Document Outline

• Service & Maintenance Manual
  • Section A. Introduction - Maintenance Safety Precautions
    • A.A General
    • A.B Hydraulic System Safety
    • A.C Maintenance
  • Section 1. Specifications
    • 1.1 Capacities
      • Hydraulic Oil Tank
      • Hydraulic System (Including Tank)
      • Fuel Tank
      • Engine Crankcase
    • 1.2 Component Data
      • Gasoline Engine
      • Diesel Engine
      • Oil Capacity
      • Drive/Steer System
    • 1.3 Performance Data
      • Travel Speed
      • Gradeability
      • Turning Radius (Outside)
      • Lift Speed - 400RTS
      • Lift Speed - 500RTS
      • Platform Capacity - Fixed Platform
      • Platform Capacity - Traversing Platform Extension (If Equipped)
      • Platform Capacity - Wide Deck, Dual Extensions (500RTS Only)
      • Machine Weight
      • Machine Height (Platform Lowered)
      • Machine Length
      • Machine Width
    • 1.4 Lubrication
    • 1.5 Lubrication Specifications
    • 1.6 Pressure Settings
      • 400RTS
      • 500RTS
    • 1.7 Limit Switches
      • High Drive Speed Cut-Out
      • Lift Cut-Out (If Equipped)
      • Drive Cut-Out (If Equipped)
      • 400RTS Tilt Alarm - 5 ˚ (If Equipped)
      • 500RTS - Tilt Alarm - 2 ˚
    • 1.8 Serial Number Locations
    • 1.9 Cylinder Specifications
    • 1.10 Major Component Weights
    • 1.11 Critical Stability Weights
  • Section 2. Procedures
    • 2.1 General
    • 2.2 Servicing and Maintenance Guidelines
      • General
      • Safety and Workmanship
      • Cleanliness
      • Components Removal and Installation
      • Component Disassembly and Reassembly
      • Pressure-Fit Parts
      • Bearings
      • Gaskets
      • Bolt Usage and Torque Application
      • Hydraulic Lines and Electrical Wiring
      • Hydraulic System
      • Lubrication
      • Batteries
      • Lubrication and Servicing
    • 2.3 Lubrication Information
      • Hydraulic Oil
      • Changing Hydraulic Oil
      • Lubrication Specifications
    • 2.4 Cylinders - Theory of Operation
    • 2.5 Valves - Theory of Operation
      • Solenoid Control Valves(Bang Bang)
      • Relief Valves
      • Crossover Relief Valves
    • 2.6 Component Functional Description
      • Piston Hydraulic Pump
      • Gear Hydraulic Pump
      • Manual Descent Valve (If Equipped)
    • 2.7 Sliding Wear Pads
    • 2.8 Pump Coupling Lubrication
    • 2.9 Cylinder Checking Procedures
      • Cylinder w/o Counterbalance Valves - Steer Cylinder, Platform Ext. Cylinder, Axle Lockout Cylinder (If Equipped)
      • Cylinders w/Single Counterbalance Valves - Lift Cylinder, Leveling Jacks (If Equipped)
    • 2.10 Cylinder Removal and Installation
      • Lift Cylinder Removal
      • Lift Cylinder Installation
    • 2.11 Cylinder Repair
      • Disassembly
      • Cleaning and Inspection
      • Assembly
    • 2.12 Tilt Alarm Switch
      • Manual Adjustment
    • 2.13 Pressure Setting Procedures - (400RTS)
      • Rexroth/Hydraforce Valve
    • 2.14 Pressure Setting Procedures - (500RTS)
      • Rexroth/Hydraforce Valve
    • 2.15 Drive Pump Start-up Procedure
    • 2.16 Throttle Checks and Adjustments - Ford Engine
      • Throttle Checks
      • Throttle Adjustments - In Sequence
    • 2.17 Throttle Checks and Adjustments - Deutz F3L1011
    • 2.18 Oscillating Axle Lockout Cylinder Bleeding Procedure - (If Equipped)
    • 2.19 Lockout Cylinder Check
    • 2.20 Piston Drive Motor - 2WD & 4WD
      • Disassembly
      • Inspection
      • Assembly
    • 2.21 Drive Torque Hub - 2WD/4WD Rear
      • Disassembly
      • Roll Test
      • Leak Test
      • Assembly
    • 2.22 Drive Torque Hub/Brake - 4WD Front
      • Disassembly
      • Roll Test
      • Leak Test
      • Assembly
    • 2.23 Drive Brake - 2WD/4WD Rear
      • Disassembly
      • Assembly
    • 2.24 Spark Arrestor Muffler
    • 2.25 Dual Fuel/LPG System
      • Changing From Gasoline to LP Gas
      • Changing From LP Gas to Gasoline
      • Using Liquid Petroleum (LP) Gas
    • 2.26 Freewheeling Feature
      • To Disengage Torque Hubs (Freewheel)
      • To Engage Torque Hubs
    • 2.27 Limit Switch Adjustment Procedure
      • Drive Cut-Out Switch
      • Drive Speed Cutout
    • 2.28 Preventive Maintenance and Inspection Schedule
  • Section 3. Troubleshooting
    • 3.1 General
    • 3.2 Troubleshooting Information
    • 3.3 Hydraulic Circuit Checks