Upright TL33 Guida

SERVICE & PARTS

MANUAL

TL33

Aerial Work Platform

Serial Numbers 1001 to current

When contacting UpRight for service or parts information,

be sure to include the MODEL and SERIAL NUMBERS

from the equipment nameplate. Should the name plate be

missing the SERIAL NUMBER is also stamped on the axle

mounting plate on the right hand side of the machine.

Manual Part Number 57009-000 Rev 0 Dec.‘96

UpRight

UpRight Ireland Ltd.,

Pottery Road,

Dun Laoire,

Ireland.

TL33 Work Platform i

Foreword

SPECIAL INFORMATION

Indicates the hazard or unsafe practice that

could result in severe injury or death.

Indicates the hazard or unsafe practice that

could result in minor injury or property damage.

Notes: Give helpful information.

WORKSHOP PROCEDURES

CAUTION: Detailed descriptions of standard

workshop procedures, safety principles and service

operations are not included. Please note that this

manual does contain warnings and cautions against

some specific service methods which could cause

cause personal injury, or could damage a machine

and make it unsafe. Please understand that these

warnings cannot cover all conceivable ways in

which service, whether or not recommended by

UpRight Ireland Ltd., might be done, or of the

possible hazardous consequences of each

conceivable way, nor could UpRight Ireland Ltd.

investigate all such ways. Anyone using service

procedures or tools, whether or not recommended

by UpRight Ireland Ltd., must satisfy themselves

thoroughly that neither personal safety nor machine

safety will be jeopardised.

All information contained in this manual is based on the

latest product information available at the time of

printing. We reserve the right to make changes at any

time without notice. No part of this publication may be

reproduced, stored in retrieval system, or transmitted, in

any form by any means, electronic, mechanical,

photocopying, recording, or otherwise, without prior

written permission of the publisher. This includes text,

figures and tables.

CAUTION

WARNING

Introduction &

Specifications

General description and machine specifications 1.0

Machine Preparation

Information on preparation for use & shipment,

transporting and storage. 2.0

Illustrated Parts

Breakdown

Schematics and valve block diagram with description

and location of components 7.0

Operation

Operating instructions and safety rules. 3.0

Maintenance

Preventative maintenance and service information

4.0

Troubleshooting

Causes and solutions to typical problems 5.0

Schematics

Schematics and valve block diagram with description

and location of components 6.0

ii TL33 Work Platform

Foreword

NOTES

TL33 Work Platform I

Contents

Section

Section Page

No. No.

1.0 Introduction & Specifications

1.0 Introduction ................................... 1-1

Purpose.................................................. 1-1

Scope..................................................... 1-1

1.1 General Information ............................... 1-1

Description............................................. 1-1

Purpose and Limitations ......................... 1-2

1.2 Specifications ................................... 1-2

2.0 Machine Preparation

2.1 Preparation for use................................. 2-1

2.2 Preparation for shipment ........................ 2-1

2.3 Forklifting of workplatform...................... 2-2

2.4 Lifting Work Platform ............................. 2-2

2.5 Transport ................................... 2-2

2.6 Storage ................................... 2-2

Preservation........................................... 2-2

Batteries................................................. 2-2

3.0 Operation

3.0 Introduction. .................................. 3-1

General Functioning............................... 3-1

Setting up machine for use..................... 3-1

Operating the booms.............................. 3-1

Design Features.................................... .3-1

3.1 Safety Rules and Precautions............. ... 3-2

3.2 Controls and Indicators....................... ... 3-3

Platform Controls................................. .. 3-3

Lower Controls....................................... 3-4

3.3 Pre-Operation Inspection....................... 3-5

3.4 Operation ................................... 3-6

Towing ................................................ . 3-6

Deploying the outriggers......................... 3-6

Elevating platform................................ .. 3-7

Emergency Lowering ............................. 3-7

Emergency Rotation .............................. 3-8

4.0 Maintenance

4.0 Introduction .................................. 4-1

4.1 Preventative Maintenance ...................... 4-1

Preventative Maintenance Table Key ..... 4-2

Preventative Maintenance Report .......... 4-2

4.2 Battery Maintenance............................... 4-3

Battery Inspection and Cleaning.......... ... 4-3

Battery Charging.................................. .. 4-3

Battery Cell Equalization ................. ...... 4-4

4.4 Lubrication .................................. 4-5

Hydraulic Oil Reservoir and Filter........ ... 4-5

Fluid Level............................................ .4-5

Oil and Filter Replacement................... .. 4-5

4.5 Setting Hydraulic pressures.................... 4-6

Main Relief valve.................................. .4-6

Section Page

No. No.

4.6 Maintenance on Elevating Assembly.......4-6

Setting Slew Cut-Out Limit Switch...........4-7

Outrigger Limit Switches...................... ...4-8

4.7 Hydraulic Manifold ..................................4-9

Removal............................................... ..4-9

Disassembly......................................... ..4-9

Cleaning and Inspection..........................4-9

Assembly................................................4-9

Installation............................................ ..4-9

4.8 Hydraulic Pump ..................................4-11

Removal............................................... 4-11

Installation............................................ 4-11

4.9 Wheel Hubs/Bearings ..........................4-11

Maintenance & Adjustment .................. 4-11

Replacing worn bearings /

Hub Oil Seal ........................................ 4-11

4.10 Braking System ................................. 4-13

Principles of Operation..........................4-13

Adjustment of /wheel Brakes ................4-13

4.11 Hydraulic Cylinders.............................. 4-14

Upper Lift Cylinder............................... .4-14

Removal.......................................... .....4-14

Cleaning and Inspection........................4-14

Assembly..............................................4-14

Installation...................................... ......4-14

4.12 Lower Lift Cylinder ...............................4-16

Lower Lift Cylinder............................... .4-16

Removal.......................................... .....4-16

Cleaning and Inspection........................4-16

Assembly..............................................4-16

Installation...................................... ......4-16

4.13 Electric Motor ..................................4-17

Troubleshooting ..................................4-17

Disassembly................................. 4-17

Inspection ................................. 4-17

Reassembly ................................. 4-18

4.14 Adjustment of Overcentre Valves......... 4-20

5.0 Troubleshooting

5.0 Introduction ................................... 5-1

General Procedure..................................5-1

5.1 Trouble shooting charts.......................... 5-2

5.2 General information .............................. 5-4

5.3 D.C. Motor Control ................................ 5-5

5.4 Troubleshooting the MOS90 .................. 5-6

6.0 Schematics

6.0 Introduction ................................... 6-1

6.1 Electrical Schematic ...............................6-3

6.2 Hydraulic Schematic ...............................6-7

Table of Contents

II TL33 Work Platform

Contents

Section

Section Page

No. No.

7.0 Illustrated Parts Breakdown

7.0 Introduction .................................. .7-1

7.1 Index .................................. .7-1

7.2 Illustrated Parts ................................... 7-2

Chassis Assembly................................ 7-2

Booms and Posts Assembly................. 7-4

Cage Assembly ................................... 7-6

Axle and Brake Hub Assembly............. 7-8

Hub Assembly ..................................7-10

Brake Assembly..................................7-12

Slew Gearbox Assembly.....................7-14

Lower Control Box Assembly ..............7-16

Tailboard Assembly ............................7-18

Coupling Assembly .............................7-20

Label Kit ..................................7-22

Main Manifold Block Assembly............7-24

Lift Cylinder Assembly ........................7-26

Hydraulic Assembly ............................7-28

Pump Motor Controller Assembly........7-30

Upper Control Box Assembly ..............7-32

Electrical Assembly.............................7-34

Fig. Title Page

No.

1-1 TL33 Work Platform................................1-1

2-1 Lifting the TL33 .................................2-2

3-1 Platform Controls .................................3-3

3-2 Lower Controls .................................3-4

3-3 Releasing Outrigger Lock Pin..................3-6

3-4 Emergency Lowering Valves...................3-8

4-1 Lubrication Points .................................4-5

4-2 Oil and Filter Replacement .....................4-5

4-3 Main Manifold Block................................4-6

4-4 Supporting the Elevating Assembly.........4-6

4-5 Slew Cut-out Limit Switch .......................4-7

4-6 Outrigger Limit Switch.............................4-8

4-7 Main Manifold Block..............................4-10

4-8 Hydraulic Pump . ..............................4-11

4-9 Replacing Bearings / Oil Seal ...............4-12

4-10 Wheel Hub Assembly............................4-12

4-11 Braking Arrangement............................4-13

4-12 Replace Brake Cable ............................4-13

4-13 Upper Lift Cylinder ...............................4-15

4-14 Lower lift Cylinder ...............................4-15

4-15 Hydraulic Cylinder Components ............4-15

4-16 Electrical Test Circuit ............................4-17

4-17 Electric Motor Assembly .......................4-19

6-1 Electrical Schematic ...............................6-5

6-2 Hydraulic Schematic................................6-8

6-3 Hydraulic Manifold...................................6-8

Table Title Page

No.

1-1 Specifications .................................1-2

3-1 Platform Controls and Indicators ............3-3

3-2 Lower Controls .................................3-4

4-1 Preventative Maintenance ......................4-2

4-3 Temperature Correction for Electrolytes..4-4

5-1 Trouble Shooting .................................5-2

5-2 MOS90 Flash Faults...............................5-6

6-1 Electrical Schematic Legend............6-3, 6-4

6-2 Hydraulic Schematic Legend...................6-7

Table of Contents

(cont’d.)

List of Illustrations

List of Tables

TL33 Work Platform 1-1

Introduction & Specifications

Section

1.0

1.0 Introduction

PURPOSE

This manual provides illustrations and instructions for the

operation and maintenance of the TL33 Work Platform

manufactured by Upright Ireland Ltd, Dun Laoire, Ireland.

(See Figure 1-1).

SCOPE

This manual includes both operation and maintenance

responsibilities concerning the TL33 Work Platform’s

readiness. The Maintenance Section covers scheduled

maintenance, trouble shooting, repair, adjustment and

replacement.

1.1 General Information

DESCRIPTION

The TL33 is a two-stage articulating boom lift platform,

designed to raise two operators with hand tools to a work

height of up to 12.3m. It is mounted on a trailer suitable

for towing on public roads at speeds of up to 50 mph /

83Km/h (subject to local regulations). The boom

assembly is operated by a hydraulic pump driven by a

DC electric motor.

Platform

The platform is large enough for two operators and has a

free-draining perforated floor with 150mm toeboards.

Hand rails are constructed from aluminium tubing and a

safety drop-bar is provided at the entrance. Safety

harness anchor points are fitted in the floor of the

platform.

Control Box

The control box is permanently fitted at the front of the

platform, and features a joystick to provide proportional

control of raising and lowering of each boom plus

rotation. A safety ‘Deadman’ switch is provided which

must be pressed at all times if operation is required. This

is integral with the joystick handle allowing one-handed

operation.

A complete explanation of control functions can be found

in chapter 3.

Elevating assembly

The platform is raised and lowered by two steel booms

each of which are operated by a hydraulic cylinder

actuated by hydraulic power from the motor driven

pump. Each cylinder features an integral holding valve to

prevent uncontrolled descent in the case of a hose burst.

Rotation Gear

The booms can be rotated to provide up to 5m side

outreach by means of a hydraulic motor driving a pinion

gear around a large diameter slew gear via a gearbox.

Power Pack

The power pack comprises four 6V batteries driving a

4HP electric motor which drives the hydraulic pump.

The batteries, charger and motor/pump set are located

under the fibreglass covers on either side of the chassis.

Control system

The machine is provided with fully proportional controls

by means of a motor control unit. This unit regulates the

drive motor/pump speed and hence the flow of oil

reaching the cylinders and slew motor via the solenoid

valves located on the manifold block.

The motor control unit is located above the electric motor

in the chassis module. The manifold block is located on

the first post.

Chassis

The chassis is designed for towing on public roads. It is

fitted with suspension and full sized road wheels. Also

fitted is a 50mm ball towhitch, jockey wheel and overrun

braking system with handbrake.

Four ‘Quick set’ fold down outriggers with screw jacks for

level adjustment are provided. Interlocks prevent

operation of the booms until all four outriggers are

deployed. The hydraulic tank is integral with the chassis

members, and a bubble level is fitted to aid levelling of

the chassis before use.

1. Platform

2. Elevating assembly

3. Chassis

4. Control Module

5. Power Module

6. Controller

Figure 1-1: TL33 Work Platform

1-2

TL33 Work Platform

Introduction & Specifications

Section

1.2

Purpose and limitations

The purpose of the TL33 work platform is to provide a quickly deployable, trailer mounted, variable height work platform.

It is capable of lifting two people with work tools up to an upper limit of 215kg in total. The unit will provide the ability to

reach over obstacles and may be used on uneven firm ground provided the chassis is correctly levelled using the screw

jack adjusters prior to elevating.

The platform must only be used on firm level ground capable of supporting

the maximum load generated under the outriggers. All outriggers must be

correctly deployed and the chassis levelled before use. Do not use on soft

or severely sloping ground.

1.2 Specifications* Table 1-1: Specifications

ITEM METRIC IMPERIAL

Duty Cycle 30% of 8hr cycle

Platform Size 0.7m x 1.3m (inside guardrails) 2.3 ft x 4.3ft

Max. Platform Capacity 215Kg 473 lbs

Max. No. of occupants 2 People

Max. Working Height 12.3m 40.3 ft

Max. Platform Floor Height 10.3m 33.8 ft

Max. Working Outreach 5 m 16.4 ft

Travelling Dimensions:

Length

Width

Height

5.5 m

1.6 m

1.99m

18 ft

4.9 ft

6.5 ft

Stabiliser spread 3 m X 3m 10 ft x 10 ft

Rotation 360onon-continuous

Gross weight 1209 Kg 2660 lbs

Max. Towable speed 83 Km/Hr. ** 50 mph **

Energy source 24V DC 4HP, 4 x 6V

220 Ah batteries

System Voltage 24V

Battery Charger 24V 25A 220/110VAC 50/60 Hz

Hydraulic Tank Capacity 8 Litres 2.1 Gallons

Max. Hydraulic System Pressure 140 Bar 2030 P.S.I

Hydraulic Fluid ISO # 46

Lift System 2 x Double acting lift cylinders with lock

valves and manual emergency lower facility

Control System One-hand proportional joystick operating

energy-efficient motor control system

Tyres 6PLY R13

Braking Automatic reverse and overrun brakes plus

handbrake.

*Specifications subject to change without notice.

** Max. speed is subject to traffic regulations in the country in question.

CAUTION

TL33 Work Platform 2-1

Machine Preparation

Section

2.1

2.1 Preparation for use

Read and familiarise yourself with all operating

instructions before attempting to operate machine.

1. Check Hydraulic oil level.

2. Check that batteries are charged.

2.2 Preparation for Shipment

1. Lubricate machine per lubrication instructions in

Section 4.4, Maintenance.

2. Fully Lower the platform.

3. Stow all 4 outriggers.

4. Disconnect the negative (-) battery cable from the

battery terminal.

2.3 Forklifting the Work Platform

NOTE: Lifting is for loading and unloading only.

NOTE: The TL33 is not designed to be forklifted,

and does not have provision on the chassis

to allow this method of lifting. Upright

recommend the procedure below for

handling the machine.

See specifications for weight of work

platform and be certain that lifting

apparatus is of adequate capacity

to lift platform.

2.4 Lifting the Work Platform

The Tl33 may be lifted by an overhead hoist/crane in the

following manner:

Four lifting straps capable of safely supporting the total

weight of the TL33 (1209Kg), and at least 220cm long

are required. This minimum length is important to ensure

the correct lifting angle.

The straps should be positioned as shown in Figure2-1.

The two rear lifting slings should be positioned inside the

“quadrant” outrigger mounting plates. Care must be

taken to ensure the slings do not damage the cable for

the outrigger limit switches (Positions 1 & 2).

the front lifting slings should be positioned under the

towing beam, directly in front of the brake cable anchor

plate. Note that two straps are essential at this point -

one must pass each side of the lower boom and be

positioned between the boom and the tension bars on

either side. (Position 3 & 4).

Care must be taken to avoid damage to covers and other

equipment on the machine.

Figure 2-1: Lifting the TL33

2.5 Transport

The TL33 is a road approved vehicle and therefore may

be transported behind a motor vehicle of suitable towing

capacity.

If the TL33 is to be transported by other means then it

must be securely tied down to the transporting unit at

several points.

Recommended securing points are the four outrigger

support members on the chassis and the towbar. Further

securing points should be used if the terrain on which the

unit is travelling is rough or uneven.

ALWAYS ensure that the handbrake is fully applied and

that all the booms are FULLY stowed.

2.6 Storage

No preparation is required for normal storage. Regular

maintenance per Table 4-1should be performed. If The

work platform is to be placed in long term storage (dead

storage) use the following preservation procedure.

PRESERVATION

1. Clean painted surfaces. If the painted surface is

damaged, repaint.

2. Fill the hydraulic tank to operating level with the

platform fully lowered.Fluid should be visible on

the dip stick.

3. Coat exposed portions of cylinder rods with a

preservative such as multipurpose grease and wrap

with barrier material.

4. Coat all exposed unpainted metal surfaces with

preservative.

BATTERIES

1. Disconnect the battery ground cable and secure to

the chassis.

2. Disconnect the remaining battery leads and secure to

the chassis.

3. Remove the batteries and place in alternate service.

CAUTION

Minimum sling length

220cm

2-2

TL33 Work Platform

Machine Preparation

Section

2.6

NOTES

TL33 Work Platform 3-1

Operation

Section

3.0

3.0 Introduction

General functioning

Refer to the Hydraulic and Electrical Schematics,

Section 6

The battery powered electric motor directly drives a two

section hydraulic pump. The low section of the pump is

not used. The high section supplies oil under pressure to

the various platform functions. The oil flow is directed to

the different functions by electrically activated

solenoid valves.

Setting up the machine for use

The TL33 must be set up on firm level ground. The

outrigger set-up is critical for sound stability of the unit

when elevated.

The outriggers are secured in the travel position by a

spring-activated retaining pin. When the outrigger is

lowered the pin locks the leg into the down position by

means of another retaining slot at the bottom of the

‘quadrant’ plate. The screw jack at the end of the

outrigger leg is then lowered until in contact with the

ground surface. Further adjustment off the appropriate

screw jack(s) are then made to level the machine using

the bubble level on the chassis as a guide.

All outriggers are fitted with electrical interlock limit

switches which prevent operation of any functions until all

outriggers are secured in the lowered position and the

outrigger foot is taking the machines weight. Should an

outrigger become unloaded during operation of the

booms an alarm sounds and further operation is

impossible except by means of an emergency override

switch on the cage control box, allowing the operator to

descend and remedy the cause.

Operating the booms

Only when the TL33 is set up according to the above

procedure can raising and lowering of the booms

commence.

The keyswitch at the lower control box can be switched

to platform or chassis controls.

Platform controls provide variable speeds for the boom

functions through the use of a joystick.

This is achieved using a motor control unit which varies

the speed of the motor/pump unit and increases

or decreases the flow of oil to the different functions.

This control unit receives a control signal from the

joystick on the upper controls.

The speed of the motor increases as the control lever is

pushed further away from the neutral (stopped) position.

Note:A deadman trigger is an integral part of the

joystick. This must be depressed for the

functions to operate. (This safety feature

prevents unwanted movement of the booms in

the case of inadvertent movement of the

joystick.)

Chassis controls provide a fixed speed for each of the

boom functions.

Design Features

The TL33 Series Work Platform has the following

features:

• The interlock system on the outriggers ensure that the

machine must be set up safely before use.

• The slew cut-out interlock ensures that the boom

support structure is clear of the towbar before

slewing can commence.

• The energy-efficient motor control units provides long

battery life and smooth proportional control of the

boom functions.

• All cylinders are fitted with hydraulic hose-burst

protection interlocks.

• The on-board charger is fully automatic and charges

the batteries efficiently and economically.

• If the work platform starts to become unstable and one

of the outrigger interlocks becomes de-activated an

alarm will sound in the upper control box. In this

situation power is cut to the upper controls to prevent

boom movement that might increase instability. An

emergency override switch is fitted to allow the booms

to be descend at a controlled speed to bring the

machine back to a stable position.

• In the event of a power loss the two lift cylinders are

fitted with emergency lowering valves which allow the

booms to be lowered at a controlled speed by an

operator on the ground.

• A manual rotation facility is fitted to allow rotation of

the booms in the event of power loss.

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