sixth Stage Mast Assembly Removal (Figure Mark all components as they are removed so as not to confuse their location during reassembly. (1) Loosen sequence strap clamp bolts (1) and pull sequence strap (2) through clamp (49). (2) Remove both roll pins (3) and shafts (4), discard roll pins (3). Then drive out chain retaining pin (5) which releases the 6th Stage lifting chains (6). (3) Back out the four mast bearing retaining screws (7) until the four top mast bearings (8) can be pulled out. (4) Slide out the 6th Stage Mast Assembly (10). NOTE The bottom mast bearings (9) will fall off the 6th Stage Mast Assembly once it is pulled out of the 5th Stage Mast Assembly (11). (5) Loosen sequence strap clamp bolts (i2) and pull Sequence strap (13) through the clamp (43). 2930 Capscrews Washers Pinch Shiela Mast Assembly ! Capscrews Washers Cage Support Figure 3-7. Assembly Cage Supppoprt Assembly Removal/Installation.THIS PAGE INTENSIONALLY LEFT BLANKLegend for Figure 3-8 (Sheet 1 of 2 Strap Clamp Bolts strap Roll Pins Shaft Retaining Pin 6th Stage Lifting Chain Retaining Screws Mast Bearings Assembly, Upper, (P.N. 62160-000-00) Mast Bearings Assembly, Lower, (P.N. 62160-001-00) 6th Stage Mast Assembly 5th Stage Mast Assembly Strap Clamp Bolts strap 5th Stage Lifting Chain Cotter Pins Retaining Screws Mast Bear in: (P.N. 6215: Mast Bearings, Upper (P.N. 62158-000-00) Mast Bearings, Lower (P.N. 62158-000-00) Mast Bearings, Lower (P.N. 62159-000-00) 4th Stage Mast Assembly Strap Clamp Bolts Strap 4th Stage Lifting Chain Roll Pins Pin Retaining Screws 28. 29. 30. 31. 32. 33. 34. 35. 36. Mast Bearings, Upper (P.N._62158-000-00) Mast ‘Bearings, Upper (P.N. 62159-000-00) Mast Bearings, Lower (P.N, 62159-000-00) Mast Bearings, Lower (P.N. 62223-000-00) 3rd Stage Mast Assembly Retaining Screws 2nd Stage Mast Assembly Mast Bearings, Upper (P.N. 62159-000-00) Mast Bearings, Upper (P.N. 62158-000-00) Retaining Screws lst Stage Mast Assembly Mast Bearings, Upper (P.N. 62158-000-00) Mast Bearings, Lower (P.N. 62158-000-00) Mast Bearings, Lower (P.N. 62159-000-00) Mast Bearings, Bottom (P.N. 62158-000-00) Clamp Strap Clamp Bolts Strap Clamp Clamp Cylinder Assembly ClampMAST BEARINGS Figure 3-8. ra a w 6 ‘PART NO, 62158-000-00 PART NO. 62160-001-00 Mast Assembly Removal/Installation (Sheet 2 of 2) 3334 (6) Disconnect the 5th Stage lifting chains (14) by removing the cotter pins from pins (15) and removing pins (15). (7) Back out the four mast bearing retaining screws (16) until the four top mast bearings (17,18) can be pulled out. (8) Slide out the 5th Stage Mast Assembly (11). NOTE The bottom mast bearings (19,20) will fall off the 5th Stage Mast Assembly once it is pulled out of the 4th Stage Mast Assembly (22). (9) Loosen sequence strap clamp bolts (22) and pull sequence strap (23) through clamp (46). (10) Disconnect the 4th Stage lifting chains (24) by extracting roll pins (25). Discard roll pins (25). Then push pin (26) through chain attachment portion of top casting of 2nd Stage Mast Assembly. (11) Back out the four mast bearing retaining screws (27) until the four top mast bearing (28,29) can be pulled out. (12) Slide out the 4th Stage Mast Assembly (21). Second and Third Stage Assembly Removal] (Figure 3-8). (1) Once the Cylinder Assembly (48) has been removed the bottom mast bearings (40) between the Ist and 2nd Stage Mast Assemblies and the bearings (41,42) between the 2nd and 3rd Stage Mast Assemblies can be pulled out from the bottom, (2) Back out the four mast bearing retaining screws (33) on the top of the 2nd Stage Mast Assembly (34) until the four top mast bearings (35,36) can be pulled out. (3) Slide out the 3rd Stage Mast Assembly (32). (4) Back out the four mast bearing retaining screws (37) on the top of the Ist Stage Mast Assembly (38) until the four top mast bearings (39) can be pulled out. (5) Slide out the 2nd Stage Mast Assembly (34). REASSEMBLY, MAST ASSEMBLY (Figures 3-7 and 3-8). (1) Slide the 2nd Stage Mast (34) into the lst Stage Mast (38). Note the orientation so that the sequence strap retainer is towards the front of the work platform. (2) Install the four top mast bearings (39) by slipping them between the two Mast Stages until the hole lines up with the bearing retaining screw (37). Then tighten the bearing retaining screw (37).(3) Install the four bottom mast bearings (40) by sliding them between the two Mast Stages from the bottom of the work platform. (4) Install the 3rd stage Mast (32) by sliding it into the 2nd Stage Mast. NOTE Fold the sequence strap so that it lays inside the 3rd Stage Mast tube before installing. (5) Install the four top mast bearings (35,36) between the 2nd and 3rd Mast Stages using the retaining screws (33). NOTE Orientate Item (35) towards the back of the work platform and Item (36) towards the front of the work platform. (6) Install the four bottom mast bearings (41,42) between the 2nd and 3rd Mast Stages from the bottom of the work platform, NOTE Mast bearing orientation same as top. (7) Install the 4th Stage Mast (21) by placing the four bottom mast bearings (30,31) between the bearing stops on the bottom of the 4th Stage Mast and sliding it into the 3rd Stage Mast. NOTE Orientation of Item (21) is with the chain towards the back of the work platform. Orien- tate Item (31) towards the back of the work platform and Items (30) towards the front. Also, fold the sequence strap so that it lays inside the 4th Stage Mast tube before instal- ling. (8) Install the four top mast bearings (28,29) between the 3ré and 4th Mast Stages using the retaining screws (27). Orientation of Items (28) is towards the front of the work platform and Items (29) towards the back. (9) Feed the 4th Stage lift chain through the sheave on the top of the 2nd Stage Mast and reconnect the chain to the chain attachment by inserting the retaining pin (26) and reinstalling new roll pins (25). Using center punch upset the ends of holes where pin (26) is inserted. 35(10) From the bottom of the work platform, pull the 4th Stage sequence strap so that it is laying out the bottom. (11) Install the 5th Stage Mast (11) by placing the four bottom mast bearings (19,20) between the bearing stops on the bottom of the 5th Stage Mast and sliding it into the 4th Stage Mast. NOTE Orientation of Item (11) is with the chain towards the back of the work platform. Orien- tate Items (20) towards the back of the work platform and Items (19) towards the front. Also, fold the sequence strap so that it iays inside the 5th Stage Mast tube before instal- ing. (12) Install the four top mast bearings (17,18) between the 4th and 5th Mast Stages using the retaining screws (16). NOTE Orientation of Items (17) is towards the front of the work platform and Items (18) towards the back. (13) Feed the 5th Stage lifting chains over the sheaves on the top of the 4th Stage Mast (21) and reconnect the chains to the chain attachment with pins (15). (14) Route the 5th Stage sequence strap (13) through the guide on the bottom of the 4th Stage Mast and up to the top strap retainer (43) between the 3rd and 4th Mast Stages and attach with clamp using strap clamp bolts (12). (15) Install the 6th Stage Mast (10) by placing the four bottom mast bearings (9) between the bearing stops on the bottom of the 6th Stage Mast and sliding it into the 5th Stage Mast. NOTE Orientation of Item (10) is with the chain towards the back of the work platform. Fold the sequence strap so that it lays inside the 6th Stage Mast tube before instal- ling. (16) Install the four top mast bearings (8) between the 5th and 6th Mast Stages using the retaining screws (7). (17) Peed the 6th Stage lifting chains over the sheave on the top of the 5th Stage Mast (11). Reconnect the chains to the chain attachment located on the top of the 4th Stage Mast (21) casting by inserting pin (5) through chain. Then insert shafts cH through attachment and sheaves and secure with roll pins(18) Route the 6th Stage sequence strap (2) through the guide on the bottom of the 5th Stage Mast and up to the top strap retainer (43) between the 4th and 5th Mast Stages. (19) Install cylinder assembly. Cage Support Assembly Installation (See Figure 3-7). (1) Install Cage Support Assembly (7) and secure with capscrews (5) and flat washers (6). (2) Ensure Key Switch is OFF and install pinch shield (3) with flat washers (2) and capscrews (1). SXLINDER ASSEMBLY REMOVAL. (Figure 3-9) (1) Disconnect the hydraulic hose (1) to the lift cylinder (2). Cap the fitting (15) on the lift cylinder. (2) Remove nuts (4), flat washers (5), tie rod locknuts (6) and retaining ring (14) to remove the cylinder mounting plate (7). (3) Refer to Figure 3-8. Loosen sequence strap clamp bolts (22,44) and pull sequence straps (23,45) through the clamps (46,47). NOTE I€ only the Cylinder Assembly is to be removed both sequence straps (23,45 Figure 3-8) must be released. To simplify the replacement of the Cylinder Assembly attach approximately 10 feet of string or banding material, etc. to the strap before it is removed. When the assembly is removed disconnect the attached string, etc. Then during reassembly reattach the string, etc. to the sequence straps. (4) Remove the screws (8) and Pinch Shields (9) on lower front and back of the Ist Stage Mast Assembly. (5) Remove the capscrews (10) and flat washers (11) which attach the 2nd and 3rd Stage bottom castings to the 2nd and 3rd Stage Mast Assemblies. (6) Partially pull out the Cylinder Assembly (2) so that 2nd Stage bottom casting (12) and 3rd Stage bottom casting (13) are obtainable, keeping tension on tie rods. (7) Install tensioner brackets (16) and tensioner spacer (17) on 2nd and 3rd Stage castings (12,13). (8) Install tie rod tensioners (18) over ends of tie rods (19), ‘Tighten until chains are taut with no slack. (9) Remove cylinder assembly (2) from mast assembly. 3 7spou OTL * SIsUOTSUDL POY ATL * zeoeds JouoTsuaz * syeyoerg JouoTsuaz * moqta ‘but33Td * buyy bututejeu * buy ase woaz0g ebeas PIE * Buy3se woazog ebeas puz *: szaysem * saazosdep * spTerys yoUuTd * sMaz0s * eaeta Buyqunow sepuTTAd * 830N * yeysem 3eTa ¢ 830N * buraatd * aepuytAD 3311 : Cylinder Assembly Removal/Installation Pigure 3-9. 38CYLINDER ASSEMBLY INSTALLATION. NOTE Reattach string, etc. to the sequence straps prior to assembly. (1) Slide the Cylinder Assembly into the bottom of the work platform as shown. (2) Install tensioner brackets (16) and tensioner spacer (17) onto 2nd and 3rd Stage bottom castings (12,13). (3) Install tie rod tensioners (18) to tie rods (19). (4) While sliding cylinder assembly (2) back into place guide sequence straps up through masts by pulling strings at top of masts. (5) Route the 4th Stage sequence strap (23, Figure 3-8) through the guide in the 3rd Stage bottom casting (13). (6) Slide the 3rd Stage bottom casting into the 3rd Stage Mast Tube and secure with fasteners (10,11). (7) Remove tensioner brackets (16), tie rod tensioners (18) and tensioner spacer (17) while still maintaining tension on tie rods (19). (8) Route the 4th Stage sequence strap (23, Figure 3-8) between the 2nd and 3rd Stage Mast tubes by "fishing" a wire, etc. down from the top and attaching it to the sequence strap. Then secure the strap using the clamp (46, Figure 3-8) and fasteners (22, Figure 3-8). (9) Route the 3rd Stage sequence strap (45, Figure 3-8) through the guide in the 2nd Stage bottom casting (12). (10) Push the 2nd Stage bottom casting (12) into the 2nd Stage Mast tube and secure with fasteners (10,11). (11) Route the 3rd Stage sequence strap (45, Figure 3-8) between the 1st and 2nd Mast Stages by "fishing a wire, etc. down from the top and attaching it to the sequence strap. Then secure the strap using the clamp (47, Figure 3-8) and fasteners (44, Figure 3-8). (12) Replace the pinch shields (9) and secure with fasteners (8). (13) Holding tie rods (19) to maintain tension on the chains, thread tie rods and tie rod end through proper hole on cylinder mounting plate (7). (14) Install cylinder mounting plate and secure with fasteners (4,5). Torque to 17 ft. lbs. 3940 (15) Install tie rod locknuts (6) and tighten as required to tension chains. (16) Reinstall retaining ring (14). (17) Reconnect the hydraulic hose (1) to the lift cylinder fitting (15). LIFT CYLINDER SEAL REPLACEMENT (Figure 3-10). The Lift Cylinder Seal can be accessed from the bottom of the Up-Right Lift without removing the Cylinder Assembly. Cage MUST be secured to ladder before pro- ceeding with this procedure. a. Secure the cage to the ladder to prevent the work platform from extending when tilted to a horizontal position. b. Using a suitable lifting means attached to the upper tie down point on the Cage Support, lower the work platform onto its back horizontally. ¢. Remove cylinder mounting plate fasteners (1), rod end fasteners (2) and retaining ring (7). a. Remove hydraulic hose (3) from the cylinder fitting (5 and cap the cylinder fitting to prevent air entering into the cylinder. @. Remove the cylinder mounting plate (4). f£, Rotate the cylinder rod so that the fittings (5,6) are pointing straight up, then remove the fittings (5,6). CAUTION Marring the surface of the cylinder rod will cause improper cylinder function. Use a strap wrench to prevent rod damage. g. Using a Strap Wrench to secure the cylinder rod, unscrew the cylinder rod end (8). h, Remove the seal retaining ring (10) using a Gland Nut Socket or a Gland Nut Wrench. i, Using the Cylinder Seal Assist Tool push the cylinder rod into the cylinder until it is past the seal. Then unscrew the Cylinder Assist Tool and extract the seal. NOTE Apply hydraulic fluid to new cylinder seal, threads and all sliding surfaces prior to assembly.pow zepurté5 Utd TIOW PaTeA 8913730 yeas bury burureaey Tees Butz-0 Bury Bururesoy butaata buraata e3eTa Sutaunoy zepurtAd 8808 DTTNeIPAR sieua3seg pug pow szoue3seg e3eta buyqunoy Lift Cylinder Seal Replacement and Orifice Valve Cleaning. Figure 3-10. 4142 j, Replace the seal (11) making sure the lip of the seal is facing inward. k, Pull the cylinder rod back through the seal using the Cylinder Seal Assist Tool. 1, Using a Gland Nut Socket or a Gland Nut Wrench reinstall the seal retaining ring (10). Scratches or nicks on the cylinder rod will prevent the seal from seating properly. m. Using a Strap Wrench to hold the rod, replace the cylinder rod end (8). n, Set the cylinder mounting plate (4) into place and secure with fasteners (1,2). 0. Reinstall retaining ring (7). Pp. Reinstall fittings (6,5). q. Reconnect hydraulic hose (3) r. Using a suitable lifting device, stand the work platform upright. 5. Remove securing straps from Cage Support and Ladder. t. Check the function of the lift cylinder by elevating the platform, If the work platform is "spungy" the cylinder will require bleeding to remove air from the system CYLINDER BLEEDING PROCEDURE TO SERIAL NUMBERS UL-20 4559, UL-24 4565, UL-31 4523, UL-38 4554 (Figure 3-7). a. Remove the pinch shield from the cage support (Item 3, Figure 3-6) to operate controls from the ground. b. Using a Cylinder Bleed Wrench open the bleed screw valve (48) approximately one half turn. ¢. Turn Key Switch on. 4, Hold the Lift/Lower Switch in the UP position to force the trapped air to escape through the bleed screw valve. e. Once the trapped air has escaped through the bleed screw valve quickly close the valve and release the Lift/Lower Switch. f. Ensure Key Switch is OFF and replace the pinch shield.CYLINDER BLEEDING PROCEDURE FOR SELF BLEEDING CYLINDER SERIAL NUMBERS UL-20 TO CURRENT, UL-24 4566 TO CURRENT, UL-31 4524 TO CURRENT, UL-38 4555 TO CURRENT. a. Cycle the cylinder four (4) times by raising and lowering the mast. Raise till each mast section is roughly one (1) foot apart from the other. LIPT CYLINDER ORIFICE VALVE CLEANING (Figure 3-10). a. Follow steps a, through g. of Cylinder Bleeding Procedure. b. Remove roll pin (13) from threaded end of rod end (8). c. Lift orifice valve (12) from inside rod end (8). d. Unplug orifice valve (12) by clearing hole with a straight pin. Flush with solvent to remove any contamination that may remain, e. Reinstall orifice valve (12) into rod end (8), Drive roll pin (13) back into rod end (8) to secure orifice valve, £. Reassembly rod end (8) into cylinder rod (14). g. Reinstall cylinder mounting plate (4) and secure with fasteners (1,2). h, Reinstall retaining ring (7). i, Reconnect hydraulic hose (3). Bleed cylinder. 43CONTENT. SECTION IV DIAGRAMS This section contains electrical diagrams, hydraulic power diagrams, and their legends which give an explanation of location and function. The legends and diagrams appear in the following order: Table 4-1. AC Electrical Diagram Legend. Table 4-2. DC Electrical Diagram Legend. Table 4-3. Hydraulic Diagram Legend. Figure 4-1, AC Electrical Diagram. Figure 4-2, DC Electrical Diagram. Figure 4-3, Hydraulic Diagram. TABLE 4-1. AC Electrical Diagram Legend. REFERENCE DESIGNATION NAME FUNCTION LOCATION B Motor, AC Elec- Provides power Top of Power tric to drive Unit. Hydraulic Pump, K1 Motor Contactor Provides power Inside Control to Motor. Box on upper left. Ll Solenoid Opens Lowering On the Power valve. Unit towards the rear of the Up-Right Lift. sl Key Switch Enables/dis- Right front side ables Control of Pinch Shield. Circuit. s2 Lift/Lower Provides power Next to Key Switch to Motor Con- Switch on the tactor or Down Pinch Shield. Solenoid. T Transformer Provides 24 VAC Inside Control control voltage Box on upper to Control right. Circuit. a4TABLE 4-2, DC Electrical Diagram Legend. REFERENCE DESIGNATION NAME FUNCTION LOCATION B Br Kl L2 sl s2 Motor, DC Elec tric Battery, 12 Volt Charger Motor Relay Solenoid Key Switch Lift/Lower Switch Provides power to drive Hydraulic Pump, Stores energy which is used by Power Unit. Supplies elec- trical energy to be stored by Battery. Provides power to Motor. Opens Lowering valve. Enables/dis- ables Control Circuit. Provides power to Motor Con tactor or Down Solenoid. Top of Power Unit. Front center of Base Frame. Above the Power Unit. On the Power Unit towards the front. On the Power Unit. Right front side of Pinch Shield. Next to Key Switch on the Pinch Shield. 4546 REFERENCE TABLE 4-3. Hydraulic Diagram Legend. DESIGNATION NAME FUNCTION LOCATION cv cYL FLTR LDV (AC Unit only) P RV vi Check Valve Lift Cylinder Filter Load Delay Valve Pump Relief Valve Down Valve Emergency Down valve Orifice Check valve Prevents fluid from flowing back thru Pump. Provides force to extend the Mast Assembly. Filters the fluid as it is drawn to Pump. Improves start-up torque characterist- ics. Provides fluid power to Lift Cylinder. Limits the hydraulic pressure to Lift Cylinder. Allows fluid to flow freely to the reservoir to lower the platform, Manually oper- ated valve which bypasses Down Valve. Controls des- cent rate of Lift Cylinder. Power Unit Drive Plate/Manifold. Inside the Mast Assembly. Mounted to Pump Pick Up Tube inside reservoir. Located on the back of the Pump. Located on the bottom of the Power Units Drive Plate/Manifold. Located on the Power Units Drive Plate/Manifold Located on the Power Units Drive Plate/Manifold. On the Power Unit. Inside the Cylinder Assembly.Ac Electrical Diagram Figure 4-1. a748 Figure 4-2. De Electrical DiagramWVHDVIG SINVEGAH -UNn YaMod os --—___-- — NO Lunn wamod DY NO (ACT AWA AVRO G¥O7 ALON Hydraulic Diagram Figure 4-3. 4950 Section V Parts List General. The information contained in this section is intended to aid the user in locating and identifying replacement parts. Exploded drawings are used to show relative location of the component parts in disassembly order. Part List. Method of Listing. Parts are listed in order according to the reference number shown in the illustration, followed by the part number and full description, The quantity of each individual part follows its description. Ordering Information. When ordering replacement parts, the complete part number and description should be used to ensure proper identification and delivery of the desired item. Abbreviations. The following is a list of abbreviations and their interpretations used in the parts lists; AC... ee ee es + Alternate Current AMP... ee. + s+ Ampere ASSY. 2... 4 es « Assembly BUTT. » ss... . . Button De... ss. ee. . Direct Current DIA... . +... + Diameter rrr GAL ee ee ee + Gauge HD... eee ee ee Head HEX... ss. + + + Hexagon HHH»... . ss « « Hexagon Head HEC... . 2... . Hexagon Head Cap HP... . 1. ses « Horse Power HWH. ...... . « Hexagon Washer Head IBS... se. «+ Pounds LG. se ee eee Long LHe. see ee ee + Left Hand MACH. . 5... +. « Machine WHA... . 4... . Next Higher Assembly NPT. 2... . Standard Pipe Thread RD. we ee ee ee + Round REF... «+s + « Reference RH... + ee ee e+ Right Hand SLFTP ....... . Self Tapping SOC. . +e ee es « Socketunc UNF ve Ww Unified National Course Unified National Fine volt with 5162694-001-00 62694-002-00 62697-001-00 62697-002-00 62400-000-00 No Number No Number No Number No Number 62269-001-00 No Number No Number No Number UP-RIGHT LIFT, 24 PT AC Model . . Serial # 4332 thru 4646 Serial # 4647 thru Current UP-RIGHT LIFT, 24 FT DC Model . . Serial # 4332 thru 4646 Serial # 4647 thru Current CAGE ASSEMBLY (See Figure 5-16) BASE FRAME/LADDER ASSEMBLY, . . (See Figure 5-4) POWER UNIT ASSEMBLY/INSTALLATION, AC Model, (See Figure 5-6) POWER UNIT ASSEMBLY/INSTALLATION, DC Model, (See Figure 5-7 CONTROL BOX ASSEMBLY (AC Models Only) (See Figure 5-10) OUTRIGGER ASSEMBLY. ..... . (See Figure 5-5) MAST ASSEMBLY (See Figure 5-13) PINCH SHIELD ASSEMBLY... . (See Figure 5-11 and 5-11A) RETRACTILE CABLE INSTALLATION . (See Figure 5-12)Ws NyUP-RIGHT LIFT, 31 FT AC Model... .. .| REF 4646 62695-001-00 Serial # 4332 thru 62695-002-00 Serial # 4647 thru Current 31 FT DC Model... ~~. 4646 UP-RIGHT LIFT, 62698-001-00 Serial # 4332 thru 62698-002-00 Serial # 4647 thru Current 62419-000-00 CAGE ASSEMBLY (See Pigure 5-16) No Number BASE FRAME/LADDER ASSEMBLY, . . . - - + (See Figure 5-4) No Number + POWER UNIT ASSEMBLY/INSTALLATION, AC Model, (See Figure 5-6) « POWER UNIT ASSEMBLY/INSTALLATION, . . .| 1 DC Model, (See Figure 5-7) CONTROL BOX ASSEMBLY (AC Models Only) (See Figure 5-10) No Number No Number OUTRIGGER ASSEMBLY... .- +--+ + +e (See Figure 5-5) 62270-001-00 No Number TILT-BACK ASSEMBLY/INSTALLATION (See Figure 5-17) No Number . MAST ASSEMBLY (See Figure 5-13) ....| 1 No Number PINCH SHIELD ASSEMBLY ..... +--+ (See Figure 5-11) No Number RETRACTILE CABLE INSTALLATION... . « (See Figure 5-12) 55DESCRIPTION 62696-001-00 62696-002-00 62699-001-00 62699-002-00 62419-000-00 No Number No Number No Number No Number 62270-001-00 No Number No Number No Number No Number UP-RIGHT LIFT, 38 FT AC Model . . Serial # 4332 thru 4646 Serial # 4647 thru Current UP-RIGHT LIFT, 38 FT DC Model . . Serial # 4332 thru 4646 Serial # 4647 thru Current CAGE ASSEMBLY (See Figure 5-16) BASE FRAME/LADDER ASSEMBLY, . . (See Figure 5-4) POWER UNIT ASSEMBLY/INSTALLATION, AC Model, (See Figure 5-6) POWER UNIT ASSEMBLY/INSTALLATION, DC Model, (See Figure 5-7) CONTROL BOX ASSEMBLY (AC Models Only) (See Figure 5-10) OUTRIGGER ASSEMBLY... .. ~~ (See Figure 5-5) TILT-BACK ASSEMBLY/INSTALLATION (See Figure 5-17) MAST ASSEMBLY (See Figure 5-13) PINCH SHIELD ASSEMBLY... . + (See Figure 5-11) RETRACTILE CABLE INSTALLATION . (See Figure 5-12) 87DESCRIPTION No Number 62803-000-00 62804-000-00 62805-000-00 00942-000-00 11248-004-00 13919-004-00 03570-000-00 62429-000-00 62430-000-00 11240-006-00 11248-006-00 11254-008-00 03491-000-00 62825-000-00 11252-028-00 62172-000-00 11753-012-00 13919-006-00 11248-004-00 62826-000-00 11248-008-00 11256-032-00 62835-000-00 BASE FRAME AND LADDER ASSEMBLY. (See Figures 5-1, 5-2, 5-3 for NHA| BASE WELDMENT, 24 FT. . BASE WELDMENT, 31 FT. . BASE WELDMENT, 38 FT. LEVEL, Orbit. . . . « LOCKNUT, 1/4-20 UNC . . CLAMP, Hose»... + PIN ASSEMBLY, Retaining LADDER WELDMENT, 24 FT and. 31 FT Models LADDER WELDMENT, 38 FT Model. WASHER, Flat 3/8 DIA. . . LOCKNUT, HEX 3/8-16 UNC SCREW, HHC 3/8-16 UNC x 0 COVER, Outrigger End. . SCREW, HHC 1/4-20 UNC x WHEL 2. eee ee ee PIN, Cotter 1/8 x 1-1/2 CLAMP, Hose... LOCKNUT, HEX 1/4-20 UNC COVER, Outrigger End. . LOCKNUT, 1/2-13 UNC HEX SCREW, 1/2-13 UNC HEC x BRACKET... ee eee 1DESCRIPTION No Number 26610-001-00 15788-000-00 29961-000-00 29962-000-00 29925-000-00 29926-000-00 11248-004-00 11239-004-00 BASE FRAME AND LADDER ASSEMBLY -. Continued BOX, Electric SUBPLATE. . . INLET... COVER... STRAIN RELIEF STRAIN RELIEF . . . LOCKNUT . . 2. eee WASHER, Flat 1/4 DIA.Figure 5-5, Outrigger Assembly= |r| ae 62269-001-00 | OUTRIGGER ASSEMBLY, 24 FT Model . (See Figure 5-1 for NHA) 62270-001-00 | OUTRIGGER ASSEMBLY, 31 FT and 38 FT . Models (See Figures 5-2 and 5-3 for NHA) 62461-000-00 OUTRIGGER TUBE, 24 FT Model . . . 62460-000-00 OUTRIGGER TUBE, 31 FT and 38 FT , Models 14996-010-00 | . WASHER, Flat 5/8 DIA. 26553-004-00 RIVET, 3/16 DIA .250 - 03534-000-00 COVER. we ee eee 03533-000-00 PAD. eee eee 11240-005-00 WASHER, Flat 5/16 DIA 11238-005-00 LOCKWASHER, 5/16 DIA. 11253-008-00 SCREW, HHC 5/16-18 x 3/4. 62459-000-00 OUTRIGGER CASTING . . . « 11248-005-00 NUT, HEX 5/16-18 UNC. . . 11252-016-00 SCREW, HHC 1/4-20 x 2. 03508-000-00 KNOB. ee ee ee eee 11240-004-00 WASHER, Flat 1/4 DIA. . 11248-004-00 NUT, HEX 1/4-20 UNC . . 11253-014-00 SCREW, HHC 5/16-18 x 3/4 11252-036-00 SCREW, HHC 1/4-20 x 4-1/2 11240-010-00 WASHER, Flat 5/8... . « 03471-000-00 ARM, Handle... ...-Figure 5-6, AC Power Unit Assembly/Installation 6364 DESCRIPTION No Number 62161-000-00 62161-007-00 62161-015-00 62161-014-00 62161-004-00 62162-017-00 62161-006-00 62161-017-00 62161-016-00 62161-023-00 13888-011-00 13888-032-00 62161-022-00 62161-024-00 62161-005-00 62161-010-00 62161-025-00 11940-010-00 29925-000-00 62192-000-00 11248-005-00 11240-005-00 AC POWER UNIT ASSEMBLY/INSTALLATION (See Figures 5-1, 5-2 and 5-3 for AC POWER UNIT»... ee + MOTOR ASSEMBLY, 110 VAC 1 HP. + + COMPOSITOR W/COVER. . . . HYDRAULIC PUMP ASSEMBLY BREATHER CAP... . ss RELIEF VALVE ASSEMBLY FILTER, Pick Up . . < RETURN LINE... . . CARTRIDGE ASSEMBLY. . + CARTRIDGE ONLY. . « + + O-RING, Large... + + O-RING, Small. 2... « 24VAC COIL... eee HYDRAULIC RESERVOIR ASSEMBLY. SEAL, Reservoir... . « GRIP PLATE... . 4 + VALVE, Emergency Down FITTING, Elbow. . . . CONNECTOR, Cable... . HOSE ASSEMBLY, 1/4 x 32 LOCKNUT, HEX 5/16-18 UNC. . WASHER, Flat 5/16 DIA. . .Figure 5-7, DC Power Unit Assembly/InstallationDESCRIPTION No Number 62162-000-00 62162-006-00 11240-006-00 11254-004-00 62162-010-00 62162-007-00 62162-012-00 62161-004-00 62162-017-00 62161-006-00 62161-017-00 62162-001-00 13888-011-00 13888-032-00 62162-002-00 62162-005-00 62162-004-00 29931-003-00 11248-005-00 11240-005-00 62162-015-00 62162-016-00 No Number == DC POWER UNIT ASSEMBLY/INSTALLATION (See Figures 5-1, 5-2 and 5-3 for DC POWER UNIT 1/2 HP... . . s + MOTOR ASSEMBLY, 12 VDC 1/2 HP « WASHER, Flat 3/8 DIAL... . + SCREW, HHC 3/8-16 UNC x BRACKET, Relay. . STARTER SOLENOID. HYDRAULIC PUMP. . BREATHER CAP... . « RELIEF VALVE ASSEMBLY FILTER, Pick Up . . RETURN LINE... . CARTRIDGE ASSEMBLY. + O-RING, Large. . + O-RING, Small . . SOLENOID, .. 1. HYDRAULIC RESERVOIR ASSEMBLY. + SEAL, Reservoir... .. 2% CONNECTOR. 2 ee ee ee ee LOCKNUT, HEX 5/16-18 UNC. WASHER, Flat 5/16 DIA . . WASHER, Split Lock. . . . SCREW... ee ee eee WIRE ASSEMBLY x 69 FT... (See Figures 5-8 and 5-8A\DESCRIPTION No Number DC POWER UNIT ASSEMBLY/ . . INSTALLATION - Continued 29601-015-00 CONNECTOR, Ring Terminal, 29601-013-00 CONNECTOR, Ring Terminal. 13963-003-00 PITTING, Elbow. . 2... . 62192-003-00 HOSE ASSEMBLY, 1/4 x 29 LG. 62162-016-00 VALVE, Emergency Down . . . 62261-000-00 BRACKET, Mounting... ... 62162-009-00 GROMMET, Mounting... .... NOTE: For Battery Installation See Figures 5-8 and 5-8A. NOTE: For Battery Charger Installation See Figures 5-9 and 5-9A.Figure 5-8, Battery Installation, DC Models Serial # 4332 thru 4646DESCRIPTION 62346-000-00 62125-002-00 11239-005-00 11246-005-00 62147-000-00 11240-005-00 15936-003-00 62145-000-00 11248-004-00 11240-004-00 62144-000-00 26554-002-00 62299-001-00 62125-001-00 BATTERY INSTALLATION, DC Models . Serial # 4332 thru 4646 (See Note Figure 5-7 for NHA) STRAP, Battery... ....- BATTERY CABLE ASSEMBLY x 69 WASHER, Flat ASTM 5/16 DIA. LOCKNUT, HEX 5/16-18 UNC. SUPPORT, Battery Cradle . WASHER, Flat 5/16 DIA. . SCREW, Shoulder 3/8 DIA BATTERY RETAINER. . . LOCKNUT, HEX 1/4-20 UNC WASHER, Flat 1/4 DIA. . BATTERY CRADLE. . . « RIVET, Pop 1/4 DIA. . « BATTERY, 12 VDC 105 AMP . . BATTERY CABLE ASSEMBLY x 30DESCRIPTION 62757-000-00 62125-002-00 11239-005-00 11246-005-00 62758-000-00 11240-005-00 15936-003-00 24611-007-00 11248-004-00 11240-004-00 62709-000-00 62299-001-00 62125-001-00 26554-002-00 27967-000-00 = BATTERY INSTALLATION, DC Models Serial # 4647 thru Current (See Note Figure 5-7 for NHA CRADLE. «2 ee ee ee eee BATTERY CABLE ASSEMBLY x 69 WASHER, Flat ASTM 5/16 DIA, LOCKNUT, HEX 5/16-18 UNC. SUPPORT, Battery Cradle . WASHER, Flat 5/16 DIA . SCREW, Shoulder 3/8 DIA PLYWOOD... . eee LOCKNUT, HEX 1/4-20 UNC WASHER, Flat 1/4 DIA. . BATTERY RETAINER. . . . «+ BATTERY, 12 VDC 105 AMP . . BATTERY CABLE ASSEMBLY x 30 RIVET, Pop 1/4 DIA... « « BATTERY CASE... . +--+ +72 Pigure 5-9. Battery Charger Installation, DC Models Serial # 4332 thru 4646BATTERY CHARGER INSTALLATION, DC Models Serial # 4332 thru 4646 (See Note Figure 5-7 for NHA) 62143-000-00 CHARGER, Battery... .... 11248-004-00 LOCKNUT, HEX 1/4-20 UNC . . 11240-004-00 WASHER, Flat 1/4 DIA. . 62315-000-00 MOUNT, Battery Charger. 11239-004-00 WASHER, Flat 1/4 DIA. . 14252-004-00 NUT, Sert 1/4-20 UNC. . 11252-008-00 SCREW, HHC 1/4-20 UNC xor) Pigure 5-9. Battery Charger Installation, DC Models Serial # 4647 thru CurrentDESCRIPTION BATTERY CHARGER INSTALLATION, DC Models Serial # 4647 thru Current (See Note Figure 5-7 for NHA) 62143-000-00 CHARGER, Battery... ... « 11248-004-00 LOCKNUT, HEX 1/4-20 UNC 11240-004-00 WASHER, Flat 1/4 DIA. . 62315-000-00 MOUNT, Battery Charger. 11273-004-00 NUT, Jam 1/4-20 UNC . . 14252-004-00 NUT, Sert 1/4-20 UNC. .. ~~ 14940-001-00 EYE BOLT, 1/4-20 UNC x 1-1/4. 62830-000-00 SHIELD, Charger (Useable on . Serial # 4332 thru Current)16 ure 5-10. Contr Seria. 01 Box Assembly 1 # 4332 thru 464662416-000-00 | CONTROL BOX ASSEMBLY. ,..- +--+ +e Serial # 4332 thru 4646 (See Figures 5-1, 5-2 and 5-3 NHA) 62752-000-00 BRACKET, Mounting, Electric . 11240-004-00 WASHER, Flat 1/4 DIA. . . « 11248-004-00 LOCKNUT, HEX 1/4-20 UNC . . 29493-099-00 CABLE, 16 GA.» see ees 62394-008-00 TERMINAL STRIP... . 4 + 05503-004-00 SCREW, HEX WSHR #6 x 1/2 LG 29977-000-00 TRANSFORMER, 24V.. ~~~ 14-73-006-00 SCREW, HEX x 3/4. wae 62415-000-00 COVER. 2 eee oe 62525-001-00 CONTACTOR . . « 62179-000-00 CORD, 110V.. 11868-011-00 BUSHING, StrainAssembly Curres Serial # 4647 thru 5-10A. Control Box FigureITEM PART DESCRIPTION ary 62416-002-00 | CONTROL BOX ASSEMBLY... ... esses Serial # 4647 thru CURRENT (See Figures 5-1, 5-2 and 5-3 NHA) 62833-000-00 BRACKET, Mounting, Electric . 11240-004-00 WASHER, Flat 1/4 DIAL... 11248-004-00 LOCKNUT, HEX 1/4-20 UNC . . 29493-099-00 CABLE, 16 GAL... eee 29977-008-00 TERMINAL STRIP... ss + + 05503-004-00 SCREW, HEX WSHR #6 x 1/2 LG 29977-000-00 TRANSFORMER, 24V. 4. « © 14-73-006-00 SCREW, HEX x 3/4. 2 2 we 62415-000-00 COVER... .. a 62525-001-00 CONTACTOR . . . 62179-000-00 corp, 110V.. 11868-011-00 BUSHING, Strain 11868-014-00 BUSHING, StrainPinch Shield Assembly Serial # 4332 thru 4646 Figure 5-11. 80= —e PINCH SHIELD ASSEMBLY,, . - + eee ees Serial # 4332 thru 4646 (See Figure 5-1, 5-2 and 5-3 for NHA) 62469-000-00 PINCH SHIELD. » 2s ee eee ee eee 62262-000-00 SHIELD, Switch... 2. ee ee eee 26553-001-00 RIVET.» eee eee 13919-003-00 08271-000-00 CLAMP GUARD, Toggle Switch. ......-e- 11249-003-00 12798-000-00 HEX 10-32 UNF. LOCKNUT, SWITCH, Toggle... « 05440-000-00 KEY SWITCH, with Key... .. eee ee 05442-000-00 + KEY... 11820-004-00 SCREW, BUTT SOC HD 10-32 UNF x 1/2. 11240-002-00 11728-004-00 WASHER, Flat 1/4 DIA... . eee eee SCREW, SOC HD 10-32 UNF x 1/2... 81Figure 5-11. Pinch Shield Assembly Serial # 4647 thru CurrentDESCRIPTION 62469-000-00 15769-000-00 29925-003-00 29925-000-00 08271-000-00 11715-005-00 12798-000-00 05440-000-00 05442-000-00 11820-004-00 11240-002-00 11728-004-00 11249-003-00 13919-009-00 PINCH SHIELD ASSEMBLY,. . . 2 + ee e+ Serial # 4647 thru Current (See Figure 5-1, 5-2 and 5-3 for NHA| PINCH SHIELD. . . « BOX, Electric... CONNECTOR.» 2. CONNECTOR... eee GUARD, Toggle Switch, . . SCREW, RD HD Machine 6-32 SWITCH, Toggle... +. +s KEY SWITCH, with Key... . . REY ee eee ee ee eee SCREW, BUTT SOC HD 10-32 UNF x 1/2. WASHER, Flat 1/4 DIA... ...- SCREW, SOC HD 10-32 UNF x 1/2. LOCKNUT, HEX 10-32 UNF... ..~ CLAMP Ce eee ee ee eeFigure 5-12. Retractile Cable InstallationITEM PART DESCRIPTION ary 5-12] No Number RETRACTILE CABLE INSTALLATION . . (See Figures 5-1, 5-2 and 5-3 62820-001-00 CORD, Retractile 24 FT Model. 62820-002-00 CORD, Retractile 31 FT Model. 62820-003-00 CORD, Retractile 38 FT Model. 62247-000-00 CABLE STORAGE TUBE WELDMENT 24 FT Models 62248-000-00 CABLE STORAGE TUBE WELDMENT 31 FT Models 62249-000-00 CABLE STORAGE TUBE WELDMENT 38 FT Models 11239-004-00 WASHER, Flat 1/4 DIA, . 11248-004-00 LOCKNUT, HEX 1/4-20 UNC 13919-009-00 CLAMP, Hose... es 20398-024-00 CLAMP, Loop... . seDESCRIPTION No Number MAST ASSEMBLY (See Figures 5-1, . . 5-2 and 5~3 for NHA) 62668-000-00 MAST ASSEMBLY, Stage #2 24 FT Model 62669-000-00 MAST ASSEMBLY, Stage #2 31 FT Model 62670-000-00 MAST ASSEMBLY, Stage #2 38 FT Model 62671-000-00 MAST ASSEMBLY, Stage #3 24 FT Model 62672-000-00 MAST ASSEMBLY, Stage #3 31 FT Model 62673-000-00 MAST ASSEMBLY, Stage #3 38 62652-000-00 . SHEAVE. . 2... ee 62399-001-00 - SHAFT. 2 ee ee 62642-010-00 + BEARING... . . 62642-016-00 + BEARING. . 2... e 62753-000-00 + + STRAP ASSEMBLY. . . . 11735-012-00 + PIN, Roll... eee 62674-000-00 MAST ASSEMBLY, Stage #4 62675-000-00 MAST ASSEMBLY, Stage #4 62676-000-00 MAST ASSEMBLY, Stage #4 62128-000-00 - SHAFT... ee eee 62654-000-00 + SHEAVE. » 2... ee 62642-010-00 + BEARING. . 2... 62758-000-00 + STRAP ASSEMBLY. . . 11735-012-00 + PIN, Roll... ee 62167-099-00 + CHAIN x 69-1/2,... 62677-000-00 MAST ASSEMBLY, Stage #5 62678-000-00 MAST ASSEMBLY, Stage #5 62679-000-00 MAST ASSEMBLY, Stage #5DESCRIPTION No Number MAST ASSEMBLY - Continued 62653-000-00 |. . SHEAVE....... 11735-012-00 |. . PIN, Roll... wee 62166-099-00 |. . CHAIN x 71-1/2.... 62347-002-00 + BEARING... ee es 62127-000-00 / SHAT. wee ee ee 62753-000-00 « STRAP ASSEMBLY. . . . 62425-000-00 MAST ASSEMBLY, Stage #6 62426-000-00 MAST ASSEMBLY, Stage #6 62427-000-00 MAST ASSEMBLY, Stage #6 62165-099-00 + CHAIN x 71-1/2, .. 6 62753-000-00 + STRAP ASSEMBLY. . . « 62158-000-00 + BEARING, Mast... . 62159-000-00 BEARING, Mast . 62160-000-00 BEARING, Mast 62223-000-00 BEARING, Mast . 62160-001-00 BEARING, Mast 11735-020-00 PIN, Roll . . 62687-000-00 PIN, Chain. . 62399-001-00 PIN, Chain... se. - eee 62686-000-00 PIN, Chain... . eee eee 62129-000-00 STRAP, Retainer... 2.6 12553-005-00 SCREW, SOC HD 1/4-20 UNC x 3/4.jew | earn oescarmion 62662-000-00 62662-001-00 62663-000-00 62663-001-00 62664-000-00 62664-001-00 MAST ASSEMBLY - Continued . . . + LIFT CYLINDER ASSEMBLY, 24 FT (See figure 5-14) Serial # 4332 thru 4591 Serial # 4592 thru Current . LIFT CYLINDER ASSEMBLY, 31 FT Serial # 4332 thru 4591 Serial # 4592 thru Current + LIFT CYLINDER ASSEMBLY, 38 FT Serial # 4332 thru 4591 Serial # 4592 thru Current 89Figure 5-14, Lift Cylinder Assembly62662-000-00 62662-001-00 62663-000-00 62663-001-00 62664-000-00 62664-001-00 62656-000-00 62657-000-00 62658-000-00 11287-012-00 11737-010-00 11248-010-00 62084-000-00 62085-000-00 62086-000-00 11735-020-00 62083-000-00 62173-000-00 13888-050-00 62071-000-00 12499-023-00 62199-000-00 DESCRIPTION LIFT CYLINDER ASSEMBLY, 24 FT Model . (See Figure 5-13 for NHA) Serial # 4332 thru 4591 Serial # 4592 thru Current LIFT CYLINDER ASSEMBLY, 31 FT Model Serial # 4332 thru 4591 Serial # 4592 thru Current LIFT CYLINDER ASSEMBLY, 38 FT Model Serial # 4332 thru 4591 Serial # 4592 thru Current TIE ROD, 24 FT Model... . ~~ TIE ROD, 31 FT Model... ~~~ TIE ROD, 38 FT Model... . ~~ SCREW, SOC HD 3/8-16 UNC x 1-1/2. ROLL PIN... ee eee LOCKNUT, HEX 5/8 UNF. . CYLINDER, 24 FT Model CYLINDER, 31 FT Model CYLINDER, 38 FT Model + ROLL PIN. . « ROD END... VALVE, Poppet . . O-RING... es . SEAL, Retaining Ring. SEAL. see ee ee VALVE, Bleeder. . . «92 DESCRIPTION 62591-000-00 62761-000-00 62593-000-00 62763-000-00 62660-000-00 62417-000-00 62815-000-00 11828-006-00 62655-000-00 62339-000-00 26553-006-00 62068-000-00 62642-016-00 62651-000-00 62168-001-00 62168-004-00 62168-003-00 12436-006-00 20908-005-00 11764-023-00 LIFT CYLINDER ASSEMBLY, 24 FT Model Continued + CASTING, 2nd Stage... .. Serial # 4332 thru 4591 Serial # 4592 thru Current CASTING, 3rd Stage... ... Serial # 4332 thru 4591 Serial # 4592 thru Current PIN, Clevis. s+. ee eee CYLINDER MOUNTING PLATE. . . Serial # 4332 thru 4591 Serial # 4592 thru Current SCREW, Flat HD SOC 1/4-20 x 3/4 PLATE, Chain Guard. ..... BEARING, Cylinder Guide... . RIVET, Pop 3/16 x1/2.....% SHAFT 6 eee ee ee ee ee BUSHING 2. ee ee ee ee eee SHEAVE, «se eee ee ee eee CHAIN x 135 Pitches, 24 FT Model. CHAIN x 170 Pitches, 31 FT Model. CHAIN x 192 Pitches, 38 FT Model. FITTING, Elbow. 2... ee eee FITTING, Nipple 1/4-18 NPT x 5. RETAINING RING. » 2. eee eeeFigure 5-15. Cage Assembly 93DESCRIPTION 62400-000-00 | CAGE ASSEMBLY, 24 FT Model... .. . (See Figure 5-1 for NHA) 62419-000-00 | CAGE ASSEMBLY, 31 FT and 38 FT Models (See Figures 5-2 and 5-3 for NHA) 11252-016-00 SCREW, HHC 1/4-20 UNC x2..... 1.240-004-00 WASHER, Flat STD 1/4 DIA... ... 62413-000-00 CAGE SUPPORT WELDMENT, 24 FT Model. 62418-000-00 CAGE SUPPORT WELDMENT,. . 31 PT and 38 FT Models 11248-004-00 LOCKNUT, 1/4-20 UNC . . 20398-012-00 CLAMP. we ee ee ee 03613-002-00 TUBE, Storage... . 03612-000-00 CAP Ce eee eee 62300-001-00 USERS MANUAL. . . « 11252-014-00 SCREW HHC 1/4-20 x 1-3/4. 62404-000-00 ANGLE, Support-RH . . . . 11248-006-00 LOCKNUT, 3/8-16 UNC. . . 11240-006-00 WASHER, Flat 3/8. . . 62499-000-00 GATE ASSEMBLY... . 62401-000-00 CAGE PAN... ee 62403-000-00 PRONT RAIL... . 62405-000-00 ANGLE, Support-LH ... . 62402-000-00 CAGE RAIL. se eee ee eee 60830-000-00 SAFETY WALK. 6 ee ee ee ee Serial # 4647 thru Current Only 26610-001-00 BOX, Electric... ..-..-- 08942-000-00 RECEPTICAL, » se ee ee eee 94DESCRIPTION 62400-000-00 29925-003-00 26611-002-00 CAGE ASSEMBLY - Continued . + CONNECTOR . + COVER . 95Figure 5-16. Loader, 24 Ft ModelITEM PART DESCRIPTION ary 5-16] 62713-000-00 |LOADER, 24 FT MODEL... . « 62193-000-00 |. TUBE, Caster Support. . . « 11248-006-00 |. LOCKNUT, HEX 3/8-16 UNC . . 11239-006-00 |. WASHER, Flat ASTM 3/8 DIA. . 03491-000-00 |. CASTER, Swivel... .. 2... 11254-008-00 SCREW, HHC 3/8-16 UNC x1. . 11254-022-00 SCREW, HHC 3/8-16 UNC x 2-3/4 62250-000-00 PIN ASSEMBLY... . «+ 62716-000-00 BAR ASSEMBLY... ss + se 11248-005-00 LOCKNUT, HEX 5/16-18 UNC. . 62724-000-00 RETAINER, Bearing... . « 26529-018-00 SCREW, Flat HD SOC 5/16-18, UNC x 2-1/4 62232-000-00 BEARING. see ee ee eeSA VIN \ Vy MP =| =) [=DESCRIPTION 62294-001-00 62250-000-00 62745-000-00 11248-005-00 62724-000-00 26529-016-00 62232-000-00 LOADER, 31 FT AND 38 FT MODELS, + PIN ASSEMBLY... . +--+ + BAR ASSEMBLY... 1... + + + LOCKNUT, HEX 5/16-18 UNC. . + RETAINER, Bearing... . + SCREW, Flat HD SOC 5/16-18, UNC x 2 + BEARING. see eee eee= osearnon 62318-000-00 | TILT-BACK ASSEMBLY, 31 FT and... . « 38 FT Models (See Figures 5-2 and 5-3 for NHA) 62735-000-00 JACK WELDMENT » 2. ee ee 11254-010-00 SCREW, HHC 3/8-16 UNC x 1-1/4 11240-006-00 WASHER, Flat 3/8 DIA, . . 62747-000-00 BRACKET, Jack Mounting. . 11248-006-00 LOCKNUT, HEX 3/8-16 UNC 62319-000-00 LANYARD ASSEMBLY. . . « 11248-008-00 LOCKNUT, HEX 1/2-13 UNC 11240-008-00 WASHER, Flat 1/2 DIA. . 11256-022-00 SCREW, HHC 1/2-13 UNC x 62822-000-00 CABLE ASSEMBLY. . . . « 11256-032-00 SCREW, HHC 1/2-13 UNC x 62749-000-00 TILT-BACK ROLLING FRAME 11254-008-00 SCREW, HHC 3/8-16 UNC x 03491-000-00 CASTER, «ee ee eee 101“Sava nanas a1 aa LO Ty aa oon na D aniva nmoa AONZOUaWS i 1 | it ef Mi Decal Installation Figure 5-19. 102No Number DECAL INSTALLATION, » +. ++ ++ 62574-000-00 |. DECAL, Emergency Procedure. . . « 62214-000-00 . DECAL, Danger, Failure To Follow. 62215-000-00 . DECAL, Caution, Before Using. . 62466-000-00 DECAL, Danger, Before Tilting . 62221-000-00 DECAL, Danger, Never Elevate. . 62217-000-00 DECAL, Hydraulic Fluid. . . « 05223-000-00 DECAL, Emergency Down Valve . 62218-000-00 DECAL, Insert Outrigger . . « 62829-000-00 DECAL, Danger, Do Not Insert. 62216-000-00 DECAL, UL-24, +e eee eee 62567-000-00 DECAL, UL-31. . 2 2 eee eee 62571-000-00 DECAL, UL-38. . . eee ee eee 05225-000-00 DECAL, Danger, Explosive Hydrogen 05221-000-00 DECAL, Battery. s+ ee eee ees 62216-000-00 DECAL, Caution Maximum Platform Cap.. 62821-000-00 DECAL, Danger, Do Not Elevate... - 62564-000-00 DECAL, Up-Right «s+ eee ee eee 03610-000-00 DECAL, Contains Important Information 62322-000-00 DECAL, On/Off s+. + +e eee eee 08272-000-00 DECAL, Up/Downs » ee ee eee ees 62220-000-00 DECAL, Caution, Pinch Point... + «+104 SECTION VI ILLUSTRATED PARTS BREAKDOWN - OPTIONS INTRODUCTION. This section lists and illustrates the Options and their replacable parts for the Up-Right Lift models contained in this manual.Detachable Cage Kit Option Figure 6-1. 105106 DESCRIPTION 62472-000-00 62375-000-00 11239-004-00 11248-004-00 62473-000-00 11252-008-00 62374-000-00 62474-000-00 11252-020-00 11252-010-00 DETACHABLE CAGE KIT OPTION. PIN AND LANYARD ASSEMBLY, WASHER, 1/4 DIA... « LOCKNUT, 1/4-20 UNC . . « SUPPORT RAIL... - + SCREW, HHC 1/4-20 UNC x 1 PIN AND LANYARD ASSEMBLY, MOUNT WELDMENT, Lower . . Lower SCREW, HHC 1/4-20 UNC x 2-1/2 . SCREW, HHC 1/4-20 UNC x 1-1/4 .108 DESCRIPTION 62550-000-00 62551-001-00 62551-000-00 62543-000-00 11238-006-00 11248-006-00 01199-000-00 11254-006-00 11252-008-00 20398-012-00 11248-004-00 03612-000-00 03613-002-00 62300-001-00 03610-000-00 62214-000-00 62547-000-00 62215-000-00 62546-000-00 62220-000-00 62322-000-00 62544-000-00 62545-000-00 FIBERGLASS CAGE KIT OPTION, 24 FT Model FIBERGLASS CAGE KIT OPTION, 31 FT Model FIBERGLASS CAGE KIT OPTION, 38 PT Model CAGE, Fiberglass. WASHER, Flat 3/8. LOCKNUT, 3/8-16 . GATE ASSEMBLY . . SCREW, HHC 3/8-16 SCREW, HHC 1/4-20 CLAMP... ee LOCKNUT, 1/4-20 (a TUBE... ee eee wee USER MANUAL... 1 eee DECAL, Operating Instructions . . DECAL, Danger Before Elev... . « SHIELD (On 31 and 38 FT Models only). DECAL, Caution Before Using... . PINCH SHIELD... 6 eee eee DECAL, Caution Pinch Point. DECAL, Key Switch... . CAGE SUPPORT WELDMENT, 24 and 31 FT Models CAGE SUPPORT WELDMENT, 38 FT ModelsDESCRIPTION 62550-000-00 | FIBERGLASS CAGE KIT OPTION -. . Continued 62558-000-00 SWITCH, ». eee ee eee 11709-006-00 SCREW, RD HD 10-24 UNC x 3/4, 29620-002-00 CONNECTOR, Butt... +... 29925-000-00 CONNECTOR, Cable. 29929-004-00 LOCKNUT . . . 11240-003-00 WASHER. » . . . 11248-003-00 LOCKNUT . . 2. 29493-099-00 CABLE... eee 109110oo PART DESCRIPTION on 62486-000-00 | NARROW CAGE OPTION. .. 1... eee ee 11252-006-00 SCREW, HHC 1/4-20 x 3/4 11240-004-00 WASHER, Flat STD 1/4, .......44% 62413-000-00 CAGE SUPPORT WELDMENT 11248-004-00 NUT, HEX 1/4-20 UNC . 20398-012-00 CLAMP oe eee ee ee ee ee 03613-002-00 TUBE, Storage... +... eee eee 03612-000-00 CAP. ee eee 63300-003-00 USERS MANUAL. 11252-014-00 SCREW, HHC 1/4-20 x 1-3/4. ...... 62404-000-00 ANGLE, Support RH . 14025-006-00 LOCKNUT, 3/816 UNC... 2... eee 11240-006-00 WASHER, Flat 3/8. . 01199-000-00 GATE ASSEMBLY . . . 62340-000-00 RETAINER, Outrigger 62483-000-00 CAGE PAN... ee ee 62485-000-00 FRONT RAIL. 6 2 ee ee ee eee eee 62405-000-00 ANGLE, Support LH... eee ee eee 62484-000-00 CAGE RAIL 2 ee ee ee ee ee ee ee 62216-000-00 62219-000-00 DECAL, Caution MAX Load DECAL, Up-Right 6. ee eee ee ee 62214-000-00 DECAL, Danger Before Elevating. 62215-000-00 DECAL, Caution Before Using . . 62574-000-00 DECAL, Emergency Procedure. . . 03610-000-00 DECAL, Operating Inst. Storage. 62821-000-00 DECAL, Danger, Do Not Elevate . 60803-000-00 SAFETY WALK... . 111Figure 6-4. Additional Height Option, 31 FtDESCRIPTION 62487-000-00 62413-000-00 62495-000-00 11254-008-00 11240-006-00 11248-006-00 62489-000-00 62492-000-00 62419-000-00 62215-000-00 62214-000-00 ADDITIONAL HEIGHT OPTION + CAGE SUPPORT WELDMENT SUPPORT PLATE, Ladder SCREW, HHC 3/8-16 x 1 WASHER, Flat 3/8. NUT, 3/8-16 UNC . LADDER WELDMENT . RAIL, Ladder RH . . RAIL, Ladder LH... ee ee DECAL, Caution Before Using . . DECAL, Danger Before Elevating. 113DESCRIPTION 62488-000-00 62413-000-00 62490-000-00 62495-000-00 11254-008-00 11240-006-00 11248-006-00 62492-000-00 62419-000-00 62496-000-00 62215-000-00 62214-000-00 11252-006-00 11240-004-00 11248-004-00 ADDITIONAL HEIGHT OPTION CAGE SUPPORT WELDMENT LADDER WELDMENT . . . SUPPORT PLATE, Ladder SCREW, HHC 3/8-16 x 1 WASHER, Flat 3/8. . NUT, 3/8-16 UNC . . RAIL, Ladder RH... RAIL, Ladder LH... OUTRIGGER POCKET WELDMENT . DECAL, Caution Before Using . . DECAL, Danger Before Elevating. SCREW, 1/4-20 x 3/4... « WASHER, Flat 1/4. ..... NUT, 1/4-20 6 2 ee eee 115Figure 6-6. Power to Platform Option Serial # 4332 thru 4646DESCRIPTION 62511-000-00 15769-000-00 26611-002-00 08942-000-00 11252-016-00 11238-004-00 11248-004-00 13919-004-00 11252-006-00 62514-000-00 11252-008-00 62500-000-00 29925-003-00 11240-014-00 62516-000-00 POWER TO PLATFORM OPTION, Serial # 4332 thru 4646 BOX, Bell»... se + COVER, Box, Electric. + RECEPTACLE. . . « SCREW, Cap HHC 1/4-20 WASHER, Flat 1/4 DIA. NUT, 1/4-20. 2... CLAMP... ee ee SCREW, Cap HHC 1/4-20 REEL MOUNT WELDMENT . SCREW, Cap HHC 1/4-20 REEL. se eee ee CONNECTOR. 2... ee ee WASHER, Flat 7/8 DIA. . . . BRACKET, Bell Box Mounting. 17Tool Tray Option Figure 6-7. 118DESCRIPTION 62530-000-00 62531-000-00 11252-014-00 11240-004-00 11248-004-00 62743-000-00 TOOL TRAY OPTION. .. ~~~ TOOL TRAY ASSEMBLY. . . SCREW, HHC 1/4-20 x 1-3/4 WASHER, Flat 1/4... . + NUT, HEX 1/4-20 UNC... eee TOOL TRAY OPTION (To be used in. . conjunction with Fiberglass Cage) 119Florescent Tube Caddy Option Figure 6-8. 120DESCRIPTION 62535-000-00 | FLORESCENT TUBE CADDY 62536-000-00 TUBE CADDY ASSEMBLY 11252-014-00 SCREW, HHC 1/4-20 x 11240-004-00 WASHER, Flat 1/4. . 11248-004-00 NUT, HEX 1/4-20 . 62542-000-00 DECAL, Caution. «eT. 62360-000-00 | AUDITORIUM KIT OPTION . . 62383-000-00 CAGE ASSEMBLY... . ~ 11239-005-00 WASHER, Flat 5/16... 62380-000-00 TOP CROSS BAR WELDMENT. 62367-000-00 END COLUMN WELDMENT . . 12610-000-00 WINCH See ee ee eee 11828-008-00 SCREW, Flat HD SOC 1/4-20 60643-000-00 PADD ee eee eee eee 11248-004-00 NUT, 1/4-20..... 11254-032-00 SCREW, HHC 3/8-16 x 4 11240-006-00 WASHER, Flat 1/4. 11248-006-00 NUT 3/8-16. ... 62370-000-00 PLATE, Bearing. . 62330-000-00 PIN ASSEMBLY. . . 13919-013-00 CLAMP, Hose . . . 11252-006-00 SCREW, HHC 1/4-20 11240-004-00 WASHER, Flat 1/4. . 62319-000-00 PIN ASSEMBLY. . . . 62372-000-00 SUPPORT TUBE WELDMENT 62171-000-00 CASTER... ee eee 62465-000-00 DECAL, Danger... - 61517-000-00 DECAL, Up-Right . .. . 62361-000-00 SUPPORT FRAME WELDMENT. 62462-000-00 RETAINING TUBE WELDMENT 08570-000-00 PIN, Retaining. . . ~~ 12312a 62360-000-00 62343-000-00 62391-000-00 11253-010-00 11240-005-00 11248-005-00 62385-000-00 62388-000-00 62384-000-00 11256-032-00 11248-008-00 62344-000-00 11254-010-00 62497-000-00 62218-000-00 62346-000-00 17416-002-00 17408-010-00 62338-000-00 11254-024-00 00942-000-00 11254-008-00 03613-002-00 62304-000-00 AUDITORIUM KIT OPTION - Continued CASTER, 6 ee ee ee ee ee LADDER SUPPORT WELDMENT, RH SCREW, HHC 5/16-18 x1... WASHER, Flat 5/16... NUT, 5/1618. . 2 ee ee LADDER WELDMENT . . . . « LADDER SUPPORT WELDMENT, DECAL, Danger... « SCREW, HHC 1/2-13 x4... NUT, 1/2-13 . 2.44% CASTER,» 2 eee eee SCREW, HHC 3/8-16 x 1-1/4 DECAL, Caution. ... + DECAL, Instructional. . . STRAP, Nylon... +. + « PIPE, 3/4 SCH 80 x 2-3/8. PIPE, 3/8 SCH 80 x 2-1/2. DECAL, Danger»... + SCREW, HHC 3/8-16 x3... LEVEL, Orbit. . . « SCREW, HHC 3/8-16 x TUBE, Storage . USERS MANUAL. . .aan 62360-000-00 AUDITORIUM KIT OPTION ~ Continued 20398-012-00 + CLAMP . 03612-000-00 |. caP . 03610-000-00 + DECAL, Operating Inst. Storage. 125wart aon Tran ‘Faure conanFigure 3-8, Mast Assembly Removal/Installation (Sheet 1 of 2)Mast Assembly Figure 5-13.Auditorium Kit Option Figure 6-9. 122