Raymond SpinGo Personnel Lifter 0.08119 0.08120 Service Manual

Service Manual SpinGo Personnel Lifter

Models

0.08119 0.08120

1244228A

Serial Numbers

PUR20161003 & Up PUR20161003 & Up

Issued: 28 Nov 2016

This publication, 1244228A, applies to the SpinGo Personnel Lifter, and to all subsequent releases of this product until otherwise indicated in new editions or bulletins. Changes occur periodically to the information in this publication.

If you need assistance with your personnel lifter, or to order additional copies of this manual, contact your local authorized Lift-Rite Sales and Service Center.

To locate your local authorized Lift-Rite Sales and Service Center, go to www.liftrite.com. ©2016

Table of Contents

SpinGo Personnel Lifter Service Manual

Table of Contents Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Transport Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . . 5-9 Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . 5-10 Symptom Tables: Brake Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Platform Assembly (Operator Compartment) . . . . . . . . . . . . . . . . . . 6-11 Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Gate Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Wiring and Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 12 V Lift/Lower Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Lift/Lower Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Adjustable Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Zero Tilt Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

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Table of Contents

SpinGo Personnel Lifter Service Manual

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Torque Chart - Thread Forming Screws . . . . . . . . . . . . . . . . . . . . . . . A-6 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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SpinGo Personnel Lifter Service Manual Document Revision History

Document Revision History Revision

Date

1244228A

28 Nov 2016

Description of Changes Initial Release

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SpinGo Personnel Lifter Service Manual Document Revision History

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SpinGo Personnel Lifter Service Manual

Section 1. How to Use This Manual

Section 1. How to Use This Manual

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Section 1. How to Use This Manual

SpinGo Personnel Lifter Service Manual

Manual Design

Manual Design This manual is designed to give personnel, with an expected level of expertise, the technical information necessary to maintain, troubleshoot, and repair a Lift-Rite product.

The two-line running page header at the top of each page contains the name of the manual, the title of the current section, and the topic of the current page.

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SpinGo Personnel Lifter Service Manual

Section 1. How to Use This Manual Abbreviations and Symbols

Abbreviations and Symbols The following abbreviations, acronyms and symbols are used in this manual.

Term/Symbol amp ANSI/SAIA

Definition

AWG

Ampere or amplifier American National Standards Institute/Scaffold and Access Industry Association American Wire Gauge

BSOC

Battery State-of-Charge

CCW cm cSt CW

counterclockwise centimeter centistokes clockwise

DC DMM DVM

Direct Current Digital Multi Meter Digital Voltmeter

EPO

Emergency Push Button

ft.

foot or feet

gal.

gallon or gallons

Ht

height

in.

inch or inches

kg kg/m 3

kilogram(s) kilogram/cubic meter

lb.

LED

pound or pounds Light Emitting Diode

mm

millimeter

Nm

Newton Meter

psi

pounds per square inch

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Term/Symbol

Definition

SAE

Society of Automotive Engineers

V

Volt or Volts

@ ® ™ © + – ± ° °F °C < > %

at registered trademark copyright plus or positive minus or negative plus or minus degrees degrees Fahrenheit degrees Celsius less than greater than percent

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Section 1. How to Use This Manual

SpinGo Personnel Lifter Service Manual

Abbreviations and Symbols

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SpinGo Personnel Lifter Service Manual

Section 2. Safety

Section 2. Safety

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Section 2. Safety

SpinGo Personnel Lifter Service Manual

Definitions

Definitions Throughout this manual, you will see two kinds of safety reminders:

Warning means a potentially hazardous situation exists, which, if not avoided, could result in death or serious injury.

Caution means a potentially hazardous situation exists, which, if not avoided, may result in minor or moderate injury or in damage to the lift truck or nearby objects. It may also be used to alert against unsafe practices.

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SpinGo Personnel Lifter Service Manual

Section 2. Safety General Safety

General Safety

Do not operate this personnel lifter if it needs repair or if it is in any way unsafe.

Do not operate or work on this personnel lifter unless you are trained, qualified, and authorized to do so, and have read the Owner’s Manual, Operating Instructions Manual, and Replacement Parts Manual; sections 6, 7, and 8 of ANSI/SAIA A92.3; Manual of Responsibilities, and decals on the personnel lifter.

Operate this personnel lifter only from the operator’s position.

Know the personnel lifter’s controls and what they do.

Operator

Before working on this personnel lifter, always turn the key switch OFF and disconnect the personnel lifter’s battery connector (unless this manual tells you otherwise).

OFF Platform

Service

Do not wear watches, rings, or jewelry when working on this personnel lifter.

Service

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Section 2. Safety

SpinGo Personnel Lifter Service Manual

General Safety Follow the scheduled lubrication, maintenance, and inspection steps.

Clean up any hydraulic fluid, oil, or grease that has leaked or spilled on the floor.

Follow exactly the safety and repair instructions in this manual. Do not take “shortcuts.”

Always use and park this personnel lifter indoors.

Do not use an open flame near the personnel lifter.

Do not wash this personnel lifter with a hose.

Do not use gasoline or other flammable liquids for cleaning parts.

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Do not add to or modify this personnel lifter until you contact your local Lift-Rite Sales and Service Center to receive written manufacturer approval.

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SpinGo Personnel Lifter Service Manual

Section 2. Safety General Safety

Take the following precautions before any adjustments and repairs are started on a personnel lifter.

•

All repairs shall be performed with the operator compartment completely lowered and the personnel lifter unloaded whenever possible.

•

Wheels shall be blocked to prevent inadvertent motion.

•

The hydraulic oil pressure should be relieved from all hydraulic circuits before loosening or removing hydraulic components.

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Section 2. Safety

SpinGo Personnel Lifter Service Manual

Battery Safety

Battery Safety

As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not correctly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Make sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury.

Battery electrolyte is a solution of sulfuric acid and water. Battery electrolyte causes burns. If any electrolyte comes in contact with your clothing or skin, flush the area immediately with cold water. If the solution gets on your face or in your eyes, flush the area with cold water and get medical help immediately.

Wear personal protective equipment to protect eyes, face, and skin when checking, handling, or filling batteries. This equipment includes goggles or face shield, rubber gloves (with or without arm shields), and a rubber apron.

Make sure a shower and eyewash station are nearby in case of an accident.

A battery gives off explosive gases. Never smoke, use an open flame, or use anything that gives off sparks near a battery.

Keep the charging area well-ventilated to avoid hydrogen gas concentration.

Turn the key switch OFF before disconnecting the battery from the personnel lifter at the battery connector. Do not break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

OFF Platform

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Service

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SpinGo Personnel Lifter Service Manual

Section 2. Safety Battery Safety

Do not lay tools or metal objects on top of the battery. A short circuit or explosion could result.

personnel lifter’s capacity tag for more information.

Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks.

Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks.

Do not allow cleaning solution, dirt, or any foreign matter to enter the cells.

Make sure you install the correct size battery. A smaller or lighter weight battery could seriously affect personnel lifter stability. See the

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Section 2. Safety

SpinGo Personnel Lifter Service Manual

Jacking

Jacking Jacking Personnel Lifter When the personnel lifter is jacked up for any reason, take the necessary precautions listed here to make sure that the personnel lifter will not tip over.

•

Lower the operator compartment completely. Remove any load.

•

Block the wheels to prevent movement of the personnel lifter.

•

Turn the key switch OFF and disconnect the battery connector.

•

Place the jack under the designated jacking points. See Figure 2-1.

•

Always use solid blocks to support the personnel lifter. Never rely on jacks or chains to hold the personnel lifter

2

Figure 2-1.

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Jacking Drive Tire Off Floor

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SpinGo Personnel Lifter Service Manual

Section 2. Safety Operator Platform

Operator Platform

should be visually inspected to make sure there are no cracks, crookedness, bowing, or other compromising feature

When it is necessary to perform a procedure with the operator platform elevated, support the operator platform with a 4 x 4 in. square section wood block that is between 30 and 40 in.

(0.76 and 1.02 m) tall. The integrity of the wood block should be visually inspected to make sure there are no cracks, crookedness, bowing, or other compromising pieces.

2

Figure 2-2.

Blocking Operator Platform

• Using the Service Controls, lift the operator platform to a height that will enable cover removal and wood block installation.

• Remove the front and rear covers.

• Position the 4 x 4 (0.1 x 0.1 m) square section wood block between the lower frame and the operator platform and adjacent to the mast assembly.

• Lower the operator platform onto the wood block. Make sure that the block is secured and prevents any movement of the operator platform.

• Take caution against dislodging the wood block while performing inspection and maintenance on the personnel lifter.

Blocking Procedure for Personnel Lifter Maintenance

Crushing hazard. Do not inspect or initiate repair on the rear part of the unit unless the operator platform is supported by a 4 x 4 in. (0.1 x 0.1 m) square section wood block that is between 30 and 40 in. (0.76 and 1.02 m) tall. The integrity of the wood block

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Section 2. Safety

SpinGo Personnel Lifter Service Manual

Emergency Lowering Valve

Emergency Lowering Valve In the event that it is necessary to lower the operator platform from the ground, do the following:

Make sure to keep any part of your body away from the operator platform.

1. Pull the lever. The operator platform will begin descent very slowly.

2. Release the lever to stop the descent of the operator platform.

Emergency Lowering Lever 21750_037.TIF

Figure 2-3.

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Emergency Lowering Valve Lever

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SpinGo Personnel Lifter Service Manual

Section 2. Safety Transport Procedures

Transport Procedures

Transport Vehicle Tie Down Strapping

General Information

With the personnel lifter turned off on the transport vehicle in position for tie down (brakes set), follow the directions indicated for tying down during transport.

The SpinGo may be transported within the workplace with the following method: •

manual pushing

•

with a fork lift truck If excessive force is exerted when tying down the personnel lifter (load on the wheels) components of the rear wheels or of the front wheel assemblies may be damaged.

The SpinGo may be transported between sites with the following method: •

in a semi-tractor trailer with the personnel lifter tied down

Before transport on floors, trucks, and other surfaces, verify that the surface can support the weight of the fork lift truck and load.

Before transport, make sure that the operator compartment has been completely lowered and all surfaces are empty (for example, no load is present).

Utilizing suitable strapping, secure the personnel lifter to the pallet by routing one strap over the platform covers and through the pallet. Route a second strap over the load tray and through the pallet (make sure the load tray is completely lowered).

Tran

2

Transport with a Fork Lift Truck Position the forks of the truck in the fork pockets. This allows the personnel lifter to be transported to the work area or to lift it to an upper level by way of a standard fork lift.

A qualified fork lift operator and a fork lift truck capable of sustaining the gross weight of the personnel lifter must be used.

Figure 2-5.

Fork Pockets

2

Figure 2-4.

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Section 2. Safety

SpinGo Personnel Lifter Service Manual

Transport Vehicle Tie Down Strapping

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SpinGo Personnel Lifter Service Manual

Section 3. Systems Overview

Section 3. Systems Overview

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Section 3. Systems Overview

SpinGo Personnel Lifter Service Manual

Introduction

Introduction This manual provides information for maintenance and repair of the SpinGo Personnel Lifter by Lift-Rite.

This manual contains the most current and accurate procedures, drawings, and photographs available at the time of publication. Subsequent releases of this product may differ slightly from that shown here. Accordingly, some changes in parts, layout, or procedures may not be reflected in this manual.

For the latest information on your Lift-Rite SpinGo Personnel lifter, contact your local authorized Lift-Rite Sales and Service Center.

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SpinGo Personnel Lifter Service Manual

Section 3. Systems Overview Lift Truck Specifications

Lift Truck Specifications Capacity Tag

Figure 3-1.

3412-645.wmf

Location of the Serial Number In order to identify it, the personnel lifter has a tag on which the serial number has been engraved. The tag is located on board the personnel lifter, on the right of the column.

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Section 3. Systems Overview

SpinGo Personnel Lifter Service Manual

Battery Specifications

Battery Specifications Length x Width x Height in. (mm)

Minimum Weight lb. (kg)

Voltage

Capacity AmpHours

10.9 x 6.6 x 9.3

46 lb. (21 kg)

12

85 @ 20 Hour Rate

(277 x 168 x 236)

Fluid Capacities Table 3-1.

Hydraulic Reservoir Fill to line.

Approximately 0.79 gal.

(3 liters)

Hydraulic Oil Specification Table 3-2.

Viscosity Grade 1260911

ISO 22

Oil Type

Paraffin

Density at 20°C (68°F)

858 Kg/m3

Viscosity at 40°C (104°F)

22 cSt

Viscosity at 100°C (212°F)

5.2 cSt

Viscosity Index

180

Pour Point

-31°C (-24°F)

Flash Point

205°C (401°F)

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SpinGo Personnel Lifter Service Manual

Section 3. Systems Overview Installation

Installation Installation procedures must be performed by a Lift-Rite Certified Sales and Service Technician to ensure warranty coverage.

During installation, a visual and functional inspection must be performed. Refer to SpinGo Personnel Lifter Installation Guide 1247985.

Storage If the personnel lifter is to be stored for any length of time, cover the personnel lifter with canvas or plastic.

Warranty Life-Rite must be contacted by an authorized Lift-Rite Sales and Service Center for the correct warranty procedures.

Hydraulic System The hydraulic system will absorb moisture when left standing for a long time. Make sure the reservoir is full before storing. Before returning the personnel lifter to service, drain the reservoir. Fill the reservoir with new hydraulic fluid. Operate the hydraulic system slowly to allow internal components to be lubricated.

Electronics Make sure all electronics stay dry.

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Section 3. Systems Overview

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SpinGo Personnel Lifter Service Manual

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SpinGo Personnel Lifter Service Manual

Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance

SpinGo Personnel Lifter Service Manual

Maintenance Guidelines

Maintenance Guidelines A successful Scheduled Maintenance program: •

promotes maximum personnel lifter performance

•

prolongs personnel lifter life

•

reduces costly down time

•

avoids unnecessary repairs

Scheduled Maintenance includes: •

lubrication

•

cleaning

•

inspection

•

service

Perform all of the scheduled checks and maintenance during the suggested intervals.

When operating under severe or extreme conditions, perform these services more often as indicated in the table below.

Table 4-1.

Maintenance Frequency

Type of Service Light to Moderate Severe

Extreme

Working Environment

Service Frequency

An eight hour shift of basic use

90 days

Extended operating hours or constant use. A duty cycle greater than 20 lift/lower cycles per hour

60 days

• Dusty or sandy conditions such as in cement plants, lumber or flour mills, coal dust, or stone-crushing areas

30 days

• High temperature areas, such as in steel mills, foundries, enclosed applications • Corrosive chemical atmosphere, such as: • fish, meat, or poultry processing plants, tanneries, or any other similar applications •

chlorine or salt-sea air environments

• Adverse high humidity, wet, damp, or moist conditions

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SpinGo Personnel Lifter Service Manual

Section 4. Scheduled Maintenance Frequent Inspection

Frequent Inspection Inspection shall be at an interval of three months, or 150 hours (whichever occurs first), or if the personnel lifter has not been used for over three months, or if the personnel lifter has

been purchased used. Any repairs necessary must be performed by a qualified mechanic. If, during any inspection, the personnel lifter is not found to be in proper operating condition, it must be removed from service and repaired.

Table 4-2.

Perform the following maintenance tasks for Frequent Inspection Component

What to do

Battery

Check the condition of the battery and verify the battery is secured and charged.

Hydraulic Reservoir

Check the hydraulic fluid.

Hydraulic System

Check for fluid leaks.

Service Controls

Verify all controls function correctly and operate freely.

Tray Lever

Verify tray lever functions correctly and operates freely.

Travel, Tilt, & Lift Alarms

Verify all alarms function correctly.

Emergency Lowering Lever

Verify control functions correctly.

Platform Controls

Verify all controls function correctly and operate freely.

Brakes

Verify brake functions correctly.

Gates and Railings

Check operator compartment gates and railings.

Emergency and Safety Devices

Verify the level indicator light works properly.

Verify that powered functions are disabled if function enable button (service controls) or deadman pedal (platform controls) is not pressed.

Verify that alarm sounds during platform descent.

Lift/Lower Mechanism

Verify that the platform raises and lowers freely without binding. Lubricate if necessary.

Structural Components

Visually inspect all structural components and fasteners for damage or wear.

Decals, Warnings, and Control Markings

Make sure all decals, warnings, and control markings are present, legible, and undamaged.

Any issues identified during the frequent inspection, and any malfunctions, shall be corrected and repaired. Further inspection shall be performed to make sure that all problems identified have been corrected prior to returning the unit to service.

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Section 4. Scheduled Maintenance

SpinGo Personnel Lifter Service Manual

Annual Inspection

Annual Inspection

any inspection, the personnel lifter is not found to be in proper operating condition, it must be removed from service and repaired.

Annual inspection shall be performed no later than 13 months from the previous inspection by a qualified mechanic, or when a unit is purchased used. Any repairs necessary must be performed by a qualified mechanic. If, during

Complete a daily checklist and perform Frequent Inspection protocol.

Table 4-3.

Perform the following maintenance tasks Annually Component

What to do

Battery

Check the weight of the battery in the personnel lifter against the minimum allowable weight on the capacity tag for the personnel lifter. Report any personnel lifters that are running with batteries under the minimum allowable weight. Inspect all battery connectors and leads for damage and cuts in protective coatings. Make sure the battery is secured in place.

Brakes

Push the unit at a walking speed (2 mph or 3.2 km/h) and release the brake release button, the unit should stop within 3 ft. (1.2 m). If the wheels lock up and slide, loosen the adjusting nuts on the spring. If the unit does not stop within 3 ft. (1.2 m) adjust the nuts. If the truck slides to one side, adjust both sides so the truck stops in a straight line.

Hydraulic System

Check for fluid leaks.

Contactors

Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips may prevent the contactor from opening or closing causing unscheduled down time.

Deadman Pedal

Check for smooth operation with no binding. Check for correct activation and deactivation of the deadman pedal.

Electrical Cables

Inspect all power cables for nicks or cuts. Give special attention to cables that are not stationary. Replace any cable that is damaged or shows signs of excessive wear. Failure to do so causes electronic failures.

Emergency Lowering Lever

Verify control functions correctly and there are no leaks from the emergency valve.

Frame Checks

General visual inspection of structural members for cracks, including but not limited to railings, platform, and base.

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Refer to

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SpinGo Personnel Lifter Service Manual

Section 4. Scheduled Maintenance Annual Inspection

Table 4-3.

Perform the following maintenance tasks Annually Component

What to do

Hardware

Check bolt torque of major components (motors, pumps, brake, and operator compartment to base). If the fastener was previously marked with a paint pen when torqued, look at the markings to verify the fastener has not moved. If the fastener has moved or is in question, remove the fastener, clean the threads, and apply the appropriate thread-locking compound, if any. Install that fastener and torque to the correct value, turning it in the tightening direction. Use a paint pen and mark the fastener for future inspection.

If the fastener was not previously marked with a paint pen, determine the correct torque values. Set the torque wrench to 85% of the required torque value and check the torque of the fastener, turning it in the tightening direction. If the fastener does not move, use a paint pen and mark the fastener for future inspections. If the fastener moves, remove the fastener, clean the threads, and apply the appropriate thread-locking compound, if any. Install the fastener and torque to the correct value. Use a paint pen and mark the fastener for future inspections.

Replace any broken or missing hardware.

Hydraulic Lines

Inspect all hydraulic lines for leaks, nicks and cuts. Replace the damaged hoses as soon as possible. Inspect all fitting for leaks. Repair any leaks immediately.

Hydraulic Power Unit

Check for correct operation. Inspect for leaks.

Hydraulic Reservoir

Check fluid level.

Level Indicator Light

Check for correct operation.

Switches

Check all switches for correct operation and adjust as needed.

Tilt Sensor

To check the accuracy of the tilt sensor, place the truck on a level surface. Place a measuring tape against the side of the tilt sensor and place a level along the top of the sensor intersecting with measuring tape. Press down on one side of the sensor. The sensor should activate if tilted more than 3/32 in. (2.4 mm). Test the sensor in four directions. If the sensor does not activate past 3/32 in. (2.4 mm) recalibrate the sensor.

Warning Decals

Replace any illegible or damaged decals.

Warning Lights

Check for correct operation.

Wheels

Examine for chunking and excessive or uneven wear.

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Refer to

4-5

Section 4. Scheduled Maintenance

SpinGo Personnel Lifter Service Manual

Annual Inspection

4-6

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SpinGo Personnel Lifter Service Manual

Section 5. Troubleshooting

Section 5. Troubleshooting

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5-1

Section 5. Troubleshooting

SpinGo Personnel Lifter Service Manual

Electrical Troubleshooting

Electrical Troubleshooting General

Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can damage an ohmmeter.

•

Many problems can be caused by a dirty battery. Make sure the battery is clean.

•

Save time and trouble by looking for simple causes first.

•

Use a Digital Multimeter (DMM) such as a Fluke meter for all measurements. Analog meters can give inaccurate readings and load down sensitive electronic circuits enough to cause failure. Make sure meter cables are connected to the correct meter jacks and that the correct function and scale are selected.

•

•

5-2

When measuring voltage, connect the positive meter lead to the connector or probe point marked (+) in the test.

Connect the negative meter lead to the connector or probe point marked (–).

Whenever measuring resistance, turn the key switch OFF and disconnect the battery connector. Battery current can damage an ohmmeter. Isolate the component from the circuit.

Shorts to Frame “Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures.

Shorts to frame may be metallic connections, such as a wire conductor contacting metal through worn insulation. More often, shorts to frame are resistive “leakage” paths caused by contamination and/or moisture.

These leakage paths can result in unwanted electrical noise on the metallic personnel lifter structure and can cause incorrect operation.

Shorts to frame are caused by: •

Accumulation of dirt

•

Battery electrolyte leakage

•

Motor brush dust

•

Motor brush leads touching the housing

•

Breakdown in insulation

•

Bare wires

•

Pinched wiring harness

•

Incorrect mounting of circuit cards

Shorts to frame can occur at numerous locations on a personnel lifter, including: •

Batteries

•

Motors

•

Cables, wiring, and harnesses

•

Solenoids

•

Contactors

•

Terminal strips

•

Switches

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 5. Troubleshooting Shorts to Frame Test

Shorts to Frame Test 1. Turn the key switch OFF and disconnect the battery connector.

2. To test the battery for shorts to case, connect a 12V test light to the battery case from battery B+, and then to the battery case from battery B–. If the light illuminates at all, even momentarily, there is a serious problem with the battery, either external contamination or internal damage. Do not continue until this condition is corrected. The meter may be damaged if you proceed before correcting this condition.

Install another battery in the personnel lifter and repeat this procedure from step 1.

If the test light does not illuminate, continue to the next step.

3. Use a DMM set on the ampere function to measure the current leakage from the battery case to battery B+ and from the battery case to battery B– (not personnel lifter B+ and B–). Begin measuring at the highest ampere scale and work toward the lowest. A reading of more than 0.001A (1mA) indicates a serious short. Do not continue until this condition is corrected.

The meter may be damaged if you proceed before correcting this condition.

Install another battery in the personnel lifter and repeat this procedure from step 1.

If the current is <0.0002A (0.2mA), go to step 4. If the current is >0.0002A (0.2mA) and <0.001A (1mA), remove the battery from the personnel lifter, then continue with step 4. Make sure the battery case does not touch the personnel lifter frame during the remaining tests.

4. With the battery disconnected (or removed and disconnected) from the personnel lifter, use a DMM to measure the resistance from personnel lifter frame to lift truck B+, to personnel lifter B– (not battery B+ and B–), and to all fuses and

Publication: 1244228A, Issued: 28 Nov 2016

motors. A reading of <1000 ohms indicates a serious short. Do not continue until this condition is corrected. The meter may be damaged if you proceed before correcting this condition. To correct the condition, perform steps a. thru e. a. To identify the cause of the short to frame, disconnect circuit components until the low resistance condition disappears. Do not reconnect components one at a time, but leave them disconnected until the low resistance reading disappears. Prevent disconnected terminals or connectors from touching the personnel lifter frame or other conductive surfaces. b. The most likely areas to check are: • Motors • Heatsinks • Power cables • Power circuit components • Control circuit components c. Repair or replace the component causing the low resistance condition.

Repeat step 4. d. Reconnect all other components previously disconnected, one at a time, measuring resistance between steps. If a reading is <1000 ohms when reconnecting a component, that component or its wiring is faulty; repair or replace as appropriate. e. When, after all components are reconnected, you get readings >1000 ohms, continue with the next step.

5. Reconnect the battery connector and turn the key switch ON. If the battery was previously removed, make sure the battery case does not touch the personnel lifter frame.

NOTE: The functions being checked must be energized. Example: to check for shorts to frame in the lift circuit, lift must be requested.

6. Use a DVM set to the current function to measure current leakage to the personnel

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Section 5. Troubleshooting

SpinGo Personnel Lifter Service Manual

Shorts to Frame Test lifter frame from personnel lifter B+, personnel lifter B– (not battery B+ and B–), and all fuses and DC motor terminals.

Begin measuring at the highest ampere scale and work toward the lowest. If the current is <0.001A (1mA), go to step 7. If the current is more than 0.001A (1mA), continue with the following steps. a. To identify the cause of the short to frame, disconnect circuit components until the leakage current reads <0.001A (1mA). Do not reconnect components one at a time, but leave them disconnected until the leakage current reads <0.001A (1mA). Prevent disconnected terminals or connectors from touching the personnel lifter frame or other conductive surfaces. b. The most likely areas to check are: • Motors • Heatsinks • Power cables • Power circuit components • Control circuit components c. Repair or replace the component(s) causing the leakage current.

Repeat step 6. d. Reconnect all other components previously disconnected, measuring current between steps. If a reading is more than 0.001A (1mA) when reconnecting a component, that component or its wiring is bad. Repair or replace as appropriate.

7. When, after all components are reconnected, you get a reading <0.001A (1mA) there is no short to frame condition with the personnel lifter or the battery. If you previously removed the battery from the personnel lifter, re-install the battery.

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SpinGo Personnel Lifter Service Manual

Section 5. Troubleshooting Fuses

Fuses

the fuses are held tightly in the clips. Fuse clips should exert resistance on both legs of the fuse when inserted. Loose clips should be tightened with pliers.

Test /Inspection Examine the fuse for signs of overheating, discoloration, cracking, or other physical damage. Replace as necessary.

Inspect the fuse clip for damage or signs of corrosion, disconnect the Fuse/Relay Card connectors, and clean the clips with a brush or dry rag as necessary. Damage may require replacement of the Fuse/Relay Card. Make sure Table 5-1.

To test a fuse, remove it from the lift truck. The resistance should be <1 ohm.

The following table lists the fuses for a personnel lifter with all available options. Not all personnel lifters will have all of the fuses listed.

Fuse Chart

Fuse

Function

Location

Amps

FU1

Main Power Fuse

Near the battery connectors

30

FU2

Motor Fuse

Near the battery connectors

100

Power Fuse for Controls

Attached to the Contactor Box

10

FU3

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5-5

Section 5. Troubleshooting

SpinGo Personnel Lifter Service Manual

Wiring

Wiring Visually inspect all wiring and electrical components for: •

Loose connections or connectors

•

Loose or broken terminals

•

Damaged terminals, blocks, or strips

•

Exposed wire at terminations, excessive strip gap

•

Abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage

•

Broken wire strands and shorted conditions (especially those that are close to metal edges or surfaces)

During troubleshooting and repairs, it may be necessary to unplug a connector, move a harness, cut a cable tie, or remove the wire from a bracket. Note the location of the wire and all protective or securing attachments before moving the harness.

After repair, return or replace all protective and/or securing hardware to its original condition. Protective materials are necessary to provide reliable performance of the interconnect system.

Examine and maintain any added materials used to dress and protect the wire. This includes spiral wrap, brackets, cable ties, fasteners, and flexible conduit.

Do not attach cable ties so tight that they pinch cable harnesses. Avoid attaching cables to hydraulic hoses that expand with pressure, pinching the attached electrical cables.

Use a DMM to check for wiring continuity.

5-6

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 5. Troubleshooting Relay Troubleshooting

Relay Troubleshooting Relays should be checked when troubleshooting any of the symptoms listed in the following table.

Relay

Circuit

Possible Symptoms

Main Relay

Key is in platform or service control and there is no function with the personnel lifter.

Brake Relay

Key is in platform control and the brakes will not disengage when the Brake Release Button is actuated.

All other functions work properly.

KM

KB

Tilt Relay

KT

KGA

Available

KP

Pump Relay

Key is in platform or service control, there is no lift function, and the level indicator light does not actuate when the tilt sensor senses a tilt condition. All other functions work properly.

Key is in platform or service control and there is no lift function.

Test 1. Turn the key switch OFF and remove the relay (refer to Removal and Replacement).

2. Measure the resistance across pins 1-A and 1-B. Resistance should measure approximately 1100 ohms. Replace as necessary.

3. Measure the resistance between circuits 2 3, and 4. Welded tips will have a resistance <0.5 ohm. Otherwise, there should be an open circuit. Replace as necessary.

Removal and Replacement Pull the relay out straight to avoid bending or damaging the pins. Install the relay by aligning the pins with the corresponding sockets. Firmly press the relay straight into the socket until it is fully seated.

NOTE: The contactor box cover is equipped with foam (located under the cover) that should contact the top of the relay to help seat it in the relay base.

Inspection Visually inspect the relay and socket for discoloration, melting, or other signs of heating.

Replace as necessary. If the socket is melted or damaged, replace the relay.

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Section 5. Troubleshooting

SpinGo Personnel Lifter Service Manual

Relay Troubleshooting

5-8

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SpinGo Personnel Lifter Service Manual Symptom Tables: Electrical Symptoms

Symptom Tables: Electrical Symptoms NOTE: Use these symptom tables in conjunction with the electrical and hydraulic schematics.

No Charging (charge status light not present) Possible Cause

Action

Battery/Charger

Verify outlet power Test charger Test charger cord Test battery Test associated wiring

No Power (charge status light present) Possible Cause

Action

Key switch

Check key switch Test key switch Test associated wiring

Emergency Push Button (EPO)

Check EPO on the platform and on the base Check EPO is not actuated Test EPO Test associated wiring

Fuse 1 (FU1)

Test fuse Test associated wiring

Fuse 2 (FU2)

Test fuse Test associated wiring

Fuse 3 (FU3)

Test fuse Test associated wiring

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5-9

SpinGo Personnel Lifter Service Manual Symptom Tables: Hydraulic Functions

Symptom Tables: Hydraulic Functions NOTE: If it is determined that a component failed as a result of hydraulic fluid contamination, replace the failed component and flush, fill, and bleed the hydraulic system.

NOTE: Use these symptom tables in conjunction with the electrical and hydraulic schematics.

Intermittent Lift/Lower Possible Cause

Action

Bad wiring

Check wiring harnesses between valves and VM. Check wiring between the valves and the contactor box.

Hydraulic contamination

Replace damaged component and flush, fill, and bleed the hydraulic system.

Lift Function No Lift, Lower, Brake Disengagement, Alarms, and Battery Gauge Possible Cause

Action

Bad battery

Replace the battery with a fully-charged battery.

See Battery Procedures.

General relay (K1)

Test relay Test associated wiring

Pump relay (KP)

Test relay Test associated wiring

No Lift from Platform or Service Controls Possible Cause

5-10

Action

Charger plugged in

Unplug charger

Tilt sensor actuated

Place personnel lifter on level ground

Bad battery

Replace the battery with a fully-charged battery.

See Battery Procedures.

Emergency Push Button (EPO)

Check EPO on the platform and on the base Check EPO is not actuated Test EPO Test associated wiring

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual Lift Function Possible Cause

Action

Lower valve

Make sure the lower valve is closed Check for contamination. If contamination is present, clean the valve, flush, fill, and bleed the hydraulic system.

Low oil

Verify oil level

Fuse 3 (FU3)

Test fuse Test associated wiring

Tilt relay (KT)

Test relay Test associated wiring

Pump relay (KP)

Test relay Test associated wiring

Lift contactor/solenoid

Test lift contactor/solenoid

Hydraulic power unit

Test hydraulic power unit

No Lift from Platform Controls (Service Controls Work) Possible Cause

Action

Key switch

Check key switch Test key switch Test associated wiring

Lift switch

Test switch Test associated wiring

Deadman pedal

Test deadman pedal Test associated wiring

No Lift from Service Controls (Platform Controls Work) Possible Cause

Action

Key switch

Check key switch Test key switch Test associated wiring

Lift switch

Test switch Test associated wiring

Enable switch

Test switch Test associated wiring

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5-11

SpinGo Personnel Lifter Service Manual Lift Function No Lowering from Platform and Service Controls Possible Cause

Action

Key switch

Check key switch Test key switch Test associated wiring

Emergency Push Button (EPO)

Check EPO on the platform and on the base Check EPO is not actuated Test EPO Test associated wiring

Lower valve

Verify lower valve

No Lowering from Platform (Service Controls Work No

Possible Cause

Action

Key switch

Check key switch Test key switch Test associated wiring

Lower switch

Test switch Test associated wiring

Deadman pedal

Test deadman pedal Test associated wiring

No Lowering from Service (Platform Controls Work)

Possible Cause

Action

Key switch

Check key switch Test key switch Test associated wiring

Lower switch

Test switch Test associated wiring

Enable switch

Test enable switch Test associated wiring

No Lowering from Emergency Lowering

5-12

Possible Cause

Action

Cable

Check cable

Lower valve

Verify lower valve

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual Symptom Tables: Brake Functions

Symptom Tables: Brake Functions Brakes not disengaging Possible Cause

Action

Brake release switch

Test switch Test associated wiring

Fully lowered limit switch

Test switch Test associated wiring

Brake relay (KB)

Test relay Test associated wiring

Brake assembly

Test brake assembly Test associated wiring

Brakes not engaging Possible Cause

Action

Brake release switch

Test switch Test associated wiring

Brake assembly

Test brake assembly Test associated wiring

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5-13

SpinGo Personnel Lifter Service Manual Symptom Tables: Brake Functions

5-14

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SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures

Section 6. Component Procedures

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6-1

Section 6. Component Procedures

SpinGo Personnel Lifter Service Manual

Table of Contents

Table of Contents Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Platform Assembly (Operator Compartment) . . . . . . . . . . . . . . . . . . 6-11 Emergency Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Gate Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 12 V Lift/Lower Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Lift/Lower Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Adjustable Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Zero Tilt Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-2

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SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures

Component Locator Photos

Section 6. Component Procedures

6

Microswitch

Tilt Sensor

Brake Solenoid

Brake Solenoid Pump Assembly

Emergency Lower Lever

Figure 6-1.

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6-3

Section 6. Component Procedures

6-4

SpinGo Personnel Lifter Service Manual

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SpinGo Personnel Lifter Service Manual Battery Procedures

Battery Procedures Before working on the battery, review “Battery Safety” on page 2-6. Batteries for this personnel lifter weigh a minimum of 46 lb. (21 kg).

and avoid contact with battery case or cable ends.

1. To remove a cable from the connector, push the retainer down while pulling the battery cable towards the rear and out of the connector.

2. Do not attempt to repair battery cables by crimping new terminals. Replace the cable.

Battery Connector/Cables Inspection 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF and remove the battery connector.

3. Check the battery connector for damaged cables.

4. Check to see if the battery cables are pulling out of the connector.

5. Check the cables at the battery terminals.

Connections should be tight, with no corrosion.

6. Look inside the connector. Check all internal contacts for damage, dirt, or corrosion. Do not use a metal object to clean the connector.

NOTE: Some degreasers and parts cleaners cause the connector shell to disintegrate. Avoid contacting battery connectors with solvents.

Removal, Replacement, and Installation The cables to either half of the connector have a lip on their forward end. This lip snaps over a spring-loaded retainer that is part of the connector.

NOTE: When replacing battery cable ends, remove only one end at a time from the connector, to avoid the cable ends touching and causing a short circuit.

Do not allow the metal cable end to touch the battery. Use insulated tools

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6-5

SpinGo Personnel Lifter Service Manual Battery Connector/Cables

Battery Exterior Cleaning 1. Wear personal protective equipment. See “Battery Safety” on page 2-6.

2. Turn the key switch OFF and disconnect the battery connector. Remove the battery from the personnel lifter.

3. Unscrew thumb screws at the back of the indicator.

4. Remove the connector.

5. Remove the indicator through the front of the frame.

3. Inspect the battery cables to make sure they are not frayed or loose. Inspect the battery connector to make sure there is no foreign material inside the connector.

Make sure the filler plugs are tight and the vent holes in the filler plugs are open.

4. Keep the top of the battery clean and dry.

Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create shorts to ground.

NOTE: Do not clean the top of the battery with the soda solution while it is installed in the personnel lifter. Water can seep into the electrical components and cause serious damage.

5. Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb. (0.45 kg) of baking soda added to 0.5 gal. (1.9 liters) of hot water.

6. Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized.

7. Rinse the battery with clean water.

8. Dry the battery completely before reinstalling it.

9. Reinstall the battery in the personnel lifter, using a suitable battery moving device.

Reconnect the battery connector.

Battery Gauge Removal, Replacement, and Installation 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF and remove the battery connector.

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SpinGo Personnel Lifter Service Manual Removal

Brake Solenoid

6. Remove the top four socket head cap screws and washers that secure the brake pad guide using a 6 mm Allen wrench.

6

Figure 6-4.

Figure 6-2.

6

7. Remove the six socket head cap screws securing the brake assembly using a 6 mm Allen wrench.

Removal 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the electrical connection to the brake solenoid with a Phillips head screwdriver.

Figure 6-5.

6

8. Remove the brake assembly and brake pad guide.

6

Figure 6-3.

5. Disconnect the electrical cable to the brake solenoid.

Figure 6-6.

Publication: 1244228A, Issued: 28 Nov 2016

6

6-7

SpinGo Personnel Lifter Service Manual Assembly 9. Hold the brake shaft with an 8 mm wrench and remove the brake pad assembly using a 30 mm wrench.

3. Slide the front mounting bracket and compression spring onto the extension shaft.

10. Remove the compression spring and front mounting bracket.

4. Screw the brake pad assembly onto the extension shaft using 9 mm and 30 mm wrenches.

11. Remove the extension shaft using locking pliers and an 8 mm wrench.

5. Loosely hand tighten the brake pad guide to the frame using four socket head cap screws.

6. Slide the brake assembly into position.

7. Tighten the four bolts securing the brake pad guide to the frame using four socket head cap screws.

8. Adjust the large nut on the front mounting bracket (this will loosen the spring to allow the front mounting bracket to be bolted to the frame).

9. Bolt the front mounting bracket to the frame using the four short socket head cap screws and a 6 mm Allen wrench.

Figure 6-7.

6

12. Remove the back three socket head cap screws and back mounting bracket using a 5 mm Allen wrench.

10. Place two socket head cap screws into the slots on the back mounting bracket, slide the solenoid as far away from the brake pad as possible and secure it to the frame using a 6 mm Allen wrench.

11. Adjust the tensioning nut so that there is a 10 mm gap between the nut and the front mounting bracket.

12. Attach the electrical connection using a Phillips head screwdriver.

13. Reconnect the battery connector and replace the base covers.

Brake Test

Figure 6-8.

6

Assembly 1. Attach the back mounting bracket to the solenoid using three socket head cap screws and a 5 mm Allen wrench.

Push the unit at a walking speed (2 mph or 3.2 km/h) and release the brake release button, the unit should stop within 3 ft. (1.2 m). If the wheels lock up and slide, loosen the adjusting nuts on the spring. If the unit does not stop within 3 ft. (1.2 m) adjust the nuts. If the truck slides to one side, adjust both sides so the truck stops in a straight line.

2. Attach the extension shaft to the solenoid using an 8 mm wrench and locking pliers.

6-8

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SpinGo Personnel Lifter Service Manual Caster Wheel

Casters

6. Jack the personnel lifter. See “Jacking” on page 2-8 for procedure.

Caster Wheel

Assembly 1. Jack the personnel lifter. See “Jacking” on page 2-8 for procedure.

2. Attach the caster to the frame using the four bolts and two 17 mm wrenches.

3. Secure bolts in this order: bolt head, washer, caster, frame, washer, split washer and nut.

4. Slowly lower and remove the jack from the truck.

5. Reconnect the battery connector.

6. Attach the base covers.

Figure 6-9.

6

Front Fixed Caster

Removal 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Follow “Jacking” on page 2-8 to safely lift the personnel lifter.

5. Remove the four bolts, eight washers, four split washers, and four nuts, securing the caster. Use two 17 mm wrenches.

Figure 6-11.

6

Removal 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the brake solenoid to access the front fixed caster.

5. Remove the holding pin.

Figure 6-10.

6

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• Use a 4.5 mm dowel punch, and remove the holding pin from the wheel shaft.

6-9

SpinGo Personnel Lifter Service Manual Assembly 6. Remove the wheel shaft.

• Use a hammer and punch if necessary.

• Remove the shaft.

• Remove the wheel.

Assembly 1. Install the wheel.

• Insert the wheel and align with hole.

• Insert the shaft.

• Use a hammer and punch, if necessary.

2. Insert the holding pin.

• Use a 4.5 mm dowel punch and insert the holding pin into the wheel shaft.

3. Slowly lower and remove jack from personnel lifter.

4. Reconnect the battery connector.

5. Replace the base covers.

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SpinGo Personnel Lifter Service Manual Removal

Platform Assembly (Operator Compartment)

2. Slowly lower the platform assembly over hydraulic column.

3. Secure platform assembly cable to the main cylinder with a 12 mm Allen wrench.

4. Secure the cable to base bracket using a 2.5 mm Allen wrench.

Platform Securing Bolt

5. Reconnect the cable to the connector located at the Fuse/Relay box.

6. Reconnect the battery connector.

7. Replace the base covers.

Figure 6-12.

6

Removal 1. Remove the covers from the base of the personnel lifter.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Disconnect the coiled platform assembly cable from the base of the personnel lifter.

5. Unscrew the cable securing bracket on the personnel lifter base with a 2.5 mm Allen wrench.

6. Remove the platform assembly securing bolt with a12 mm Allen wrench.

7. Secure the platform assembly to a suitable lifting device with strapping. The platform weights approximately 300 lbs. (136 kg).

8. Lift the platform assembly straight up and away from the center column.

Installation 1. Using secure strapping and a suitable lifting device, align the platform assembly over the hydraulic column.

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6-11

SpinGo Personnel Lifter Service Manual Removal

Emergency Lowering Valve

a. Use an 18 mm wrench to loosen the emergency lower lever cable connection to the lowering valve. b. Use two 10 mm wrenches to remove the emergency lower lever cable from the valve.

7. Remove the emergency lowering valve. a. Remove the lowering solenoid from the valve by loosening the connector with a Phillips heads screwdriver.

Figure 6-13.

6

Removal 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the cover support bracket. a. Use a 7 mm Allen wrench to remove bolts, washers, and lock nuts from the support bracket.

Figure 6-15.

6

b. Use a 7/8 in. (20 mm) deep socket (3 in. or more) and an extender to remove the lowering valve from the pump housing.

Installation 1. Install the emergency lowering valve. a. Insert the valve into the pump housing and tighten using a 7/8 in. (20 mm) deep socket (3 in. or more) with an extender. b. Place the lowering solenoid onto the valve.

2. Install the emergency lowering cable. a. Pull the emergency lowering cable through the opening in the base of the personnel lifter.

Figure 6-14.

6

5. Loosen the emergency lowering handle from the bracket using two 14 mm wrenches.

6. Remove the emergency lowering cable from the valve.

6-12

b. Use two 10 mm wrenches to tighten the emergency lower lever cable onto the valve. c. Use an 18 mm wrench to tighten the emergency lower lever cable connection to the lowering valve.

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual Installation 3. Tighten the emergency lowering handle onto the bracket using two 14 mm wrenches.

4. Replace the cover support bracket. a. Use a 7 mm Allen wrench to install bolts, washers, and lock nuts onto the support bracket.

5. Reconnect the battery connector.

6. Replace the base covers.

Publication: 1244228A, Issued: 28 Nov 2016

6-13

SpinGo Personnel Lifter Service Manual Removal

Gate Hinges

Figure 6-16.

6

Removal 1. Remove the inner two bolts using a13 mm wrench and a 6 mm Allen wrench.

2. Remove the two inner bolts, two lock nuts, four washers, gate, and spacing block.

3. Remove the outer two bolts using a13 mm wrench and a 6 mm Allen wrench.

4. Remove the two outer bolts, two lock nuts, four washers, and gate hinge.

Assembly 1. Bolt the gate hinge to the carriage frame using two socket head cap screws, two lock nuts, and four washers.

2. Place the washer on the opposite side from the gate hinge and outside of the carriage frame. Use a 13 mm wrench and a 6 mm Allen wrench.

3. Bolt the gate and spacing block onto the gate hinge. Place the spacing block towards the outside of the personnel lifter.

Use two socket head cap screws, two lock nuts, and four washers.

4. Place the washers on opposite sides of the gate hinge and outside of the carriage frame. Use a 13 mm wrench and 6 mm Allen wrench.

6-14

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual Wiring and Harness Repair

Wiring and Harness Repair

•

Do not cut away a terminal lug and reuse the wire strands that were crimped into the original lug.

•

When stripping wire, use new wire strands for new terminations. Make sure to use a new wire with extra length to allow for cutting and stripping of the ends to install new terminations.

Inspection

•

Whenever working on the personnel lifter, use care around wiring harnesses.

Use a new wire that is the same gauge (typically gauge 18 AWG), size, type, and color as the wire it is replacing.

•

Use a hand stripper capable of stripping by wire gauge number. Use care not to nick or cut any of the wire strands.

Discard and replace a wire with damaged strands. Insert the wire strands the correct length into termination before crimping.

General Connector Repair Procedures

•

Carefully connect and disconnect all connections.

•

Do not pry connectors apart with unspecified tools.

NOTE: It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to the harness.

Repair •

Turn the key switch OFF.

•

Disconnect the battery connector.

When pulling a wire out through a bundle, cut off the pin or socket so it does not snag. When replacing wires, in some cases you can tape or solder one end of a new wire to one end of the failed wire. Then you can pull the old wire out of the bundle and pull the new wire into the bundle, all at the same time. Make sure to disconnect the old wire from the new wire.

In other cases, it is easier to secure a new wire to the outside of the existing wire bundle with cable ties of an appropriate size. The failed wire can be left in the bundle, or can be pulled by one end to remove it from the bundle.

When replacing wires, follow these guidelines: •

Use the appropriate tools to remove and insert terminations at each connector.

•

Remove damaged terminations and discard. Never reuse a termination from a wire.

Publication: 1244228A, Issued: 28 Nov 2016

Soldering Procedures To prevent damage from excessive heat when soldering small components in assemblies, follow these guidelines: •

Make sure the soldering tip is clean. A dirty tip does not transfer heat well and encourages long dwell time and greater pressure. Apply light pressure on the terminal.

•

Flux: rosin base

•

Solder: 60/40 rosin core or equivalent

•

Solder Iron: 15-25 watt “pencil-type” maximum

•

Tip Size: 0.118 in. (3 mm) diameter x 1.182 in. (30 mm) long screwdriver tip.

Make sure the tip is clean.

•

After soldering, clean the terminals with a brush dampened with an alcohol based cleaner. Do not allow any cleaner to seep into the switches or potentiometers, or contact contamination may occur.

6-15

SpinGo Personnel Lifter Service Manual Removal

12 V Lift/Lower Solenoid Removal

6. Remove the solenoid. a. Remove the connector to the solenoid using a Phillips head screwdriver. b. Slide the solenoid off the valve.

1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF.

Installation 1. Install the solenoid. a. Slide the solenoid onto the valve.

3. Disconnect the battery connector.

4. Remove the cover support bracket. a. Use a 7 mm Allen wrench to remove bolts, washers, and lock nuts from the support bracket.

b. Connect and tighten the connector using a Phillips head screwdriver.

2. Replace the emergency lower lever cable from the valve. a. Use two 10 mm wrenches to install and tighten the emergency lower lever cable onto valve. b. Use an 18 mm wrench to tighten the emergency lower lever cable connection to the lowering valve.

3. Replace the cover support bracket. a. Use a 7 mm Allen wrench to install and tighten bolts, washers, and lock nuts onto the support bracket.

Figure 6-17.

6

5. Remove the emergency lowering cable from valve.

4. Reconnect the battery connector.

5. Replace the base covers.

a. Use an 18 mm wrench to loosen the emergency lower lever cable connection to the lowering valve.

Figure 6-18.

6

b. Use two 10 mm wrenches to remove the emergency lower lever cable from the valve.

6-16

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures

Hydraulic Components

Section 6. Component Procedures

Publication: 1244228A, Issued: 28 Nov 2016

6-17

Section 6. Component Procedures

SpinGo Personnel Lifter Service Manual

Removal of Column/Cylinder

Hydraulic Cylinder Removal of Column/Cylinder 1. Remove the covers from the base of the personnel lifter.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the operator compartment.

5. Remove the top column cover.

6. Remove the snap ring.

7. Secure the column in the center with a screw clamp and strap.

8. Place a suitable sized container under the personnel lifter. Remove the connection to the hydraulic reservoir to drain the hydraulic fluid from the cylinder.

9. Remove the four bolts securing the bottom of the column using a 19 mm socket with an extension.

6

Figure 6-19:

10. Remove the center snap ring from the bottom of the cylinder.

11. Remove the column from the base of SpinGo. 12. Remove the hydraulic fitting on the cylinder with a 22 mm wrench.

13. Replace the cylinder.

For installation repeat steps in reverse.

NOTE: Remember to bleed the cylinder before placing the operator compartment on the column.

6-18

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures Removal

Lift/Lower Button

6. Loosen the mechanical switch support using a Phillips head screwdriver.

Removal 1. Remove the covers from the base of the personnel lifter.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the control box cover using a Phillip head screwdriver.

6

Figure 6-22:

7. Release a mechanical switch using a Phillips head screwdriver.

6

Figure 6-20:

5. Release the wire terminal locking mechanism using small flat head screwdriver.

6

Figure 6-23:

Installation 1. Place the mechanical switch into the control box hole and snap together.

2. Tighten the mechanical switch to the control box using a Phillips head screwdriver.

6

Figure 6-21:

3. Attach the wire terminal to the mechanical switch. a. Place the pivot end into the appropriate hole. b. Press the terminal down until it snaps in place.

4. Reinstall the control box using a Phillips head screwdriver.

5. Reconnect the battery connector and replace the base covers.

Publication: 1244228A, Issued: 28 Nov 2016

6-19

Section 6. Component Procedures

SpinGo Personnel Lifter Service Manual

Removal

Adjustable Tray

• Route the strap between the hole in the center of the two bearings.

Removal 1. Turn the key switch OFF. 2. Remove the top cover.

• Remove the top cover using a 2 1/2 in.

Allen wrench.

6

Figure 6-26:

• Put tension on the strap so it supports the weight of the tray.

5. Remove the bolt from the suspa rim.

6

Figure 6-24:

• Use two 13 mm wrenches to remove the bolt and washers.

6. Lift the adjustable tray up and out of the channel.

3. Remove the tray stoppers.

• Using a 3 in. Allen wrench, remove pitch bolts.

6

Figure 6-25:

4. Secure the tray with strapping.

6

Figure 6-27:

6-20

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures Tray Lever Removal

Tray Lever Removal Cylinder/Cable 1. Use a 2 1/2 in. Allen wrench to remove the bolts from the tray lever.

2. Remove the cable from the cable lever using an 8 mm wrench.

6

Figure 6-28:

3. Remove the cylinder from the load tray using a 13 mm wrench.

4. Pry the cable off the end of the cylinder using vice grips.

Attach Cable/Cylinder 1. Thread the cable through the load tray.

2. Attach the cable to the cylinder using vice grips.

3. Attach the cylinder to the load tray using a 13 mm wrench.

4. Attach the cable to the tray lever using a 8 mm wrench.

5. Attach the tray lever to the load tray using a 2 1/2 in. Allen wrench.

Testing Test the tray to make sure you cannot push down and move the tray unless the tray lever is actuated. If the tray moves, adjust cable.

Publication: 1244228A, Issued: 28 Nov 2016

6-21

Section 6. Component Procedures

SpinGo Personnel Lifter Service Manual

Removal/Installation

Pump Assembly

• Use a 20 mm socket to remove the upper plug and the two copper fittings inside.

• Copper fittings should rest on either side of the connecting upper plug.

• Remove the upper connector (separating the pump from the cylinder) and cap the connector. Turn the connector away from the pipe and reconnect the upper connector.

• Disconnect the associated wiring.

• Battery to pump • Battery to pump directional solenoid 6

Figure 6-29:

Removal/Installation 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

• Use a 17 mm wrench to remove the bolt, lock nut, and washer securing the pump assembly to the base of the personnel lifter.

8. For reassembly, reverse steps 1 thru 7.

9. Fill the reservoir with oil to the recommended level.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the cover support bracket.

• Use a 7 mm Allen wrench to remove bolts, washers, and lock nuts from the support bracket.

• Drain oil from reservoir.

5. Remove the emergency lower lever.

• Use a 14 mm wrench to loosen the nut assembly that holds the emergency lower lever handle to the bracket.

• Use an 18 mm wrench to loosen the emergency lower lever cable connection to the lowering valve.

• Use two 10 mm wrenches to remove the emergency lower lever cable from the valve, leaving the valve in the pump.

6. Remove the lowering valve.

• Remove the lowering solenoid from the valve.

• Use a 7/8 in. (20 mm) deep socket (3 in. or more) and an extender to remove the lowering valve from the pump housing.

7. Remove the pipe connecting the pump motor to the main cylinder.

6-22

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures Removal

Microswitch

4. Reconnect the battery connector and replace the base covers.

6

Figure 6-30:

Removal 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Remove the microswitch from the support with two 17 mm wrenches.

5. Remove two bolts using a Phillips head screwdriver and a 7 mm wrench.

6. Remove the switch from the housing.

Remove wires using flat head screwdriver.

Assembly 1. Attach wires to the switch. Tighten with a flat head screwdriver.

• Top screw: Blue wire, TP1 • Middle screw: Brown wire, K2 • Bottom screw, Black wire, K4 2. Insert the switch into the plastic housing and connect with two bolts using a Phillips head screwdriver and a 7 mm wrench.

3. Install two 17 mm nuts and tighten the switch to the support using two 17 mm wrenches. Make sure the switch is activated when against the limit switch plate and deactivated when in center of limit switch plate.

Publication: 1244228A, Issued: 28 Nov 2016

6-23

Section 6. Component Procedures

SpinGo Personnel Lifter Service Manual

Power Cable Repair

Power Cables Check power cables for: •

evidence of overheating

•

burned spots in the cable

•

nicks in the insulation

•

damaged or overheated terminal lugs

•

damaged mounting hardware or brackets

a. For short barrels, use 1.75 in. (45 mm) of tubing. Apply 1 in. (25 mm) over the jacket extending 0.75 in. (19 mm) over the barrel. b. For long barrels, use 2.5 in. (64 mm) of tubing. Apply 1 in. (25 mm) over the jacket extending 1.5 in. (38 mm) over the barrel.

Replace damaged cables or mounting hardware as necessary.

Power cables are marked on the terminal lug with the location where they belong. If the marking is missing or is not readable, remark the cable with the correct information.

NOTE: Terminal lugs may be replaced in the field using the appropriate crimping tools. Failure to use correct cables, terminal hardware, and torque values can result in overheating and damage to components.

Power Cable Repair Traditional lug crimping techniques for power cables on DC motors may not meet the higher current requirements of AC motors. Use manual crimp tool to crimp power cables for all AC motors. This tool may also be used to repair power cables for DC motors.

1. Turn the key switch OFF. 2. Disconnect the battery connector.

3. Remove the bad cable(s).

4. Using the removed cable(s) for reference, cut an appropriate amount of replacement cable of the same gauge.

5. Set the adjustment screw on the manual crimp tool head to match the cable gauge.

6. Strip the cable jacket to fit the terminal to be crimped.

7. Insert the cable into the terminal.

8. Place the cable and terminal into the tool die and crimp.

9. Apply heat-shrink tubing to terminal after crimping.

6-24

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section 6. Component Procedures Removal

Tilt Sensor

6

Figure 6-31:

Removal 1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch OFF. 3. Disconnect the battery connector.

4. Unplug the tilt sensor from the base of the personnel lifter.

• Unplug connecting wire.

5. Remove the tilt sensor screws.

• Using two 10 mm wrenches or sockets, remove the tilt sensor screws then lift the tilt sensor from the personnel lifter.

Installation 1. Secure the tilt sensor screws. a. Using two 10 mm wrenches or sockets, install the tilt sensor to the base bracket.

2. Plug the tilt sensor in to the base of personnel lifter. a. Connect wires to the tilt sensor. b. Reconnect the battery connector.

3. Calibrate the Tilt Sensor following the procedure on page 6-25.

4. Remove blocking, reconnect the battery connector, and replace the base covers.

Publication: 1244228A, Issued: 28 Nov 2016

6-25

Section 6. Component Procedures

SpinGo Personnel Lifter Service Manual

Tilt Sensor Test

Zero Tilt Calibration Procedure

6. Remove the cable connected to the tilt device.

1. Block the operator compartment, refer to “Blocking Procedure for Personnel Lifter Maintenance” on page 2-9.

2. Turn the key switch ON. 3. Make sure the personnel lifter is on a flat level surface.

4. Use a cable connected to the tilt device from the screw inside the plastic cap to the -12 V (negative) of the battery.

6

Figure 6-34:

7. Turn the key switch OFF and then ON in order to refresh the system. The tilt zero angle calibration has been stored.

8. Conduct the Tilt Sensor Test. If results are successful, remove the blocking and replace the covers.

Tilt Sensor Test 6

Figure 6-32:

5. The green LED underneath the tilt device will start to blink for a few seconds and then will turn to a steady light.

To check the accuracy of the tilt sensor, place the truck on a level surface. Place a measuring tape against the side of the tilt sensor and place a level along the top of the sensor intersecting with measuring tape. Press down on one side of the sensor. The sensor should activate if tilted more than 0.087 in. (2.2 mm). Test the sensor in four directions. If the sensor does not activate past 0.087 in. (2.2 mm) recalibrate the sensor.

6

Figure 6-33:

6-26

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section A. Appendix

Section A. Appendix

Publication: 1244228A, Issued: DRAFT

A-1

Section A. Appendix

SpinGo Personnel Lifter Service Manual

Lubrication Specification Chart

Lubrication Specification Chart Approved Lubricants Where Used Hydraulic Reservoir

A-2

Type Hydraulic Fluid

Specification ISO 22

Part Number 1260911

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section A. Appendix Torque Chart - Hydraulic Fittings

Torque Chart - Hydraulic Fittings SAE Dash Size

Thread Size

-2

JIC (37° Flare Thread)

SAE Straight Thread Steel Plugs Hollow Hex Head Plug HP50N

Hex Head Plug P50N

ft. lb.

Nm

ft. lb.

Nm

ft. lb.

Nm

5/16-24

3 ±1

4 ±1

3 ±0.5

4 ±0.6

7.5 ±0.5

10 ±0.6

-3

3/8-24

6 ±1

8 ±1

5 ±0.5

7 ±0.6

14 ±1

19 ±1

-4

7/16-20

12 ±1

16 ±1

11 ±1

15 ±1

18 ±1

24 ±1

-5

1/2-20

15 ±1

20 ±1

15 ±1

20 ±1

22 ±1

30 ±1

-6

9/16-18

21 ±1

28 ±1

18 ±1

24 ±1

27 ±2

37 ±3

-8

3/4-16

45 ±2

61 ±3

46 ±2

62 ±3

48 ±2

65 ±3

-10

7/8-14

60 ±5

81 ±7

75 ±5

102 ±7

90 ±5

122 ±7

-12

1 1/16-12

85 ±5

115 ±7

85 ±5

115 ±7

110 ±5

149 ±7

-14

1 3/16-12

105 ±5

142 ±7

130 ±6

176 ±8

145 ±6

197 ±8

-16

1 5/16-12

120 ±5

163 ±7

135 ±6

183 ±8

160 ±6

217 ±8

-20

1 5/8-12

170 ±10

230 ±14

225 ±12

305 ±16

225 ±12

305 ±16

-24

1 7/8-12

200 ±15

271 ±20

250 ±12

339 ±16

250 ±12

339 ±16

-32

2 1/2-12

270 ±20

366 ±27

325 ±15

441 ±20

325 ±15

441 ±20

Publication: 1244228A, Issued: DRAFT

A-3

Section A. Appendix

SpinGo Personnel Lifter Service Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous) Grade Marking

Size 4-40 4-48 6-32 6-40 8-32 8-36 10-24 10-32 1/4-20 1/4-28

None

SAE Grade 2 Bolts Tightening Torque Dry** Oiled*

SAE Grade 5 Bolts Tightening Torque Dry** Oiled*

SAE Grade 7 Bolts Tightening Torque Dry** Oiled*

SAE Grade 8 Bolts Tightening Torque Dry** Oiled*

in. lb

Nm

in. lb

Nm

in. lb

Nm

in. lb

Nm

in. lb

Nm

in. lb

Nm

in. lb

Nm

in. lb

Nm

5 6 10 12 19 20 27 31 66 75 ft. lb

0.56 0.68 1.1 1.4 2.1 2.2 3.0 3.5 7.5 8.5 Nm 15.1 16.3 27 31 43 47 68 75 95 109 129 150 231 258 231 252 339 373 475 544 680 746 881 1017 1180 1329

4 5 8 9 14 15 21 24 49 56 ft. lb 8 9 15 17 24 25 35 40 50 60 70 85 130 140 125 140 190 205 270 300 375 420 490 560 650 730

0.45 0.56 0.9 1.0 1.6 1.7 2.4 2.7 5.5 6.3 Nm 10.9 12.2 20 23 33 34 47 54 68 81 95 115 177 190 169 190 258 278 366 407 509 569 664 759 881 990

8 9 16 18 29 31 42 48 100 120 ft. lb 17 19 30 35 50 55 75 85 110 120 150 170 260 300 430 470 650 700 800 880 1120 1240 1460 1680 1940 2200

0.9 1.0 1.8 2.0 3.3 3.5 4.8 5.4 11.3 13.6 Nm 23.0 26 41 47 68 75 102 115 150 163 203 231 353 407 583 637 881 949 1085 1193 1523 1681 1980 2278 2630 2983

6 7 12 13 22 23 32 36 76 87 ft. lb 13 14 23 25 35 40 55 65 80 90 110 130 200 220 320 350 480 520 600 660 840 920 1100 1260 1460 1640

0.68 0.8 1.4 1.5 2.5 2.6 3.6 4.1 8.6 9.8 Nm 18 19 31 34 47 54 75 88 109 122 150 177 272 298 434 475 651 705 813 895 1139 1247 1491 1708 1980 2224

11 12 20 22 36 38 52 60 125 143 ft. lb 21 24 40 45 60 70 95 105 135 150 190 210 330 370 530 580 800 860 1120 1260 1580 1760 2080 2380 2780 3100

1.5 1.4 2.2 2.5 4.1 4.3 5.9 6.8 14.1 16.2 Nm 29 33 54 61 81 95 129 143 183 203 258 285 448 502 719 786 1085 1166 1519 1708 2142 2386 2820 3227 3769 4203

8 9 15 17 27 29 39 45 94 107 ft. lb 16 18 30 30 45 50 70 80 100 110 140 160 240 280 400 440 600 660 840 940 1200 1320 1560 1780 2080 2340

0.9 1.0 1.7 1.9 3.0 3.3 4.4 5.1 10.6 12.1 Nm 22 24 41 41 61 68 95 109 136 150 190 217 326 381 544 598 813 895 1139 1274 1627 1790 2115 2413 2820 3173

12 13 23 25 41 44 60 68 143 164 ft. lb 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 1280 1440 1820 2000 2380 2720 3160 3560

1.4 1.5 2.6 2.8 4.6 5.0 6.8 7.7 16.2 18.5 Nm 34 34 61 68 95 109 150 163 203 231 298 326 515 569 813 895 1224 1360 1136 1952 2468 2720 3227 3688 4298 4857

9 10 17 19 31 33 45 51 107 123 ft. lb 18 20 35 35 55 60 80 90 110 130 170 180 280 320 460 500 680 740 960 1080 1360 1500 1780 2040 2360 2660

1.0 1.1 1.9 2.1 3.5 3.7 5.1 5.8 12.1 13.9 Nm 24 27 47 47 75 81 109 122 150 177 231 244 381 434 624 680 925 1003 1302 1464 1884 2034 2413 2766 3200 3606

5/16-18 11 5/16-24 12 3/8-16 20 3/8-24 23 7/16-14 32 7/16-20 35 1/2-13 50 1/2-20 55 9/16-12 70 9/16-18 80 5/8-11 95 5/8-18 110 3/4-10 170 3/4-16 190 7/8-9 170 7/8-14 185 1-8 250 1-12 275 1 1/8-7 350 1 1/8-12 400 1 1/4-7 500 1 1/4-12 550 1 3/8-6 650 1 3/8-12 750 1 1/2-6 870 1 1/2-12 980 NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.

NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

A-4

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section A. Appendix Torque Chart - Metric (Ferrous)

Torque Chart - Metric (Ferrous) Ferrous Metric Bolts, Coarse Thread (The grade rating is stamped on the head of the bolt.)

Grade 4.8 Dry**

Size

in. lb.

Nm

Grade 8.8

Oiled* in. lb.

Nm

Dry** in. lb.

Nm

Grade 10.9

Oiled* in. lb.

Nm

Dry** in. lb.

Nm

Grade 12.9

Oiled* in. lb.

Nm

Dry** in. lb.

Nm

Oiled* in. lb.

Nm

M1.6-0.35

0.8

0.09

0.6

0.07

1.6

0.18

1.2

0.14

2.2

0.25

1.7

0.19

2.6

0.30

2.0

0.22

M2-0.40

1.7

0.19

1.3

0.14

3.3

0.37

2.5

0.28

4.6

0.52

3.4

0.39

5.3

0.60

4.0

0.45

M2.5-0.45

3.5

0.40

2.6

0.30

6.7

0.76

5.1

0.57

9.3

1.1

7.0

0.79

11

1.2

8.2

0.93

M3-0.5

6.2

0.70

4.7

0.53

12

1.4

9

1.0

17

1.9

12

1.4

19

2.2

15

1.7

M3.5-0.6

9.8

1.1

7.3

0.83

19

2.1

14

1.6

26

3.0

20

2.2

31

3.5

23

2.6

M4-0.7

14

1.6

11

1.5

28

3.2

21

2.4

39

4.4

29

3.3

45

5.1

34

3.8

M5-0.8

29

3.3

22

2.5

57

6.4

42

4.8

78

8.9

59

6.6

91

10.4

69

7.8

ft. lb.

Nm

ft. lb.

Nm

ft. lb.

–

–

–

–

8

10.9

6

8.2

11

15.1

8

11.3

13

17.6

10

13.2

M8-1.25

–

–

–

–

19

26

15

20

27

37

20

27

31

43

24

32

M8-1

–

–

–

–

21

29

16

22

29

39

22

30

34

6

25

34

M10-1.5

–

–

–

–

38

52

29

39

53

72

40

54

62

85

47

63

M10-1.25

–

–

–

–

41

56

30

41

56

76

42

57

66

90

49

67

M12-1.75

–

–

–

–

65

88

50

68

90

122

70

95

110

150

80

109

M12-1.25

–

–

–

–

75

102

55

75

100

136

75

102

120

163

90

122

M14-2

–

–

–

–

105

143

80

109

150

204

110

150

175

238

130

177

M14-1.5

–

–

–

–

115

156

85

116

160

218

120

163

190

258

140

190

M16-2

–

–

–

–

165

224

125

170

230

313

170

231

270

367

200

272

M16-1.5

–

–

–

–

175

238

130

177

245

333

185

252

280

381

215

292

M20-2.5

–

–

–

–

325

442

240

326

450

612

340

462

520

707

400

544

M20-1.5

–

–

–

–

360

490

270

367

500

680

375

510

580

789

440

598

M24-3

–

–

–

–

560

762

420

571

780

1061

580

789

900

1224

680

925

M24-2

–

–

–

–

610

830

460

626

850

1156

640

870

1000

1360

740

1006

M30-3.5

–

–

–

–

1120

1523

840

1142

1550

2108

1160

1578

1800

2448

1350

1836

M30-2

–

–

–

–

1240

1686

920

1251

1700

2312

1280

1741

2000

2720

1500

2040

M36-4

–

–

–

–

1950

2652

1460

1986

2700

3671

2000

2720

3160

4298

2350

3196

M36-2

–

–

–

–

2200

2992

1640

2230

3000

4080

2250

3060

3500

4760

2650

3604

M6-1

Nm

ft. lb.

Nm

ft. lb.

Nm

ft. lb.

Nm

ft. lb.

Nm

ft. lb.

Nm

NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.

NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Publication: 1244228A, Issued: DRAFT

A-5

Section A. Appendix

SpinGo Personnel Lifter Service Manual

Torque Chart - Thread Forming Screws

Torque Chart - Thread Forming Screws Size

Standard Thread-Forming Screws Torque Nearest Plate Thickness (in.) in. lb.

Nm

2-56

3-48

4-40

5-40

6-32

8-32

10-24

10-32

12-24

1/4-20

5/16-18

3/8-16

7/16-14

1/2-13

A-6

0.0469 0.0625 0.0938 0.0625 0.0938 0.1250 0.0312 0.0625 0.0938 0.0625 0.0938 0.1250 0.0625 0.0938 0.1250 0.0938 0.1250 0.1875 0.0938 0.1250 0.1875 0.0938 0.1250 0.1875 0.1250 0.1875 0.2500 0.1250 0.1875 0.2500 0.1875 0.2500 0.3125 0.2500 0.3125 0.3750 0.3125 0.3750 0.5000 0.2500 0.3750 0.5000

4 4 5 6 7 7 6 9 11 12 18 20 14 20 22 30 45 45 35 45 55 35 50 70 65 75 85 85 125 125 160 225 250 350 400 450 500 600 700 500 850 1000

0.5 0.5 0.6 0.7 0.8 0.8 0.7 1.0 1.2 1.4 2.0 2.3 1.6 2.3 2.5 3.4 5.1 5.1 4.0 5.1 6.2 4.0 5.6 7.9 7.3 8.5 9.6 9.6 14.1 14.1 18.1 25.4 28.2 39.5 45.2 50.8 56.5 67.8 79.1 56.5 96.0 113.0

Size

Metric Thread-Forming Screws Nearest Plate Torque Thickness in. lb.

Nm in. (mm)

M3 x 0.5

M4 x 0.7

M5 x 0.8

M6 x 1.0

M8 x 1.25

M10 x 1.5

M12 x 1.75

0.039 (1.0) 0.079 (2.0) 0.118 (3.0) 0.079 (2.0) 0.118 (3.0) 0.157 (4.0) 0.098 (2.5) 0.138 (3.5) 0.197 (5.0) 0.118 (3.0) 0.177 (4.5) 0.236 (6.0) 0.157 (4.0) 0.236 (6.0) 0.315 (8.0) 0.197 (5.0) 0.315 (8.0) 0.394 (10.0) 0.236 (6.0) 0.354 (9.0) 0.472 (12.0)

9 9 14 16 29 38 25 53 62 44 89 89 177 248 266 266 398 487 531 575 885

1.0 1.0 1.6 1.8 3.3 4.3 2.8 6.0 7.0 5.0 10.0 10.0 20.0 28.0 30.0 30.0 45.0 55.0 60.0 65.0 100.0

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section A. Appendix Decimal Equivalent Chart

Decimal Equivalent Chart 4ths

8ths

16ths

32nds

64ths 1/64

1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16

Publication: 1244228A, Issued: DRAFT

To 3 Places

To 2 Places

MM Equivalent

.016 .031 .047 .062 .078 .094 .109 .125 .141 .156 .172 .188 .203 .219 .234 .250 .266 .281 .297 .312 .328 .344 .359 .375 .391 .406 .422 .438 .453 .469 .484 .500 .516 .531 .547 .562 .578 .594 .609 .625 .641 .665 .672 .688 .703 .719 .734 .750 .766 .781 .797 .812

.02 .03 .05 .06 .08 .09 .11 .12 .14 .16 .17 .19 .20 .22 .23 .25 .27 .28 .30 .31 .33 .34 .36 .38 .39 .41 .42 .44 .45 .47 .48 .50 .52 .53 .55 .56 .58 .59 .61 .62 .64 .66 .67 .69 .70 .72 .73 .75 .77 .78 .80 .81

.397 .794 1.191 1.587 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.593 6.350 6.747 7.144 7.540 7.937 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700 13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.065 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.637

A-7

Section A. Appendix

SpinGo Personnel Lifter Service Manual

Decimal Equivalent Chart 4ths

8ths

16ths

32nds

64ths 53/64

27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64

A-8

To 3 Places

To 2 Places

MM Equivalent

.828 .844 .859 .875 .891 .906 .922 .938 .953 .969 .984 1.000

.83 .84 .86 .88 .89 .91 .92 .94 .95 .97 .98 1.00

21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 25.400

Publication: 1244228A, Issued: 28 Nov 2016

SpinGo Personnel Lifter Service Manual

Section A. Appendix Standard/Metric Conversions

Standard/Metric Conversions To Convert...

Area Square Inches to Square Centimeters Square Centimeters to Square Inches Square Feet to Square Meters Square Meters to Square Feet Square Yards to Square Meters Square Meters to Square Yards Distance Inches to Millimeters Millimeters to Inches Inches to Centimeters Centimeters to Inches Feet to Meters Meters to Feet Yards to Meters Meters to Yards Miles to Kilometers Kilometers to Miles Mass Ounces to Grams Grams to Ounces Ounces to Kilograms Kilograms to Ounces Pounds to Kilograms Kilograms to Pounds Pressure Pounds per Square Inch (PSI) to kiloPascals kiloPascals to Pounds per Square Inch (PSI) Speed Miles per hour to Kilometers per hour Kilometers per hour to Miles per hour Temperature Fahrenheit to Celsius Celsius to Fahrenheit Torque Inch Pounds (in. lb.) to Newton Meters (Nm) Newton Meters (Nm) to Inch Pounds (in. lb.)

Foot Pounds (ft. lb.) to Newton Meters (Nm) Newton Meters (Nm) to Foot Pounds (ft. lb.)

Volume Pints to Liters Liters to Pints Quarts to Liters Liters to Quarts Gallons to Liters Liters to Gallons

Publication: 1244228A, Issued: DRAFT

Multiply, Add, or Subtract...

Square Inches x 6.452 Square Centimeters x 0.155 Square Feet x 0.093 Square Meters x 10.753 Square Yards x 0.836 Square Meters x 1.196 Inches x 25.4 Millimeters x 0.039 Inches x 2.54 Centimeters x 0.394 Feet x 0.305 Meters x 3.281 Yards x 0.914 Meters x 1.094 Miles x 1.609 Kilometers x 0.621 Ounces x 28.35 Ounces x 0.035 Ounces x 0.028 Kilograms x 35.27 Pounds x 0.454 Kilograms x 2.2 PSI x 6.894 kiloPascals x 0.145 Miles per hour x 1.609 Kilometers per hour x 0.6214 (°F minus 32) x 0.555 (°C x 1.8) plus 32 Inch Pounds x 0.113 Newton Meters x 8.85 Foot Pounds x 1.3568 Newton Meters x 0.737 Pints x 0.473 Liters x 2.113 Quarts x 0.946 Liters x 1.057 Gallons x 3.785 Liters x 0.26

A-9

SpinGo Personnel Lifter Service Manual

Section I. Index Index

Index

I

Section I. Index

B Battery Cables . . . . . . . . . . . . . . . . . . . . . . 6-5 Safety . . . . . . . . . . . . . . . . . . . . . . 2-6

C Capacity Tag . . . . . . . . . . . . . . . . . . . . 3-3 Caution, Definition . . . . . . . . . . . . . . . 2-2 Cleaning Lift Truck . . . . . . . . . . . . . . . . . . . 2-4 Connector Battery . . . . . . . . . . . . . . . . . . . . . 6-5 Connectors General . . . . . . . . . . . . . . . . . . . . 6-15 Repair . . . . . . . . . . . . . . . . . . . . . 6-15 Conversion Decimal to Fraction . . . . . . . . . . . . A-7 Fraction to Decimal . . . . . . . . . . . . A-7 Conversions, Standard/Metric . . . . . . . A-9

D Decimal to Fraction Conversion . . . . . . A-7

E Emergency Lower Valve . . . . . . . . . . . 2-10

F Flow Sensor Disassembly . . . . . . . . . . . . . . . . 6-24 Fraction to Decimal Conversion . . . . . . A-7 Fuse/Relay Card Troubleshooting . . . . . . . . . . . . . . . 5-7

H Harness Connectors . . . . . . . . . . . . . . . . . 6-15 Soldering Procedures . . . . . . . . . . 6-15

Publication: 1244228A, Issued: 28 Nov 2016

Inspection Battery Connector . . . . . . . . . . . . . . 6-5 Wiring/Harness . . . . . . . . . . . . . . 6-15

L Lubrication Specification Chart . . . . . . A-2

S Safety Battery . . . . . . . . . . . . . . . . . . . . . . 2-6 Definitions . . . . . . . . . . . . . . . . . . . 2-2 Emergency Lower Valve . . . . . . . . 2-10 General . . . . . . . . . . . . . . . . . . . . . . 2-3 Scheduled Maintenance Guidelines . . . . . . . . . . . . . . 4-2 to 4-5 Shorts to Frame Test . . . . . . . . . . . . . . 5-2 Soldering Procedures . . . . . . . . . . . . . 6-15 Specifications, Vehicle . . . . . . . . . . . . . 3-3 Standard/Metric Conversions . . . . . . . . A-9 Symptom Tables Brake Functions . . . . . . . . . . . . . . 5-13

T Tests Shorts to Frame . . . . . . . . . . . . . . . 5-2 Thread-Forming Screws, Torque Chart . A-6 Torque Chart Ferrous, Metric . . . . . . . . . . . . . . . . A-5 Hydraulic Fittings . . . . . . . . . . . . . . A-3 Thread-Forming Screws . . . . . . . . . A-6 Transport Procedures . . . . . . . . . . . . . 2-11 Troubleshooting Electrical . . . . . . . . . . . . . . . . . . . . 5-2 Electrical Symptoms . . . . . . . . . . . . 5-9 Fuse/Relay Card . . . . . . . . . . . . . . . 5-7 Hydraulic Functions . . . . . 5-10 to 5-12 Shorts to Frame Test . . . . . . . . . . . 5-2

V Valves Emergency Lower . . . . . . . . . . . . . 2-10 Vehicle Specifications . . . . . . . . . . . . . . . . . 3-3

I-1

Section I. Index

SpinGo Personnel Lifter Service Manual

Index

W Warning, Definition . . . . . . . . . . . . . . . .2-2 Wiring Connectors . . . . . . . . . . . . . . . . . . 6-15 Soldering Procedures . . . . . . . . . . . 6-15

I-2

Publication: 1244228A, Issued: 28 Nov 2016

WIRING DIAGRAM

HYDRAULIC SCHEMATIC

P 12V DC 7l/min

100bar max

2,1 cc/rev

M 800W 12V DC

3 liters