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1532ES / 1932ES

1. 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 7 THIS PAGE INTENTIONALLY LEFT BLANK October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 5 8 ELECTRIC SCHEMATICS NOTES Unless otherwise specified 1 Switch S1 BASE PLATFORM makes contact from the CENTER to the LEFT position when placed in BASE 2 Switch S2 UP DOWN makes contact from the CENTER to the LEFT position when the switch is held in the CONTACT position and automatically returns to the CENTER position when released 3 Switch LS1 opens the N C set of contacts and closes the N O set of contacts when the platform reaches approximately 7 feet 4 Switch LS2 closes the N C set of contacts when the Pothole Bars are down and locked in place ILLUSTRATION No ART_2236 ART_2243 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 9 1532ES S N 9000500 9001099 1932ES S N 9104000 9104999 Tilt Light 28V Warn when Machine is Tilted Upper Control Box Level Sensor Activates Tilt Light In Lower Control Box Push Button Switch Activat
2. MOTION ALARM CYLINDER MANIFOLD SV9 DOWN 5 _ 6 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 13 Canadian Models 1532ES S N 9002000 Current 1932ES S N 9105000 Current Tilt Light 28V Warn when Machine is Tilted Upper Control Box Level Sensor Activates Tilt Light Inside Lower Control Box Push Button Switch Activates Horn Upper Control Box Horn 12V 48V option Activated by Operator Under Platform Overload Motion Alarm option Warn of Movement Outside Lower Control Box Motion Light option Warn of Movement Front Left Corner of Machine Hour Meter Record Machine Usage Time Lower Control Panel Battery Indicator Show Battery Status Lower Control Panel 6 V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment Battery Disconnect Switch Disconnect All Electrical Power Lower Control Box Circuit Breaker 15AMP Manual Control Circuit Protection Lower Control Panel Battery Charger Recharges 24 VDC Battery Pack Machine Base Rear Charger Relay Disconnect Electric when Charger ON Inside Charger 24 V Contactor Connects Battery to Motor Inside Lower Control Box Circuit Board Diodes Directs Si
3. Revision History March 2008 Reason for update Service Section 5 Update Electrical Schematic October 2008 Pages Reason for update Service Section 5 5 1 Update contents 5 14 15 Add Canadian electric schematic 5 16 20 Update page numbers Parts Table of Contents Update to include new pages in Section C Section 1 Update contents A 17 Update parts list Wire Harness Communication Cable Early Model A 19 Update parts list Wire Harness Communication Cable Current Model A 20 New illustration Cutout Relays Canadian A 21 New parts list Cutout Relays Canadian Section C C 1 20 Update illustrations Scissor Assembly all models Update parts list Scissor Assembly all models Update illustration Lift Cylinder installation Update parts list Lift Cylinder without Emergency Lowering Cable Update page numbers Section D D 15 Update parts list Hydraulic Hoses X32ES early models D 16 Update illustration Hydraulic Hoses X32ES late models D 17 Update parts list Hydraulic Hoses X32ES late models Section E E 3 Update parts list Ladder and Control Brackets E 9 Update parts list Brake Assembly E 10 Update Illustration Steering Assembly E 11 Update parts list Steering Assembly Aerial Platform Sales Corp 1775 Park Street Suite 77 Selma 93662 USA Ph 1 800 387 4575 559 891 2488 Fax 559 891 2448 E mail info Web www mecawp com Tabl
4. 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 8 Update October 2008 Page C 13 lt E SS i Sz ILLUSTRATIONNo 1532 Serial 9001000 9001008 _2266 1932 Serial 9100000 x 91 04470 25237 Hyd raulic Cylinder October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page C 14 Lirr CYLINDER 25237 1 7 1 CYLINDER LIFT 3 8 1 FITTING PIPE ADAPTOR SCREW CAP SOCKET HD 1 4 20 X 1 50 GRADE 8 5 13551 1 MANIFOLD LIFT CYLINDER STANDARD 7 4 1 COIL 24 VOLT DOUBLE SPADE W DIODE SCREW CAP HD 5 16 18 X 50 GRADE 2 13728 1 BRACKET CYLINDER VALVE GUARD WELDMENT KIT SEAL LIFT CYLINDER SERVICE 11 6 O RING MANIFOLD BLOCK 13 6984 4 BEARING DU 1 3 8 ID X 1 5 8 LG 15 90439 1 ORIFICE 0 047 1932ES 90889 1 ORIFICE 0 055 1532ES m t HARNESS WIRE DOWN VALVE SEE PARTS SECTION E 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page C 15 ILLUSTRATION No ART_2267 October 2008 Page C 16 1532 Serial 9001009 9001031 1932 Serial 9104471 9105000 90801 Hydraulic Clyinder 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION 153256 SERIAL 9001009 TO 9001031 REF HOSE ASSEMBLY LIFT CYLINDER SEE SECT
5. 5 1532ES 1932ES Scissors 1 90717 1 DECAL MAINTENANCE LOCK 2 9910 3 DECAL PINCH POINT 3 7982 2 DECAL SAFETY STRIPE 4 8503 1 DECAL KEEP CLEAR 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page F 7 Inside Manual Case OPTION CERTIFIED LANYARD ANCHORAGE POINT 8805 4X 10 5 Nc 9137 1532ES _ Y DISTRIBUTED INSIDE PLATFORM AREA 90718 90722 2 90721 0 PLATFORM EXTENSION MUST BE LOCKED IN PLACE AT ALL TIMES SHEET LOADING GATE MUST BE IN LOWERED LOCKED POSITION BEFORE OPERATING FROM PLATFORM 90736 1932E PLATFORM ENTRANCE MUST BE PROPERLY CLOSED AND ALL GUARDRAILS PROPERLY IN PLACE AND SECURED BEFORE OPERATING FROM PLATFORM ET 500 LBS 227 kg 113 kg 113 kg ve 27 SIDE LOAD 100 LBS 444 N 2 1 PERSON 1 PERSON 7155 LOCATE CONTROL BOX HERE FOR NORMAL OPERATION OF TH
6. Emergency Lowering Early Models The Emergency Down System is used to lower the platform in case of power or valve failure To lower the platform perform the following steps AC 6 PULL AND TURN KNOB 1 Pull and turn knurled knob on lift cylinder SS TO LOCK VALVE OPEN counterclockwise to lock the valve in open position 2 Pull manual activator override valve on main manifold to lower platform to desired height 4 ILLUSTRATION No 3 To return to normal operation turn knurled ART_2248 knob on lift cylinder clockwise Valve will automatically lock Emergency Lowering Current models Emergency Down system is used to lower the platform in case of power or valve failure To lower the platform pull the red T handle located at the rear of the machine Lowering stops when you release the handle ILLUSTRATION No ART_2163 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 7 STEERING CIRCUIT Note Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure Refer to Section 3 for Remove and Replace instructions Refer to Parts Section E for hose routing The steering system consists of the following components The wheel motor housings have pivots on the top and bottom and are mechanically linked together via a tie rod Steering is accomplished hydraulically by using one 1 double acting cylinder
7. With the switch flipped there should be a low resistance reading Check Emergency Stop Button Disconnect wires and connect one probe of ohm meter to connection on button and other probe on other connection There should be no reading with the button pressed and a low resistance with it reset Check Limit Switch Operation Disconnect wires With one probe of ohm meter to common and other probe to open contact move limit switch arm Low resistance should be seen With one probe of ohm meter to common and other probe to closed contact low resis tance should be seen Move limit switch arm and zero to very low resistance should be seen October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 12 DIODE BOARD The diode board is located inside the lower control box SIGNAL INPUT J1 Plug Pin Identification FUNCTION Drive Reverse INPUT Drive Forward OUTPUT Brake Decel Valve signal INPUT Steer Left OUTPUT Steer signal to Sevcon INPUT Down signal OUTPUT Signal to Motion Alarm s optional OUTPUT Sevcon amp Hour Meter motor function requested INPUT Battery Negative INPUT Steer Right INPUT Lift Up 8601 INPUT Limit Switch 24V platform down OUTPUT Enable from lower Lift switch ILLUSTRATION No ART_2181 1532ES 1932ES Servi
8. October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 1 10 Preparation 2 3 Take care not to damage rod surface and guard against dirt or other foreign objects entering system Drain all fluid from cylinder Clean all dirt and grit from outside of cylinder Insert cylinder into vise Cylinder Disassembly T 2 10 Remove the head from the cylinder body Remove the shaft assembly from the barrel pulling in a straight line so as not to scar the internal parts Insert shaft into a soft jawed vise so that the head and piston can be removed Be sure the shaft and vise are both clean before using Remove nut at the end of the shaft and pull head and piston off of the rod Remove all seals from the head and piston using a non sharp seal tool These tools are available from various seal suppliers Clean all fluid and debris off of the head piston shaft collar and barrel using solvent rags and an air hose Inspect parts for scratches pits or polishing Check seal groves and sealing surfaces a Scratches or pits deep enough to catch the fingernail are unacceptable replace the cylinder b Polishing is a sign of uneven loading Check for roundness If a polished surface is not round within 007 in 0 18 mm replace the cylinder 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 11 Cylinder Assembly
9. amp 5 9 EMERGENCY stop ES2 OPTIONAL S 1 151 SLOW SPEED 06 HORN OPTION 2 22 P1 2 E 6 1 5 P6 2 5 6 3 _ 20 6 4 P6 5 6 6 7 em P6 7 _ 20 J 1 P6 8 CIRCUIT BOARD 456 9 P6 10 gt gt 407 DS P611 17A 015 4 P6 12 17 R2 D13 4 09 0 6 0 14 2 12A P5 6 08 101 MS 01 02 12 4 3 15 4 1 BLK LEVEL 9 m pio RED SENSOR PLATFORM I 1 OFF LS2 BASE 03 olo P5 37 22 1 EMERGENCY evap ESA 4 D174 16 17 HOUR 103 i MOTION METER CHRL1 12 2 P3 6 5 12 lt lt 104 2 P3 5 P5 11 CHARGER INTERLOCK CYLINDER MANIFOLD BATTERY GAUGE 104 CIRCUIT BREAKER n 200 AMP 05 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008
10. HYDRAULIC Reservoir PLASTIC 1 9 1 HYDRAULIC RESERVOIR PLASTIC FITTING ELBOW 90 MALE 1 4 MALE BARB 1 4 REF HOSE RETURN LINE RETURN HOSE HDW6510 1 FITTING ELBOW 90 MALE 1 2 SAE MALE 1 2 NPT 1 SUCTION STRAINER 6156 FILTER OIL CARTRIDGE FITTING ELBOW 90 MALE 3 8 MALE 1 2 HDW6752 ADAPTER MALE 3 4 FML 1 2 FILTER HEAD 90215 FITTING ELBOW 90 FML 3 4 MALE 3 4 7788 PIPE NIPPLE 3 4 x 2 ILLER BREATHER 19714 HDW6455 HDW6455 9 4 5 6 9 0 1 3 6 7 8 9 0 1 5 6 N CD z 12 14 1 F 1 CLAMP HOSE x 2 SCREW 1 4 20 1 2 66 2 SCREW 22 16125 BRACKET TOP RESERVOIR 24 16344 BRACKET REAR RESERVOIR 2 NN WASHER NO LONGER USED 2 NUT NO LONGER USED 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page D 13 LIFT CYLINDER NOTE This drawing identifies hydraulic hoses and the component that they connect to and NOT the actual hose positions on the machine FRONT LEFT STEER CYLINDER DRIVE o MANUAL BRAKE RELEASE HAND PUMP only used up to 1532ES serial 9001099 1932ES serial 9104999 ILLUSTRATION No ART_2238 October 2008 Page D 14 Hydraulic Hoses X32ES 1532155 1932195 Service amp Parts Manual ANSI Specifications HYDRAULICc Hoses EARLY MopELs 11532ES SERIAL TO 9001099 1932 5 SERIAL T
11. K p H lt gt di q gt 1 u A i i di lt Lift Drive Selector Switch p 1 CS Emergency Stop Switch Torque Switch ORS Tilt Warning Light NY Horn Button option Steering Micro Switches Drive Enable Switch Reverse Down Rocker Switch Forward Up Rocker Switch Potentiometer ILLUSTRATION No Terminal Strip _2234 1532ES 1932ES Service amp Parts Manual ANSI Specifications J1 Plug Pin Identification PIN WIRE SIGNAL FUNCTION INPUT Drive Reverse INPUT Drive Forward OUTPUT Brake Decel Valve signal INPUT Steer Left OUTPUT Steer signal to Sevcon INPUT Down signal OUTPUT Signal to Motion Alarm s optional OUTPUT Sevcon amp Hour Meter motor function requested INPUT Battery Negative INPUT Steer Right INPUT Lift Up MEC 860 INPUT Limit Switch 24V platform down OUTPUT Enable from lower Lift switch m No OUTPUT To Sevcon for speed cutback ART 2181 2 Contactor 3 Tilt Sensor 4 Circuit Diode Board 5 MotorControl Unit 6 Main Harness Connection 7 Control Cable Connection 8 Motion Alarm option 9 Lift Lower Switch 10 Platform Base Selector 11 Emergency Stop Switch 13 Battery Gauge 14 Hour Meter
12. 18 SCREW 5 16 18 1 LG 25555 B HDW5006 LOCKWASHER 5 16 NN RKT ELECTRIC MOTOR MOUNT SCREW 5 16 18 3 4 LG 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page E 13 5 5 M 53259 S N 9001041 UP M 11 ILLUSTRATION No ART_2315 October 2008 Page E 14 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION POTHOLE ASSEMBLY HDW5920 4 PIN COTTER 1 8 X 1 3 HDW5039 7 LOCKNUT 3 8 16 BEARING OIL IMPREGNATED 3 4 X 3 4 FLANGED 5 8602 3 SPACER STEPPED PVC 7 4541 1 ROLLER 9 HDW13556 3 WASHER FLAT 3 8 ID 1 1 2 OD 1 8 THICK PLASTIC 3 WASHER FLAT 3 8 ID 1 1 2 OD 1 8 THICK STEEL 11 HDW8279 3 SCREW 3 8 16 2 1 2 LG GRADE 5 PLATE POTHOLE ACTUATOR 13 25151 2 POTHOLE BAR WELDMENT 15 7202 8 BEARING 5 8 ID X 7 16 LG FLANGED 12 WASHER FLAT 18 9027 4 SPRING TENSION 1 OD X 5 LG RETRACTION STABILIZER PIVOT BAR 20 HDW5724 2 SCREW 5 16 18 3 4 LG GRADE 5 WASHER FLAT 1 2 ID 7 8 OD 1 16 THICK RING RETENTION 1 2 SHAFT 23 11181 4 SPACER SCREW 1 4 20 1 LG 25 HDW5470 1 WASHER FLAT 1 1 2 OD 9 32 ID X 1 8 WEAR BLOCK POTHOLE ACTUATOR 27 HDW5217 1 WASHER FLAT 11 16 OD 11 32 ID X 1 16 153
13. DESCRIPTION Counterbalance Valve Main manifold MA 1 Steering Cylinder Machine Base Front Lift Cylinder Scissor Assembly Flow Divider Main manifold MA 1 Steering Relief Flow Control Main manifold MA 1 Hand Pump Brakes Brake Release Manifold MA 2 Main Manifold Assembly Machine Base Battery Compartment Manifold Assembly Lift Cylinder Manifold Valve Main manifold MA 1 Needle Valve Orifice Plug Wheel Motors Main manifold 1 Orifice Disc Brake Release Main manifold MA 1 Main manifold MA 1 Orifice Down Valve Lift Cylinder Manifold MA 3 Pump Pump Compartment Relief Valve Lift Relief Main manifold 1 Relief Valve Main Relief Main manifold MA 1 Spool Valve Steering Main manifold MA 1 Spool Valve Lift Main manifold MA 1 Spool Valve Drive Spool Valve Brake Decel Main manifold MA 1 Spool Valve Torque Main manifold MA 1 Spool Valve Torque Main manifold MA 1 Main manifold MA 1 Spool Valve Down Lift Cylinder Manifold MA 2 Wheel Brake Drive Wheel Wheel Brake Drive Wheel Wheel Motor Right Side Machine Base October 2008 Page 5 4 Wheel Motor Left Side 1532ES 1932ES Service amp Parts Manual ANSI Specifications Machine Base HYDRAULIC SCHEMATIC Model S
14. E 932ES ILLUSTRATION No 1532ES Serial 9001048 UP ART_2393 1932ES Serial 9105459 UP 91 055 Hyd raulic Clyinder October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page C 20 ITEM NO DESCRIPTION CYLINDER 91055 WITH EMERGENCY LowERING CABLE 1532 5 SERIAL 9001048 UP 1 HOSE ASSEMBLY LIFT CYLINDER SEE SECTION D 4 90439 ORIFICE 0 047 193288 12B 6984 BEARING DU 1 3 8 ID X 1 5 8 LG 91051 KIT SEAL LIFT CYLINDER SERVICE 91082 1 CABLE 100 IN BOLT VALVE 2 WAY N C CABLE ATTACH 91001 COIL 24 VOLT HDW8879 FITTING PIPE 90 MALE BARB 7078 REF HOSE RETURN LINE SEE SECTION D 7788 CLAMP HOSE HARNESS WIRE DOWN VALVE SEE PARTS SECTION A 91104 CABLE 80 IN SPRING 16062 BRACKET LIFT CYLINDER VALVE GUARD 8152 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page C 21 12 2A October 2008 Page C 22 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION D HYDRAULICS BRAKE RELEASE MANIFOLD MODEL pp D 3 MAIN MANIFOLD ASSEMBLY EARLY MODEL Nt D 5 MAIN MANIFOLD ASSEMBLY LATE MODELS pp D 9 HYDRAULIC RESERVOIR STEEL D 11 HYDRAULIC RESERVOIR PLASTIC D 13 HOSES EARLY ______ __ 0 15 HYDRAULIC Hoses LATE MODELS Nt D 17 1532ES 1932ES Service amp Parts Manual ANSI Sp
15. Publication Art 4 _2206 1 RIGHT 4 ia MODE SELECT SWITCH DRIVE NS 53 1 2 0 5 Ow 5 REV LIFT FWD DOWN 7 8 53 8 3 sal EMERGENCY STOP TORQUE 59 POTI ON OFF OPTIONAL QUICK DISCONNECT LS1 SLOW SPEED 2 olo 22 4 HORN OPTION P3 3 P6 1 gt P6 2 P6 3 P6 4 6 4 O 01 7 5 6 9 PLATFORM 1 OFF 03 EMERGENCY CIRCUIT BOARD D7 D14 D9 105 P6 5 P6 6 gt gt P6 7 P6 8 gt P6 9 P6 10 5 P6 11 17A ipt D10 1 1 STOP 6 12 17 14 1 12 14 2 12 4 3 WHT P4 1 LEVEL P4 2 RED SENSOR 17 LS2 ale HOUR 4 103 METER CHRL 1 1044 12 2 P3 6 P5 12 lt 7914 CHARGER INTERLOCK P12 1 P3 5 P5 11 200 AMP 05
16. 1932ES Service amp Parts Manual ANSI Specifications Page 4 6 Troubleshooting continued PROBLEM POSSIBLE CAUSE No lift from either control station Pump motor runs Lift Valve SV2 not energized Main system pressure inadequate No lift from either control station Pump motor NOT operating while attempting lift Micro switch S7 inoperative Mode Selector Switch S6 faulty Damaged wiring or poor plug connection Failed diode in diode board Maintenance lock in maintenance position Platform will not lower Lowering valve s not energized SV9 SV8 Lowering valve s not shifting Lowering orifice ORF3 plugged Emergency lowering not working E down cable freyed later models only Lowering valve not shifting 1532ES 1932ES Service amp Parts Manual ANSI Specifications REMEDY SOLUTION Check lift circuit on wire 4 from control box to lift valve SV2 Checkmain relief RV2 adjustmnt Check pump output pressure using a flow meter Check operation of micro switch located in upper control box on joystick Check power through S6 on wire 10 Check wire 10 through plug connections from upper control box to Diode Board Test diodes on diode board replace diode board Elevate platform slightly and return maintenance lock to the stowed position Check lowering circuit wire 5 from control box to lowering valve located on lift cylinder On earlier units check valve SV8 also Clea
17. 4 NUT 1 4 20 SCREW 1 4 20 X 1 2 10 HDW90879 SCREW 6 32 X 1 1 4 2 12 HDW90803 4 LOCKNUT 10 32 14 8698 1 ALARM MOTION OPTION 17 HDW8364 12 NUT 6 32 2 LOCKNUT 1 4 20 19 CLAMP 10 SCREW 6 32 X 3 4 LG 1 CIRCUIT BOARD 1 CONTACTOR 24 V 24 8344 1 FUSE 200A 1 FUSE HOLDER 2 1 2 25 8345 26 9 SCREW 1 4 20 1 LG 90991 H MOTOR CONTROLLER 28 HDW90288 SCREW 1 4 20 3 LG 29 90217 1 TILT SENSOR 30 90749 2 RECEPTACLE 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 13 23 5967 20 HDW90833 21 8601 S x Y W Pump Motor Pump Motor ILLUSTRATION No Harnesses and Cables Lower Control Box ART_2237 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 14 ITEM NO DESCRIPTION 1 90962 1 BATTERY CABLE BLACK 3 8836 1 BATTERY CABLE RED 5 8837 1 BATTERY CABLE RED 7 6208 3 BATTERY CABLE BLACK 9441 45 WIRE 14 GA CE COLORS TERMINAL PUSH ON 1 4 MALE FI 22 18 NS 9356 2 CLAMP NYLON 1532ES SERIAL 9001000 9001010 1932ES SERIAL 9104001 9104541 HARNESS INSTRUMENT 1532ES SERIAL 9001011 UP 10 90800 1 HARNESS INSTRUMENT 90896 JUMPER WIRE ANSI 1932ES SERIAL 9104542
18. Circuit breaker tripped Check for short circuits and Reset Located in lower control box panel Damaged upper control box Inspect from harness plug to terminal strip under harness platform Batteries discharged Look for a 7 or 9 flash code while attempting function Check battery voltage under load Check for motor controller flash See Sevcon Motor Speed Controller in this section codes for troubleshooting flash codes Functions from Upper Emergency Stop switch Pull upper emergency stop switch lower controls pushed in but not from upper controls Interlock switch joystick check power to red wire power to switch and power to purple wire power out of switch at joystick plug Damaged harnesses Check scissor and upper box harness for damage Partial or Low battery voltage at 18 volts Lift will stop a 9 flash code will be displayed on the intermittent lift operating motor controller while attempting to lift from either control station Platform overloaded Check platform load and compare with posted Maximum Weight labels reduce load Lift relief valve RV1 out of Adjust relief valve to rated capacity adjustment Lowering valve SV9 pulled out Inspect lowering valve located on lift cylinder or emergency down cable if Check cable adjustment operation if equipped equipped sticking 6 flash code at motor controller Test potentiometer POT1 for open circuit Located in upper control box replace October 2008 1532ES
19. DECK AND RAILS 5 0 RARA DINS 7 27912412 49 WING GATE OPTION e NR 11 E DECK LOCK MN UR B 13 RorrouT DECK ROLLER IN TT B 15 8 B 17 OPERATOR HORN ANSI OPTION pp B 17 AIRLINE TO PLATFORM OPTION pp B 17 POWER TO B 19 SECTION C SCISSORS Scissor ASSEMBLY 1532ES SERIAL UP 9001099 C 3 Scissor ASSEMBLY 1532ES SERIAL 9001100 UP C 5 Scissor ASSEMBLY 1932ES SERIAL UP 9105899 C 7 Scissor ASSEMBLY 1932 5 SERIAL 9105900 UP pp C 9 SCISSOR ASSEMBLY MOUNT C 11 LIFT CYLINDER MOUNT C 13 LIFT CYLINDER 15 CYLINDER 90801 WITHOUT EMERGENCY LOWERING CABLE 17 CYLINDER 90801 WITH EMERGENCY LOWERING CABLE C 19 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Parts Section Table of Contents SECTION D HYDRAULICS LIFT CYLINDER 91055 WITH EMERGENCY LOWERING CABLE BRAKE RELEASE MANIFOLD EARLY MODEL Main MANIFOLD ASSEMBLY EARLY MOpEL Main MANIFOLD ASSEMBLY LATE MODELS HYDRAULIC RESERVOIR STEEL HYDRAULIC RESE
20. Drive Speed Platform Elevated Forward Drive Speed Platform Lowered 3 in 7 62 m 3 in 7 62 m 2 725 105 1236 kg 3 060 Ibs 1388 kg 0 0 5 mph 0 2 5 mph 0 0 8 km h 0 4 02 km h 0 0 5 mph 0 2 5 mph 0 0 8 km h 0 4 02 km h Lift Lower Speed Approx 17 sec 20 sec 17 sec 20 sec 17 sec 20 sec 17 sec 20 sec Gradeability 25 14 25 14 25 14 25 14 Ground Pressure Wheel Maximum 105 psi 7 4kg cm2 113 psi 7 9 kg cm Wind Speed Maximum Tire Size Standard Solid non marking rubber 25 m p h 14 in dia x 4 5 in 40 km h 35 56 cm x 11 43 cm 25 m p h 14 in dia x 4 5 in 40 km h 35 56 cm x 11 43 cm Wheel Lug Nut Torque 75 85 ft Ibs 102 115 Nm 75 85 ft Ibs 102 115 Nm Hydraulic Pressure Main System Lift System Steer 2750 psi 1900 psi 850 psi 190 bar 131 bar 59 bar 2750 psi 2600 psi 850 psi 190 bar 180 bar 59 bar Hydraulic Fluid Capacity 3 gal 11 36 liters 3 gal 11 36 liters Power System Voltage 24 Volts DC 24 Volts DC 24 Volts DC 24 Volts DC Battery Charger Input Output 100 220 Volt AC 50 60 Hz 5 6 Amp 24 Volt DC 25 Amps Tapering Timed Shutoff 220 Amp hours Q 20 hour rating 2 0 h p 1 49 kW 3000 r p m 4 0 h p 2 98 kW 3000 r p m 100 220 Volt AC 50 60 Hz 5 6 Amp 24 Volt DC 25 Amps Tapering Timed Shutoff 2
21. EARLY MODELS pp A 17 WIRE HARNESSES UPPER CONTROLS EARLY MODELS pp A 17 WIRE HARNESSES OTHER EARLY MODELS Ne A 17 WIRE HARNESSES COMMUNICATION CABLE CURRENT MODELS A 19 WIRE HARNESSES UPPER CONTROLS CURRENT MODELS pp A 19 WIRE HARNESSES OTHER CURRENT MODELS pp A 19 Curour RELAYS CANADIAN MODELS Ne A 21 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 1 LIFT DRIVE 32 31 10 3 5 8 1142 S TORQUE E 4 p NS A b G OVERLOAD TILT 15 12 END VIEW OF REMOVABLE CONTROL HARNESS TERMINAL BLOCK ON UNDERSIDE OF PLATFORM DECK ILLUSTRATION No ART_2218 Upper Control Box Removable ES Machines October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page A 2 ITEM NO DESCRIPTION tere _ _ S 8638 1 SWITCH TOGGLE 2 POSITION 4 POLE 9345 BLOCK CONTACT N C THUMBSCREW 5 16 18 FLOWER HDW8294 WASHER FLAT BE 1 PN 6350 5 TAPE FOAM 13865 1 BRACKET CONTROL BOX HOLDER 10 HDW7120 1 NUT 5 16 18 SWITCH TOGGLE TORQUE 13 9179 1 SOCKET LIGHT 918
22. HH TERMINAL PUSH ON 3 16 8753 1 MOTION SWITCH ON xs SERVICE Bu SWITCH SERVICE ONLY 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 9 ILLUSTRATION No ART_2222 October 2008 Page 10 Reference ART_925 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION s 1 1313 1 SWITCH GUARD 3 9549 1 TUMBLER KEY SWITCH I NH EN 8082 4 BLOCK N O CONTACT B NEHE C RN 9345 BLOCK CONTACT N C ABB ee 7099 BATTERY GAUGE 24 VOLT OPTIONAL PLUG IF BATTERY GAUGE 1 PRESENT wen 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 11 Base Controls ES Machines ILLUSTRATION No ART_2223 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 12 1 153256 SERIAL 9001000 9001010 NN 1 15111 1 WELDMENT CONTROL BOX 1 CONTROL BOX MOUNT 1532ES SERIAL 9001011 UP BN gt gt gt 1 16609 1 WELDMENT BASE CONTROL BOX 3 16053 1 CONTROL PANEL 5 5863 1 GROMMET HDW5276
23. ILLUSTRATION No 15 Battery Cutoff Switch 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 13 SEVCON MOTOR SPEED CONTROLLER The Sevcon Motor Speed Controller MC 1 is a microprocessor designed with the express purpose of operating the D C electric motor at varying speeds The controller uses Pulse Width Modulation PWM technology on the Ground side of the motor to control motor speed Out of concern for operator safety and to prevent short circuiting the Controller monitors certain circuits for potential abnormalities When the controller senses a problem it errs to the side of safety and stops all motor operation The green LED will flash a code indicating the reason for the shutdown Refer to the LED Diagnostics Definitions and Sevcon Motor Speed Controller Connections on the following pages Cable Connection Identification Battery Positive Cable from 250 AMP Fuse Negative Battery Cable and GROUND wire 15 connection Motor Ground Pulse Width Modulated PWM variable speed control J5 Plug Pin Identification FUNCTION 22 B power input power up 17 Lift Drive or Steer functions input functions requiring motor Steer Requested adds additional motor speed for steer Enable Switch signal input Speed cut back 24 Volts full speed 0 Volts creep speed Motor Start Relay signal GROUND signal to activate Motor Start Relay Lift Valve B provides GR
24. Parts Manual ANSI Specifications October 2008 Page E 19 ILLUSTRATION No Battery Installation 1532ES 1932ES 1532ES 1932ES Service amp Parts Manual ANSI Specifications ART_2319 October 2008 Page E 20 ITEM NO DESCRIPTION BATTERY INSTALLATION 5970 BATTERY 6 VOLT CABLE BLACK SEE HARNESSES PARTS SEC 1 REF 1 CABLE BLACK HARNESSES PARTS SEC 1 CABLE RED SEE HARNESSES PARTS SEC 1 1 9243 BOOT TERMINAL INSULATOR BLACK NOT SHOWN 4 7172 BOOT TERMINAL INSULATOR RED NOT SHOWN 4 7173 HOLD DOWN BATTERY 2 16039 5 ROD HOLD DOWN 2 13263 6 HDW6110 NUT WING 1 4 20 n HDW5355 WASHER FLAT 7 16 HDW90825 1 SCREW 7 6 14 X 1 LG 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page E 21 226 5 N 4 n lt INS 7 S Limit Switches Installation 153255 6 ifications 1532ES 1932ES Service amp Parts Manual ANSI Spec October 2008 Page E 22 Limit X32 SERIES 90531 SWITCH LIMIT H NHE HDW5723 2 SCREW TE n 3 4 LG ae HDW8482 2 SCREW 8 32 1 1 2 LG HDW5251 NUT 8 32 SET SCREW vons oasen k gt 25269 1 CAM LI
25. UP 10 90810 1 HARNESS INSTRUMENT 90896 JUMPER WIRE ANSI 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 15 TERMINAL BLOCK ON UNDERSIDE OF PLATFORM DECK ILLUSTRATION No ART 2394 Control Cable and Manifold Harness October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page A 16 Wire Harnesses COMMUNICATION CABLE EARLY MODELS 1532ES SERIAL 9001000 TO 9001010 E 1932ES SERIAL 9104000 TO 9104541 1 9 1 COMMUNICATION CABLE 1532ES 1 8 1 COMMUNICATION CABLE 1932ES BEEN Wire Harnesses UPPER ControLs EARLY MopELs 1532ES SERIAL 9001000 TO 9001099 1932ES SERIAL 9104000 TO 9105000 90817 CONTROLLER CABLE FIXED 3 7656 1 CONTROLLER CABLE REMOVABLE OPTION 6318 PIN REPAIR KIT FOR CABLE SEE PAGE A 2 90100 E CONTROL BOX HARNESS USED WITH REMOVABLE CABLE Wire Harnesses OTHER EARLY MODELS 1532ES SERIAL 9001000 TO 9001099 1932ES SERIAL 9104000 TO 9105000 i BASE MANIFOLD HARNESS NS 9054 1 LIFT CYLINDER HARNESS DOWN VALVE NOT SHOWN NS 5 1 SAFETY SWITCH HARNESS SHOWN HORN OPTION SEE SECTION 8 POWER CONVERTER OPTION SEE SECTION E OPTIONS 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 17 TERMINAL BLOCK ON UNDERSIDE OF PLAT
26. 15 90378 1 VALVE NEEDLE TOW VALVE 16 8373 1 VALVE SPOOL 4 WAY 17 9985 1 VALVE SPOOL N O 18 9998 1 ORIFICE 0 040 DIA 19 5 1 VALVE MANUAL BRAKE RELEASE 20 0 1 VALVE CHECK 25575 HOSE KIT SEE HYDRAULIC HOSES THIS SECTION BENE CONTINUED ON NEXT PAGE 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page D 5 CHECK VALVE FLOW CONTROL FLOW DIVIDER PEuEF 588 COUNTER 80 1532ES Serial Up To 9001099 29 1932ES Serial Up To 9104999 m 9999 Hydraulic Manifold Assembly X32ES ART 2286 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page D 6 Main MANIFOLD AssEMBLY EARLY MopELs CONTINUED gt eem m FITTING 90 ELBW MALE 3 8 MALE 1 2 O RING 22 HDW7389 2 ADAPTER MALE 3 8 MALE 3 8 O RING FITTING 90 ELBW MALE 3 8 MALE 3 8 O RING 24 HDW7601 1 FITTING 90 ELBW MALE 3 8 MALE 3 8 O RING 2 FITTING 90 ELBW MALE 3 8 FML 3 8 MALE 3 8 26 0 1 FITTING 90 ELBW MALE 3 8 O RING FML 1 4 NPT UNION MALE 1 4 NPT MALE 1 4 NPT 3 LG 28 HDW7971 1 DISCONNECT MALE 1 4 30 7 2 WASHER LOCK 32 90327 1 FITTING 90 ELBW MALE 1 4 MALE 3 8 O RING PLUG METERING 34 HDW90285 1 FITTING MALE 3 8 TEE FITTING 90 ELBW MALE 1 4 MALE 3 8 O RING 36 HDW9200 1 FITTING MALE PLUG 1 4 NPT FLOW DIV
27. 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page B 9 ILLUSTRATION No ART_2253 October 2008 Page B 10 Reference ART_ 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION ee 1 25605 1 SWING GATE WELDMENT 3 40006 1 ROD LATCH LEVER 5 HDW8277 1 SCREW 3 8 16 1 3 4 LG 7 25615 1 BRKT STRIKER SWING GATE 9 15043 1 SWING GATE MOUNT WELD LOWER 11 8300 1 SPRING TORSION 1 OD 4 LG PIN SLOTTED SPRING 3 16 DIA X 3 4 LG 13 2 1 BLOCK PIVOT 4 CAP SCREW 5 16 18 X 2 25 15 HDW8294 FLAT WASHER 0 328 ID 17 HDW5724 2 CAP SCREW 5 16 18 X 3 4 18 HDW5217 2 FLAT WASHER 11 32 ID 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page B 11 ILLUSTRATION No ART_2174 October 2008 Page B 12 Reference ART_686 Roll out Deck Lock Pin Assembly 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION e 1 8814 2 SLEEVES OVAL ALUMINUM 3 7184 WIRE CABLE COATED 8 ROLLED 5 HDW8303 1 SCREW 5 6 18 2 LG 7 8513 1 SPRING PIN 1 8 DIA 3 4 LG WASHER 1 2 ID 7 8 OD eee 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page B 13 Roll out Deck Ro
28. 24V 2HP Turn the Hydraulic Pump Inside Pump Compartment 24 V Contactor Connects Battery to Motor Inside Lower Control Box Controller DC 250AMP Changes the Motor Speed Inside Lower Control Box Potentiometer 20K Ohms Senses Operator Input Upper Control Box Circuit Board Resistors Inside Lower Control Box Key Switch N O Contact Block Select Base or Platform Controls Lower Control Panel Switch Toggle Lift Lower at Lower Controls Lower Control Panel Switch Push Button Enable Other Functions at Platform Upper Control Box Handle Switch Micro Right Turn Switch Upper Control Box Handle Switch Micro Left Turn Switch Upper Control Box Handle Switch Toggle Select LIFT or DRIVE Upper Control Box Switch Micro Reverse or Lift Switch Upper Control Box Switch Micro Forward or Down Switch Upper Control Box Switch Toggle TORQUE Switch Upper Control Box Coil Turn Right Solenoid Activate Turn Right Valve SV1 Main Manifold Coil Turn Left Solenoid Activate Turn Left Valve SV1 Main Manifold Coil Decel Solenoid Activate Decel Valve SV5 Main Manifold Coil Lift Solenoid Activate Lift Valve SV2 Main Manifold Coil Torque Solenoid Activate Torque Valves SV4 SV6 Main Manifold Coil Reverse Solenoid Activate Reverse Valve SV3 Main Manifold
29. 318 350 431 474 3 4 16 274 302 371 409 365 402 495 544 7 8 9 350 386 474 523 466 515 631 698 7 8 14 407 448 551 607 543 597 736 9 1 8 537 592 728 802 716 790 970 1070 1 14 670 740 908 1003 894 987 1211 7 3 00 872 1066 1181 1444 1224 1496 1658 2027 Torque values apply fasteners as received from the supplier dry or when lubricated with normal engine oil If special graphite grease molydisulphide grease or other extreme pressure lubricants are used these torque values do not apply Hydraulic Components Use the following values to apply torque to hydraulic components Always lubricate threads with clean hydraulic oil prior to installation SAE PORT SERIES FITTINGS FT LBS Nm FT LBS Nm 9 11 12 15 16 18 22 24 19 24 25 32 28 32 38 43 39 42 53 57 38 42 52 57 58 62 78 84 58 62 79 84 79 85 107 115 83 87 113 118 136 144 184 195 100 110 136 149 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 3 2 MECHANICAL COMPONENTS Following is a description of the major mechanical components of the scissors lift Base Undercarriage When cleaning the base undercarriage cover electrical components to prevent water pe
30. ANSI Specifications October 2008 Page C 5 1 DENOTES LOCATION OF HDW3802 Y DTO EQ 19 ILLUSTRATION No ART_2261 R1 Serial Up to 9105899 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page C 6 ITEM NO DESCRIPTION 2 25410 1 BEAM WITH PINS 4 8 1 BEAM WITH BEARINGS 5 25413 1 BEAM WITH BEARINGS 25409 1 BEAM WITH BEARINGS Spa e ameme 7 9 1 BEAM WITH BEARINGS e Brane 25407 1 BEAM WITH BEARINGS 25121 1 CYLINDER MOUNT UPPER 10 9 1 CYLINDER MOUNT LOWER e a amame o 11 5 1 SUPPORT BEAM 1 LIFT CYLINDER SEE END OF THIS SECTION 8907 1 BEARING 512832 24 15 HDW3802 WASHER FLAT NYLATRON 6 12 18 16 8919 RETAINING RING 7041 HOSE CLAMP 9146 1 HOSE CLAMP CABLE WRAP 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page C 7 90765 SX ILLUSTRATION No ART 2794 October 2008 Page C 8 Serial 9105900 Up 1532ES 1932ES Service amp Parts Manual ANSI Specifications Scissor Assembly 1932ES ITEM NO DESCRIPTION 0 als 2 8 BEAM 18 WL 4 4 25454 MAINTENANCE LOCK WELDMENT 6 2
31. Coil Forward Solenoid Activate Forward Valve SV3 Main Manifold Coil Brake Solenoid Activate Brake Valve SV7 Main Manifold Coil Down Solenoid Activate Down Valve SV8 Main Manifold Coil Down Solenoid October 2008 Page 5 10 Activate Down Valve SV9 1532ES 1932ES Service amp Parts Manual ANSI Specifications Lift Cylinder Manifold ELECTRIC SCHEMATIC Model Serial 1532ES 9000500 9001099 1932ES 9104000 9104999 Reference Art 681R4 Publication Art ART_2205 MODE 4 SWITCH DRIVE LIFT SWITCH CONTACT POSITIONS HELD OPEN w gt Ow as ON OS 8 LO REV LIFT FWD DOWN 7 8 3 Sai MIN VO k O Lo HELD CLOSED WIRE CONNECTOR LEGEND TERMINAL gt LE PIN 7 N FEMALE SOCKET gt o TORQUE 59 1 2 39 9 ON OFF ENABLE 3 EMERGENCY ES2 STOP 7 OPTIONAL QUICK DISCONNECT UPPER TERMINAL STRIP HORN OPTION LS1 SLOW SPEED 1 1 2 0 3 A P10 1 P10 2 6 J 1 CIRCUIT BOARD D5 D13 D10 MOTION po WARNING 2 48 LIGHT PLATFORM 6 1 O
32. Og Retraction Lock Nut e 1532ES 1932ES Service amp Parts Manual ANSI Specifications Pothole Actuator Rod Deployment Spring Flat Washer Lock Nut Spring a Pothole Bar WN Weldment SS Flat Washer Snap Ring Wear Block Spacer Flat Washer Actuator Plate Flat Washer ILLUSTRATION No October 2008 Page 3 9 Platform Removal Raise platform and support with the maintenance lock see General Safety Tips Connect overhead crane by appropriate lifting device to platform Remove the terminal strip cover and disconnect all platform wires Remove any compo nents that will obstruct the scissor slide path 4 Remove the bolts from both fixed blocks at the rear of the platform 5 Lift the rear of the platform until the fixed blocks are clear G Slide the platform assembly forward until the slide blocks align with the slide track open 7 8 ing at the rear of the platform Remove the platform assembly Installation is reverse of removal Horn option _____ Terminal Srtip Cover TORQUE Ft Ibs Nm ILLUSTRATION No Fixed Block Bolts 86 96 116 180 ART_2202 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 3 10 Lift Cylinder Removal and Installation Note Refer to Section 1 for seal replacement instructions Refer to
33. Page 5 15 Component Locations Model Serial ES Models all ANSI LIFT DRIVE 3A 10 3 Reference Art none Publication Art 2211 4 7 0 5 L g tit 6 9 12 ELECTRIC SCHEMATIC TORQUE 13 11 2 N OVERLOAD TILT 15 D 12 15 REMOVABLE CONTROL HORN BUTTON 6 HARNESS PIN WIRE END VIEW OF REMOVABLE CONTROL HARNESS OPTIONAL QUICK DISCONNECT TERMINAL BLOCK ON UNDERSIDE OF PLATFORM DECK October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 5 16 Component Locations Model Serial 1532ES 1932ES all Reference Art none Publication Art ART_2212 REFERTO ELECTRIC SCHEMATIC 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 17 Component Locations Model Serial ES Models all Reference Art none Publication Art ART_2213 ELECTRIC SCHEMATIC CYLINDER October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 5 18 STEER RIGHT STEER LEFT TORQUE REVERSE DRIVE FORWARD MAI
34. Park Street Suite 77 BATTERIES PRODUCE EXPLOSIVE GAS CHARGE BATTERIES IN WELL VENTILATED AREA DO NOT EXPOSE TO SPARKS OR FLAMES 8779 90750 elma California 93722 Phone 800 387 4575 559 891 2488 Fax 559 891 2493 BATTERY CHARGER 9 90751 POWER PLATFORM PLATFORM CAPACITY 600 LBs 272kg PLATFORM CAPACITY 500 LBS 226kg 90268 1532ES 90401 1932ES SELECT ACTIVATE SIDE LEVER TO CONTROL DIRECTION AND SPEED DRIVE TORQUE AMBER LIGHT INDICATES UNSAFE LEVEL CONDITION LOWER PLATFORM AND REPOSITION MACHINE BEFORE ELEVATING AGAIN THIS CONTROL BOX TO BE USED WITH EC 1532ES 1932ES 2033ES 2633ES AND 47ES MODELS ONLY cut label and rotate arrow to EN face switch DO NOT POWERWASH OR SPRAY ELECTRONIC COMPONENTS OR CONNECTORS MOISTURE MAY CAUSE DAMAGE AND OR ERRATIC OPERATION 90732 ILLUSTRATION No ART_2332 October 2008 Page F 2 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION rss 2 1 9 1 DECAL UPPER CONTROL BOX SIDE 3 7156 1 DECAL FRONT 5 90723 1 DECAL WARNING LEVEL 7 90263 1 DECAL LOWER CONTROL BOX FRONT PANEL 9 190750 1 DECAL BATTERY CHARGER 11 2 1 DECAL WARNING NOT PRESSURE WASH
35. Parts Section C for detailed parts list and illustration CAUTION Clean all fittings before disconnecting hoses Tag hoses for proper reassembly Plug all openings to prevent contamination 1 Raise the scissor arm assembly and support using the maintenance lock 2 Remove the support beam Remove the upper and lower retaining rings Remove the upper and lower nylon washers 3 Disconnect hoses and wires and cables from the lift cylinder s 4 Use a suitable lifting device to support the lift cylinder CAUTION Attach the lifting device to the cylinder body Lifting by the rod end will cause the cylinder to extend 5 Remove the upper retaining plate cylinder mount pin and two 2 nylon washers 6 Remove the lower retaining plate 7 While supporting the cylinder carefully remove the cylinder mount pin and two 2 nylon washers CAUTION The cylinder may shift suddenly when the pin is removed 8 Lift the cylinder from Cylinder the scissor assembly Mount using a suitable Pin x lifting device Retaining say v 9 Clean all parts Plate T Mem before reassembly Replace worn or damaged parts with new parts 10 Installation is reverse Lift of removal Cylinder Support Retaining Ring _ B __ Nylon Washer mu No TORQUE Ft Ibs Nm ART 2203 Retaining Plate Bolts 61 4 71 4 8 5 10 1532ES 1932 Service amp Parts Manual ANSI Specifications Octo
36. Plug Slide the removal tool along the wire to be re placed and push into the connector to release the contact Pull the wire and contact out of the plug Crimping Strip 1 4 in 6 mm insulation from the wire Connector Plug male Socket Contacts 22 gt Removal Tool Gasket Locking Wedge Sealing gt lt Pin Contacts Connector Receptacle female H Locking Wedge Y p n Tool Locking Finger Push removal tool into connector to release contact no Deutsch Connector Field Kit ART 2041 MEC part 84091 Insert the contact into the crimping tool and insert the stripped wire into the contact making sure no wires are outside the contact barrel Close the handles of the crimping tool then release the handles to remove the crimped contact 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 2 3 BATTERIES CHARGING BATTERIES CREATE EXPLOSIVE HYDROGEN GAS KEEP SPARKS FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH BATTERIES BATTERY FLUID IS CORROSIVE THOROUGHLY RINSE SPILLED FLUID WITH CLEAN WATER REPLACE WITH MANUFACTURER APPROVED BATTERIES BEFORE DISCONNECTING THE BATTERY NEGATIVE LEAD MAKE SURE THAT ALL SWITCHES ARE OFF IF ON A SPARK WILL OCCUR AT THE GROUND TERMINAL THAT COULD IGNITE HYDROGEN GA
37. 0 PIN COTTER 8812 2 WHEEL TIRE NON MARKING 6 6 10 LUG 8007 0 RING RETAINING 5 8 HDW9219 2 WASHER SPACER e 10 2 2 FITTING GREASE INSERT WASHER 2 1 2 NYLON 13 2 MOTOR HYDRAULIC WHEEL lE 193255 SERIAL TO 9105299 1932 5 SERIAL 9105300 UP 15 4 1 WELDMENT TIE ROD 90990 SEAL KIT STEER CYLINDER FITTING 90 ELBW MALE 4 SAE MALE 3 8 JIC 20 HDW90770 1 PIN CLEVIS II 7 22 9 RING RETAINING eer 1532 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page E 11 SUCTION SIDE TO MANIFOLD 4 SUCTION SIDE _ 4 lt lt FROM RESERVIOR PRESSURE SIDE ILLUSTRATION No ART_2313 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page E 12 QTY HYDRAULIC PUMP ASSEMBLY 2 8544 24 VDC 2 HP COUPLER 1 1932ES S N 9105300 UP 1 90970 1 POWER UNIT ASSEMBLY MONARCH 2 90997 1 OTOR 24 VDC 2 HP 91226 BRUSHES 3 8 1 PUMP 14 90999 1 COUPLER ALL MODELS 4 HDW8081 1 FITTING 90 ELBW MALE 1 2 O RING MALE 3 8 SIZE 37 5 HDW90967 1 FITTING 90 ELBW MALE 3 8 O RING MALE 1 2 SIZE 50 BATTERY CABLE RED SEE HARNESSES PARTS SEC 1 7172 BOOT TERMINAL INSULATOR RED NOT SHOWN 7 REF 7172 BATTERY CABLE BLACK HARNESSES PARTS SEC 1 BOOT TERMINAL INSULATOR BLACK NOT SHOWN SCREW 1 4 20 1 2 LG HDW5005 NUT 5 16
38. 000 9104999 es 1532ES Serial 9001100 Current 1932ES Serial 9105000 Current Ne Electric 5 5 1532ES S N 9000500 9001099 1932ES S N 9104000 9104999 1532ES S N 9002000 Current 1932ES S N 9105000 Current Canadian Models 1532ES S N 9002000 Current 1932ES S N 9105000 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page 5 1 HYDRAULIC SCHEMATICS 1532ES Serial 9001000 9001099 1932ES Serial 9104000 9104999 ITEM DESCRIPTION Counterbalance Valve Main Manifold MA 1 Check Valve Main Manifold MA 1 Steering Cylinder Machine Base Front Lift Cylinder 2047 2647 Scissor Assembly Flow Divider Main Manifold MA 1 Hand Pump Brakes Brake Release Manifold MA 2 Main Manifold Assembly Battery Compartment Brake Release Manifold Battery Compartment Manifold Assembly Lift Cylinder Manifold Valve Main Manifold MA 1 Needle Valve Main Manifold MA 1 Orifice Plug Wheel Motors Main Manifold MA 1 Orifice Down Valve Lift Cylinder Manifold MA 3 Pump Pump Compartment Steering Relief Flow Control Main Manifold MA 1 Relief Valve Lift Relief Main Manifold MA 1 Relief Valve Main Relief Main Manifold MA 1 Relief Valve Steering Main Manifold MA 1 Spool Valve Steering Main Manifold MA 1 Spool Valve Lift Main Manifold MA 1 Spool Valve Drive Main
39. 13 90268 1 DECAL PLATFORM CAPACITY 1532ES 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page F 3 SERIAL NUMBER MODEL YEAR EH 1775 PARK STREET SUITE 77 XXXXXXKI SELMA CA 93662 USA MAX HYDRAULIC MAX GROUND MAX LOAD SYSTEM PRESSURE WHEEL PER WHEEL PRESSURE H RELEASE Ep REPLACE TIRES WITH MANUFACTURER S EQUIPMENT ONLY FAILURE TO USE MANUFACTURER S TIRES MAY CAUSE MACHINE INSTABILITY REFER TO SERVICE AND PARTS MANUAL FOR REPLACEMENT PART NUMBER 826 Et 50 75 100 o 0 to 50 charged Blinking OFF OFF 50 to 75 charged ON Blinking OFF 75 to 100 charged ON ON Blinking 100 charged ON ON ON 9 1 083 6 Please see service manual for additional information 90826 EMERGENC 90748 8 FORK LIFT 2 POCKETSD PULL RED HANDLE TO LOWER PLATFORM 91083 EACH REPLACEMENT BATTERY MUST WEIGH A MINIMUM OF 60 POUNDS 27 3 kg FAILURE TO MEET MINIMUM WEIGHT REQUIREMENT MAY CAUSE MACHINE INSTABILITY No ART 2333 Base Labels 1532ES 1932ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page F 4 ITEM NO DESCRIPTIO
40. 17 18 CAUTION Toinsure a quality repair cylinder parts must be thoroughly cleaned dry and free of solvents and assembly must be performed in a clean area free of dust and contamination 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 restore to their original shape before assembling the cylinder Torque all hardware according to the Hydraulic Components Torque Table unless otherwise specified Lubricate all components with clean hydraulic fluid Install new seal kit components Install all seals on the head and piston using the non sharp seal tool Place a small amount of fluid on the inside seals of the head and reinstall it on the shaft by slipping head over the piston end of the shaft being very careful not to damage the inside seals Place a small amount of fluid on the inside seals of the piston and reinstall it on the shaft by slowly twisting the piston on over the threads of the shaft being very careful not to damage the inside seals Reinstall the shaft nut torque 1 1 2 nut to 160 ft Ibs Grease the outside seals of the head and piston Reinstall the shaft into the barrel of the cylinder and push in until groove of the head lines up with the slot in the barrel Reinstall the cylinder retainer Cycle the cylinder using air to check for proper operation NOTE It is very important to
41. 2 1 SWITCH MANUAL HORN OPTION BOOT OPTION 17 7656 1 CABLE UPPER CONTROL SEE WIRE HARNESS ee 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 3 LIFT DRIVE TORQUE E OVERLOAD TILT 15 D 12 TERMINAL BLOCK ON UNDERSIDE OF PLATFORM DECK ILLUSTRATION No ART 2219 Upper Control Box Fixed ES Machines October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page A 4 ITEM NO DESCRIPTION ees 0 90824 CONTROL BOX ASSEMBLY 2 7800 1 EMERGENCY STOP SWITCH ASSEMBLY 8826 1 THUMBSCREW 5 16 18 FLOWER WASHER FLAT 5 13864 1 LOCK CONTROL ARM 7 HDW5724 1 SCREW 5 16 18 3 4 LG CONTROL BOX HOLDER 9 13867 WRAPPER CONTROL BOX 11 5630 SWITCH TOGGLE TORQUE 14 9184 1 LENS YELLOW Pa oe SWITCH MANUAL HORN OPTION 16 9 1 BOOT OPTION 18 9 1 STRAIN RELIEF WASHER 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 ILLUSTRATION No ART_2220 October 2008 Page 6 Reference ART_13868 Control Box Cover Assembly ES Machines 1532ES 1932ES Serv
42. 20 Amp hours 20 hour rating 2 0 h p 1 49 kW 3000 r p m 4 0 h p 2 98 kW 3000 r p m Batteries Electric Motor Four 6 Volt deep cycle Early Models Current Models Meets Requirements of ANSI A92 6 2006 Section 4 Metric equivalent of working height adds 2m to platform height U S adds 6 ft to platform height Weight may increase with certain options or country standards 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page V Work Platform Early Models are equipped with Uppe i Deck Eos a Welded Steel Hydraulic Reservoior Extension AER L SS N Main Deck Fluid Level 8 Sight Gauge Hydraulic Fluid Filter Plastic Hydraulic Reservoir current models Oe Scissor ST Assembly Hu x Fluid Level 17 S Indicator y Lift Cylinder Hydraulic Pump Hydraulic and Motor Manifold 2 _ PUMP COMPARTMENT __ Maintenance ower Battery Compartment Controls Lower Control Box Manual Brake Release early models Emergency Lowering Cable Both Si pale abe current models Both Sides Battery Pump Pothole Bar Charger Compartment Both Sides Ladder No ART_2153 October 2008 1532ES 1932ES Service amp
43. 2ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page E 15 ILLUSTRATION No ART_2315 October 2008 Page E 16 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION res 25158 1 LEFT REAR ROLLER ARM ASSEMBLY jme atan noue anassen ___ 25160 1 LEFT FRONT ROLLER ARM ASSEMBLY jew 00 32 25145 4 BAR INNER ROLLER 34 0 8 PIN SPACER 36 11119 8 TUBE SPACER 38 7200 8 BEARING NYLINER 1 2 ID 1 2 LG 8 BEARING NYLINER 1 2 ID 7 32 LG 40 HDW5988 8 SCREW 1 4 20 X 1 1 4 LG GRADE 5 WASHER SPLIT LOCK 1 4 BEARING 080010 1 2 X 5 8 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page E 17 ILLUSTRATION No ART_2318 October 2008 Page E 18 1532ES 1932ES Service amp Parts Manual ANSI Specifications Wheel Motor Assembly ES ITEM NO DESCRIPTION WHEEL 1532ES SERIAL 9001034 1932ES SERIAL TO 9105299 90231 WHEEL MOTOR 90419 SEAL KIT FOR WHEEL MOTOR 90231 1932ES SERIAL 9105300 UP 90809 WHEEL MOTOR SEAL KIT FOR WHEEL MOTOR ae 2 STATER HALVES 2 HDW8568 1 NUT 11 8 18 5 SEAL RING 1 SEAL RING BETWEEN HALVES 1532ES 1982 5 Service amp
44. 4 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 3 12 SECTION 4 TROUBLESHOOTING General Troubleshooting Sa 4 2 Hydraulic Pressure Adjustment 4 4 Troubleshoaoilinmg Rm 4 6 Sevcon Motor Speed Controller U u u uu 7 4 14 LED Diagnostics Definitions Flash Godesy L U U N radar anen tabes l daut Cent den kas nnne 4 15 Sevcon Motor Speed Controller Connections ssiri aessa niania naida Vene nd cadea 4 17 Troubleshooting Battery Charger 4 19 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 1 GENERAL TROUBLESHOOTING TIPS The ES series Aerial Work Platform operates on a Motor Control theory in which fluid flow volume is controlled by varying the speed of the DC electric motor 100 of the fluid produced by the pump goes to the selected function The ES series is designed for easier troubleshooting There is a terminal strip located under the platform for checking signals to and from upper controls There is also an LED s located on the Motor Control Unit located inside the lower control box that will help in the event the DC electric motor fails to operate see Motor Controller Flash Codes in this section for troubleshooting with flash codes lt is important to note that not all failures will cause a flash code on the motor controller Before you begin tr
45. 5095 1 BEAM SUPPORT WELDMENT W BEARINGS 25411 1 BEAM 4 x 4 x 25 W PINS 2X 10 25409 1 BEAM 4 x 4 x 25 W BEARINGS 12 HDW3802 17 WASHER NYLON 2 06 ID 2 62 OD 030 THK 14 7 1 BEARING 2 25 OD x 2 ID x LG 25429 SPACER RUBBER 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page C 9 ILLUSTRATION No ART_2262 October 2008 Page C 10 Reference ART_ Scissor Mounting Detail X32ES 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION Scissor AssEMBLY Mount 13778 BLOCK SLIDE PLATFORM 3 HDW8486 4 SCREW 5 16 18 1 87 LG GR 8 5 HDW8294 4 WASHER 328 ID X 1 000 OD 100 12 HDW8283 SCREW 1 2 13 1 5 LG GR 8 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page 11 ILLUSTRATION No ART_2265 R1 October 2008 Page C 12 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM _PART NO DESCRIPTION 1 2 CYLINDER MOUNT WELDMENT REFER TO SCISSOR ASSEMBLY 2 25219 2 PLATE RETAINER CYL MOUNT 3 75 X 1 25 X 0 179 HDW5723 4 SCREW 1 4 20 1 2 LG GR 5 4 HDw13339 4 WASHER NYLON 1 385 ID X 2 255 OD 030 THK 5 2 2 PIN 1 373 X 5 382 CYL MOUNT 6 6984 4 BEARING 1 375 LG 7 6669 2 BEARING 2 0 X 2 0 LG Bi 6875 RETAINING RING 1 375 DIA
46. ATE THE CHARGER IF IT IS MALFUNCTIONING PERSONAL INJURY OR PROPERTY DAMAGE MAY RESULT Incorrect assembly may result in a risk of electric shock or fire The following procedures are intended only to determine if a malfunction may exist in the charger Most returned chargers test good it is very important that this procedure is followed and that other problems are corrected before assuming the charger has failed The MEC battery charger is a fully automatic type with a maintenance feature that will maintain battery voltage indefinately when connected to an AC power source The battery charger should be plugged into an unswitched AC source if stored for long periods of time 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 19 INDUSTRIAL BATTERY CHARGER 50 75 100 BATTERY CHARGER INDICATOR 010 50 charged 50 to 75 charged 75 to 100 charged 100 charged 50 75 100 OFF Blinking Blinking OFF OFF Blinking ON Please see service manual for additional information 90826 LED Status All 3 LED lamps blink once simultaneously All 3 LED lamps blink twice simultaneously Fault All 3 LED lamps blink three times simultaneously All 3 LED lamps blink four times simultaneously 100 LED lamp blinks INPUT INTERLOCK OUTPUT
47. DO NOT CHANGE THE INPUT VOLTAGE BEFORE THREE LEDS TURN OFF LEDs 50 75 100 ILLUSTRATION No ART_2185 Output is open or short or output voltage is over a limit Otherwise output terminals are reversed Input voltage is out of the range The internal temperature of the charger exceeds a limit Output current exceeds a limit Battery pack has a bad cell To determine if a charger is malfunctioning identify the problem from the following list and refer to the appropriate section for detailed instructions 1 Charger does not turn on All 3 LEDs blink simultaneously 2 3 4 Batteries do not fully charge 5 100 LED blinks while 50 and 75 LEDs are OFF The AC supply circuit breaker or fuse is blown If the problem is not listed above refer the problem to a qualified service agent for additional trouble shooting procedures October 2008 Page 4 20 1532155 1932ES Service amp Parts Manual ANSI Specifications Troubleshooting Battery Charger continued PROBLEM Charger does not turn ON All 3 LEDs blink ONCE simultaneously All 3 LEDs blink TWICE simultaneously All 3 LEDs blink THREE TIMES simultaneously All 3 LEDs blink FOUR TIMES simultaneously 100 LED blinks while 50 and 75 LEDs are OFF DIAGNOSIS The AC plug must be disconnected and reconnected to start the charger once it has turned off from a charge cycle e Connect t
48. FF BASE amp A3 LEVEL SENSOR EMERGENCY 1 STOP HOUR CHRL1 12 2 P3 6 P5 12 o gt 104 21 P3 5 5 11 BATTERY CHARGER GAUGE INTERLOCK 71 CYLINDER MANIFOLD D 15AMP BREAKER 281 200 105 BD1 1 MANIFOLD 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 11 1532ES S N 9002000 Current 1932ES S N 9105000 Current Tilt Light 28V Warn when Machine is Tilted Upper Control Box Level Sensor Activates Tilt Light Inside Lower Control Box Push Button Switch Activates Horn Upper Control Box Horn 12V 48V option Activated by Operator Under Platform Overload Motion Alarm option Warn of Movement Outside Lower Control Box Motion Light option Warn of Movement Front Left Corner of Machine Hour Meter Record Machine Usage Time Lower Control Panel Battery Indicator Show Battery Status Lower Control Panel 6 V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment Battery Disc
49. FITTING 90 ELBOW MALE 1 4 x MALE 1 4 TALL FITTING 90 ELBW MALE 3 8 MALE 3 8 O RING HDW7971 TEST PORT 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page D 9 FROM LIFT CYLINDER ILLUSTRATION No ART_2289 Hydraulic Reservoir Assembly Steel X32ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page D 10 HYDRAULIC RESERVOIR STEEL 1 8 1 HYDRAULIC RESERVOIR WELDMENT FITTING ELBOW 90 MALE 1 4 MALE BARB 1 4 3 REF HOSE RETURN LINE BANH 7 5 HDW6510 FITTING ELBOW 90 MALE 1 2 SAE MALE 1 2 NPT 7 HDW9200 FITTING MALE 1 4 9 6156 FILTER OIL CARTRIDGE EINE FITTING ELBOW 90 MALE 3 8 MALE 1 2 11 HDW6752 ADAPTER MALE 3 4 FML 1 2 L FILTER HEAD 13 90215 FITTING ELBOW 90 FML 3 4 MALE 3 4 FITTING SIGHT GAUGE 15 5 2 SCREW 1 4 20 1 2 66 FILLER BREATHER _ 000 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page D 11 Early Style Mounting Brackets replaced by brackets 18 and 19 LIFT CYLINDER Sa ILLUSTRATION No ART 2288 Hydraulic Reservoir 1532ES amp 1932ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page D 12
50. FORM DECK ILLUSTRATION No ams Control Cable and Manifold Harness October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page A 18 Wire 55 5 COMMUNICATION CABLE CURRENT MODELS 1532ES SERIAL 9001011 UP BENE 1932ES SERIAL 9104542 UP 1 90913 1 COMMUNICATION CABLE 1532ES 1 90812 1 COMMUNICATION CABLE 1932ES HEHE Wire Harnesses UPPER CURRENT MODELS 1532ES SERIAL 9001100 UP 1932ES SERIAL 9105001 UP 90817 CONTROLLER CABLE FIXED CONTROLLER CABLE REMOVABLE OPTION 6318 NE PIN REPAIR KIT FOR CABLE SEE PAGE A 2 90100 CONTROL BOX HARNESS USED WITH REMOVABLE CABLE Wire Harnesses OTHER CURRENT MODELS 1532ES SERIAL 9001100 UP BEEN 1932ES SERIAL 9105001 UP 91071 BASE MANIFOLD HARNESS 91070 LIFT CYLINDER HARNESS DOWN VALVE NOT SHOWN HORN OPTION SEE SECTION B EN POWER CONVERTER OPTION SEE SECTION E OPTIONS 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 19 i S lt gt o e LLI e 9 O ILLUSTRATION No ART_2523 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 20 ITEM NO DESCRIPTION Cutout RELAYS CANADIAN M
51. FT LBS Nm FT LBS Nm millimeters FT LBS Nm FT LBS Nm MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX 14 20 6 25 7 25 5 10 8 25 95 11 13 M6 X 1 00 6 8 8 11 9 11 12 15 1 4 28 8 9 11 12 10 5 12 14 16 M8 X 1 25 16 20 21 5 27 23 27 31 36 5 5 16 18 14 15 19 20 185 20 25 27 M10 X 1 50 29 35 39 47 42 52 57 70 5 16 24 17 5 19 23 26 23 25 31 34 M12 X 1 75 52 62 70 84 75 91 102 123 3 8 16 26 28 35 38 35 37 47 5 50 14 X 2 00 85 103 115 139 120 146 163 198 3 8 24 31 34 42 46 41 45 55 5 61 M16 X 2 50 130 158 176 214 176 216 238 293 7 16 14 41 45 55 5 61 55 60 74 5 81 M18 X 2 50 172 210 233 284 240 294 325 398 7 16 20 51 55 69 74 5 68 75 92 102 M20 X 2 50 247 301 335 408 343 426 465 577 1 2 13 65 72 88 97 5 86 96 116 130 22 X 2 50 332 404 450 547 472 576 639 780 1 2 20 76 84 103 114 102 112 138 152 24 X 3 00 423 517 573 700 599 732 812 992 9 16 12 95 105 129 142 127 140 172 190 27 X 3 00 637 779 863 1055 898 1098 1217 1488 9 6 18 111 123 150 167 148 164 200 2 5 8 11 126 139 171 188 168 185 228 251 5 8 18 152 168 206 228 203 224 275 304 3 4 10 238 262 322 255
52. Hydraulic Schematic for proper setting Lift Cylinder Note Refer to Cylinder Repair 1532ES 1932ES One 1 single acting type hydraulic cylinder The cylinder has an integrated 2 position 2 way solenoid operated platform lower valve for hold ing the platform in position The valve is also externally actuated for manually lowering the platform Early models use a pull to release knob at the cylinder while current models use a cable release with a pull handle lo cated near the ladder see Emergency Systems and Procedures 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 9 CYLINDER REPAIR CYLINDERS ARE HEAVY SUPPORT CYLINDERS BEFORE REMOVING HARDWARE THAT SECURES THE CYLINDER TO THE MACHINE Return to Tank Rod Seals Seals Piston Vent to Tank Ut 6 000 00000 0000 C 0 Head Piston Securing Nut Typical Single Acting Cylinder Seals Piston Securing Nut Piston Rod Return Pron YODDA Head Ms un No Typical Dual Acting Cylinder ART 2040 Removal Note Refer to Section 3 for Remove and Replace instructions and the Parts Section for a list of hardware specific to the cylinder being repaired 1 Tag hoses for proper reassembly 2 Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination 3 Remove cylinder from the machine as described in Section 3
53. IDER me 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page D 7 NA gt 2 N A Ms 91000 Hydraulic Manifold Assembly X32ES 55 c c T LO c C TH H ec nn LII Lu N CN LO _2287 ILLUSTRATION No 5 S 8 2 7 3 amp a 3 gt D n S E e id E October 2008 Page D 8 Main MANIFOLD AssEMBLY Late MopELs ee 1932ES SERIAL 9105000 UP 91001 COIL 91004 VALVE SPOOL 4 WAY 3 POSITION STEERING p VALVE SPOOL 4 WAY 2 POSITION TORQUE 91008 VALVE SPOOL 4 WAY 3 POSITION DRIVE 2 1 VALVE SPOOL 2 WAY N O TORQUE 91006 VALVE SPOOL 4 WAY 2 POSITION DRIVE DUMP DECEL sss 10 6 VALVE N NEEDLE TOW FREEWHEEL PUMP MANUAL BRAKE 12 91012 1 VALVE MANUAL BRAKE RELEASE VALVE RELIEF MAIN 14 91009 1 VALVE RELIEF LIFT VALVE RELIEF STEER PRIORITY FLOW CONTROL 16 91013 1 VALVE RELIEF WITH PISTON VALVE CHECK FLOW DIVIDER 21 HDW91080 1 FITTING 90 ELBOW MALE x NPT FITTING 90 MALE 3 8 3 8 O RING MALE FITTING 90 ELBOW MALE x MALE 1 4 24 HDW91081 1
54. ION D FITTING PIPE ADAPTOR 90439 ORIFICE 0 047 1932ES XH ORIFICE 0 055 1532ES 5 6984 4 BEARING DU 1 3 8 ID X 1 5 8 LG VALVE 2 WAY N C CABLE ATTACH 7 90816 1 COIL 24 VOLT HH FITTING PIPE 90 MALE BARB 7078 1 KIT SEAL LIFT CYLINDER SERVICE HOSE RETURN LINE SEE SECTION D 7788 CLAMP HOSE 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page C 17 50 Bow M Emergency Lowering Cable m 932ES ILLUSTRATION No 1532 Serial 9001009 9001047 2268 1932 Serial 9104470 9105458 90801 Hydraulic Clyinder October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page C 18 ITEM NO DESCRIPTION _ 153256 SERIAL 9001032 7 me REF HOSE ASSEMBLY LIFT CYLINDER SEE SECTION D FITTING PIPE ADAPTOR 90439 ORIFICE 0 047 1932ES ORIFICE 0 055 1532ES 5 6984 4 BEARING DU 1 3 8 ID X 1 5 8 LG VALVE 2 WAY N C CABLE ATTACH 7 91001 1 COIL 24 VOLT FITTING PIPE 90 MALE BARB 9 7078 1 KIT SEAL LIFT CYLINDER SERVICE 14 HOSE RETURN LINE SEE SECTION D op eA 12A 1 SPRING 8152 2 BOLT 15 1 CLEVIS PIN ODER 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page C 19 90 Pu Emergency Lowering Cable 1532
55. IS UNIT ILLUSTRATION No ART 2335 October 2008 Page F 8 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION _ Wn 1 90721 1 DECAL DANGER OVER 3 90730 1 DECAL WARNING PLATFORM LOCK 90733 1 DECAL MANUALS INSIDE sje imeem 8806 DECAL WARNING LANYARD OPTION DECAL ANCHORAGE POINTS OPTION 11 90718 1 DECAL WARNING INSPECTION 13 9138 gt DECAL 1532ES DECAL LOCATE CONTROL BOX HERE 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page F 9 October 2008 Page F 10 1532ES 1932ES Service amp Parts Manual ANSI Specifications Service Parts Order Form Fax to 559 263 9631 Please fill out completely Date Ordered By Account Your Fax No Bill to Ship to Purchase Order Number Ship VIA All orders MUST have a Purchase Order Number Fed Ex shipments require Fed Ex account number Part Number Description Quantity Price All backordered parts will be shipped when available via the same ship method as original order unless noted below Ship complete order only no backorders e Ship all available parts and contact customer on disposition of backordered parts other please specify Limited Owner Warranty Aerial Platform Sales Corp warrants its equipment to the orig
56. Incomplete circuit to the Sevcon pin 6 If the motor and contactor circuits are diagnosed as working properly e Sevcon internal fault continued 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 15 LED Diagnostics Definitions continued LED READING DIAGNOSIS Accelerator fault Set with unit at rest a 6 flash will result in an 80 cutback of motor speed The Accelerator is the proportional control circuitry for the Sevcon It works in conjunction with the potentiometer located in the upper control box which is connected to the joystick handle through a gear arrangement Measure voltage at terminals 14 and 15 on the platform terminal strip or at the potentiometer plug connection With the joystick handle in neutral 3 6 volts should be measured on the accelerator circuit wire 14 Voltage proportionally decreases with the travel of the joystick with 0 volts at full stroke With the joystick centered voltages lower than 3 1 or higher than 3 9 will trigger a 6 flash code 7 Flashes Battery voltage fault e This includes battery voltage below 12 volts or above 45 volts as measured on pin 71 e This code will disable all functions 8 Flashes Thermal cutback Sevcon internal temperatures above 176 degrees F Will limit motor speed in comparison with over temperature Resets when cooled Battery voltage at or below 18 volts As measured on pin 1 This code will interrupt or prev
57. LOCATION OF HDW3802 ILLUSTRATION No ART_2260 R1 Serial Up to 9001099 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page C 2 Scissor Assembly 1532ES ITEM NO DESCRIPTION UU 1 25406 1 BEAM WITH PINS 3 25558 1 BEAM WITH BEARINGS Spa e maoe 4 25413 1 BEAM WITH BEARINGS NE 5 25409 1 BEAM WITH BEARINGS Cpa o emae 25405 1 BEAM WITH BEARINGS 7 25121 1 CYLINDER MOUNT UPPER 25119 1 CYLINDER MOUNT LOWER a 9 5 1 SUPPORT BEAM 1 X 3 11 4 1 MAINTENANCE LOCK i 12 25429 8 SPACER RUBBER _ _ 9146 1 HOSE CLAMP NE 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page C 3 ILLUSTRATION No ART_2793 October 2008 Page C 4 Serial 9001100 Up 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION U 1 17059 1 BEAM WELDMENT 3 1 BEAM WELDMENT 5 17058 2 CYLINDER MOUNT WELDMENT 7 17056 BEAM WELDMENT 9 25407 BEAM WELDMENT 11 25429 12 SPACER RUBBER 13 REF 1 LIFT CYLINDER FOLLOWING PAGES BEARING 2 25 OD x 2 ID x 1 5 LG 1532ES 1932ES Service amp Parts Manual
58. LOWER SWITCH a ART_2177 THE MOVEMENT ALARM IS PROVIDED FOR YOUR PROTECTION AND PROTECTION OF PERSONS WORKING IN THE IMMEDIATE AREA DISABLING THIS IMPORTANT SAFETY DEVICE MAY RESULT IN SERIOUS INJURY OR DEATH 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 2 9 Tilt Alarm The tilt sensor is located in the Lower Control Box Tilt Alarm Visual z T Ge A warning light provided at the upper console will Level Bubble give a visual warning when the machine is at an unsafe angle the platform should not be elevated when the warning indicator light is on Flange Nut Flange nut Tilt Alarm Test This can be tested by tipping the sensor This Push To Test feature enables the tilt alarm to be tested without losing its adjustment Individually push down on each of the three fastened corners of the tilt alarm There should be enough travel to cause the Tilt Base alarm to sound as each corner is pressed There is approximately a 1 3 second delay If the alarm does not sound the flange nuts have been tightened too ILLUSTRATION No Mounting Plate far Loosen the nut on the 90 corners and repeat this test procedure Tilt Alarm Sensor Adjustment Before attempting to adjust the alarm park the machine on a firm flat level surface Use of an inclinometer is recommended to ensure front and rear of chassis is level Open the low
59. Loose connections Be sure all cable connections are tightly secured and that good con tact is made with terminals Broken or Frayed cables Be sure all connections are good and that no loose or broken wires are exposed Replace as necessary Check battery electrolyte level Replenish the electrolyte if necessary Remove vent caps before filling and USE ONLY DISTILLED WATER DO NOT OVERFILL Fill to level indicator or 1 2 inch over the top of separators if there is no level indicator Fill after charging to prevent overflow of acid due to expansion Do not use a hose to add water to batteries Allowing the electrolyte level to drop below the top of the separators will lead to shortened battery life Excessive water usage can indicate that a battery has been overcharged has been subjected to excessively high temperatures or is nearing the end of its service life Battery Preventative Maintenance Every 15 hours after battery has been charged spot check the specific gravity of two or more cells A fully charged battery should indicate 1 28 specific gravity If low reading are noted check the following Check terminals for corrosion loose connections and broken or frayed cables Check all cells with a hydrometer for variance in specific gravity A variation of 0 03 points or more between cells is a cause for concern Mark the low cells Recheck specific gravity of all cells after recharging Wash the top of the battery ma
60. MIT SPEED 1 SET SCREW HDW5276 2 NUT 1 4 HDW8482 2 8 32 1 1 2 LG 8932 1 SWITCH LIMIT SPEED HONEYWELL BRAND 90996 1 SWITCH LIMIT SPEED TELEMECANIQUE BRAND HDW5251 NUT 8 32 HDW8273 CREW 1 4 20 1 LG 13838 1 BRKT LIMIT SWITCH MOUNT 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page E 23 11 12 DC OUTPUT AC INPUT ILLUSTRATION No Battery Charger ES ART_2323 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page E 24 ITEM NO DESCRIPTION 90712 1 CHARGER 24 VOLT 110 220V 50 60 H HDW7888 4 SCREW 10 32 1 2 LG 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page 25 October 2008 Page E 26 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION F DECALS DECALS 1532ES 1932 5 CoNTROLS 3 DECALS 1532ES 0 F 5 DECALS 1532ES 1932ES SCISSORS Eua a ad E F 7 DECALS 1532ES 1932ES F 9 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page F 1 90735 IF UNIT DOES NOT DRIVE DURING ELEVATION CHECK FOR OBSTRUCTION UNDER OR AGAINST AUTOMATIC POTHOLE STABILIZERS ENABLE BAR MUST BE DEPRESSED DURING ALL ENABLE FUNCTIONS MEC Aerial Platform Sales Corp LEFT RIGHT 1775
61. Manifold MA 1 Spool Valve Decel Main Manifold MA 1 Spool Valve Torque Main Manifold MA 1 Spool Valve Torque Main Manifold MA 1 Spool Valve Brakes Main Manifold MA 1 Poppet Valve Down Main Manifold MA 1 Spool Valve Down Lift Cylinder Manifold MA 3 Test Port Main Manifold MA 1 Wheel Brake Drive Wheel Wheel Brake Drive Wheel Wheel Motor Right Side Machine Base Wheel Motor Left Side Machine Base October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 5 2 HYDRAULIC SCHEMATIC Model Serial 1532ES 9001000 9001099 1932ES 9104000 9104999 2033ES 8804000 8804099 2633ES 11100000 11100599 Reference Art 915 Publication Art ART_2194 STEERING CYLINDER 2400 PSI 1932ES 1900 PSI 1532ES 2750 PSI 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 3 1532ES Serial 9001100 Current 1932ES Serial 9105000 Current ITEM
62. N 1 91553 1 SERIAL PLATE 3 90267 1 DECAL BRAKE RELEASE 5 90726 1 DECAL WARNING BATTERY REPLACEMENT 7 90826 1 DECAL BATTERY CHARGER INDICATOR 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page F 5 90717 MAINTENANCE LOCK F 7982 2X 1532ES 1932ES 90717 MAINTENANCE LOCK 9910 3X ILLUSTRATION No ART_2334 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page F 6 ITEM NO DESCRIPTION
63. N MANIFOLD EARLY MODELS MAIN MANIFOLD STEER RIGHT STEER LEFT CURRENT MODELS TORQUE REVERSE pRIVE FORWARD Controller Plug Pin Identicication Model Serial REFER TO PWM ES Models all ERA Motor Controller Reference Art Publication Art 2217 J5 Pin Identification PIN WIRE FUNCTION B power input power up Lift Drive or Steer functions requested functions requiring motor Steer Requested adds additional motor speed for steer Enable signal input Speed cut back 24 Volts full speed O Volts creep speed Motor Start Relay signal GROUND signal to activate Motor Start Relay Lift Valve B provides GROUND signal to Lift Valve none Accelerator reference signal 3 6 Volts to Potentiometer none none none Terminal Identification FUNCTION Battery Positive Cable from 200 AMP Fuse Negative Battery Cable and GROUND wire 15 connection Motor Ground Pulse Width Modulated PWM variable speed control Circuit Board J1 Plug Pin Identification PIN WIRE SIGNAL FUNCTION L INPUT Drive Reverse 1 2 INPUT Drive Forward OUTPUT Brake Decel Valve signal INPUT Steer Left OUTPUT Steer signal to Sevcon INPUT Down signal OUTPUT Signal to Motion Alarm s optional OUTPUT Sevcon amp Hour Meter motor function requested INPUT Battery Negative IN
64. O 9104999 1 90286 4 HOSE ASSEMBLY DRIVE MOTORS 6675 As REQ SEAL KIT DRIVE HOSE SWIVEL 2 9404 2 HOSE ASSEMBLY STEER CYLINDER 3 90276 1 HOSE ASSEMBLY BRAKE TO MANIFOLD 4 90275 1 HOSE ASSEMBLY BRAKE TO BRAKE 5 9038 1 HOSE ASSEMBLY MANIFOLD TO FILTER m 9959 HOSE ASSEMBLY SUCTION m 6458 HOSE ASSEMBLY LIFT CYLINDER TO RESERVOIR 1532ES H 6458 13 FT HOSE ASSEMBLY LIFT CYLINDER TO RESERVOIR 1932ES 1532ES SERIAL TO 9001007 1932ES SERIAL TO 9104474 g 9245 HOSE ASSEMBLY LIFT CYLINDER 1532ES SERIAL 9001009 TO 9001099 1932ES SERIAL 9104475 TO 9104999 90819 HOSE ASSEMBLY LIFT CYLINDER 10 90274 1 HOSE ASSEMBLY HAND PUMP 11 7598 1 HOSE ASSEMBLY HAND PUMP RETURN 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page D 15 NOTE This dr hydrau compo Equipped with STEER CYLINDER High Torque Manifold LIFT CYLINDER MANIFOLD awing identifies lic hoses and the nent that they connect to and NOT the actual hose positions on the ma chine 153265 Serial 9001100 zzoop1 1932 5 Serial 9105000 UP October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page D 16 HYDRAULICc Hoses Late MopELs 1 90286 2 HOSE ASSEMBLY DRIVE MOTORS 2 91047 2 HOSE ASSEMBLY STEER CYLINDER 4 90275 1 HOSE ASSEMBLY BRAKE TO BRAKE 6 91396 1 HOSE ASSEMBLY S
65. ODELS 1 7 2 RELAY SPDT 2 POLE 2 1 2 BASE RELAY 16333 BRACKET RELAY 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 21 October 2008 Page 22 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION B PLATFORM AND RAILS PLATFORM AND 0 B 3 RottouT DEOK 5 LANYARD ATTACHMENT TT a a 7 ENTRY 9 11 DECK LOCK 13 8 5 TERMINAL B 17 OPERATOR HORN ANSI OPTION eee B 17 RING GREATEGORMT 1 B 17 8 B 19 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page B 1 Reference ART 684 Work Platform Main Deck X32ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page B 2 ITEM NO DESCRIPTION PLATFORM AND RAILS LL 2 RAIL MAIN PLATFORM 3 HDW8304 16 NUT 5 16 18 WASHER FLAT 5 HDW5217 24 WASHER FLAT 7 25502 1 PLATFORM MAIN 9 HDW5724 16 SCREW 5 16 18 3 4 LG BLOCK SLIDE PLATFORM 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page B 3 ILLUSTRATION No ART_2250 October 2008 Page B 4 Reference ART_683 Extension Deck X32 E
66. OOT INSULATOR RED ABLE POWER SUPPLY 7130 C CAPACITOR 1 1 SCREW 5 16 18 1 LG 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page E 7 _ 4 5 6 7 12 5 5 5 5 5 13 Stacking arrangement for discs and spacers ILLUSTRATION No ART_2309 October 2008 Page E 8 1532ES 1932ES Service amp Parts Manual ANSI Specifications Brake Installation ES ITEM NO DESCRIPTION BRAKE ASSEMBLY 9544 HYDRAULIC BRAKE ASSY MICO BRAND 1532ES SERIAL 9001000 9001066 1932ES SERIAL 9104000 9105783 91599 HYDRAULIC BRAKE ASSY AUSCO BRAND 1532ES SERIAL 9001067 UP 1932ES SERIAL 9105784 UP HDW8881 2 ADAPTER MALE 1 4 O RING MALE 1 4 4 HDW90332 1 FITTING MALE 1 4 MALE 1 4 FEMALE 1 4 TEE HDW8498 SCREW 1 2 13 4 LG bi 90413 BRAKE REPAIR KIT SEE HYDRAULIC HOSES PARTS SECTION D 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page E 9 to PORT 7 E gt RIGHT SIDE to PORT 8 LEFT SIDE to PORT 10 RIGHT SIDE to PORT 9 LEFT SIDE to PORT 11 ILLUSTRATION No 2310R1 Steering Assembly Installation 1532ES 1932ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page E 10 ITEM NO DESCRIPTION STEERING HDW8568 NUT SLOTTED 1 1 8 HDW529
67. OUND signal to Lift Valve none Accelerator reference signal 3 6 Volts to Potentiometer none none none ILLUSTRATION No ART_2182 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 4 14 LED Diagnostics Definitions Flash Codes LED READING DIAGNOSIS LED Steady On Controller is operational and detects no irregularities on monitored circuits LED Off No power up powerto pin 1 No ground to B post LED failure or internal controller fault Procedure fault Enable depressed at power up Enable depressed for more then 15 seconds without function request No signal on wire 17 pin 2 when function requested No B to diode board Failed diode s Damaged wire harness Internal controller fault Motor circuit low Set with unit at rest and is the result of the voltage at M 2 dropping to approximately 4 volts or lower Possible causes Short to ground in the motor circuit between the motor contactor and the M 2 terminal Motor circuit high Set with the unit at rest and is the result of the voltage at M 2 terminal rising above 21 volts Possible causes Motor contactor points are welded shut Motor contactor circuit open Set when a function is requested but no current can flow through the motor circuit to the M 2 terminal Possible causes Blown 200 amp fuse e Malfunctioning motor contactor Worn motor brushes
68. PSI 59 bar 550 PSI 38 bar 1932ES 2750 PSI 190 bar 2600 PSI 180 bar 850 PSI 59 bar 550 PSI 38 bar Check and Adjust Pressure except counterbalance If adjustment is required set pressure to the correct setting as follows Connect pressure gauge 0 3500 psi with a female quick disconnect to the main test port Main System Disconnect forward or reverse coil of drive valve Energize drive function by moving joystick lever in the direction of the already disconnected coil Hold the switch for 10 seconds to get an accurate reading on the pressure gauge Lift Energize the platform to full extension with no load on platform Hold the switch for 10 seconds to get an accurate reading on the pressure gauge Steering Energize the steering to full left Hold the switch for 10 seconds to get an accurate reading on the pressure gauge Early Models Early models do not have a tamper proof cap Turn adjustment screw IN to increase the pressure Turn adjustment screw OUT to decrease the pressure Current Models Remove the tamper proof cap Turn adjustment screw IN to increase the pressure Turn adjustment screw OUT to decrease the pressure When correct pressure is obtained replace tamper proof cap with a new one CAUTION Do not operate pump with tamper proof cap removed as fluid will emit under pressure October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 4 4 Set
69. PUT Steer Right INPUT Lift Up INPUT Limit Switch 24V platform down OUTPUT Enable from lower Lift switch OUTPUT To Sevcon for speed cutback 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 5 19 October 2008 Page 5 20 1532ES 1932ES Service amp Parts Manual ANSI Specifications Parts Section Table of Contents SECTION A CONTROL BOXES REMOVABLE CONTROL ASSEMBLY A 3 FIXED CONTROL Box ASSEMBLY pp A 5 UPPER CONTROL Box COVER ASSEMBLY A 7 0 9 LOWER CONTROL PANEL 4 A 11 MOWER CONTROL BOX A 13 WIRE HARNESSES LOWER CONTROLS 1 nnns nnns 15 WIRE HARNESSES COMMUNICATION CABLE EARLY MODELS A 17 WIRE Harnesses UPPER CONTROLS EARLY MODELS A 17 WIRE HARNESSES OTHER EARLY MODELS pp A 17 WIRE HARNESSES COMMUNICATION CABLE CURRENT MODELS A 19 Wire Harnesses UPPER CONTROLS CURRENT MopEts A 19 WIRE HARNESSES OTHER CURRENT MODELS A 19 Curour RELAYS CANADIAN MODELS 5 nennen A 21 SECTION B PLATFORM AND RAILS PLATFORM AND RAIES uu ua cn uu uu B 3
70. Parts Manual ANSI Specifications Page VI PRIMARY MACHINE COMPONENTS Use this chart to find information relating to a specific component Component Platform Assembly Service Section Parts Section Component Pump Compartment Service Section Parts Section Upper Controls 21415 Hydraulic Pump amp Motor intro 1 4 5 E Deck and Rails 3 B Hydraulic Reservoir intro 1 D Chain Closure B Hydraulic Filter intro 1 D Optional Gate B Hydraulic Manifold 11415 D Deck Extension B Control Terminal Strip 2 5 Horn optional 2 4 5 A B Power to Platform B Lift Assembly Battery Compartment Scissor Assembly 3 Battery Pack 214 Maintenance Lock intro Lift Cylinder 1131415 Base Assembly Lower Control Box Drive Motors intro 1 3 4 5 E Lower Controls 2 4 5 Brakes intro 11314 5 Power to Platform 2 Steering Components 1131415 E Tilt Sensor 21415 Wheels amp Tires 3 E Diode Board 2 4 5 Emergency Lowering 1 Motor Controller PWM 2 4 5 Hoses amp Cables 113 A B D Battery Disconnect Switch 2 A Battery Charger 21415 Motion Alarm 2 5 E Pothole Components 3 E Pothole Switch 2 4 5 E Limit Switch 2 4 5 Lubrication Points intro C Brake Release Hand Pump 5 D Page VII LUBRICATION SPECIFICATION FREQUENCY OF LUBRICATION 4 Check daily Hydraulic Fill to the middle of the sight g
71. ROL BOX MOUNT HDW6432 SCREW 3 8 16 3 4 LG 1532ES SERIAL TO 9001040 1932ES SERIAL TO 9105299 16149 LOWER CONTROL BOX SUPPORT 1532ES SERIAL 49001041 UP 1932ES SERIAL 9105300 UP 16334 LOWER CONTROL BOX SUPPORT m HDW5904 SCREW 9 HDW5470 2 WASHER 10 HDW8267 2 NUT 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page E 3 ILLUSTRATION No Base and Covers 1532ES 1932ES ifications ART_2304 October 2008 Page E 4 1532ES 1932ES Service amp Parts Manual ANSI Spec ITEM NO DESCRIPTION 1 25487 1 DOOR BATTERY 2 8386 2 LATCH 3 25623 1 CONVERTER MOUNT BRKT 4 HDW8273 4 SCREW 1 4 O 12 1 0 LG 5 7 1 DOOR HYDRAULIC 6 25453 1 COVER HYDRAULIC HDW6455 SCREW 1 4 0 12 1 2 LG 25621 BASE WELDMENT 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page E 5 SUPPLIED WITH ITEM 6 ILLUSTRATION No ART_2307 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page E 6 ITEM NO DESCRIPTION OPTIONS MorioN ALARM 2 8709 1 INSULATOR TERMINAL RED 8782 1 HARNESS MOTION ALARM CREE 9770 1 LIGHT STROBE 90213 1 GUARD LENS NUT 5 16 18 HDW8310 2 SCREW 5 16 18 1 1 4 LG BRKT LIGHT MOUNT L1 7103 CONVERTER 7110 B
72. RTANCE OF THOROUGH HYGIENE AND THE PROPER METHODS FOR HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL HAZARDS TO HEALTH If mineral based hydraulic fluid is SPLASHED INTO THE EYES it must be WASHED OUT THOROUGHLY using abundant quantities of water If irritation persists medical advice should be sought HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN SKIN DAMAGE EYES AND MAY CAUSE SERIOUS INJURY OR BLINDNESS FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE Fluid Recommendations MEC recommends the use of ISO Grade 32 hydraulic fluid A 150SSU EQUIVALENT substitute can be used if absolutely necessary Mineral based hydraulic fluids produced by different compa nies will USUALLY mix with each other satisfactorily but this IS NOT RECOMMENDED When in doubt consult with your supplier ISO Grade 32 has proven to be suitable for use in all climates For continued operation in tem peratures below 32 F 0 C use of an ATF hydraulic fluid is satisfactory The only exception to the above is to drain and fill the system with ATF fluid or its equivalent This will also start up at temperatures down to 20 F 29 However use of this fluid will give poor performance at temperatures above 120 F 49 C October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 1 2 System Flushing Procedure 1 J eS Sx d Jw ak wk N CD With platform f
73. RVOIR PLASTIC HYDRAULIC HOSES EARLY MOopE s SECTION E BASE HYDRAULIC HOSES LATE MODELS LADDER AND CONTROL Box BRACKETS BASE C VERS ee oc UE LUI BRAKE ASSEMBLY eda taa a aae Be STEERING aquya qaqay qayanku blat HYDRAULIC PUMP ASSEMBLY POTHOLE ASSEMBLY WWHEEL MOTOR BATTERY INSTALLATION Nt POTHOLE LIMIT SWITCH X32 SERIES DRIVE CUTOUT SWITCH X32 SERIES SECTION F DECALS BATTERY DECALS 1532ES 1932ES 5 DECALS 1532ES 1932ES Basz DECALS 1532ES 1932ES Scissons DECALS 1532 5 1932 5 PLATFORM October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION A CONTROL BOXES REMOVABLE CONTROL BOX ASSEMBLY A 3 FIXED CONTROL Box ASSEMBLY pe 5 UPPER CONTROL Box COVER ASSEMBLY 4 7 lors ee rr A 9 LOWER CONTROL 8 A 11 LOWER CONTROL 13 WIRE HARNESSES LOWER CONTROLS pp A 15 WIRE HARNESSES COMMUNICATION CABLE
74. S 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION ress ______ 1 25057 2 RAIL MAIN EXTENSION PLATFORM 3 HDW8294 4 WASHER FLAT 5 16034 1 RAIL FRONT EXTENSION PLATFORM 7 HDW7471 8 SCREW 5 16 18 3 LG PLATFORM EXTENSION WELDMENT 9 HDW8486 8 SCREW 5 16 18 1 7 8 LG 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page B 5 ILLUSTRATION No ART_2229 October 2008 Page B 6 Lanyard Attachment Option 1532ES 1932ES 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION LANYARD ATTACHMENT 3923 4 BRKT ATTACHMENT POINT 3 8606 1 DECAL WARNING RESTRAINT LOCK NUT 3 8 16 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page B 7 656 3 ILLUSTRATION No ART_2252 October 2008 Page B 8 Reference ART_685 1532ES 1932ES Service amp Parts Manual ANSI Specifications Entry Chain and Rail X32ES ITEM NO DESCRIPTION ENTRY GATE alwe 1 oven an mo ornon 000 7805 3 FT PAD RAIL HON ONLY i HDW90792 2 PIN LOCK 5 16 6 8304 4 NUT 3 8 16 5239 2 LINK CONNECTING S HOOK Fir W jme cramouroassrmmouuoesmeus7 0a9
75. S OR FUEL VAPORS Four 4 6 volt batteries supply the 24 volt electrical power required to operate the electrical circuits Battery Maintenance in storage Follow these procedures for maintenance of battery on a machine not in use Keep battery clean Electrolyte of wet batteries should be checked regularly and kept at proper level Never stack one battery directly on top of another because post or container damage can result If batteries are stored individually place supporting boards between layers Rotate stock so that oldest batteries are used first batteries should be kept fully charged A wet battery while in storage should be recharged to full charge at recommended intervals Leaving the MEC charger connected during prolonged storage will maintain battery voltage automatically A battery fully 100 96 charged at 80 F 26 6 C drops to 65 at 32 0 drops to 40 96 at 0 F 32 Recommended Intervals If Stored At Recharge Below 40 F 4 None required Above 60 F 15 Every month 40 60 F 4 15 C Every 2 months October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 4 Battery Maintenance in use Check battery and surrounding area for signs of damage or corrosion Check battery terminals for Corrosion Regularly clean connections and apply nonmetallic grease or protective spray to retard corrosion
76. SED FOR PROPERTY DAMAGE ONLY ACCIDENTS 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page I NOTE The best method to protect yourself and others from injury or death is to use common sense If you are unsure of any operation don t start until you are satisfied that it is safe to proceed and have discussed the situation with your supervisor Service personnel and machine operators must understand and comply with all warnings and instructional decals on the machine MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATIONS WITHOUT WRITTEN PERMISSION FROM MEC ARE STRICTLY FORBIDDEN A MODIFICATION MAY COMPROMISE THE SAFETY OF THE MACHINE SUBJECTING OPERATOR S TO SERIOUS INJURY OR DEATH MEC s policies and procedures demonstrate our commitment to Quality and our relentless ongo ing efforts towards Continuous Improvement due to which product specifications are subject to change without notice Any procedures not found within this manual must be evaluated by the individual to assure one self that they are proper and safe Your MEC Scissor Lift has been designed built and tested to provide many years of safe de pendable service Only trained authorized personnel should be allowed to operate or service the machine MEC as manufacturer has no direct control over machine application and operation Proper safety practices are t
77. STRATION No ART_2162 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 5 PARKING BRAKE AND TOWING CIRCUIT Note Refer to Parts Section E for hose routing Machine can be winched or moved short distances in case of power failure at speeds not to exceed 5 mph 8 05 km h PRIOR TO MANUALLY RELEASING BRAKES INSURE WHEELS ARE CHOCKED TO PREVENT MACHINE FROM MOVING Release Brakes Before Towing Open the tow valve by turning counter clockwise Push in the manual brake release valve located on the main manifold Using the hand pump on the manifold pump valve until pressure is built Machine is now ready for towing AFTER RELEASING THE BRAKES THERE IS NOTHING TO STOP THE MACHINE S TRAVEL MACHINE WILL ROLL FREELY ON SLOPES BE ON GUARD AGAINST RUNAWAY To Reset Brakes Close the tow valve by turning it clockwise Brakes will reset when drive function is activated or reset by pulling on manual brake re lease valve October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 1 6 EMERGENCY SYSTEMS AND PROCEDURES IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE PLATFORM DO NOT ATTEMPT TO CLIMB DOWN SCISSOR ASSEMBLY BEFORE LOWERING PLATFORM RETRACT THE DECK EXTENSION
78. Sevcon Motor Speed 2 14 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page i Table of Contents SECTION 3 MECHANICAL COMPONENTS ee 3 1 Torque SpecificatlOTnis 3 2 Mechanical 3 3 Base lt d aod 3 3 Hoses and Cables pe 3 3 Raising the Machine pe 3 4 VVC GS NR n 3 5 Front Drive NUON S naana 3 6 Rear Wheel Brakes 3 7 Steer Cylinder 3 8 To replace steer cylinder 3 8 RR 3 9 Platform RR ea Ead me 3 10 Lift Cylinder Removal and Installation 3 11 Scissor uu 3 12 SECTION 4 TROUBLESHOOTING uu uuu u usa uaa anec Creav b db dedi 4 1 General Troubleshooting Tips J J 4 2 Hydraulic Pressure Adjustment Procedures 4 4 Troubleshooting 4 6 Sevcon Motor Speed Controller ee 4 14 LED Diagnostics Definitions Flash 4 15 S
79. UCTION _ ver 496 100 9 90819 1 HOSE ASSEMBLY LIFT CYLINDER 11 90286 2 HOSE ASSEMBLY DRIVE MOTORS 6675 AS REQ SEAL KIT DRIVE HOSE SWIVEL use when equipped with High Torque Manifold use when NOT equipped with High Torque Manifold 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page D 17 October 2008 Page D 18 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION E BASE LADDER AND CONTROL BOX BRACKETS Nt E 3 BASE COVERS M E 5 7 BRAKE ASSEMBLY Nt E 9 STEERING 1 HYDRAULIC 13 Por cd TETTE Em 15 WHEEL MOTOR susan DN Cc ME n M A E 19 BE INSTALLATION e E 21 POTHOLE LIMIT SWITCH X32 SERIES pp 23 DRIVE CUTOUT SWITCH X32 SERIES Ne E 23 BATTERY CHARGER pp E 25 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 1932ES m No ART 2301 Ladder Installation 1532ES 1932ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page E 2 ITEM NO DESCRIPTION LADDER AND Box BRACKETS 16063 LADDER 1532ES 16040 LADDER 1932ES HDW8283 SCREW 1 2 13 1 1 2 LG 4 HDW8457 4 NUT 4 2 13 5 25476 1 BRKT CONT
80. UNCTION Counter Balance PORTS PUMP SOL1 Coil SV1 Steer Right TANK SOL2 Coil SV1 Steer Left SOL3 Coil SV5 Brake Decel TEST PORT N A SOL4 Coil SV2 Lift BRAKE Torque STEER SV2 SOL5 Coil SV4 5016 Coil SV6 Torque STEER SOL8 Coil SV3 SOL7 Coil SV3 Drive Forward Drive Reverse RIGHT B FD1 Flow Divider NI gt gt coro LEFT A RIGHT A FRR1 Flow Control Steer Relief LEFT B HP1 Hand Pump Brake Pump MV1 Manual Valve Brake Release NV1 Needle Valve ORF1 Orifice Plug Freewheel Flow Restriction ORF2 Orifice Disc Flow Restriction PP1 Pilot Piston Counter Balance RV1 Relief Valve Lift Relief RV2 Relief Valve Main Relief SV1 Spool Valve Steering Control SV2 Spool Valve Lift Control SV3 Spool Valve Direction Control SV4 Spool Valve Torque SV5 Spool Valve Drive Dump Decel SV6 Spool Valve SOL11 Coil SV9 Torque Down Lift Cylinder SV9 Spool Valve Down Lift Cylinder LIFT
81. able jack stands under solid support points at the outer ends of the frame 5 Lower the machine to rest on the jack stands and inspect for stability To lower the machine 1 Raise machine slightly and remove jack stands 2 Lower the machine remove the jack 3 Remove chocks October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 3 4 Tires Wheels Tires are solid non marking rubber permanently mounted on a steel wheel Inspect for cuts chunking side wall damage or abnormal wear Any tire faults MUST BE CORRECTED before further machine operation Refer to Parts Section for replacements FAILURE USE APPROVED PARTS CAUSE DEATH OR SERIOUS PERSONAL INJURY NOTE Replace tires wheels with the correct parts to maintain the rating of this equipment Changing Tires Wheels ALWAYS BLOCK THE MACHINE BEFORE RAISING THE MACHINE When a tire wheel change is necessary follow these tips 1 While the machine is on the ground loosen but do not remove lug nuts NOTE Wheels may spin when attempting to loosen lug nuts without the weight of the machine on the wheels Loosen lug nuts enough to break free but leave them tight for safety Raise and support the machine see Raising the Machine Remove lug nuts and pull the wheel off Install the replacement wheel and tighten the lug nuts Lower the machine to the ground Torque l
82. achine see Raising the Machine 2 Remove the wheel and tire assembly to access brake 3 Disconnect hose assemblies from the brake 4 Remove the cap screws and remove the brake from the housing Replace Installation is reverse of removal b each Mounting Bolt uu 4 each Brake to Manifold Mounting Nut 4 each Hose Brake Hose lt Female to Male lt Hose Adapter TORQUE Ft Ibs Nm Lug Nuts 75 85 102 115 Brake Mount Bolts 65 72 88 97 5 T Fitting male male female ILLUSTRATION No Female to Male ART_2188 Hose Adapter 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 3 7 Steer Cylinder There is one 1 double acting type steer cylinder on this machine During operation cylinder should not leak but a slight damping at the rod seal is acceptable The pins should be checked for wear To replace steer cylinder CAUTION Clean all fittings before disconnecting hoses Tag hoses for proper reassembly Plug all openings to prevent contamination Raise and support the front end of machine see Raising the Machine Disconnect hydraulic hoses and cap them Remove the pins and cotter pin holding the steer cylinder to the motor mounting bracket Remove the pin and cotter pin holding the steer cylinder to the steer axle cross member Carefully lift off the steer cylinder ocu S m mI Position
83. all with a brass drift punch 1 Install fittings plugs springs balls and orifices Use one drop of Locktite 4424 or equiva lent thread locker on each screw in orifice 2 Install valves Installation 1 Attach manifold assembly to mounting plate with mounting bolts Connect solenoid leads as previously tagged Connect hydraulic hoses as previously tagged Be certain to tighten hoses Connect the battery Operate each hydraulic function and check for proper operation and leaks Adjust valve pressures W N 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 13 October 2008 Page 1 14 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION 2 ELECTRICAL SYSTEM Electrical System General DP 2 2 Deutsch Connectors 2 3 ren 2 4 Alarms SWIEChes 2 8 Continuity COCKS 3 2 12 Diode Board SOON 2 13 Sevcon Motor 2 14 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 2 1 ELECTRICAL SYSTEM GENERAL The electrical control system consists of a lower control box and an upper control box Lower Control box The ground station when enabled via the Base Platform Selector Switch disables t
84. and a 4 way 3 position solenoid operated hydraulic directional control cartridge valve Maximum steering pressure is limited by the relief valve refer to Relief Pressure Adjust ment Procedure Steer Cylinder There is one 1 cylinder utilized in the steering system This cylinder is a double acting type which requires fluid flow to operate the cylinder rod in both directions Directing fluid forces the piston to travel towards the rod end of the barrel extending the cylinder rod By directing fluid to the rod side of the cylinder the piston will be forced in the opposite direction and the cylinder rod will retract Refer to the Mechanical Section of this manual for cylinder disassembly or replacement Motor Mount Steer Pivot 1532 1932ES ILLUSTRATION No ART 2164 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 1 8 PLATFORM LIFT CIRCUIT Note Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure Refer to Section 3 for Remove and Replace instructions The lift system uses the hydraulic pump to obtain proportional lifting function controlled by the lift valve and pump speed Lowering is single speed controlled by the holding valves on the lift cylinder s and regu lated by a fixed orifice located on the lift cylinder s Platform capacity is limited by a hydraulic relief valve in the lift circuit Refer to Machine Specifications or the
85. auge bi Reservoir with platform in the stowed position Change yearly or every 1 000 hours whichever occurs first Anti Wear 150 SSU ISO 32 mil spec 0 5606 Hydraulic Filter element Change every six months or Filter 500 hours whichever occurs first for normal usage Change every three months or 300 hours whichever occurs first for Severe usage Lithium N L G 2 EP Weekly or every 25 hours purge old grease whichever occurs first Wheel Mount Pivot Point Filler Cap with Strainer Plastic Hydraulic Reservoir late models Return Filter Steel Hydraulic Reservoir early models October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page VIIT ILLUSTRATION No ART 2154 SECTION 1 HYDRAULIC SYSTEM Hydraulie AA 1 2 Hydraulic System Components sa 1 4 Parking Brake and Towing CIr iIt 1 6 Emergency Systems And Procedures U U 1 7 Sieenng 6 38 Platform B gelu 1 9 Cylinder E RE 1 10 Hydraulic Manifold J 1 13 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page 1 1 HYDRAULIC FLUID Handling Precautions PERSONS IN REGULAR CONTACT WITH MINERAL BASED HYDRAULIC FLUID NEED TO BE AWARE OF THE IMPO
86. ber 2008 Page 3 11 Scissor Beam Assembly Note Refer to Parts Section C for detailed parts list and illustration Clean the scissor assembly once a year or as necessary and inspect along the beam surfaces especially the welds and brackets Scissor Beam Removal 1 Remove the platform and ladder Attach a suitable lifting device to the scissor assembly Remove the stationary mounts Carefully lift until the rear of the scissor is clear and remove the limit speed cam Slide the scissor assembly to the rear until the slide block reaches the end of slide chan nel and lift the scissor assembly CAUTION The scissor assembly may shift suddenly upon clearing the slide channel C0 N 6 Remove slide blocks and wear pads 7 Clean all parts before installation Replace worn or damaged parts with new parts 8 Installation is reverse of removal X32bES Slide 0 Block E Limit Speed Cam SUN X33ES Nylon D Washer E S Set Screw lt 7 2 quw 4 Ladder X47ES Nylon Washer 3 Wear Bearing Pad lt gt 629 X 6 TORQUE Ft Ibs Nm ie Stationary Mount Bolts 86 96 116 180 ILLUSTRATION No Slide Block Ladder Mount Bolts 86 96 116 180 ART 220
87. ce amp Parts Manual ANSI Specifications OUTPUT To Sevcon for speed cutback October 2008 Page 2 13 SEVCON MOTOR SPEED CONTROLLER The Sevcon Motor Speed Controller located in the lower control box is a microprocessor de signed with the express purpose of operating the D C electric motor at varying speeds The controller uses Pulse width Modulation PWM technology on the Ground side of the motor to control motor speed Out of concern for operator safety and to prevent short circuiting the Con troller monitors certain circuits for potential abnormalities When the controller senses a problem it errs to the side of safety and stops all motor operation The green LED will flash a code indicat ing the reason for the shutdown Refer to Section 4 Troubleshooting for diagnostic codes Cable Connection Identification Battery Positive Cable from 250 AMP Fuse Negative Battery Cable and GROUND wire 15 connection Motor Ground Pulse Width Modulated PWM variable speed control J5 Plug Pin Identification Pin wiRE FUNCTION ___ B power input power up Lift Drive or Steer functions input functions requiring motor Steer Requested adds additional motor speed for steer Enable Switch signal input Speed cut back 24 Volts full speed 0 Volts creep speed Motor Start Relay signal GROUND signal to activate Motor Start Relay Lift Valve B provides GROUND signal to Lift Valve non
88. cerncccoven 000 3 HDW5636 1 SCREW 6 32 x 0 25 5 HDW8267 LOCKNUT 1 4 20 22 1 RECEPTACLE DUPLEX 7 8208 CONDUIT 3 8 FLEXIBLE 9 8479 BUSHING 3 4 ID CONNECTOR OUTLET BOX 3 8 CONDUIT 11 16221 BRACKET HDW8501 2 CLIP SELF RETAINING E E ss NIN NIN 28 FT 1532ES 35 FT 1932ES i HDW5217 FLAT WASHER 11 32 ID 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page B 19 October 2008 Page B 20 1532ES 1932ES Service amp Parts Manual ANSI Specifications SECTION C SCISSORS Scissor ASSEMBLY 1532ES SERIAL UP 9001099 Scissor ASSEMBLY 1532ES SERIAL 9001100 UP Scissor ASSEMBLY 1932ES SERIAL UP 9105899 Scissor ASSEMBLY 1932ES SERIAL 9105900 UP SCISSOR ASSEMBLY MOUNT pp LIFT CYLINDER MOUNT pp LiFt CYLINDER 25297 uu aquqa au aa CYLINDER 90801 WITHOUT EMERGENCY LOWERING CABLE CYLINDER 90801 WITH EMERGENCY LOWERING CaABLE CYLINDER 91055 WITH EMERGENCY LOWERING CaABLE 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page C 1 oenores
89. clean the surrounding area before opening E hydraulic systems M Use only recommended lubricants Improper lubri E cants or incompatible lubricants may as harmful V as no lubrication Watch for makeshift fixes which can jeopardize 2 nec ILLUSTRATION No X safety as well as lead to more costly repair AN ART_2152 1532ES 1932ES Service Parts Manual ANSI Specifications October 2008 Page IIT Hydraulic System HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN SKIN DAMAGE EYES AND MAY CAUSE SERIOUS INJURY BLINDNESS AND EVEN DEATH CORRECT LEAKS IMMEDIATELY Hydraulic fluid leaks under pressure may not always be visible Check for pin hole leaks with a piece of cardboard not your hand Electrical System Prevent damage to battery and or electrical system Always disconnect the negative battery cable first Always connect the positive battery cable first When connecting battery cables connect the positive terminal first If the negative cable is in stalled first and contact is made between the positive side of the battery and a metal surface on the machine while connecting the positive cable a spark will occur This can cause damage to the electrical system battery explosion and personal injury Total System Failure to perform preventive maintenance at recommended intervals may result in the unit being
90. cribed in the following Charging State table If all 3 LEDs blink together there is a problem Take proper action according to the trouble shooting guide found in Section 4 Troubleshooting The charger goes into an equalizing charge mode after the batteries are charged and all 3 LEDs are ON The charger will continue to charge at a low cur rent then shut off automatically when complete Charging State amp LED Display Charging State LED 0 to 50 charged Blinking OFF OFF 50 to 75 charged ON Blinking OFF 75 96 to 100 charged ON ON Blinking 100 charged ON ON ON Abnormal Cycle Blinking October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 6 Battery Replacement BEFORE REMOVING THE BATTERIES FROM THE MACHINE TURN OFF THE SELECTOR KEY SWITCH THERE SHOULD BE NO POWER Prevent damage to battery and or electrical system Always disconnect the negative battery cable first Always connect the positive battery cable first Main Electrical Power To remove batteries follow these procedures Batteries are located in the side compartment of the machine Always disconnect the negative battery cable first Remove bolts holding battery Lift the battery from the compartment Put the battery to the side and dispose of properly 24 VDC BATTERY CHARGER To install the battery reverse the process by posi tioning the battery
91. deployed Pothole limit switch s LS2 amp LS3 inoperative Decel valve SV7 inoperative earlier units only Pump output reduced due to wear Counterbalance Valve CBV1 out of adjustment Steer valve SV1 not shifting Steering linkage binding No power to SV1 Steering Cylinder internal failure Selector switch S6 inoperative Broken wire in joystick Micro switch S4 inoperative Damaged wiring or poor plug connection Failed diode in diode board 1532ES 1932195 Service amp Parts Manual ANSI Specifications REMEDY SOLUTION Clear debris from under pothole bars Check pothole linkage operation Check switche s for presence of Ground on wire 151 when pothole bars completely deployed Check for power to SV7 while driving Check valve for contanimation Replace valve Test pump with a flow meter Replace See Setting Counterbalance Valves in this section Replace valve Check power to SV1 remove SV1 and check for contanimation Replace SV1 Inspect lube linkage replace as necessary Check for broken wires between lower control box and SV1 valve Inspect replace seals Check for power on wire 3 and 3a when steer attempted Check for broken Blue wire in joystick handle Check operation of micro switch located in uppercontrol box in joystick handle Check wire 7 through plug connections from upper control box to Diode Board Test diodes on diode board Replace diode board Troubleshooting cont
92. e Accelerator reference signal 3 6 Volts to Potentiometer none none none ILLUSTRATION No ART_2182 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 14 SECTION 3 MECHANICAL COMPONENTS Torque Sp cifications fim 3 2 Mechanical 6 0 3 3 3 3 HOSES ANG 65 E 3 3 Raising Machine 3 4 3 5 Front Drive e E 3 6 nium sir 3 7 Steer Cylinde hn 3 8 To replace SteSr www 3 8 0 7 3 9 Platform Removal 3 10 Lift Cylinder Removal 3 11 Scissor Beam ASSembly 3 12 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 3 1 TORQUE SPECIFICATIONS Fasteners Use the following values to apply torque unless a specific torque value is called out for the part being used AMERICAN STANDARD CAP SCREWS METRIC CAP SCREWS SAE GRADE 5 8 METRIC GRADE 8 8 10 9 92 99 es C CAP SCREW CAP SCREW SIZE TORQUE TORQUE SIZE TORQUE TORQUE inches
93. e of Contents Service Manual INTRODUCTION u L u Gen ral Safety v Hydraulic SV IV Electric IV Total System IV Machine Specifications 73 0 V Primary Machine Components T VII VIII SECTION 1 HYDRAULIC SYSTEM ee 1 1 Hydraulic nM 1 2 Hydraulic System 7 4 Parking Brake and Towing Circuit 1 6 Emergency Systems And Procedures 1 7 Steering uas ias cniin ara ER SR NO 1 8 Platform Lift Circuit 1 9 Cylinder Repair ee 1 10 Hydraulic MODITOIQ aeneae uM EE SE aaa 1 13 SECTION 2 ELECTRICAL SYSTEM 2 1 Electrical System General 2 2 Deutsch J l 2 3 Batterie S P 2 4 Alarms and Switches 24242 2 08 2 8 ConiinuiltyeChnecks uro iiia ond dx exa 2 12 Diode Board ME 2 13
94. ecifications October 2008 Page D 1 CHASSIS REAR ILLUSTRATION No ART_2285 October 2008 Page D 2 1532ES 1932ES Service amp Parts Manual ANSI Specifications Brake Release Pump X32ES ITEM NO DESCRIPTION 153255 SERIAL 9001000 4 9001099 90234 E BRAKE RELEASE MANIFOLD 2 90325 1 BLOCK MANIFOLD FITTING 90 MALE 1 4 O RING MALE 3 8 4 HDW7438 1 FITTING ADAPTOR MALE 3 8 O RING MALE 3 8 6 REF 1 HOSE ASSY B bud SCREW 1 4 20 2 LG 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page D 3 CHECK VALVE FLOW CONTROL FLOW DIVIDER PEuEF 588 COUNTER 80 1532ES Serial Up To 9001099 29 1932ES Serial Up To 9104999 9999 Hydraulic Manifold Assembly X32ES ART_2286 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page D 4 Main MANIFOLD AssEMBLY EARLY MobeL 1932ES SERIAL 9104000 9104999 1 8343 1 VALVE SPOOL POP 2 WAY W MAN OVERRIDE slime NONNE 9992 1 VALVE RELIEF p VALVE SPOOL 4 WAY 3 POSITION STEERING 9988 3 COIL 24 VOLT i wam 0 9982 VALVE SPOOL 4 WAY i wana 5954 VALVE PRIORITY FLOW CONTROL es 11 9995 VALVE SPOOL 4 WAY 3 POSITION DRIVE 13 6 1 VALVE SPOOL 3 WAY
95. ent during drive operation e Provides a minimum motor speed for steer requirement when only steer is operated Enable signal When joystick trigger pulled input 5 less than battery voltage e Motor will not start without this input e A signal here longer then 15 seconds without a signal on pin 2 or pin 3 will result in a 2 flash code failure Speed cut back Full speed 24 V DC signal from limit Creep speed 0 V DC switch or Lift circuit Speed cut back is the elevated drive speed 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 17 Sevcon Motor Speed Controller Connections continued FUNCTION VOLTAGE READING PIN 6 WIRE 16 Motor Start Idle 24 V DC Relay ground When function requested 0 V DC signal This is how the Controller maintains control over the motor circuit Sevcon controls the Motor Start Relay function ground signal Will not operate the motor start relay when 2 3 4 amp 7 flash codes occur PIN 7 WIRE 41 Ground signal to O volts Lift solenoid No ground presence until lift is requested valve By providing the ground signal lift function can be prevented anytime battery voltage falls below 18 volts This will result in a 9 flash code PIN 9 WIRE 14 Accelerator From 3 5 V DC with joystick in the neutral to 0 V DC at full stroke reference signal Controller uses this circuit to monitor joystick input after pins 2 amp 4 to
96. ent lift function but will allow drive and steer functions When lift is interrupted due to a 9 flash the electric motor will still run October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 4 16 Sevcon Motor Speed Controller Connections The following two pages describe the connections to the Sevcon Motor Speed Controller with a brief description of their function and the voltage measurements under normal conditions Important Batteries must be fully charged before troubleshooting A fully charged battery set on a 24 V DC system will have a nominal voltage of 25 6 V DC EARLY UNITS 9 PIN 1 WIRE 22 WIRE Battery Positive Switched Input 5 less than battery voltage e Controller power up and reference point for battery state of charge e Green LED indicates controller power up e Power travels through the upper emergency stop switch with upper controls selected e 7 Flash code and 9 flash code indicate low voltage at this terminal Pin 2 Wire 17 Lift Drive or Motorized function is requested Steer functions 15 18 less than battery voltage requested e Controller begins the motor run sequence with this signal but still requires a signal on pin 4 and a change on pin 9 before the motor will operate Pin 3 Wire 18 Steer Function When steering is operated Requested 1506 1896 less than battery voltage e Adds motor speed to compensate for addition of steer requirem
97. er control panel to access the sensor Adjust the three flange nuts until the bubble on top of the sensor is centered Check that the electrical connections are correct and secured tight Close shut the lower control panel October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 10 Limit Switch There is a limit switch to prevent driving in high speed When the platform is raised above approximately 7 feet 2 13 meters the machine will be in the slow speed mode Pothole Switch When the platform is elevated above 8 feet the pothole switch cam rotates to activate the pothole switch causing the pothole bars to extend Limit Switch When the platform is lowered the pot hole switch cam rotates until the switch aligns with the cam low spot to deacti vate the switch and cause the pothole bars to retract ILLUSTRATION No b ART_2178 Pothole Switch 1532ES 1932ES Service amp Parts Manual ANSI Specifications Motion Light October 2008 Page 2 11 CONTINUITY CHECKS Check Toggle Switch Disconnect wires and connect one probe of ohm meter to the connection on toggle switch and the other probe on the other connection When toggle is open there should be no reading and when closed there should low resistance reading Check Selector Switch Disconnect wires and connect one probe of ohm meter to common and the other to nor mally open terminal
98. erial 1532ES 9001100 1932ES 9105000 2033ES 8804100 2633ES 1101000 Reference Art 965 Publication Art _2195 LIFT CYLINDER STEERING CYLINDER 1 1 0 GPM 850 PSI October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 5 5 Hydraulic Manifold early style Model Serial 1532ES 1932ES 2033ES 2633ES Reference Art none Publication Art ART_2196 NOTE Early style manifold Refer to Hydraulic Schematic for serial break COMPONENTS CBV1 Relief Valve FUNCTION Counter Balance LIFT CYLINDER 1532ES 1932ES 2033ES 2633ES PORTS PUMP CV1_ Check Valve Flow Control Brakes TANK 5011 Coil SV1 Steer Right TEST PORT 5012 Coil SV1 Steer Left BRAKE RELEASE SOLS Drive Decel BRAKE 5014 Lift STEER SOL5 Torque STEER SOL6 Torque RIGHT A SOL7 Drive Forward ojo NI RIGHT B SOL8 Drive Reverse SOL9 Brakes LEFT B LEFT A SOL10 Down FD1 Flow Divider Manual Valve Brake Release Needle Valve Orifice Plug Freewheel Flow Control Steer Relief Relief Valve Lift Relief Relief Valve Main Relief Relief Valve Steering Relief Spool Valve S
99. es Horn On Upper Control Box Horn 12V 48V option Activated by Operator Under Platform Overload Motion Alarm option Warn of Movement Outside Lower Control Box Motion Light option Warn of Movement Front Left Corner of Machine Hour Meter Record Machine Usage Time Lower Control Panel Battery Indicator Show Battery Status Lower Control Panel 6 V Deep Cycle Battery Power for Motor And Control Circuit Inside Battery Compartment Battery Disconnect Switch Disconnect All Electrical Power Lower Control Box Circuit Breaker 15AMP Manual Control Circuit Protection Lower Control Panel Battery Charger Recharges 24 VDC Battery Pack Machine Base Rear Charger Relay Disconnect Electric when Charger ON Inside Charger Circuit Board Diodes Directs Signal to Proper Location Inside Lower Control Box Diode w Ring Terminals Suppression Diode Across Contactor Coil Diode Optional Out of Level Alarm Main Harness Switch Emergency Stop Shutdown All Moving Functions Lower Control Panel Switch Emergency Stop Shutdown All Platform Functions Upper Control Box Fuse 200AMP Main Line Fuse Inside Lower Control Box Limit Switch Double Pole Enable Drive and High Speed Right Rear Corner of Machine Limit Switch Single Pole Drive Enable if Pothole Deployed On pothole Linkage Motor
100. evcon Motor Speed Controller Connections se 4 17 Troubleshooting Battery Charger 097 4 19 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page ii Table of Contents SECTION 5 SCHEMATICS 153255 Serial 9001000 9001099 19325 Serial 9104000 9104999 esun 153255 Serial 9001100 Current 1932ES Serial 9105000 Current Electric Schematics 1532ES S N 9000500 9001099 1932ES S N 9104000 9104999 1532 S N 9002000 Current 1932ES S N 9105000 Current Canadian Models 1532 5 S N 9002000 Current 1932bS S N 9105000 Current 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page iii Table of Contents Parts Manual SECTION A CONTROL BOXES SECTION B PLATFORM AND RAILS SECTION C SCISSORS SECTION D HYDRAULICS SECTION E BASE SECTION F DECALS October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications age INTRODUCTION This manual consists of Service and Parts sections The Service Section of this manual is designed to provide you the customer with the instructions needed to properly maintain the MEC self propelled scissor lift When used
101. f fitness for a particular purpose are hereby excluded No Dealer Sales Representative or other person purporting to act on behalf of MEC Aerial Platform Sales Corp is authorized to alter the terms of this warranty or in any manner assume on behalf of MEC Aerial Platform Sales Corp any liability or obligation which exceeds MEC Aerial Platform Sales Corp s obligations under this warranty Aerial Platform Sales Corp 1775 Park Street Suite 77 Selma 93662 USA Ph 1 800 387 4575 559 891 2488 Fax 559 891 2448 E mail info mecawp com Web www mecawp com
102. gnal to Proper Location Inside Lower Control Box Circuit Board Resistors Inside Lower Control Box Diode w Ring Terminals Suppression Diode Across Contactor Coil Switch Emergency Stop Shutdown All Moving Functions Lower Control Panel Switch Emergency Stop Shutdown All Platform Functions Upper Control Box Fuse 200AMP Main Line Fuse Inside Lower Control Box Limit Switch Double Pole Enable Drive and High Speed Right Rear Corner of Machine Limit Switch Single Pole Drive Enable if Pothole Deployed On pothole Linkage Motor 24V 2HP Turn the Hydraulic Pump Pump Compartment Controller DC 250AMP Changes the Motor Speed Inside Lower Control Box Potentiometer 20K Ohms Senses Operator Input Upper Control Box Relay SPDT 2 Pole Cutout Function when Tilted Inside Lower Control Box Key Switch N O Contact Block Select Base or Platform Controls Lower Control Panel Switch Toggle Lift Lower at Lower Controls Lower Control Panel Switch Push Button Enable Other Functions at Platform Upper Control Box Handle Switch Micro Right Turn Switch Upper Control Box Handle Switch Micro Left Turn Switch Upper Control Box Handle Switch Toggle Select LIFT or DRIVE Upper Control Box Switch Micro Reverse or Lift Switch Upper Control Box Switch Micro Forward or Down Switch U
103. he AC supply cord securely to a live AC outlet Double check the outlet to ensure it is working by connecting a known good piece of equipment with the outlet Inspect the DC output wires and connections to be sure they are in good working condition Refer to LED Flash Codes below if all 3 LEDs are flashing Replace charger if everything else is correct Output connection error Check the battery and charger connection and correct The output may not be connected to the batteries The connections to the batteries may have corroded or loosened The output may be shorted due to improper connection to the batteries or pinched wires The output may be connected in reverse polarity to the batteries The charger will not be damaged by any of these problems AC input voltage tolerance beyond limit Check the AC input voltage The charger is indicating the AC voltage is too low or too high This is an unusual problem and would most likely occur with a very poorly regulated engine generator set providing the AC voltage to the charger Charger is overheated No action required When the charger cools charging will restart automatically Check and correct for dirt or other debris on charger that may be reducing cooling Input or output over current No action required charger will correct and restart automatically The 18 hour timer has elapsed and stopped charging Batteries are unable to complete constant current and constant vo
104. he responsibility of the user and all operating personnel If There Is A Question On Application And Or Operation Contact Aerial Platform Sales Corp 1775 Park Street Suite 77 Selma 93662 USA Ph 1 800 387 4575 559 891 2488 Fax 559 891 2448 www mecawp com October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page II GENERAL SAFETY TIPS Regular inspection and conscientious maintenance is the key to efficient economical operation of your scissor lift will help to assure that your equipment will perform satisfactorily with a mini mum of service and repair The actual operating environment of the machine governs the inspection schedule Correct lubri cation is an essential part of the preventative maintenance to minimize wear on working parts and ensure against premature failure By maintaining correct lubrication the possibility of me chanical failure and resulting downtime is reduced to a minimum DANGER MA NEVER PERFORM SERVICE ON THE MACHINE WITH THE PLATFORM ELEVATED WITHOUT FIRST BLOCKING THE SCISSOR ASSEMBLY IN PLACE USING THE MAINTENANCE LOCK Block scissor assembly using Maintenance Lock if machine is in the elevated extended position Never leave hydraulic components or hoses open They must be protected from contamination includ ing rain at all times Never open a hydraulic system when there are contaminants in the air Always
105. he upper station and provides control for a fixed speed Lift UP DOWN functionality Upper Control box The upper station consists of a joystick controller with enable switch trigger Lift Drive Mode Forward Down Reverse Up and accelerator demand Steer Right Left A torque mode switch causes both hydraulic motors to operate in parallel rather than in series for speed control mode normal October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 2 DEUTSCH CONNECTORS Deutsch connectors used on MEC equipment is designed so that individual parts may be replaced without replacing the entire component Special tools and detailed instructions are provided in Deutsch Connector field kits MEC part 84091 Male Plug Connector Use the flat end of the Removal Tool or a flat blade screwdriver to pry the locking wedge from the connector taking care not to damage the Sealing Gasket Inspect and replace damaged parts Replace or re crimp wires and contacts Female receptacle Connector Use the notched end of the removal tool or a wire hook to pull the locking wedge from the connector Replace worn or damaged parts Replace or re crimp wires and contacts Locking Fingers Remove the locking wedge as outlined above Using the removal tool or a flat blade screwdriver push the Locking Fingers aside to release the contact Pull the wire and contact out of the connector Heavy Duty
106. hifting Drive valve SV3 sticking Drive valve SV3 powered in one direction 1532ES 1932ES Service amp Parts Manual ANSI Specifications REMEDY SOLUTION Check operation of micro switch Located in upper control box on joystick Check power through S6 on wire 10 Check wire 10 through plug connections from upper control box to Diode Board Test diodes on diode board Replace diode board Check operation of micro switch Located in upper control box on joystick Check power through S6 on wire 11 Check wire 11 through plug connections from upper control box to Diode Board Test diodes on diode board Replace diode board Check power to SV3 remove SV3 Check for contanimation Replace SV3 Check power to SV3 remove SV3 Check for contanimation Replace SV3 Check SV3 for contanimation Replace SV3 Short in wiring faulty diode board October 2008 Page 4 9 Troubleshooting continued PROBLEM DRIVE CoNTINUED No Drive above limit switch HIGH pressure indicated at Test Port TP 1 No Drive above limit switch LOW pressure indicated at Test Port TP 1 Speed uncontrolable while decending a hill No Steer Either direction Pump motor OPERATES while attempting to steer No Steer Either direction Pump motor NOT operating while attempting to steer No Steer Right only Pump motor NOT operating while attempting to steer October 2008 Page 4 10 POSSIBLE CAUSE Pothole system not
107. ice amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION trees 0000 1 13647 1 CONTROL ARM 4 7875 1 6 768 1 WASHER FLAT HDW7887 1 SCREW 6 32 1 2 LG b BRACKET CENTERING 10 3763 1 STEP 12 HDW8531 2 WASHER FLAT 14 3782 DIRECTIONAL 16 6917 CLAMP CABLE 1 4 WASHER FLAT 19 5736 1 RING RETAINING 1 2 SCREW 4 40 5 8 LG 21 8383 1 POTENTIOMETER 23 8389 1 GEAR SPUR SCREW 10 32 1 2 LG 25 3764 2 PLATE SPACER 27 3765 2 PLATE STRAP 29 7819 1 BEARING BRONZE FLANGED SPRING JOYSTICK CENTERING 31 13527 1 POTENTIOMETER ASSEMBLY INCLUDES 21 22 amp 23 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page A 7 ILLUSTRATION No ART_2221 October 2008 Page 8 Reference ART_188 1532ES 1932ES Service amp Parts Manual ANSI Specifications Control Arm Joystick ITEM NO DESCRIPTION JOYSTICK 13647 CONTROL ARM ASSEMBLY TGK 8453 1 SWITCH SERVICE SCREW 6 1 2 LG SERVICE ONLY 8752 GRIP TOP HALF SERVICE ONLY GRIP BOTTOM HALF SERVICE ONLY 6 13638 1 CONTROL ARM WITHOUT WIRE TRIGGER SERVICE ONLY 8456 1 ROCKER BOOT SERVICE ONLY sem 8630 1 HANDLE GRIP _ ms Siro pesem moron 00000 8089 1 WIRE BLK 18GA 300V
108. in conjunction with the illustrated Parts Section and the Operators Manual provided separately this manual will assist you in making necessary adjustments repairs identifying and ordering the correct re placement parts All parts represented here are manufactured and supplied in accordance with MEC s quality standards We recommend that you use Genuine MEC parts to insure proper OPERATION and reliable PERFORMANCE To obtain maximum benefits from your MEC scissor lift always follow the proper operating and maintenance procedures Only trained authorized personnel should be allowed to operate or service this machine Service personnel should read and study the Operator s and Service and Parts Manual in order to gain a thorough understanding of the unit prior to making any repairs To help you recognize important safety information we have identified warnings and instructions that directly impact on safety with the following signals DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME SITUATIONS WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES CAUTION IS U
109. in the compartment securely with hold down bolts Connect battery cables ees 6 VDC eee 4 gt No ART_2184 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 2 7 ALARMS AND SWITCHES Emergency Stop Button There are two red emergency stop buttons one located on the upper con trols and the other on the lower control panel This stop button when in the ON OUT position provides power to the desired control box Also the stop button in the event of an emergency can be used to turn off the power by pushing IN All functions stop immediately when de pressed ENABLE BAR TRIGGER STEERING SWITCH JOYSTICK FORWARD REVERSE UP DOWN LIFT DRIVE SWITCH lt EMERGENCY STOP SWITCH Turn button clockwise to reset NOTE As a safety feature 7 TORQUE selecting and operating NN _ 7 SWITCH the lower controls will 76 override the upper y TILT controls emergency stop INDICATOR button 224 HORN BUTTON The lower control box emergency stop OPTIONAL TH 6 2 15 1 button will stop machine operations even if the selector switch is switched to upper controls ILLUSTRATION No ART_2176 Horn It is activated at the upper controls and sounds at the g
110. inal purchaser against defects in material and or workmanship under normal use and service for one 1 year from date of registered sale or date the unit left the factory 11 not registered Aerial Platform Sales Corp further warrants the structural weldments of the main frame and scissor arms to be free from defects in material or workmanship for five 5 years from date of registered sale or date unit left the factory if not registered Excluded from such warranty is the battery s which carries a ninety 90 day warranty from described purchase date Warranty claims within such warranty period shall be limited to repair or replacement MEC Aerial Platform Sales Corp s option of the defective part in question and labor to perform the necessary repair or replacement based on MEC Aerial Platform Sales Corp s then current flat rate provided the defective part in question is shipped prepaid to MEC Aerial Platform Sales Corp and is found upon inspection by MEC Aerial Platform Sales Corp to be defective in material and or workmanship MEC Aerial Platform Sales Corp shall not be liable for any consequential incidental or contingent damages whatsoever Use of other than factory authorized parts misuse improper maintenance or modification of the equipment voids this warranty The foregoing warranty is exclusive and in lieu of all other warranties express or implied All such other warranties including implied warranties of merchantability and o
111. inued PROBLEM DRIVE CoNTINUED No Steer Left only Pump motor NOT operating while attempting to steer No Steer Right only Pump motor OPERATES while attempting to steer No Steer Left only Pump motor OPERATES while attempting to steer Drives in one direction regardless of direction request POSSIBLE CAUSE Micro switch S5 inoperative Damaged wiring or poor plug connection Failed diode in diode board Steer valve SV1 not shifting Steering linkage binding Steering Cylinder internal seal failure Steer valve SV1 not shifting Steering linkage binding Steering Cylinder internal seal failure Steer valve SV1 sticking Drive valve SV1 powered in one direction 1532ES 1932ES Service amp Parts Manual ANSI Specifications REMEDY SOLUTION Check operation of micro switch located in uppercontrol box in joystick handle Check wire 8 through plug connections from upper control box to Diode Board Test diodes on diode board Replace diode board Check power to SV1 Remove SV1 and check for contanimation Replace SV1 Inspect lube linkage replace as necessary Inspect replace seals Check power to SV1 Remove SV1 and check for contanimation Replace SV1 Inspect lube linkage replace as necessary Inspect replace seals Inspect SV1 valve for debris Replace SV1 Short in wiring faulty diode board October 2008 Page 4 11 9 10 11 October 2008 Page 4 12 on
112. keep all parts clean when working with hydraulic cylinders even one small piece of dirt or grit can damage the cylinder October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 1 12 HYDRAULIC MANIFOLD Note Refer to Section 3 for Remove and Replace instructions and the Parts Section for a list of hardware Tag all components as they are removed so as not to confuse their location during reassembly Hydraulic Manifold Removal 1 Disconnect the negative battery terminal 2 Tag and disconnect the solenoid valve leads 3 Tag and disconnect hydraulic hoses and IMMEDIATELY cap the openings to prevent contamination 4 Remove the bolts that hold the manifold to the mounting bracket 5 Remove the manifold block Disassembly 1 Remove coils from solenoid valves 2 Remove valves 3 Remove fittings plugs springs balls and orifices Cleaning and Inspection 1 Wash the manifold in cleaning solvent to remove built up contaminants then blow out all passages with clean compressed air 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 defective parts and O rings Assembly Note Lubricate all O rings before installation to prevent damage to the O ring Seat balls in manifold block by lightly tapping on the b
113. king sure all vents are in place Do not allow cleaning water or other foreign mater to enter the cells Use a solution of bicarbonate of soda 5 tsp of baking soda per quart of warm water and water to wash the battery if there is an accumulation of acid Battery Specific Gravity and Voltage Table SPECIFIC GRAVITY VOLTS DC BATTERY Fully Charged 1 280 12 60 Fully Discharged 1 130 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 2 5 Battery Charging Main Electrical Power The use of an improper extension cord could result in a risk of fire or electric shock The use of long extension cords with the charger should be minimized If an extension cord is used ensure that it has three conductors with a ground and that the wire size and length meet your electrical code for the voltages and currents of the Electrical Specifications table Locate all cords so that they will not be driven over stepped on tripped over or otherwise subjected to damage or stress Connect the power supply cord to a properly grounded 100 v 50 or 60 Hz 115 v 60 Hz or 230 v 50 or 60 Hz socket This charger automatically senses and adjusts to the AC input voltage range The charger will start automatically within four to six seconds The charger will start even with severely discharged batteries down to 1 volt terminal voltage Once charging starts the LEDs indicate the charging progress as des
114. ller ITEM NO DESCRIPTION 1 5918 1 RING RETAINING HEAVY DUTY 1 2 0 1 WASHER 3 18230 1 ROLLER 4 13267 1 ROLLER PLATE WELDMENT 1532ES 1932 ES Service amp Parts Manual ANSI Specifications October 2008 Page B 15 Connect Horn Wires to Terminals 6 and 9 2 4 55 Cu ILLUSTRATION No ART_2227 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page B 16 ITEM NO DESCRIPTION TERMINAL BLOCK HDW5363 2 SCREW 6 32 1 LG 3 5882 2 CABLE CLAMP 5 5991 1 TERMINAL BLOCK REF 1 WIRE HARNESS UPPER CONTROLS E HoRN ANSI OPrioN HDW5723 1 4 3 4 LG 2 2 2 Nor SuowN i HOSE 1 4 AIRLINE 1532ES 27 FT 19328 33 CLAMP HOSE FITTING 1 4 MALE MALE HOSE BARB 8559 HDW5052 2 2 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page B 17 ILLUSTRATION No ART_2228 October 2008 Page B 18 Power to Platform Outlet Installation 1532ES 1932ES Service amp Parts Manual ANSI Specifications ITEM NO DESCRIPTION POWER TO PLATFORM 90827 BOX RECEPTACLE eee 1 oumexc
115. ltage charge cycle Batteries are weak old or have one or more bad cells Batteries will still charge but capacity will be reduced Replace batteries Battery pack too large for charger Use higher output charger or unplug then plug in charger to restart charge cycle to complete charging 1532ES 1982 5 Service amp Parts Manual ANSI Specifications October 2008 Page 4 21 Troubleshooting Battery Charger continued PROBLEM Batteries do not fully charge The AC line circuit breaker or fuse is blown October 2008 Page 4 22 DIAGNOSIS If the batteries are charged overnight make sure the AC supply is not being switched off at night with other building items Check battery condition following the battery supplier s instructions Check for dead cells or reduced capacity Replace charger only if other problems are not found defective circuit breaker or fuse overloaded circuit or a charger problem can cause this condition Connect the charger to a different AC outlet a different circuit in the building f the charger operates properly on other outlets a qualified Person should correct the AC outlet problem f the AC supply checks good the charger should be replaced 1532ES 1932195 Service amp Parts Manual ANSI Specifications SECTION 5 SCHEMATICS Hydraulic Schematics ge 1532ES Serial 9001000 9001099 1932ES Serial 9104
116. lve SV7 is eliminated Valve SV8 is eliminated Steering flow control valve PFC1 and relief valve RV3 are replaced by a single valve FRR1 Refer to the accompanying illustrations when using the Troubleshooting Guide October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 4 2 BRAKE RELEASE LIFT CYLINDER 2 lt All Models lt SA TI Located at H TU Rear of Machine on Early Models MAIN MANIFOLD Early Models MAIN MANIFOLD Current Models z Hydraulic Valve Locations 1532ES 1932ES 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 3 HYDRAULIC PRESSURE ADJUSTMENT PROCEDURES Before attempting to check and or adjust pressure relief valves operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid Insert a 0 3500 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no 8434 Pressure Adjustment Table MODEL MAN LIFT STEER COUNTERBALANCE PRESSURE 1532 5 2750PSI 190 bar 1900 PSI 131 bar 850
117. m 3 Check power to SV3 Remove SV3 and check for contanimation Replace SV3 Check Limit Switch LS1 for sticking or failure Loosen up with lubricant Replace Replace CBV1 Turn counter clockwise to close Inspect torque valves SV4 amp SV6 replace Check for power to SV7 while driving Check valve for contanimation Replace valve Test wheel motors Replace wheel motors Check power on wire 22 and 2 in limit switch with platform below 6 feet Test potentiometer POT1 for open circuit Located in upper control box Replace Check voltage on wire 13 while driving Check valves for contanimation replace SV4 SV6 Test wheel motors Replace wheel motors Troubleshooting continued PROBLEM DRIVE CoNTINUED No Drive in REVERSE only Pump motor NOT operating while attempting to drive No Drive in FORWARD only Pump motor NOT operating while attempting to drive No Drive in REVERSE only Pump motor OPERATES while attempting to drive No Drive in FORWARD only Pump motor OPERATES while attempting to drive Drives in one direction regardless of direction operated POSSIBLE CAUSE Micro switch S7 inoperative Mode Selector Switch S6 faulty Damaged wiring or poor plug connection Failed diode in diode board Micro switch S8 inoperative Mode Selector Switch S6 faulty Damaged wiring or poor plug connection Failed diode in diode board Drive valve SV3 not shifting Drive valve SV3 not s
118. n debris replace Clean orifice located under fitting at lift cylinder replace e down cable Clean debris replace October 2008 Page 4 7 Troubleshooting continued PROBLEM No drive either direction Pump motor runs while attempting to drive LOW pressure indicated at Test Port TP 1 No drive either direction Pump motor runs while attempting to drive HIGH pressure indicated at Test Port TP 1 Reduced slow or sluggish drive either direction Torque switch OFF Reduced slow or sluggish drive either direction Torque switch ON October 2008 Page 4 8 POSSIBLE CAUSE Freewheel Valve NV1 open Brake valve SV5 not shifting Brake valve SV5 not shifting no power on wire 19 Drive valve SV3 not shifting Drive valve SV3 not shifting no ground to valve coils on wire 151 Counterbalance Valve CBV1 failure Freewheel Valve NV1 partially open Torque valve s SV4 amp or SV6 sticking Decel valve SV7 inoperative earlier units only One or both Wheel motors WM1 WM internal bi pass Limit Switch LS1 inoperative 6 flash code at motor controller One Torque valve SV4 or SV6 not shifting One or both Wheel motors amp WM internal bi pass 1532ES 1932ES Service amp Parts Manual ANSI Specifications REMEDY SOLUTION Turn counter clockwise to close Check power to SV5 Remove SV5 and check for contanimation Replace SV5 Check power back to diode board ter
119. netration Steam clean the chassis as necessary and inspect all welds and brackets Check for cylinder pins that turn in their mounting which will indicate sheared retaining pins Hoses and Cables Note Refer to Parts Section E for detailed hydraulic hose diagrams Inspect all hoses and electrical cables for security and damage Hoses and cables should be examined for rubbing and chafing Check for leaks at fittings Replace any damaged hose or cable 1 Tag hoses for proper reassembly 2 Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination 3 Torque hose fittings according to the Hydraulic Torque Specification Table 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 3 3 Raising the Machine V DANGER THE USE OF SUBSTANDARD LIFTING DEVICES AND OR JACK STANDS MAY CAUSE THE MACHINE TO FALL RESULTING IN DEATH OR SERIOUS PERSONAL INJURY The following are needed to safely raise and support the machine a jack with a lifting capacity of two 2 tons or more jack stands with a rating of one 1 ton or more To raise the machine 1 Move machine to a firm level surface capable of supporting the weight of the machine 2 Chock tires on one end of machine and raise the other end of machine 3 Position a jack at the end of the machine to be lifted under a solid lifting point in the center of the frame 4 Raise the machine and place two 2 suit
120. onnect Switch Disconnect All Electrical Power Lower Control Box Circuit Breaker 15AMP Manual Control Circuit Protection Lower Control Panel Battery Charger Recharges 24 VDC Battery Pack Machine Base Rear Charger Relay Disconnect Electric when Charger ON Inside Charger 24 V Contactor Connects Battery to Motor Inside Lower Control Box Circuit Board Diodes Directs Signal to Proper Location Inside Lower Control Box Circuit Board Resistors Inside Lower Control Box Diode w Ring Terminals Suppression Diode Across Contactor Coil Switch Emergency Stop Shutdown All Moving Functions Lower Control Panel Switch Emergency Stop Shutdown All Platform Functions Upper Control Box Fuse 200AMP Main Line Fuse Inside Lower Control Box Limit Switch Double Pole Enable Drive and High Speed Right Rear Corner of Machine Limit Switch Single Pole Drive Enable if Pothole Deployed On pothole Linkage Motor 24V 2HP Turn the Hydraulic Pump Pump Compartment Controller DC 250AMP Changes the Motor Speed Inside Lower Control Box Potentiometer 20K Ohms Senses Operator Input Upper Control Box Key Switch N O Contact Block Select Base or Platform Controls Lower Control Panel Switch Toggle Lift Lower at Lower Controls Lower Control Panel Switch Push Button Enable Other Functions at Platfo
121. operated with a defect that could result in injury or death of the operator Immediately report to your supervisor any Defect or malfunction Any defect shall be repaired prior to continued use of the scissor lift Inspection and maintenance should be performed by qualified personnel familiar with the equipment October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page IV MACHINE SPECIFICATIONS Working Height 1532 1932 Platform Height Stowed Height Rails Up Rails Folded Down NA NA NA NA Maximum Number of Occupants 2 2 2 2 Lift Capacity Evenly Distributed Rollout Deck Capacity 600 Ibs 250 Ibs 272 2 kg 113 4 kg 500 Ibs 250 Ibs 226 8 kg 113 4 kg Platform Dimensions With Deck extended With Deck Retracted Guardrail Height Toeboard Height Deck Extension Length 102 in 66 in 40 5 in 7 5 8 in 36 in 2 59 m 1 68 m 1 03 m 0 19 m 0 91 m 102 in 66 in 40 5 in 7 5 8 in 36 in 2 59 m 1 68 m 1 03 m 0 19 m 0 91 m Overall Length Overall Width 74 in 31 5 in 1 88 m 0 80 m 74 in 31 5 in 1 88 m 0 80 m Wheelbase 50 in 1 27 m 50 in 1 27 m Wheel Track 27 37 in 0 70 m 27 37 in 0 70 m Turning Radius Inside Outside 2 in 67 in 5m 1 7 m 2 in 67 in 5m 1 7m Ground Clearance Machine Weight Unloaded Approx Drive System Proportional
122. oubleshooting this model check the battery state of charge and inspect the battery connections for loosness or corrosion A fully charged battery set on a 24 V DC system will have a nominal voltage of 25 6 V DC Before investigating a malfunction check the following items Check that battery connections are secure and battery is fully charged Check that the emergency stop button is released UP OUT position Check that the hydraulic fluid is at the correct level Check that the brake release valve is open Check that the circuit breaker is in the ON position Common Causes of Hydraulic System Malfunctions Incompatible hydraulic fluids mixed destroying the additives and causing varnish buildup resulting in the valves sticking Water in the hydraulic fluid due to a damp climate Improper hydraulic fluid used Viscosity too high in cold climates Viscosity too low in warm climates NOTES Contamination always causes failure in any hydraulic system It is very important to be careful not to introduce any contamination into your hydraulic system during the assembly procedures Make sure all ports and cavities of the manifold and cylinders are properly covered while other work is performed Early Model vs Current Model Current model hydraulics are modified in the following ways Electrical componentss use Deutsch style connectors The brake release hand pump is on the main manifold Valve CV1 is eliminated Va
123. pper Control Box Switch Toggle TORQUE Switch Upper Control Box Coil Turn Right Solenoid Activate Turn Right Valve SV1 Main Manifold Coil Turn Left Solenoid Activate Turn Left Valve SV1 Main Manifold Coil Decel Brake Solenoid Activate Decel Brake Valve SV5 Main Manifold Coil Lift Solenoid Activate Lift Valve SV2 Main Manifold Coil Torque Solenoid Activate Torque Valves SV5 SV6 Main Manifold Coil Reverse Solenoid Activate Reverse Valve SV3 Main Manifold Coil Forward Solenoid Activate Forward Valve SV3 Main Manifold Coil Down Solenoid Activate Down Valve SV9 Lift Cylinder October 2008 Page 5 14 1532ES 1932ES Service amp Parts Manual ANSI Specifications ELECTRIC SCHEMATIC CANADA Model Serial 1532ES 9002000 MODE SELECT SWITCH DRIVE LIFT 1932ES 9105000 Reference Art 1007 SWITCH CONTACT POSITIONS HELD OPEN NS I REV LIFT FWD DOWN 7 8 5 31 8 3 L 5 HELD CLOSED RIGHT 54 WIRE CONNECTOR LEGEND dL TERMINAL PUE LE 7 _ FEMALE SOCKET OS o TORQUE S9 2 39 POT1 ON OFF Ow as ENABLE 3 o
124. rm Upper Control Box Handle Switch Micro Right Turn Switch Upper Control Box Handle Switch Micro Left Turn Switch Upper Control Box Handle Switch Toggle Select LIFT or DRIVE Upper Control Box Switch Micro Reverse or Lift Switch Upper Control Box Switch Micro Forward or Down Switch Upper Control Box Switch Toggle TORQUE Switch Upper Control Box Coil Turn Right Solenoid Activate Turn Right Valve SV1 Main Manifold Coil Turn Left Solenoid Activate Turn Left Valve SV1 Main Manifold Coil Decel Brake Solenoid Activate Decel Brake Valve SV5 Main Manifold Coil Lift Solenoid Activate Lift Valve SV2 Main Manifold Coil Torque Solenoid Activate Torque Valves SV5 SV6 Main Manifold Coil Reverse Solenoid Activate Reverse Valve SV3 Main Manifold Coil Forward Solenoid Activate Forward Valve SV3 Main Manifold Coil Down Solenoid October 2008 Page 5 12 Activate Down Valve SV9 1532ES 1932ES Service amp Parts Manual ANSI Specifications Lift Cylinder ELECTRIC SCHEMATIC Model Serial 1532ES 9002000 1932ES 9105000 Reference Art 1007 SWITCH CONTACT POSITIONS ojo HELD OPEN NO HELD CLOSED WIRE CONNECTOR LEGEND TERMINAL E MALE PIN 7 Y FEMALE SOCKET ENABLE lt
125. round alerting personnel to clear the machine s path to avoid hazards or unsafe conditions uii D 7 gt Horn option option L ILLUSTRATION No Terminal Block 2183 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 2 8 Selector Switch Machine can be operated from the lower or upper controls Activation of one or the other is achieved with this switch With the upper controls selected from the lower control panel if the platform up lower function is operated there should be NO movement Similarly with the lt lower controls selected from the upper d controls if any machine function is oper PLATFORM ated there should movement CONNECTION Master Disconnect Switch gt ALARM The switch is used primarily to shut off 5 control circuit The battery disconnect is provided to facilitate servicing and also to prevent unauthorized use of the vehicle by using a padlock to provide security BATTERY CHARGER CONNECTION Movement Alarm This alarm is activated as soon as the upper control box joystick controller lever is moved off the center Neutral position 5 AB BATTERY DISCONNECT SWITCH HOUR METER BATTERY INDICATOR EMERGENCY STOP ELECTOR SWITCH S CTOR SWITC LIFT
126. teering Control Spool Valve Lift Control Spool Valve Direction Control Spool Valve Torque Spool Valve Drive Dump Decel Spool Valve Torque Spool Valve Brakes SV8 Poppet Valve _IDown MA3 Coil SV9 Down Lift Cylinder Spool Valve Emergency Lowering LIFT BRAKE RELEASE HAND PUMP 1532ES 1932ES 2033ES 2633ES October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 5 6 Hydraulic Manifold current style Model Serial 1532ES 1932ES 2033ES 2633ES Reference Art none NOTE Current style manifold Refer to Hydraulic Schematic for serial break Publication Art ART_2197 LIFT CYLINDER COMPONENTS CBV1 Relief Valve F
127. the energize potentiometer upper control box Voltages above 4 0 V DC or below 3 0 V DC will result in a 6 flash code Controls motor speed in reference to the voltage on this circuit POST B Battery positive Full battery voltage cable from 200 No real diagnostic value amp fuse Battery positive Battery ground cable connection cable from 200 amp fuse Ground path for motor operation All system ground wires wire s 15 amp 15A terminate here Best place to connect ground lead from multi meter while troubleshooting POST M 2 PWM controlled Idle 12 V DC 13 V DC motor ground During operation between 5 V DC amp 24 V DC 12 13 volts is reference voltage used by the controller to monitor motor circuit irregularities at idle O volts at idle 3 flash code Above 20 volts at idle 4 flash code No voltage change after Motor Start Relay signal 5 flash code October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 4 18 TROUBLESHOOTING BATTERY CHARGER To be able to use the trouble shooting guide safely and effectively it is important to read through this guide before beginning any tests Do not disassemble charger Return to MEC when service or repair is required DANGER TO REDUCETHE RISK OF ELECTRIC SHOCK ALWAYS DISCONNECT BOTHTHE POWER SUPPLY CORD ANDTHE OUTPUT WIRES BEFORE ATTEMPTING MAINTENANCE DO NOT OPER
128. the new steer cylinder and install pin and cotter pin to hold cylinder to the steer axle cross member 7 Install pin and cotter pin to hold cylinder to motor mounting bracket 8 Connect hydraulic hoses 9 To purge air from cylinder place a suitable container beneath the hose connections to catch spilled oil loosen hose fittings slightly actuate steer function when all air is purged tighten hose connections Motor Mount Steer Pivot Steer Cylinder Seal Replacement Refer to Section 1 for seal replacement instruc tions 1532 1932ES ILLUSTRATION No ART 2164 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 3 8 Pothole Circuit The Pothole Depression Rails are raised and lowered mechanically When the platform is el evated the depression rails are pulled into position by spring tension When the platform is low ered the bottom fixed beam in the scissor stack presses downward on the pothole actuator and raises the depression rails Repair 1 Raise and support the scissor assembly using the maintenance lock 2 Refer to the illustration and Section E of the Parts Manual Cotter Pin Clevis Pin Front Bulkhead Outer Roller Bar Spacer Tube Nyliner Bearing Flat Split Lock Washer Washer Lock Nut Q i 2 Oil Impregnated Flanged Bearin 4 9 9 2
129. ting Counterbalance Valves Before attempting to check and or adjust counterbalance valves operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid Insert a 0 1000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no 8434 Check and Adjust Pressure counterbalance If adjustment is required set pressure to the correct setting as follows Open freewheel valve NV1 completely drive in either direction Hold the switch for 10 seconds to get an accurate reading on the pressure gauge Early Models Loosen the jamnut Turn counterclockwise to increase the pressure Turn clockwise to decrease the pressure Current Models Using pliers or other gripping tool carefully remove the tamper proof cap Turn adjustment screw IN to increase the pressure Turn adjustment screw OUT to decrease the pressure When correct pressure is obtained replace tamper proof cap with a new one 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 4 5 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY SOLUTION GENERAL LOSS OF POWER No operation Main battery switch turned off Located on of lower control box from upper or j j lower control Emergency switch pushed in or Pull upper and lower emergency stop switches to station Base Platform switch turned off initiate power
130. ts for tightness Hydraulic Filter All machines are equipped with a filter It is a 10 micron spin on bypassing filter When the filter is clogged hydraulic flow bypasses the filter element The filter element must be changed every 6 months or 500 hours Extremely dirty conditions may require that the filter be replaced more often Beware of hot fluid Contact with hot fluid may cause burns Hydraulic Pump An electric motor drives the fixed displacement gear pump The pump provides hydraulic fluid flow to operate the machine functions at 3 gpm There are no adjustments on the pump The pump provides power for the lift drive brake and steering functions Filler with Strainer Late Models are equipped with a Translucent Plastic Hydraulic Reservoior Fluid Level Indicator Return Early Models are equipped with Filter Welded Steel Hydraulic Reservoior Plastic SIN Hydraulic Hydraulic Pump Heservoior and Motor ILLUSTRATION No ART_2160 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 1 4 Wheel Drive Circuit There are two 2 hydraulic fixed displace i ment gear wheel motors to provide power Wheel Motor the two 2 front wheels ILLUSTRATION No ART_2161 Braking Circuit Rear brakes are released whenever the machine is commanded to drive ILLU
131. ug nuts to 75 to 85 ft lbs 102 to 115 Nm Remove the chocks Oo O N 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 3 5 Front Drive Motors There are two 2 hydraulic motors on the front axle These can be damaged or leaks may occur repair or replace as necessary Refer to Section 1 Hydraulics for motor service and repair proce dure CAUTION Clean all fittings before disconnecting hoses Tag hoses for proper reassembly Plug all openings to prevent contamination Front Drive Motors Remove NOTE Removal of the motor does not require disconnection or removal of steering components Loosen the lug nuts Raise and support the front end of machine see Raising the Machine Remove the wheel and tire assembly to access drive motor R N Remove the cotter pin motor shaft nut and hub from the drive motor shaft 5 Turn the motor housing to gain ac cess to the motor and hose assem blies 6 Disconnect hose assemblies from drive motor 7 Remove the cap screws and remove the drive motor Replace Installation is reverse of removal Nm Lug Nuts 102 115 ILLUSTRATION No Motor Mount Bolts 88 97 5 ART_2186 Motor Shaft Nut 475 October 2008 1532ES 1932ES Service amp Parts Manual ANSI Specifications Page 3 6 Rear Wheel Brakes Refer to Parts Section E for brake kit Remove 1 Raise and support the rear end of m
132. ully down drain hydraulic fluid from hydraulic reservoir into an empty con tainer When the hydraulic reservoir is empty remove suction strainer and hoses Remove return line on the hydraulic reservoir Remove the bypass filter and hose Flush the hoses with clean hydraulic fluid Discard old bypass filter element and replace Flush out the tank with hoses removed from the hydraulic reservoir Reinstall all hoses in the previous steps Fill hydraulic reservoir with filtered fresh hydraulic fluid refer to Lubrication Chart Loosen output hose fittings at pump to flood with hydraulic fluid Tighten fittings Briefly operate all functions Two or three lift cycles may be necessary to purge all air from lift cylinder s When the above procedures have been completed fill hydraulic reservoir to full mark on sight gauge Check all leaks and correct as necessary Machine is now ready to be placed back into operation NOTE Avoid mixing petroleum and synthetic base fluids It is not advisable to mix fluids of different brands or types except as recommended 1532ES 1932ES Service amp Parts Manual ANSI Specifications October 2008 Page 1 3 HYDRAULIC SYSTEM COMPONENTS Hydraulic Fluid Reservoir This consists of the tank a filler cap with breather a drain plug and a bypass filler with a 10 micron filter element Perform the following steps weekly Check tank for signs of leakage Inspect tank securing bol

1532ES / 1932ES

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