Document Outline

• 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
• Drive/Steer System
  • 1.3 Performance Data
• Travel Speed
• Gradeability
• Turning Radius (Outside)
• Lift Speed
• Platform Capacity - Fixed Platform
• Platform Capacity - Mechanical Platform Extension with Deck Extended
• Platform Capacity - Mechanical Platform Extension with Deck Retracted
• Machine Weight
• Machine Height (Platform Lowered)
• Machine Length
• Machine Width
  • 1.4 Lubrication
• Lubrication Specifications
  • 1.5 Pressure Settings
• 2-W/S
• 4-W/S
  • 1.6 Serial Number Locations
  • 1.7 Limit Switches
  • 1.8 Cylinder Specifications
  • 1.9 Major Component Weights
  • 1.10 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 System
• 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
  • 2.7 Sliding Wear Pads
  • 2.8 Pump and Coupling Lubrication
  • 2.9 Cylinder Checking Procedures
• Cylinder w/o Counterbalance Valves - Steer Cylinder, Axle Lockout Cylinder (If Equipped)
• Cylinders w/Single Counterbalance Valves - Lift Cylinder
  • 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
• Voltmeter Adjustment
  • 2.13 Limit Switch Adjustment Procedure
  • 2.14 Drive Pump Start-up Procedure
  • 2.15 Throttle Checks and Adjustments - Ford
• Throttle Checks
• Throttle Adjustments - In Sequence
  • 2.16 Throttle Checks and Adjustments - Deutz
  • 2.17 Automatic Choke Adjustment - Ford Engine
  • 2.18 Hydraulic Component Start-Up Procedures and Recommendations
  • 2.19 Pressure Setting Procedures - (2 W/S)
• Racine Two Stack Valve
• Lift Down Speed Adjustment
• Leveling Jacks Valve (If Equipped)
  • 2.20 Pressure Setting Procedures - (4 W/S)
• Racine Three Stack Valve (If Equipped)
• Lift Down Speed Adjustment
• Leveling Jacks Valve (If Equipped)
  • 2.21 Oscillating Axle Lockout Cylinder Bleeding Procedure
  • 2.22 Lockout Cylinder Check
  • 2.23 Piston Drive Motor
• Disassembly
• Inspection
• Assembly
  • 2.24 Drive Torque Hub - 2WD/4WD Rear
• Disassembly
• Roll Test
• Leak Test
• Assembly
  • 2.25 Drive Torque Hub/Brake - 4WD Front
• Disassembly
• Roll Test
• Leak Test
• Assembly
  • 2.26 Drive Brake - 2WD/2WS Rear
• Disassembly
• Assembly
  • 2.27 Spark Arrestor Muffler
  • 2.28 Dual Fuel/LPG System
• Changing From Gasoline to LP Gas
• Changing From LP Gas to Gasoline
• Using Liquid Petroleum (LP) Gas
  • 2.29 Freewheeling Feature
• To Disengage Torque Hubs (Freewheel)
• To Engage Torque Hubs
  • 2.30 Preventive Maintenance and Inspection Schedule
• Section 3. Troubleshooting
  • 3.1 General
  • 3.2 Troubleshooting Information
  • 3.3 Hydraulic Circuit Checks