Document Outline

• Maintenance safety precautions
  • a. GENERAL
  • b. HYDRAULIC SYSTEM SAFETY
  • c. MAINTENANCE
• REVISION LOG
• TABLE OF CONTENTS
• LIST OF FIGURES
• LIST OF TABLES
• Section 1. MACHINE specifications
  • 1.1 Capacities
    • System Voltage
    • Hydraulic System
  • 1.2 Component Data
    • Hydraulic Pump/Pump Motor Assembly
    • Batteries/Battery Charger
  • 1.3 Performance Data
    • Platform Capacity
    • Platform and Material Tray Size
    • Machine Height (platform stowed)
    • Base Footprint
  • 1.4 Torque Requirements
  • 1.5 Lubrication
    • Hydraulic Oil
    • Lubrication Specifications
  • 1.6 Hydraulic Pressure Adjustment
  • 1.7 Cylinder Specifications
  • 1.8 Serial Number Locations
• Section 2. GENERAL
  • 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
  • 2.4 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.5 Positioning Lift for Access to Components Located Under The Base Frame
• SECTION 3. BASE COMPONENTS
  • 3.1 Base Assembly Components
  • 3.2 Platform Descent - Beacon and alarm
    • Descent Beacon - Remove/Install
    • Descent Alarm - Remove/Install
  • 3.3 Wheel Assemblies
    • Front Caster Wheel - Remove/Install
    • Rear Locking Caster Wheel - Remove/Install
    • Rear Wheel (Straight Axle)- Remove/Install
  • 3.4 Floor Stop Assembly
    • Floor Stop - Remove/Install
    • Floor Stop Interlock Switch Assembly - Remove/Install
    • Floor Stop Interlock Switch - Remove/Install
  • 3.5 Base Mast SupportS
    • Mast Support to Base - Straight Axle Base - Remove/Install
    • Mast Support to Base - Rear Caster Wheel Base - Remove/Install
• SECTION 4. CONTROL COMPONENTS
  • 4.1 CONTROL Components Overview
  • 4.2 Control Cover Installation
    • Battery/Battery Charger Cover - Remove/ Install
    • Ground Control Station Cover - Remove/ Install
  • 4.3 Battery and Charger - Installation
    • Battery - Remove/Install
    • Battery Charger - Remove/Install
  • 4.4 Ground Station - Servicing
  • 4.5 Platform Station - Servicing
  • 4.6 Pump-Motor Assembly - Service Procedure
    • General
    • Pump/Motor/Reservoir - Remove/Install
    • Tank Removal/Installation
    • Filter Screen Removal/Installation
    • Pump Removal/Installation
    • Pressure Adjust Valve Removal/Installation
    • Pressure Check Valve - Removal/Installation
    • Lift Down Valve - Removal/Installation
    • Motor - Remove/Install - Reference Marks
    • Motor Top Cover - Removal/Installation
    • Motor Components - Removal/Installation
    • Brush Carrier - Removal/Installation
    • Brush Housing Final Assembly Tips
  • 4.7 Battery Charger - Service Procedures
    • General Information
    • General Component Installation Notes
    • Charger Cover - Remove/Install
    • DC Circuit Breaker - Remove/Install
    • AC Circuit Breaker/Voltage Select Switch - Remove/Install
    • Battery Discharge Indicator - Remove/Install
    • Printed Circuit Board - Remove/Install
    • Shunt Assembly and Capacitors - Remove/Install
    • SCR Rectifier - Remove/Install (Either Side)
    • Transformer Installation
• SECTION 5. MAST COMPONENTS
  • 5.1 Mast Components Overview
  • 5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
    • Mast Chain Adjustment (See Figure 5-2.)
    • Sequencing Cable Adjustment (See Figure 5-2.)
  • 5.3 Hydraulic Lift Cylinder - Removal, Inspection and Rebuild
    • Lift Cylinder Removal
    • Cylinder Disassembly
    • Lift Cylinder Component Inspection
    • Cylinder Assembly
    • Cylinder Installation
  • 5.4 Mast Assembly - Remove/Install
    • Mast Removal
    • Mast Installation
  • 5.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
    • Mast Disassembly Procedure
    • Mast Assembly - 9MP
  • 5.6 9MP Platform - Remove/Install
• Section 6. troubleshooting
  • 6.1 General
  • 6.2 Troubleshooting Information
  • 6.3 ELECTRICAL AND Hydraulic Circuit Checks