SERVICE AND PARTS MANUAL. Micro 19. Serial Number Range Up

Transcription

1 SERVICE AND PARTS MANUAL Micro 19 Serial Number Range Up Part # 94554r1

2 Revision History Original Release Date: Date Reason for Update New Release Aerial Platform Sales Corp S. Madera Avenue Kerman, CA USA Ph: FAX Web:

3 Service Table of Contents Introduction I Page Machine Specifications II MEC Operator Policy III Safety Symbols IV General Safety Tips V Maintenance Lock V Hydraulic System VI Electrical System VI Total System I Primary Machine Components VII Emergency Systems and Procedures X Emergency Lowering X Free-Wheel Configuration For Winching or Towing XI Lift and Support the Machine XII Section 1: Maintenance Page Machine Maintenance General Pre-Start Inspection Checklist Day Service Frequent Inspection Checklist Hydraulic Fluid Batteries Electrical Wiring Tires & Wheels Emergency Stop Key Switch Horn Drive Brakes Drive Speed - Stowed Drive Speed - Raised Drive Speed - Slow Hydraulic Oil Analysis Tank Venting System Annual Inspection Checklist Scissor Slide Blocks Hydraulic Tank Breather Cap Hydraulic Oil Inspection Section 2: Error Codes & Troubleshooting Page Control Component Locations Fault Codes Troubleshooting Table "Micro 19" Service and Parts Manual Page i

4 Service Table of Contents Section 3: Schematics Page Hydraulic Schematic Electrical Schematic Page ii "Micro 19" Service and Parts Manual

5 INTRODUCTION This manual consists of Service and Illustrated 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 aerial work platform. When used in conjunction with the Illustrated Parts Section and the Operators Manual (provided separately), this manual will assist you in making necessary adjustments and repairs, and identifying and ordering the correct replacement parts. All parts represented here are manufactured and supplied in accordance with MEC quality standards. We recommend that you use genuine MEC parts to ensure proper operation and reliable performance. To obtain maximum benefits from your MEC Aerial Work Platform, 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, Service and Parts Manuals in order to gain a thorough understanding of the unit prior to making any repairs. CONTENTS PAGE Machine Specifications II MEC Operator Policy III Safety Symbols V General Safety Tips V Maintenance Lock V Hydraulic System VI Electrical System VI Total System I Primary Machine Components VII Emergency Systems and Procedures X Emergency Lowering X Free-Wheel Configuration For Winching or Towing XI Lift and Support the Machine XII "Micro 19" Service and Parts Manual Page I

6 Specifications Micro 19 Working Height* 24 ft 4 in 7.6 m Platform Height 18 ft 4 in 5.6 m Maximum Drive Height 18 ft 4 in 5.6 m Stowed Height Top Guardrail 79 in. 2.0 m Platform Floor 39 in. 1.0 m Platform Extension Length 23.6 in. 0.6 m Machine Weight** (Unloaded) 2690 lb 1220 kg Lift Capacity Total 500 lb 227 kg Deck Extension Capacity 1 Person / 250lb (113 kg) Maximum Occupants 2 Platform Length (Extended) 78 in. 2 m Platform Length (Retracted) 54 in. 1.4 m Width (Overall) 32 in m Platform Dimensions (length x width) 53.9 x 27.6 in 1.37 x 0.7m Wheel Base 44.5 in 1.13 m Turning Radius--Inside 17.7 in. 0.45m Ground Clearance--Stowed 2.4 in 6 cm Ground Clearance--Elevated 0.6 in 1.5 cm Drive Speed (Proportional) Stowed mph 0-4 km/h Raised or extended 0-.5 mph 0-8 km/h Gradability 25%/14 Maximum Side Slope--Stowed 5 Ground Pressure/Wheel Min/Max 83/112 psi 5.8/7.9 kg/cm 2 Maximum Wheel Load 960 lb 435 kg Occupied Floor Pressure Full Load Platform Retracted Occupied Floor Pressure Platform Deck Extended Maximum Operating Wind Speed 28 mph / 12.5 m/sec (45 km/h) Tire Size 9 x 4 inch/230 x 100mm Wheel Nut Torque ft-lb / 226 Nm Secured with cotter pin Hydraulic Pressure 2320 psi/ 160 bar Power System Voltage 24 Volt DC Battery Charger Input V AC, Hz Output 24 Volt DC Batteries Two 12 Volt Deep Cycle 115Ah Airborne Noise Emissions 239 psf 1167 kg/m psf 835 kg/m 2 <70 db Meets applicable requirements of ANSI A *Working Height adds 6 feet (2 m) to platform height. **Weight may increase with certain options. Page II "Micro 19" Service and Parts Manual

7 MEC OPERATOR POLICY 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 body of the machine, at the ground controls, and platform control console. 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 ongoing 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 oneself that they are proper and safe. Your MEC Aerial Work Platform has been designed, built, and tested to provide many years of safe, dependable 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 the responsibility of the user and all operating personnel. If there is a question on application and/or operation contact: MEC Aerial Work Platform 1401 S. Madera Avenue Kerman, CA USA Ph: "Micro 19" Service and Parts Manual Page III

8 SAFETY SYMBOLS To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals: 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 without alert symbol indicates a situation which, if not avoided, may result in property damage. Page IV "Micro 19" Service and Parts Manual

9 GENERAL SAFETY TIPS Regular inspection and conscientious maintenance is the key to efficient economical operation of your aerial work platform. It will help to assure that your equipment will perform satisfactorily with a minimum of service and repair. The actual operating environment of the machine governs the inspection schedule. Correct lubrication 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 mechanical failure and resulting downtime is reduced to a minimum. Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times. Never open a hydraulic system when there are contaminants in the air. Always clean the surrounding area before opening hydraulic systems. Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication. Watch for makeshift fixes which can jeopardize safety as well as lead to more costly repair. MAINTENANCE LOCK DEATH OR SERIOUS INJURY HAZARD! NEVER PERFORM WORK OR INSPECTION ON THE MACHINE WITH THE PLATFORM ELEVATED WITHOUT FIRST BLOCKING THE SCISSOR ASSEMBLY WITH THE MAINTENANCE LOCK. Figure 1-1: Support Platform 1. Raise the platform approximately 8ft / 2.5m from the ground. 2. Rotate the Maintenance Lock away from the machine and let it hang down. 3. Lower the platform until the Maintenance Lock rests securely on the link. Keep clear of the Maintenance Lock when lowering the platform. Maintenance Lock ART_4995 "Micro 19" Service and Parts Manual Page V

10 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 the negative cable is installed, a spark will occur if contact is made between the positive side of the battery and a metal surface on the machine. 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 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 AERIAL WORK PLATFORM. INSPECTION AND MAINTENANCE SHOULD BE PERFORMED BY QUALIFIED PERSONNEL FAMILIAR WITH THE EQUIPMENT. Page VI "Micro 19" Service and Parts Manual

11 PRIMARY MACHINE COMPONENTS Platform controller 2 Platform guard rails 3 Platform extension release pedal 4 Platform entry gate 5 Main Platform 6 Lift Cylinders 7 Entry ladder 8 Drive wheels 9 Emergency lowering knob 10 Ground Control Panel 11 Batteries charger 12 Main power switch 13 Steer wheels 14 Scissor 15 Safety chock 16 Lanyard anchorage points 17 Platform extension 18 Manual storage container "Micro 19" Service and Parts Manual Page VII

12 TORQUE SPECIFICATIONS FASTENERS Use the following values to apply torque unless a specific torque value is called out for the part being used. SAE GRADE AMERICAN STANDARD CAP SCREWS METRIC CAP SCREWS 5 8 METRIC GRADE CAP SCREW SIZE - inches - TORQUE FT. LBS Nm MIN MAX MIN MAX CAP SCREW TORQUE SIZE TORQUE TORQUE FT. LBS Nm - millimeters- FT. LBS Nm FT. LBS Nm MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX 1/ / / / / / / / / / / / / / / / / / M6 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.50 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X Torque values apply to fasteneers 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 Page VIII "Micro 19" Service and Parts Manual

13 HYDRAULIC COMPONENTS TORQUE TABLE NOTE: Always lubricate threads with clean hydraulic fluid prior to installation. Type: SAE PORT SERIES Use the following values to torque hydraulic components when a specific value is not available. Always check for torque values in the following places before relying on the Hydraulic Components Torque Table: parts drawings and service instructions in this manual. packaging and instruction sheets provided with new parts. instruction manuals provided by the manufacturer of the component being serviced. Cartridge Poppet Fittings Hoses Ft. Lbs. Nm Ft. Lbs. Nm In. Lbs. Nm #4 N/A N/A N/A N/A #6 N/A N/A # # # # "Micro 19" Service and Parts Manual Page IX

14 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 ELEVATING ASSEMBLY. EMERGENCY STOP ART_4979 The machine is equipped with an EMERGENCY STOP switch at the base controls and the platform control box. Press the EMERGENCY STOP switch at any time to stop all machine functions. Pull switch to reset. Either switch will stop all machine functions. Both switches must be reset or machine will not operate. EMERGENCY LOWERING IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED, USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE PLATFORM. DO NOT CLIMB DOWN THE ELEVATING ASSEMBLY OR EXIT THE PLATFORM. The Emergency Lowering System is used to lower the platform in case of power failure. To lower the platform, pull the Emergency Lowering Knob, located near the Base Control panel. Emergency Lowering Knob Page X "Micro 19" Service and Parts Manual

15 FREE-WHEEL CONFIGURATION FOR WINCHING OR TOWING RUNAWAY HAZARD! AFTER RELEASING THE BRAKES THERE IS NOTHING TO STOP MACHINE TRAVEL. MACHINE WILL ROLL FREELY ON SLOPES. ALWAYS CHOCK THE WHEELS BEFORE MANUALLY RELEASING THE BRAKES. The machine can be winched or towed short distances at speeds not to exceed 2.5 MPH (4 km/h). Before towing or winching the machine, it is necessary to release the brakes. Reset the brakes after towing or winching. Push Down & Hold Turn to Ground DISENGAGE BRAKES BEFORE TOWING OR WINCHING 1. Chock the wheels. 2. Turn the Key Switch to the OFF position. 3. Turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 4. At the Ground Controls panel, push red rocker switch to the left & Push Down and Hold The Lift/Lower Switch to the Lower Position Pull or turn the Red Emergency Stop button clockwise to the ON position at the ground controls. An alarm will sound, signaling that the brakes have been released. ART_ Push red rocker switch to left RESETTING BRAKES Press the Emergency Stop button, then push the Brake Release Switch to the right to reset the brake. 2 Reset E-Stop (pull out) BE SURE THAT THE BRAKES ARE ENGAGED BEFORE REMOVING THE WHEEL CHOCKS. "Micro 19" Service and Parts Manual Page XI

16 LIFT AND SUPPORT THE MACHINE DEATH OR SERIOUS PERSONAL INJURY MAY RESULT FROM THE USE OF SUBSTANDARD LIFTING DEVICES AND/OR JACK STANDS. ENSURE THAT ALL LIFTING DEVICES AND JACK STANDS ARE OF ADEQUATE CAPACITY AND IN GOOD WORKING CONDITION BEFORE USE. The following are needed to safely lift and support the machine; a jack with a lifting capacity of two (2) tons or more. jack stands with a rating of two (2) tons 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) suitable 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 and remove the jack. 3. Remove chocks. Page XII "Micro 19" Service and Parts Manual

17 Section 1 MAINTENANCE CONTENTS PAGE Machine Maintenance General Pre-Start Inspection Checklist Day Service Frequent Inspection Checklist Hydraulic Fluid Batteries Electrical Wiring Tires & Wheels Emergency Stop Key Switch Horn Drive Brakes Drive Speed - Stowed Drive Speed - Raised Drive Speed - Slow Hydraulic Oil Analysis Tank Venting System Annual Inspection Checklist Scissor Slide Blocks Hydraulic Tank Breather Cap Hydraulic Oil Inspection "Micro 19" Service and Parts Manual Page 1-1

18 MACHINE MAINTENANCE GENERAL M ACHINE MAINTENANCE GENERAL Instructions in this portion of the manual are to be used in conjunction with the Pre-Start, Frequent and Annual Inspection checklists found in this machine s Operator s Manual. IMPORTANT:Scheduled maintenance inspection checklists are included in the Operator s Manual for use only by qualified service technicians. Only qualified service technicians may perform repairs to the machine. After repairs are completed, the operator must perform a Pre-Start Inspection before proceeding to the Functions Test. HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY, BLINDNESS, AND DEATH. REPAIR LEAKS IMMEDIATELY. FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE. CHECK FOR PIN HOLE LEAKS WITH A PIECE OF CARDBOARD, NOT YOUR HAND. NEVER PERFORM WORK OR INSPECTION ON THE MACHINE WITH THE PLATFORM ELEVATED WITHOUT FIRST BLOCKING THE SCISSOR ASSEMBLY WITH THE MAINTENANCE LOCK (SEE THE INTRODUCTION PORTION OF THIS MANUAL). PERFORM SCHEDULED MAINTENANCE AT RECOMMENDED INTERVALS. FAILURE TO PERFORM SCHEDULED MAINTENANCE AT RECOMMENDED INTERVALS MAY RESULT IN A DEFECTIVE OR MALFUNCTIONING MACHINE AND MAY RESULT IN INJURY OR DEATH OF THE OPERATOR. KEEP MAINTENANCE RECORDS CURRENT AND ACCURATE. IMMEDIATELY REPORT ANY DAMAGE, DEFECT, UNAUTHORIZED MODIFICATION OR MALFUNCTION TO YOUR SUPERVISOR. ANY DEFECT MUST BE REPAIRED PRIOR TO CONTINUED USE. DO NOT USE A DAMAGED, MODIFIED OR MALFUNCTIONING MACHINE. Never leave hydraulic components or hoses open. Plug all hoses and fitting immediately after disassembly to protect the system from outside contamination (including rain). Never open a hydraulic system when there are contaminants in the air. Always clean the surrounding area before opening hydraulic systems. Use only recommended lubricants. Improper lubricants or incompatible lubricants may cause as much damage as no lubrication. Watch for makeshift fixes which can jeopardize safety as well as lead to more costly repair. Inspection and maintenance should be performed by qualified personnel familiar with the equipment. Page 1-2 "Micro 19" Service and Parts Manual

19 PRE-START INSPECTION CHECKLIST P RE-START INSPECTION CHECKLIST Items on this checklist should be inspected before each work shift. Refer to the Operator s Manual. 30-DAY SERVICE The 30 day maintenance procedure is a one-time procedure to be performed after the first 30 days or 40 hours of usage. Maintaining the tires and wheels in good condition is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. 1. Check the tire surface and sidewalls for cuts, cracks, punctures and unusual wear. 2. Check each wheel for damage, bends and cracks. 3. Remove the wheel covers and check each center lock nut for proper torque and presence of cotter pin. FRONT REAR Castle nut torque, dry ft-ibs / 226 Nm Locknut 100 ft-ibs / 135 Nm Castle nut torque, lubricated ft-ibs / 170 Nm FREQUENT INSPECTION CHECKLIST THIS CHECKLIST MUST BE USED AT 3-MONTH INTERVALS OR EVERY 150 HOURS OF MACHINE USE, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. Frequent Maintenance Inspections should be conducted by qualified service technicians only. Photocopy the Frequent Inspection Checklist page from the Operator s Manual to keep record of this inspection. Keep inspections records up to date. Record and report all discrepancies to your supervisor. Perform all checks listed on Pre-Start Inspection, then proceed with the following checks. HYDRAULIC FLUID Inspect the condition of hydraulic fluid in the reservoir. Oil should be a clear and amber in color. "Micro 19" Service and Parts Manual Page 1-3

20 F REQUENT INSPECTION CHECKLIST BATTERIES Proper battery condition is essential to good machine performance and operational safety. Improper or damaged cables and connections can result in component damage and hazardous conditions. ELECTROCUTION / BURN HAZARD. CONTACT WITH ELECTRICALLY CHARGED CIRCUITS COULD RESULT IN DEATH OR SERIOUS INJURY. REMOVE ALL RINGS, WATCHES AND OTHER JEWELRY. BODILY INJURY HAZARD. BATTERIES CONTAIN ACID. AVOID SPILLING OR CONTACTING BATTERY ACID. NEUTRALIZE BATTERY ACID SPILLS WITH BAKING SODA AND WATER. 1. Put on protective clothing and eye wear. 2. Slide out the component tray from the chassis. 3. Be sure that the battery cable connections are free of corrosion. NOTE: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 4. Be sure that the battery retainers and cable connections are tight. 5. Fully charge the batteries. Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize. 6. Check each battery pack and verify that the batteries are wired correctly. 7. Inspect the battery charger plug and pigtail for damage or excessive insulation wear. Replace as required. 8. Connect the battery charger to a properly grounded V / Hz single phase AC power supply. Result: The charger should operate and begin charging the batteries. 200A Fuse Batteries Result: If, simultaneously, the charger alarm sounds and the LEDs blink, correct the charger connections at the fuse and battery. The charger will then operate correctly and begin charging the batteries. NOTE: For best results, use an extension cord of adequate size with a length no longer than 50 ft / 15m. Motor Controller (ECU2 (TMI) Power Switch If you have any further questions regarding the battery charger operation, please contact the MEC Customer Service. Battery Charger ART_5050 Page 1-4 "Micro 19" Service and Parts Manual

21 ELECTRICAL WIRING F REQUENT INSPECTION CHECKLIST Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. ELECTROCUTION / BURN HAZARD. CONTACT WITH ELECTRICALLY CHARGED CIRCUITS COULD RESULT IN DEATH OR SERIOUS INJURY. REMOVE ALL RINGS, WATCHES AND OTHER JEWELRY. 1. Inspect the following areas for burnt, chafed, corroded and loose wires: Ground control panel Hydraulic power unit module tray Platform controls 2. Turn the key switch to ground control and turn the red Emergency Stop button clock-wise to the on position at both the ground and platform controls 3. Raise the platform approximately 8 ft / 2.5 m from the ground. 4. Lift the safety arm, move it to the center of the scissor arm and rotate up to a vertical position. 5. Lower the platform onto the safety arm. CRUSHING HAZARD. KEEP HANDS CLEAR OF THE SAFETY ARM WHEN LOWERING THE PLATFORM. 6. Inspect the center chassis area and scissor arms for burnt, chafed and pinched cables. 7. Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Scissor arms ECU to platform controls Power to platform wiring 8. Inspect for a liberal coating of dielectric grease in the following locations: Between the ECU and platform controls All wire harness connectors Level sensor 9. Raise the platform and return the safety arm to the stowed position. 10. Lower the platform to the stowed position and turn the machine off. "Micro 19" Service and Parts Manual Page 1-5

22 F REQUENT INSPECTION CHECKLIST TIRES & WHEELS Maintaining the tires and wheels in good condition is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. 1. Check the tire surface and sidewalls for cuts, cracks, punctures and unusual wear. 2. Check each wheel for damage, bends and cracks. 3. Remove the wheel covers and check each center lock nut for proper torque and presence of cotter pin. FRONT REAR Castle nut torque, dry ft-ibs / 226 Nm Locknut 100 ft-ibs / 135 Nm Castle nut torque, lubricated ft-ibs / 170 Nm EMERGENCY STOP A properly functioning Emergency Stop system is essential for safe machine operation. An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions, resulting in a hazardous situation. As a safety feature, selecting and operating from the ground controls will override all platform controls except the platform red Emergency Stop button. 1. Turn the key switch to ground control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 2. Push in the red Emergency Stop button at the ground controls to the off position. Result: No machine functions should operate. 3. Turn the key switch to platform control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 4. Push in the red Emergency Stop button at the platform controls to the off position. Result: No machine functions should operate. NOTE: The red Emergency Stop button at the ground controls will stop all machine operation, even if the key switch is switched to platform control. Page 1-6 "Micro 19" Service and Parts Manual

23 KEY SWITCH F REQUENT INSPECTION CHECKLIST Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation. Perform this procedure from the ground using the platform controls. Do not stand in the platform. 1. Turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 2. Turn the key switch to platform control. 3. Check the platform up/down function from the ground controls. Result: The machine functions should not operate. 4. Turn the key switch to ground control. 5. Check the machine functions from the platform controls. Result: The machine functions should not operate. 6. Turn the key switch to the off position. Result: No function should operate. HORN The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel. An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions. 1. Turn the key switch to platform control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 2. Push down the horn button at the platform controls. Result: The horn should sound. DRIVE BRAKES Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulicallyreleased individual wheel brakes can appear to operate normally when not fully operational. Perform this procedure with the machine on a firm level surface that is free of obstructions, with the platform extension deck fully retracted and the platform in the stowed position. 1. Mark a test line on the ground for reference. 2. Turn the key switch to platform control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 3. Press the drive function select button. 4. Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line. 5. Bring the machine to top drive speed before reaching the test line. Release the function enable switch or the joystick when your reference point on the machine crosses the test line. "Micro 19" Service and Parts Manual Page 1-7

24 F REQUENT INSPECTION CHECKLIST 6. Measure the distance between the test line and your machine reference point. Result: The machine stops within the specified braking distance. No action required. Result: The machine does not stop within the specified braking distance. NOTE: The brakes must be able to hold the machine on any slope it is able to climb. 7. Replace the brakes and repeat this procedure beginning with step 1. Maximum Braking Distance High Speed on paved surface 24 in ± 11.8 in 61 cm ±30 cm DRIVE SPEED - STOWED Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Perform this procedure with the machine on a firm, level surface that is free of obstructions. 1. Create start and finish lines by marking two lines on the ground 40 ft /12.2 m apart. 2. Turn the key switch to platform control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 3. Lower the platform to the stowed position. 4. Press the drive function select button. 5. Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 6. Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 7. Continue at full speed and note the time when your reference point on the machine passes over the finish line. The time should be 9-11sec. DRIVE SPEED - RAISED Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Perform this procedure with the machine on a firm, level surface that is free of obstructions. 1. Create start and finish lines by marking two lines on the ground 40 ft /12.2 m apart. 2. Turn the key switch to platform control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 3. Press the lift function select button. 4. Press and hold the function enable switch on the joystick. 5. Raise the platform approximately 4 ft /1.2 m from the ground. 6. Press the drive function select button. 7. Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. Page 1-8 "Micro 19" Service and Parts Manual

25 F REQUENT INSPECTION CHECKLIST 8. Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 9. Continue at full speed and note the time when your reference point on the machine passes over the finish line. The time should be sec. DRIVE SPEED - SLOW Proper drive functions are essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Perform this procedure with the machine on a firm, level surface that is free of obstructions. 1. Create start and finish lines by marking two lines on the ground 40 ft /12.2 m apart. 2. Turn the key switch to platform control and turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls. 3. Lower the platform to the stowed position. 4. Press the slow speed select button. 5. Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 6. Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 7. Continue at full speed and note the time when your reference point on the machine passes over the finish line. The time should be sec. HYDRAULIC OIL ANALYSIS Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. Hydraulic oil should be tested yearly and replaced if it fails. If the hydraulic oil is not replaced at the Annual Inspection, test the oil quarterly. Replace the oil when it fails the test. "Micro 19" Service and Parts Manual Page 1-9

26 F REQUENT INSPECTION CHECKLIST TANK VENTING SYSTEM A free-breathing hydraulic tank cap is essential for good machine performance and service life. A dirty or clogged cap may cause the machine to perform poorly. Extremely dirty conditions may require that the cap be inspected more often. 1. Remove the breather cap from the hydraulic tank. 2. Check for proper venting. Result: Air passes through the breather cap. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3. NOTE: When checking for positive tank cap venting, air should pass freely through the cap. 3. Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat step Install the breather cap onto the hydraulic tank. Page 1-10 "Micro 19" Service and Parts Manual

27 A NNUAL INSPECTION CHECKLIST ANNUAL INSPECTION CHECKLIST THIS CHECKLIST MUST BE USED AT 12-MONTH INTERVALS OR EVERY 600 HOURS OF MACHINE USE, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. Annual Maintenance Inspections should be conducted by qualified service technicians only. Photocopy the Annual Inspection Checklist page from the Operator s Manual to keep record of this inspection. Keep inspections records up to date. Record and report all discrepancies to your supervisor. Perform all checks listed on Pre-Start Inspection and the Frequent Inspection, then check all items listed on the Annual Inspection Report. See specific instructions below. SCISSOR SLIDE BLOCKS Maintaining the condition of the scissor arm slide blocks is essential to safe machine operation. Continued use of worn out wear pads may result in component damage and unsafe operating conditions. Perform this procedure with the platform in the stowed position. 1. Measure the distance between the number one inner arm cross tube and the chassis deck at the ground controls side of the non-steer end of the machine. Result: The measurement is 1.18 in / 30 mm or more. Proceed to step 2. Result: The measurement is less than 1.18 in / 30 mm. Replace both wear pads. Inner Arm Cross Tube Slide Block 2. Measure the distance between the Chassis Deck number one inner arm cross tube ART_5051 and the chassis deck at the battery pack side of the non-steer end of the machine. Result: The measurement is 1.18 in / 30 mm or more. Proceed to step 3. Result: The measurement is less than 30mm. Replace both wear pads. 3. Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact. "Micro 19" Service and Parts Manual Page 1-11

28 A NNUAL INSPECTION CHECKLIST HYDRAULIC TANK BREATHER CAP The hydraulic tank is a vented-type tank. The breather cap has an internal air filter that can become clogged or, over time, can deteriorate. If the breather cap is faulty or improperly installed, impurities can enter the hydraulic system which may cause component damage. Extremely dirty conditions may require that the cap be inspected more often. 1. Remove and discard the hydraulic tank breather cap. 2. Install a new cap onto the tank. HYDRAULIC OIL INSPECTION Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. Hydraulic oil should be tested yearly and replaced if it fails. If the hydraulic oil is not replaced at the Annual Inspection, test the oil quarterly. Replace the oil when it fails the test. NOTE: Perform this procedure with the platform in the stowed position. 1. Slide out the Component Tray. 2. Disconnect the battery pack from the machine FULL ADD Component Tray Hydraulic Unit ELECTROCUTION / BURN HAZARD. CONTACT WITH ELECTRICALLY CHARGED CIRCUITS COULD RESULT IN DEATH OR SERIOUS INJURY. REMOVE ALL RINGS, WATCHES AND OTHER JEWELRY. 3. Tag and disconnect the hydraulic pump outlet line and remove the line from the pump. Cap the fitting on the pump. 4. Loosen the bolts and remove the hydraulic power pack form the tray. 5. Open the oil plug of tank. Drain all of the oil into a suitable container. 6. Loosen and remove the bolts and separate the tank from the pump body. ART_5000 Page 1-12 "Micro 19" Service and Parts Manual

29 A NNUAL INSPECTION CHECKLIST BODILY INJURY HAZARD. SPRAYING HYDRAULIC OIL CAN PENETRATE AND BURN SKIN. LOOSEN HYDRAULIC CONNECTIONS VERY SLOWLY TO ALLOW THE OIL PRESSURE TO DISSIPATE GRADUALLY. DO NOT ALLOW OIL TO SQUIRT OR SPRAY. 7. Clean up any oil that may have spilled. Properly discard the used oil. 8. Clean the inside of the hydraulic tank using a mild solvent. Allow the tank to dry completely. 9. Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners. Torque to specification. Hydraulic tank retaining fasteners, dry Hydraulic tank drain plug, lubricated 35 in-ibs 4 Nm 26 in-ibs 3 Nm 10. Install the hydraulic power pack into the component tray. Install the fitting and hydraulic hoses onto the hydraulic power pack and torque. 11. Fill the tank with hydraulic oil to the middle of the dipstick. Do not overfill. 12. Activate the pump to fill the hydraulic system with oil and bleed the system of air. COMPONENT DAMAGE HAZARD. THE PUMP CAN BE DAMAGED IF OPERATED WITHOUT OIL. BE CAREFUL NOT TO EMPTY THE HYDRAULIC TANK WHILE IN THE PROCESS OF FILLING THE HYDRAULIC SYSTEM. DO NOT ALLOW THE PUMP TO CAVITATE. "Micro 19" Service and Parts Manual Page 1-13

30 NOTES: A NNUAL INSPECTION CHECKLIST Page 1-14 "Micro 19" Service and Parts Manual

31 Section 2 CONTROL SYSTEM CONTENTS PAGE Control Component Locations Fault Codes Troubleshooting Table "Micro 19" Service and Parts Manual Page 2-1

32 CONTROL COMPONENT LOCATIONS C ONTROL COMPONENT LOCATIONS Hydraulic Unit Platform Controls (PCU) Steer Valve Pump Motor Lift Valve Lift Up Limit Switch Main Power Lower Emergency Stop Switch Component Tray Hydraulic Unit Motor Controller/ ECU2 (TM1) Batteries Pothole Switch (each side) (inside wheel well) Battery Charger & Power To Platform Lower Controls (ECU) Lift Down Limit Switch Drive Motor (under cover) Drive Motor (under cover) Page 2-2 "Micro 19" Service and Parts Manual

33 FAULT CODES Fault Codes, when present, appear on the LED Indicator at the Upper Controls station and on the LED Screen at the Lower Controls station. F AULT CODES Upper Controls LED Indicator LED Indicator LowerControls "Micro 19" Service and Parts Manual Page 2-3

34 F AULT CODES ERROR INDICATOR READOUT If the LED diagnostic readout displays an error code, such as LL, push in and turn the red Emergency Stop button to reset the system. Error Code Description Lift Reaction 01 System Initialization Fault 02 System Communication Fault 03 Invalid Option Setting Fault 12 Chassis Up / Down Switch ON at Power-Up Fault 18 Pothole Guard Fault 31 Pressure Sensor Fault 32 Angle Sensor Fault 34 Reserved 42 Platform Left Turn Switch ON at Power-Up Message 43 Platform Right Turn Switch ON at Power-Up Message 46 Platform Joystick Enable Switch ON at Power-Up Fault 47 Platform Joystick Not In Neutral at Power-Up Message 52 Drive Forward Coil Fault 53 Drive Reverse Coil Fault 54 Lift Up Coil Fault 55 Lift Down Coil Fault 56 Right Turn Coil Fault 57 Left Turn Coil Fault 58 General Brake Coil Fault 59 Parallel Coil Fault 61 Motor Controller Current Sensor Fault 62 Motor Controller Hardware Failsafe Fault 63 Motor Controller Motor Output Fault 64 Motor Controller SRO Fault 65 Motor Controller Throttle Fault 66 Motor Controller Emergency Reverse Fault 67 Motor Controller HPD Fault 68 Low Voltage Fault 69 High Neutral Current Fault 70 Steering Input Out Of Range Disables All Motion Disables All Motion Disables All Motion Disables Chassis Control Disables Lifting And Driving Disables All Motion Disables All Motion Reserved Diagnostic Message Only Diagnostic Message Only Disables Platform Control Diagnostic Message Only Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Controller Dependent Controller Dependent Controller Dependent Controller Dependent Controller Dependent Controller Dependent Controller Dependent Disables All Motion Disables All Motion Disables All Motion Page 2-4 "Micro 19" Service and Parts Manual

35 F AULT CODES Error Code Description Lift Reaction 71 Motor Controller Main Contactor Fault 72 Motor Controller Over Voltage Fault 73 Motor Controller Thermal Cutback Fault 74 Motor Controller Motor Fault 75 Motor Controller Pump Motor Fault 76 Motor Controller Left Drive Motor Fault 77 Motor Controller Right Drive Motor Fault 78 Pump Motor Short Fault 79 Left Drive Motor Short Fault 80 Over 80% Load Warning 81 Right Drive Motor Short Fault 82 Right Brake Coil Fault 83 Left Brake Coil Fault 90 Over 90% Load Warning 99 Over 99% Load Warning OL Overloaded Platform Fault LL Machine Tilted Beyond Safe Limits Fault Disables Lifting And Driving Controller Dependent Controller Dependent Controller Dependent Controller Dependent Controller Dependent Controller Dependent Disables Lifting And Driving Disables Lifting And Driving Warning Only Disables Lifting And Driving Disables Lifting And Driving Disables Lifting And Driving Warning Only Warning Only Disables All Motion Disables Lifting And Driving "Micro 19" Service and Parts Manual Page 2-5

36 TROUBLESHOOTING TABLE TROUBLESHOOTING TABLE Error Code Troubleshooting 01 System Initialization Fault: ECU may be malfunctioning, replace it. 02 System Communication Fault: Check communications cable connections and other wiring. If that does not resolve the problem, try replacing the PCU or ECU. 03 Invalid Option setting Fault: Set appropriate option for this lift Chassis Toggle Switch ON at power-up Fault: Check the wires to the Toggle Switch or look for a stuck Toggle Switch. Pothole Guard Fault: Check that the pothole guards are extended, check the pothole limit switches. Check wires to the switches, check the down limit switch and connections. Pressure Sensor Fault: Check the wiring to the sensor and then the sensor itself. Also check to make sure that the correct option is properly selected (or not) for load sensing. Angle Sensor Fault: Check the wiring to the sensor and then the sensor itself. Also check to make sure that the correct option is properly selected (or not) for load sensing Platform Left Turn Switch ON at power-up Message: Ensure that nothing is holding the Joystick Toggle Switches down. If OK, consider replacing the Joystick or PCU. Platform Right Turn Switch ON at power-up Message: Ensure that nothing is holding the Joystick Toggle Switches down. If OK, consider replacing the Joystick or PCU. Platform Joystick Enable Switch ON at power-up Fault: Ensure that nothing is holding the Enable switch closed. Also check the neutral zone parameters. If OK, consider replacing the Joystick or PCU. Platform Joystick not in neutral at power-up Message: Make sure that the Joystick is in the neutral (upright) position. Check the neutral zone parameter setting in Dingli Scissor Programmer. If it s OK, consider replacing the Joystick or the PCU. Drive Forward Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Drive Reverse Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Lift Up Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Lift Down Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Right Turn Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Left Turn Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. General Brake Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Page 2-6 "Micro 19" Service and Parts Manual

37 TROUBLESHOOTING TABLE Error Code Troubleshooting Parallel Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Motor Controller Current Sensor Fault: Drive or Lift Motor may be overheating. Let the lift cool down. If that does not help, cycle power to reset the Motor controller. If the problem persists, check the wiring and if OK, try replacing the Motor Controller. Motor Controller Hardware Failsafe Fault: Cycle power. If that does not resolve the issue check for noise sources. If still needed, try replacing the Motor Controller. Motor Controller Motor Output fault: Check wiring first then cycle power. If needed replace controller. Motor Controller SRO Fault: Look at motor enable delay with the Dingli Scissor Programmer, it may be too short. Make sure other Motor Controller parameters are properly selected Motor Controller Throttle Fault: Check wiring. Make sure the correct throttle type is selected in the Motor Controller. Motor Controller HPD Fault: Look at motor enable delay with the Dingli Scissor Programmer, it may be too short. Make sure other Motor Controller parameters are properly selected Low Voltage Fault: Check battery voltage and charge batteries if necessary. Check the battery connections and tighten or clean. Check the voltage to the ECU and PCU. High Neutral Current: The MC is sensing current in the motors when there should not be. This could occur anytime the MC thinks the brakes are on and the motors are still turning. This message sometimes comes just before other faults but should be ignored in those cases Steering Input Out of Range: There is an inappropriate voltage at the steering input of the motor controller. The controller may need to be trained for the three steering voltages (on Differential Steered machines). Or the steering voltage from the ECU was at some point outside of the range that was recorded during the training session. Retrain the controller and/or check for fluctuating voltages due to lose wires, etc. Motor Controller Main Contactor Fault: Check the connections to the main contactor. Replace the contactor if necessary. Replace the Motor Controller if necessary. Motor Controller Over Voltage Fault: Check battery voltage and make sure the battery charger is not on. The cycle power to the lift. If that does not resolve the issue, try replacing the Motor Controller Motor Controller Thermal Cutback Fault: Drive or Lift Motor may be overheating. Let the lift cool down. If that does not help cycle power to reset the Motor controller. If that doesn t resolve the issue, replace the Motor Controller. Motor Controller Motor Fault: Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller. Motor Controller Pump Motor Fault: Check connections to the Pump Motor. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller. "Micro 19" Service and Parts Manual Page 2-7

38 TROUBLESHOOTING TABLE Error Code Troubleshooting Motor Controller Left Drive Motor Fault: Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller. Motor Controller Right Drive Motor Fault: Check connections to the motors. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller. Pump Motor Short Fault: Check connections to the pump motor. Cycle power to the lift and if that does not resolve the issue, replace the Motor Controller. Left Drive Motor Short Fault: Check the Motor connections and make sure they are tight. Check the Motor for a short. Over 80% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load. Right Drive Motor Short Fault: Check the Motor connections and make sure they are tight. Check the Motor for a short. Right Brake Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Left Brake Coil Fault: Check the connections to the Coil s terminals and make sure they are tight. If so, check the coil itself to see if it is open or shorted. Over 90% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load. Over 99% Load Warning: Platform has reached its limit of weight. Do not add more load. OL LL Overloaded Platform Fault: Remove the excess load immediately. Machine Tilted Beyond Safe Limits Fault: If the machine is tilted, find a way to make it level. If the machine is level, check the wiring to the tilt sensor and then the sensor itself. Page 2-8 "Micro 19" Service and Parts Manual

39 Section 3 SCHEMATICS CONTENTS PAGE Hydraulic Schematic Electrical Schematic "Micro 19" Service and Parts Manual Page 3-1

40 HYDRAULIC SCHEMATIC H YDRAULIC SCHEMATIC Flat overload(option) Lift Cylinder Upper Lift Cylinder Sensor SCV3 RV3 150Bar SCV4 Steer Cylinder 1.5mm IN CV2 Lower valve: mm IN CV2 Lower valve: A B C 1.0mm 1.0mm SCV2 SCV1 RV2 100bar RPCV1 CV1 RV1 160bar Pump unit B Pump unit parameter: Motor:24V,2200W,2800rpm Pump:Displacement 2.0cc/r Tank:4L Micro 19 HYDRAULIC SCHEMATIC Page 3-2 "Micro 19" Service and Parts Manual

41 PLATFORM CONTROL BOX ECU MC1 JOYSTICK PCU JUMP GN/WH (16) 14 LED JS1 JUMP GN/WH (16) 10 CAN LOW LED 5 BU(16) 5 1C GN/RD (16) 8C WH/VT (16) 8C WH/VT (16) 5 PB3 CAN HIGH 2 YE (16) 2 1B GN/YE (16) 5CBN/YE (16) 5CBN/YE (16) 3 JOYSTICK ENABLE PB8 10BWH/BU (16) 10B WH/BU (16) 6 SS3 4 GN (16) 4 POTHOLELIMIT SWITCH LS3 DRIVEINDICATOR 10B BU(20) STEER LEFT PLATFORM E-STOP A RD(20) A12 WH(16) STEERRIGHT 3 RD (16) 3 LS4 10B BU(20) 010A RD(20) PB4 LOW SPEED INDICATOR 1 WH (16) 1 POTHOLELIMIT SWITCH 7A BN/WH (16) 7A BN/WH (16) 4 LIFT ENABLE PB5 6C BN/GY (16) 6C BN/GY (16) 8 START INDICATOR DRIVEENABLE 10CGN/VT(16) 10CGN/VT(16) 5 PB6 10AGN/BU (16) 10AGN/BU(16) 1 LOW SPEED B2 BRAKERELEASESWITCH SA3 006 BN/BU(16) 6 PB7 12CGN/BU(16) 12C GN (16) A12 WH(16) BUZZER 5BBK (16) 5B BK(16) GND BK(16) Fuse RD (16) 2 HORN GND BN/BK (16) 010BGN/WH(16) 010A-1 BU/RD (16) 9A BN/BK (16) 9A BN/BK (16) 9 4C GN/WH (16) 4C GN/WH (16) 4 8A BN/GN (16) 8A BN/GN (16) 6 3B WH/BK (16) 010ARD/BU(16) 1 11CGN/VT(16) 010ARD/BU(16) 2 J1 J2 J3 2 CAN L GN(20) 5 010ABU/RD(20) 1 CAN H YE (20) A-12 RD (16) SS2 KEY SWITCH INPUT LIFT UP LIFTDOWN 2B BN/RD (16) 12B BN/WH (16) 12A BN/GY(16) TILT SENSOR DEBUGGING LINE 11CGN/VT(20) TILT GND BK (20) V 010ARD(14) 230VAC 2C RD/BU (16) 8A BN/GN (16) HM GND BK (16) 输入 B+-Z BU/RD (16) 4A RD/BU (16) 1 2 HL2 GN/YE(16) BU (16) BN (16) PE N GN/YE(16) L CH-2 BK (10) 010A-1 BU/RD(20) CH-1 RD (10) + 010A-8 BU/RD (20) 010ABU/RD(16) 5A RD/BU (16) OVERLOAD INDICATOR 3A BN/YE(16) GND BK (16) YB2 010ABU/RD(16) 010ABU/RD(16) M3 LEFT LEFT DRIVE MOTOR H1 PB1 010ABU/RD(16) 010ABU/RD(16) HORN BRAKE 8BBN/RD (16) GND BK (16) GROUND E-STOP 010ABU/RD(16) 010ABU/RD(16) 010ABU/RD(16) STEERLEFT VALVE SCV2A 7B WH (16) GND BK (16) B1 BUZZER SCV2B STEER RIGHT VALVE B+-A RD (16) 9B WH/BK (16) 7C WH (16) GND BK (16) W 9C BU/RD (16) 3 KACH SCV1 LIFT UP VALVE 6A VT/YE (16) GND BK (16) ANGLE SENSOR SCV3 LIFT DOWN VALVE1 6B RD/BU (16) 5 LIFT DOWN VALVE2 SCV4 PRESSURE SENSOR 11AGN/RD(20) 11AGN/RD (16) 010ABU/RD(20) LS1 3C GN/RD (20) 3C GN/RD (16) 11B BU/RD (16) CHARGER 010ABU/RD(20) 4B WH/VT (16) YB1 _ RIGHT SS1 BRAKE KEY SWITCH KA1 001 RD(4) PB2 POWERSWITCH GB1 BATTERY 12VDC FU2 B+ RD (14) B+A RD (14) 010A-11 RD(14) 010A-9 BU/RD (16) 010A-8 BU/RD (16) 7A GND BK (14) B+Z YE(14) HOURMETER M2 RIGHT DRIVEMOTOR LS1 010ABU/RD(20) 11B BU/RD (20) U LIFT UP LIMIT SWITCH LS2 P- BK (4) P- 010ABU/RD(20) 12CGY/BU(20) 12CGN/BU(16) LIFT DOWN LIMIT SWITCH M1 HY. PUMP MOTOR GND BK (20) GND BK (16) GND BK (16) 6 B+ BF+1 RD (4) GND BK (16) HL1 BEACON 010ABU/RD(20) GNDBK (20) GNDBK (20) GND BK (16) GND BK (14) GND BK (20) GND BN/BK (16) GND BK (16) GND BK (14) GND BK (16) 4 FU3 B-A RD (16) 10A 10C GN/VT (16) 10A GN/BU(16) U RD (4) W2 BK (4) W1 BK (4) V RD (4) BF+ B- GB2 B+-Z BU/RD (16) BATTERY FU1 KM1 12VDC B+ RD (4) BF+ RD (4) 150A DC CONTACTOR GND BK (4) B- BK (4) 6 =6POSITION AMP CONNECTOR LOC1 16 =16POSITION CONNECTOR 5 =5POSITION SIBAS CONNECTOR LOC2 NOTE:ALL WIRES ARE 18AWG OR 0.8mm UNLESS NOTED OTHERWISE Micro 19 ELECTRICAL SCHEMATIC Micro 19 Service and Parts Manual Page 3-3

42 NOTES: Page 3-4 "Micro 19" Service and Parts Manual

43 Parts Table of Contents Section A: Chassis Page Chassis Assembly A-3 Pothole Protection Assembly A-5 Steer Linkage A-7 Left Drive Wheel Assembly A-9 Right Drive Wheel Assembly A-11 Battery Pack Module A-13 Ground Control Panel Assembly & Standard Pre Kit A-15 Section B: Scissor Page Scissor Assembly B-3 Section C: Platform Page Main Platform Assembly C-3 Platform Extension Assembly C-5 Platform Extension Lock C-7 Platform Controls C-9 Section D: Hydraulics Page Lift Cylinder Assembly D-3 Upper Lift Cylinder Assembly D-5 Hydraulic Hoses & Fittings D-7 Section E: Electrical System Page Electrical Harness E-3 Section F: Decals Page Decals F-3 "Micro 19" Parts Section Page i

44 NOTES: Page ii "Micro 19" Parts Section

45 SECTION A CHASSIS CONTENTS PAGE Chassis Assembly A-3 Pothole Protection Assembly A-5 Steer Linkage A-7 Left Drive Wheel Assembly A-9 Right Drive Wheel Assembly A-11 Battery Pack Module A-13 Ground Control Panel Assembly & Standard Pre Kit A-15 "Micro 19" Parts Section Page A-1

46 Chassis Assembly Page A-2 "Micro 19" Parts Section

47 Chassis Assembly ITEM PART NO. QTY DESCRIPTION 1 REF 1 Right Drive Wheel Assembly {See Page A-11} SHMS M5 X Lift Up Limit Switch CSCS M X 25 PHILLIPS Hydraulic Hoses Manifold HHMS M6 X Electric Bar PHP Cover Plate Lift Down Limit Switch WSHR M06 ZP STANDARD FLAT WSHR M6 Spring Washer HHCS M X ZP F Tilt Sensor Plate Level Sensor WSHR M05 Standard Flat ZP WSHR M5 Spring Washer SHMS M5 X Down Limit Switch Seat Ladder WSHR M08 ZP STANDARD FLAT WSHR M8 Spring Washer HHCS M X ZP F Cover Nut M SHCS M05-.8 x Beacon Beacon Seat Plate BHCS M X 12, 10.9, ZP, F 30 REF 1 Left Drive Wheel Assembly {See Page A-9} HHCS M X ZP F WSHR M10 Spring Washer WSHR M10 ZP STANDARD FLAT Lock Plate 35 REF 1 Pot Hole Protection Assembly {See Page A-5} 36 REF 1 Battery Tray Module {See Page A-13} Screw, Steering Wheels, 1930SE Switch, Limit SHCS M04x Switch Cover Seal Bearing 43 REF 1 Steer Linkage {See Page A-7} Cover, Switch WSHR M04 ZP STANDARD FLAT WSHR M4 Spring Washer BHCS M X ZP Chassis Weldment Cover as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page A-3

48 Pot Hole Protection Assembly Page A-4 "Micro 19" Parts Section

49 Pothole Protection Assembly ITEM PART NO. QTY DESCRIPTION Bearing, (PHP Plunger) Pressure Head Pressure Lever Adjusting Washer PHP Guard Plate HHCS M X ZP F PHP Guard Plate CROSS BOARD ANNUL (AXLE, PHP) Bearing, Axle WSHR M10 ZP STANDARD FLAT NNYL M10X ZP NYLON INSE LIMIT, ANNUL (POTHOLE BAR) GAS POLE ANNUL (PHP PIVOT) PHP Linkage Arm BEARING (PHP PIVOT BNG) WSHR M14 Flat NNYL M14X ZP NYLON INSE Gas Spring NNYL M14X ZP NYLON INSE WHEEL ANNUL (PHP ROLLER AXLE) HHMS M5 X WHEEL (PHP ROLLER) Mid Linkage Weldment NNYL M10X ZP NYLON INSE Mid Linkage Weldment PRESS AXES SEAT (PHP HOUSING) as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page A-5

50 Steer Linkage Page A-6 "Micro 19" Parts Section

51 Steer Linkage ITEM PART NO. QTY DESCRIPTION NNYL M10X ZP NYLON INSE WSHR M10 ZP STANDARD FLAT Bearing, Axle Tie Rod Bearing (Thrust Washer) Steering Cylinder Pin Pin 4x Bearing, Steer Cylinder Washer, Thrust Left Yoke Wheel Shim NUT M16X1.5 (CASTLE NUT) Out Cover BHCS M X BK Shaft End Baffle CSCS M5 X Bearing KEY 8X7X Wheel Shaft Connecting Plate, Wheel Hub HHCS M X ZP F Shaft End Cover Plate FHSC M X ZP Right Yoke as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page A-7

52 Left Drive Wheel Assembly Page A-8 "Micro 19" Parts Section

53 Left Drive Wheel Assembly ITEM PART NO. QTY DESCRIPTION Support, Motor Screw HX-SHCS 3/ N WSHR M10 Spring Washer WSHR M10 ZP STANDARD FLAT KEY 8X7X WSHR M16 ZP STANDARD FLAT (DIN 125) BHCS M X BK Out Cover NUT M16X1.5 (CASTLE NUT) Wheel Drive Motor (Ground Control Right Side) Motor Reducer (Gearbox) Brake as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Novembe r 2017 Page A-9

54 Right Drive Wheel Assembly Page A-10 "Micro 19" Parts Section

55 Right Drive Wheel Assembly ITEM PART NO. QTY DESCRIPTION Support, Motor Screw HX-SHCS 3/ N WSHR M10 Spring Washer WSHR M10 ZP STANDARD FLAT KEY 8X7X WSHR M16 ZP STANDARD FLAT (DIN 125) BHCS M X BK Out Cover NUT M16X1.5 (CASTLE NUT) Wheel Drive Motor (Ground Control Left Side) Motor Reducer (Gearbox) Brake as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page A-11

56 Battery Tray Module Page A-12 "Micro 19" Pa rts Section

57 Battery Tray Module ITEM PART NO. QTY DESCRIPTION Hydraulic Power Unit Valve Body Motor Pump Lift Valve Solenoid Steer Valve Solenoid Tank Flow Comp Valve Joint Nut Hose Assembly Straight Fitting (Adapter) SHCS M X ZP F WSHR M10 Spring Washer WSHR M10 ZP STANDARD FLAT Horn Alarm 10 REF 2 Battery Group 31 AGM 115AH Hose Track FHSC M06-1.0X12,10 ZP SHCS M06-1.0X16, 10 ZP WSHR M6 Spring Washer WSHR M06 ZP STANDARD FLAT Plate, Hose Track DC Contactor SDFH M X 12MM PHILLIPS WSHR M5 Spring Washer WSHR M05 Standard Flat ZP HHMS M5 X Mounting Plate, MC Fuse HHMS M5 X Motor Controller HHCS M X ZP F Lock HHCS M X ZP F NNYL M06X ZP NYLOCK 30 REF 1 Ground Control Panel Assembly {See Page A-15} SHMS M5 X BHCS M X BK Input Socket Battery Box Weldment Power Switch Charger BHCS M X20 08 ZP F Glide Track WSHR M14 ZP NORDLOCK FHSC M X F Fix Panel Fuse Seat as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page A-13

58 Ground Control Panel Assembly & Standard Pre Kit Page A-14 "Micro 19" Parts Section

59 Ground Control Panel Assembly & Standard Pre KIt ITEM PART NO. QTY DESCRIPTION Motor Hour Meter Emergency Stop Indicator Brake Reset Switch Up-Down Switch Panel Key Switch AR Key Replacement, Spare BHCS M X BK ECU Modular WSHR M04 ZP STANDARD FLAT NNYL M04X ZP NYLON INSE Relay SPDT 24V Silicone, Smoke Seal (3.5 feet) Plastic Edge Trim W/ Metal Core Yellow 22 Inches Battery Hold Down Channel NNYL M06x ZP NYLOCK HHCS M X ZP P M6 X 25 LG PHILLIPS ROUND HEAD NYLON 6/6 PLASTIC (WING NUT) Water Deflector Enclosure Service Manual NNYL # Z THMS #10-32X00.50 ZP as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page A-15

60 SECTION B SCISSOR CONTENTS PAGE Scissor Assembly B SE Parts Section Page B-1

61 Scissor Assembly Page B-2 "Micro 19" Parts Section

62 Scissor Assembly ITEM PART NO. QTY DESCRIPTION Circlips For Shaft D Circle, WASHER Axle Axle, Scissor Stack, Upper Bottom Slider Hose Carrier Axle, Scissor Stack, Lower CSCS M X 25 PHILLIPS WSHR M6 Spring Washer WSHR M06 ZP STANDARD FLAT Cylinder Pin Fixing Board Plate Cylinder Axle 3 13 REF 1 Upper Lift Cylinder Assembly {See Page D-5} Hose Carrier Safety Holder Safety Arm Inner Arm Inner Arm NNYL M06X ZP NYLOCK Bolt M Bearing CSB-50F Top Slider Axle Bottom Slider Outer Arm CSCS M X 25 PHILLIPS Pot Hole Pressboard HHCS M X ZP F Pin Retainer Base Axle Block 31 REF 1 Lift Cylinder Assembly {See Page D-3} Cylinder Axle BHCS M05X12mm Collar Inner Arm Outer Arm HHCS M X ZP F Cylinder Axle Inner Arm Bearing, Lift Cylinder Inner Arm Axle Outer Arm 5 as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page B-3

63 NOTES: Page B-4 "Micro 19" Parts Section

64 SECTION C PLATFORM CONTENTS PAGE Main Platform Assembly C-3 Platform Extension Assembly C-5 Platform Extension Lock C-7 Platform Controls C-9 "Micro 19" Parts Section Page C-1

65 Main Platform Assembly Page C SE Parts Section

66 Main Platform Assembly ITEM PART NO. QTY DESCRIPTION Platform Guardrail Hinge A Platform Guardrail Connector BHCS M X BK Clip NHEX M , ZP WSHR M08 ZP STANDARD FLAT HHCS M X ZP P Waterproof Joint CIRCLIP Bearing Roller Roller Installation FHSC M x Platform Deck Weldment Shield Sleeve Box Cover Outlet SHMS M5 X HHCS M X ZP P Washer Hinge B HHCS M X ZP WSHR M06 ZP STANDARD FLAT HHCS M X45 08 ZP P Spring Door Knob (Latch) Door, Entry Gate as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page C-3

67 Platform Extension Assembly Page C-4 "Micro 19" Parts Section

68 Platform Extension Assembly ITEM PART NO. QTY DESCRIPTION Platform Guardrail Platform Guardrail 3 REF 1 Platform Controls {See Page C-9} PHMS M6 X Control Box Mount Bracket CARB M X25 08 ZP CARRIAGE Fixed Plate Star Handle BHCS M X 16, G08, ZP Rubber Gasket NHEX M , ZP WSHR M08 ZP STANDARD FLAT HHCS M X ZP P Platform Guardrail HHCS M X ZP P Platform Extension WSHR M08 ZP STANDARD FLAT HHCS M X ZP F Platform Extension Lock Assembly Slide Pad HHMS M5 X CSCS M06x Roller Mount Roller Bearing Circlip as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page C-5

69 Platform Extension Lock Page C-6 "Micro 19" Parts Section

70 Platform Extension Lock ITEM PART NO. QTY DESCRIPTION NNYL M10X ZP NYLON INSE WSHR M10 ZP STANDARD FLAT Footpedal Lock Pin Housing Spring Lock Pin Bracket HHCS M X ZP P as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page C-7

71 Platform Controls Page C-8 "Micro 19" Parts Section

72 Platform Controls ITEM PART NO. QTY DESCRIPTION Decal, Platform Controls Joystick Dustproof Cover Switch Boot Coil Cord Alarm Enclosure Button PC Board Emergency Stop Switch Platform Control Box as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page C-9

73 NOTES: Page C-10 "Micro 19" Parts Section

74 SECTION D HYDRAULICS CONTENTS PAGE Lift Cylinder Assembly D-3 Upper Lift Cylinder Assembly D-5 Hydraulic Hoses & Fittings D-7 "Micro 19" Parts Section Page D-1

75 Lift Cylinder Assembly Page D-2 "Micro 19" Parts Section

76 Lift Cylinder Assembly ITEM PART NO. QTY DESCRIPTION Lift Cylinder Piecing Devices Washer, M14 Sealing Pipeline Bolt Joint Nut Hose Assembly Straight Fitting (Adapter) Tee Fitting Elbow Lowering Knob Lowering Anchor Line Set Screw WSHR M06 ZP STANDARD FLAT NNYL M06X ZP NYLOCK SHMS M5 X Bracket, EMR Lowering Lever, EMR Down Guide Sleeve Lowering Valve Throttle Valve Plag 4MN-14WD Seal Kit as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page D-3

77 Upper Lift Cylinder Assembly Page D-4 "Micro 19" Parts Section

78 Upper Lift Cylinder Assembly ITEM PART NO. QTY DESCRIPTION Upper Lift Cylinder Washer, M14 Sealing Piecing Devices Pipeline Bolt Nut Hose Assembly Straight Fitting (Adapter) Lowering Valve Throttle Valve Plag 4MN-14WD Relief Valve Seal Kit as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page D-5

79 Steer Cylinder Lift Cylinder 10 7 Upper Lift Cylinder A B C Hose Assembly Hydraulic power unit Adapter Union Hydraulic Hoses and Fittings Page D-6 "Micro 19" Parts Section

80 Hydraulic Hoses and Fittings ITEM PART NO. QTY DESCRIPTION Hose Assembly Hose Assembly Hose Assembly Hose Assembly Straight Fitting (Adapter) Straight Fitting (Adapter) Straight Fitting (Adapter) Elbow Tee Fitting Plag 4MN-14WD as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page D-7

81 SECTION E ELECTRICAL SYSTEM CONTENTS PAGE Electrical Harness E-3 "Micro 19" Parts Section Page E-1

82 26 Platform Control Box Charger Pressure Sensor (Not Used) Angle Sensor (Not Used) 12 Battery Battery 29 Tilt Power 23 sensor switch 9 30 Lift Up 22 Limit switch Fuse 200A 31 8 Lift Down Limit switch 21 DC Drive Motor Contactor Pothole 6 Travel switch 7 M Drive Controller Pothole Drive Motor Travel switch M M Motor Horn Buzzer 16 Hour meter Hydraulic Relay 35 Power Unit 15 3 Ground Control Beacon Panel ECU Modular 13 Electrical Harness Page E-2 "Micro 19" Parts Section

83 Electrical Harness ITEM PART NO. QTY DESCRIPTION Harness, ECU Modular Harness, Electrical Component Harness, Platform Control Box Harness, Drive Motor Battery Harness Pump Motor Negative Battery Negative Harness 1330 Pump Motor Positive Harness, DC Contactor 1330 Drive Controller Harness, DC Contactor Harness, Fuse Harness, Battery Positive Harness, Battery Battery Negative Harness ECU Modular {See Page A-15} Ground Control Panel {See Page A-15} Relay {See Page A-15} Hour Meter {See Page A-15} Drive Motor {See Page A-9} Drive Motor {See Page A-11} Motor Controller 19 {See Page A-13} Motor {See Page A-13} DC Contactor {See Page A-13} Fuse {See Page A-13} Power Switch {See Page A-13} 24 REF 2 Battery Group 31 AGM 115 AH {See Page A-13} Charger {See Page A-13} 26 REF 1 Platform Controls {See Page C-9} Not used Not Used Level Sensor {See Page A-3} Lift Up Limit Switch {See Page A-3} Lift Down limit Switch {See Page A-3} Limit Switch, Pothole {See Page A-3} Horn {See Page A-13} Buzzer, Alarm {See Page A-13} Hydraulic Power Unit {See Page A-13} Beacon {See Page A-3} as req: as required INCL: Included with assembly NS: Not a Stock item REF: Reference only "Micro 19" Parts Section Page E-3

84 NOTES: Page E-4 "Micro 19" Parts Section

85 SECTION F DECALS CONTENTS PAGE Decals F-3 "Micro 19" Parts Section Page F-1

86 Micro 19 Decal Locations Warning and Instructional Decals "Battery Charger and Power To Platform" Std "Battery Charger" only if Inverter option fitted Page F-2 "Micro 19" Parts Section

87 Micro 19 Warning and Instructional Decals Warning and Instructional Decals All warning and instructional decals must be present, legible and secure. ITEM PART NO. QTY DESCRIPTION Danger - Safety Rules Danger - Tip - Over Hazard Decal, Manual Inside Instructions - Platform Controller Normal Position Instructions - Refer The Operator To The Instructions For Use Label - Lanyard Anchorage Label - Capacity 500 lbs MEC Oval Small MEC Square MEC Oval Large Decal, MEC OVAL ON BLACK Decal, Control Handle, Side Instructions - Safety Arm Decal, Tip Over Hazard Decal, Battery Charger and Power to Platform Instructions - Tie Down Point Instructions - Lift Point Instructions - Emergency Lower Warning - Tip-Over Hazard Notice - Main Power Switch Option Danger - Explosion / Burn Hazard Warning - Inspected and Operation Properly Decal - Manufacturer's Plate Decal, Floor Loading Decal, Crush Hazard Decal, Micro Decal, Tie Down Decal, Ground Console Panel Decal, Direct Electric Drive Decal, Electrical Moisture Warning Decal, Power to Platform "Micro 19" Parts Section Page F-3

88 Micro 19 Warning and Instructional Decals Decals (continued) Micro MEC Aerial Work Platform Sales Corp S. Madera Ave Kerman, CA XXX LB/XXX KG (X PERSONS + TOOLS) XX VOLTS THIS MACHINE HAS BEEN CONSTRUCTED IN ACCORDANCE WITH SECTION 4 OF ANSI AND WITH SECTION 4 OF CSA B Page F "Micro 19" Parts Section