Upright AB38 Mode d’emploi

Operation and Parts

Manual

AB38 BI-ENERGY

SERIAL NO. 2767 to Current

WARNING

All personnel shall carefully read, understand and follow all safety rules,

operating instructions, and National Safety Instructions/Requirements

before operating or performing maintenance on any UpRight Aerial Work

Platform.

p/n : 502513-000

USA

UI Distribution North America inc.

2686 S. Maple Avenue

Fresno, CA, 93725

Tel: (559) 443 6600

Fax: (559) 268 2433

Email: info@uidistribution.com

www.uidistribution.com

UpRight

Unit S1, Park West Industrial Park

Friel Avenue

Nangor Road

Dublin 12, Ireland

TEL: +353 1 620 9300

FAX: +353 1 620 9301

ENGLISH

When contacting UpRight for service or parts information, be sure to include the MODEL and SERIAL NUMBERS from the

equipment nameplate. Should the nameplate be missing, the SERIAL NUMBER is also stamped on top of the chassis

above the front axle pivot.

AB38 Bi - Energy

Serial Numbers 2767 – Current

Serial number stamped on floor of

chassis beneath the steering cylinder.

Operation Manual Page 1

OPERATION MANUAL

WARNING

All personnel shall carefully read, understand and follow all safety rules and operating instructions

before operating or performing maintenance on any UpRight aerial work platform.

Safety Rules

USE OF THE AERIAL WORK PLATFORM: This aerial work platform is intended to lift persons and his tools as well as the material used

for the job. It is designed for repair and assembly jobs and assignments atoverhead workplaces (ceilings, cranes, roof structures, build-

ings etc.). All other uses of the aerial work platform are prohibited!

THIS AERIAL WORK PLATFORM IS NOT INSULATED!For this reason it is imperative to keep a safe distance from live parts of electri-

cal equipment!

Exceeding the specified permissible maximum load is prohibited! See “Platform Capacity” on page4 for details.

The use and operation of the aerial work platform as a lifting tool or a craneis prohibited!

NEVER exceed the manual force allowed for this machine.See “Manual Force” on page 4 for details.

DISTRIBUTE all platform loads evenly on the platform.

NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs, bumps, curbs, or debris;

and avoiding them.

OPERATE machine only on surfaces capable of supporting wheel loads.

NEVER operate the machine when wind speeds exceed this machine’s wind rating. See “Beaufort Scale” on page 4 for details.

IN CASE OF EMERGENCY push EMERGENCY STOPswitch to deactivate all powered functions.

IF ALARM SOUNDS while platform is elevated, STOP, carefully lower platform. Move machine to a firm,level surface.

Climbing up the railing of the platform, standing on or stepping from the platform onto buildings, steel or prefab concrete structures, etc.,

is prohibited!

Dismantling the entry gate or other railing components is prohibited! Always make certain that the entry gate is closed and securely

locked!

It is prohibited to keep the entry gate in an open position when the platformis raised!

To extend the height or the range by placing of ladders, scaffolds or similar devices on the platformis prohibited!

NEVER perform service on machine while platform is elevated without blocking elevating assembly.

INSPECT the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire connections, and damaged

cables or hoses before using.

VERIFY that all labels are in place and legible before using.

NEVER use a machine that is damaged, not functioning properly, or has damaged or missing labels.

To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platformand inits working range.

NEVER charge batteries near sparks or open flame. Charging batteries emitexplosive hydrogen gas.

Modifications to the aerial work platform are prohibited or permissible only at the approval by UpRight.

AFTER USE, secure the work platform from unauthorized use by turning the keyswitch off and removing key.

UpRightAB38

NEVER elevate the platform or drive

the machine while elevated unless

the machine is on a firm, level

surface.

NEVER climb, stand, or sit on

platform guardrails or midrail.

NEVER position the platform

without first checking for overhead

obstructions or other hazards.

Electrocution Hazard Tip

ver Hazard

ollision Hazard Fall Hazard

THIS MACHINE IS NOT

INSULATED!

Page 2 Operation Manual

ONTENTS

Operation

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Introduction & General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

Special Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

Controls & Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

Pre-Operation & Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 & 7

Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7

Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10

Inspection & Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11

Daily Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

Parts & Electrical Schematics

General Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 & 3

Engine Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

Alternator Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

Introduction

Operation Manual Page 3

NTRODUCTION

This manual covers the AB38 Bi-Energy Aerial Work Platform. This manual must be stored on the machine

at all times.

Read, understand and follow all safety rules and operating instructions before attempting to operate the

machine.

ENERAL

ESCRIPTION

Figure 1: AB38 Bi-Energy

1. Platform

WARNING

DO NOT use the maintenance platform

without guardrails properly assembled and

in place

2. Entry Bar

3. Elevating Assembly

4. Platform Controls

5. Manual Case

6. Lower Controls

7. Hydraulic Reservoir

8. Level Sensor

9. Batteries

10. Emergency Lowering Valves

11. Battery Charger

Page 4 Operation Manual

Special Limitations

PECIAL

IMITATIONS

Travel with the platform raised is limited to creep speed range.

Elevating the platform is limited to firm, level surfaces only.

DANGER

! !

The elevating function shall ONLY be used when the work platform is level and on a firm surface.

The work platform is NOT intended to be driven over uneven, rough, or soft terrain.

LATFORM

APACITY

The maximum platform capacity for the AB38 Bi-Energy is 215kg (475lbs). Two people and tools may

occupy the platform.

DANGER

! !

DO NOT exceed the maximum platform capacity or the platform occupancy limits for this machine.

ANUAL

ORCE

Manual force is the force applied by the occupants to objects such as walls or other structures outside the

work platform.

The maximum allowable manual force is limited to 200 N (45 lbs.) of force per occupant, with a maximum

of 400 N (90 lbs.) for two occupants.

DANGER

! !

DO NOT exceed the maximum amount of manual force for this machine.

IFT

VERLOAD

LARM

The AB38 Bi-Energy is fitted with a load sensing system designed to comply with the requirements os BS EN

280 : 2001

If a load equivelent to 90% of safe working load is lifteda fault code “03” will be displayed on the digital

display on the platform control box. If a load which is greater than the safe working load is present in the

basket all machine functions will cease to operate and an acoustic warning will sound. In order to return to

normal operation a load equal to or less than thesafe working load must be present in the basket and the

power must be re-cycled, power can be re-cycledby pushing the emergency stop button and releasing it

again.

EAUFORT

CALE

Never operate the machine when wind speeds exceed 25 km/h (15 mph) [Beaufort scale 4].

BEAUFORT

RATING

WIND SPEED GROUND CONDITIONS

m/s km/h ft/s mph

3 3,4~5,4 12,25~19,4 11.5~17.75 7.5~12.0 Papers and thin branches move, flags wave.

4 5,4~8,0 19,4~28,8 17.75~26.25 12.0~18 Dust is raised, paper whirls up, and small branches sway.

5 8,0~10,8 28,8~38,9 26.25~35.5 18~24.25 Shrubs with leaves start swaying. Wave crests are apparent in ponds or swamps.

6 10,8~13,9 38,9~50,0 35.5~45.5 24.5~31 Tree branches move. Power lines whistle. It is difficult to open an umbrella.

7 13,9~17,2 50,0~61,9 45.5~56.5 31.~38.5 Whole trees sway. It is difficult to walk against the wind.

Controls and Indicators

Operation Manual Page 5

ONTROLS

AND

NDICATORS

The operator shall know the location of each control and indicator and have a thorough knowledge of the

function and operation of each before attempting to operate the unit.

Figure 2: Controls and Indicators

-O

PERATION

AFETY

NSPECTION

NOTE: Carefully read, understand and follow all safety rules, operating instructions, labels and National Safety

Instructions/Requirements. Perform the following steps each day before use.

1. Remove the Chassis Covers and inspect for damage, fluid leaks or missing parts.

2. Check the level of the hydraulic fluid with the platform fully lowered. Remove the Chassis Covers and

remove the reservoir cap, fluid should be visible on the dipstick. Add recommended hydraulic fluid if nec-

essary. See “Specifications” on page 14.

3. Check that the fluid level in the batteries is correct. See “Battery Maintenance” on page 10.

4. Verify that the batteries are charged.

5. Check that the A.C. extension cord has been disconnected from the chassis outlet.

6. Check that all guardrails are in place and all fasteners are properly tightened.

7. Inspect the machine thoroughly for cracked welds and structural damage, loose or missing hardware,

hydraulic leaks, damaged control cable and loose wire connections.

11 10

Lower Controls

45 6

678

1. Emergency Stop

2. Cage Level

3. Upper Boom

4. Lower Boom

5. Drive

6. Horn

7. Slew (Rotate)

8. Display

9. Telescope

10. Joystick

11. Key Switch (on side of box)

Upper Controls

1. Emergency Stop

2. Upper Boom

3. Lower Boom

4. Slew (Rotate)

5. Telescope

6. Enable

7. Analog Rocker

Page 6 Operation Manual

System Function Inspection

YSTEM

UNCTION

NSPECTION

Refer to Figure 1 and Figur e2 for the locations ofvarious controls and indicators.

WARNING

STAND CLEAR of the work platform while performing the following checks.

Before operating the machine, survey the work area for surface hazards such as holes, drop-offs, bumps

and debris.

Check in ALL directions, including above the work platform,for obstructions and electrical conductors.

Protect the control console cable from possible damage while performing checks.

1. Move the machine, if necessary, to an unobstructed area to allow for full elevation.

2. Pull Chassis Emergency Stop Switch to the ON position.

3. Pull Platform Emergency Stop Switch to the ON position.

4. Visually inspect the elevating assembly, lift cylinder, cables, and hoses for cracked welds and structural

damage, loose hardware, hydraulic leaks, loose wire connections, and erratic operation. Check for

missing or loose parts.

5. Test each machine function (Lift, Slew, Telescope) from the lower control station by pressing and hold-

ing the desired function button thenmoving the Analog Rocker to the Up or Downposition (ref: chassis

controls illustration on page 5)

6. Open the Emergency Lowering Valve (see Figure 3) by pulling the knob out to check for proper opera-

tion. When the platform is lowered, release the knob.

7. Push the Chassis Emergency Stop Switch to check for proper operation. All machine functions should

be disabled.Twist the Chassis Emergency Stop Switch to resume.

8. Climb onto the cage.

9. Check that the route is clear of obstacles (persons, obstructions, debris), is level, and is capable of sup-

porting the wheel loads.

10. Mount the platform and properly close the drop bar.

11. Test each machine function (Drive, Lift, Slew, Telescope, Platform Rotate, Cage Level) from the upper

control station by pressing the desired function button then moving the Joystick to the Forward or Back

position (ref: platform controls illustration on page 5)

12. Push the Platform Emergency Stop Switch to check for proper operation. All machine functions should

be disabled. Pull out the Platform Emergency Stop Switch to resume.

PERATION

Before operatingthe work platform, ensure that the Pre-Operation Safety Inspection has been completed

and that any deficiencies have been corrected. Never operate a damaged or malfunctioning machine.

The operator must be thoroughly trained on this machine.

LEVATING

THE

LATFORM

1. Select either the lower or upper boom lift function button (the button will illuminate to confirm selection).

2. While engaging the Interlock Switch, push the Control Handle forward.

3. If the machine is not level the tilt alarm will sound and the machine will not lift.

OWERING

THE

LATFORM

1. Select either the lower or upper boom lift function button (the button will illuminate to confirm selection).

2. While engaging the Interlock Switch, pull the Control Handle backwards.

3. If the machine is not level the tilt alarm will sound and the machine will only descend.

Operation

Operation Manual Page 7

OTATING

THE

LATFORM

1. Select the rotate function button (the button will illuminate to confirm selection).

2. While engaging the Interlock Switch, move the Control Handle forwards or backwards to achieve clock-

wise or counterclockwise rotation.

3. If the machine is not level the tilt alarm will sound and the machine will not rotate.

PERATING

THE

ELESCOPE

1. Select telescope function button (the button will illuminate to confirm selection).

2. While engaging the Interlock Switch, move the Control Handle forwards or backwards to extend or

retract the telescopic boom.

3. If the machine is not level the tilt alarm will sound and the telescope boom will only retract.

EVELLING

THE

CAGE

1. Select platform level function button (the button will illuminate to confirm selection).

2. While engaging the Interlock Switch, move the Control Handle forwards or backwards to adjust the floor

angle of the cage (this can only be done when the machine is in the stowed position).

3. If the machine is not level the tilt alarm will sound and the machine will not operate.

TARTING

THE

NGINE

1. The engine is started by turning the key on the control box to “Start”, the key will spring back to the “Run”

position during normal operation of the engine.

2. The engine can be used to charge the batteries or power the machine when the batteries arelow.

MERGENCY

OWERING

WARNING

If the platform should fail to lower, NEVER climb down the elevating assembly.

Stand clear of the elevating assembly while operating the Emergency LoweringValve Knob.

Figure 3: Emergency Lowering Valve

Ask a person on the ground to open the Emergency

Lowering Valve to lower the platform. The Emergency

Lowering Valve is located on the base of each lift cyl-

inder.

1. Open the Emergency Lowering Valve by pulling the

knob out.

2. To close, release the knob.

NOTE: The platform will not elevate if the Emergency

Lowering Valve is open.

FTER

ACH

1. Ensure that the platform is fully lowered.

2. Park the machine on a firm level surface, preferably under cover, secure againstvandals, children and

unauthorized operation.

3. Turn the Chassis Key Switch to OFF and remove the key to prevent unauthorized operation.

Emergency Lowering Valves

Page 8 Operation Manual

Transporting the Machine

RANSPORTING

THE

ACHINE

RANE

Secure the straps to chassis lifting/tie down points only.

ORKLIFT

DANGER

! !

Forklifting and Lifting by Crane are for transport only.

See specifications for weight of machine and be certain that forklift is of adequate capacity to lift the

machine.

Figure 4: Transporting the Machine

Forklift from the side by lifting under the Chassis.

RUCK

1. Maneuver the machine into transport position and

chock wheels.

2. Secure the machine to the transport vehicle with

chains or straps of adequate load capacity

attached to the chassis lifting/tie down points.

CAUTION

Overtightening of the chains or straps attached to the

Tie Down lugs may result in damage to the machine

Lift / Tie Down Points

2 Rear & 2 Front

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