Document Outline

• INTRODUCTION - operation/safety precautions
• INTRODUCTION - Maintenance safety precautions
  • General
  • Hydraulic System Safety
  • Maintenance Safety
• Effectivity Changes
• TABLE OF CONTENTS
• Section 1. specifications
  • 1.1 Capacities
    • Hydraulic Oil Reservoir
  • 1.2 Component Data
    • Hydraulic Pump/Electric Motor Assembly
    • Batteries (1) – DC Models
    • Battery Charger – DC Models
  • 1.3 Performance Data
    • Platform Capacity
    • Platform Cycle Performance
    • Machine Weight (with Standard Platform)
    • Machine Height (Platform Stowed)
    • Maximum Platform Height (Mast Extended)
    • Maximum Working Height (Average Person)
    • Machine Overall Width and Length (Base)
    • Outrigger Footprint
    • Outrigger Machine Leveling Capability
  • 1.4 Torque Requirements
  • 1.5 Lubrication
    • Hydraulic Oil (HO)
  • 1.6 Hydraulic Pressure Adjustment
  • 1.7 Cylinder Specifications
  • 1.8 Serial Number Locations
• Section 2. SERVICE PROCEDURES
  • 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
  • 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
    • Mast Cable Inspection Procedure
  • 2.4 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.5 Battery Charger - Assembly and Disassembly
    • General Information
    • Battery Charger Removal
    • Cover Removal
    • Transformer Replacement
    • Printed Circuit Board Replacement
    • DC Circuit Breaker Replacement
    • AC Circuit Breaker and Voltage Selection Switch Replacement
    • Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)
  • 2.6 hydraulic LIFT pump - servicing
    • FENNER BRAND PUMP - Brush Replacement
    • Motor Cap/Motor Installation
    • Motor Brush Installation
    • Brush Housing Final Assembly Tips
    • MONARCH BRAND PUMP - Brush Replacement
    • Motor Assembly - Remove/Install - Reference Marks
    • Motor/Brush Cover - Remove/Install
    • Brush Carrier Assembly - Remove/Install
    • Brush Assembly - Remove/Install
    • TANK AND PUMP REMOVAL - (All Pumps)
    • Tank Installation
    • Filter Screen Installation
    • Pump Installation
    • Pressure Adjust Valve Installation
    • Pressure Check Valve Installation
  • 2.7 Hydraulic Lift Cylinder - Removal, Inspection and rebuild
    • Cylinder Removal
    • Cylinder Disassembly
    • Lift Cylinder Component Inspection
    • Cylinder Assembly
    • Installation
  • 2.8 Mast Assembly And Disassembly Procedures
    • Mast Disassembly Procedure
    • Platform Section Removal (All Masts)
    • Mast Section 6 Removal (7 Section Mast)
    • Mast Section 5 Removal (6 & 7 Section Mast)
    • Mast Section 4 Removal (All Masts)
    • Mast Section 3 Removal (All Masts)
    • Mast Section 2 Removal (All Masts)
    • Mast Section 1 Disassembly (All Masts)
  • 2.9 Mast Assembly
    • Mast Section 1 - Assembly (All Masts)
    • Mast Section 2 - Assembly (All Masts)
    • Mast Section 3 - Assembly (All Masts)
    • Mast Section 4 - Assembly (All Masts)
    • Mast Section 5 - Assembly (25/30/36/41 ft. Masts)
    • Mast Section 6 - Assembly (30/41 ft. Masts)
    • Platform Mounting Section - Assy. (All Masts)
  • 2.10 Mast To Base Frame Installation
  • 2.11 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT
    • Mast Chain/Cable Adjustment
    • Sequencing Cable Adjustment
  • 2.12 Sequence Cable replacement kit
    • Remove Old Cable
    • Replacement Cable Installation
    • Clamp Installation (Drum/Socket Type)
• Section 3. troubleshooting
  • 3.1 General
  • 3.2 Troubleshooting Information
  • 3.3 Hydraulic Circuit Checks
  • 3.4 ELECTRICAL SYSTEM - MULTIMETER BASICS
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 3.5 ELECTRICAL SWITCH TESTING
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 3.6 Outrigger Interlock Contacts
    • Outrigger Socket and Outrigger Beam - Interlock Contacts
    • Outrigger Socket - Contactor Screw Mounting Instructions
    • Outrigger Beam - Interlock Contactor Plate Mounting Instructions
    • Detent Screws