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2. LS2 PROXIMITY SWITCH SNSR1 1 TILT ALARM LS1 LINKAGE L S TO LOWER CONTROLLER CONNECTOR D Pi BLK TO LOWER CONTROLS CONNECTOR maMenenr ans man 1 BLK 55 a 122 CONTROL MODULE BOOM VALVE BLOCK RED x ol 8 Ber BLU WHT WHT TRIM DOWN BLU RED BLK BLU VV RED BRN w WHT JIB MAG SOL4 T SOL5 mvax RED 6 CABLE MIN A A DDMN SOLE ow MIN 46 eie SOL 7 BLACK 6 MINIMUM RED CABLE HT BLK BOOM ReTRACIO OL 8 R15 12V0C T IC MAIN AUXILIARY uw 9 reor BATTERY E BATTERY RISER A ADDWN ONZE EMERGENCY SOL11 PUMP UT ei BAT2 SOL12 POWER ELI RELAY SOL
3. Won J MOT4 J CYL1 PES 2 oe 2 pi s en CYL11 CYL12 gt MOT3 3 35 ss x in in m 500 5 i 3 l 5 500 PSI 5 ES nod LHT paces 4 2 E DOES ders LT Qe ip a qd il LIC LIE V1 V ORF2 gt sooorst 3000PSI 300051 3000PST 750PSI i CB10 rapEd eo 3000PST 1000 CV8 CB9 3 D2 BOOM TRIM TURRET CAGE CYL9 10 1 steer v2 RISER RAISE JIB LEVEL ee dn ROTATE MEXE DITE EKE Ae 4 He BRAKES iy V3 4 V5 V6 V7 SPEED V8 2 xd 1 22 Tr 1 ORF1 L CV4 5 RVI CV6 CV7 i rw LOW 1 se 2700 V11 VALVE BLDCK 1 114 51 5 7 6 8 81 8 2 3 MANIFOLD
4. Lower Control Box W X 3ur EJ PSOE 1 fic 4 E a E 18 187 1 a m ela wE wE wE os B ex THN 0 31 104 139301 344104 39V Ss zs Ot B M sa ls gde S E FERREE REBBE P ux HEU EAT 9 2 B 3 SAM FN 9 8 Y Y T ws 89109 13437 39v3 Lm Er H ow ose 5 Te Tee e e Te e e 12 62 e HH HH Dog TE EE gt gt THE Xu 122 1 ku EE E E o gt o gt o gt 007 D z 9 2506 OJ 8 350 E sos es x EN 5 p 7 ar am an tO 5 asiva WODB ON31X3 ISIYA fete 1 4 ax l 3S0E l tk mE ERE B s 5 wl 818 q0 QV 8 A E 12 vies ifs H ZN EN ON ON fh 6 e d 41 B EE 50
5. H T O lo QO 0995 ore 5 r z a 3 Drawing 2 of 3 Turret Page 6 52 AB62 Work Platform European Illustrated Parts Breakdown Hose Kit Installation Chassis Turret Linkage OC 009 g 1 ss SO o 138 D 138 1x3 GO 009 2078 JAVA NIVN S3UNITAJ W008 1x3 zm Bm E 15 YSONITAD HLSW Da 138 SIY L Y xa s x 3UNITAJ 3 13 c 20 L 34 amp 3ONI 43 8IP 8019108 Pele SNA CA 3lVlD3 39v3 d Drawing 3 of 3 Linkage Page 6 53 AB62 Work Platform European Parts Breakdown Drive Pump Assembly Drive Pump Assembly 104029 000 ITEM PART NO PART MATERIAL DESCRIPTION PART NO PART MATERIAL DESCRIPTION 104361 000 PUMP REXROTH 1004
6. ERESHES 7 s8RNRwusz72 225mRBR 9 E amp ae I EL FELE E BE 53 gg ee Sa 3 z s B ju d 8 HEB 5 03345 s rac 8 Uwe SNL 8 Ear ie DU s Wr jo re SHAN NINA amp e be B RT UE TONNEN 8 WEE WE ELI Shar 3 Eg 9 EE 4 e EI e 9 a E Is H LIN o S z LLI oo 15 po riS 5 2 Es ES ven gt Wad USVR3Uj SAINT 85E IHSISH NaH TSE SIF TTSWIATHU ore oz FO TS SR TE poses 0 C 1804 voor emm BE ONSET NSO 5 9 29104 00 ON 00 SIH9I1 SNIATSO VINO 26 vive 123 00 vivo VIT 571 woos 94 So SSH 290 cens zin ee SS 02818 s le 2190 zo e18 EECC We 2190 oaa ANANI 71081405 ONNO 9I LLNOO ross e i ez TSE NER smssssa NAST zs a Factus SL X ISI 80 218 UU en Hoza EIS TEE 70 718
7. OAN Oa GQ S O Figure 5 6 Upper Controller Bottom Half AB62 Work Platform European Q lt 2 Q 7 HOLIMS wu NULLINDI 98 58 HOST 1051 2051 I sos 10 3051 5 1 8 vost 801 zje HE TT K mm 6 E LIK O L 3 s e wor WOT afer EXIT kK a 181 90159 05 wo 5 32101190 y 2 901 52 WIT T 80 c ec 1 E 91 2 lt zi D Y e gti 02 z SEL S m zi ZL us IL 9r amp Su vi 7 9 xi 1 6 5 5 EE E E 5 iors S remp m _ Shr E m tr 9 001
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9. Page 6 6 AB62 Work Platform European Illustrated Parts Breakdown Basic Assembly AB62 Diesel ORIENT SCREW ITEM 55 UPWARD Page 6 7 AB62 Work Platform European Parts Breakdown Chassis Assembly Chassis Assembly 104007 000 ITEM PART NO PART MATERIAL DESCRIPTION A PARTNO PART MATERIAL DESCRIPTION 104125 000 CHASSIS WELDMENT 011239 008 WASHER 1 2 DIA ASTM A325 104016 000 FRONT AXLE ASSEMBLY 011254 006 SCREW 3 8 16 UNC HEX HD CAP X 3 4 100090 001 WHEEL amp TIRE ASSEMBLY 011238 006 LOCKWASHER 3 8 SPLIT 100090 000 WHEEL amp TIRE ASSEMBLY L H 011248 010 LOCKNUT 5 8 11 UNC HEX 104507 000 MOTOR COVER WELDMENT 011239 010 WASHER 5 8 DIA ASTM A325 104147 000 TURRET STOP 014033 036 SCREW 1 2 13 UNC HEX HD CAP GR 8 X 4 1 2 104228 000 PIN WELDMENT 011291 026 SCREW 5 8 11 UNC HEX HD CAP GR 8 X3 1 4 104482 000 CYLINDER PIN WELDMENT 011239 010 WASHER 5 8 ASTM A325 100556 000 AXLE CYLINDER 014033 008 SCREW 1 2 13 UNC HEX HD CAP GR 8 X 1 100556 010 SEAL KIT AXLE CYLINDER 104462 000 DRIVE BLOCK ASSEMBLY 104144 003 WASHER NYLATRON 104142 000 ROTARY BRACE 100244 001 SLEW BEARING 104461 000 BRACKET DRIVE VALVE 104362 000 DRIVE MOTOR 45CC MAX x 17CC MIN 100434 002 FITTING ELBOW 4FFORB 4MB 90 102279 000 BRAKE AUSCO 011934 026 NG ELBOW 4MB 6MJ 90 100254 000 PLANETARY
10. AB62 Work Platform European DMT 30 Transmitter Figure 4 2
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12. 2 1 2 5 Transportation 2 7 By Truck or Trailer 2 7 After Use Each Day 2 7 draco ues een a ee 2 7 2 6 Maintenance 2 8 Fueling 2 8 Hydraulic 2 8 Lubrication 221 34 ai ERR petes 2 8 Battery Maintenance 2 8 Tires c uk eager wise nn E ERR Pe aM se 2 8 Maintenance RR exar RU YY ees o ee kp v vea 6 ess SECTION 1 1 1 1 1 Purpose q s RS AE RETE 1 1 SCOD8 survie TUE e IE 1 1 1 2 General Description 1 1 Platform E ea s 1 1 Platform Controller 1 1 Elevating Assembly 1 1 GASSIS EE 1 1 SECTION 2 2 1 2 2 2 2 Pre Operation and Safety Inspection 2 2 System Function Inspection 2 2 2 3 Controls and Indicators 2 3 2 4 Operation gt ee a ete eee 2 4 sae di ahah ah bade 2 4 From the Lower Controls 2 4 From the Platform 8 2 4 With Boom Lowered 2 4 With Boom Elevated 2 5 Steering
13. 418 SIE 8 2 NU o ste 1 8 2 ut jz L ie BLE 99 6 8i SER EELEE WR 9 5 0 5 oe oo Se M S o x Er sze 01 v BIE om m epp eit HOE QAE 9 we Tc ore 8 2 zz OW MD NE d gt ae EVEN W dS 14015 ox QE 9 ALS ANIONS ee ELE Q J peu E B9 vLE r 8D1293 88 69 SLE 5 E un i 8 915 1 XSTdLLTWW 7911910 eg 1 2 53 718 2 ece 2 8 BSE Tlei s r E 6 09 vee 15 7 1 P EA PR 17 amp D O amp X 1 gcse 5 42 1 15 fe 53 24900 z HW x YE 01 es E m D 2 amp G any D P 9 1576 99 cse DIO D G h M Ky oY dav ol a zs 83134 dial Sus ME SS s z z Q AV AI we 8 HEB BS 85285535508 SERES 5 10 AB62 Work Platform European Section 5 2 SCHEMATICS WIRE ND
14. 129795 SVD 129795 0 0 18 033 NAMNA ma somd 079 01 J N 1HR 033 033 7 1LHM AI HJIH X 18 1HA 3a8 1HA 3 18 18 30 088 918 AON3933W3 v9 91 o8 91 T3058 dH 35119 4 31 dWV1 38155384 710 033 118 gam A na r5 t N dhi Id v9 01 9 034 3NIDN3 7145310 034 v9 OI TWALNOD NI Adillv8 XIW LIDA ZI 30 WNIWAAL SDd 01 01 034 Drawing 2 of 2 AB62 Work Platform European Page 6 24 NOTES AB62 Work Platform European Page 6 25 Parts Breakdown Cover Assembly Cover Assembly 104015 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PARTNO PART MATERIAL DESCRIPTION 104075 000 TURRET COVER RIGHT 104416 000 COVER PANEL RIGHT 068904 000 LATCH 104415 000 COVER PANEL LEFT 104099 000 LATCH BLOCK 011248 004 LOCKNUT 1 4 20 UNC HEX 104098 000 LATCH BLOCK 011252 022 SCREW 1 4 20 UNC HEX HD CAP X 2 3 4 104292 000 EXHAUST PIPE 013923 008 SCREW 10 TYPE AB SLFTP HWH X 1 104450 000 STRUT BRACKET RIGHT 061692 099 GROMMET MATERIAL
15. ADG A bA o Y Yes Acceptable Service Interval 02 NzNo Not Acceptable R Repaired Acceptable Table 3 1 Preventative Maintenance Check List COMPONENT INSPECTION OR SERVICES INTERVAL Y N R COMPONENT INSPECTION OR SERVICES INTERVAL Y R Check electrolyte level Battery Clean exterior Clean terminals Check level and condition Engine Oil and Check for leaks Filter Change oil amp filter Diesel Change oil amp filter Gas Check fuel level Engine Fuel Check for leaks Check for leaks Daily Check oil level 250h 6m Change after break in period 501 309 Change Oil SAE 90 wt gear oil 2000h 2y Check hardware amp fittings for proper torque 6m Check linkage for wear areas 30d Oil all pivot points 30d Check steering cylinder for leaks 30d Check for missing loose retainers Inspect for structural cracks Check pivot points for wear Check pivot pin retaining bolts for proper torque Check members for deformation Check hoses for pinch or rubbing points Check component mounting for proper torque Check welds for cracks Check the cylinder rod for wear 30d Check pivot pin retaining bolts for proper Torque Hubs Steering System System Replace fuel filter Check air cleaner Engine Check coolant level with engine cold Coolant Replace coolant Check oil level Elevating Assembly Hydraulic Oil See Note Change filter
16. e szia 5e m Ld an arr 11 118 77 WOD8 vozia 8291 ga DEVTE p arvin 5595 en 911 UNGDG W G T B ze 1 88545 TEORI zo zig IOVSISS WOOS EZE 1997 83815 stn Feo zig RAOT 85578 aE T EIE spas n Wn ees TERI ux rt c m Mem m en WOO EIT See T era ten boss arum z 52 i DE EZEL incl 927 AY AIVOS EWT 23 u LALN 7 VO E 28 ez 8191 sen rris RA WISI we T z i z sa NADO WIBL Las e ren IWI T Sza 1 WISE sore o RUDE UE T k 8 NADO OOE ln zE a woos Li Vise vise eara E 60 218 433 8315 BIE T T 2 TE o 921 ATS TE Fena le 0E11 zo vig vit Tu 5 LH ee mms MEME Ur Rm PEM a Ey ne zon Hus ISO srt rego WR TE m ETE SES ie 80 7 Fao rig SIE y s 80 518 i 3 Ong H 01 ONT TIE 248 gt ZMS ADLV3IONI 10 518 am ED TE vdNV1 eed SVE eas ext Ura 5091 7 oco sana vex SH woe as z anv wx mn 9 END vex
17. NIvaO awag Da a gt 0 8 v o 1 o9 e 1331 Ro 19 D S Di JO 8 L _ Hen d SN Qv exp o se WA zd 1 jJ i O d o m m O Y 8 2 Q 8 606 3 uma 0 0 vee 9 IH9I ADLOW 180 22018 3ATVA NIVA SIONI TAI 1084 IH9I3 SOLOW 3AISQ O AJANI IAI ONTASSLS Drawing 1 of 3 Chassis Page 6 51 AB62 Work Platform European Parts Breakdown Hose Kit Installation Chassis Turret Linkage LA LA ILI d lt 8 FILTERS HYDRAULIC TANK C a ROTARY MANIFOLD POWER UNIT tf d
18. AB62 Work Platform European Illustrated Parts Breakdown Valve Block Sub Assembly Valve Block Sub Assembly 104251 000 ITEM PART NO PART MATERIAL DESCRIPTION 104250 000 VALVE BLOCK 013987 009 SPRING 0 1 4 X 19 32 LG 012004 004 PLUG 4 S A E 011240 001 WASHER FLAT 6 STD 063977 001 PLUG KOENIG 9MM MB 800 090 061827 006 STEEL BALL 3 16 DIA 063977 010 PLUG KOENIG 1 4 104496 000 SPRING COMP 05135 000 STEEL BALL 5 16 DIA lt oe lt N AB62 Work Platform European Page 6 45 Illustrated Parts Breakdown Drive Block Assembly Drive Block Assembly 104035 000 ITEM PARTNO PART MATERIAL DESCRIPTION ITEM PART NO PART MATERIAL DESCRIPTION 104253 000 VALVE BLOCK DRIVE 020021 006 PLUG 6MB 015736 004 FITTING ELBOW 8MB 10MJ EXTENDED 90 061827 003 BALL 3 8 011941 020 FITTING STR 12MB 12MJ 102292 002 VALVE FLOW DIVIDER 011934 004 FITTING ELBOW 6MB 6MJ 90 011941 011 FITTING STR 8MB 10MJ Page 6 46 AB62 Work Platform European Illustrated Parts Breakdown Valve Block Assembly Two Speed Brake Axle Lock Valve Block Assembly Two Speed Brake Axle Lock 104036 000 ITEM PARTNO PART MATERIAL DESCRIPTION ITEM 0 PART MATERIAL DESCRIPTION 100258 001 VALVE BLOCK BRAKE AXLE LOCK 2 SPEED 015717 015 FITT
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20. NaS TE alvipa dua 977575 TENI 303 6 7 TANS anum 921 73 038780 os x3 EAEN 00 VTE TE fe 7 mini XE oan TE C Nia 0 YEAST D EAA nana THA C387 1HN THOSE TS esas THE 008 0387918 HECHOS X08 1051402 SST OLD 8 Jo v9 91 UND 338 WODE LHOIVaLS NSO n JY LWA 021 488 MIS 0109 08 LHOIVALS CHaDd1V7d LUND SBWOd I v 170A 021 334 M3aDS amp 3 71 ACT NIVW ia 0 a1LJ3NNDJ 0078 JAWA OL V9 BIZONDD ve 108102 AJADI LY HISLNIO 372193238 9 2v LDA 021 Enz ra2 e02 va gt SIMIA 3345 wel 088 SETIDSLINDO AMDT 01 2 B LJ9NNQJ 3NI9N3 WI WA us 91 ae JR MEOS CTS AMSLLVE XV DO wo THANE ITS KI 4 69 O Om o 6 S NaDH 2 4 1 6 EAE us gu 9 O 87118 T AE E 9 EAEN 1981402 a3N07 OL 90078 ININA OL m Z L 85 HOLINS ALIWIXOYd 008 DL Y9 gI UNDD Gif 9
21. 5 PRE 5 8 amp 5 V X L y T ele O Y La us 09395 008 NaOH BAS BA31 393 83TID31ND3 319108 352 LINL AB62 Work Platform European Drawing 3 of 4 Parts Breakdown Upper Controller Assembly AB62 Diesel WIRE NU SIZE FROM WIRE SIZE FROM 00 8 AWG SWIB 1 3 36 8 AWG L3 A 20 01 AWG SWLA 1 A 4 37 8 AWG L1 A 12 02 18 AWG 8W13 2 IGN CBAT 38 18 AWG L2 A 13 03A 5 AWG H RN 4 SWIA 2 39A 8 AWG 15104 TB3 5 03B 6 AWG HORN 4 39B 8 AWG 11 TB3 5 03D 8 AWG TB3 4 SWIA 2 40 8 AWG A 15 1 03E 6 AWG 22 TB3 4 41 8 AWG A 16 2 8 AWG CONT TB 2 CONTR 42 8 AWG A 17 IPT 4 03AC 18 AWG CUNT TB 2 K1 87 43 18 AWG A 18 3 04 8 AWG 7 44 AWG 5 1 1 04A 8 AWG SW10 2 SW11 2 45 8 AWG 1 2 04 AWG SW9 2 SW10 4 47 AWG TB3 1 CONTR TB 1 04 18 AWG SW9 4 SW9 2 47B 8 AWG TB3 1 1 87 04D 8 AWG SW10 2 SW10 4 48 8 AWG A 26 CUNTR CR 04E 8 AWG SW6 2 SW7 2 50 18 AWG 1 TB3 8 04 8 AWG SW7 2 50 AWG
22. 8051 2 ON ON aDL23NNOD 9015 EON AINADSAWA 3SIV a aIr 0N31X3 W008 3SIV3 WOOS ISIA TIAS ETAS 8 ZINS fo 3 io 3 T 2 MD z a to 3 o 48 z m ais 8 eo eo eo eo aud 03395 XIN OVIH E a 8 ERE E E 5 E S Jo ls ES s RE 5 5 0 01 A sgg ER A X l E f Z o o v o E oj x Cag us 03345 008 NaH OTAS GAS 13437 30 2 SSTIONINGD 39v3 rcm I 1 of 2 iagram Diese D iring Upper Controller W Figure 5 7 AB62 Work Platform European 5 10 Section SCHEMATICS 5 2 WIRE ND SIZE FROM WIRE SIZE FROM 00 8 AWG SWIB 1 A 3 36 8 AWG SWIS 1 20 01 8 AWG SWIA 1 4 37 8 AWG L1 A 12 02 8 AWG SW13 2 IGN BAT 38 8 AWG L2 A 13 6 HORN 4 SWIA 2 39A 8 AWG 510 TB3 5 038 6 AWG x HORN 4 398 AWG 11 TB3 5 03D AWG TB3 4 SWIA 2 40 8 AWG 15 OPT 1 03E 6 AWG 22 TB3 4 4l 8 AWG A 16 2 03AB 8 AWG CONT TB 2 CONTR 42 8 AWG A 17 4 8 AWG CONT TB 2 K1 87 43
23. 81 70 418 81 BLE 0 10 218 OMY 8I cal 8225 ZI 0 210 0 18 81 BLE Eza 05 LIN OMY 8I Z 8ZZMS Z YZZMS OMY 0 510 20 118 8I N Lin 21 18 81 JIEE 1 10 130010 81 910 10 218 OMY 81 SLE 05 Ling 8I 130010 2 81 8T 410 21 018 OMY 81 SLE 05 Lind 11 18 81 82 81 cal 0 eI SM 11 818 81 90 218 E SEMS 8I OEE 2 83 OMY 81 6 cal eI 810 01 818 81 10 218 T SEMS 8T EZE 2 2 83 81 WOE c BINS E VECMS EM 03 43 34 60 918 SAY 81 0 c18 T VEMS SAV 81 cal 87 81 vOE 5 2 80 80 918 OMY 81 c0 c18 E VEMS OMY 81 LZE 81 5 T VIMS ZI AOE ea OMY ZI IK 40 10 918 81 OLE 11 218 1 EENS 81 92 e VIMS 8 2 5 OMY ZI ZOE ON 9 710 vI 91 007 e 90 918 8I 59E 01 218 81 SZE 82 5 ZI c cBl vc OMY ST noor 10 50 918 SAY 81 9 718 I ENS SAV 81 vee c VIMS 5 81 220 81 ST 1007 90 70 918 OMY 81 LOE 20 718 OMY 8I EZE v 8ccNS 81 070 1 c8l ST 5007 50 918 OMY 81 99 1 718 1 TIENS OMY 8I ect 8225 E VZZMS SMV ZI 20 c cBl c EBL OT 8007 92
24. 3 3 Figure 3 6 Supporting Elevating Assembly 3 5 Figure 3 7 Elevating Assembly Brace 3 5 Figure 3 8 Turret Gear 3 7 Figure 3 9 Turret Bearing Grease 4 3 7 Figure 3 10 Sensor 3 8 Figure 3 11 Linkage Limit Switch 3 8 Figure 3 12 Proximity Switch 3 8 Figure 3 13 Hydraulic 3 11 SECTION 4 Troubleshooting Figure 4 1 DMR 30 Receiver 4 2 SECTION 5 Schematics Figure 5 1 Electrical Schematic Diesel 104049 000 1 5 3 Figure 5 2 Electrical Schematic Diesel 104049 000 2 5 4 Figure 5 3 Hydraulic Schematic 104048 000 5 7 Figure 5 4 Valve Manifold Assembly 5 8 Figure 5 5 Upper Controller Top 5 9 Figure 5 6 Upper Controller Bottom Half 5 9 SECTION 6 Illustrated Parts Breakdown 6 1 AB62 Work Platform European Figure 2 6 Disengaging Drive Hub 2 7 Figure 2 7 Securing the Machine for Transportation 2 7 Figure 2 8 Fuel 2 8 Figure 2 9 Hydraulic Oil Tank 2 8 Figure 3 14 Torque Hub Assembly 3 12 Figure 3 15 Torque Hub
25. erra MX LING OLMS zoia e eer wa KMS Ue dINV1 18 b sor rers 6MS SNVHL ADI HOO n 1 ona Hara arma 027 1 8MS ilz Stil assia rimar Ran TSI HIE Tra CERTO aT wT 5 8094 8018 orem UVIH Ble 00 1013 oE g mjg 9094 vola 85 E18 W3MUd EOT Isi ssm sos sola Luar v 518 1213 BAVA HIT 30 ONS toos sola zo eig Tavis SOT LS UMS 501 6LMS sa 2094 2214 5 CWNUTIJUSISISSV NINI e gt vor p 1004 1098 SRO TOT ene owes vor SH IPSIS SSS TIT Sr 49 si x THT SSIS ort ar S g is xu cola oera wer SL 9 9 CEU ZYT vi SITHR zr S us Tg toi Sor cuir Scr cor 04 WAd V wem ISL 19 api err E m H3TIOHLNOO gel avis E 3 var wor STS uve e 6 NOLLINOI E on S ins 05 NS EL Qa AB62 Work Platform European 104049 000 2 of 2 ic Diese Schemat Ica AB62 Electr Figure 5 2 5 4 SCHEMATICS Notes AB62 Work Platform European Section 5 1 5 5 SCHEMATICS 5 2 HYDRAULIC SCHEMA
26. Flan MES PSI DRIVE PUMP 5 5 GPM 3 0 wm tub 1 12 M13 v14 s EE 881 PMP2 1 BRAKE AXLE FLOAT HICH SPEED TI AP 4 pui llc NN lt FL2 FLA 4 Aeon NOTE MAIN PUMP RELIEFS 4 FILTER A FILTER WILL READ RELIEF SETTING ID MIERUN 10 MICRON FL1 PLUS CHARGE RELIEF CV12 FL3 FL5 SiE e SUCTIDN lt gt SUCTIDN STRAINER STRAINER Figure 5 3 Hydraulic Schematic 104048 000 AB62 Work Platform European 5 7 Section 5 2 Diverter Valve V11 Ce Platform Rotate Flow Control Valve 5 8 C SCHEMATICS High Flow Proportional Valve V10 7 AL 4 High Pressure Gauge Port e Steering V1 Relief RV2 Riser V2 Boom Extend Retract V3 O Low Flow Valve V9 em Boom Raise V4 ES Jib V5 Level V6 Turret Rotate V7 7 Pressure Gauge Port Cage Rotate V8 Low Pressure Relief RV1 Figure 5 4 Valve Manifold Assembly AB62 Work Platform European Section SCHEMATICS 5 2 Riser Boom Raise Boom Extend Jib Raise Emergency Stop Engine Temperature Tilt Indicator Hi Lo Speed Fuel Selector Glow Plug Auxiliary Power Turret Rotate Cage Rotate Cage Level Horn Boom Speed Drive Alarm Key Switch Optimizer Connection
27. OMY 81 SIE ca 81 91 roor 30010 30010 8I 819 80 118 E LZMS OMY 8T SIE 18 c e8l ST H00v 30010 30010 8I 819 10 718 81 VIE 9 0 1 81 91 500v 30010 98 6 8I VISE 10 118 1 82 5 81 JHE LEO 1 81 91 3007 30010 01 518 81 19E z 81 gt 1 81 91 300v 30010 98 63 OMY 8I 19E Y BZMS V veMs OMY 81 1 281 91 0007 50 60 518 OAV 81 09 V 8cMS IMV 8T JHE 0489 IU UNaD dW3l 91 200 012 80 518 81 65 E 8T 2 1 81 9 110 ST 800 10 518 81 01 281 30010 81 039 991 3313W3llDH 91 voor 715 90 518 81 8LSE amp amp vcMS OMY 81 YME e vea 81 2 90 618 8I 6 281 98 82 81 122 88 81 6 1 181 50 518 8I 95 0 0D3 98 8 IMV 8T 9 1 81 69 70 518 OMY 81 SSE 48 01 81 8 0E 718 E X3LIW NOH 8I VL6E eia 0 518 8I YSE 023 48 010 81 VLOE cca EEO OMY 81 96 610 20 518 OMY 8I 01 281 30010 81 LOE 5 9 31 8I SBE 813 10 518 8T TE 281 0 8T SSOE 615 5 1 DMY 81 820 Tea OMY 8I ISE 8 2 18 83 aSOE 2 181 12 181 81 5 30010 81 56 181 02 181 81 BS0E 11 181 91 181 81 2 1 281 BCNS
28. Sw ee es 2 5 Positioning the Platform 2 5 Multifunction Controls 2 5 Lower Control Operation 2 5 Emergency Operation 2 6 Emergency Towing 2 6 SECTION 3 3 1 3 1 3 2 Special 1 3 1 UpRight Connectors 3 2 3 3 Preventative Maintenance 3 3 Preventative Maintenance Table Key 3 4 Preventative Maintenance Report 3 4 3 4 Supporting Elevating Assembly Figure 3 6 3 5 Installation t Red ee We 3 5 Removal VERRE 3 5 3 5 Battery 3 6 Battery Inspection and Cleaning 3 6 Battery 0 3 6 3 6 Lubrication 3 6 Grease Fittings 3 6 Lubricating Turret Gears 3 6 Hydraulic and Filter 3 7 3 7 Tilt Sensor Figure 3 11 3 8 AB62 Work Platform European 3 8 Hydraulic Manifold Figure 3 14 3 9 Removal irere rewrite 3 9 Disassembly 3 9 Cleaning and Inspection 3 9 Asseribly EA Re ues 3 9 Installation 3 9 3 9 Setting Hydrauli
29. 1 Open covers check hydraulic components hoses for damage or leaks Check electrical com ponents wiring for damage or loose connec tions Inspect chassis axles hubs and steering linkage for damage deformation buckled paint loose or missing hardware and cracked welds Check tires for damage punctures and inflation tire pressure must be 5 5 bar 80 psi Check all hoses cables for wear Inspect elevating assembly for damage deforma tion buckled paint loose or missing hardware and cracked welds Inspect platform and guardrails for damage deformation buckled paint loose or missing hardware and cracked welds Ensure that gate operates freely and latches securely Check hydraulic fluid level with platform fully low ered Check battery fluid level see Battery Mainte nance page 2 8 Check fuel level add fuel if necessary see Fuel ing page 2 8 Ensure that radiator is cold check coolant level Add if necessary A WARNING 2 2 NEVER remove the cap from a hot radiator Hot coolant can cause severe burns MACHINE PREPARATION amp OPERATION System Function Inspection NOTE Refer to figures 2 1 and 2 2 for chassis and platform control locations 1 1 1 12 0 1 Before performing the following tests check area around machine and overhead for obstructions holes drop offs and debris Turn chassis key switch to chassis and pull out the em
30. 066805 012 CONTACT BLOCK N O N C 012797 000 TOGGLE SWITCH SPDT 029939 002 100334 000 LOCKNUT 1 2 NPT SWITCH LEVER 104497 000 CONTROLLER ASSEMBLY 066807 001 ALARM 107DB 104497 002 066544 013 PC BOARD W POT BOOT HANDLE 068132 001 RELAY 12 VDC 026553 003 RIVET 3 16 126 250 GRIP 066786 011 HANDLE HALVE FRONT 065926 012 CONNECTOR PLUG 31 SOCKET 066786 012 066786 013 HANDLE HALVE REAR GASKET HANDLE 015790 003 SOCKET 16 18 GA 066786 016 BOOT ROCKER 028800 015 104387 000 PLUG SEALING CONNECTOR 066786 021 066786 024 SWITCH PUSH BUTTON SWITCH STEERING MICRO 029928 010 TERMINAL STRIP 06892 008 SWITCH DRIVE MICRO 011252 006 011240 004 SCREW 1 4 20 UNC HHC X 3 4 LG WASHER 1 4 FLAT 012798 004 SWITCH TOGGLE DPDT MOMMENTARY 011248 004 LOCKNUT 1 4 20 UNC 068590 000 068591 001 BASE INDICATOR LAMP LAMP T 2 1 2 104383 000 011248 002 MULTIPLEX TRANSMITTER LOCKNUT 8 32 HEX 068595 002 LENS AMBER 011708 006 SCREW 8 32 RD HD MACH X 3 4 068595 001 064446 003 LENS RED EMERGENCY STOP BUTTON 104480 000 MOUNTING PLATE UPPER CONTROLLER 2 m m 2 amp al al alata 064443 002 CONTACT BLOCK N C 100337 099 029610 002 O RING CORD 3 16 CONN FORK 16 14 8 064417 001 067654 000 FLANGE MOUNT SW
31. 12 AWG SW23A 3 E2 358 18 AWG BT5 07 3056 18 AWG 1 27 TB2 8 W4 12 AWG TB2 8 358 18 AWG 5 08 CIO 305H 18 AWG 1 12 1 27 WS 12 AWG KB 30 2 3 360 18 AWG 5 09 5 305 18 AWG 1 2 1 7 362 18 AWG BTS 11 Cl2 305K 18 AWG 1 7 1 12 gt E 4 363 18 AWG 5 12 09 307 18 AWG K10 87 C20 gt 3 364 18 AWG 6 01 010 307 18 AWG 10 30 B7 E 365 18 AWG 6 02 1 26 307C 18 AWG K8 86 K10 30 x x 366 18 AWG 876 03 Bll 3070 18 AWG K8 86 TB2 8 A 357 18 AWG BT6 04 D6 311A 18 AWG 5024 3 SW22B 1 s s 368 18 AWG 6 05 01 3118 18 AWG SW24 3 DIDDE 2 d E 369 18 AWG 6 06 02 311C 18 AWG SW24 3 SW27 4 E E 370 18 AWG BT6 07 07 3110 18 AWG 5424 3 SW28 4 a 371 18 AWG 6 08 08 18 5027 4 5028 4 i B 372 18 AWG BT6 08 RESERVED 18 AWG SW22B 1 BT1 03 2 373 18 AWG 6 10 331A 18 AWG 1 11 BUTT CONN 374 18 AWG BT6 11 813 3318 18 AWG BUTT CONN 031 375 18 AWG BT6 12 017 331C 18 AWG 1 12 BUTT CONN ad Es 376 18 AWG 7 01 016 3310 18 AWG BUTT CONN B23 u d Figure 5 11 Lower Control Box Wiring Diagram Diesel 2 of 2 5 14 AB62 Work Platform European Section 6 ILLUSTRATED PARTS BREAKDOWN 6 1 INTRODUCTION This section lists and illustrates the replaceable assemblies and parts of this product as manufactured by UpRight Inc Ea
32. 2 TB3 8 04H 8 AWG SW12 2 SW12 4 500 8 AWG TB3 8 BT2 02 04 AWG SW8 2 SW8 4 50D 8 AWG TB3 8 BT2 04 04K 8 AWG SW13 2 SW13 4 SOE 8 AWG TB3 10 EST 04L 8 AWG SW11 2 5011 4 506 AWG TB3 10 CUNTR 04 AWG SW12 4 TB3 6 50H 18 AWG K1 85 TB3 10 04 8 AWG SW12 2 SW8 2 W 01 8 AWG L1 GND TB3 10 8 AWG SW13 4 SW11 2 W 02 8 AWG L1 GND L2 GND O4R 8 AWG SW8 4 8W13 2 W 03 8 AWG L2 GND TB3 10 048 8 AWG SW4 4 SW6 2 E 041 8 AWG SW4 4 TB3 8 z E 04W 8 AWG T83 7 BT2 01 04 8 AWG TB3 7 BT2 03 04 8 AWG IGN IGN 8 04AA 8 AWG RS1 RED TB3 6 06 8 AWG A 25 TB3 2 07 8 AWG CONTR B 08 8 AWG BT3 2 CONTR A 09 8 AWG BT3 2 CUNTR X 0 8 AWG BT4 10 CUNTR TB 3 11 18 AWG 4 5 CONTR TB 4 3 8 AWG A 23 BT3 12 4 AWG BT3 3 TB3 3 4B 8 AWG 3 3 K1 86 4C 8 AWG K1 30 TB3 3 5 AWG SW4 3 BT3 08 17 18 AWG SW5 3 BT3 10 8 8 AWG SW7 1 4 11 9 8 AWG SW7 3 4 6 20 AWG SW8 1 BT4 8 21 8 AWG SW8 3 4 4 22 8 AWG SW8 1 BT3 1 23 18 AWG SW9 3 BT3 7 24 8 AWG SW10 1 4 12 25 8 AWG SW10 3 4 1 26 8 AWG SWII 1 4 2 27 8 AWG SW11 3 4 2 28 8 AWG SW11 3 14 2 24 18 AWG SW12 3 BT3 8 30 8 AWG 8W13 3 BT3 11 3l 8 AWG SW13 1 BT3 6 32 8 AWG RS1 BLK 9 33 8 AWG HORN 3 21 Drawing 4 of 4 Page 6 32 AB62 Work Platform European NOTES AB62 Work Platform European Page 6 33 Illustrated Parts Breakdown Lower Controller Assembly AB62 Diesel Lower Controller
33. 3 660 1 65 2 2 3 5 gt 4 932 2 59 3 45 4 i 6 387 3 83 5 11 5 6 177 4 63 2 2 8 840 6 63 2 2 10 330 7 75 10 3 6 8 743 7 87 3 2 12 512 11 3 3 2 14 623 13 2 17 6 7 12 570 13 2 4 2 17 990 18 9 4 2 21 025 22 1 29 4 8 15 921 19 1 25 5 22 784 27 3 36 5 26 626 32 42 6 10 52 230 37 8 50 5 36 105 54 1 72 2 42 195 63 3 84 4 12 36 670 66 88 52 475 94 5 125 61 328 110 147 14 50 025 105 140 71 587 150 200 83 663 175 234 16 70 650 170 226 97 732 235 313 114 218 274 365 18 86 400 233 311 119 520 323 430 139 680 377 503 20 10 250 330 441 152 513 458 610 178 238 535 713 22 136 350 450 600 188 618 622 830 220 433 727 970 24 158 850 570 762 219 743 791 1055 256 808 925 1233 27 206 550 837 115 285 728 1157 1543 333 923 1352 1803 30 252 450 1136 1515 349 223 1572 2095 408 128 1837 2450 33 312 300 1546 2061 432 015 2138 2851 504 885 2500 3332 36 367 650 1985 2647 508 582 2746 3662 594 368 3210 4279 AB62 Work Platform European 3 23 Section 3 13 MAINTENANCE NOTES 3 24 AB62 Work Platform European TROUBLESHOOTING Introduction This section contains troubleshooting Truth Tables for the AB62 Work Platform AWARNING A When troubleshooting ensure that the work platform is resting on a firm level surface When performing any service which requires the platform to be raised the Elevating Assem
34. AWG 18 OPT 3 04 8 AWG A 7 44 AWG 5 1 1 8 SW10 2 SW11 2 45 8 AWG A 6 1 2 04 8 AWG SW9 2 10 4 46 8 AWG 5415 2 14 04 8 AWG SwW9 4 SW9 2 47 AWG TB3 1 CONTR TB 1 04D 8 AWG SW10 2 SW10 4 47B AWG TB3 1 K1 87 04E 8 AWG SW6 2 SW7 2 48 8 AWG A 26 CONTR R 04F 8 AWG SW7 2 lt 50 AWG 1 TB3 8 04H 8 AWG 12 2 SW12 4 508 AWG 2 TB3 8 04J 8 AWG SW8 2 SW8 4 50C 8 AWG TB3 8 BT2 02 04 8 AWG SW13 2 SW13 4 500 AWG TB3 8 BT2 04 04L 8 AWG SW11 2 SW11 4 SOE 8 AWG TB3 10 LSI 04 8 AWG 12 4 TB3 6 506 AWG 3 10 CUNTR 04 8 AWG SW12 2 SW8 2 S0H B AWG K1 85 TB3 10 04 8 AWG SW13 4 5411 2 W O1 8 AWG L1 GND TB3 10 04R 8 AWG SW8 4 SW13 2 W 02 AWG L1 GND L2 GND 045 8 AWG SW4 4 SW6 2 W 03 AWG L2 GND TB3 10 041 8 AWG SwW4 4 TB3 8 04 8 AWG 3 7 2 01 04 8 AWG TB3 7 BT2 03 04Y 8 AWG IGN IGN TB3 8 O4AA 8 AWG RS1 RED TB3 6 06 8 AWG 25 TB3 2 07 8 AWG A 8 CONTR B 08 8 AWG BT3 2 CONTR A 09 8 AWG BT3 2 CONTR X 0 8 AWG BT4 10 CONTR TB 3 1 8 AWG BT4 5 CONTR 4 3 8 AWG A 23 BT3 12 4A 8 AWG BT3 3 1B3 3 4B 8 AWG TB3 3 K1 86 4 8 AWG K1 30 TB3 3 5 8 AWG 54 3 BT3 08 7 8 AWG SW6 3 BT3 10 8 8 AWG SW7 1 BT4 11 8 8 AWG SW7 3 4 6 20 8 AWG SW8 1 BT4 8 2l 8 AWG SW8 3 4 4 22 8 SwW9 1 BT3 1 23 8 AWG 59 3 BT3 7 24 8 AWG SW10 1 BT4 12 25 8 AWG 10 3 BT4 1 26 8 AWG 11 1 BT4 2 27 8 AWG 5411 3 4 2 28 AWG 511 3 4 2 29 8 AWG 512 3 BT3 8 30 8 AWG SW13 3 BT3 11
35. NOTE If necessary refer to Supporting Elevat ing Assembly in Section 3 4 2 Mark and disconnect hoses and IMMEDIATELY cap the openings to prevent contamination A WARNING Cylinders may be very heavy Support heavy cylinders before removing pins which secure a cylinder to the machine Disassembly 1 Remove head from cylinder body 2 Carefully slide rod assembly out of cylinder 3 Remove seal kit components wipers rod seals O rings and backup rings from 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 fin gernail are unacceptable replace the cylinder Polishing is a sign of uneven loading When this occurs the surface should be checked for round ness Cylinders not round within 007 should be replaced 3 16 MAINTENANCE Assembly NOTE Torque all hardware to torques listed on pages 3 22 and 3 23 unless otherwise speci fied 1 Lubricate all components with clean hydraulic fluid 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 origi nal shape before assembling cylinder 2 Install new seal kit components 3 Lubricate rod wiper and seal with hydraulic fluid and slide head onto rod 4 Lubricate seals on piston and head 5 Carefully slide rod assem
36. a 00 XE 5 u 8 We R gg T s g TO w 030 Of WE m Os amp E Bog Eee y a o 8 m s s 8 go uo Ds dud 8 Wor COR oS XE x OOO z C 295 u an g m We 5 ao z g or a Z ua E E d 0 2 0 gt m R SIE amp a 4 t3 m y E We E 5 B TE 8 WE eis TE J5 Lu 33 72 E 7 Z 000 2 m 5 SY RY E 8 8 80 2 0 Qa WEE S 40 801 3 gt lt TE TE 2 0 5530 8 p2 E E eB U Be Ow u Dv 8 WE ait oll Uie TE a a c Su R zi tK Drawing 2 of 3 Page 6 36 AB62 Work Platform European Illustrated Parts Breakdown Lower Controller Assembly 62 Diesel S8 83 91 07 21 518 81 v0 c18 E OEMS 81 BIE 01 281 58 8 91 WOOP 210 11 518 8I 60 218 E BCMS 81 8IE 58 017 58 63 91 1007 gt x 80 218 1 6 5 OMY 81 LIE 58 82 58 63 91 200v 98 017 8I 219 60 118
37. 62 Work Platform European 2 3 Section 2 4 MACHINE PREPARATION amp OPERATION 2 4 OPERATION e Starting the Engine Before operating the work platform ensure that Pre operation and safety inspection has been com From the Lower Controls pleted and any discrepancies have been corrected 1 From the platform controls turn the key switch The operator has been thoroughly trained on the on operation of the machine 2 Turn the chassis key switch to CHASSIS position The work area is clear of all obstructions holes 3 Press the start button to crank the engine drop offs or persons in the route of travel Release when the engine starts The surface is capable of supporting wheel loads 4 For diesel machines Turn key to ON position and Refer to figures 2 1 and 2 2 for control locations wait for glow plug light to go off Start engine From the Platform Controls 1 Turn the chassis key switch to platform controls 2 Turn the platform switch fully clockwise to crank the engine Release when engine starts 3 For diesel machines Turn key to ON position and wait for glow plug light to go off When glow plu At any time during operation press the emergency light Ed on start ono stop button to stop all functions an emergency De Service Horn g Driving At any time during operation press the service horn button to sound an audible warning if necessary With Boom Lowered 1 Turn chassis key switch to PLATFORM
38. 8I HOSE 1 81 Ling 81 950 0 22 181 81 Z ZENS 2 VEMS 8I 905 NNOD LIN 620 81 NS0E 12 11 181 81 c TIENS e VENS 8I 305 05 LIN 8T WSOE 83 56 181 81 18 OEMS OMY 8I 305 9 c81 T af DH ZI 150 5 02 81 c 0ENS c SENS 81 005 ci 18l 4 181 81 250 83 51 181 81 06E 9 5 2 SEMS OMY 8I JOSE 4 181 OMY 81 PSOE 42 01 181 81 58E 9 5 8I 805 12 181 21 181 OMY 81 HS0E Le 6 81 5 Y VoNS 81 VOSE 9 c8l 12 181 81 950 020 05 LIN 81 898E 018 OMY 81 Gre L cBl E0 1118 81 ASOE 05 Ling 50 118 OMY 81 VIBE 98 20 618 OMY 8I 1 81 90 1118 81 3S0E 012 11 81 5 10 619 LVE 9 c8l 50 1118 81 050 028 81 818 70 818 81 9 81 20 1118 8T 250 11 181 v1 DMY 81 118 0 818 OMY 81 1 81 1 82 ZI 850E 9 181 81 918 20 818 OMY 81 L c8l E 118 81 via 50 418 81 518 10 818 81 EVE 0 v c8L OMY 81 AVOE 80 418 81 0 E18 81 8n 18 63 81 0 va L0 L18 81 ID 80 718 OMY 8I SEE 0E 63 l dW3l 8T HOE 90 418 81 60 718 OMY 81 1 1 1 1
39. MOTOR SEAL KIT SWING MOTOR 011248 006 LOCK NUT 3 8 16 UNC HEX 011741 010 SCREW 3 8 16 FLT HD 506 X 1 1 4 100261 001 MOTOR VALVE BLOCK 104053 000 RISER PAD 101016 002 068904 000 BEARING 1 50 I D X 1 25 LG LATCH ANCHOR 104322 000 ROD STOP PIN 104052 000 LINK PAD 011707 016 011273 008 SCREW 1 2 13 UNC SET HEX SOC X 2 NUT JAM 1 2 13 UNC 011715 006 104237 000 SCREW 6 32 RD HD MACH X 3 4 STOP PIN 104142 000 ROTARY BRACE 101016 006 BEARING 1 50 I D X 2 50 LG 011240 006 011254 008 WASHER 3 8 DIA STD FLAT SCREW 3 8 16 UNC HEX HD CAP X 1 011934 026 FITTING ELBOW 90 4MB 6MJ 100394 000 WASHER 011941 002 011424 012 FITTING STR 4MB 6MJ SCREW 5 8 11 UNC SOC HD CAP GR 8 X 1 1 2 011240 001 011248 047 WASHER 6 STD FLAT LOCKNUT 46 32 HEX 011239 010 WASHER 5 8 DIA ASTM A325 013336 001 FITTING GREASE 011256 010 011239 008 SCREW 1 2 13 UNC HEX HD CAP X 1 1 4 WASHER 1 2 DIA ASTM A325 068679 003 FITTING BULKHEAD 011253 016 SCREW 5 16 18 UNC HEX HD CAP X 2 011239 005 Page 6 20 WASHER 5 16 DIA ASTM A325 068678 024 029958 001 TUBING POLYURETHANE HORN 12 VOLT alol po s AB62 Work Platform European Turret Assembly Illustrated Parts Breakdown
40. Riser Cylinder Assembly Riser Cylinder Assembly 104037 000 S N 1100 1108 ITEM PARTNO PART MATERIAL DESCRIPTION ITEM PART NO PART MATERIAL DESCRIPTION 104260 000 RISER CYLINDER 102477 008 ORIFICE ASSEMBLY 104260 011 SEAL KIT RISER CYLINDER 068778 013 COUNTERBALANCE VALVE 011941 005 FITTING STRAIGHT MB6 MJ6 Page 6 58 AB62 Work Platform European Riser Cylinder Assembly 104037 001 S N 1109 Current ITEM PARTNO 104260 001 PART MATERIAL DESCRIPTION RISER CYLINDER Illustrated Parts Breakdown Riser Cylinder Assembly ITEM PART NO PART MATERIAL DESCRIPTION 102477 008 ORIFICE ASSEMBLY 104260 010 SEAL KIT RISER CYLINDER 011941 005 FITTING STRAIGHT MB6 MJ6 AB62 Work Platform European 100555 015 COUNTERBALANCE VALVE Page 6 59 Illustrated Parts Breakdown Extend Cylinder Assembly Extend Cylinder Assembly 104038 001 S N 1100 1108 ITEM PART NO PART MATERIAL DESCRIPTION 104255 000 EXTEND CYLINDER 104255 011 SEAL KIT EXTEND CYLINDER 011941 005 FITTING STRAIGHT MB6 MJ6 068778 011 VALVE COUNTERBALANCE Page 6 60 AB62 Work Platform European Parts Breakdown Extend Cylinder Assembly Extend Cylinder Assembly 104038 001 S N 1109 Current ITEM PART NO PART MATERIAL DESCRIPTION 104255 001 EXTEND CYLINDER 104255 010 SEAL KIT EXTEND CYLINDER 011941 005 FITTING STRAIGHT
41. SEAL KIT LEVEL CYLINDER 1 011937 003 FITTING ELBOW 6MB 6MJ 90 AB62 Work Platform European Page 6 65 Illustrated Parts Breakdown Boom Cylinder Assembly Boom Cylinder Assembly 104039 000 S N 1100 1108 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PARTNO PART MATERIAL DESCRIPTION 1 104256 000 BOOM CYLINDER 1 011941 005 FITTING STRAIGHT MB6 MJ6 104256 011 SEAL KIT BOOM CYLINDER 1 068778 013 COUNTERBALANCE Page 6 66 AB62 Work Platform European Illustrated Parts Breakdown Boom Cylinder Assembly Boom Cylinder Assembly 104039 001 S N 1109 Current ITEM PART NO PART MATERIAL DESCRIPTION ITEM PART NO PART MATERIAL DESCRIPTION 1 104256 001 CYLINDER 1 011941 005 FITTING STRAIGHT MB6 MJ6 104256 010 SEAL KIT BOOM CYLINDER 1 100555 015 COUNTERBALANCE VALVE AB62 Work Platform European Page 6 67 Illustrated Parts Breakdown Label 62 Diesel Label Kit AB62 Diesel 104047 100 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PARTNO PART MATERIAL DESCRIPTION 061205 002 NAME PLATE 104429 000 LABEL AB62 RT 065368 000 TACK 068632 000 LABEL HOLD DOWN 101210 000 LABEL BATTERY LEVEL 068633 001 LABEL READ amp UNDERSTAND EURO 066555 000 LABEL CAUTION DO NOT ADJUST 068635 000 LABEL HARNESS POINT 101208 000 LABEL PINCH POINT 068637 000 LABEL ARROW YELLOW 101203 001 LABEL HYDRAULIC FLUID 068637 001
42. WORK PLATFORMS European Specification Service amp Parts Manual SERVICE amp PARTS MANUAL AB62 European Specification Diesel Models Serial Numbers 1100 current When contacting UpRight for service or parts infor mation 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 at the rear of the machine UpRigtivr Ime 1775 PARK ST SELMA CALIFORNIA 93662 USA Serial numbers bs kg Mig dates m allowable incline of machine when elevated deg nts and equipment must not exceed the rated maximum DS kg Maximum platform occupants lowable side force on platform 3 N atom weights ft each ft m owa nd speed mp Stamped Serial Number km h h ydraulic system pressure psi m system voltage vde ine is manufactured to comply with AINSI A92 5 1992 ON CONSULT OPERATORS MANUAL BEFORE USE PLATFORM IS NOT ELECTRICALLY INSULATED UpRight Upright Inc Call Toll Free in U S A UpRight International 1775 Park Street 1 800 926 LIFT Support Centre Selma California 93662 Innsbrukweg 114 TEL 559 891 5200 3047 AH Rotterdam FAX 559 891 9012 Netherlands PARTS 1 888 UR PARTS TEL 31 10 238 0000 PARTSFAX 559 896 9244 FAX 31 10 238 0001 Parts Tel 3
43. a a gt a a us x WITH Page 6 21 AB62 Work Platform European Parts Breakdown Engine Module Assembly AB62 Diesel Engine Module Assembly AB62 Diesel 1004013 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PART NO PART MATERIAL DESCRIPTION 104060 000 ENGINE TRAY WELDMENT 011253 006 SCREW 5 16 18 UNC HEX HD CAP X 3 4 104352 000 ENGINE PERKINS DIESEL 011248 005 LOCKNUT 5 16 18UNC HEX 100180 030 AIR CLEANER 012702 002 FITTING STR 2MP 2MP 100180 038 CLAMP AIR CLEANER 011915 001 FITTING TEE ADAPTER 2FP 2FP 2FP 104352 010 RAIN 068954 001 OIL PRESSURE SWITCH 104368 000 MUFFLER 100333 000 OIL PRESSURE SENDING UNIT 100180 041 CLAMP MUFFLER 029945 018 LEVEL SENSOR 100180 051 SEPARATOR FUEL 011937 004 FITTING ELBOW 90 8FJ 8MJ 104297 000 MUFFLER MOUNT WELDMENT 011922 006 FITTING ADAPTER 6MP 8FP 100180 042 THROTTLE CONTROL 100332 000 SENDING UNIT TEMP 100180 043 SPLINED COUPLER 063947 005 JAM 5MM 100180 044 GASKET EXHAUST FLANGE 012865 099 WIRE LOOM 3 4 100180 045 NUT EXHAUST FLANGE 011254 024 SCREW 3 8 16 UNC HHC X 3 LG 104296 000 EXHAUST PIPE 020541 001 CLAMP 100180 046 EXHAUST CLAMP 012739 099 1 4 FUEL LINE 100180 050 GLOW PLUG CONTROLLER 012733 099 HOSE 5 16 FUEL LINE 100180 048 FLANGE 015790 015 CONNECTOR 24 PIN 104295 000 EXHAUST PIPE 015790
44. with boot seal installed or 46 Ib in with out boot seal means that the cone 13 was pressed on to tightly in step 4 In this case back off bearing cone 13 by pressing spindle 3 out of cone 13 until initial preload is relieved See step 10 of disassembly procedure Section 3 10 9 Torque bearing nut 16 with Bearing Locknut Tool Service Kit 100254 020 until a bearing rolling torque of 42 50 Ib in with a boot seal installed or 38 46 Ib in without a boot seal is reached This may require several trials of press ing the cone 13 by torquing the nut 16 and then checking the rolling torque Rotate hub 11 by hand as nut is being tightened in order to seat bearings NOTE Up to 250 Ib ft of torque may have to be applied to bearing nut 16 in order to press cone 13 into position 10 Remove bearing nut 16 and install lock washer 15 Replace bearing nut 16 11 Re torque bearing nut 16 to 80 90 Nm ft 60 70 Ib 12 Secure bearing nut 16 by bending a lock washer 15 tab into one of four bearing nut slots If no tab aligns with a slot the nut may be tight ened until one of the slots aligns with a lock washer tab 13 Assemble a washer 18 spring 19 a second washer 18 and a retaining ring 17 in the mid dle grooves of input shaft 2 Install a second retaining ring 17 in groove near small end of input shaft 2 14 Assemble the splined end of the input shaft 2 down int
45. 3 15 Figure 3 16 Master Cylinder S N 1109 Current 3 17 Figure 3 17 Riser Cylinder S N 1109 Current 3 17 Figure 3 18 Boom Cylinder S N 1109 Current 3 18 Figure 3 19 Extend Cylinder S N 1109 Current 3 18 Figure 3 20 Axle Lock Cylinder 3 19 Figure 3 21 Steering Cylinder 3 19 Figure 3 22 Jib Cylinder S N 1111 Current 3 20 Figure3 23 SettingRotationalGearBacklash Viewedfrombottomofturret 3 20 Figure 3 24 Rotary Manifold 3 21 Figure 4 2 DMT 30 4 2 Figure 5 7 Upper Controller Wiring Diagram Diesel 1 of 2 5 10 Figure 5 8 Upper Controller Wiring Diagram Diesel 2 of 2 5 11 Figure 5 9 Lower Control Box 5 12 Figure 5 10 Lower Control Box Wiring Diagram Diesel 1 of 2 5 13 Figure 5 11 Lower Control Box Wiring Diagram Diesel 2 of 2 5 14 LisT TABLES SECTION 1 Introduction amp Specifications Table 1 1 Work Platform Specifications 1 2 SECTION 2 Machine Preparation amp Operation SECTION 3 Maintenance Table 3 1 Preventative Maintenance Check List 3 4 Table 3 2 Torque Specifications for Hydraulic Components 3 22 Table 3 3 Torque Specifications for SAE Fasteners 3 22 Table 3 4 Torque Specif
46. 3 8 16 UNC HEX HD X 2 0 104038 001 EXTEND CYLINDER ASSEMBLY 011240 006 WASHER 3 8 DIA STD FLAT 104255 001 EXTEND CYLINDER Serial 1109 Current 104375 006 BEARING 2 I D X2 1 2 LG 104255 010 SEAL KIT EXTEND CYLINDER Serial 1109 Current 011248 006 LOCKNUT 3 8 16 UNC HEX 104175 000 BOOM WELDMENT 011248 005 LOCKNUT 5 16 18 UNC HEX 104176 000 WEAR PAD 011253 008 SCREW 5 16 18 UNC HEX HD CAP X 1 104177 000 WEAR PAD 011238 006 LOCKWASHER 3 8 SPLIT 104222 000 WEAR PAD 011254 006 SCREW 3 8 16 UNC HEX HD CAP X 3 4 104223 000 WEAR PAD 104335 000 TUBE HOSE 104182 000 EXTENSION TUBE WELDMENT 011254 008 SCREW 3 8 16 UNC HEX HD CAP X 1 104181 000 EXTENSION TUBE MOUNTING BRACKET 104411 000 SHORT TUBE GUIDE 068691 030 CATRAC 104412 000 LONG TUBE GUIDE 104315 000 EXTEND CYLINDER SUPPORT 011253 006 SCREW 5 16 18 UNC HEX HD CAP X 3 4 104207 000 PIN WELDMENT CYLINDER po po pol po Page 6 16 AB62 Work Platform European Parts Breakdown Straight Boom Assembly Parts Breakdown Jib Assembly Jib Assembly 104012 000 ITEM PART NO 104151 000 PART MATERIAL DESCRIPTION BOTTOM JIB FRAME WELDMENT ITEM 0 104034 000 PART MATERIAL DESCRIPTION CAGE ROTATE VALVE ASSEMBLY 104156 000 ROTATOR FRAME WEL
47. BT1 03 chassis selected BT2 04 lift input BT5 09 lift output to valve BT6 12 low flow output BT5 06 throttle output Boom Down Function enable pushed LEDs on DMR 30 illuminated BT1 03 chassis selected BT2 05 boom down input BT6 04 boom down output to valve BT6 12 low flow output BT5 06 mid throttle output Boom Riser Up Function enable pushed LEDs on DMR 30 illuminated BT1 03 chassis selected BT2 02 riser up input BT5 12 riser up to valve output BT6 10 high flow output to valve BT5 06 throttle output Riser Lower Function enable pushed LEDs on DMR 30 illuminated BT2 03 riser lower input BT6 01 riser lower out put BT6 10 high flow output to valve BT5 06 throttle output Boom Extend Function enabled LEDs on DMR 30 illuminated 4 3 Section 4 2 TROUBLESHOOTING BT2 06 boom extend input BT6 07 boom extend output to valve BT6 10 high flow output BT5 06 throttle output Boom Retract Function enabled LEDs on DMR 30 illuminated BT2 07 boom retract input BT6 08 boom retract output to valve BT6 10 high flow output BT5 06 throttle output Turret Rotate Swing Right Function enabled LEDs on DMR 30 illuminated BT2 09 swing right input BT7 09 turret valve out put BT5 06 throttle output BT6 12 low flow valve output Swing Left Function enabled LEDs on DMR 30 illuminated BT2 08 swing left input BT7 08 turret valve out pu
48. Drain and replace with ISO 46 compatible Check for leaks Check hose connections Check hoses for exterior wear Chassis Hydraulic System pictus Operate the emergency lowering valve and torque 30d check for serviceability Daily Lift Cylinder System Check seals for leaks 30d Controller Check operation of all controls Daily Inspect pivot points for wear 30d Consi Cable Check the exterior of the cable for Daily Check tor propertorqug 30d pinching binding or wear Check ring gear for proper Daily Check fasteners for proper torque Daily Turret lubrication and wear Check welds for cracks Daily Lubricate ring gear 052 grease 150h 3m Check condition of platform Daily Check for and repair collision damage Daily Check condition of anchorage points Daily Entire Unit Check fasteners for proper torque 3m Check condition of operator manual Daily Check for corrosion remove and repaint 6m Check for damage Daily Lubricate 30d heck for peeling missing or unreadable TS torque Vp na 308 tabels on amp 2 Check air pressure 80 psi 5 5 bar Daily Wipe clean 30d SO grade 46 for temperatures above 32 F 0 C Hydraulic Check for leaks at mating surfaces 30d For colder climates ISO grade 32 for temperature range of 0 F 17 C up to 32 0 C Pump Check for hose fitting leaks Daily 5150 grade 15 for t
49. EF CBS IF Z 4 78431 01 V9 91 0000 Am o gem 6 Olm IH 3187033 o NNOH 01 91 002 2 HSE Gf WANO 34d HON V9 91 0NU Z au g iss 5521 wW AITIOALNOI NI zo LAM THA QUN ELANI 22078 WNIWB3l oio pmi Drawing 2 of 2 AB62 Work Platform European Page 6 4 NOTES AB62 Work Platform European Page 6 5 Parts Breakdown Basic Assembly AB62 Diesel Basic Assembly AB62 Diesel 104006 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PART MATERIAL DESCRIPTION 104007 000 CHASSIS ASSY 011248 004 LOCKNUT 1 4 20 UNC 104008 000 TURRET ASSY 0104469 00 PIN WELDMENT 104009 000 ELEVATING ASSY 104088 000 ENGINE SUPPORT WELDMENT 104021 000 CONTROL MODULE ASSY 011256 008 SCREW 1 2 13 UNC HEX HD CAP X 1 104013 000 ENGINE MODULE ASSY DIESEL 011238 008 LOCKWASHER 1 2 DIA SPLIT 104015 000 COVER ASSY 104328 000 COVER HOSE WIDE 104100 000 COUNTER WEIGHT 104329 000 RETAINER HOSE WIDE 100550 002 CAGE ROTATE MOUNT 104333 000 COVER HOSE NARROW 104306 000 CAGE MOUNT 104334 000 RETAINER HOSE NARROW 104025 000 HYDRAULIC RESERVOIR ASSEMBLY 104342 000 COVER VALVE BLOCK 011291 028 SCREW 5 8 11 UNC HHC GR 8 X 3 1 2 104346 000 COVER 011239 010 WASHER 5 8 DIA FLAT ASTM A325 013923 006 SCREW 10 TYPE AB HEX WASHER HD X 3 4 014918
50. ITEM PARTNO PART MATERIAL DESCRIPTION PART NO PART MATERIAL DESCRIPTION ary 066807 004 ALARM 112 db 1 5 011240 004 WASHER FLAT 1 4 1 029616 002 CONN F PUSH 16 14 GA 1 6 029617 002 CONN M PUSH 16 14 GA 1 029452 099 WIRE 16 GA BLK 011252 004 SCREW HHC 1 4 20 UNC X 1 2 EXISTING WIRE BRAKE SOLENOID BRAKE SOLENOID 2 JUMPER Page 6 72 AB62 Work Platform European Illustrated Parts Breakdown Flashing Beacon Option Flashing Beacon Option 104486 000 ITEM PART NO PART MATERIAL DESCRIPTION 012848 004 FLASHING STROBE LIGHT 029610 002 CONN FORK 16 14GA 013283 002 CABLE TY WRAP 029620 002 CONN BUTT 16 14GA 029496 099 WIRE 2 COND 16 GA 029620 002 DIODE 5 011709 008 SCREW 10 24 X UNC X 1 LG 011248 003 LOCKNUT 10 24 UNC ESNA 3 16 DIA 2 HULES 1 4 DIA FOR WIRING CENTER HOLE AS REQUIRED AVOID REINFORCING RIB IN COVER COUNTERWEIGHT HOLE LAYOUT TYP EACH SIDE COVER SUPPORT RIB TYPICAL WIRING INSIDE COVER WHT WHT BLK BLK BATTERY ISOLATOR AB62 Work Platform European Page 6 73 NOTES Page 6 74 AB62 Work Platform European Upright Inc 1775 Park Street Selma California 93662 TEL 559 891 5200
51. LABEL ARROW ORANGE 027898 001 LABEL DIESEL FUEL 104430 000 LABEL AB62 010076 001 LABEL ATTENTION 062814 000 LABEL INSERT PIN 010076 000 MANUAL CASE 061683 018 LABEL UPRIGHT 104044 020 USER MANUAL 104433 000 LABEL BOOM 011248 004 LOCKNUT 1 4 20 UNC HEX 104432 000 LABEL LIFT 011252 008 SCREW 1 4 20 UNC HD CAP X 1 061683 019 LABEL UPRIGHT 062557 012 MAX LOAD 500 LBS 225 Kg 061683 011 LABEL UPRIGHT 104434 000 LABEL 4WD 100339 099 TAPE SAFETY YELLOW amp BLACK 064444 000 LABEL USA 100104 000 LABEL OPERATING INSTRUCTIONS 066554 000 LABEL BEFORE OPERATING 100100 000 LABEL EMERGENCY DOWN 068979 000 CHOCK WHEELS 100102 000 LABEL NON INSULATED 104332 000 LABEL UPPER CONTROLS 100103 000 LABEL TILT ALARM 104347 001 LABEL UPPER CONTROLS 030768 002 LABEL GS 100340 002 LABEL UPPER CONTROLS EMERGENCY STOP 100105 000 CG LOGO 104331 000 LABEL UPPER CONTROLS 100101 000 LABEL ENTRY 104330 000 LABEL LOWER CONTROLS 30 066562 005 LABEL TIRE PRESSURE 4 Page 6 68 AB62 Work Platform European Illustrated Parts Breakdown Label AB62 Diesel ABB2 CENTER GRAVITY AK V s 8 ot Page 6 69 AB62 Work Platform European Illustrated Parts Breakdown Tire amp Wheel Assembly Tire amp Wheel Assembly 1
52. PLATFORM LEVEL UP DOWN PLATFORM ROTATE CW CCW TILT LIGHT TURRET ROTATE PARKING BRAKE RELEASE TILT ALARM TORQUE HiGH LOW EMERGENCY LOWERING DRIVING LIGHTS OPTIONAL GENERATOR OPTIONAL THROTTLE CONTROLLER Axle Release Right Axle Release Signal Power to DMR 30 gt gt x FRONT AXLE Lock Auxiliary Pump Relay Drive Enable Relay Auxiliary Pump Motor Relay Emergency Stop Switch Ignition Switch Auxiliary Power Switch Upper Generator Switch Upper Drive Hi Lo Switch Upper Cage Level Switch Upper Boom Up Down Switch Upper Turret Rotate Upper Cage Rotate Upper Jib Up Down Upper Riser Up Down Upper Boom Retract Extend Upper Driving Lights Upper Oil Pressure Switch Horn Upper Foot Interlock Upper Emergency Stop Lower Selector Switch Lower Auxiliary Power Switch SW23 Lower Enable Switch Lower Boom Hi Lo Speed Lowe Engine start Switch Lowe Turret Rotate Switch Lowe Boom Up Down Switch Lowe Cage Level Switch Lower 4 10 AB62 Work Platform European Section TROUBLESHOOTING 4 4 COMPONENT FUNCTION ENGINE START RUN UPPER CONTROLS ENGINE START RUN LOWER CONTROLS UPPER CONTROL FUNCTIONS LOWER CONTROL FUNCTIONS RISER RAISE LOWER Boom UP DOWN Boom EXTEND RETRACT DRI
53. SIZE FROM WIRE NO 517 FROM WIRE SIZE FROM 300 12 AWG SW1A 1 El 377 18 AWG 7 02 015 350 18 AWG SW24 4 8433 2 307 18 AWG DIUDE 2 TB2 10 378 18 AWG 817 03 012 3508 18 AWG 3033 2 546 4 308 18 AWG 2 83 378 18 AWG 7 04 011 350C 18 AWG SW35 2 SW6 4 309 18 AWG 4 380 18 7 06 03 3500 18 AWG SW35 2 SW30 2 310 18 AWG SW22A 1 BT1 01 381 18 AWG 817 07 D4 350E 18 AWG 3430 2 5031 2 314 18 AWG 506 3 4 01 382 18 AWG 817 08 D13 350F 18 AWG SW34 2 SW31 2 315 18 AWG 5027 3 1 08 383 18 AWG 7 09 014 3506 18 AWG SW34 2 5032 2 316 18 AWG 5028 3 1 02 384 18 AWG TBI 6 BIS 350H 18 AWG SW29 2 TB2 1 317 18 AWG SW29 1 BT2 09 385 18 AWG 1 11 B20 357A 18 AWG 5 06 15 318 18 AWG 5029 3 5032 2 388 18 AWG 1 5 027 3578 18 AWG C14 319 18 AWG SW30 3 BT2 04 388 18 AWG 1 10 C7 361A 18 AWG SW23B 4 5 10 320 18 AWG 5030 1 2 05 390 18 AWG 1 15 C8 3618 18 AWG DIUDE K10 86 321 18 AWG 5031 3 814 02 391 18 AWG 1 20 cs 361C 18 AWG SW23B 4 814 07 322 18 AWG 5031 1 2 12 392 18 AWG 1 25 C6 361D 18 AWG K9 86 K10 86 323 18 AWG 5032 3 4 03 394 18 AWG DIL S cig 385A 18 AWG 1 05 1 1 324 18 AWG 5032 1 2 08 395 18 AWG 5 4 3868 18 AWG 1 16 020 325 18 AWG SW33 3 2 10 396 18 AWG 033 B22 393A 18 AWG 1 17 1 22 326 18 AWG 8433 1 2 11 398 18 AWG 88 C21 3938 18 AWG TB1 22 TB1 30 327 18 AWG 5034 3 BT2 02 388 18 AWG 824 C22 397A 18 AWG H LRMETER 1 B14 328 18 AWG
54. and turn A WARNING A on turn clockwise the chassis emergency stop switch Emergency Stop Always wear an approved fall restraint properly attached to designated platform anchorage 2 Mount the platform close and latch the gate point when driving or elevating the machine 3 Attach approved fall restraint to designated plat see figure 2 5 Attach only one fall restraint to form anchorage point Attach only one fall each anchorage point restraint to each point OOe 4 Start engine 5 Check that the area around and above the work platform is clear of obstructions holes drop offs persons in the route of travel and the surface is capable of supporting wheel loads 6 Depress the foot switch and move the drive con trol handle forward to travel forward and reverse to travel in the reverse direction NOTE When the boom is rotated to the front of the chassis steering wheels aft directions of travel and steering will be reversed Observe the color coded arrows on the control panel near the drive control handle and on the chas sis They will indicate the direction of travel when the drive control handle is moved Figure 2 5 Typical Fall Restraint Anchorage Point 2 4 AB62 Work Platform European Section MACHINE PREPARATION amp OPERATION 2 4 With Boom Elevated Travel with boom elevated is restricted to firm level surfaces only When driving elevated the machine will travel at creep s
55. 001 S N 1109 Current Level Cylinder Assembly 104041 000 S N 1100 1108 Level Cylinder Assembly 104041 001 S N 1109 Current Master Cylinder Assembly 104042 000 S N 1100 1108 Master Cylinder Assembly 104042 001 S N 1109 Current Boom Cylinder Assembly 104039 000 S N 1100 1108 Boom Cylinder Assembly 104039 001 S N 1109 Current Label Kit AB62 Diesel 1040471002 Pare Tire amp Wheel Assembly 100090 000 Left 100090 001 Right Control Cable 104032 000 Motion Alarm Option 104485 000 Flashing Beacon Option 104486 000 Parts Breakdown Final Assembly 62 Diesel Final Assembly AB62 Diesel 104000 001 ITEM PART NO 104043 000 PART MATERIAL DESCRIPTION SPECIFICATION SHEET ITEM PART NO 011715 006 PART MATERIAL DESCRIPTION SCREW 96 32 RD HD MACH X 3 4 104006 000 BASIC ASSEMBLY AB62 DSL 011248 047 LOCKNUT 46 32 HEX 102037 100 PLATFORM 6 FT EURO 104017 000 UPPER CONTROL BOX ASSY DSL 104032 000 029433 099 CONTROL CABLE ASSEMBLY CONTROL CABLE 18 GA X 24 COND 104046 000 HOSE KIT 068865 000 OUTLET PLATE 104049 000 104048 000 ELECTRICAL SCHEMATIC HYDRAULIC SCHEMATIC 029961 000 PLUG INLET 100385 099 HOSE GUARD 068820 000 RETAINING STRAP FOOTSWITCH 100386 099 HOSE GUARD 063906 000 064479 000 FOOT SWITCH SWITCH GUARD FOOT 061692 099 TRIM LOK 10038
56. 013 BOOT 104029 000 PUMP DRIVE ASSEMBLY 015790 003 SOCKET 16 18 GA 104027 000 PUMP LIFT ASSEMBLY 067990 030 CONNECTOR 8 PIN 068823 000 OVER FLOW BOTTLE 067990 031 CONNECTOR 8 PIN 100209 000 ENGINE MOUNT ISOLATOR 100338 013 CONTACT 16 GA PIN 027972 000 SOLENOID START 12 VOLT 100338 014 CONTACT 16 GA SOCKET 104036 000 VALVE BLOCK ASSY BRAKE 029480 099 10 GA RED 104323 000 ISOLATOR BRACKET 029470 099 12 GA RED 100324 000 POWER CONVERTER 029454 099 16 GA RED 068565 001 ACCUMULATOR 029452 099 WIRE 16 GA BLACK 010150 005 FITTING BULKHEAD 029451 099 WIRE 16 GA WHITE 011979 008 O RING 029368 099 WIRE 16 GA RED YEL 104409 000 ISOLATOR COVER WELDMENT 029453 099 WIRE 16 GA ORANGE 011252 006 SCREW 1 4 20 UNC HEX HD CAP X 3 4 068334 080 BATTERY CABLE ASSY X 80 LG 011239 004 WASHER 1 4 DIA FLAT ASTM 068334 050 BATTERY CABLE ASSY X 50 LG 011248 004 LOCKNUT 1 4 20 UNC HEX A325 068334 032 BATTERY CABLE ASSY X 32 LG 011252 020 SCREW 1 4 20 UNC HEX HD CAP X 2 1 2 029610 006 FORK TERM 8 14 16 GA 011248 006 LOCKNUT 3 8 16 UNC HEX 029601 012 CONN RING TERM 8 16 14 GA 011254 028 SCREW 3 8 16 UNC HEX HD CAP X 3 1 2 029601 039 CONN RING TERM 0 5 16 12 10 GA 100192 000 WASHER SNUBBER 029617 002 CONN MALE PUSH 25 16 14 GA 014996 008 WASHER 1 2 DIA FLAT 029931 003 CONN FEM PUSH 25 16 14 GA 011238 008 LOCKWASHER 1 2 DIA SPLIT 029931
57. 016 SCREW 1 8 UNC HHC GR 5 X 2 LG 011254 024 SCREW 3 8 16 UNC HEX HD CAP X 3 011239 016 WASHER FLAT ASTM A325 1 DIA 061796 099 TRIM 104226 000 TRAY PIN WELDMENT 104375 005 BEARING 2 01 0 X 2 0 LG 104144 004 WASHER THRUST 104375 004 BEARING 2 0 I D X 1 5 LG 101016 002 BEARING 1 50 I D X 1 25 LG 104504 000 ROTATOR PIN WELDMENT 011254 006 SCREW 3 8 16 UNC HHC GR 5 X 3 4 011239 012 WASHER 3 4 STD FLAT 011240 006 WASHER 3 8 DIA STD FLAT 011248 012 LOCK NUT 3 4 10 UNC HEX 011248 006 LOCKNUT 3 8 16 HEX 011254 028 SCREW 3 8 16 UNC HEX HD CAP X 3 1 2 104019 000 LOWER CONTROLLER ASSEMBLY DIESEL 011254 020 SCREW 3 8 16 UNC HEX HD CAP X 2 1 2 104285 000 TOP CONTROL BRACKET 015736 001 FITTING ELBOW 4MB 4MJ 90 LONG 104284 000 BOTTOM CONTROL BRACKET 011765 024 RETAINING RING 1 1 2 EXTERNAL 104211 000 PIN WELDMENT 104470 001 SLEEVE PIN HEAD 104326 000 PIN WELDMENT 104074 000 ENGINE SLIDE MOUNT 011254 008 SCREW 3 8 16 UNC HEX HD CAP X 1 011828 010 SCREW 1 4 20 FLAT HD X 1 1 4 011238 006 LOCKWASHER 3 8 SPLIT 011256 010 SCREW 1 2 13 UNC HEX HD CAP X 1 1 4 011252 006 SCREW 1 4 20 UNC HEX HD CAP X 3 4 011240 004 WASHER 1 4 STD FLAT DOP ro r PO Aj CO PO MR MS oG rS o rS CO PO PO Nl PO N
58. 104056 000 RIGHT COVER BRACE 100370 099 DOOR SEAL C 104084 000 HINGE 104374 000 SPRING GAS 104089 000 HINGE MOUNT RIGHT FRONT 104374 001 BALL JOINT ASSEMBLY 104090 000 HINGE MOUNT RIGHT REAR 011240 005 WASHER 5 16 DIA STD FLAT 104078 000 RIGHT DOOR MOUNT 104479 000 SPACER DOOR MOUNT 104077 000 LEFT DOOR MOUNT 011253 008 SCREW 5 16 18 UNC HEX HD CAP X 1 104451 000 STRUT BRACKET LEFT 011253 006 SCREW 5 16 18 UNC HEX HD CAP x 3 4 104093 000 HINGE MOUNT LEFT REAR 011248 005 LOCKNUT 5 16 18 UNC HEX 104092 000 HINGE MOUNT LEFT FRONT 011826 004 SCREW 10 32 UNF RD HD MACH X 1 2 104057 000 LEFT COVER BRACE 011240 006 WASHER 3 8 DIA STD FLAT 104076 000 TURRET COVER LEFT 011248 006 LOCKNUT 3 8 16 UNC HEX 104455 000 SPRING MOUNT pn po po a Page 6 26 AB62 Work Platform European Parts Breakdown Cover Assembly 104457 000 ON TURRET REF AB62 Work Platform European Page 6 27 Parts Breakdown Upper Controller Assembly 62 Diesel Upper Controller Assembly AB62 Diesel 104017 000 ITEM PART NO 104270 000 PART MATERIAL DESCRIPTION ENCLOSURE UPPER CONTROLS ITEM PARTNO 104270 000 PART MATERIAL DESCRIPTION UPPER CONTROL BOX 068594 000 JOYSTICK OPERATOR 029925 002 CONNECTOR CABLE 1 2 NPT
59. 13 _ L m TURRET ACC 141 1 gie QL 1 5 STEER a ISO ENGINE MODULE gt RED 10GA GROUND RED 10 GA CHARGE SOL17 skane ISILATUR ENGINE BLACK CAP A 1 PHAR REVERSE HIGH FLOW SOL18 zl RIGHT PMP1 LEFT 5 BLK RED PUMP gt uid BLK g ACT1 L GROUND DIL PRESS VALVE BLOCK N RED SWITCH TROT E THROTTLE ACTUATOR KA ALT swi7 gt SNSR2 SNSR3 GENERATDR VALVE STARTER TEMPERATURE DIL PRESSURE Bl AA SOL19 d MOTOR GAGE SENDER GAGE SENDER 4 REO GRN D SOLENOIO 4 amp GENERATOR VALVE BLOCK g tL i L RLUAMT TENPEBATURE LAMP g a h SOL23 m VALVE BLOCK Zs D7 MOT2 B D9 H 7 BLU BLK BRAKE 50120 g 2 2 D PRESSURE LIGHT 16 824 g 50121 SOLENOID TORGUE HIGH SPEED AA ORN ORN da AXLE LOCK SOL22 8 gt 5 URV RED 1 CBLCANT RED BLK WHT RED p HBK re IOLE COMMON TMR WHT 15 R1 m WIT RED g IV TD LOWER CONTROLLER B Heena TEP SW NC HIGH IDLE N C T Si zia j 7 GRN BLK GRN 8 aK PROPANE SELECT A N I D8 as SELECT GLO PLUGS DRN 2 GRN a T 2 LIRE n a 5 a4 me CONT2 Figure 5 1 AB62 Electrical Schematic Diesel 104049 000 1 of 2 AB62 Work Platform European 5 3 TU ENGINE CONNECTOR
60. 325 30 3 8 16 4 950 23 31 6950 32 5 44 3 3 24 5 600 26 35 7900 37 50 N 7716 14 6 800 37 50 9600 53 70 SE 7 16 20 7 550 42 55 10700 59 78 1 2 13 9 050 57 75 12800 80 107 1 2 20 110 200 64 85 14400 90 120 m 9 16 12 11 600 82 109 16400 115 154 N 9716 18 13 000 92 122 18300 129 172 5 8 11 14 500 113 151 20300 159 211 5 8 18 16 300 128 170 23000 180 240 3 4 10 21 300 200 266 30100 282 376 3 4 16 123 800 223 298 33600 315 420 7 8 9 29 435 321 430 41550 454 606 7 8 14 32 480 355 473 45855 500 668 1 8 38 600 483 640 54540 680 900 1 12 42 270 528 704 59670 745 995 3 22 AB62 Work Platform European Section MAINTENANCE 3 13 Table 3 4 Torque Specifications for Metric Fasteners U S Customary Units 7 LO S TENE T uu 8 8 Grade 10 9 Grade 12 9 Nominal Clamp Tightening Torque Tightening Torque Tightening Torque siz Load K 15 K 20 15 K 20 4 5 195 6 18986 887 283 283 8 5 122 0 273 EU 8 117 57 733 75 069 56 753 91 751 70 208 8 113 503 ade 0 6 ac Nominal Clamp Tightening Torque Clamp Tightening Torque Clamp Tightening Torque Sue Load K 15 20 Load K 15 K 20 Load K 15 K 20 3
61. 5034 1 2 03 302A 12 AWG SW22A 4 SW22B 4 3978 18 AWG H LIRMETER I C17 329 18 AWG SW35 1 2 07 3028 18 AWG 5 22 4 50228 4 400 16 AWG HOURMETER 2 TEMP GRND 330 18 AWG 5035 3 2 06 302C 18 AWG SW22A 2 SW22B 4 400B 16 AWG TEMP GRND TB2 1 333 18 AWG BT2 01 030 3020 18 AWG 5 22 2 50228 2 400 16 AWG TEMP GRND DIL 334 18 AWG 874 08 302 12 AWG SW22A 2 SWIA 2 4000 16 AWG TB2 2 039 335 18 AWG BT4 08 Cll 302F 12 AWG SW22B 2 SWIB 2 400E 16 AWG 2 1 038 342 18 AWG 873 03 B8 3026 18 AWG SW22B 2 9 30 4007 16 AWG 2 1 037 343 18 AWG BT8 01 BIS 302H 18 AWG K9 87 C16 4006 16 AWG TB2 1 036 344 18 AWG BT8 02 BI6 304A 18 AWG CB 3 CB 2 400H 16 AWG TB2 2 345 18 AWG 878 03 BI7 304B 18 AWG CB 2 TB2 4 400J 16 AWG 2 2 B2 346 18 AWG BT8 04 BI8 304C 18 AWG CB 3 TEMP 1 400K 16 K9 85 K8 85 347 18 AWG BT9 01 B5 304D 18 AWG TEMP 1 011 1 4001 16 AWG K9 85 K10 85 348 18 AWG BT8 02 B6 304E 12 AWG SW22A 3 SW22B 3 400M 16 AWG K8 85 TB2 10 348 18 AWG B10 D35 304F 12 AWG SW22B 3 TB2 3 400 16 AWG 11 01 TB3 1 351 18 AWG B21 D28 305A 12 AWG CB 1 2 5 400 16 AWG BT11 04 TB3 2 352 18 AWG BT5 01 3058 12 AWG CB 1 2 6 400R 16 AWG TB3 2 K10 85 353 18 AWG 5 02 019 305C 18 AWG BT11 02 2 7 4005 16 AWG 2 1 040 354 18 AWG 5 03 Bl2 3050 18 AWG 11 05 2 8 12 AWG SW1B 1 SW23A 4 355 18 AWG 5 04 cg 305 18 AWG 8111 06 182 8 2 18 AWG SW23A 3 OIODE1 356 18 AWG 5 05 TBI 1 305F 18 AWG 8111 03 TB2 7
62. 6MJ 011935 004 FITTING ELBOW 45 8MB 8MJ 020021 012 FITTING PLUG MB12 100433 002 FITTING ELBOW 45 4MFFOR 6MB 100448 001 FITTING TEE 4FFOR 4MFOR 011934 003 FITTING ELBOW 90 6MB 4MJ 011935 013 FITTING ELBOW 45 6MB 4MJ 011934 015 FITTING ELBOW 12MB 12MJ 020733 002 FITTING TEE 6FJ 6MJ w a AB62 Work Platform European Page 6 49 Parts Breakdown Hose Kit Installation Chassis Turret Linkage Hose Kit Installation Chassis Turret Linkage 104046 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PARTNO PART MATERIAL DESCRIPTION 062192 083 1 4 HOSE ASSY X 83 467 6FJX 6FJX 063469 032 3 8 HOSE ASSY X 32 6675 6FJX 6FJX 102403 040 1 4 HOSE ASSY X 40 4M3K 4FFORX 4FFORX 104437 087 1 2 HOSE ASSY X 87 8M3K 6FJX 8FJX 102403 034 1 4 HOSE ASSY X 34 4 4FFORX 4FFORX 068739 098 1 HOSE ASSY X 98 1604 16FJX 16FJX 102403 057 1 4 HOSE ASSY X 57 4 4FFORX 4FFORX 068763 121 1 4 HOSE ASSY X 121 4675 4FJX 6FJX 100424 059 1 4 HOSE ASSY X 59 4M2T 4FFORX 4FFORX 104458 099 3 4 HOSE ASSY X 99 12C1T 12FJX 12FJX 068737 038 1 4 HOSE ASSY X 38 4675 4FJX 4FJX 064156 151 1 2 HOSE ASSY X 151 8075 8FJX 8FJX 068737 073 1 4 HOSE ASSY X 73 4675 4FJX 4FJX 104458 137 3 4 HOSE ASSY X 137 12C1T 12FJX 12FJX90 100424 040 1 4 HOSE ASSY X 40 4 2 4FFOR
63. BUSHING 2 ID x 2 00 LG 011254 006 SCREW 3 8 16 UNC HEX HD CAP X 3 4 104375 004 BUSHING 2 ID x 1 50 LG 014033 040 SCREW 1 2 13 UNC HEX HD CAP GR 8 X 5 LG 104210 000 PIN WELDMENT 011254 008 SCREW 3 8 16 UNC HEX HD CAP X 1 104211 000 PIN WELDMENT 011248 008 LOCKNUT 1 2 13 UNC HEX 104212 000 WELDMENT 011238 006 LOCKWASHER 3 8 DIA SPLIT 104274 000 PIN UPPER BOOM 104375 006 BUSHING 2 00 ID X 2 1 2 LG 104216 000 PIN WELDMENT 104241 000 PIN WELDMENT 104178 000 LOWER RISER WELDMENT 065214 001 ROD END RETAINER 104191 000 LOWER BOOM WELDMENT 011254 010 SCREW 3 8 16 UNC HEX HD CAP X 1 1 4 104185 000 UPPER TENSION LINK WELDMENT 104375 007 BUSHING 2 ID x 1 75 LG 104195 000 UPPER WELDMENT 104183 000 LOWER TENSION LINK WELDMENT Page 6 14 AB62 Work Platform European Illustrated Parts Breakdown Linkage Assembly AB62 Work Platform European Page 6 15 Parts Breakdown Straight Boom Assembly Straight Boom Assembly 104011 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PARTNO PART MATERIAL DESCRIPTION 104163 000 BASE WELDMENT 011254 016 SCREW
64. C
65. Lowe Limit S witch inkage Limit S witch Lower Linkage Limit Switch oximity S witch Right side rea main Boo Or iliary Pump Control M Or Engine Engin er ine Temperature Lowe d d d d d d Boom Down d Boom Extend Boom Retract d Riser Up d Riser Dow d Cage Rota id Cage Rota id d d d d d d d d d d ngine S tart Relay ive Motion Alarm Not Used Not Used Left Axle Release Right Axle Release Axle Release Signal Powerto DMR 30 Auxiliary Pump Relay ay Ignition cutout during Auxiliary Power ay Drive Enable ay Auxiliary Pump Motor itch Emergency Stop itch Ignition Start Engine Turret Rotate CW Turret Rotate CCW Steer Righ Steer Left Low Flow P roportional High Flow Proportional m Va Generator Valve Valve B Brake ine Module Torque ine Module Axle Lock ine Module Fuel ine Module Module Fuel Solenoid P ull Circuit ine Auxiliary Power itter DMT 30 Transmit signal to controller Platform Control Box Generator Drive Hi Low Speed 5 2 AB62 Work Platform European Section SCHEMATICS 5 1
66. NNA Nid NOTA eet don 25 251 Six 8 01 5 18 Clg T TT aN N3MDd ISU A 9 NId 2101 NOLDMHINId pA 6114100 649 5 TOT 18 H mm SA 8 e Es 1001 Ws 7001 v 8211 IF gom bol 00 FN kai 2001 12 8011 12 o 9 ul 1001 11 to NOTLINT NId NId 5104100 98 SUNdNI 719 719 4 2 Section 4 1 TROUBLESHOOTING 4 1 TROUBLESHOOTING DMR 30 CONTROLLER There are two components to the DMR 30 system A DMT 30 transmitter in the upper control box transmits inputs from the operator controls to the DMR 30 receiver in the lower control box The DMR 30 receives the digital signal and commands the appro priate functions A corresponding LED for each input and output is added to the DMR30 DMT 30 for eas ier diagnosis These LEDs correspond to wire position in the plugs and acknowledge a signal on the wire Using the charts in figures 4 1 and 4 2 a signal or series of sig nals can be followed from switch to actuator to help in determining the cause of a problem Four blinking diagnostic LEDs located at the bot tom center of the DMR 30 are labeled as to their function and are also used for diagnostic purposes A CPU LED DMR 30 is powered up operating prop erly Solid light indicates internal failure Not lit when no power input B INPUT LED Indicates an input from
67. Port Check Valve Main Valve Block Diverter Valve Brake Valve in Valve Block Brake Axle Lock 2 Speed Valve Block Check Va Check Va Low Pressure Test Port Check Valves Boom Extend Cylinder Check Valve Main Valve Block Boom Extend Cylinder Axle Float Valve Brake Axle Lock 2 Speed Valve Block Check Va Turret Rotate Check Valve Turret Rotate Valve Block High Speed Valve Rear Drive Valve Brake Axle Lock 2 Speed Valve Block Drive Valve Block Check Va Boom Pump High Pressure Check Valve Boom Pump Check Va Boom Pump Low Pressure Check Valve Boom Pump Check Valve Return Filter Check Valve Return Filter Cylinder Steering Cylinder Riser Cylinder Chassis Riser Boom Extend Cylinder Inside Boom Boom Raise Cylinder Front of Boom Jib Cylinder Jib Master Cylinder Slave Cylinder Rear of Boom Front of Boom Cylinder Turret Rotate Brake Cylinder Brake Cylinders Turret Rotate Motor Brakes Cylinder Left Axle Lock Cylinder Front Axle Cylinder Right Axle Lock Cylinder Front Axle Flow Divider Flow Divider Drive Valve Block Filter Filter Suction Filter Return Filter Tank Tank Filter Suction Filter Tank Filter Return Filter Tank Filter Suction Filter Tank Manifold Drive Motor Rotary Manifold Lef
68. S oza aw 972b P ower ren oe IP Pe z a T3 8001 EDI wax ISL vei sae Sat cur Py ona P B IVESNSS mum A 1013 sr UTE os we wx ve WRCONVET 00 1 3 AMLLYB TO ELE SIS UESHO 18 xz s 89 sua a HS aL pa SOSNSS WI 30 Np OR e T a ux LZMS AE de We M d e 282 r zi he MIN BAL NL NAGE vee 8013138 EE m eh Nar E 1 55541510 SN u z 1 Post 9 res oz SET SDINGIUNT Sd EI s vLMS lor Der SAT80 TRITT STATS FTR EDT WE EI 249 BIMS ere S e FOLTS ITRTT SD3 BROT m Cu tor z po GS QE masa REE suns mem F 15 S ONE 0 sz 57 m E ces osi a svi T vival ds ere UNIX WOOT UT i 5 2 1 18 n e err Bk STINTS INBISH RODE LMS lx f r NAOT ESTS aie r q st ron 3013 Herem LNS E z BOT A38 sena NN S E8L ORT SATS are ZI FEMS B WIS 112 Hosa RO SVS sat 3 n s ara Em
69. bly must be blocked Disconnect the battery when replacing or test ing the continuity of any electrical component This manual cannot cover all possible problems that may occur If a specific problem is not covered in this manual call our toll free number for service assis tance Referring to Sections 2 0 and 5 0 will aid in under standing the operation and function of the various components and systems of the AB62 and help in diagnosing and repair of the machine Troubleshooting Procedure Determine whether the problem is mechanical inter ference electrical or hydraulic Some functions require power at more than one solenoid Thoroughly study hydraulic and electrical schematics in Section 5 Check for loose connections and short circuits Check repair replace each component in the Truth Table which is listed under each machine func tion which does not operate properly Use the charts on the following pages to help deter mine the cause of a fault in your UpRight 62 1 Verify your problem Do a full function test from both platform controlsand chassis controls and note all functions thatare not operating correctly 2 Narrow the possible causes of the malfunction Use the troubleshooting guide to determine which components are common to all circuits that are not functioning correctly 3 Identify the problem component Test compo nents that are common to all circuits that are not functioning correctly Remem
70. drive is sealed at spindle fill with lubricant to proper level and replace all plugs Carrier Assemblies Do not attempt to service primary or secondary car rier assemblies Sealing Compound Silastic RTV732 sealer and General Electric Silimate RTV No 1473 or RTV No 1503 are currently recom mended for sealing gasket surfaces Sealant should be applied in a continuous bead which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole loca tion AB62 Work Platform European Section MAINTENANCE 3 10 1 Coupling 22 Primary Carrier Assembly 2 Input Shaft 23 Retaining Ring Service Kit 100254 020 contains 3 Spindle 24 Primary Sun Gear seal 9 Hex Head Bolt Grade 8 26 Disengage Plunger eal 10 Flat Washer 28 Large Cover Bearing Cong 11 Hub 29 Hex Head Bolt 2 16 Bearing Nut 30 Magnetic Plug s A 17 Retaining Ring 31 Disengage Cover 13 Beari 9 C 18 Washer 32 Hex Head Bolt e 19 Disengage Spring 33 Quick Disconnect Gasket hp ars 20 Ring Gear 34 Quick Disconnect Assembly 25 Thrust Washer 21 Secondary Carrier Assembly 35 Hex Head Bolt 27 O Ring Figure 3 15 Torque Hub AB62 Work Platform European 3 15 Section 3 11 3 11 CYLINDER REPAIR Removal 1 Remove cylinder from machine NOTE Refer to Illustrated Parts Section for location of cylinder and list of parts which secure cylinder
71. footswitch push the turret rotation control lever right to rotate counterclock wise left to rotate clockwise Release the switch to stop rotation Observe the area around the boom when rotating the turret to avoid any obstructions Warning If tilt alarm sounds retract boom and drive machine to a level surface Stop When Tilt Alarm Sounds Section 2 4 MACHINE PREPARATION amp OPERATION Elevating the Riser 1 Setthe function speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease 2 While depressing the foot switch push the riser control lever forward to elevate the riser rearward to lower the riser Release the control lever to stop elevating lowering gl Elevating the Upper Boom 1 Setthe function speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease If you are not sure what speed to use start out slow the speed can be varied while operating the function 2 While depressing the foot switch push the upper boom control lever forward to elevate the upper boom rearward to lower the upper boom Release the control lever to stop elevating lowering j j Extending the Upper Boom 1 Setthe function speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease If you are not sure
72. illuminated BT5 04 boom down output BT5 06 throttle out put BT6 12 low flow valve output Boom Extend Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT3 11 boom extended LEDs on DMR 30 illuminated BT6 07 boom extend output BT5 06 throttle out put BT6 10 high flow valve output Boom Retract Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT3 06 boom retract LEDs on DMR 30 illuminated BT6 08 boom retract output BT5 06 throttle out put BT6 10 high flow valve output AB62 Work Platform European Turret Rotate Functions Swing Right Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT3 07 turret rotate right LEDs on DMR 30 illuminated BT7 09 turret rotate right output BT5 06 throttle output BT6 12 low flow valve output Swing Left Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT3 01 turret rotate left LEDs on DMR 30 illuminated BT7 08 turret rotate left output BT5 06 throttle out put BT6 12 low flow valve output Jib Jib Up Function enabled foot switch depressed LEDs on 30 illuminated BT4 03 foot pedal 4 07 jib up LEDs on DMR 30 illuminated BT7 06 jib up output BT5 06 throttle output BT6 12 low flow valve output Jib Down Function enabled foot switch depressed
73. lift functions The drive system uses an electrically controlled variable displacement piston pump that powers four piston type wheel motors The high flow system uses a gear type pump to power riser up down boom extend retract and steer func tions The low flow system also using a gear type pump operates Boom up down Jib up down Swing right left Cage rotate and Cage level High flow and low flow system pressures can be veri fied by connecting a 3000 PSI gauge to the upper port on the valve block Operate Riser down to test high flow system or Jib up to test the low flow system Operate function until it stops and system bypasses The high flow relief valve is located just below the gauge port The low flow relief valve is located below the high flow relief valve High flow pressure 2700 PSI Low flow pressure 1400 PSI AWARNING Counterbalance valves must never be removed if the platform is raised and hydraulic system is under pressure Be sure the platform is com pletely stowed before removing counterbalance valves 4 8 AB62 Work Platform European Section TROUBLESHOOTING 4 4 Table 4 1 Electrical Truth Table AB62 Diesel FUNCTION UPPER CONTROL FUNCTIONS LOWER CONTROL FUNCTIONS RISER RAISE LOWER Boom Up Down Boom EXTEND RETRACT DRIVE FORWARD REVERSE SPEED HIGH CREEP STEER LEFT RIGHT UP DOWN BATTERY CHARGE PLATFORM LEVEL UP DOWN PLATFORM ROTATE CW CCW FRONT AXLE Lock TILT L
74. move the machine or when winching onto a trailer for transportation 1 Insure that the platform is fully lowered and that the turret is rotated so that the platform is to the rear of the machine 2 Attach chain cable of sufficient strength for towing the machine to front or rear tie down lugs Chock wheels before disengaging hubs Machine may roll Refer to Figure 2 6 and disengage all four drive hubs Remove two screws and center cap Re install center cap in the opposite direction NOTE When hubs are disengaged the brakes are ineffective The machine will roll freely AB62 Work Platform European Section MACHINE PREPARATION amp OPERATION 2 5 4 When ready to move the machine remove the NOTE When hubs are disengaged the brakes chocks Tow or winch into position and replace are ineffective The machine will roll freely chocks 6 Secure the machine to the transport vehicle using 5 Engage all four drive hubs by returning the center chains straps of adequate load capacity refer to caps to their original orientation specifications on page 1 2 attached to chassis tie down lugs See Figure 2 7 7 Place a wooden block 20cm x 10cm x 75cm 7 5 x 4 x 28 under platform support braces as CAUTION A shown See Figure 2 7 DO NOT move the machine faster than 5 km h 8 Attach ratchet strap under platform floor grating 3 mph Faster speeds will damage drive com over support braces See Figu
75. will say ERROR push again high flow will appear Push ENTER The TH MX RU RD LR icons will appear and TH will be flashing Push ENTER and the display will read CHANGE YES NO ENTER Push and the preset value will be displayed To adjust push to raise value or to lower value If preset value is right or after resetting the value push ENTER You will be back to Run mode normal functions off To reset the other functions repeat the procedure until TH is flashing as it did above then use the or to scroll to other functions then con tinue IMPORTANT After making changes thoroughly test all functions for smoothness and proper operation Settings Serial Numbers 1100 to 1115 Low Flow System Threshold 58 62 High 80 87 Ramp Up 5 Sec Ramp Down 0 Sec Low Range 25 50 High Flow System Threshold 67 High Range 95 Ramp Up 5 Sec Ramp Down 0 Sec Low Range 95 Settings Serial Numbers 1116 Current Low Flow System Threshold 28 30 High Range 56 58 Ramp Up 2 Sec Ramp Down 0 Sec Low Range 46 48 High Flow System Threshold 27 29 High Range 95 Ramp Up 2 Sec Ramp Down 0 Sec Low Range 95 Section 4 4 TROUBLESHOOTING 4 4 HYDRAULIC TROUBLESHOOTING The AB62 has three independent hydraulic systems one for drive one for high flow lift functions and one for low flow
76. wires and contacts Refer the removal of the Locking Wedge of either the to Crimping procedure male or female connector 2 Use the removal tool or flat blade screwdriver to Female Connector Receptacle push the Locking Fingers aside This will release 1 Disconnect the male connector plug from the the grip on the contact female connector receptacle 2 Using the notched end of the Removal Tool or a 3 Pull the wire and contact out of the connector wire hook pull the Locking Wedge from the Crimping Female Connector Note Complete crimping instructions are 3 Check all parts for damage Replace all parts included n Fiala Kit which are damaged or worn 1 Strip 1 4 6 mm from the wire 4 Replace or recrimp the wires and contacts Refer 2 Insert the contact into the crimping tool to Crimping procedure 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 3 2 AB62 Work Platform European Section MAINTENANCE 3 3 5 Inspect the crimped contact to ensure that all 3 3 PREVENTATIVE MAINTENANCE strands are secure in the crimp barrel TERN The complete inspection consists of periodic visual Removing Contact From Heavy Duty Plug and ope
77. 00090 000 Left 100090 001 Right ITEM PARTNO PART MATERIAL DESCRIPTION ary 1 100091 000 WHEEL 19 5 X 12 9 HOLE 2 100092 000 TIRE 19 5 X 15 NHS 14 PLY 3 012282 001 VALVE STEM i RIGHT HAND SHUWN NOTES LEFT HAND REVERSED 1 FILL TIRE amp WHEEL ASSY WITH 115 120 FL 07 OF TRAC SEAL OR EQUIV TIRE SEALANT LUG INFLATE TO 80 PSI MIN TIRE PRESSURE TRAC SEAL REB WT 12 5 13 5 LBS REF Page 6 70 AB62 Work Platform European Illustrated Parts Breakdown Control Cable Control Cable 104032 000 ITEM PART NO PART MATERIAL DESCRIPTION 015790 012 CONNECTOR PLUG 24 CONTACT 065926 012 CONNECTOR PLUG 31 CONTACT 029433 099 CABLE 18 24 COND 015790 003 SOCKET CONTACT 16 18 000 ENS 2 GRN 3 RED 4 WHT G 5 ORG GRN T RT 0 8 WHT BLK RED Oia 9 WHT BLK RED GRN BLK 12 086 1 Soorte RED ELK WHT y 2 G y 15 WHT RED 9 lt 16 BLK RED 3 9 7 17 URG 8LK ee Z x Y 20 WHT BLK G RED WHT 2 2 D 29 TRNEK 3 EEG 24 GRN WHT 25 BLK WHT ES LENT 25 RED NHT RED BLK 2 28 24 394 3 o y EN STRIP BACK STRIP BACK AB62 Work Platform European Page 6 71 Parts Breakdown Motion Alarm Option Motion Alarm Option 104485 000
78. 005 CONN FEM PUSH 25 10 12 GA 011252 012 SCREW 1 2 13 HEX HD CAP X 1 1 2 029825 002 DIODE 5 011238 006 LOCKWASHER 3 8 DIA SPLIT 029433 099 18 GA 24 COND 011254 008 SCREW 3 8 16 UNC HEX HD CAP X 1 029496 099 CABLE 16 GA 2 COND 067672 020 SCREW M8 X 1 25 HEX HD CAP X 20MM 011238 005 LOCKWASHER 5 16 DIA SPLIT Fro PO PO N NOTE Items 3 through 18 included with Item 2 4 Page 6 22 AB62 Work Platform European Illustrated Parts Breakdown Engine Module Assembly AB62 Diesel PUMP ITEM 19 APPLY LOCTITE 242 OR EQUIVALENT TO CLEAN DRY THREAD DETAIL A Drawing 1 of 2 AB62 Work Platform European Page 6 23 Parts Breakdown Engine Module Assembly AB62 Diesel S1NOOW LV 0 049 SISSVHI 2 9 UN O Ad3l1V8 IDA cI 4 17108 3NISN3 LV 0 039 aaa 18 3 Mana 7091405 3 ulDaHl eR 7081405 JNLLO HL 010 970 330 1 13IHS HV iva 38 38 XT8 1HA
79. 011934 001 NG ELBOW 4MB 4MJ 90 011469 006 LUGNUT 5 8 011941 019 NG STR 12MB 10MJ F F F F 011254 010 SCREW 3 8 16 UNC HD CAP X 1 1 4 011934 024 FITTING ELBOW 10MB 6MJ 90 5 CO N CO PO N HP PO HPP PoP poy po PO Po poy By HS 011248 006 LOCKNUT 3 8 16 UNC 011257 024 SCREW 5 8 11 UNC HD CAP X 3 011239 006 WASHER 3 8 DIA ASTM A325 068680 007 FITTING 90 100782 000 O RING WHEEL MOTOR 003556 001 FITTING 011257 040 SCREW 5 8 11 UNC HEX HD CAP X 5 011253 008 SCREW 5 16 18 UNC HEX HD CAP X 1 011254 008 SCREW 3 8 16 UNC HEX HD CAP X 1 011238 005 LOCKWASHER 5 16 DIA SPLIT 23 011240 006 WASHER 3 8 DIA STD FLAT 4 4 Nh N Page 6 8 AB62 Work Platform European Illustrated Parts Breakdown Chassis Assembly AB62 Work Platform European Page 6 9 Parts Breakdown Front Axle Assembly Front Axle Assembly 104016 000 ITEM 0 104114 000 PART MATERIAL DESCRIPTION FRONT AXLE WELDMENT ITEM 0 011248 010 PART MATERIAL DESCRIPTION LOCKNUT 5 8 11 UNC HEX 104120 000 RIGHT FRONT MOUNT WELDMENT 011239 010 WASHER 5 8 DIA FLAT AST
80. 02 BACKSHELL CONNECTOR 3 COND 011248 012 011238 004 LOCKNUT 3 4 10 UNC HEX LOCKWASHER 1 4 DIA SPLIT 104387 003 CONTACT CONNECTOR 029931 001 CONN FEM PUCH 18 22 GA 100783 000 RECEPTACLE FEMALE 029961 001 Page 6 2 SEAL Poy BY AH Pp 029610 002 CONN FORK 16 4 GA 8 AB62 Work Platform European Parts Breakdown Final Assembly AB62 Diesel APPLY LOCTITE 242 UR EQUIVALENT TU CLEAN DRY THREADS EUROPE ONLY ENGINE MODULE TRAY REF 1 INSTALL C RING ON THE TAMPER PROOF LOCK NUT 2 REMOVE LOCK NUT FROM MAIN PRESSURE RELEIF VALVE AND INSTALL TAMPER PROOF LOCK NUT MAIN PRESSURE SETTING AND RE ADJUST IF NEEDED TIGHTEN LOCK NUT A PUSH TAMPER PROOF CAP OVER LOCK NUT UNTILL IT SNAPS INTO PLACE Drawing 1 of 2 AB62 Work Platform European Page 6 3 Parts Breakdown Final Assembly AB62 Diesel MUSN3S BAJI 039 co H THR lt TH Xl 2 A a OH 71081402 XAT V9 91 002 L SNISIM HILIMS ALIWIXO d WOO8 IH9IV IS HILIMS LIWIT SSVANTT 222 A2078 JAWA NIVW 1V 9NISIM X08 108109 33WDT 043 VI 81 0N0J v
81. 04 PLUG 4 00 DIA 104206 000 PIN WELDMENT 10 011765 024 104343 000 RETAINING RING BRACKET LIMIT SWITCH 104207 000 PIN WELDMENT EXTEND 068556 002 SWITCH LIMIT 104160 000 104213 000 PIN ROTATOR PIN MASTER CYLINDER 104375 005 011708 012 BEARING 2 0 I D X 2 LG SCREW 98 32 UNC RD HD MACH X 1 1 2 104224 000 PIN WELDMENT CYLINDER 011248 002 LOCKNUT 8 32 HEX 104244 000 104242 000 SUPPORT BRACKET WELDMENT SUPPORT PLATE 014033 040 SCREW 1 2 13 UNC HEX HD CAP GR 8 X 5 104321 100 Page 6 12 SWITCH MOUNT PLATE 011248 008 LOCKNUT 1 2 13 UNC HEX POP PS PE POT Aj HPP mH DY oo A AH pe AB62 Work Platform European Parts Breakdown Elevating Assembly URIENT FLAT SIDE PIN DDWN AB62 Work Platform European Page 6 13 Parts Breakdown Linkage Assembly Linkage Assembly 104010 000 ITEM PARTNO PART MATERIAL DESCRIPTION PARTNO PART MATERIAL DESCRIPTION 104037 001 RISER CYLINDER SUB ASSEMBLY 104188 000 UPPER RISER WELDMENT 104260 001 RISER CYLINDER Serial 1109 Current 104187 000 TENSION LINK WELDMENT 104260 010 SEAL KIT RISER CYLINDER Serial 1109 Current 104221 000 RISER 104375 005
82. 1 10 490 8090 Parts Fax 31 10 490 8099 P N 104045 020 05 00 K FOREWORD How TO USE THIS MANUAL This manual is divided into six sections The section number printed at the top corner of each page can be used as a quick reference guide Special Information A DANGER A Indicates an imminently hazardous situation which if not avoided will result in death or seri ous injury AWARNING A Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTES Give helpful information WORKSHOP PROCEDURES CAUTION Detailed descriptions of standard work shop procedures safety principles and service oper ations are not included Please note that this manual does contain warnings and cautions against some specific service methods which could cause personal injury or could damage a machine or make it unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommended by UpRight Inc might be done or of the possible hazardous consequences of each con ceivable way nor could UpRight Inc investigate all such ways Anyone using service procedures or tools whether or not recommended by UpRight Inc must satisfy themselves thoroughly that neither per sonal safety nor machine safety will be jeop
83. 20 918 81 SOE 21 218 E TEMS 8I IZE OMY 81 10E 1 81 v0 1118 91 9007 010 10 818 81 vE 50 1 1 0EMS 81 02 I VINS el 00 01 3215 01 093 3715 ON 33IM Wa 3215 JAIM 01 Wa 3215 XIM Drawing 3 of 3 Page 6 37 AB62 Work Platform European Parts Breakdown Six Foot Cage Assembly Six Foot Cage Assembly 102037 100 ITEM PARTNO PART MATERIAL DESCRIPTION TEM PARTNO PART MATERIAL DESCRIPTION 102193 001 CAGE WELDMENT 6 FT 102271 061 GRIP STRUT 100478 000 LIFT GATE WELDMENT 011252 008 SCREW HHC 1 4 20 UNC X 1 100481 000 ROLLER TUBE 014996 004 WASHER 1 4 FLAT 011248 005 LOCKNUT HEX 5 16 18 UNC ESNA 026554 001 RIVET POP 1 4 125 250 GRIP 100468 001 PANEL DECAL MOUNT 011248 004 LOCKNUT HEX 1 4 20 UNC ESNA 1 1 2 011253 022 SCREW HHC 5 16 18 UNC X 2 3 4 2 102244 000 SILL GATE EURO 2 1 M LINE DRILL 0 25 1 LINE mnt 6 25 MOUNTING HOLES DETAIL hw LINE DRILL 0 25 GRIP STRUT 901013 GRIP STRUT MOUNTING LINE DRILL 6 25 GRIP STRUT TYP Page 6 38 AB62 Work Platform European Illustrated Parts Breakdown Eight Foot Cage Assembly Option Eight Foot Cage Assembly Option 102037 001 ITEM
84. 34 002 FITTING 90 4MFOR 4MB 011935 016 FITTING 45 10MB 12MJ 011934 007 FITTING 90 8MB 6MJ 068812 000 MANIFOLD FITTING KIT 104376 001 FITTING 45 12 FLANGE 12MJ CODE 62 100433 016 FITTING 45 12MFOR 16MJ O RING amp HARDWARE SUPPLIED WITH FLANGE KIT Page 6 54 AB62 Work Platform European Illustrated Parts Breakdown Lift Pump Assembly Lift Pump Assembly 104027 000 ITEM PART NO PART MATERIAL DESCRIPTION 1 104360 000 PUMP 2 015717 002 FITTING REDUCER 8MB 6FB AB62 Work Platform European Page 6 55 Parts Breakdown Jib Cylinder Assembly Jib Cylinder Assembly 104040 000 S N 1100 1110 ITEM PART NO PART MATERIAL DESCRIPTION NO PART MATERIAL DESCRIPTION 104257 000 JIB CYLINDER 060390 022 VALVE RELIEF 104257 011 SEAL KIT CYLINDER 068778 013 VALVE COUNTERBALANCE 011941 001 FITTING STRAIGHT MB4 MJ4 Page 6 56 AB62 Work Platform European Illustrated Parts Breakdown Jib Cylinder Assembly Jib Cylinder Assembly 104040 001 S N 1111 Current ITEM PART NO PART MATERIAL DESCRIPTION ITEM PART NO PART MATERIAL DESCRIPTION 1 104257 001 CYLINDER 1 011941 002 FITTING STRAIGHT MB4 MJ6 104257 010 SEAL KIT JIB CYLINDER 1 100555 015 COUNTERBALANCE VALVE AB62 Work Platform European Page 6 57 Parts Breakdown
85. 3l 8 AWG SW13 1 BT3 6 32 8 AWG RS1 BLK 9 33 8 AWG HORN 3 21 35 8 AWG SW15 3 A 18 Figure 5 8 Upper Controller Wiring Diagram Diesel 2 of 2 AB62 Work Platform European 5 11 Section 5 12 5 2 Water Temp Cil Pressure Circuit Breaker Key Switch Engine Start Enable Choke Glow Plug Light 10 11 12 13 14 15 16 SCHEMATICS Emergency Stop 17 Platform Level Riser 18 Auxiliary Power Boom Raise 19 Relay 12 Volt Boom Speed HI LOW 20 Terminal Strip Boom Extend 21 Relay Card Assembly Jib 22 Multiflex Receiver Turret Platform Rotate Figure 5 9 Lower Control Box AB62 Work Platform European I 1 of 2 iese D iagram D 5 13 iring
86. 4 3 Adjustment Procedures 4 1 Checking Pump Pressure 4 1 4 3 Optimizer Settings and Sequence 4 7 4 4 Hydraulic Troubleshooting 4 8 SECTION 5 Schematics whe etn eae ee Introduction l 5 1 5 2 Hydraulic Schematic 62 5 6 5 1 Electrical Schematic AB62 Diesel 5 2 SECTION 6 SECTION 6 Illustrated Parts Breakdown 6 1 6 1 Introduction 6 1 iv AB62 Work Platform European LisT FIGURES SECTION 1 Introduction amp Specifications Figure 1 1 Work Platform 1 1 SECTION 2 Machine Preparation amp Operation Figure 2 1 Chassis Controls 2 3 Figure 2 2 Platform Controls 2 3 Figure 2 3 Key Switch 2 3 Figure 2 4 Foot Switch 2 3 Figure 2 5 Typical Fall Restraint Anchorage Point 2 4 SECTION 3 Maintenance Figure 3 1 UpRight Connector Kit Small 3 1 Figure 3 2 UpRight Connector Kit Large 3 1 Figure 3 3 Plugs and Receptacles UpRight Connectors 3 2 Figure 3 4 Locking Finger UpRight Connector 3 2 Figure 3 5 Heavy Duty UpRight
87. 7 000 CAP TAMPER PROOF 15790 005 15790 003 CONNECTOR DEUTSCH PLUG SOCKET CONTACT 16 18 104047 100 029945 013 LABEL KIT DIESEL EURO LEVEL SENSOR 15790 008 SOCKET CONTACT 14 16 029435 099 CONTROL CABLE 3 12GA 15790 009 29496 099 BOOT DEUTSCH PLUG CABLE 2 COND 16 GA 011252 006 SCREW 1 4 20 UNC HEX HD CAP X 3 4 029620 002 CONN BUTT 14 16 014996 004 011248 004 WASHER 1 4 DIA SAE FLAT LOCKNUT 1 4 20 UNC HEX 068334 010 068334 095 BATTERY CABLE ASSY X 10 BATTERY CABLE ASSY X 95 011252 010 SCREW 1 4 20 UNC HEX HD CAP X 1 1 4 029447 099 CABLE 3 COND 16 GA 066695 006 020032 001 SCREW 10 24 UNC FLAT HD X 3 4 FITTING AERO 2033 4 45 29601 008 CONN RING 22 18 5 16 DIA 100436 001 FITTING AERO FF1898T 04048 014914 001 29601 005 CONN MALE PUSH 16 14 CONN RING 18 22 GA 10 020032 003 011252 008 FITTING AERO 2033 6 65 SCREW 1 4 20 UNC HEX HD CAP X 1 029931 003 CONN FEM PUSH 16 14 013949 003 LOCKWASHER 10 STAR EXT TOOTH 029601 039 029473 099 CONN RING 12 10 GA 5 16 DIA WIRE 12 GA WHITE 011250 003 NUT 10 24 UNC HEX 029470 099 WIRE 12 GA RED 102373 000 BRACKET CHAIN TIE DOWN 011723 036 SCREW 3 4 10 UNC HEX HD CAP X 4 1 2 029472 099 104387 001 WIRE 12 GA BLACK CONNECTOR 3 COND 011240 012 WASHER 3 4 DIA ST FLAT 104387 0
88. A Hazard of explosive gas mixture Keep sparks flame and smoking material away from battery Always wear safety glasses when working with batteries Battery fluid is highly corrosive Thoroughly rinse away any spilled fluid with clean water Battery Inspection and Cleaning Check battery fluid level daily especially if the work platform is being used in a warm dry climate If required add distilled water ONLY Use of tap water will shorten battery life The battery should be inspected regularly 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 Clean the battery when it shows signs of corrosion at the terminals or when electrolyte has overflowed dur ing charging Use a baking soda solution to clean the batteries taking care not to get the solution inside the cells Rinse thoroughly with clean water Clean battery and cable contact surfaces to a bright metal finish whenever a cable is removed 3 6 MAINTENANCE Battery Charging AWARNING A Charge the battery only in a well ventilated area Do not charge the battery when the work plat form is in an area containing sparks or flames Permanent damage will result if the battery is not immediately recharged after discharging Never leave the charger unattended for more than two days Never disconnect the cables from the battery when the ch
89. ALE PUSH 22 16 INSULATED 104397 000 MULTIFLEX RECEIVER ASSEMBLY 029610 002 BUTT 14 16 068132 001 RELAY 12 VDC 029610 001 BUTT 22 18 029928 010 TERMINAL STRIP 029617 004 MALE PUSH 22 16 INSULATED 104398 000 RELAY CARD ASSEMBLY 029428 099 18 AWG WHITE 015790 006 CONNECTOR RECEPTICAL 40 PIN 029371 099 16 AWG YELLOW GREEN 015790 011 CONNECTOR RECEPTICAL 24 PIN TYPE A 029473 099 12 AWG WHITE 1 1 2 1 1 5 2 1 7 7 1 2 1 1 2 1 1 1 1 3 1 1 1 1 1 015790 014 CONNECTOR RECEPTICAL 24 PIN TYPE B 029472 099 12 AWG BLACK 015790 004 PIN 16 18 GA 029507 099 12 AWG GREEN N 1 Page 6 34 AB62 Work Platform European Illustrated Parts Breakdown Lower Controller Assembly 62 Diesel 5 50 Ge E Wed Drawing 1 of 3 AB62 Work Platform European Page 6 35 Parts Breakdown Lower Controller Assembly AB62 Diesel
90. Assembly AB62 Diesel 104019 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PARTNO PART MATERIAL DESCRIPTION 104271 000 LOWER CONTROLS ENCLOSURE 028800 015 PLUG SEALING 104312 000 CIRCUIT MOUNT 011709 004 SCREW 10 24 UNC RD HD MACH X 1 2 068582 010 CIRCUIT BREAKER 10 AMP 011708 004 SCREW 98 32 UNC RD HD MACH X 1 2 068582 020 CIRCUIT BREAKER 20 011248 003 LOCKNUT 10 24 HEX 067652 000 BUTTON PUSH GREEN 011248 002 LOCKNUT 8 32 UNC HEX 064443 001 CONTACT BLOCK 011708 003 SCREW 48 32 UNC RD HD MACH X 3 8 067654 000 BUTTON PUSH BLK 104387 004 CONNECTOR 104499 000 BUTTON PUSH YELLOW 011709 010 SCREW 10 24 UNC RD HD MACH X 1 1 4 012798 000 SWITCH TOGGLE SPDT 011715 005 SCREW 46 32 UNC RD HD MACH X 5 8 008271 000 GUARD SWITCH 011248 032 LOCKNUT 6 32 HEX 064446 003 SWITCH E STOP 011708 006 SCREW 8 32 RD HD MACH X 3 4 064443 002 CONTACT BLOCK N C 029610 007 CONN FORK 22 16 8 100335 000 KEY SWITCH KEYED 029610 002 CONN FORK 16 14 8 068807 010 KEY 029615 001 FEMALE PUSH 22 18 UNINSLATED 068860 000 CONTACT BLOCK 029615 002 FEMALE PUSH 16 14 UNINSULATED 100331 000 OIL PRESSURE GUAGE 029616 003 FEMALE PUSH 10 12 INSULATED 100330 000 TEMPERATURE GUAGE 029616 002 FEMALE PUSH 16 14 INSULATED 015752 000 HOUR METER 029616 004 FEM
91. BOLT BATTERY HOLD DOWN 104077 000 LEFT DOOR MOUNT 104472 000 HOLD DOWN 104309 000 TOP BLOCK MOUNT 100295 000 J BOLT BATTERY HOLD DOWN 104310 000 BOTTOM BLOCK MOUNT 014435 001 TERMINAL BATTERY 104291 000 REAR PAN SUPPORT 011240 006 WASHER 3 8 STD FLAT 104287 000 FRONT PAN SUPPORT 010154 000 COVER BATTERY TERMINAL 104288 000 LEFT PAN WELDMENT 011253 008 SCREW 5 18 18 UNC HEX HD CAP X 1 011254 008 SCREW HHC GR5 3 8 16 UNC X 1 011253 022 SCREW 5 16 18 UNC HEX HD CAP X 2 3 4 011254 006 LOCK NUT 3 8 16 UNC ESNA 011248 005 LOCKNUT 5 16 18 UNC HEX 011254 024 SCREW GR 5 3 8 16 UNC X 3 011709 006 SCREW 10 24 UNC RD HD MACH X 3 4 011253 006 SCREW HHG GR 5 5 16 18 UNC X 3 4 011252 028 SCREW 1 4 20 UNC HEX HD CAP X 3 1 2 011238 005 LOCKWASHER 5 16 SPLIT PUMP FUEL 011252 006 SCREW HHC GR5 1 4 20 UNC X 3 4 104396 016 CLAMP BLOCK 011238 004 LOCKWASHER 1 4 DIA SPLIT 011252 020 SCREW 1 4 20 UNC HEX HD CAP X 2 1 2 010149 000 FUSE BLOCK 020331 000 FILTER FUEL INLINE 011828 010 SCREW 1 4 20 UNC FLT HD SOC X 1 1 4 020541 001 CLAMP HOSE 011934 004 FITTING ELBOW 6MB 6MJ FUEL LINE 011248 004 LOCKNUT 1 4 20 UNC HEX 2 2 4 1 1 1 4 1 2 1 2 2 7 4 4 4 6 2 1 Page 6 40 AB62 Work Platform European Illustrated Parts B
92. DMENT 104375 003 BEARING 1 1 2 1 0 X2 LG 104040 001 CYLINDER JIB ASSEMBLY 104257 001 JIB CYLINDER Serial 1111 Current 104467 000 011248 005 ROTATE VALVE SPACER LOCKNUT 5 16 18 UNC HEX 104257 010 SEAL KIT CYLINDER Serial 1111 Current 011253 022 SCREW 5 16 18 UNC HHC GR 5 X 2 3 4 LG 104375 001 104161 000 BEARING 1 1 4 I D X 1 1 4 LG PIN CYLINDER 011252 014 SCREW 1 4 20 UNC GR 5 X 1 3 4 LG 011248 004 LOCKNUT 1 4 20 UNC HEX 104159 000 PIN 104151 001 TOP JIB FRAME WELDMENT 104375 002 Page 6 18 BEARING 1 1 2 I D X 1 1 4 LG 104389 001 FITTING SWIVEL MB4 MJ4 90 AB62 Work Platform European NOTES AB62 Work Platform European Page 6 19 Parts Breakdown Turret Assembly Turret Assembly 104008 000 ITEM PART NO 104101 000 PART MATERIAL DESCRIPTION TURRET WELDMENT ITEM 0 011424 028 PART MATERIAL DESCRIPTION SCREW 5 8 UNC SOC HD CAP GR 8 X 3 1 2 104113 000 SLEW DRIVE MOUNT 011248 010 LOCKNUT 5 8 11 UNC HEX 100242 000 SWING GEAR BOX 100242 011 GASKET GEAR BOX 011256 020 104378 001 SCREW 1 2 13 UNC HEX HD CAP X 2 1 2 SNAP PIN 3 8 DIA X 3 GRIP 104026 000 ROTARY MANIFOLD ASSEMBLY 063783 003 LANDYARD ASSEMBLY 100241 001 100241 010
93. FAX 559 891 9012 PARTS 1 888 UR PARTS PARTSFAX 559 896 9244 UpRight Call Toll Free in U S A 1 800 926 LIFT UpRight International Support Centre Innsbrukweg 114 3047 AH Rotterdam Netherlands TEL 31 10 238 0000 FAX 31 10 238 0001 Parts Tel 31 10 490 8090 Parts Fax 31 10 490 8099 P N 104045 020 05 00 K
94. FB10 POP PO PSP AININ AJ AJA AB62 Work Platform European Illustrated Parts Breakdown Front Axle Assembly AB62 Work Platform European Page 6 11 Parts Breakdown Elevating Assembly Elevating Assembly 104009 000 ITEM PART NO 104010 000 PART MATERIAL DESCRIPTION LOWER LINKAGE ASSEMBLY ITEM PART NO 100380 000 PART MATERIAL DESCRIPTION SWITCH SENSOR 104011 000 STRAIGHT BOOM ASSY 013923 006 SCREW 10 SELF TAPPING HWH TYPE AB X 3 4 104012 000 JIB ASSEMBLY 104041 001 LEVEL CYLINDER SUB ASSEMBLY 011254 010 011254 006 SCREW HHC 3 8 16 UNC X 1 1 4 SCREW HHC 3 8 16 UNC X 3 4 104258 001 LEVEL CYLINDER Serial 1109 Current 011254 026 SCREW HHC 3 8 16 UNC X 3 1 4 104258 010 104039 001 SEAL KIT LEVEL CYLINDER Serial 1109 Current BOOM CYLINDER SUB ASSEMBLY 011828 006 SCREW FH 1 4 20 UNC X 3 4 011254 020 SCREW 3 8 16 UNC HEX HD CAP X 2 1 2 104256 001 BOOM CYLINDER Serial 1109 Current 011238 006 WASHER LOCK 3 8 104256 010 104042 001 SEAL KIT BOOM CYLINDER Serial 1109 Current MASTER CYLINDER SUB ASSEMBLY 104375 002 BEARING 1 1 2 I D X 1 1 4 LG 104202 000 PIN WELDMENT 8 011248 004 011248 006 NUT HEX ESNA 1 4 20 UNC NUT HEX ESNA 3 8 16 UNC 104203 000 104201 000 PIN WELDMENT 9 PIN STRAIGHT BOOM PIN 10 066516 0
95. G 014902 005 FITTING TEE 12MP 12FP 011940 034 FITTING ELBOW 12MP 6MJ 90 011916 008 FITTING ELBOW 12FP 12FP 011940 020 FITTING ELBOW 12MP 12MJ 90 068840 000 BREATHER FILLER 100287 000 GAUGE FLUID LEVEL 100286 001 SUCTION STRAINER 100288 000 PLUG MAGNETIC PO HS PO PO HYP PO PO HA POY CO mH AB62 Work Platform European Page 6 43 Parts Breakdown Valve Block Assembly Valve Block Assembly 104033 000 ITEM PARTNO 104354 000 PART MATERIAL DESCRIPTION SOLENOID SPOOL VALVE 104370 000 VALVE FLOW CONTROL 063965 001 PLUG GAGE PORT 011941 005 FITTING STRAIGHT 6MB 6MJ 068683 000 3 POS 4 WAY VALVE 060390 018 RELEIF VALVE 011939 021 104251 000 FITTING STRAIGHT 12MP 12MJ VALVE BLOCK SUB ASSEMBLY 104355 000 3 POS 4 WAY VALVE 012004 004 PLUG 4 SAE 104353 000 SOLENOID SPOOL VALVE 068558 000 VALVE DIVERTER CO Gy AJ co Page 6 44 104357 000 RELIEF VALVE 104356 000 3 POS 4 WAY CLOSED CENTER VALVE 3 4 068684 000 3 POS 4 WAY CLOSED MOTOR SPOOL VALVE 3 4 1 2 1 1 1 1 1 2 3 104377 000 REMOVE O RING PRIOR INSTALLING IN BLOCK PDL 95 ZU P PPP 3 POS 4 WAY MOTOR SPOOL VALVE
96. IGHT TURRET ROTATE PARKING BRAKE RELEASE TILT ALARM TORQUE HIGH LOW EMERGENCY LOWERING DRIVING LIGHTS OPTIONAL THROTTLE CONTROLLER COMPONENT gt lt ENGINE START RUN UPPER CONTROLS gt lt ENGINE START RUN LOWER CONTROLS gt lt GENERATOR OPTIONAL Throttle Actuator Alarm Tilt Alternator Battery Engine Start Battery Auxiliary Power Circuit Breaker 20 AMP Circuit Breaker 10 AMP Circuit Breaker 10 AMP Controller DMR 30 Controller Glow Plug Diode Auxiliary Power Diode Power to Platform Diode Diode Auxiliary Pump Relay Diode Diode Alternator Diode Spike Protection Diode Spike Protection Fuse 175 AMP Horn Charge Isolator Distress Lamp Tilt lamp Glow Plug Lamp Linkage Limit Switch Proximity Switch Auxiliary Pump Motor Engine Start Motor Engine Temperature Meter Oil Pressure Meter Hour Meter Drive Pump Engine Start Relay Drive Motion Alarm Axle Release Left AB62 Work Platform European 4 9 TROUBLESHOOTING COMPONENT FUNCTION ENGINE START RUN UPPER CONTROLS ENGINE START RUN LOWER CONTROLS UPPER CONTROL FUNCTIONS LOWER CONTROL FUNCTIONS RISER RAISE LOWER Boom UP DOWN Boom EXTEND RETRACT DRIVE FORWARD REVERSE SPEED HIGH CREEP STEER LEFT RIGHT Jip UP DOWN BATTERY CHARGE
97. ING STR ADAPTER 6FB 4MB 011934 026 FITTING ELBOW 90 4MB 6MJ 015919 002 ORIFICE 815 011941 001 FITTING STR ADAPTER 4MB 4MJ 100432 004 FITTING STR ADAPTER 4MFFOR 6MB 011941 004 FITTING STR ADAPTER 6MB 4MJ 100258 005 SOLENOID 100432 002 FITTING STR ADAPTER 4MFFOR 4MB o s ce 3 NOTE ORIENT ITEM 7 015818 002 ORIFICE WITH SLOT AWAY FROM VALVE BLDCK AND TOWARD ITEM 8 100432 004 AB62 Work Platform European Page 6 47 Parts Breakdown Cage Rotate Valve Block Assembly Cage Rotate Valve Block Assembly 104034 000 ITEM PART NO PART MATERIAL DESCRIPTION ITEM PART NO PART MATERIAL DESCRIPTION 1 100269 000 VALVE BLOCK STERLING 012004 004 FITTING PLUG SAE 4 2 104389 001 FITTING ELBOW MB4 MJ4 90 SWIVEL 068778 015 COUNTERBALANCE VALVE 3 011941 001 FITTING STRAIGHT MB4 MJ4 Page 6 48 AB62 Work Platform European Illustrated Parts Breakdown Rotary Manifold Assembly Rotary Manifold Assembly 104026 000 ITEM PART NO PART MATERIAL DESCRIPTION A ITEM PART MATERIAL DESCRIPTION 100558 000 ROTARY MANIFOLD 011937 003 FITTING ELBOW 6FJ 6MJ 100558 010 SEAL KIT ROTARY MANIFOLD 011941 027 FITTING STRAIGHT 16MB 12MJ 011935 003 FITTING ELBOW 45 6MB 6MJ 011941 009 FITTING STRAIGHT 8MB
98. ITCH PUSH BUTTON 029610 007 CONN FORK 22 16 8 068593 004 SWITCH 029616 004 029617 004 CONN FEMALE PUSH 22 16 CONN MALE PUSH 22 16 008271 001 SWITCH GUARD 029428 099 WIRE 18 GA WHITE 064443 001 CONTACT BLOCK 0 067652 000 SWITCH PUSH BUTTON 029371 099 029601 005 WIRE 16 GA YELLOW GREEN CONN RING 22 16 710 DIA 104307 000 MAIN COVER 104308 000 011709 004 TOP COVER SCREW 10 24 RD HD MACH X 1 2 011248 003 LOCKNUT 10 24 UNC HEX 015964 000 Page 6 28 PLUG HOLE m e e 2 2 ce m ro ro ro co e 2 4 2 4 4 RI 029601 016 CONN RING 22 16 2 DIA Not shown AB62 Work Platform European Upper Controller Assembly 62 Diesel Illustrated Parts Breakdown Drawing 1 of 4 Page 6 29 AB62 Work Platform European Parts Breakdown Upper Controller Assembly 62 Diesel 6 MOUNTING HARDWARE PROVIDED WITH ALARM Drawing 2 of 4 Page 6 30 AB62 Work Platform European
99. LEDs on DMT 30 illuminated BT4 03 foot pedal 4 02 jib down LEDs on DMR 30 illuminated BT7 07 jib down output BT5 06 throttle output BT6 12 low flow valve output Cage Rotate Cage Right Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT4 01 cage rotate right LEDs on DMR 30 illuminated BT7 03 cage rotate right output BT5 06 throttle output BT6 12 low flow valve output Cage Left Function enabled foot pedal depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT4 12 cage rotate left 4 5 Section 4 2 LEDs on DMR 30 illuminated BT7 04 cage rotate left output BT5 06 throttle out put BT6 12 low flow valve output Cage Trim Up Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT4 11 cage trim up LEDs on DMR 30 illuminated BT6 05 cage trim up output BT5 06 throttle out put BT6 12 low flow valve output Cage Trim Down Function enabled foot switch depressed LEDs on DMT 30 illuminated 4 03 foot pedal BT4 06 cage trim down LEDs on DMR 30 illuminated BT6 06 cage trim down valve BT5 06 throttle out put BT6 12 low flow valve output Auxiliary Power Emergency Functions 30 BT3 08 auxiliary power DMR 30 BT5 10 auxiliary output NOTE If the auxiliary switch is depressed when the engine is running the engine will stop immediately Dri
100. M A325 104123 000 LEFT FRONT MOUNT WELDMENT 100557 000 STEERING CYLINDER 011291 022 011254 010 SCREW 5 8 11 UNC HEX HD CAP GR 8 X 2 3 4 SCREW 3 8 16 UNC HEX HD CAP X 1 1 4 100557 010 SEAL KIT STEERING CYLINDER 011238 006 LOCKWASHER 3 8 SPLIT o 104143 000 104148 001 STEERING LINK SLEEVE STEERING LINK 011291 024 SCREW 5 8 11 UNC HD GR 8 CAP X 3 a N 014033 010 SCREW 1 2 13 UNC HD GR 8 X 1 1 4 104232 000 BOTTOM KING PIN WELDMENT 011239 008 WASHER 1 2 DIA FLAT ASTM A325 104245 000 101016 005 TOP WHEEL PIN BEARING 2 5 I D X 2 5 LG 011257 034 SCREW 5 8 11 UNC HEX HD CAP X 4 1 4 101016 004 BEARING 2 01 0 X 2 0 LG 104144 002 011254 032 THRUST WASHER 2 I D SCREW 3 8 16 UNC HEX HD CAP X 4 101016 003 100254 000 BEARING 1 01 0 X 2 0 LG PLANETARY 011248 006 LOCKNUT 3 8 16 UNC HEX 100254 010 SEAL KIT W BEARINGS DRIVE HUB 011941 011 100434 002 FITTING 8MB 10MJ FITTING ELBOW 4FFORB 4MB 90 100254 011 STUD 5 8 DRIVE HUB 011934 024 FITTING ELBOW 10MB 6MJ 90 104363 000 104386 004 WHEEL MOTOR 40 CC MAX x 15 CC MIN FITTING ELBOW 90 MB10 FB10 068885 000 FITTING SWIVEL 90 011934 004 Page 6 10 FITTING ELBOW 6MB 6MJ 100782 000 015717 007 O RING WHEEL MOTOR FITTING ADAPTER MB12
101. MB6 MJ6 AB62 Work Platform European Page 6 61 Parts Breakdown Level Cylinder Assembly Level Cylinder Assembly 104041 000 S N 1100 1108 ITEM PARTNO PART MATERIAL DESCRIPTION TEM PARTNO PART MATERIAL DESCRIPTION 104258 000 LEVEL CYLINDER 020021 004 PLUG 4 104258 011 SEAL KIT LEVEL CYLINDER 068778 013 VALVE COUNTERBALANCE 100434 002 FITTING ELBOW MB4 MFOR4 90 Page 6 62 AB62 Work Platform European Illustrated Parts Breakdown Level Cylinder Assembly Level Cylinder Assembly 104041 001 S N 1109 Current ITEM PART NO PART MATERIAL DESCRIPTION 104258 001 LEVEL CYLINDER 104258 010 SEAL LEVEL CYLINDER 100434 002 FITTING ELBOW MB4 MFOR4 90 AB62 Work Platform European Page 6 63 Parts Breakdown Master Cylinder Assembly Master Cylinder Assembly 104042 000 S N 1100 1108 ITEM PART NO PART MATERIAL DESCRIPTION 104258 000 LEVEL CYLINDER 104258 011 SEAL KIT LEVEL CYLINDER 011934 026 FITTING ELBOW MB4 MJ6 90 Page 6 64 AB62 Work Platform European Parts Breakdown Master Cylinder Assembly Master Cylinder Assembly 104042 001 S N 1109 Current ITEM PART NO PART MATERIAL DESCRIPTION PARTNO PART MATERIAL DESCRIPTION 1 104258 001 LEVEL CYLINDER 1 011941 002 FITTING STRAIGHT 4MB 6MJ 104258 010
102. PART NO PART MATERIAL DESCRIPTION A ITEM PARTNO PART MATERIAL DESCRIPTION 102193 000 CAGE WELDMENT 8 FT 026551 005 POP RIVET 1 8 DIA 3 16 1 4 GRIP 100478 000 LIFT GATE WELDMENT 102271 082 GRIP STRUT 100481 000 ROLLER TUBE 014996 004 WASHER 1 4 FLAT 011253 022 SCREW 5 16 18 UNC X 2 3 4 011248 004 LOCKNUT HEX 1 4 20 UNC ESNA 011248 005 LOCKNUT HEX 5 16 18 UNC ESNA 011252 008 SCREW 1 4 20 UNC X 1 100468 001 PANEL DECAL MOUNT LINE DRILL 0 25 GRIP STRUT MOUNTING HOLES DETAIL GRIP STRUT MOUNT ING O00 AB62 Work Platform European Page 6 39 Parts Breakdown Control Module Assembly Control Module Assembly 104021 000 ITEM PART NO PART MATERIAL DESCRIPTION PART NO PART MATERIAL DESCRIPTION 104023 000 FUEL TANK ASS Y 014252 005 INSERT 5 16 18 UNC 062299 002 BATTERY 12 V M C 014252 004 INSERT 1 4 20 UNC 062299 004 BATTERY 12V DRY 014252 006 INSERT 3 8 16 UNC 104391 000 BATTERY 12 V 104418 000 ADAPTER AUX POWERUNIT 104033 000 VALVE BLOCK ASS Y 104402 000 STRAP FUEL TANK 104359 000 AUX POWER UNIT 12 VDC 1 GPM 104404 000 ANCHOR FUEL TANK STRAP 027972 000 RELAY MOTOR START 011240 004 WASHER 1 4 STD FLAT 010148 001 FUSE 175 AMP 064040 001 BATTERY HOLD DOWN BAR 104421 000 GENERATOR FRAME WELDMENT 063082 000 J
103. SE ASSY X 92 6675 6FJX 6FJX 104508 848 1 4 HOSE ASSY X 848 4075 6FJX 6FJX 45 020032 001 FITTING TEE 4FUX 4FJX 062192 427 1 4 HOSE ASSY X 427 4675 6FJX 6FJX 100436 001 FITTING TEE 4FFORX 4FFORX 102400 467 1 4 HOSE ASSY X 467 4 4FFORXAFFORX 90 020032 003 FITTING TEE 6FJX 6FJX 068763 827 1 4 HOSE ASSY X 827 4675 4FJX 6FJX Po po pol po pol po pol po pof a a rol a ap a a a a a a at a 100424 032 1 4 HOSE ASSY X 32 4M2T 4FFORX 4FFORX 062192 067 1 4 HOSE ASSY X 67 4675 4FJX 4FJX Page 6 50 AB62 Work Platform European Illustrated Parts Breakdown Hose Kit Installation Chassis Turret Linkage aS0NT A2 CETT 501108 SID m g
104. TIC AB62 Table 5 2 Hydraulic Schematic Legend 104048 000 REFERENCE Counterbalance Valve FUNCTION Riser Counterbalance LOCATION Riser Cylinder REFERENCE FUNCTION Variable Drive Pump LOCATION Engine Module Counterbalance Valve Boom Extend Counterbalance Boom Extend Cylinder Rotator Auxiliary Pump Cage Rotator Engine Module Platform Counterbalance Valve Boom Raise Counterbalance Boom Raise Cylinder Relief Valve Low Pressure Relief Main Valve Block Counterbalance Valve Jib Counterbalance Jib Cylinder Relief Valve Relief Valve High Pressure Relief Jib Cylinder Relief m Valve Block Jib Cylinder Counterbalance Valve Master Counterbalance Master Cylinder Valve Steer Valve Riser Valve in Valve Block Boom Extend Valve Counterbalance Valve Counter Slave Counterbalance Cage Rotate Counterbalance Slave Cylinder Cage Rotate Valve Block Boom Raise Valve Jib Valve Counter Val Turret Rotate Counterbalance Turret Rotate Motor Cage Level Turret Rotate in Valve Block Cage Rotate in Valve Block Counter Val Counterbalance Valve Left Axle Counterbalance Right Axle Counterbalance Left AXle Lock Cylinder Right Axle Lock Cylinder Low Flow Valve in Valve Block High Flow Valve in Valve Block Check Va High Pressure Test
105. VE FORWARD REVERSE SPEED HIGH CREEP STEER LEFT RIGHT UP DOWN BATTERY CHARGE PLATFORM LEVEL UP DOWN PLATFORM ROTATE CW CCW FRONT AXLE Lock TILT LIGHT TURRET ROTATE PARKING BRAKE RELEASE TILT ALARM TORQUE HIGH LOW EMERGENCY LOWERING DRIVING LIGHTS OPTIONAL GENERATOR OPTIONAL THROTTLE CONTROLLER Cage Rotate Switch Lower Jib Up Down Switch Lower gt gt Rise Up Down Switch Lower Boom Extend Retract Lower Tilt Sensor Engine Temperature SNSR2 Sensor Engine Oil Pressure SNSHS Sensor Cage Level Solenoid Cage Level Solenoid Jib Up Solenoid Jib Down Solenoid Boom Up Solenoid Boom Down Solenoid Boom Extend Solenoid Boom Retract Solenoid Riser Up Riser Down Cage Rotate CW Cage Rotate CCW Turret Rotate CW Turret Rotate CCW Steer Right Steer Left Low Flow High Flow Generator Valve Brake Torque Axle Lock Fuel Transmitter DMT 30 AB62 Work Platform European 4 11 TROUBLESHOOTING Table 4 2 Hydraulic Truth Table AB62 FUNCTION BooM EXTEND RETRACT BooM RAISE LOWER JIB UP DOWN CAGE LEVEL UP DOWN CAGE ROTATE CW CCW TURRET ROTATE CW CCW DRIVE FORWARD REVERSE FRONT AXLE LOCK BRAKE RELEASE EMERGENCY LOWER COMPONENT gt lt RISER ELEVATE DESCEND Counterbalance Valve Riser Coun
106. X 4FFORX 104436 059 3 4 HOSE ASSY X 59 12013 12FJX90 12FJX90 063469 055 3 8 HOSE ASSY X 55 667 6FJX 6FJX 104436 061 3 4 HOSE ASSY X 61 12013 12FJX90 12FJX90 063469 042 3 8 HOSE ASSY X 42 6675 6FJX 6FJX 068737 056 1 4 HOSE ASSY X 56 4C78 4FJX 4FJX 063469 017 3 8 HOSE ASSY X 17 6C7S 6FJX 6FJX 102404 066 1 4 HOSE ASSY X 66 4 2 4FFORX 4FFORX90 S 062192 094 1 4 HOSE ASSY X 94 4675 6FJX 6FJX 100424 065 1 4 HOSE ASSY X 65 4M2T 4FFORX 4FFORX 068963 084 5 8 HOSE ASSY X 84 10613 10FJX 10FJ 062192 133 1 4 HOSE ASSY X 133 4075 6FJX 6FJX 068963 082 5 8 HOSE ASSY X 82 10613 10FJX 10FJ 064156 028 1 2 HOSE ASSY X 28 8C7S 8FJX 8FJX 068963 090 5 8 HOSE ASSY X 90 10613 10FJX 10FJ 068965 093 3 8 HOSE ASSY X 93 6 6FJX 6FJX90 X X X X 068963 099 5 8 HOSE ASSY X 99 10C13 10FJX 10FJ 068965 097 3 8 HOSE ASSY X 97 6M3K 6FJX 6FJX90 068963 095 5 8 HOSE ASSY X 95 10C13 10FJX 10FJX 100424 023 1 4 HOSE ASSY X 23 4 2 4FFORX 4FFORX 068963 109 5 8 HOSE ASSY X 109 10C13 10FJX 10FJX 062192 027 1 4 HOSE ASSY X 27 4 75 6FJX 6FJX 063469 017 3 8 HOSE ASSY X 17 6675 6FJX 6FJX 104440 305 3 8 HOSE ASSY X 305 6M3K 6FJX 6FJX 102421 029 3 4 HOSE ASSY X 29 12013 12FJX 12FJX90 068965 475 3 8 HOSE ASSY X 475 6 6FJX 6FJX 90 102421 038 3 4 HOSE ASSY X 38 12013 12FJX 12FJX90 104440 449 3 8 HOSE ASSY X 449 6 6FJX 6FJX 063469 092 3 8 HO
107. age point Exceeding the specified permissible maximum load of 225 kg 500 Ibs or two persons on the platform is prohibited The use and operation of the aerial work platform as a lifting tool or a crane lifting of loads from below upwards or from up high on down is prohibited Never exceed 200 N 45 Ibs of side force per occupant Distribute all platform loads evenly on the platform Never operate the machine without first surveying the work area for surface hazards such as holes drop offs bumps curbs or debris and avoiding them Operate the machine only on surfaces capable of supporting wheel loads Never operate the machine when wind speeds exceed 45 km h 28 mph 12 5 m sec Beaufort scale 6 In case of emergency push emergency stop button to cut power to all machine functions Climbing up the railing of the platform standing on or stepping from the platform onto buildings steel or prefab concrete structures etc is prohibited Dismantling the swing gate or the liftable bar or other railing components is prohibited Always make certain that the swing gate or the liftable bar is closed and securely locked It is prohibited to keep the swing gate or the liftable bar in an open position e g held open with tie straps when the platform is raised To extend the height or the range by placing of ladders scaffolds or similar devices on the platform is prohibited Inspect the machine thoroughly for cracked welds loose or missin
108. ance between tooth sur faces of adjacent teeth in mating gears 1 Position boom directly over center of rear axle standard forward driving position 5 Place the magnetic indicator base on the bottom of the turret assembly Set the dial indicator probe on the gearbox pinion straight across from the bearing Figure 3 24 and adjust the dial to ZERO Move the gearbox away from the bearing until the indicator shows the correct amount of backlash 007 009 Carefully torque the gearbox mounting bolts while watching the indicator to make sure the correct backlash is maintained Snug the adjusting bolts against the gearbox and tighten the jamb nuts GEARBOX PINION Figure 3 23 Setting Rotational Gear Backlash Viewed from bottom of turret 2 Loosen the grearbox mounting bolts just enough to allow the gearbox to be adjusted in and out 3 Turn adjusting screws in until gearbox teeth make contact with bearing teeth and adjusting screws become snug 4 Unscrew adjusting screws five turns Do not move the gearbox DIAL INDICATOR MOUNTING PLATE 3 20 AB62 Work Platform European Section MAINTENANCE 3 13 Lipseal 2 ong 7 Ring 2 Oil Seal a 7 7 Retaining Ring 2 Bs 9 2 Y Z Z dele Vl Vue NAS MAN Figure 3 24 Rotary Manifold 3 13 ROTARY MANIFOLD REMOVAL 1 Mark and tag all hoses 2 Remove all hoses from Rotar
109. ardized All information contained in this manual is based on the latest product information available at the time of printing We reserve the right to make changes at any time without notice No part of this publication may be reproduced stored in retrieval system or transmitted in any form by any means electronic AB62 Work Platform European mechanical photocopying recording or otherwise without the prior written permission of the publisher This includes text figures and tables Introduction amp Specifications General description and machine specifications Machine Preparation amp Operation Information on how to operate the work platform and how to prepare it for operation Maintenance Preventative maintenance and service information Troubleshooting 4 0 Causes and solutions to typical problems Schematics Schematics and valve block diagram with description and location of components Illustrated Parts Breakdown Complete parts lists with illustrations FOREWORD NOTES 11 AB62 Work Platform European TABLE OF CONTENTS Introduction amp Specifications 1 1 1 3 Purpose Of 1 1 1 4 Special Limitations 1 1 1 5 1 2 Machine Preparation amp Operation
110. arger is operating Keep the charger dry Charge battery as follows 1 Check the fluid level If the electrolyte level is lower than 10mm 3 8 in above the plates add clean distilled water only 2 Connect the charger plug to a properly grounded outlet of the proper voltage and frequency 3 Usea charger which turns off automatically when the batteries are fully charged 3 6 LUBRICATION Refer to Table 3 1 for the lubrication intervals and Figures 3 8 and 3 9 for location of items that require lubrication service Refer to the appropriate sections for lubrication information on the Steering Linkage Torque Hubs Hydraulic Oil Filter and Engine Oil and Filter Grease Fittings Wipe each fitting before and after greasing Using multipurpose grease in a grease gun pump the grease into the fitting until grease just begins to appear at the edges of the pivot Wipe off any excess grease Lubricating Turret Gears Using a brush apply open gear grease to the turret gears Figure 3 8 AB62 Work Platform European Section MAINTENANCE 3 6 v Hi E mod Open gear lube Figure 3 9 Turret Bearing Grease Zerk Hydraulic Oil and Filter Fluid Level With the platform fully lowered check oil level on sight gauge If the oil is NOT in operating range add hydraulic fluid until oil is visible in operating range on dipstick or visible in sight gauge DO NOT fill above operating range or when the p
111. at particular group will react to the rheostat control on the upper control box Each adjustment will affect that whole group For example setting high flow will change the threshold on boom riser extend and steer It is important not to deviate very far from the listed settings Before making any changes record the current settings This will help to diagnose an existing or potential problem with a func tion on the machine Make all settings only in the order in which they are displayed Max Out or MX pertains to the extension of the cylin ders in the group Low Range or LR pertains to the retraction of the cyl inders in the group Sequence Emergency stop switches must be pulled and ignition switches on It is not necessary to have the engine running when retrieving the initial settings or resetting the DMR 30 Plug the Optimizer in at either location and it should read Run mode normal functions off If not ensure that all switches are on and the Opti mizer is plugged into P 8 If plugged into the upper control box ensure that there is a four wire plug in P 8 port in the lower control box Low Flow Select THRESHOLD by pushing the threshold button The preset value will appear AB62 Work Platform European If it needs to be changed use the or to raise or lower the value Continue to MAXOUT and so on until all low flow ranges are set then push ENTER to save changes High flow Push ENTER then readout
112. ber to check wires and terminals between suspect components Be sure to check connections to battery negative 4 Repair or replace faulty component AB62 Work Platform European 5 Verify that repair is complete Do a full function test from both platform and chassis controls to verify that all functions are operating correctly and machine is performing to specified values UPRIGHT USA TEL 1 559 891 5200 FAX 1 559 891 8931 UPRIGHT TEL 31 10 238 0000 INTERNATIONAL FAX 31 10 238 0001 Adjustment Procedures Hydraulic settings must be checked whenever a com ponent is repaired or replaced Remove counterbalance valves and bench test them if they are suspect Connect a pressure meter of appropriate range to the test port located on the right side of the hydraulic manifold Correct pressure settings are listed in Section 5 Refer to DMR 30 See page 4 3 settings listed in this section Checking Pump Pressure Drive Pump Check charge pressure at tee added to charge filter line To check drive pressure connect pressure tester to port G on the 2 speed axle lock valve block
113. bly into cylinder 6 Secure head into cylinder Installation 1 Installation is the reverse of removal 2 Carefully remove elevating assembly support 3 Slowly cycle cylinder several times to remove air from the hydraulic system 4 Check for proper cylinder operation Check cylin der and hydraulic connections for leaks AB62 Work Platform European Section MAINTENANCE 3 11 Seal Kit 104258 010 S N 1109 Current includes O ring Rod Wiper Seal Wear Ring O Ring Back up Ring O Ring Seal Wear Ring O Q gt G N A Rod B Head C Piston D Nut E Cylinder F Counterbalance Valve Seal Kit 104260 011 S N 1100 1108 Seal Kit 104260 010 S N 1109 Current includes Rod Wiper Wear Ring O Ring Back up Ring O Ring Seal O ring Wear Ring cO Oo O Qn gt G N lt i A Rod x B Head C Piston D Nut E Oylinder F Counterbalance Valve Figure 3 17 Riser Cylinder S N 1109 Current AB62 Work Platform European 3 17 Section 3 11 MAINTENANCE Seal Kit 104256 011 S N 1100 1108 Seal Kit 104256 010 S N 1109 Current includes 1 Rod Wiper 2 Seal 3 Wear Ring 4 O Ring 5 Back up Ring 6 O Ring 7 Wear Ring 8 Seal A Rod B Head C Spacer D Piston E Set Screw F Cylinder G Counterbalance Valve Seal Kit 104255 011 S N 1100 1108 Seal Kit 104255 010 S N 1109 Cur
114. c Pressures 3 10 High Flow Relief Valve 5 3 10 Low Flow Relief Valve 9 3 10 Counterbalance Relief Valves 3 10 3 10 Torque 3 12 Changing Fluid 3 12 Torque Hub Removal 3 12 Installation 3 12 Disassembly of Torque Hub Figure 3 16 3 13 Assembly of Torque Hub 3 13 Carrier Assemblies 3 14 Sealing Compound 3 14 iii TABLE OF CONTENTS 3 11 Cylinder Repair 3 16 3 13 Rotary Manifold 3 21 Removal ete GR RM WEE ee 3 16 Disassembly 3 21 Disassembly 3 16 Assembly 234 tae cote eee eed 3 21 Assembly 22 sues a Rem EA 3 16 Installation u iier Rc RES 3 21 Installation eere eR ER en des 3 16 3 14 Torque 3 22 3 12 Setting Backlash on Rotational Gear 3 20 Hydraulic Components 3 22 Fasteners n BERI ERAS 3 22 SECTION 4 Troubleshooting ao Introduction l ss ee 4 1 4 1 Troubleshooting DMR 30 Controller 4 3 Troubleshooting Procedure 4 1 4 2 Machine Operation
115. cessary 10 Remove jack stands and lower rear end 11 Connect battery terminal 12 Operate machine and check for proper operation of torque hub Check function of brake Figure 3 14 Torque Hub Assembly AB62 Work Platform European MAINTENANCE Section 3 10 Disassembly of Torque Hub Figure 3 16 1 Slide the coupling 1 from splines on input shaft 2 2 Position the assembly upright on face of spindle 3 Remove the disengage cover 31 if necessary 4 Remove eight bolts 29 and the large cover 28 from the unit The thrust washer 25 and the dis engage plunger 26 usually remain attached to the large cover 28 when it is removed Remove thrust washer 25 disengage plunger 26 and O ring 27 from the large cover 28 5 Remove primary sun gear 24 from end of input shaft 2 6 Remove the primary carrier assembly 22 7 Remove the secondary carrier assembly 21 8 Remove the input shaft 2 from spindle 3 Remove the retaining rings 17 washers 18 and disengage spring 19 from input shaft 2 only if replacement is required 9 One tab of lock washer 15 will be engaged in slot of bearing nut 16 bend back to release Remove the bearing nut 16 lock washer 15 and thrust washer 14 NOTE A special locknut wrench is required for the removal of the bearing locknut The Bearing Locknut Tool Bearing Cone Driver and Spin dle Shaft Drive Tool are included in the Serv
116. ch parts list contains the component parts for that assembly CONTENTS Final Assembly AB62 Diesel 104000 001 Basic Assembly AB62 Diesel 104006 000 Chassis Assembly 104007 000 Front Axle Assembly 104016 000 Elevating Assembly 104009 000 Linkage Assembly 104010 000 Straight Boom Assembly 104011 000 Jib Assembly 104012 000 Turret Assembly 104008 000 Engine Module Assembly AB62 Diesel 1004013 000 Cover Assembly 104015 000 Upper Controller Assembly AB62 Diesel 104017 000 Lower Controller Assembly AB62 Diesel 104019 000 Six Foot Cage Assembly 102037 100 Eight Foot Cage Assembly Option 102037 001 Control Module Assembly 104021 000 Fuel Tank Assembly 104024 000 Hydraulic Tank Assembly 104025 000 Valve Block Assembly 104033 000 Valve Block Sub Assembly 104251 000 Drive Block Assembly 104035 000 Valve Block Assembly Two Speed Brake Axle Lock 104036 000 AB62 Work Platform European Cage Rotate Valve Block Assembly 104034 000 Rotary Manifold Assembly 1040260001 ipu e ere PO tee de e bbb Hose Kit Installation Chassis Turret Linkage 104046 000 Drive Pump Assembly 104029 000 Lift Pump Assembly 104027 000 Jib Cylinder Assembly 104040 000 S N 1100 1110 Jib Cylinder Assembly 104040 001 S N 1111 Current Riser Cylinder Assembly 104037 000 S N 1100 1108 Riser Cylinder Assembly 104037 001 S N 1109 Current Extend Cylinder Assembly 104038 001 S N 1100 1108 Extend Cylinder Assembly 104038
117. chine is out of level or the level sensor fails the machine will stop Red wire on level sensor is power in and white wire is signal out Interlocks There are two interlocks on the machine 1 Lift Interlock A12 Volt signal is sent to BT2 01 DMR 30 allows high speed travel 2 Telescope interlock at tail end of boom A 12 volt signal is sent to BT1 11 amp BT1 12 on DMR 30 when boom is fully retracted allows high speed travel AB62 Work Platform European Section TROUBLESHOOTING 4 3 4 3 OPTIMIZER SETTINGS AND SEQUENCE The AB62 uses a Digital Multiplex Receiver DMR 30 system manufactured by OEM to control the pro portionality of boom functions There is a transmitter DMT 30 in the upper control box that takes the operator s control inputs and relays them to the receiver via data link two wires The Optimizer can be plugged into the upper control box with the use of an adapter part 100329 005 or directly to the DMR 30 in the lower control box on port P 8 Remove existing plug on P 8 to access port The 62 uses two groups of settings High flow which pertains to the BOOM RISER BOOM EXTEND and STEER functions and the Low flow pertaining to the BOOM RAISE JIB TURRET ROTATE and CAGE LEVEL functions CAGE ROTATE is also altered by adjusting the flow control valve located on the bottom of the valve block below the cage rotate valve All settings correspond with how all the functions in th
118. ctric Proportional Tires 19x 15 NHS 14 PLY 5 5 bar 80 PSI NOTE Specifications subject to change without notice Hot weather or heavy use may affect perfor mance 1 2 AB62 Work Platform European MACHINE PREPARATION amp OPERATION Warning All personnel shall carefully read understand and follow all safety rules and operating instructions before operating or performing maintenance on any UpRight aerial work platform Safety Rules Electrocution Hazard Tip Over Hazard Collision Hazard Fall Hazard THIS MACHINE IS NOT INSULATED NEVER operate the boom or NEVER position the plat NEVER climb stand or drive with the platform ele form without first checking sit on the platform guard vated unless on firm level for overhead obstructions rails or midrail surface or other hazards Use of the aerial work platform This aerial work platform is intended to lift persons and his tools as well as the material used for the job It is designed for repair and assembly jobs and assignments at overhead workplaces ceilings cranes roof structures build ings etc All other uses of the aerial work platform are prohibited This aerial work platform is not insulated For this reason it is imperative to keep a safe distance from live parts of electrical equipment occupants must wear an approved fall restraint properly attached to designated platform anchorage point Attach only one fall restraint to each anchor
119. emperatures below 0 F 17 C Check mounting bolts for proper torque 30d Check hydraulic drive motor operation Daily Hydraulic Drive System Check valve block for Daily 3 4 AB62 Work Platform European Section MAINTENANCE 34 3 4 SUPPORTING ELEVATING ASSEMBLY FIGURE 3 6 AWARNING A Never perform service on the work platform in the elevating assembly area while the platform is elevated without first blocking the elevating assembly DO NOT stand in the elevating assembly area while deploying or storing brace Installation 1 Park the work platform on a firm level surface 2 Fully retract upper boom 3 Verify that the platform emergency stop switch is ON 4 Turn platform chassis switch to CHASSIS 5 Using the Boom Raise Lower Switch elevate the boom 6 Use a brace figure 3 6 with a minimum capacity of two tons to support the elevating assembly 7 Using the Boom Raise Lower Switch gradually lower the elevating assembly until the brace is supporting the elevating assembly as shown in figure 3 7 Removal 1 Using the Boom Raise Lower Switch gradually raise the platform until boom is free of support 2 Remove support 3 Using the Boom Raise Lower Switch completely lower the platform Figure 3 7 Elevating Assembly Brace 62 Work Platform European 3 5 Section 3 5 3 5 BATTERY MAINTENANCE AWARNING
120. ergency stop switches to the ON position at the chassis control panel and at the platform control panel Turn key switch on and wait for glow plug light to go off When glow plug light goes off start engine Push in the chassis emergency stop button engine should stop Repeat for platform emer stop button Return both emergency stop buttons to the ON position and start engine Operate each function switch to raise lower extend retract rotate left right each section of the elevating assembly and observe the opera tion of the machine All functions should operate through full cycle smoothly Make sure that the Boom Speed Control is not at zero Turn chassis key switch to PLATFORM Mount the platform lower the bar and attach approved fall restraint to designated platform anchorage point Attach only one fall restraint to each point Start the engine Without depressing the foot switch move the drive control handle machine should not func tion Depress the foot switch and move the drive con trol handle forward and reverse Observe that proportional functions operate smoothly and that brakes apply quickly after control is released While depressing foot switch operate steer switch to left and right Observe that steering wheels turn properly While depressing foot switch turn function speed control knob to desired setting and operate boom controls Observe that boom operates smoothly and that u
121. es supplied by UpRight unless approved by the manufacturer in writing Check air filled tire pressure daily 5 5 bar 80 psi YADRAULIC FLUID Level Gauge LN A CAUTION Figure 2 9 Hydraulic Oil Tank AB62 Work Platform European MAINTENANCE 3 1 INTRODUCTION AWARNING A Be sure to read understand and follow all infor mation in the Operation Section of this manual before attempting to operate or perform service on any work platform NOTE For Information on the engine refer to your local engine dealer This section contains instructions for the mainte nance of the AB62 Work Platform Procedures for the operation inspection adjustment scheduled mainte nance and repair removal are included Referring to Section 2 will aid in understanding the operation and function of the various components and systems of the work platform and help in diag nosing and repair of the machine Refer to Preventative Maintenance Check List on page 4 for recommended maintenance intervals NOTE Unless otherwise specified torque all fit tings according to Torque Specifications Chart pages 3 22 amp 3 23 a LET M RS SS as a i VA vA Figure 3 1 UpRight Connector Kit Small AB62 Work Platform European 3 2 SPECIAL TOOLS The following is a list of special tools which may be required to perform certain maintenance procedures on
122. g cone 13 over spindle 3 Press bearing cone 13 over spindle bearing journal using press and cylindrical Bearing Cone Driver Service Kit 100254 020 Press bearing cone 13 down until rollers just touch cup 12 Take care to avoid pressing cone 13 too far NOTE If a press is not available place Bearing Cone Driver Tool over spined end of spindle 3 on the edge of bearing cone 13 and drive into place with hammer or mallet If this method is used care must be taken to avoid damage to bearing cone and spindle 5 Install thrust washer 14 with tab in keyway of spindle and bearing nut 16 DO NOT install lock washer 15 at this time 6 Clean mating surfaces and apply a bead of sili cone sealant to face of hub 11 that mates with ring gear 20 See instructions on sealant pack age Hub 11 is attached to ring gear 20 with 18 3 8 24 grade 8 hex head cap screws 9 and flat washers 10 Torque cap screws to 50 52 Ib ft 70 81 Nm 7 Place Spindle Drive Tool Service Kit 100254 020 over spindle 3 and bolt or pin to ring gear 20 Make sure center bolt of Drive Tool is not touching spindle and is prevented from rotating by jam nuts provided on tool 8 Check initial rolling torque by installing a Ib in torque wrench arm or dial type on center nut of Spindle Drive Tool and turning hub 11 slowly and steadily with the torque wrench Note mean torque An initial bearing torque of greater than 52
123. g hardware hydraulics loose wire connections and damaged cables or hoses before using Verify that all labels are in place and legible before using Never use a machine that is damaged not functioning properly or has damaged or missing labels If Alarm Sounds while boom is elevated STOP carefully retract boom and lower the platform without rotating Move the machine to a firm level service To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platform and in its working range Never charge battery near sparks or open flame Charging batteries emit explosive hydrogen gas Modifications to the aerial work platform are prohibited or permissible only at the approval by UpRight Never tow the machine Transport by truck or trailer only After use secure the work platform from unauthorized use by turning both keyswitches off and removing all keys AB62 Work Platform European 2 1 Section 2 1 2 1 INTRODUCTION This manual covers the operation of internal combus tion powered models of the AB62RT Articulated Boom This manual must be stored on the machine at all times 2 2 PRE OPERATION AND SAFETY INSPECTION Carefully read understand and follow all safety rules labels and operating instructions then perform the following steps each day before use Perform a complete visual inspection of the entire unit prior to operating Check the following areas for discrepancies
124. ications for Metric Fasteners U S Customary Units 3 23 Table 3 5 Torque Specifications for Metric Fasteners SI Units 3 23 SECTION 4 Troubleshooting Table 4 1 Electrical Truth Table AB62 4 9 Table 4 2 Hydraulic Truth Table AB62 4 12 SECTION 5 Schematics Table 5 1 Electrical Schematic Diesel 104049 000 5 2 Table 5 2 Hydraulic Schematic Legend 104048 000 5 6 vi AB62 Work Platform European INTRODUCTION amp SPECIFICATIONS 1 1 INTRODUCTION Purpose The purpose of this service and parts manual is to provide instructions and illustrations for the operation and maintenance of the AB62 Work Platform manu factured by UpRight Inc of Selma California Scope The manual includes procedures for proper opera tion maintenance adjustment and repair of this product as well as recommended maintenance schedules and troubleshooting 1 2 GENERAL DESCRIPTION The AB62 Work Platform consists of the platform controller elevating assembly power module control module and chassis Platform The platform has a non slip aluminum floor 45 inch 1 4 m high guardrails with midrail 6 inch 152 mm toeboards and an entrance gate at the rear of the platform AWARNING DO NOT use the work platform without guararails properly assembled and in place Platform Controller The controller c
125. ice Kit part number 100254 020 10 Bolt Spindle Drive Tool Service Kit 100254 020 to ring gear 20 Grade 8 bolts should be used Drive spindle 3 from hub by turning the center bolt of Spindle Drive Tool Care should be taken to avoid damaging splines and threads on spindle NOTE Bearing cone 13 has been designed with a press fit with respect to spindle 3 Consider able force will be required to remove cone from spindle 11 Remove Spindle Drive Tool from ring gear 20 12 Remove the eighteen bolts 9 and washers 10 from hub 11 and remove ring gear 20 It may be necessary to strike ring gear 20 with a rub ber mallet to loosen from hub 11 13 Remove the boot seal 4 and oil seal 5 and bearing cones 6 amp 13 from hub 11 Inspect bearing cups 7 amp 12 in position and remove only if replacement is required AB62 Work Platform European Assembly of Torque Hub 1 Press new bearing cups 7 amp 12 in each side of the hub 11 It is recommended that bearing cups 7 amp 12 and cones 6 amp 13 be replaced in sets 2 Assemble bearing cone 6 into cup 7 at seal end of hub 11 and press a new seal 5 into hub 11 Install boot seal 4 on hub 11 if unit is so equipped 3 Position spindle 3 upright on bench Lubricate lips of seal b and lower hub 11 on to spindle 3 Hub 11 should be centered as it is lowered over spindle 3 to prevent seal damage 4 Assemble bearin
126. ir 2 Inspect the manifold for cracks thread damage and scoring where O rings seal against internal and external surfaces 3 Wash and dry each component and check for thread damage torn or cracked O rings and proper operation 4 Replace parts and O rings found unserviceable Assembly NOTE Lubricate all O rings before installation to prevent damage to O rings Seat all balls in manifold block by lightly tapping on the ball with a brass drift punch 1 Install fittings plugs springs balls and orifices Use one drop of Locktite 242 on each screw in orifice 2 Install solenoid valves lift relief valve counterbal ance valves divider combiner valve and spool valve AB62 Work Platform European Installation 1 Attach manifold assembly to mounting plate with bolts 2 Connect solenoid leads to terminal strip as previ ously tagged 3 Connect hydraulic hoses Be certain to tighten hoses to manifold 4 Reconnect the battery 5 Operate each hydraulic function and check for proper operation and leaks 6 Adjust lift relief and counterbalance valve pres sures according to instructions in Section 3 10 3 9 Section 3 9 MAINTENANCE 3 9 SETTING HYDRAULIC PRESSURES Figure 3 14 shows complete hydraulic manifold assembly NOTE Check hydraulic pressures whenever the pump manifold or any relief valve has been serviced or replaced High Flow Relief Valve 5 1 Operate the hydraulic s
127. k the wheels to prevent the work platform from rolling 2 Disconnect battery negative terminal 3 Loosen the wheel lug nuts on the torque hub to be removed 4 Raise the axle of the work platform using an eight ton jack 5 Position two eight ton jack stands under the axle to prevent the work platform from falling if the jack fails 6 Remove the wheel nuts and wheel 7 Disconnect hydraulic brake line from brake CAUTION A Clean all fittings before disconnecting the hose assemblies Plug all port holes and hose assemblies IMME DIATELY to prevent contamination from dust and debris 8 Mark and remove hoses from drive motor 9 Remove mounting bolts from drive motor 10 Separate drive motor from brake Discard gasket 3 12 MAINTENANCE 11 Separate brake from torque hub Discard gasket 12 Remove 1 2 20 nuts and washers from torque hub 13 Remove torque hub Installation NOTE Torque all hardware to torques listed on pages 3 22 and 3 23 unless otherwise speci fied 1 Install the torque hub using hardware previously removed 2 Using SAE 90W weight gear lube fill the torque hub Torque hub must be half full 3 Install new gasket and brake 4 Install new gasket and drive motor 5 Secure assembly using washers and bolts 6 Connect hydraulic brake lines 7 Connect hoses to drive motor 8 Install wheels Torque lug nuts to 257Nm 190 ft Ibs 9 Bleed brake lines if ne
128. latform is elevated Oil and Filter Replacement 1 Operate the platform for 10 15 minutes to bring the hydraulic oil up to normal operating tempera ture CAUTION The hyaraulic oil may be hot enough to cause burns Wear safety gloves and safety glasses when handling hot oil 2 Provide a suitable container to catch the drained oil AB62 Work Platform European Remove the drain plug and allow all oil to drain into the container Be sure to dispose of oil prop erly Reinstall the drain plug Remove filter element from filter head Apply a thin film of clean hydraulic oil ISO No 46 to the gasket of the replacement filter Thread replacement filter onto the filter head until the gasket makes contact then rotate 3 4 of a turn further Fill the hydraulic oil tank to operating level on sight gauge with ISO No 46 hydraulic oil 3 7 Section 3 7 MAINTENANCE 3 7 TILT SENSOR FIGURE 3 11 The Tilt Sensor has three wires red power 12v in black ground and white output 12v out To verify ha sd eng p w that the sensor is working properly there is one red e My LED under the sensor that indicates the sensor is off 4 level r 1 Check tires for proper pressure uM 3 7 Adjustment 2 Place the machine on firm level surface 3 Use Inclinometer to ensure that the front and rear of the chassis are level 4 Adjust the three leveling lock
129. lower control panel switches including ignition switch This LED should flash with CPU LED C OUTPUT LED Indicates an output to boom or drive functions This LED flashes only when operat ing boom or drive functions from either controller D BUSS LED Indicates an input from the DMT 30 upper controller This LED should flash with CPU LED and INPUT LED as the upper ignition must be on to operate 4 2 MACHINE OPERATION Lower Control Box Electrical Power Up Both Emergency Stop Switches are pulled out Lower control box key switch in CHASSIS position Upper key ON BT1 03 chassis selected will be illuminated Other LEDs on DMR 30 that may be illuminated BT 1 05 tilt BT2 01 telescope interlock BT1 11 lift interlock 1 BT1 12 lift interlock 2 AB62 Work Platform European The CPU LED on the DMR 30 should be flashing on off The BUSS LED on the DMR 30 should be flash ing on off The INPUT LED should be flashing ON OFF Engine Start BT1 02 on DMR 30 start illuminated when operat ing start switch The hour meter should flash BT4 08 oil pressure input will illuminate while engine is running NOTE If no oil pressure is detected ignition sig nal is deactivated Engine will not continue to run Glow Plug BT1 08 on DMR 30 illuminated Glow plugs are auto matic Boom Speed control knob in UPPER control box must be turned past 5 to operate Boom Up Function enable pushed LEDs on DMR 30 illuminated
130. n tight areas Lower Control Operation All boom functions will operate at the speed selected by upper speed control functions 1 Turn chassis keyswitch to chassis controls 2 With the engine running operate the boom con trol switches to position the platform AB62 Work Platform European 3 The High Low switch will select between maxi mum speed depending on the position of the platform Boom Speed control and a lower fixed boom speed w X I gt Leveling the Platform amp Quo AWARNING DO NOT operate the machine if the platform does not maintain level when elevated NOTE Platform leveling should be done only to 1 calibrate the automatic leveling system Set the function speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease If you are not sure what speed to use start out slow the speed can be varied while operating the function While depressing the foot switch push the plat form level control switch forward to swing the plat form upward rearward to swing the platform downward Release the switch to stop leveling j 4 Rotating the Turret oO 1 Set the function speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease If you are not sure what speed to use start out slow the speed can be varied while operating the function While depressing the
131. nuts until the bubble is centered in the circle on the attached bubble level 5 Elevate the platform until down limit switch opens and push the tilt sensor base to test the alarm cir cuit The red LED should turn on and the tilt alarm should sound Figure 3 11 Linkage Limit Switch Bubble Level Figure 3 12 Proximity Switch 3 8 AB62 Work Platform European Section 3 8 MAINTENANCE 3 8 HYDRAULIC MANIFOLD FIGURE 3 14 It is not necessary to remove the manifold to perform all maintenance procedures Prior to performing maintenance determine if the manifold needs to be removed Removal 1 Disconnect the battery 2 Tag and disconnect the solenoid valve leads from the terminal strip 3 Tag disconnect and plug hydraulic hoses 4 Remove the bolts that hold the manifold to the mounting bracket 5 Remove the manifold block Disassembly NOTE Mark all components as they are removed so as not to confuse their location during assembly Refer to Figure 3 14 often to aid in disassembly and assembly 1 Remove coils from solenoid valves 2 Remove spool valve cover and spool valve 3 Remove solenoid valves lift relief valve counter balance valves and divider combiner valve 4 Remove fittings plugs springs balls and ori fices Cleaning and Inspection 1 Wash the manifold in cleaning solvent to remove built up contaminants then blow out all passages with clean compressed a
132. o spindle 3 15 Assemble the secondary carrier assembly 21 to spindle 3 at splines 16 Assemble the primary carrier assembly 22 into the ring gear 20 It will be necessary to rotate carrier to align secondary sun gear part of pri mary carrier assembly 22 with planet gear teeth in secondary carrier assembly 21 Assem ble primary sun gear 24 over input shaft 2 Rotate primary sun gear 24 to align input shaft 2 to gear splines and gear teeth in primary car rier assembly 22 17 Lubricate O ring 27 and assemble in groove inside cover hole push disengage plunger 26 into cover 28 with pointed end facing inside of unit 18 Assemble the thrust washer 25 with tangs engaged with cover 28 NOTE A small amount of grease applied to the back side of thrust washer 25 will hold washer in place Apply a bead of silicone sealant to end of face of ring 3 14 MAINTENANCE gear 20 Assemble cover 28 aligning holes of cover and ring gear Assemble the eight 5 16 18 x 1 inch hex head bolts 29 Torque bolts to 27 34 Nm 20 25 Ib ft 19 Assemble the disengage cover 31 with dimpled center protruding out if wheel is to be used to drive the vehicle Assemble and torque the two 5 16 18 x 1 2 inch bolts 32 Torque bolts to 13 27 Nm 10 20 Ib ft 20 Invert the torque hub assembly and assemble the coupling 1 with counterbore out to the input shaft 2 21 After motor is assembled to drive or
133. ontains the controls to operate the machine It is located at the front of the platform cage The foot switch must be depressed to operate any function from the platform A complete explana tion of control functions can be found in Section 2 Elevating Assembly The platform is raised and lowered by the elevating assembly an articulated boom powered by two sin gle stage lift cylinders The hydraulic pump driven by the engine powers the cylinders Solenoid operated valves control raising and lowering AB62 Work Platform European Chassis The chassis is a structural frame that supports all the components of the AB62 Work Platform 1 3 PURPOSE OF EQUIPMENT The objective of the work platform is to provide a quickly deployable self propelled variable height work platform to elevate personnel and materials to overhead work areas and be driven over normal ter rains 1 4 SPECIAL LIMITATIONS Travel with the platform raised is limited to a creep speed range Elevating of the work platform is limited to firm level surfaces only Any degree of slope greater than 5 will sound a warning alarm A DANGER A The elevating function shall ONLY be used when the work platform is level and on a firm surface The work platform is NOT intended to be driven over uneven rough or soft terrain when elevated 1 Platform 2 Platform Controller 3 Elevating Assembly 4 Boom 5 Chassis Control Module 6 Chassis Figure 1 1 Wo
134. pean 5 1 SCHEMATICS 5 1 ELECTRICAL SCHEMATIC AB62 DIESEL Table 5 1 Electrical Schematic Diesel 104049 000 REFERENCE FUNCTION LOCATION REFERENCE FUNCTION LOCATION Actuator Throttle Engine Module Level the Platform arm Tilt Provide warning sound when Lower Control Boom Up Down machine is off level i Turret R otate Cage Rotate ib Up Down ircuit Breaker ection for DMR 30 ircuit Breaker ection Platform i iving Lights ressure Switch Breaker ection Platform ock Foot gency Stop Controller DMR 30 5 machine functions lug Controller iliary Power ble m Speed to Platform Controls ents Auxiliary P ump operation n ignition is on Engine Start iliary Pump Relay Signal Rotate Power to Lower Controls Lowe m Up Down Alternator exciter signal Engine near the Platform Alternator i Rotate Spike Protection Diode Engine Modu i p Down Spike Protection Diode Engine Modu i Up Down Auxiliary Power Motor Control Modu i Extend R etract Horn Sound Alarm Contro tiltalarm Disable all solator harge Isolator e ne functions except Platform when machine is more than level ne Temperature ne Oil Pressure Lamp istress Engine Contro Lamp ilt Contro Lamp ow Plug amp
135. peed 0 3m 1 foot per second Steering 1 While depressing the foot switch push the steer ing switch located on top of the control handle to the left to turn left and right to turn right Note Steering is not self centering Wheels must be returned to the straight ahead position by operating the steering switch Positioning the Platform Positioning the platform as close as possible to the work area requires some planning First you must survey the work site to find a suitable place to park the machine This must be a firm level area as close as possible to the work area Take into consideration all obstructions on the ground and overhead and avoid them Once you have moved the machine to a firm level surface as near as possible to the work area follow instructions on pages 2 5 and 2 6 to position the plat form as close to the work area as possible Always before operating any function check the area around and overhead for any obstructions or electrical conductors NEVER exit the platform while the boom is ele vated Keep both feet firmly planted on the plat form floor at all times Multifunction Controls The UpRight AB62 employs the use of multifunction controls This means that riser or boom extension will function at full speed while simultaneously operating upper boom jib turret or rotating the platform The turret may be rotated while driving when the boom is lowered if necessary to make turns i
136. pper boom jib turret rotation platform level riser and boom extend operate proportionally in conjunction with function speed control knob Observe that platform maintains level when boom is elevated AB62 Work Platform European Section MACHINE PREPARATION amp OPERATION 13 With the upper boom elevated one foot operate drive control handle Observe that drive speed is limited to creep 0 3m 1 foot per second Lower upper boom to stowed position 14 Press the service horn button Observe that horn is audible AWARNING DO NOT use a machine that is damaged or malfunctioning Tag and remove the unit from service until it is repaired 2 3 CONTROLS AND INDICATORS Figure 2 2 Platform Controls 19 Riser 28 Auxiliary Power 20 Boom Raise 29 Turret Rotate 21 Boom Extend 30 Cage Rotate 22 Jib Raise 31 Cage Level 23 Emergency Stop 32 Auxiliary Light 24 YELLOW Tilt 33 Horn 25 RED Oil Pressure 34 Generator Warning 35 Boom Speed 26 Hi Low Speed 36 Drive Control Handle 27 Gas Propane Select 37 Key Switch Glow Plug Light 38 Foot Switch Figure 2 1 Chassis Controls 1 Hour Meter 11 Boom Extend 2 Water Temp 12 Jib Raise 3 Oil Pressure 13 Boom Raise Lower 4 Breaker 14 Turret Rotate 5 Glow Plug Light 15 Platform Rotate 6 Function Enable 16 Platform Level 7 Engine Start 17 Boom Speed HI LOW 8 Key Switch 18 Auxiliary Power 9 Emergency Stop 10 Riser
137. r Orifice Drive Orifice Boom Pump Low Flow Boom Pump High Flow Variable Drive Pump Auxiliary Pump Cage Rotator Low Pressure Relief Valve High Pressure Relief Jib Cylinder Relief Steering Valve Riser Valve Boom Extend Valve Boom Raise Valve Jib Valve Cage Level Valve Turret Rotate Valve Cage Rotate Low Flow Valve High Flow Valve Diverter Valve Brake Valve Axle Float Valve High Speed Valve Rear Drive Torque Speed Valve Front Drive Torque Speed Valve AB62 Work Platform European 4 13 Section 4 4 TROUBLESHOOTING Notes 4 14 AB62 Work Platform European SCHEMATICS Introduction Schematic Page This section contains electrical and hydraulic power 1 schematics and associated information for mainte Electrical Schematic AB62 Diesel 2 nance purposes Hydraulic Schematic 62 6 The diagrams are to be used in conjunction with the Troubleshooting Truth Tables in Section 4 They allow understanding of the makeup and functions of the systems for checking tracing and faultfinding during troubleshooting analysis The components that comprise the electrical and hydraulic systems are given a reference designation and are explained as to function and location in the following tables AB62 Work Platform Euro
138. rational checks together with all necessary minor adjustments to assure proper performance Daily inspection will prevent abnormal wear and pro long the life of all systems The inspection and main tenance schedule is to be performed at regular intervals Inspection and maintenance shall be per formed by personnel who are trained and familiar with mechanical and electrical procedures AWARNING A Before performing preventative maintenance familiarize yourself with the operation of the Push removal tool into connector to release contact machine Figure 3 5 Heavy Duty UpRight Connector Always block the elevating assembly whenever i i it is necessary to perform maintenance while 1 ES A tool along the wire to be Hie Dato 2 Push the removal tool into the connector until the contact is released 3 Pull the wire and contact out of the plug The preventative maintenance table has been designed to be used primarily for machine service and maintenance repair Please photocopy the fol lowing page and use this table as a checklist when inspecting the machine for service AB62 Work Platform European 3 3 Section 3 3 MAINTENANCE Preventative Maintenance Table Key Preventative Maintenance Report Interval Date gt Daily each shift or every day 2 50h 30d every 50 hours or 30 days Model No 250h 6m every 250 hours or 6 months Serial No 2220 1000h 2y every 1000 hours or 2 years Serviced
139. re 2 7 Tighten ponents and void warranty securely do not overtighten AWARNING A NEVER elevate the machine while on a truck or trailer gt 4 Wooden Block Chassis Tie Down gt 20 cm x 10 cm x 75 Lifting Lug typ _ Center 2 8 x 4 x 28 Figure 2 6 Disengaging Drive Hub Figure 2 7 Securing the Machine for Transportation After Use Each Day 2 5 TRANSPORTATION 1 Ensure that the platform is fully lowered By Truck or Trailer 2 Park the machine on level ground preferably 1 Insure that boom is fully lowered and retracted under cover secure against vandals children or unauthorized operation 2 Raise the jib before the machine starts up or 3 Tumth k itch to OFF the down ramp avoid platform contacting ground x MER SWIIC 10 bet I ME INVEST Key switch to PLATFORM and remove all keys to pre 3 Maneuver the machine onto the bed of truck vent unauthorized operation trailer 4 When winching follow instructions for emergency towing on page 2 6 Attach winch cable to front tie down lugs Do not winch machine faster than 5 km h 3 mph 5 After winching ensure that wheels are chocked AB62 Work Platform European 2 7 Section 2 6 MAINTENANCE Fueling Gasoline 1 Open left turret cover then open fill cap See Figure 2 8 2 Fill to capaci
140. reakdown Control Module Assembly NOTE AISI S ITEM 54 AND ITEM 49 SUPPLIED WITH 104366 000 GAS ENGINE USED ON ENGINE MODULE ASSEMBLY 104014 000 Page 6 41 AB62 Work Platform European Parts Breakdown Fuel Tank Assembly Fuel Tank Assembly 104024 000 ITEM PART NO PART MATERIAL DESCRIPTION RS 0 PART MATERIAL DESCRIPTION 1 104337 000 FUEL TANK 1 104456 000 WITHDRAWL TUBE WELDMENT 2 068982 002 FILLER CAP 1 010178 005 FITTING BARBED 1 4 ttf A af 2 80 Page 6 42 AB62 Work Platform European Illustrated Parts Breakdown Hydraulic Tank Assembly Hydraulic Tank Assembly 104025 000 ITEM PARTNO PART MATERIAL DESCRIPTION PARTNO PART MATERIAL DESCRIPTION 068711 000 BREATHER TANK 104318 000 ACCESS COVER GASKET 104317 000 ACCESS COVER 011919 006 PLUG 12 061818 000 STRAINER 026526 004 SCREW 10 TYPE AB SELF TAP SLOTTED X 1 2 104414 000 SHIELD OIL DRIP 011253 008 SCREW 5 16 18 UNC HEX HD CAP X 1 011248 005 LOCKNUT 5 16 18 UNC HEX 011939 029 FITTING STR 20MP 16MJ 020343 008 FITTING PLUG 8FJ 104265 000 HYDRAULIC TANK 011940 018 FITTING ELBOW 12 MP 8MJ 90 100285 000 FILTER 100285 010 FILTER ELEMENT 012467 006 PIPE NIPPLE 3 4 NPT X 3 L
141. rent includes 1 Rod Wiper 2 Seal 3 Seal 4 O Ring 5 Back up Ring 6 O Ring 7 Wear Ring 8 Wear Ring A Rod Wiper B Head C Spacer D Set Screw E Piston F Cylinder G Counterbalance Valve Figure 3 19 Extend Cylinder S N 1109 Current 3 18 62 Work Platform European Section MAINTENANCE 3 11 Seal Kit 104556 010 includes NOTE Torque Locknut to 237 271 Nm 175 200 ft Ibg 1 O Ring 2 Rod Wiper 3 Seal 4 Wear Ring 5 O Ring 6 Back up Ring 7 O Ring 8 Seal 9 Wear Ring A Rod B Head C Piston D Nut E Oylinder F Counterbalance Valve G Washer Seal H Bleeder Plug Seal Kit 100557 010 includes 1 O Ring 2 Rod Wiper 3 Seal 4 Wear Ring 5 Back up Ring 6 O Ring 7 Wear Ring A Rod B Head C Spacer D Cylinder Figure 3 21 Steering Cylinder AB62 Work Platform European 3 19 Section 3 12 Seal Kit 104257 011 S N 1100 1110 Seal Kit 104257 010 S N 1111 Current includes 1 2 3 4 5 6 7 8 9 O Ring Rod Wiper Seal Wear Ring Back up Ring O Ring Cast Iron Ring Wear Ring Seal MAINTENANCE NOTE Torque Locknut to 237 271 Nm 175 200 ft Ibs A Rod B Head C Piston D Nut E Cylinder F Relief Valve G Counterbalance Valve Figure 3 22 Jib Cylinder S N 1111 Current 3 12 SETTING BACKLASH ON ROTATIONAL GEAR Backlash is the shortest dist
142. rk Platform 1 1 INTRODUCTION amp SPECIFICATIONS 1 5 SPECIFICATIONS Table 1 1 Work Platform Specifications ITEM AB62 4WD Diesel Height Working Height 20 7 m 68 ft Max Platform Height 18 9 m 62 ft Platform step in Height 343 mm 13 5 in Up and Over Height 9 1m 30 ft Drivable Height 18 9 m 62 ft Horizontal Outreach 10 7 m 35 ft Turret Rotation 360 Continuous Platform Rotation 180 Tail Swing 0 ft Jib Length 1 9 m 6ft 4 in Jib Arc 140 Inside Turning Radius 2 5 m 8 ft Outside Turning Radius 5 5 m 18 ft Drive Speed boom stowed and lowered 6 8 km h 4 25 mph high 2 6 km h 1 6 mph low Drive Speed Elevated 96 km h 6 mph Maximum Gradeability 22 40 Dimensions boom stowed Platform Size 1m x 1 8 39 in x 72 in Optional 8 ft 2 4 m Platform 1mx 2 4 39 in x 96 in Guardrails 14 m 45 in Toeboard 152 mm 6 in Platform Capacity Maximum 221 kg 500 Ibs Occupants Maximum 2 Weight 10 614 kg 23 400 Ibs Overall Height 2 5 m 8 ft 2 in Overall Length 8 2 mor 7 2 m Minimum 27 ft or 23 ft 6 in Minimum Overall Width 2 3 m ft 7 5 in Wheel Base 2 5 m 8 Ground Clearance 0 46 m center 0 32 m axle 18 in center 12 5 in axle Power Source Perkins 704 30 System Voltage 12 VDC Maximum Hydraulic Pressure 345 bar 5000 P S1 Controls Ele
143. s are operating properly 3 21 Section 3 13 MAINTENANCE 3 14 TORQUE SPECIFICATIONS Hydraulic Components NOTE Always lubricate threads with clean hydraulic oil prior to installation Use the following values to torque hydraulic components used on UpRight Work Platforms Table 3 2 Torque Specifications for Hydraulic Components SAE Part Series Cartridge Poppet Fittings Ft Lbs 135 145 215 245 430 470 680 750 12 85 90 115 122 85 90 115 122 950 1050 107 119 16 130 140 176 190 130 140 176 190 1300 1368 147 155 Fasteners This standard applies to the preloading of fasteners measured by installation torque NOTE For other preloading methods or fasteners consult UpRight Engineering Department This general standard applies to all SAE and Metric fasteners unless otherwise specified Thread Condition For lubed or zinc plated fasteners use 15 For dry unplated fasteners use 20 Torque Tables Table 3 3 Torque Specifications for SAE Fasteners l 429 ade B 429 ade 6 429 i 429 ade 6 veas oues doa Size Load Size Load 15 20 15 20 15 20 15 20 1 4 20 2 000 75 100 2850 107 143 1 4 28 2 300 85 115 3250 120 163 5 16 18 3 350 157 210 4700 220 305 TE 5 16 24 3 700 173 230 5200 245
144. stop immediately Upper Control Box Power Up Both Emergency Stops are pulled out upper and lower Lower Control Box key switch in PLATFORM posi tion Platform key switch on LEDs on DMR 30 illuminated BT1 01 platform selected LEDs DMT 30 illuminated BT1 11 amp BT1 12 limit switch BT1 05 tilt Engine Start Operate start switch LEDs on DMT 30 illuminated BT5 11 starter output BT5 08 glow plug output diesel only 4 04 oil pressure LED s on DMR 30 illuminated BT3 03 start input AB62 Work Platform European TROUBLESHOOTING Section 4 2 Boom Lift Function Riser Up Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot switch BT 3 09 riser up LEDs on DMR 30 Illuminated BT5 12 riser up out put BT5 06 throttle output BT6 10 high flow valve output Riser Down Function enabled foot switch depressed LED s on DMT 30 illuminated BT4 03 foot switch BT 4 08 riser down LED s on DMR 30 Illuminated BT6 01 riser down output BT5 06 throttle output BT6 10 high flow valve output Boom Up Function enabled foot switch depressed LEDs on DMT 30 illuminated BT4 03 foot pedal BT4 09 boom up LEDs on DMR 30 illuminated BT5 09 boom up output BT5 06 throttle output BT6 12 low flow valve output Boom Down Function enabled foot switch depressed LEDs illuminated BT4 03 foot pedal BT4 04 boom down LED s on DMR 30
145. t BT5 06 throttle output BT6 12 low flow out put Jib Jib Up Function enabled LEDs on DMR 30 illuminated BT2 10 jib up input BT7 06 jib up output to valve BT6 12 low flow valve output BT5 06 throttle out put Jib Down Function enabled LEDs on DMR 30 illuminated BT2 11 jib down input BT7 07 jib down output to valve BT6 12 low flow valve output BT5 06 throt tle output Cage Rotate Cage Right Function enabled LEDs on DMR 30 illuminated 4 03 cage right input BT7 03 cage right output to valve BT6 12 low flow valve output BT5 06 throttle output 4 4 Cage Left Function enabled LEDs on DMR 30 illuminated BT4 02 cage left input BT7 04 cage left output to valve BT6 12 low flow valve output BT5 06 throt tle output Cage Trim Up Function enabled LEDs on DMR 30 illuminated BT2 12 cage trim up input BT6 05 cage trim up output to valve BT6 12 low flow valve output BT5 07 throttle output Cage Trim Down Function enabled LEDs on DMR 30 illuminated BT4 01 cage trim down input BT6 06 cage trim down output to valve BT6 12 low flow valve output BT5 07 throttle output Auxiliary Power Emergency Functions Both Emergency Stops are pulled out upper and lower Auxiliary Switch enabled Relay 9 activated 12 volts at relay 9 terminals 30 amp 87 NOTE If the auxiliary switch is depressed when the engine is running the engine will
146. t Rear Drive Motor Turret Assembly Left Rear Axle Drive Motor Drive Motor Right Front Drive Motor Right Rear Drive Motor Right Front Axle Right Rear Axle Drive Motor Left Front Drive Motor Left Front Axle Orifice Orifice Limit Turret Rotate Speed Limit Riser down speed Main Valve Block Riser Cylinder Orifice Limit Flow Between Front and Rear Drive Motors Drive Valve Block Pump Boom Pump Low Flow Engine Module Pump Boom Pump High Flow Engine Module Valve Front Drive Valve Drive Valve Block AB62 Work Platform European Section SCHEMATICS 52
147. terbalance Valve Boom Extend Counterbalance Valve Boom Raise Counterbalance Valve Jib Cylinder Counterbalance Valve Master Cylinder Counterbalance Valve Slave Cylinder Counterbalance Valve Cage Rotate Counterbalance Valve Turret Rotate Counterbalance Valve Left Axle Cylinder Counterbalance Valve Right Axle Cylinder High Pressure Test Port Check Valve Low Pressure Test Port Check Valve Boom Extend Cylinder Check Valve Turret Rotate Check Valve High Pressure Check Valve Low Pressure Check Valve Return Filter Check Valve Steer Cylinder Riser Cylinder Boom Extend Cylinder Boom Raise Cylinder Jib Cylinder Master Cylinder Slave Cylinder Turret Rotate Brake Cylinder Wheel Brake Cylinders Left Axle Lock Cylinder Right Axle Lock Cylinder Flow Divider Suction Filter Return Filter Suction Filter Return Filter Suction Filter Left Rear Drive Motor Right Front Drive Motor Right Rear Drive Motor Left Front Drive Motor Swing Motor 4 12 AB62 Work Platform European Section TROUBLESHOOTING 4 4 COMPONENT FUNCTION RISER ELEVATE DESCEND Boom EXTEND RETRACT Boom RAISE LOWER JiB UP DOWN CAGE LEVEL UP DOWN CAGE ROTATE CW CCW DRIVE FORWARD REVERSE FRONT AXLE LOCK BRAKE RELEASE EMERGENCY LOWER gt lt TURRET ROTATE CW CCW Turret Orifice Rise
148. tform Level 3 Gage Port Plug High Pressure 12 Platform Rotate Flow Control Valve 4 4 Way Valve Steering 13 Fitting Straight 5 High Pressure Relief Valve 14 Fitting Straight 6 4 Way Motor Spool Valve Riser 15 Fitting Straight 7 4 Way Valve Boom Extend Retract 16 4 Way Center Valve 3 4 Jib 8 Low Flow Proportional Valve 17 4 Way Motor Spool Valve 3 4 Turret Rotate 9 Low Pressure Relief Valve 18 Gage Port Plug Low Pressure 19 4 Way Motor Spool Valve 3 4 Platform Rotate Figure 3 13 Hydraulic Manifold AB62 Work Platform European 3 11 Section 3 10 3 10 TORQUE HUBS NOTE Change fluid in torque hubs after the first 50 hours of operation Change every 1000 hours thereafter Changing Fluid NOTE It is not necessary to remove torque hub to change fluid 1 Raise the axle using an eight ton hydraulic jack Place eight ton jack stands under each end of the axle 2 Remove wheel and rotate torque hub so drain plug on side is at bottom of hub 3 Remove drain plugs at bottom of hub and front cover and drain oil from unit 4 Rotate hub so plug opening in front cover is slightly above half full position and side plug opening is at the top 5 Fill unit with 90 wt gear oil until oil comes out front plug opening torque hub must be 1 2 full 6 Replace plugs 7 Install wheel and lower machine to the ground Torque Hub Removal 1 Parkthe work platform on firm level ground and bloc
149. the work platform 0 69 bar 0 1000 psi Hydraulic Pressure Gauge with Adapter Fittings 0 207 bar 0 3000 psi Hydraulic Pressure Gauge with Adapter Fittings Small UpRight Connector Field Kit UpRight P N 030899 000 Large UpRight Connector Field Kit UpRight P N 030898 000 Inclinometer UpRight P N 010119 000 Optimizer UpRight P N 100329 000 Optimizer Adapter Cable 100329 005 Quick Disconnect Hydraulic Adapter 063965 002 Figure 3 2 UpRight Connector Kit Large 3 1 Section 32 MAINTENANCE UpRight Connectors Connector Sealing Plug Contacts Contacts Gasket 4 onnector 6 AS gt Receptacle 23 female Locking Wedges Removal lt a Socket Pin Figure 3 3 Plugs and Receptacles UpRight Connectors Deutsch connectors are designed so that connector Releasing Locking Fingers parts contacts or electrical cables may be replaced without replacing the entire connector Male Connector Plug 1 Disconnect the male connector plug from the female connector receptacle 2 Using the flat end of the Removal Tool or flat blade screwdriver pry the Locking Wedge from the Male Connector Care should be taken that the Silicon Gasket is not damaged during this procedure 3 Check all parts for damage Replace parts Figure 3 A Locking Pinger which are damaged or worn 1 Locking Fingers can be released following 4 Replace or recrimp the
150. ty with unleaded motor fuel only 3 Fuel tank full capacity is 159 L 42 US gallons Diesel 1 Open left turret cover then open fill cap See Figure 2 8 2 Fill to capacity with diesel motor fuel only grade 1 D or 2 D Use distillate fuel only do not use residual or blend 3 Fuel tank full capacity is 159 42 US gallons Hydraulic Oil 1 Open turret cover and check oil level at sight gauge with the boom stowed and retracted engine running or stopped See Figure 2 9 2 If necessary fill to capacity with clean ISO 46 compatible hydraulic oil 3 Clean area around cap before opening 4 Open filler oreather cap to add hydraulic oil 5 Replace cap Lubrication Refer to Maintenance Section for lubrication chart and guidelines Figure 2 8 Fuel Tank 2 8 2 6 MACHINE PREPARATION amp OPERATION Battery Maintenance AWARNING A Hazard of explosive gas mixture Keep sparks flame and smoking materials away from batter ies Always wear safety glasses when working with batteries Battery fluid is highly corrosive Rinse away any spilled fluid thoroughly with clean water Check battery fluid level daily especially if the work platform is being used in a warm dry climate If electrolyte level is lower than 10mm 3 8 in above the plates add distilled water only DO NOT use tap water it will shorten battery life Tires Tire selection can affect the stability of the machine Use only tir
151. ve Functions Drive functions are relayed to the drive pump from the joystick control All adjustments are made at the joystick controller Brake release and throttle com mands are relayed from the joystick controller to the DMT 30 on BT3 08 JSA Joystick actuator Drive Forward Function enabled footswitch depressed BT3 02 on DMT 30 jsa joystick actuator BT5 06 on DMR 30 throttle output BT5 04 brake release Drive Reverse Function enabled footswitch depressed BT3 02 on DMT 30 jsa joystick actuator BT5 06 on DMR 30 throttle output BT5 04 brake release Steer Right Function enabled foot switch depressed BT4 05 on DMT 30 steer right BT5 06 on DMR 30 throttle output BT6 10 on DMR 30 high flow valve BT7 02 on DMR 30 steer right output 4 6 TROUBLESHOOTING Steer Left Function enabled foot switch depressed BT4 10 on DMT 30 steer left BT5 06 on DMR 30 throttle output BT6 10 high flow valve BT7 01 on DMR 30 steer left output High Torque Position No signal on DMT 30 or DMR 30 High Speed Position BT3 10 on DMT 30 high speed is illuminated BT5 07 on DMR 30 shift is illuminated Braking Brakes are normally locked when the machine is not in use Brakes are unlocked by a charge pressure 880 PSI from the drive pump A 12 volt signal is sent to the brake solenoid by BT5 04 on DMR 30 Tilt A 12 volt signal is at BT1 05 tilt signal input when the machine is level If the ma
152. what speed to use start out slow the speed can be varied while operating the function 2 While depressing the foot switch push the boom extension control lever rearward to extend the boom forward to retract the boom Release the control lever to stop extending retracting ESA tievating the ting the Ji al eva lt 1 Setthe function speed control dial to the desired setting Rotate the dial clockwise to increase speed counterclockwise to decrease If you are 2 6 not sure what speed to use start out slow the speed can be varied while operating the function 2 While depressing the foot switch push the jib control lever forward to elevate the jib rearward to lower the jib Release the control lever to stop elevating lowering gt Rotating the Platform 1 While depressing the foot switch push the plat form rotation control lever right to go counter clockwise and left to go clockwise Release the lever to stop rotation Emergency Operation In the event of powered function failure the elevating assembly may be operated by using the Emergency Power Unit Hold in the Emergency Power button and operate the Lowering Controls as normal AWARNING NEVER climb down the elevating assembly If controls do not respond ask someone on the ground to lower the boom manually Emergency Towing Perform the following only when the machine will not operate under its own power and it is necessary to
153. y Manifold 3 Remove Rotary Manifold from the machine NOTE Provide a clean work area for this opera tion and observe clean assembly practices Seals and O rings are highly sensitive to con tamination that may not be visible to the naked eye Disassembly 1 Remove Retaining Rings from each end of Rotary Manifold 2 Carefully slide body out of housing 3 Remove seal kit components O rings seals and retaining rings 4 Thoroughly clean all parts with solvent Rinse the inside of the tube and allow to drain A high pres sure rinse and wipe with a lint free rag is prefera ble 5 Inspect the body and housing for scratches pits or polishing Check seal grooves and sealing sur faces Scratches or pits deep enough to catch the fingernail are unacceptable replace the manifold AB62 Work Platform European Assembly NOTE Torque all hardware and fittings to torques listed on pages 3 22 and 3 23 unless otherwise specified Lubricate all seals with clean hydraulic oil prior to assembly 2 Install new seals on body and housing 3 Carefully slide body into housing 4 Reinstall O rings and retaining rings Installation 1 Installation is reverse of removal 2 Replenish hydraulic fluid in tank 3 Run hydraulic system for several minutes to remove air from hydraulic lines Cycle cylinders for each boom function 4 Rotate turret completely 5 Check Rotary Manifold for leaks Check that all boom function
154. ystem 10 15 minutes to warm the oil 2 Install a 0 3000 PSI pressure gauge to the pres sure test port 43 using Part 063965 002 Quick Disconnect Adapter 3 Retract boom completely 4 While activating the boom retract function set the pressure to 186 bar 2700 PSI maximum by slowly turning the adjusting screw Turning the adjusting screw clockwise increases pressure counterclockwise decreases pressure 5 Remove the pressure gauge and reinstall all plugs Low Flow Relief Valve 9 1 Operate the hydraulic system 10 15 minutes to warm the oil 2 Install a 0 207 bar 0 3000 psi pressure gauge to the pressure test port Completely extend jib function 4 Continue activating function and set the pressure to 97 bar 1400 psi by slowly turning the adjust ment screw Turning the adjusting screw clock wise increases pressure counterclockwise decreases pressure 5 Remove the pressure gauge and reinstall all plugs Counterbalance Relief Valves 1 counterbalance relief valve is faulty com pletely lower the jib and retract the boom 2 Replace or recalibrate the counterbalance valve 3 Slowly cycle function related to replaced counter balance valve several times to remove air from the system 3 10 AB62 Work Platform European Section MAINTENANCE 3 9 1 Diverter Valve 10 4 Way Center Valve 3 4 Boom Raise 2 High Flow Proportional Valve 11 4 Way Motor Spool Valve 3 4 Pla

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