Document Outline

• Maintenance safety precautions
  • a. GENERAL
  • b. HYDRAULIC SYSTEM SAFETY
  • c. MAINTENANCE
• REVISION LOG
• TABLE OF CONTENTS
• Section 1. MACHINE specifications
  • 1.1 Capacities
    • System Voltage
    • Hydraulic System
    • Drive Motor GearBox (Gear Oil)
  • 1.2 Component Data
    • Hydraulic Pump/Pump Motor Assembly
    • Rear Wheel Drive Motors
    • Batteries/Battery Charger
  • 1.3 Performance Data
    • Platform Capacity
    • Maximum Horizontal Manual Side Force
    • Platform Size
    • Material Tray Size
    • Platform Height - (Fully Elevated)
    • Platform Maximum (Working) Height
    • Machine Height
    • Machine Overall
    • Platform Entry Height (Floor to Platform Floor)
    • Machine Ground Clearance
    • Machine Turning Radius (Outside)
  • 1.4 Torque Requirements
  • 1.5 Cylinder Specifications
  • 1.6 Serial Number Locations
  • 1.7 Lubrication
    • Hydraulic Oil
    • Lubrication Specifications
  • 1.8 Torque SPEcifications
• Section 2. GENERAL Service Information
  • 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 Preventive Maintenance and Inspection Schedule
    • Maintenance and Inspection Table Codes:
    • Footnotes:
  • 2.3 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 and Servicing
    • Batteries
    • Mast Chain Inspection Procedure
  • 2.4 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
• Section 3. BASE COMPONENTS
  • 3.1 Base Assembly Components
  • 3.2 Base Frame Covers
    • Carry Deck Support Frame - Installation
    • Rear Bumper Cover - Installation
    • Drive Motor Cover - Installation
  • 3.3 Drive And Caster Wheels
    • Tire Wear and Damage
    • Wheel and Tire Replacement
    • Wheel Installation
    • (Front) Caster Wheel - Installation
  • 3.4 Drive/Elevation Cut-out switch Installation
  • 3.5 Wheel Drive Assembly - Servicing
    • Roll and Leak Testing
    • Oil Type and Capacity
    • Drive Motor Brush Wear - Warning Indication
    • Wheel Drive Assembly - Removal From Machine
    • Wheel Drive Disassembly - Main Components
    • Replacing Drive Motor Brushes
    • Gear Box Main Disassembly
    • Input Carrier Disassembly
    • Hub - Disassembly
    • Spindle Disassembly
    • Spindle Sub-Assembly
    • Hub Sub-Assembly
    • Input Carrier Sub-Assembly
    • Main Gear Box Sub-Assembly
    • Motor, Brake and Gear Box Assembly
  • 3.6 Pump-Motor Assembly - Service Procedure
    • General
    • Hydraulic Pressure Settings and Adjustment
    • Hydraulic Pressure Gauge Connection
    • After Filter Pressure Check
    • Pump-Motor Assembly - Remove/Install
    • Pump-Motor Assembly - Remove/Install
    • Motor Assembly - Remove/Install - Reference Marks
    • Motor/Brush Cover - Remove/Install
    • Brush Carrier Assembly - Remove/Install
    • Brush Assembly - Remove/Install
    • Tank Remove/Install
    • Filter Screen Remove/Install
    • Pump Remove/Install
    • Pressure Adjust Valve Remove/Install
    • Pressure Check Valve - Remove/Install
  • 3.7 bATTEries and Battery Charger - Service Procedures
    • Battery Condition Testing
    • Battery Replacement
    • Battery - Installation (2-12V Batteries)
    • Battery Installation - (4-6V Batteries) (OPTION)
    • Battery Charge LED Indicator on Platform Control Console
    • Battery Low Voltage Warning Indicators
    • Battery Charger General Information
    • Battery Charging Status Indicators
    • Battery Charger Maintenance Information
    • Battery Charger Check/Change Charging Algorithm
    • Battery Charger Removal/Installation
• Section 4. CONTROL COMPONENTS
  • 4.1 CONTROL Components Overview
  • 4.2 Control Components - Installation
    • Ground Control Module
    • Traction Control Module
    • Platform Control Console Installation
    • Platform Junction Box - Install/Remove
    • Junction Box to Ground Control Harness - Remove/Install
    • Platform Interlock Switch Circuit
  • 4.3 Ground Control Module - Service Procedure
    • Cover Removal/Installation
    • Power Selector/EStop Switch Installation
  • 4.4 Ground Control Module - Programming
    • General
    • Programming Levels
    • Activating Programming Mode
    • Entering Password
    • Programming Mode Selection
    • Selecting Programmable Item to Adjust
    • Adjusting Programmable Setting
    • Service Programming Mode - (Level-2)
    • Operator Programming Mode - (Level-3)
  • 4.5 Platform Control Console - Service Procedures
    • General
    • Remove Platform Control Console
    • Display/Controller Module Electrical Connections
    • Mounting Bracket - Install/Remove
    • Rear Cover - Install/Remove
    • Display/Controller Module - Install/Remove
    • Drive/Lift Mode Switch - Install/Remove
    • Horn Button Switch - Install/Remove
    • Key Switch - Install/Remove
    • E-Stop/ShutDown Switch - Install/Remove
    • Joystick Assembly - Install/Remove
• Section 5. MAST COMPONENTS
  • 5.1 Mast Components Overview
  • 5.2 Mast Cover - Install/Remove
  • 5.3 Platform Assembly - install/ remove
  • 5.4 Material Tray - Install/Remove
  • 5.5 Platform - 7 FT. HEIGHT Limit Switch - OPTION
  • 5.6 Hydraulic Line - Disconnect - Special Tool
    • Tool Use - In-Line Style Fittings
    • Tool Use - Angled Style Fittings
  • 5.7 Mast Assembly Install/REmove
    • Mast Removal
    • Mast Installation
  • 5.8 MAST DISASSEMBLY PROCEDURE
    • Mast Disassembly Procedure
    • Mast Section-4 - Removal (Platform Mount)
    • Mast Section-3 - Removal
    • Mast Section-2 - Removal
    • Mast Section-1 - Disassembly
  • 5.9 Cylinder Disassembly
    • Lift Cylinder Component Inspection
    • Cylinder Assembly
  • 5.10 Mast Assembly
    • Mast Section 1 - Assembly
    • Mast Section 2 - Assembly
    • Mast Section 3 - Assembly
    • Mast Section 4 - Assembly
  • 5.11 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
    • Mast Chain/Cable Adjustment
    • Sequencing Cable Adjustment
• SECTION 6. TROUBLESHOOTING
  • 6.1 General
  • 6.2 Troubleshooting Information
  • 6.3 Hydraulic Circuit Checks (See Figure 6-8.)
  • 6.4 ELECTRICAL CIRCUIT CHECKS
    • General
  • 6.5 MULTIMETER BASICS
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 6.6 ELECTRICAL SWITCH TESTING
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 6.7 Ground Control Module LCD Display
  • 6.8 TROUBLESHOOTING TABLES Index
    • SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE
    • SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
    • FAULT CODE TROUBLESHOOTING TABLES
    • MAIN POWER CIRCUIT TROUBLESHOOTING
    • MAST TROUBLESHOOTING
    • HYDRAULIC LEAK TROUBLESHOOTING
    • BASE FRAME COMPONENTS TROUBLESHOOTING
    • DRIVE SYSTEM TROUBLESHOOTING
  • 6.9 SPECIFICATIONS FOR VARIOUS COMPONENTS
  • 6.10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
  • 6.11 FAULT CODE TROUBLESHOOTING TABLES
    • Machine in Drive Speed Cut-Back (Turtle) Mode All The Time
    • Code 01 - Low Battery Voltage
    • Code 02 - RESERVED
    • Code 03 - RESERVED
    • Code 04 - Tilt Condition
    • Code 05 - RESERVED
    • Code 06 - Drive Motor Brush Wear Warning Indicator
    • Code 07- Left Drive Motor - Disconnected
    • Code 08 - Right Drive Motor - Disconnected
    • Code 09 - Left Brake - Disconnected
    • Code 10 - Right Brake - Disconnected
    • Code 11 - Left Drive Motor - Short Circuit
    • Code 12 - Right Drive Motor - Short Circuit
    • Code 13 - Traction Module - In Fold Back
    • Code 14 - Pump Motor - Disconnected
    • Code 15 - Lift Down Valve - Disconnected
    • Code 16 - Lift Down Valve - Short Circuit
    • Code 17 - Ground Control Module - In Fold Back
    • Code 18 - Alarm - Short Circuit
    • Code 19 - Alarm - Disconnected
    • Code 20 - Beacon - Short Circuit
    • Code 21 - Beacon - Disconnected
    • Code 22 - Horn - Short Circuit
    • Code 23 - Horn - Disconnected
    • Code 24 - P1-Auxiliary #1 Circuit - Short Circuit
    • Code 25 - P1-Auxiliary #1 Circuit - Disconnected
    • Code 26 - P1-Auxiliary #2 - Short Circuit
    • Code 27 - P1-Auxiliary #2 - Disconnected
    • Code 28 - RESERVED
    • Code 29 - RESERVED
    • Code 30 - Traction Module - No Communication with Ground Control Module
    • Code 31 - Platform Control Console - No Communication with Ground Control Module
    • Code 32 - Pump Motor - Over Current
    • Code 33 - RESERVED
    • Code 34 - P2-Auxiliary #1 - Inhibit
    • Code 35 - P2-Auxiliary #1 - Tie Down
    • Code 36 - RESERVED
    • Code 37 - RESERVED
    • Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit
    • Code 39 - Battery Voltage Low - Warning Level 3 - One (1) LED/LCDs lit
    • Code 40 - RESERVED
    • Codes 41 thru 46 - RESERVED
    • Codes (100 - 199) Ground Control Module - Fault Condition
    • Codes (200 - 299) Platform Control Console - Fault Condition
    • Codes (300 - 399) Traction Control Module - Fault Condition
  • 6.12 MAIN POWER CIRCUIT TROUBLESHOOTING
    • Machine Will Not Power Up
  • 6.13 MAST TROUBLESHOOTING
    • Platform Will Not Lower Manually
    • Platform Lift Up And Down Jerky
    • Mast Noisy When Lifting And Lowering
    • Platform (Mast) Won’t Stay Elevated
    • Platform (Mast) Descends Too Slowly
  • 6.14 HYDRAULIC LEAK TROUBLESHOOTING
    • Miscellaneous Hydraulic Leak Troubleshooting
  • 6.15 BASE FRAME COMPONENTS TROUBLESHOOTING
    • Caster Wheels Not Operating Freely
  • 6.16 DRIVE SYSTEM TROUBLESHOOTING
    • Won’t Climb Grade
    • Machine Drives in Opposite Direction
    • Machine Won’t Drive Straight
    • Noise From Drive Assembly