Upright POWERED ACCESS TL34 Service Manual
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Upright POWERED ACCESS TL34 Service Manual

Upright POWERED ACCESS TL34 Service Manual

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POWERED ACCESS
TL34
WORK PLATFORM
Manual part number
for serial numbers 00001 to current.
510468-000
Sep 2009

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Summary of Contents for Upright POWERED ACCESS TL34

  • Page 1 POWERED ACCESS TL34 WORK PLATFORM Manual part number for serial numbers 00001 to current. 510468-000 Sep 2009...
  • Page 3 Operation M ANUAL TL34 This manual covers Serial Numbers to Current When contacting UpRight Powered Access for service or parts information, always include the from the machine namplate. MODEL SERIAL NUMBER The serial number is st mped into the chassis above the machine nameplate.

  • Page 6: Table Of Contents

    CONTENT SECTION Introduction Description of Equipment Technical Specification Working Envelope Operator Requirements Warning Notices Towing Instructions Pre-Start Checks 9-10 Batteries, & Power Pack Setting Up 12-14 Extending Structure Lowering Structure Slewing Structure Safety Harness & Emergency Controls 18-21 Stowing the Machine Maintenance 23-26...

  • Page 7: Introduction

    Operators should have read and understood the contents of the manual, and received full training in the safe use of the machine before attempting to use it. UpRight has a global reputation for innovation and a proud heritage in the design and manufacture of high quality powered equipment.

  • Page 8: Description Of Equipment

    DESCRIPTION OF EQUIPMENT The TL34 is a trailer mounted work platform with a 2-man cage giving access to maximum height of 12.20m. It offers safe, versatile and easy access for two men plus tools up to a total of 215Kg. Its unique boom configuration allows this height to be reached while still offering compact closed dimensions and exceptional manoeuvrability.

  • Page 9: Technical Specification

    TECHNICAL SPECIFICATION Operating Dimensions Maximum Working Height 12.20 m Maximum Cage Height 10.20 m Maximum Outreach 5.00 m Outrigger Footprint (manual) 3.6 m x 3.6 m Outrigger Footprint (hydraulic) 3.7 m x 3.7 m Cage Dimensions Length 1.20 m Width 0.80 m Guard-rail Height 1.10 m...

  • Page 10: Working Envelope

    WORKING ENVELOPE...

  • Page 11: Operator Requirements

    OPERATOR REQUIREMENTS To operate the machine you must be medically fit and have no problems with eyesight or hearing. You must have a good head for heights. Your primary concern must be the safe operation of the work platform, the safety of the people working with you, and the safety of other persons in your working area.

  • Page 12: Warning Notices

    The stabilisers are designed to operate on firm level ground with a minimum bearing strength of 50N/cm The maximum load imposed by an outrigger is 10.3kN. Advice should be obtained from UpRight as to the type of supports and precautions required before attempting to operate the machine outside these parameters.
  • Page 13 WARNING NOTICES DO NOT operate the machine unless all four outriggers are down and in full contact with the ground. The machine must be level and the wheels lifted visibly clear of the surface before the booms are raised. DO NOT move the machine with the basket raised and never allow cage or booms to slew into the path of oncoming vehicles.

  • Page 14: Towing Instructions

    TOWING INSTRUCTIONS The TL34 is designed to be towed from one site location to another behind saloon cars and light commercial vehicles (see vehicle manufacturers specification for suitability) at speeds up to 50mph (80km/h) where permitted paying regard to your relevant national traffic regulations.

  • Page 15: Pre-Start Checks

    PRE-START CHECKS The following Pre-Start Checks should be carried out before taking the machine to the place of work. Damaged or Loose Fittings. Visually Inspect the machine for signs of wear and tear, damage, loose or missing parts. Wheels. (For towing only) Check tyres are at the correct pressure, 55 psi (3.8 bar) and that the wheel nuts are tightened using the correct torque setting (100Nm).
  • Page 16 If the Emergency Lower is used during normal operation, DO NOT use the machine, Contact your local UpRight representative. g. From the cage controls test each machine function, lift and lower both Booms and slew clockwise and counterclockwise.

  • Page 17: Batteries, & Power Pack

    CONTROLS, BATTERIES & POWER PACK FIG. 3 DIPSTICK BATTERIES BATTERY CHARGER LOWER CONTROLS EMERGENCY LOWER OIL FILLER POWERPACK STOP CONTROL BOX CAGE CONTROLS EMERGENCY ‘GREEN’ ELEVATE BOOM & SLEW STOP MOTOR RUN BUTTON CONTROL LEVERS...
  • Page 18 SETTING UP MANUAL OUTRIGGERS. 1. Park the unit in an appropriate location at the workplace. 2. Apply the handbrake on the trailer and remove from the towing vehicle. Do not attempt to set up the machine on steep slopes, ramps or soft ground.

  • Page 19: Setting Up

    SETTING UP HYDRAULIC OUTRIGGERS Do not attempt to set up the machine on steep slopes, ramps or soft ground. 1. Park the unit in an appropriate location at the workplace. 2. Apply the handbrake on the trailer and remove from the towing vehicle. 3.
  • Page 20 SETTING UP Hydraulic Outriggers FIG. 5 MOTOR HYDRAULIC VALVE LEVERS LEVEL BUBBLE...

  • Page 21: Extending Structure

    EXTENDING STRUCTURE From Cage Controls At the Ground Control Station, turn the key towards the ‘basket‘ icon. Climb into the basket. Check that all emergency stop switches are released (twisting release). The platform may now be raised, lowered or slewed in any direction by operating the control levers at the basket, whilst depressing the ‘Green’...

  • Page 22: Lowering Structure

    LOWERING STRUCTURE From Cage Controls Push and hold the ‘Black ’ descent button on the control box (on machines with a footswitch in the cage, press the footswitch). See Fig 9 Push the lever for the boom you require (top or bottom) DOWN as indicated on the label.

  • Page 23: Slewing Structure

    SLEWING THE STRUCTURE From Cage Controls Push and hold the ‘Green’ Motor Run button on the control box (on machines with a footswitch in the cage, press the footswitch). See Fig 10 Push DOWN the slew/rotation lever to slew/rotate LEFT or LIFT the slew/rotation lever to slew/rotate RIGHT.

  • Page 24: Safety Harness & Emergency Controls

    SAFETY HARNESS & EMERGENCY CONTROLS In accordance with IPAF recommendations, UpRight recommend the use of a Full Body Harness with an adjustable work restraint lanyard is used when operation from the basket. The lanyard length should be as short as possible.
  • Page 25 EMERGENCY CONTROLS Emergency Stop Stop buttons are fitted on the machine to stop the motor in an emergency. In addition to the basket emergency stop button, an emergency stop is fitted at the base control station. The emergency stops can be reset by twisting (Fig. 12 ). Turning the key switch at the ground controls to the ‘Off’...
  • Page 26 EMERGENCY CONTROLS Emergency Slew / Rotate Fig. 14 JACK BOLT JACK NUT SLEW MOTOR BYPASS BALL VALVE SHOWN WITH PROTECTIVE CAP REMOVED 1. Turn the slew motor bypass ball valve 90 degrees anticlockwise. 2. Remove the slew motor brake release protective cap using the Hex Key provided. 3.
  • Page 27 EMERGENCY CONTROLS Emergency Procedures (from the Ground) – Without Power Turn the 2 ball valves fitted under the cabinet 90 degrees (Fig 16 )– photo below shows normal operating position. BALL VALVE FIG. 16 Now pull on the red emergency lower knob on the solenoid fitted to the top and botton boom cylinders.

  • Page 28: Stowing The Machine

    STOWING THE MACHINE Fully lower all the booms. Manual Outriggers – wind up the screw jacks as far as t hey will go, unlock the spring bolts by pulling th em out, then lift the outriggers until they are fully stowed. The spring bolt can then be relea sed and the outrigger adjusted to lock the sping bolt in its hole.

  • Page 29: Maintenance

    Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by UpRight, might be done, or of the possible hazardous consequences of each conceivable way, nor could UpRight, investigate all such ways.
  • Page 30 MAINTENANCE The unit must have a thorough inspection carried out every 6 months in accordance with LOLER Regulations 1998 or your relevant national regulations and a Certificate of Thorough Inspection produced by a competent person. Always ensure the machine structure is in good, sound, undamaged condition.
  • Page 31 MAINTENANCE Slew Drive Gears. The slew drive gear is designed to be largely maintenance free. However, we recommend the gear teeth be greased on a monthly basis with a high pressure grease. Checking Limit Switch Operation. The limit switches require no maintenance, other than a visual inspection, on a pre operation basis.
  • Page 32 MAINTENANCE Pin No. Ref. Colour Function YELLOW L.H.INDICATOR BLUE FOG LIGHT(S) WHITE EARTH GREEN R.H. INDICATOR BROWN R.H. TAIL & No. PLATE STOP LIGHT BLACK L.H. TAIL & No. PLATE...
  • Page 34 The machine is extremely safe in operation providing that basic rules are observed in setting up the machine. This manual focuses on the Maintenance and repair of the machine. Please read the Operators Manual available from UpRight or from your local distributor prior to operating the machine...

  • Page 35: Technical Characteristics

    TECHNICAL CHARACTERISTICS Trailer / Superstructure / Outriggers. This consists of a variety of welded and folded fabrications, which, where necessary, contain bushed stainless steel pivots with grease nipples. The main components are shot blasted and them powder coated, and the cylinders are wet painted. The machine also includes fully automatic running gear with auto reverse and also integrated trailer lighting.
  • Page 36 TECHNICAL CHARACTERISTICS Power Pack (Battery Power). Fully integrated power pack consisting of Motor, Pump, Relief valve, non return Check, Return filter with dip stick for checking oil level. Pump is fitted with internal suction strainer. Return filter is fitted with a breather and is used for topping up if oil is required. The tank is fitted with a drain plug on the bottom face.
  • Page 37 TECHNICAL CHARACTERISTICS Operating Speeds and Noise Level. Due to oil viscosity and the fluctuating supply of power on a machine fitted with Batter- ies as its power source the following nominal operating speeds are indicated. All speeds have been taken with fully charged batteries and at ambient temperature of +10deg. Significant speed differences will be experienced if operating in cold climates and with batteries in a semi discharged state.

  • Page 38: Fault Finding

    Whilst every effort has been made to ensure these procedures are as comprehensive as possible, they will not cover all eventualities. If difficulty is experienced in identifying a fault, contact UpRight or their local representative. 1. DC motor not turning when trying to lower outriggers: Key selector switch must be on ground.

  • Page 39: Fault Finding Matrix

    Reset Emergency stops & Read Operators Manual Are the Batteries Fully Charged? Charge Batteries & Read Operators Manual Has the Circuit Breaker tripped? If further advice is required, consult Reset the Circuit Breaker UpRight & Read Operators Technician. Manual Page 5...
  • Page 40 Operators Manual Are the Hydraulics under pressure? A change of motor tone can be heard. If further advice is Is there enough Oil in the tank? required, consult UpRight Technician. Top up Oil Level & Read Operators Manual Page 6...
  • Page 41 Is the Motor Run / Deadman being pressed? Press the Deadman & Read Operators Manual Are all the Outriggers under load ? (LEDs) Reset the Outriggers until all LEDs are Illuminated & Read Operators Manual If further advice is required, consult UpRight Technician. Page 7...
  • Page 42 Press the Deadman & Read Operators Manual Is the Boom Down Switch Made and working correctly? Lower the booms until the switch is made & Read Operators Manual If further advice is required, consult NO CHANGE UpRight Technician. Page 8...
  • Page 43 Are the Emergency Lower Ball Valves Closed Close Ball Valves and read Operators Manual Is there enough Oil in the tank? NO CHANGE If further advice is required, consult UpRight Top up Oil Level & Read Operators Technician. Manual Page 9...

  • Page 44: Maintenance Schedule

    Maintenance Schedule—What is shown here is very much worst case scenario covering most eventualities. If further advice is needed contact UpRight or its local representative. The reference number shown on the far left hand side of the table refers to the relevant Maintenance Procedure Sheet in this manual.
  • Page 45 Check and replace motor brushes if machine is 2/3 worn = Replace used heavily Wheel bearings Check for wear - Do checks at every 3000 miles 6 MONTHLY CHECKS Thorough Inspection Contact UpRight or its local representative. Change oil and filter ! Page 11...

  • Page 46: Maintenance Procedure

    MAINTENANCE PROCEDURE Power Pack. The hydraulic system is fully self contained. Oil tank capacity is 15 Litres. When operating above 0C we recommend using ISO22 Grade Hydraulic Mineral Oil (See Health & Safety guidelines supplied with the oil prior to handling). Replace oil and filter every 6 months.
  • Page 47 MAINTENANCE PROCEDURE When the pump has been removed it can be split and the gears can be inspected for wear. If the gears are worn (or broken) we recommend replacing the complete pump. The replacement pump is complete with gears, front and back plate all ready to bolt on in place of the old unit (strainer is not included).
  • Page 48 MAINTENANCE PROCEDURE BOTTOM BOOM CYL. SOL4 TOP BOOM CYL. SOL3 EMERGENCY LOWERING VALVES BANJO FLOW CONTROL BOLT BASE VALVE CAGE VALVE SOLENOID OPERATED LOWERING VALVE WITH MANUAL OVERRIDE 50 BAR 140 BAR 140 BAR 1.0mm 1.0mm BYPASS VALVE FOR MANUAL EMERGENCY SLEW TL34 with Manual Outriggers MOTOR &...
  • Page 49 MAINTENANCE PROCEDURE Page 15...
  • Page 50 MAINTENANCE PROCEDURE Page 16...
  • Page 51 MAINTENANCE PROCEDURE Cage Controls Is identical to the base control apart from the extra valve bank needed to control the slewing basket ram. The orifice in the Basket slew fitting are there to prevent the machine turning too quickly. Boom Cylinders Have solenoid operated lowering valves with manual override for emergency down.
  • Page 52 Battery 12VDC powered machine. See the relevant circuit diagram for your machine at the end of this handbook or contact UpRight or its local representativefor further information if required TOP & BOTTOM RAM Each ram is fitted with a manual release to...
  • Page 53 MAINTENANCE PROCEDURE TOP & BOTTOM RAM continued Ram not holding under load. TOP BOOM CYL. When you let go of the controls the cylinder movement must stop. SOL3 We do not advise that a machine is left extended unattended for any great length of time (over night etc.) It is normal to expect some slight creep over time, but during normal operating conditions the ram should...
  • Page 54 MAINTENANCE PROCEDURE OUTRIGGER RAM Is fitted with two check valves. They have no adjustment. If the outrigger is not holding under load it is most likely that the check valve for the full bore side is leaking. The check valves are difficult to get to as the block is well protected from falling objects by being tucked well away on the underside of the ram.
  • Page 55 MAINTENANCE PROCEDURE CONTROL VALVE - CAGE Is shown on the diagram below. The relief valve shown here is set at 140 should adjusted accordance with the setting up procedure. Shown elsewhere, see section : Pressure relief Valve relief valve can be seen on the picture insert in the bottom right hand corner.
  • Page 56 MAINTENANCE PROCEDURE CONTROL VALVE - BASE Pressure relief Valve Is similar to the cage control valve apart from the following: Only 2 sections. You are not able to operate the slew from the ground. A high pressure carry over plug has been fitted to the ground control valve to allow oil under full system pressure to pass through it.
  • Page 57 MAINTENANCE PROCEDURE OUTRIGGER CONTROL VALVE STABILISER VALVE When the spool is in the neutral position the annular side of the ram is attached to the tank line. This is done to ensure that the pilot pressure holding the check valve on the full bore open, is drained off quickly to tank so that the check 160 BAR...
  • Page 58 MAINTENANCE PROCEDURE SLEW MOTOR SHUTTLE VALVE The Slew Motor rotates the slew platform MANUAL SLEW via a pinion gear and pinion spacer, the PRESSURE REDUCING BYPASS VALVE pinion gear is meshed into a slew gear VALVE wheel which is welded to the Chassis. The motor has an integral brake which requires hydraulic pressure to release, this pressure is provided via a shuttle valve...
  • Page 59 MAINTENANCE PROCEDURE LEVEL GAUGE The level gauge used for setting up the machine is located next to the outrigger control valve block. If the level is damaged or has been removed do not use the machine until a new level has been fitted. Top Face of Slew Ring The reference point (datum) for the level is the top face of the slew ring.
  • Page 60 IMPORTANT Always err on the side of caution - If in doubt replace, or ask UpRight or its local representative for advice Page 26...
  • Page 61 MAINTENANCE PROCEDURE NUTS & BOLTS Replace any missing bolts immediately. The main pivot shafts and pivot pins are secured with one or two locking pegs. The locking peg not only secures the shafts from falling out but also stops them turning. Most nuts used are Nyloc nuts which are superior to the normal full nut and spring washer.
  • Page 62 MAINTENANCE PROCEDURE LOCKING PEG Each shaft is secured with a locking peg as mentioned above. If you find that a peg is broken or that the bolt and peg is missing then this can be a sign that the shaft is seized due to lack of lubrication. If a seized shaft is suspected, check that the x-drilling for the locking peg lines up with the bolt hole for the locking peg securing bolt.
  • Page 63 MAINTENANCE PROCEDURE BATTERY & CHARGING Your machine is fitted with a fully automatic charger which can be connected to either 85~138Vac or 195~264Vac, 50/60 Hz. The Charger has the following advantages: Waterproof Ip64 ∗ Capable of charging batteries when motor is ∗...
  • Page 64 MAINTENANCE PROCEDURE I. Battery Charging Cycle Amps Volts 15[A] 15.3[V] 15.3 Charger off Time 〔Hr〕 75~80% Bat. Cap. 100% 1) At bulk mode from To to T1, approximately 80% of battery capacity is returned. 2) At absorption mode from T1 to T2, approximately 20% of battery capacity is returned. 3) At float mode afterT2, charger is turned off.
  • Page 65 MAINTENANCE PROCEDURE II. Protective Function & Alarm Display by LED ▶ 3 LEDS BLINK ONCE SIMULTANEOUSLY: OUTPUT CONNECTION ERROR. -> CHECK THE BATTERY AND CHARGER CONNECTION AND CORRECT ▶ 3 LEDS BLINK THREE TIMES SIMULTANEOUSLY: CHARGER IS OVERHEATED. -> NO ACTION REQUIRED. WHEN THE CHARGER COOLS, CHARGING WILL RE- START AUTOMATICALLY.
  • Page 66 MAINTENANCE PROCEDURE CHARGING TIMES The charger will recharge 2/3 discharged batteries in 8 to 10 hours. In reality batteries are often discharged more than 2/3 when used on a access platform. The operator tend to use the machine until the motor stops (This causes arcing of the motor contactor, and severe heat rise in the motor.
  • Page 67 MAINTENANCE PROCEDURE BATTERY When charging the battery will give off explosive hydrogen gas. Keep away from open flames. Always wear appropriate personal safety equipments such as eye protection and rubber gloves to prevent injury in case of spillage. Keep the top of the batteries clean and free from dirt. It is very easy for the battery to be contaminated when topping up with distilled water.
  • Page 68 MAINTENANCE PROCEDURE EMERGENCY STOP Two emergency Stops are fitted. One at each control post. When depressed they must stop all movements within a few seconds maximum. When activated it must not be possible to operate the machine. To release, turn 1/4 turn and the Emergency stop head will pop back out.
  • Page 69 MAINTENANCE PROCEDURE Page 35...
  • Page 70 MAINTENANCE PROCEDURE Page 36...
  • Page 71 MAINTENANCE PROCEDURE ELECTRICAL COMPONENTS DESCRIPTIONS CT1 is mounted on top of the DC motor and switches the motor on/off MCB1 is a 4A Re -settable circuit breaker to protect the wiring loom from damage in the event of a short circuit. SW1 is the key switch for selecting Cage or Ground Controls or switching th e machine Off.
  • Page 72 MAINTENANCE PROCEDURE You must not be able to raise the outriggers with the booms up in the air. If you are, you must check the boom limit switch and the diverter valve. If you are not able to lift up the outriggers after lowering the booms.
  • Page 73 Tyre size is : 165 R13C 8Ply IMPORTANT For fully service and maintenance information on the running gear contact UpRight and request a copy of the running gear OEM service handbook. Below are a few important extracts which covers the some of the basic checks to carry out when servicing the machine.
  • Page 74 When purchasing a brake drum the bearings are normally included, fitted to the brake drum. If replacing bearings only, contact UpRight or its local representative for further information. Always use a new flanged nut and torque to 280—300Nm when refitting the drum.
  • Page 75 MAINTENANCE PROCEDURE 7 PIN PLUG INTERIOR VIEW YELLOW BLUE BLACK WHITE BROWN GREEN YELLOW GREEN BROWN WHITE WHITE BLACK L.H. STOP No. PLATE STOP R.H. FLASHER TAIL LIGHT LIGHT LIGHT TAIL FLASHER Ref. Colour Function Ref. Colour Function YELLOW L.H. Indicator BROWN R.H.
  • Page 76 MAINTENANCE PROCEDURE GENERAL GREASE POINTS Regular greasing not only greatly improves the service life of the bushes, it also will remove any moisture which may cause internal corrosion on the wall of the bosses making it difficult to remove the pivot shafts for inspection. Slew Drive LUBRICATION SPECIFICATIONS We recommend only using premium quality grease.
  • Page 77 When the machine has passed its test the machine will be issued with a sticker showing the Certificate number and the date of next Examination. A copy of the Certificate is available upon request. Contact UpRight Group for further details. Page 43...
  • Page 78 Page 44...
  • Page 79 Local Distributor: Lokaler Vertiebshändler: Distributeur local: El Distribuidor local: Il Distributore locale: Europe TEL: +1 (559) 443 6600 TEL: +44 (0) 845 1550 058 FAX: +1 (559) 268 2433 FAX: +44 (0) 195 2299 948 www.upright.com Page 45...

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