OPERATING/MAINTENANCE AND PARTS MANUAL ae —_—) 3 =e eS == ies : = a = ! oo 5000 SERIES DIESEL Dual Wheel/4 Wheel Solid/Articulating Axle, Hydraulic Drive, Self Propelled Elevating Work Platform 1aS3Id sass GOOSPRODUCT WARRANTY ‘Snorkel-Economy —A Figgie International Company war- rants each new product to be free of defective parts and workmanship. During the first six months, any defective parts will be replaced or repaired by your local authorized Snorkel-Economy distributor at no charge for parts or labor. During the second six months, any defective parts will be replaced or repaired at no charge, but labor may be charged by the distributor. A Warranty Card is supplied with each product. To ineure the effectiveness of this warranty program, the card supplied must be filled out and mailed to Snorkel- Economy within 10 days of the date any product is firs Dut into use. Where products are put into dealer's "stock, the warranty period does not commence until such products have been shipped to a bona-fide dealer's “customer When a unit is put into service and no warranty card has ‘been mailed to Snorkel-Economy, the warranty period will ‘commence 10 days from the date the Dealer was invoiced for such product. During the Warranty Period Snorkel-Economy will pair ‘or replace free of charge (material for 1 year and labor a spelled out in point 4) any item deemed to be defective. Snorkel-Economy's authorized Service Department will exercise final judgment as to what constitutes "defective parts and/or labor” This Warranty does not cover batteries. All Heavy-Duty Batteries will be pro-rated over a one (1) year period. Industrial Batteries are guaranteed for one (1) year and pro-rated over four (4) years, Parts purchased from sources other than Snorkel-Economy will not be covered by our warranty. Misuse or neglect in operation, lack of normal maintenance, alteration or accident shall void the warranty. ‘The above warranty statement is exclusive and no other warranty, whether written, oral or implied shall apply. ‘Snorkel-Economy expressly excludes any implied warranty of merchantability and fitness and accepts no liability for ‘consequential damages or for the negligence of others. WARRANTY PROCEDURE The selling Distributor or authorized Dealer shali be responsible for complete handling of customer claims Under this warranty. Here's what to do: 1. When a customer files a claim under this warranty, contact Snorkel-Economy’s Service Department to verity warranty coverage. (Gnorkel externas 484 Thomas Or, PO Box 1507, Benserwie, IL 60106 USA NOTE: Complete serial number of unit is required to verity claim. Example AC 50285 ka. Prefix ‘Serial Number Suffix 2. When Snorkel-Economy’s Service Department verifies warranty coverage, they will also issue an RA (Return Authorization) Number for the return of any defective ‘component(s). All items over $25.00 in value must be returned to Snorkel-Economy. 3, Select and fil out a Warranty Claim Form from Dealer's supply of claim forms, Be sure to enter the RA Number in the appropriate place on the Claim Form. (Failure to do so could delay issuance of proper credit) Then notity ‘Snorkel-Economy's Service Department of the warranty claim number on the form used. 4, Distributor/dealer should then file warranty claim with ‘Snorkel-Economy, describing nature of defect and Corrective action taken. Warranty labor allowance is, 75% of dealer's current shop rate or $23.00 per hour. whichever is less. This rate will be paid portal to portal within dealers specified teritory and is subject to change without notice. 5, Warranty claims must be received by Snorkel-Economy within 18 working days from the date of repair. Warranty claims received with insufficient information will be returned for correction or completion 6. Material returned for warranty inspection must be: a, Carefully packaged to prevent additional damage during shipping, . Drained of contents and all open ports capped or plugged, cc. Shipped in container tagged or marked with RA number. 4. Shipped PREPAID. Any items) returned for warranty by any other means can be refused and returned Unless prior approval from Snorkel-Economy is noted, Failure to comply with the above procedures could result in delay of warranty approval or eventual denial of the warranty claim: (Subject to change without notice)SECTION 1 INTRODUCTION PURPOSE OF EQUIPMENT . il WARNINGS 14 DESCRIPTION .. foe 4 , settee 1 OPERATING CONTROL IDENTIFICATION «os... cee ris, Base Controls poveenoHco000 15 Platform Controls SECTION 2 OPERATION 17 OPERATOR QUALIFICATIONS ........ 7 cetecseeeees 24 OPERATING CONTROLS Sos0op00000000 : : 24 Base Controls—Electrical .......... ceeee . 21 Base Controls—Hydraulic . Bapoooene 22 Base Controls—Manual and/or ee 22 Platform Controls 24 SET-UP PROCEDURE .. 28 OPERATING PROCEDURES ........-. 210 SECTION 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS ‘TABLE OF CONTENTS : 5 : 34 SECTION 4 MAINTENANCE AND TROUBLESHOOTING OPERATOR'S RESPONSIBILITY FOR MAINTENANCE, at MAINTENANCE SCHEDULE .... at HYDRAULIC SYSTEM AND COMPONENTS . 42 ‘TROUBLESHOOTING 45 SECTION 5 PARTS LISTS LIST OF ILLUSTRATIONS. 53 LIST OF TABLES TABLE 1-1, SPECIFICATIONS... 13 TABLE 2-1, FUEL PREHEATING TIMES... 24 TABLE 22. DISABLE LIGHT OPERATION 25 TABLE 41, MAINTENANCE SCHEDULE ... 43 TABLE 42. TORQUE SPECIFICATIONS .. 44 TABLE 43. TIRE SPECIFICATIONS ... 44 TABLE43. PLATFORMCAPACITIES ....... WIIEEEE EEE 44Operator Safety Reminders ‘The National Safety Council reminds us that most accidents are caused by the failure of some in- dividuals to follow simple and fundamental safety rules and precautions. Common sense dictates the use of protective clothing when working on ornear machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body. You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this work platform is manditory. The contents of this manual should be read and understood completely before operating the work platform. Any modifications from the original design are strictly forbidden without written permission from Snorkel-Economy—A Figgie International Company. ‘This Safety Alert Symbot means Attention! Become Alert! Your Safety is Involved. ‘The Safety Alert Symbol identifies important safety mes- sages on machines, safaty signs, in manuals, or else- where. When you see this symbol, be alert to the possibilty of personal injury or death. Follow the instruc- tions in the safety message. ABOUT THIS MANUAL ‘This manual is designed to aid in the proper operation, ‘maintenance and ordering of service parts for your 5000 Series Diesel Work Platform. ithas been divided into five sections as follows: SECTION 1—INTRODUCTION ‘SECTION 2—OPERATION ‘SECTION 3—SYSTEMS OPERATION SECTION 4—MAINTENANCE AND ‘TROUBLESHOOTING SECTION 5—PARTS LISTS Page numbers, figure numbers and table numbers are displayed so that the section number appears first, fol lowed by the page, figure or table number. (ie. 32 Sec- tion 3, Page 2) NOTE ‘A condensed version of this manual, @ “OPERATING MANUAL” has been supplied with this work platform, OPERATING MANUA ENCLOSEDSECTION 1 INTRODUCTION PURPOSE OF EQUIPMENT ‘The 5000 Series Work Platform is designed to transport and raise men and materials to overhead work areas. The hydraulic work platform (Figure 1-2.) (hereatter referred to as work platform) is @ highly maneuverable, mobile work station. WARNINGS Read and: Understand the safety pate decals (Figure 1-1,)and ALL other Caution and Danger wamings. DESCRIPTION ‘The work platform has a platform, raised and lowered by 8 scissor-type elevating mechanism. The elevating mechanism is mounted toa base having front (steer) and ‘ear axies and four wheels. An operator's control console is located on the platform. Auxiliary and emergency con- trols are located at the base. PLATFORM. The platform deck has an embossed pat- tern to minimize skidding, 40-inch high ralings with mic ‘ails, 6" toe boards, and entrance chain or optional gate, SCISSOR-TYPE ELEVATING MECHANISM. The plat- form is raised by telescoping cylinders. Telescoping Cylinders lower through fixed flow regulators to assure ry controlled lowering speed. Independent check vaives in the hydraulic system prevent platform descent in the eventof a single-iine or related component tailure. During maintenance, inspection or repairs, a swing-up safety bar(s), when property positioned, prevents the scissor ‘section from being lowered. BASE. The base has two trays with swing-up side covers. One contains electrical and hydraulic com- Ponents, the other holds fuel supply. The front axle has two steerable wheels, each driven by a hydraulic wheel motor, and steered by two double-acting hydraulic cylinders. The rear axle is either solid non-driven, or ac- ticulating with or without hydraulic whee! motors. A flow divider is used to balance the fluid flow to each whee! ‘motor from the hydraulic pump. SERIAL NUMBER NAMEPLATE. The serial number ‘nameplate, located on the rear of the machine, ists the ‘model number, serial number, capacity, lit and voltage. Use the information both for proper operation of the ‘machine and when ordering service parts. OPTIONAL ACCESSORIES. The 5000 Series Work Platform is designed to accept a variety of optional acces- ‘ories. These are listed on Table 1-1. Specifications. NOTE ‘See the detailed specifications, limitations and ‘warnings for each option.rey Needy Jr IMEAB AND UNDERSTAND ALL CAUTION AND DANOER WARNINGS AND OPERATING Sanaa? com 12, PERFORM DAILY SAAINTENANCE INSPECTIONS. 3. RAVE ALL WORM OR DAMAGED PARTS REPLACED. 4. FARTEN ENTRY GATE;CHAINMAR, {8,_Ust WoRK PLATFORM ONLY ON HARD LEVEL SURFACES Quins ANON URERS AE RERPOWRIGLE rOR INSPECTION ANO MAINTENANCA ane AR ACQUIRED ev A ASE © AND Toe © MMdirenance aNo PanTe MANUAL Caution Decal for Fixed Axle Models A _ CAUTION ORK RLATTORM 79 BEUBED BY TRAINED AND AUTHORIZED OPERATORS ONLY. 75 akvow's Ressowsiein tag ARO UNDERSTAND ALL CAUTION AND DANGER WABWINGS ANO OPERATING PERFORM DAILY MAINTENANCE iNBPECTION®. WAVE ALL WORN OR OAMAGED PARTS REPLACED. [RAIBE PLATFORM ONLY ON HARD LEVEL SURFACES. Soren secret ee Bane init Au REQUIRED BY ANGI ABE.G AND THE GOERATING ‘OTHER HAZARDS DEATH OR SERIOUS INJURY WILL RESULT FROM IMPROPER USE OF THIS EQUIPMENT! Figure 1-1. 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LTenaTune GUARDRALS ‘CONTROL (COMPARTMENT CONSOLE REAR AXLE HYDRAULIGIELECTRIC SIDE TRAY FUEL SIDE ‘TRAY BASEFRAME STEER (FRONT) ARLE, Figure 1-2. 5000 Series Work Platform 14OPERATING CONTROL IDENTIFICATION NOTE The following descriptions are for identification and locating purposes only. A qualified operator must read and understand "SECTION 2 OPERATION" in this manual before operating any control Both standard and optional controls for this work platform are identified in the following list. Therefore, the list may include controls which are not furnished on your work platform, Base Controls (Figures 1-3, 1-4, 1-5.) HOURMETER PLATFORM UP/DOWN SWITCH MAIN POWER ON/OFF KEY SWITCH ENGINE START SWITCH GLOWPLUG SWITCH EMERGENCY STOP SWITCH 15 AMP CIRCUIT EREAKER RESET PLATFORM/BASE CONTROL SELECT AMP CIRCUIT BREAKER RESET swiTcH Figure 1-3. WARNING DO NOT ALTER OR DISABLE LIMIT SWITCHESISAFETY SWITCHES OR INTERLOCKS. ro i ___90wn rar Po e@ 4 “ oN Man poy Crag Rd Base Control Panel and Decal at Rear of HycrauliclElectric Side TrayyFigure 1-4. Manifold Sub-Assembly (Left View) EMERGENCY LOWERING VALVE TURN KNOB Counter Clockwise YY TO LOWER PLATFORM 10. EMERGENCY LOWERING VALVE DISENGAGE BRAKE FREE WHEELING VALVE 11, FREE-WHEELING VALVE 16 Figure 1-6. Parking Brake (Left Rear of Rear Axle) Q\ CAUTION THIS CYLINDER IS SPRING LOADED. INCORRECT ASSEMBLY OR DISASSEMBLY COULD CAUSE PHYSICAL INJURY. BEFORE REMOVING SNAP RING, RETRACT CYLINDER ROD 25 INCH. REMOVE SNAP RING AND SLOWLY EXTEND CYLINDER ROD UNTIL SPRING PRESSURE IS RELEASED, ASSEMBLE IN REVERSE ORDER 12, PARKING BRAKE ASSEMBLYPlatform Controls Ns Operator's Control Console (Figure 1-7.) DEATH OR SERIOUS FOR USE BY TRAINED INJURY CAN RESULT | AUTHORIZED PERSONNEL FROM IMPROPER USE | ONLY! OF THIS EQUIPMENT. Figure 1-7. Operator's Control Console STEERINGROCKER ‘SPEED/TORQUE SELECT SWITCH LIFTIDRIVE SELECT SWITCH SELECTORHANDLE EMERGENCY STOPBUTTON LIFTDISABLELIGHT RAISED PLATFORM DRIVE DISABLE LIGHT ENGINE START PUSHBUTTON LOWENGINEOI Litre Outrigger Control Box (Figure 1-8.) SeNOnEeN= Figure 1-8. Outrigger Control Box LEFT FRONT OUTRIGGER CONTROL SWITCH LEFT REAR OUTRIGGER CONTROL SWITCH RIGHT FRONT OUTRIGGER CONTROL SWITCH RIGHT REAR OUTRIGGER CONTROL SWITCH aeons 17SECTION 2 OPERATION OPERATOR QUALIFICATIONS Only trained and authorized persons should use this work platform, Safe use of this work platform requires the ‘operator to understand the limitations and warnings, operating procedures and operator's responsibility for maintenance. Accordingly, the operator must under- stand and be familiar with this operating manual, its ‘warnings, and all warnings and instructions on the work platform, Operator also must be familiar with employer's work rules and related government reguiations and be lable to demonstrate his/her ability to understand and operate this make and model work platform in the presence of a qualified person. OPERATING CONTROLS Base Controls—Electrical HOURMETER—Activated by ignition system, measures ‘work platform operating time. PLATFORM UP/DOWN (MOMENTARY) SWITCH— ‘Toggle-type switch that raises and lowers the platform. To raise platform, pull up on toggle switch until desired height is reached. Release switch to stop. To lower plat- form, push down on toggle switch. As platform lowers, @ lowering alarm will sound. MAIN POWER ON/OFF KEY SWITCH—Key to "ON" position directs power to the Base Emergency Stop ‘Switch, thus powering the control circuit. Key to “OFF” position disconnects power from all work platform controls, ENGINE START (MOMENTARY) SWITCH—When pushed, this toggle- type switch activates the engine Starter. To start engine, push and hold switch until engine starts, then release. BASE EMERGENCY STOP SWITCH—Toggle-type switch with red safely guard which disconnects power from all control circuits when pushed down. Push switch up to restore power. CIRCUIT BREAKER RESETS—These pushbutton switches are used for resetting circuit breakerinthe event of a power overload or positive circuit grounding, (Con- ‘sult the TROUBLESHOOTING section in this manual for further information.) PLATFORMIBASE CONTROL SELECT SWITCH—To activate control functions at the operator's control con. sole on the platform, "PLATFORM" position must be selected with this toggle-type switch. “BASE” position must be selected when base control function is desired. “The “OFF” position disconnects power from both control operating areas. GLOW PLUG (MOMENTARY) SWITCH—Usage is recommended for first daily operation and as required thereatter. When pushed down andheld, this toggle-type switch activates the glow plug(s)to preheat the fuel. Refer to Table 2-1 for proper preheating times. Table 2-1. Fuel Preheating Times KUBOTA DIESEL ENGINE ‘Temperature Preheating Time Over 0°C (82°F) 15 Seconds Below0°C (32°F) | 30 Seconds (Max.) LOMBARDINI DIESEL ENGINE "Temperature Preheating Time All | 20 Seconds (Max.) |e Base Controls—Hydraulic EMERGENCY LOWERING VALVE—Located on the valve manifold sub-assembly. Accessis thru ahoie at the rear of the hydrauliclelectrc tray below the base controts. ‘This valve allows platform ioweringin the event of electi- cal system failure. Tuming the valve handie counter- Clockwise (see decal on tray) allows the platform to gradually lower. Valve handle must be turned clockwise (fully closed) to restore normal operation. (Figure 21.) EMeAGENCY LOWERING. YALE, Figure 2-1. Emergency Lowering Valve Access Hole a4FREE-WHEELING VALVE—Valve is located on the hy- draulic manifold subassembly inthe right-hand tray tis. accessed by unlatching, then swinging up to the tray Cover and supporting the cover with the cover brace. Turning the valve handle counter-clockwise to a fully ‘opened position allows hydraulic fluid to flow through the wheel motors, providing “free-wheeling” so work plat- form can be towed or pushed without damaging the Wheel motors. Fallure to open the free-wheeling valve when towing or manually moving the work platform may Figure 2.3. Manually Disengaging Parking Brake B. Using a 9/4” wrench, rotate lockout block 90° (clockwise) to retract the cylinder rod. Remove wrench immediately. (Figure 2-3.) C. Open free-wheeling valve (turn handle counter- clockwise). NOTE Freewheeling valve must be closed tightly (clockwise) for normal operation. Parking brake will reset automatically when the work platform is put back in service.DEATH OR SERIOUS INJURY MAY RESULT IF SAFETY BAR IS NOT USED AND/OR PROPERLY POSITIONED, USE SAFETY BAR AT ALL TIMES WHEN SERVICING MACHINE WITH PLATFORM RAISED. ROPER USE OF SAFETY BAR “REMOVE ALL MATERIAL FROM PLATFORM. “RAISE PLATFORM UNTIL THE OPEN HEIGHT IN SCISSORS IS APPROXIMATELY 28 INCHES. “SWING SAFETY BAR UP FROM RETAINING BRACKET, “REMOVE HANDS AND ARMS FROM SCISSORS AREA “LOWER PLATFORM UNTIL SCISSORS ARE SUPPORTED BY SAFETY BAR. TO STORE SAFETY B, “RAISE PLATFORM UNTIL THE OPEN HEIGHT IN SCISSORS IS APPROXIMATELY 28 INCHES. “SWING BAR DOWN ONTO RETAINING BRACKET. “LOWER PLATFORM Figure 2-4. Safety Bar Decal SAFETY BAR(S)—Designed to support the scissors mechanism (when properly positioned) (see decal on scissor arm), the safety bar(s) must be used for inspec- tion and performing maintenance or repairs within the scissors mechanism. (Figure 2-4.) NOTE (On 40 ft. models, both safety bars mustbe used A.cauTION Clear platform of men and materials prior to using safety bar, Platform Controls OPERATOR'S CONTROL CONSOLE—The console is mounted at the right front of the platform. (Figure 2-5.) It contains the following: SPEED/TORQUE (SELECT) SWITCH—Rocker-type ‘switch for selecting high “SPEED” or high “TORQUE’ LIFTIDRIVE (SELECT) SWITCH—This rocker-type ‘switch controls the lit system or drive system in conjunc tion with the Selector Handle. SELECTOR HANDLE WITH 2 SPEED CONTROL—A one-hand toggle-type lever to control 2 speed for wardireverse motion, lefuright steering motion, and 2 speed lf speed lower motion. It is a “dead-man" con: trol which returns to neutral and locks when released. With LityDrive Switch in "DRIVE" position; to drive for- ward, lift lock ring and push handle forward, selecting desired speed. To drive in reverse, litt lock ring and pull handle backwards, selecting desired speed. To steer 23 right or left, move the rocker on top of selector handle in the direction you wish to steer. With LifvDrive Switch in 'LIFT” position; to lift platform, lt lock ring and push han. dle forward, selecting desired speed. Release handle to stop. To lower platform, lift lock ring and pull handle backwards. EMERGENCY STOP BUTTON—A red "mushroom. head” shaped button switch is designed to cut power to the platform controls when “struck” in event of emergen- cy. The button will remain in until reset. To restore power to the operator's control console, simply pull Button out. SELECTOR RAISED PLATFORM eee DRIVE DISABLE a _—, + LIFT o1sapue UGH ‘SPEEDITORQUE SELECT SWITCH LFTiDRWE lsetect swircH on encive on! on EMERGENCY == *Nenaine star See Sr ean Figure 2.5. Operator's Control ConsoleLIFT DISABLE LIGHT—Light indicates when conditions ‘are not met for raising platform, (See Table 2-1 for cond- tions and remedies.) RAISED PLATFORM DRIVE DISABLE LIGHT—Lightin- dicates when conditions are not met for driving work plat- form when platform is elevated. (See Table 2-1 for conditions and remedies.) LOW ENGINE OIL LIGHT—Light comes on when key switch is in “ON” position. Should go off when engine is started. Ilight remains on, shut off engine and check en- gine oillevel, (Refer to TROUBLESHOOTING section for additional information.) ENGINE START PUSHBUTTON—To start engine, depress and hold this rubber-covered switch untilengine starts, then release. (Refer to TROUBLESHOOTING. section if engine fais to start.) Optional Operator's Control Console Controts SELECTOR HANDLE WITH PROPORTIONAL CON- TROL OPTION—Operates the same as 2 speed control cexceptthe twodrive andlit speeds arereplaced bya vari- able speed range Optional Platform Controls 4 FT. ROLLOUT EXTENSION DECK—Provides addi- tional 24.q, ft. ofwork area. To extend deck, lit detenton lett rear of extension deck. Using handle on railing, push deck forward (releasing detent) until detent locks past front detent ramp. To retract deck, it detent, Use handle to pull deck backwards (releasing detent) until detent locks past rear detent ramp. OUTRIGGER CONTROL BOX—A movable control box with four toggle- type switches for operating the hydrau- lic outriggers. (Figure 2-6.) OPERATING INSTRUCTIONS A, Before Operation 1. Check overhead clearances and ground obstruc tions. Check that the supporting surtace under the tires, and outrigger pads is firm and stable, (The operator is responsible for deciding whether blocking (such as timber mats) is needed.) Check that the platform is lowered. (The outrigger Controls are cutout when the platform is raised.) 2a CiGiscas Figure 2.6. Outrigger Control Box B. Outrigger Operation-Extending The Outriggers 1. Push and hold each toggle switch to “DOWN” posi- tion, extending each of the four outriggers to the ground, Check the Bubble Level, Extend each outrigger just enough to level the machine. The Lift Disable Light should go out. Outrigger Operation Retracting The Outriggers 1, Fully lowerthe platform. 2. Pushandhold toggle switches to “UP” position until outriggers are fully retracted. D. During Operation c. 1. Check the level of the machine frequently during operation, lower platform and relevel when neces- sary.‘Table 2-2. Disable Light Operation FIXED AXLE MODELS PLATFORM LOWERED PLATFORM RAISED: Lifting R Driving R Lifting a Driving R e e e e Possible m Possible m Possible m Possible m MACHINE [ LEVEL YES: Yes YES YES: MACHINE NOT LEVEL NO 1 YES NO 21 NO 2 Remedies: 1, Reposition machine. 2. Lower platform. 25FT. & S2FT. ARTICULATING AXLE MODELS W/O OUTRIGGER OPTION PLATFORM LOWERED L PLATFORM RAISED MACHINES W/O Lifting R Driving R Lifting R Driving R LEVEL SENSOR e e e e Possible m Possible m Possible m Possible m AXLE LEVEL YES: YES 1 Yes: YES: AXLE NOT LEVEL (OROPPED) NO 1 YES NO 24 NO 2 Remedies: 1, Reposition machine to level axle. 2. Lower platform. PLATFORM LOWERED. PLATFORM RAISED MACHINE Wr Liting | A] Driving | A | biting | A | Driving | R LEVEL SENSOR e e e e Possible m Possible m Possible m Possible m MACHINE rag LEVEL YES YES YES YES LEVEL MACHINE 7 NOT LEVEL NO 2 YES" NO 32 NO | 3 re ee no | 1] yes no |32]| no |3 NOT LEVEL T— MACHINE 7 (OROPPED) NOT LEVEL NO 182 YES" NO 31,2) NO. 3 Remedies: 1, Reposition machine to level axle. 2, Reposition machine to level machi 3, Lower platform. Note: “Light will be on when not driving, but will go off when driving. 25‘Table 2-2. Disable Light Operation (Cont.) 25FT & 32FT. ARTICULATING AXLE MACHINE W/OUTRIGGER OPTION PLATFORM LOWERED | _ PLATFORM RAISED Lining | | Driving | A | Uiting | | Driving | A e e ° e Possible | m | Possible | m | Possible | m | Possible | m ‘OUTRIGGERS | AXLE | MACHINE i te | We | Yes ves yes ves MACHINE ; MACHINE | No | 1 | ves no |21] no |2| AXLE nor Lever | MACHINE | No | 1 | ves" no j21| no |2 (OROPPED) | MACHINE : neve, | NO ves no [2] no fa] Remedies: *. Reposition machine or use outriggers to level machine 2. Lower platform. Note: “Light wil be on when not driving, but will go off when drive is engaged PLATFORM LOWERED PLATFORM RAISED | iting | R | Oriving | A| Liking | A | Driving | A ° e ° ° Possible | m | Possible | m | Possible | m_| Possible | m OUTRIGGERS | AXLE | MACHINE an te | Mier | YES vesy |3 | yes yesr |23 MACHINE 7 MACHINE | No | 1 | ese [3 | NO [21] NO [20 AXLE nor tever | MACHINE | ves vesr; | 3| Yes No 23 (DROPPED) iE MACHINE e wmcrine | wo [1 | ves | 3] no j2t] no |20 Remedies: “1 leposition machine of use outriggers to level machine. 2. Lower platform. 3. Retract outriggers. Notes: *Light will be on when not driving, but will go off when drive is engaged. sBrive wheels can spin, but drive operation not recommended. 26‘Table 2-2. Disable Light Operation (Cont.) 40FT MODEL PLATFORM LOWERED PLATFORM RAISED Liting | R | Driving | A| biting | R | Oriving | A e e e e Possible | m | Possible | m | Possibie | m | Possibie | m | OUTRIGGERS | AXLE | MACHINE UP LEVEL uever_| YES Mod e elie MACHINE A a eNO) ||| VES! No |21] xo | 2 AXLE nor Lever | MACHINE | No [1] vest no |21| no | 2} (OROPPED) MACHINE 7 | eee | NO | 1 | Yes wo 21] no | 2| Remedies: 1. Reposition machine or use outriggers to level machine. 2. Lower platform. Notes: “Light will be on when not driving, but will go off when driving. @YES it platform height is below 25 tt, NO If platform height is above 25 f. PLATFORM LOWERED: PLATFORM RAISED Lifting | A | Driving | A | Lifting | A | Driving | A e e e ° Possible | m | Possible | m | Possible | m | Possible | m OUTRIGGERS | AXLE | MACHINE race Rue | MINE | ves yess | 3 | ves @r |23 MACHINE : WMACHINE | Wo | 1 | ves | 3] No |21] no |2a AXLE nor Lever | MACHINE | ves yesr; | 3 | YES No 23 (OROPPED) MACHINE a pMACHINE,| wo | 1] veser | 3] No [21] NO |20 Remedies: 1. Reposition machine or use outriggers to level machine. 2, Lower plattorm. Notes: ‘Drive wheels can spin, but drive operation not recommended. “Light will be on when not driving, but will go off when drive is engaged. @YES if plattorm height is below 25 ff., NO if plattorm height is above 25 ftAcauTion 6. Do not operate any control betore reading and completely understanding the preceding Operating Controls section of this manual. 7 SET-UP PROCEDURE ‘The following steps are normally required for equipment ‘being put into service for the first time. 1. Remove all packing materials and inspect for damage incurred in transit. 2. Inspect work platform thoroughly and remove any foreign objects. 3. Place the railings and step around the work platform as shown in Figure 2-7 and install in the sockets. Secure tightly with hardware provided. NOTE Railing installation is much easier with two men. 10. Figure 2-7. Railing Installation ‘4. Uniatch and swing-up fuel side tray cover. Support the cover with the cover brace. 5. Remove carton containing entrance chain. Install chain to rear railing. 28 Remove and install the operator’s control console to the right-hand railing, securing to mounting tab with bolt and washer provided. Connect the console plug to the scissors control cable plug. FF the fuel tank with proper fuel. (See decal on fuel tank) DIESEL ONLY EXPLOSIVE FUMES! NO SMOKING OR OPEN FLAMES! USE EXTREME CAUTION WHEN REFUELING TANKS. WIPE UP ANY SPILLED FUEL Unlatch and swing-up hydraulic/electric side tray ‘cover. Support the cover with the cover brace. Check fluid tevel in hydraulic reservoir. Fluid should appear at level indicated on decal. If filing is neces- ‘sary use 10W40 hydraulic fluid with a viscosity of 320 @ 100°F and pour point of -35°F) NOTE Work plattorm must be fully lowered when ‘checking hydraulic fluid level. ‘Check the battery fluid level in the battery. it all plates are not covered, add distiled or de-mineral- ‘zed water only. warning EXPLOSION HAZARD Keep flames and sparks away. Do not smoke near batteries FIRST AID Immediatiey flush eyes with cold water if electrolytic acid is splattered into them. Seek ‘medical attention if discomfort continues. Open the free-wheeling valve. (Rotate valve handle counter-clockwise to fully opened position.) (Figue 2-8.) NOTE Freewheeling valve must be fully opened to avoid damaging the wheel motors.13. Release the parking brake (see Operating Controls section of this manual for proper procedure). and manually move the work platform to a level area for testing FREEWHEELING VALVE Figure 2.8. Free-Wheeling Valve AccauTion ‘Adequate overhead space must be available for full extension of the scissor mechanism. ELECTROCUTION HAZARD THis MACHINE 1S NOT INSULATED MAINTAIN SAFE CLEARANCES 10 las te sun wns YOU MUST ‘RCLOW Forum 1a et DEATH om SERIOUS IURY mas 14, Close the free-wheeling valve. (Rotate valve handle clockwise to fully closed position.) (Figure 2-8.) 15, Glose and latch both tray covers. 29 Using The Base Controls: 16, Remove key from Operating Manual Compartment and insert into Main Power Key Switch. Rotate to “ON'" position. NOTE Make sure Emergency Stop Switch is in the “ON” position. 17. Select “BASE” on Platform/Base Control Select Switch. 48. Push down and hold Glow Plug Switch for recom- mended time (Refer to Table 2-1.) Use Engine Start Switch to start the engine. (If en- gine fails to start, refer to TROUBLESHOOTING section in this manual.) 19. NOTE No personnel or materials are to be on platform during work platform testing, 20. With the Platform Up/Down Switch, raise platform until open height in scissors is approximately 28 inches. 24 22, ‘Swing up safety bar(s). (See decal on scissor arms) Lower the platform with the Platform Up/Down Switch until the scissors mechanism is completely supported on the safety bar. 23. Inspect all hoses, fitings, wires, valves, etc. for leaks, looseness, hidden damage, and foreign mat- ter. 24, Use the Platform Up/Down Switch to raise platform until open height in scissors is approximately 28 inches. 25. 26. ‘Swing down safety bar(s) to storage position. Again, use the Platform Up/Down Switch to raise platform to full height. NOTE Refer to Table 1-1., Specifications for proper raise and lowering speeds. 27. Use the Platform Up/Down Switch to fully tower platform. 28. The 5000 Series Work Platform is now ready for use by a qualified operator who has read and complete- ly understands ALL of Section 2, OPERATION in this manualOPERATING PROCEDURES Prestart Checks 1. Carefully read and completely understand all of Section 2, in this manual and all warning and in- struction decals on the work platform. Check for any obstacles around the work platform and in the path of travel such as holes, drop otts, debris, ditches, sof fill, etc 3. Check overhead clearance. (See ee INSPECT AND/OR TEST THE FOLLOWING PYAR Vea TOI aoa Start And Operation Using The Base Controls: 1. Turn Main Power Key Switch to “ON” position. (Figure 1-3) NOTE Make sure Emergency Stop Switch is in “ON” position, 2. Push down and hold Glow Plug Switch for recom: ‘mended time. (Refer to Table 2-1.) NOTE Fuel preheating is recommended for first daily operation and as required thereatter. 2:10 10. Push Engine Start toggle switch down. Hold until engine starts, then release. (Figure 1-3.) (If engine fails to start, refer to TROUBLESHOOTING section in this manual.) Select “PLATFORM” on Base/Plattorm Control Select Switch. (Figure 1-3.) 5. Enter work platform at rear. Close gate or hook entry chain. Using The Platform Controts: 6. TO RAISE PLATFORM: Select "LIFT" on LiftDrive Select Switch Lift lock ring on selector handle and push handle forward. To stop at desired height, release selector handle. (Figure 1-7.) TO LOWER PLATFORM: Select "LIFT" on LifvDrive Select Switch. Lift lock ring on selector handle and pull handle backward. To stop at desired height, release selector handle. (Figure 1-7.) TO STEER: Press rocker on top of selector handle in direction you wish to steer. (Figure 1-7.) TO TRAVEL FORWARD: Select “DRIVE” on Lift/Drive Select Switch. Select “SPEED” or TORQUE” with Speed/Torque Select Switch. Lift lock ring on selector handle and push handle for ward, To stop, release handle. (Figure 1-7.) TO TRAVEL IN REVERSE: Select “DRIVE” on LittDrive Select Switch. Select “SPEED” or "TORQUE" with Speed/Torque Select Switch. Lift lock ring on selector handle and pull handle back ward, To stop, release handle. (Figure 1-7.) ‘Shutdown Procedure 1. Completely lower the work platform. 2. Turn Main Power Key Switch to “OFF” positon. (Figure 1-3.) 3. Remove key from Main Power Key Switch.SECTION 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS ‘TABLE OF CONTENTS ELECTRICAL SYSTEM LADDER DIAGRAMS Fixed Axle Machines w/2 Speed Control and Lombardini Diesel Engine 25Ft &S2Ft. Ataling Poe Machine w2 Spend Conta ané Lombardi Diesel Eine Articulating Axle Machines w/All Options and Kubota Diese! Engine 5 CIRCUIT BOARD IDENTIFICATION ........ OUTRIGGER MODULE CIRCUIT IDENTIFICATION HYDRAULIC SYSTEM OUTRIGGER MANIFOLD IDENTIFICATION . MANIFOLD SUB-ASSEMBLY IDENTIFICATION SCHEMATIC . 33 a4 37 39 310 1 ont 343 atELECTRICAL DIAGRAM PARTS LIST (Fixed Axle Machines W/Two Speed Control and Lomberdini Diese! Engine) Ret No. Bt D1 be 03 De D9 DOA Dio D10a om O16 p17 D19 025 25a D109 D109 D126 D203 D224 Date Dat2a D1224 012244 HI 2H6 2H-7 2H 2HA12 2H512-1 2H5122 2H51203, 2H512A4 aH 4H-2 4H8 4H 4H-10 aut Part No. 479596 417346 417346 417346 417346 417346 417346 417348 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 6229-6 56408-6 56408-6 564086 56408-6 564096 564096 56409-6 564096 42103-8 42103-6 421036 421036 421036 421036 Description BATTERY, 12 Volt 50 AIH DIODE, 6 Amp 1000 PIV DIODE: 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE: 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV HORN, Audible ala COIL, 1st Speed COIL, 2nd Speed COIL, Down COIL, Reliet/selector COIL! Drive COIL, Drive COIL! Drive COIL Drive COIL, Lett steer COIL, Right steer COIL, Forward COIL, Up COIL, Reverse COIL; Down * Reter to engine parts manual Ret No, uw Rt Ra Ra Re R7 Re st 82 83 S4 85 86 si2 S15 S15A $103 112 S118 $120 S212 $213 ‘$2240 $312 S424 S424 S724 1512 Part No. 614966 562326 562326 962326 56232-6 562326 231176 485706 485706 485756 465756 465756 458486 475366 413136 475986 48677-6 56227-6 56368-6 563676 417316 4682-6 477556 239926 562216 239926 Description LIGHT, Indicator, low engine oil RELAY, 12 Volt, hilo throttle RELAY, 12 Volt, series parallel drive RELAY, 12 Volt, lowered Platform functions RELAY, 12 Volt, engine shutott RELAY, 12 Volt, raised platform drive speed RELAY, Starter (Switch) SWITCH, Controller, left steer SWITCH, Controller, right steer SWITCH, Controller, power ‘SWITCH, Controller, directional NOTUSED SWITCH, Controller, high speed SWITCH, Oniotl key SWITCH, Engine start (Base) ‘SWITCH, Engine start (Plattorm) ‘SWITCH, Lowered plattorm limit (Reed) SWITCH, Emergency stop (Base) SWITCH, Series parallel (Speediorque) ‘SWITCH, Circuit breaker, 15 amp SWITCH, Circuit breaker, Bamp SWITCH, Engine oil pressure SWITCH, Platform upidown (Base) SWITCH, Emergency stop (Plattorm) ‘SWITCH, Vacuum SWITCH, Fuel select SWITCH, Lifvdrive select SWITCH, Plattormibase selectELECTRICAL LADDER DIAGRAM — Fixed Axle Machines wi2 Speed Control and Lombardini Diesel Engine POSITIVE NOTE: FOR ALL OPTIONS AND/OR KUBOTA DIESEL ENGINE, SEE FIGURE 3:3 a] Jae ne Bibi 7 7 " a | = ba [ae a b EE ap py ° sae | NEGATIVE 33 Figure 3-1, Electrical Ladder DiagramELECTRICAL LADDER DIAGRAM — 25 Ft. & 32 Ft. Articulating Axle machines w/2 Speed Control and Lombardini Diese! Engine & 2 é 8 3 § a 25 3 32 a 2u a ae 3 sy g ES ihe : 3 85 in ithe ® & 2a 26 34 : al zkl4 a] ta ome le ie = ' : toa ele g ay4,|= aELECTRICAL DIAGRAM PARTS LIST (25 Ft. & 32 Ft. Articulating Axle Machines W/Two Speed Control and Lombardini Diesel Engine) Ret No. BI oD: 02 D3 08 Ds DOA p10 DI0A D1 16 017 19 025 D25A D109 D109 D124 0203 D224 Date Da12a Di224 12244, HI 2H6 2H7 2H 2H-412 2H5124 2H5122 2H512A3 2HS12A4 aH} a2 as 4H9 4H-10 4H Part No. 479596 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 417346 4173466 417346 417346 417346 417346 417346 417346 417346 417346 417346 56229-6 564086 564086 564086 564086 564096 564096 564096 564096 421036 42103-6 421036 421036 42103-6 42103-6 Description BATTERY, 12 Volt 50 AH DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PiV DIODE, 6 Amp 1000 PIV DIODE! 6 Amp 1000 PIV DIODE! 6 Amp 1000 PIV DIODE! 6 Amp 1000 PIV DIODE: 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE. 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE! 6 Amp 1000 PIV DIODE. 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV DIODE, 6 Amp 1000 PIV HORN, Audible alarm COIL, 1st Speed COIL, 2nd Speed COIL! Down COIL’ Reliet/selector COIL! Drive COIL! Drive COIL; Drive COIL, Drive COIL, Left steer COIL! Right steer COIL, Forward COIL Up COIL! Reverse COIL; Down * Refer to engine parts marwal Ref No. u 35 Part No. 614966 614966 614966 562326 562326 562326 562326 562326 562326 562326 231176 485706 485706 465756 465756 46575-6 45848-6 475366 413136 475986 486776 862276 56368-6 563676 417316 496826 477556 239926 562216 614286 239926 Description LIGHT, Indicator, raised platform drive disable LIGHT, Indicator. lit disable LIGHT, Indicator, low engine oil RELAY, 12 Volt, hilfo throttle RELAY. 12 Volt, series parallel drive RELAY, 12 Volt, lowered platform functions RELAY, 12 Volt, drive cut-out RELAY. 12 Volt, lft cut-out RELAY, 12 Volt, engine shutoff RELAY, 12 Volt, raised platform drive RELAY, Starter (Switch) SWITCH, Controller, left steer SWITCH, Controller, right steer SWITCH, Controller, power SWITCH, Controller, directional NOT USED SWITCH, Controller, high speed SWITCH, On/otl key SWITCH, Engine start (Base) SWITCH, Engine start (Platform) SWITCH, Lowered platform limit (Reed) SWITCH, Emergency stop (Base) SWITCH, Series parallel (Speeditorque) SWITCH, Circut breaker, 15 amp SWITCH, Circuit breaker, 8 amp SWITCH, Engine oi! pressure SWITCH, Platform upidown (Base) SWITCH, Emergency stop (Platform) SWITCH, Vacuum SWITCH, Fuel solect SWITCH, Lifvdrive select SWITCH’ Articulating axle limit SWITCH, Platform/base selectELECTRICAL DIAGRAM PARTS LIST {Articulating Axle Machines W/All Options and Kubota Diesel Engine) Ref No. Part No. Description Ref No. Part No. Description: Bt 47959-6 BATTERY, 12 Volt 50 AH AI 56232-6 RELAY, 12 Volt, hi/lo throttle o1 41734-6 DIODE, 6 Amp 1000 PIV R2 §6232-6 RELAY, 12 Volt, series parallel By 1738 BIOBE, 6 Amp 1000 PIV are B 4N73e6 BIGDE. 6 amp 1000 PIV Ra ———56282-8 FELAY, 12 Vol, lowered Bs Aif3es DIODE. 6 amp 1000 PIV platform functions be «417348 DIODE, 6 Amp 1000 PIV Re $6232 RELAY" T2 Volt cive cutout D9A 417346 DIODE, 6 Amp 1000 PIV RS 562326 RELAY, 12 Volt, lift cut-out B85 «17846 DIODE, 8 Amp 1000 PIV Ae 862308 AELAY 12 \oll engine shutott DI0A 41734-6 DIODE. 6 Amp 1000 PIV RT 56232-6 RELAY, 12 Volt, raised platform Bie {7348 DIODE: 6 Amp 1000 PV ive speed Bis 417846 BIODE, 6 Amp 1000 PIV Re «231176 AELAY Starter (Saiten) OtS ifaes DIODE 6 Amp 1000 PV Bo Beasaie RELAY Teo oumnager O17 41734-6 DIODE. 6 Amp 1000 PIV si 465706 SWITCH. Controller, lett steer 019 417346 DIODE, 6 Amp 1000 PIV S2 465706 SWITCH. Controller. ight steer 025 41734-6 DIODE, 6 Amp 1000 PIV $3 46575-6 SWITCH, Controller, power 025A 417346 DIODE. 6 Amp 1000 PIV S4 46575-6 SWITCH, Controller. directional Bio tee DIGDE, Samp 1000 PIV Se eS STG nt key D109A 41734-6 DIODE, 6 Amp 1000 PIV S15 47536-6 SWITCH, Engine start (Base) Di24 41734-6 DIODE. 6 Amp 1000 PIV ‘S15A 41313-6 SWITCH, Engine start Bis 17386 BIODE, 6 Amp 1000 PIV me 0224 417346 DIODE, 6 Amp 1000 PIV $103 47598-6 SWITCH, Lowered platform D412 41734-6 DIODE. 6 Amp 1000 PIV limit (Reed) 4124 417346 DIODE. 6 Amp 1000 PIV $112 48677-6 SWITCH, Emergency stop 0612 41734-6 DIODE, 6 Amp 1000 PIV (Base) O712 417346 DIODE, 6 Amp 1000 PIV S118 56227-6 SWITCH, Series parallel De12 41734-6 DIODE, 6 Amp 1000 PIV (Speeditorque) D912 41734-6 DIODE, 6 Amp 1000 PIV $120 56368-6 SWITCH. Circuil breaker, 1012 41734-6 DIODE, 6 Amp 1000 PIV 15 amp, D1n12 41734-6 DIODE, 6 Amp 1000 PIV. $124 56373-6 SWITCH, Alternator select 1212 41734-6 DIODE, 6 Amp 1000 PIV $212 6367-6 SWITCH, Circuit breaker, Bias 417348 BIODE, 6 Amp 1000 PIV yl Dizeaa 41734-8 DIODE.6 Amp 1000 PIV $212A 41731-8 SWITCH, Outrigger conto, Bisa. 17348 DIODE’ 6 Amp 1000 PIV Wight rear Ht $6229.68 HORN, Aucbie alarm 52128 417916 SCH. Ounger contol, ropotticn: left rear aie Sees et le S220 417818 SWITCH, Ounger conta H-17 864086 COIL. Alternator ron Br:10a 605608 COIL, Oulngger pilot vent S220 417818 SWITCH: Outrgger conta : I" Reliet/solect Fight front Bee Sete CO ine sav9 + SUCH Engine ot BNgI22, $6008 COL. Dive sean 17318 SHEA rte acown . 564096 COIL, Drive ase) BS GSiog6 COIL’ Leh steer sare deans SWIGH, Emergeney to ‘ SOIL, Right steer ator S42 421088 GOL. i ste eee a. oo $831 Gyrase SWITCH. Vacuum aHe 421036 CO Ue Bin 24ge88 SWITCH, Fuel select ae S218 28551.8 | SWITCH! Litre select "I wutriager, 1 rai $1024 61428-6 SWITCH. Articulating axle limit Hole 421035 CON. Ourager nanromr tage Sih24S7a0z8 SWifcH Dive cutout ime 4H-812, 42103-6 ©. 1L. Outrigger, left rear raise (40'only) sete eee Goll Gumager tet wear tower $1924 615026 SWITCH, Oulrigger pressure, Stesotg 42105 COIL, Ounager. let front raise 7 “ight ear 4Hini2 421036 COIL’ Outrigger, let tront lower $1424 615036 SWITCH, ‘Outrigger pressure, AHazi2 421036 COIL, Quingger. ight front raise ft rear eee eee COIL, Guieger ngntiront wr $1512 29092-6 SWITCH, Platformfbase u 61496-6 LIGHT, indicator. raised $1524 61503. SWITCH. Outrigger pressure, attorm stive disable WITCH. we 614966 LiGHT Inoecator If disable $1624 615036 SWITCH, Outrigger pressure, 3 614966 LIGHT Indicator, tow engine oft sant ent * Refer to engine parts manus! 36ELECTRICAL LADDER DIAGRAM — Articulating Axle Machines w/All Options and Kubota Diesel Engine POSITIVE NOTE! FOR 2 SPEED CONTROL, AND/OR LOMBAROINI OIESEL ENGINE, SEE FIGURE 8-2. B4 rye E is Wee | gh | wae | oe ze | re fost feet lee | | Jere | fet | fests | foe i Ca ee vend “ee Te = Silt [tfhaat hs Mac TET FE : = NEGATIVE a7 Figure 3-3. Electrical Ladder Diagramfo} Ele 4 8 a8 oR o> (OER 25 Se 2g RPE Rea Sees ese ' ae eae oe ss pehssweeeer gels ‘ — er Poh pe $ee eeeeeeys ee eee ee ee LY PES eas Beg ele E ares eae E Os Os00s 0S O i B OL 1 =wy ‘&- AS o & ns RS RELAY CONNECTIONS Figure 3-5. Outrigger Module Circuit Identification 39anne ————a 2 aoe anew anor Zs ee 44.91% —__ oe ova ze at LLL) ovis ove ova cvz0 ovat -" i ovis var ova ovis Figure 3-7. Outrigger Manifold Identification 3-10Lae 2Hs122 DRIVE NC. VALVE DRIVE NC. VALVE Fos a FLOW DIVIDER valve ws 2ist2k4 4 WHEEL ORIVE ORIVE NO. VALVE a MANIFOLD cB. COUNTERBALANCE. eM nen VALVE 2HSI2A3 Sone NO valve RELIEF VALVE PROPORTIONAL oe F ane fe enordttionat a fF rea ee { aj MANIFOLD. 4 vs Pratt i CV THAU CV-6 e : oe utes aaa FREEWHEELIM NY ae NAIVE ee Figure 3-8. Hydraulic Manifold Assembly (4WD WeProportional Control) (Shown) attHYDRAULIC SCHEMATIC—ALL MODELS AND OPTIONS Ret No. AM cA thru ca C4 C5 ca cr C8 co thru CA2 ce cv thru cvs cv7 thru evo cvat thru cvs cv1g thru cue cves cv25 Fa FCA Fo2 FD4 FD2 on 02 0-3 thru Os 0-6 thru 0-9 Pa Rt R2 Part No. Description RefNo. Part No. Descriotion 605276 MOTOR, Alternator RS 452206 RELIEF VALVE, Steering va 620956 VALVE, Emergency lowering 561056 CYLINDER, Lift (3) ve 417036 VALVE, Brake metering (2 for 25 ft. models) vs 620958 VALVE, Free wheeling 603054 CYLINDER, Steer LH va 615946 VALVE, Forwardireverse 603054 CYLINDER, Steer F.H. shuttle 463904 GYLINDER, Brake vs 561946 VALVE, Unloading 608964 GYLINDER, Cushion WM-1 562076 WHEEL MOTOR, Drive, 57201-6 CYLINDER, Articulating axle 2WD (2), 4WD (4) 2HU 561946 VALVE, Unloading 561066 CYLINDER, Outrigger (4) 2Hs 561076 VALVE, Speed (low) 2H-7 561078 VALVE, Speed (high) 561146 VALVE, Counterbalance 2H-7P 56196. VALVE, Proportional (option) 211 §8107-6 _VALVE, Down 56117-6 VALVE, Check, lftfower (6) 2H-19 562136 VALVE, Steering priority 2H-412 861076 VALVE, Reliol/selector 2H-103 60551-8 _VALVE, Outrigger pilot vent 615026 VALVE, PO. check (4) 2H5121 561986 VALVE, NCC. drive 2H5122 561986 VALVE, NCC. drive 2HS12A3 561996 VALVE, NO. drive 6117-6 VALVE, Check, outrigger (8) 2H-S12A4 561996 VALVE, N.O. drive aH 479636 VALVE, Left steer (includes 442) 615026 VALVE, PO. check, outrigger (4) 4H-2 479636 VALVE, Right steer (includes 44-1) 562796 VALVE, Check, anti-syphon 4H8 479636 VALVE, Forward 56117-8 _VALVE, Check, pilot vent (includes 4H-10) 452108 FILTER, Oil return 4H9 479636 VALVE, Up (includes 4H-11) 451896 ELEMENT, filter 4H10 479636 VALVE, Reverse 561636 FLOW CONTROL, Steering (includes 44-8) priority 4H-11 479636 VALVE, Down (includes 41-9) 615336 FLOW CONTROL, Bleedotf «4H.612.-—47963.8 VALVE, Right rear outrigger, (40 ft. models only) down (includes 44-712) 561976 FLOW DIVIDER, Drive 4H-712 479636 VALVE, Right rear outrigger 561976 FLOW DIVIDER, Drive up (includes 44-612) (AWD only) 4H-812 479636 VALVE, Left rear outrigger, 571644 ORIFICE, .089 down (includes 44912) 570184 ORIFICE, .016 4H.912 479636 VALVE, Loft rear outrigger, up (includes 4-812) 561236 ORIFICE, .060 (3) 4H-1012 47963 VALVE, Left front outrigger, down (includes 4H-1112) 4H-1112 479636 VALVE, Loft front outrigger, 7420-4 ORIFICE, 094 (4) up (includes 4H-1012) 4H-1212 479636 VALVE, Right front outrigger, 562056 PUMP, Gear (Fenner Hyd.) down (includes 44-1312) 452206 RELIEF VALVE, System 4H-1912 47963-6 VALVE, right front outrigger, 452206 RELIEF VALVE, Lowered up (includes 4H-1212) platform lift HYDRAULIC PRESSURE SETTINGS (PS!) MODEL CAPACITY (LBS) | SYSTEM | LIFT] STEER SPL25.80 2000 2250 1550 | 1400 SPL25.842A 2000 2250 1860 | 1400 SPL25-84.48 2000 2250 1550 | 1400 SPL32.80 1500 2250 1350 | 1400 SPL32842A 1500 2250 1350 | 1400 SPL3284-4A 1500 2250 1950 | 1400 ‘SPL40-84-4A 1000 2250 | 1850 | 1400 342HYDRAULIC SCHEMATIC — ALL MODELS AND OPTIONS Figure 3-8. Hydraulic SchematicSECTION 4 MAINTENANCE AND TROUBLESHOOTING OPERATOR'S RESPONSIBILITY FOR MAINTENANCE Death or serious injury can result if the work platform is ot kept in good working order. Inspection and mi tenance should be performed by competent personnel who are familiar with mechanical procedures. An operat. ing, maintenance and parts manual has been provided in @ weather-proot plastic compartment attached to the work platform, ‘The operator should be assured that the work platform is being properly maintained before using it. The main- tenance portion of this manual, referred to above, in- ‘cludes information on lubrication, troubleshooting, and inspection points that must be performed daily, weekly and monthly. Even if the operator is not responsible for the main- tenance of this work plattorm, the operator should per- form the daily inspections found in the maintenance schedule. NOTE Replace all worn or damaged parts discovered uring inspection. at WARNING Do not reach through scissors mechanism un- less the safety bar is properly positioned. (See decal on the scissor arm.) MAINTENANCE SCHEDULE ‘The actual operating environment of the work platform governs the use of the maintenance schedule. The in- pection points on the maintenance schedule (Table 4-1.) indicates the areas of work platform to be checked and the intervals at which they should be checked. LUBRICATION Check with your local supplier for his recommended lubricant for local conditions. GENERAL MAINTENANCE HINTS * Before attempting any repair work, disconnect bat- tery ground negative (-) lead, ‘+ Properly position safety bar if the scissors ‘mechanism is raised. * Preventive maintenance is the easiest and least ex- pensive type of maintenance.HYDRAULIC SYSTEM AND COMPONENTS ‘The following points should be kept in mind when work ing on the hydraulic system or any hydraulic component: 1. Any structure hastimits of strength and durability. To prevent the failure of structural parts of hydraulic components, relief valves which limit pressure to sale operating values are included in the hydraulic, circuits, Tolerances of working parts in the hydraulic system are very close. Even small amounts of dirt or foreign material in the system can cause wear or damage to components, as well as general faulty operation ofthe system. Every precaution must be taken to as- sure absolute cleanliness of the hydraulic ol. ‘Samples of hydraulic oil should be drawn from the reservoir every six months. These samples should be about two quarts, and should be taken while the ‘lis warmed through normal operation. If possible, the sample should be analyzed by a qualified lubrication specialist to determine whether it is suitable for further use. The intervals between oil changes depend on operating conditions, and on the care used in keeping the oil clean. Whenever there is a hydraulic component failure ‘which gives reason to believe that there are metal particles or foreign materials in the system, drain and flush the entire system, and replace the fitter cartridges. A complete change of hydraulic oil must be made under these circumstances. Whenever the hydraulic system is drained, check the magnets in the hydraulic reservoir for metal par- ticles. If metal particles are present, flush the sys- tem and add a new change of oil. The presence of metal particles also may indicate the possibilty ot imminent component failure A very smal! amount of fine particles is normal Do not use synthetic or fre resistant ois in this work platform. A good grade 10W40 hydraulic oll with a viscocity of 320 sus @ 100°F and a pour point of— 35°F should be used All containers and funnels used in handling hydrau- lic oil must be absolutely clean, Use a funnel when 42 necessary for filing the hydraulic oll reservoir, and fil the reservoir only through the filler opening. The use of cloth to strain the oil should be avoided to prevent lint from getting into the system. ‘When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also plug the ports of the removed components. ‘All hydraulic components must be disassembled in spotlessly clean surroundings. During disassemb- |y, pay particular attention to the identification of parts to assure proper reassembly. Clean all metal parts in a clean mineral oil solvent. Be sure to thoroughly clean all internal passages. After the parts have been dried thoroughly lay them on a lean, lint-free surface for inspection. 10. Replace all o-rings and seals when overhauling any ‘component. Lubricate all parts with clean hydraulic oil before reassembly. Use small amounts of petroleum jelly to hold o- rings in place during assembly, Be sure to replace any lost hydraulic oll when com- pleting the installation of the repaired component, and bleed any air from the system when required. Allhydraulic connections must be kept tight. A loose connection in a pressure will permit the oil to leak ‘out oF air to be drawn into the system. Air in the sys- tem can cause damage to the components and noisy or erratic system operation. MAINTENANCE. Three simple maintenance proce- dures have the greatest etfect on hydraulic system per- formance, efficiency, and life. Yet, the very simplicity of them may be the reasons they are so often overlooked. What are they? Simply these: W 12. Change titers Maintaining a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the reservoir Kesping all connections tight, but not to the point of distortion, so that air is excluded from the system.Table 4-1. Maintenance Schedule Deity | Weekly | Monthly | 3-months | 6-months + _ Engine oil (11) ~ - _ 7 Engine APM (12) _ Fuel fiter (9) = 7 Mutter (23X13) [ eee _ "Ar cleaner (12) 5 Fuel tank cap (23) > __ _ Radiator water level (Kubota engine) (1) -_ Mechanical a _| Structural damage and welds (1) + | Parking brake (2) - za) Tires and wheels (12) i I “Guides, rollers and siides (1) + —| Eniry chains or gate (2) 5 t “Bolts and fasteners (3) + Safety bar (2) + Z Ru - Wihee! bras King pin & bros (1) [Steer ev pins (@) Ti rod pin (1) r a | Front axle u-boits (14) Electrical _ | Battery fluid level (1) . I 7 Control switches (1X2) Ez — | Cords and wiring (2) — ~ Batiery terminals (13) [ a _| Generator and receptacie (2) _ 7 Terminals and plugs (3) [ Hydraulic fluid lever (1) ae | Hydraulic leaks (1) [ Hyd titer cartridge (9) | | Proportional controis (2) o Notes: (1) Visualyinspect (2) Check operation 3) Check tghtoess (7) Check pation can tt max load if) Labia I9)_ Replace (10) S0e Table 1-1. Speciicavons (11) Check Mad ievel (32) eter to engine manual (03) Check nose leve {14} Torque ater month of aperabon, then every 6 months 43Table 4-2. Torque Specifications Directional Valve Mounting Screws: 40-83 Inbs. Parking Brake Cylinder Rod Nut: 30-25 Ftibs. Steering Cylinder Rod Nut: 30-35 Ftibs. Wheel Bolts: 64-70 Ft.lbs. Wheel Motor Mounting Bolts: 73-77 Fibs. ‘Wheel Motor Castle Nut: 350-400 Fibs. King Pin Bolts: 18-20 Ftibs. Front Axle U-bolts: 73-77 Ftibs. Fixed Rear Axle Mounting Bolts: 165-175 Fibs. TIP-OVER HAZARD PNEUMATIC AND CALCIUM CHLORIDE FILLED. ‘+ TIRES SHOULD HAVE PRESSURE CHECKED AND MAINTAINED DAILY. « ANY TIRE NEEDING REPLACEMENT MUST BE REPLACED WITH AN EQUIVALENT TIRE. ‘+ FILL MUST BE REPLACED AS REQUIRED. « REFER TO MAINTENANCE MANUAL FOR ‘SPECIFICATIONS. Table 4-3. Tire Specifications Tire Fill Specification Model Size Rating ‘Type Pressure ‘SPL25-80 & Soft Trac 23x 8.5 x 12NHS 4 ‘Solid Urethane 0 SPL32-80 “2K 8-48 ‘Super Terra Grip 26x 12x 12NHS | 4 Solid Urethane ("*) Models (Std.) -4A Models Xtra-Trac 31 x 15.5 x 1SNHS 8 Air (40-44psi) (Opt) (*) Solid urethane used for filling the tire must be 35-37 durometer installed at a pressure of 20-22 psi. (**) Solid urethane used for filing the tire must be 21-23 durometer installed at a pressure of 20-22 psi Table 4-4. Platform Capacities | apecity wo Piaform | Capacity w/Pattorm ‘SPL25-80 2000 Lbs. i 1750 Lbs. ‘SPL25-84-2A 2000 Lbs. 1750 Lbs. peed ea | sou ‘SPL32-80 1500 Lbs. | 1250 Lbs. Beem oe —T ‘SPL32-84-44 1500 Lbs. 1250 Lbs. a we | Ue * See Capacity Decal on work platform for extension capacities, 44TROUBLESHOOTING The following pages contain a Table of Troubleshooting information for locating and correcting most of the troubles which may develop. Careful inspection and ac- curate analysis of the symptoms listed in the Table of ‘Troubleshooting information will localize the trouble ‘more quickly than any other method. This manual can- ‘not cover all possible troubles and deficienciesthat may Occur, therefore, if a specific trouble is not covered herein, proceed to isolate the major component in which the trouble occurs and then isolate and correct the trouble. 1C. Dirty or loose battery terminals or | 16. ‘connector pins. 2. Circuitbreakers (S-120)or(S212) 2 tripped or detective. 3. Main Power On/Off Key Switch 3 (S-12) open or defective, | 4, Plattorm/BaseControlSelectSwitch | 4. (81512) in neutral position or ‘Switch is detective, Base Start Switch (S-15) detective. 6. Emerg. Stop Button (S-312)or | 6. Switch (S-112) open or detective. | 7. Platform Engine Start Pushbutton 7. (S-15A) detective, | 8. Engine ShutotfRelay(R-6) 8 defective. 9. Fuel Shut-off Solenoid(S212E) 8 | detective. 10, Start Relay (R-8) detective. 10. 11. Starter Solenoid detective. "1 12, Engine not drawing tuel. 12 13, Broken or loose #15 wire in 13. scissors control cable. (Engine will | Rot start from platform.) Troubleshooting Information ‘Trouble Probable Cause Remedy Electrical System . Engine Wit! Not_ | 1A. Battery disconnected. ~[414. Connect battery sen 1B. Battery not fully charged. | 1B. Check each cell with hydrometer; reading should be 1.275 (fully charged). Recharge if low reading, Replace if reading difference between coll is 0.050. Clean and/or tighten, Reset switch or replace if detective. Close switch or replace it no continuity reading. Select correct position, orreplaceit detective. ‘Check continuity thru switch, repla detective. Check continuity thru switch, replac detective ‘Check continuity thru switch, replace if defective ‘Check continuity thru switch, replace if defective. ‘Check coil continuity and solenoid operation if defective. Check relay operation, replace it detective. ‘Check coil continuity and solenoid operation, replace if detective. Check tor leaking fuel connection, clogged fuel line, no fuel in tank, vent ‘on tank closed, ‘Check continuity, replace if open. 45Troubleshooting intormation (Cont.) Trouble Probable Cause Remedy Electrical System (Cont.) Engine Will Not | 14. Hydraulic pump seized. 14. Replace pump. Start (cont.) 15. Improper engine or hydraulic ollfor | 15. Install correct oil per engine manual ‘cold weather operation. 16. Nofuel. 16. Check fuel level; add if necessary. 17. Clogged fitters. 17. Check fuel and air fiters; replace if necessary 48. Glow Plug Switch (S-26) detective. | 18. Check continuity thru switch, replace if detective. 49. Glow Plug Relay (R-10) detective. | 19. Check coll continuity and relay opers- tion 20. Glow Plug defective. 20. Check continuity across thread at end ‘of glow plug and engine body, ‘ohmmeter indicates "0", replace glow plug. KUBOTA ENGINE ONLY KUBOTA ENGINE ONLY 21. Engine Temperature Switch | 21. Allow engine to cool, check radiator (6-1013) in closed position. High coolant level. ‘Temperature Engine Shut-off Relay (P12) energized. 22. Engine Temperature Switch 22, Allow engine to cool, check continuity (G-1013) defective. ‘across switch. I switch remains closed, replace 23. Electric Fuel Pump not working. 23. Check wire £324 for continuity, replace if defective. Check coil con- tinuity, replace it detective, Check fue! pump output, should be 3,051 cu. in./minute) All Controts 1. Platiorm/BaseControtSelectSwitch | 1. Selectcorrect position, orreplacelt inoperative, (6-212) in neutral position, or detective, Engine Runs switch is defective, 2. PlatlormEmergency StopButton 2. Check continuity thru switch, replaceit (S-312A) open or defective detective 3. Broken or loose £312 pin in plug 3. Replacepin, detective. disconnect cable. 4. Detective #312 wireincontroteable. | 4. Check continuity between #3120" Base/Plattorm Control Select Switch (-212) and pin £312 of plug discon- | ect cable assembly. If no reading, replace wire. 8. Pump coupling detective 5. Replace coupling. 46Troubleshooting Information (Cont.) Trouble Probable Cause Remedy Electrical System (Cont.) Up Circult 1. Base Up/Down Switch(S-224A)or | 1. Check continuity thru switch, replace it inoperative Platform LittDrive Select Switch detective. {S-724) detective. 2. Diode (0-9) or(0-8-A) openor 2. Checkcontinuity thru diodes, replace it shorted, detective 3. Upsolenoid valve coil (4H-9) open 3. Check coil continuity, replace if detec- or shorted. tive. 4. LiftCut-outRelay(R-5) detective. 4. Check continuity thru relay, replace it detective. 5. Diode (0-9) open or shorted. 6. Check and repiaceif detective. 6. Broken orloose £107 wirein 6. Check continuity, replace if defective scissors contro! cable. 7. Controller defective. 7. Check continuity in switches, replace it detective. If proportional controller is furnished, check output; replace it detective. 8. Articulatingaxieonunievelground. | 8. Levelrearaxie. (See Note) 9A. Articulating Axle Cut-out Switch | 8A. Check switch, replace if defective. (S-1024) bad. 98. Articulating Axle Cut-out Switch 9B. Reposition machine. (See Note) {8-1024) not actuated. 40. Level Sensor (S-324) detective. (it | 10. Replace level sensor. equipped) 11. One or more pressure switches 411. Extend one or more outiggers so that (G-1924, $-1424, S-1524, S-1624) {ground pressure on outrigger pad is not actuated. (i equipped with sufficient to activate switch. (See Hydraulic Outrigger Option) Note) 12, Pressure switch open. 12. Replace pressure switch. NOTE ‘See Table 2-1 for conditions and remedies. Down Circutt +. Base Up/Down Switch (S-224-A)or | 1. Checkcontinuity thruswitch, replace it Inoperative Platform Litt/Drive Select Switch defective. (S-724) detective. 2. Broken orloose #11 wireinscissors | 2. Check continuity; replaceit open. control cable. 3. Down solenoid valve coil (4H-11) 3. Check coil continuity, replace it defec- (2H-11) open or shorted. tive. a7‘Troubleshooting Information (Cont.) ‘Trouble Probable Cause Remedy Electrical System (Cont.) Down Cireult 4. Controtier detective. ‘4. Check continuity in switches, replace if Inoperative defective. (cont) : Right Steering 1, Rightsteer switch (S-2) detective. 1, Check continuity thru switch, replace if inoperative defective, 2. Rightsolenoid valve coil (4H-2) open 2. Check coil continuity; replace if detec- or shorted. tive. 3. Diode (D-2)open or shorted. 3. Check continuity, replace it defective. 4. Broken or loose #2 wire in scissor 4. Check continuity, replace wire if control cable. detective. 5. Drive/SteerCut-out Relay(R-4) 5. Check continuity thru relay, replace if detective. detective. Left Steering 1. Leftsteer switch (S-1) detective. 4. Check continuity thru switch, replace if inoperative defective. 2. Leftsolenoid valve coil (4H-1)open 2. Check continuity, replace if detective. or shorted. 9. Diode (D-1)open or shorted. 3. Check continuity, replace if defective. 4. Broken or loose #1 wire in scissors 4, Check for continuity, replace wire if control cable. defective. 5. Drive/Steer Cut-out Relay (R-4) 5. Check continuity thru relay, replace it defective. detective. Forward 1. Controller defective. 4. Check continuity in switches, replace if Direction defective. If proportional controller is Inoperative furnished, check out; replace if detective. 2. Platform Litt/Drive Select Switch 2. Check continuity thru switch, replace if (6-724) detective. detective 3. Forward solencid valve coil (4H-8) 3. Check coil continuity, replace if detec- ‘open or shorted. tive. 4. Diode (D-8)shorted or open. 4. Check continuity, replace if detective. 5. Broken or loose #8 wire in scissors 5. Check for continuity, replace wire if control cable detective 6. Drive/Steer Cut-out Retay(R-4) 6. Check continuity thru relay, replace if detective detective 7. Proportional valve coil(2H-7P) 7. Check continuity thru coil, replace if defective. (if equipped) defective. . Articulatingaxleonunievelground. | 8. Levelrearaxle. (See Note) 9, Articulating Axle Cut-out Switch 9. Check switch, replaceit defect ($-1024) bad.Troubleshooting Information (Cont.) ‘Trouble Probable Cause Remedy Electrical System (Cont.) Forward 10. Articulating Axle Cut-out Switch 10. Lower platform (See Note) Direction (S-1024) not actuated. Inoperative (cont.) NOTE ‘See Table 2-1 for conditions and remedies Reverse 1. Controlter detective. 1. Check continuity in switches, replace if Direction detective. t proportional controller is inoperative furnished, check output; replace if defective, 2. Platform Li/Drive Select Switch 2. Check continuity thru switch, replace it (8-724) detective. defective, 3. Reverse solenoidvalvecoil(4H-10) | 3. Check coil continuity, replace if detec | open or shorted. tive. ‘4, Diode(D-10)shortedor open. 4. Check continuity. replace if detective. | 5. Broken orloose #10wirein scissors | 5. Check for continuity, replace wire it | control cable. | detective. 6. Drive/Steer Cut-out Relay(A-4) | 6. Check continuity thru relay, replaceit detective. detective. 7. Proportional valve coil(2H-7P) 7. Check continuity thru coil, replace if defective, (if equipped) | defective. 8. Articulatingaxleonunievelground. | 8. Levelrearaxle(See Note) 9. Articulating Axle Cut-outSwitch 9. Check switch, replace it detective. (S-1024) bad 10. Articulating Axle Cut-out Switch 10. Lower platform. (See Note) (S-1024) not actuated NOTE See Table 2-1 for conditions and remedies. Work Platform 1. RaisedPlattorm Drive/SpeedRelay | 1. Check continuity thrurelay, replaceit Drive Stow (P-7) defective. defective, Speed Only | 2. Diodes(D-BA)or(D-108) detective. | 2. Check diodes, replaceiit detective. Sterecreusccsr names |etcrer enema, detective. | detective 4, Broken orloose #118 wire in | 4. Check continuity, replace it detective. scissors control cable. | Outriggers 4. Platform not completely lowered. 41. Lower the platform. Inoperative 2. Outrigger Control Switch(S-212A, $-212B, $-212C, $-212D) detective 2. Check cor ity, replace if detective. 49Troubleshooting Information (Cont.) — Trouble Probable Cause Remedy Hydraulic System Outriggers Prossure Switch (S-1324, 51424, | 3. Check continuity, replace it detective. inoperative $-1524, §-1624) detective. (cont) Outrigger Relay(R-8) detective. | 4. Chock continuity thru relay. replace it detective . Lowered Platform Limit Switch 5. Check continuity thru switch, replace (6-103) detective if necessary . Diode Open 6. Check diode 0-612, 0-712, D-812, D812, 0.1012, D-1112, D-1212 or +1312. If detective replace. a Platform Drifts Down Valve 24-11 conteminatedor | 1. Clean valve and reinstall. It detective. Down detective. replace Emergency Lowering Valve 1 2. Close valve, or clean and reinstall ‘opened or contamineted. Electrical malfunction in 2H-11 and | 3. Referto electrical troubleshooting aH-tt circuit. “Down Gircut inoperative.” ‘All Systeme System contaminated. 1. Flush aystem and then replace new ol Siuggish . Defective System Relief Valve Rt. | 2. Check setting wth pressure gauge ‘should read 2250PS1. rl! valve tan'tbe adjusted, replace valve |. Wor Hydraulic Pump Pt 3. Repair or replace Unloading Valve 2H-U stuck open. | 4. Clean valve and reinstall. detective replace. . Proportional Valve 2H-7P not 5. Clean valve and reinstall, Replace i shifting all the way. defective ‘Workplatform Proportional Valve 2H-7P not TA. Giean vaive and reinstall. Replace it Drives Low shifting all the way. defective. ome 18. Electrical malfunction. See Electrical Troubleshooting Workplatform Drives, —, Low Speed Oniy .Unioading Valve 24-U stuck 2. Clean valve and reinstall. I detective, replace WD Valves 25121, 2H512-2, | 3A, Clean valves and reinstal. It detec- 2HS12-43, or 2H512-A-4 not twve, replace working, 3B. Electrical malfunction, Soe Electrical Troubleshooting "Work Platform Drives in Low Speed Oniy." FD-1 Flow Divider Valves 4. Clean valves and reinstal. It detective ‘malfunctioning. replace ‘|‘Trouble Probable Cause Hydraulic System (Cont.) Workplattorm 1. 2H-19 Steer Priority Valve not 4A. Electrical malfunction, see Electrical does not steer. shiting, Troubleshooting “Work Platform will not Steer.” 1B. Clean valve and reassembi. it detec- tive, replace. 2. Left Valve Spool 4H-1 or RightValve | 2. Depress manualoverrideonattected Spool 4H.2 sticking. valve. If workplattorm steers, clean valve and reassemble. I! defective replace 3. SteerRoliet Valve R-3stuckopen. | 3. Checkreliet pressure, shouldread 1500 PSI with unit steered full right or lef. reading is low adjust valve to 41500 PSI. I 1600 PSI can not be reached, replace valve. 4. LH.SteerCylinderC4 or RH Steer | 4. Replacepackingondetective cylinder. Gylinder C-5 packing bad. Workplattorm 1. Free Wheeling Valve V-3 opened. 1. Close valve. milinot Move in) 2. Unloading Valve2H-Ustuckopen, | 2. Cleanvalveandreinstall.tdetective Reverse replace Direction. 3. Proportional Valve 2H-7P not 3. Cleanvaiveandreinstal.tdetective shitting. replace 4, Forward Valve Spool 4H-8 or 4. Depress manual override on affected Reverse Spool 4H-10 sticking valve it workplattorm drives, clean valve and reassemble. if defective replace. 5. Electrical malfunction 5. RetertoElectrical Troubleshooting “"Workplatform will not Move in For- ward or Reverse Direction.” 6. Sories Parallel Vaives2H-512-1, 6. Cleanaffectedvalve and reassemble. 2H-512-2, 2H-512-A3, oF defective replace. 2H.512-A-4 not shifting. 7. Cushion CylinderC-7bypassing. 7. Check or leakage. Replace if defec- tive. 8. BrakeCylinderC-6notreleasing. | 8. Checkforleakage. Use caution when disassembling to repack. Cylinder is spring loaded. Refer to parts list Sec- tion 8 Workplatform 1. Electrical maitunetion 1. ReertoElectrical Troubleshooting Does Not Lift “Up Circuit Inoperative.” 2. UpValveH-@not shitting 2. Cleanvaiveand reassemble. Itdetec- tive replace. antTroubleshooting Information (Cont.) Trouble Probable Cause Remedy Hydraulic System (Cont.) Workplattorm ‘3. Down Valve 2H-11 not allowing oil 3. Checkvalve, if defective replace. Does Not Litt. thru. (cont.) _ - = Down Circult 1. Electrical malfunction 1, RelertoElectrical Troubleshooting inoperative “Down Circuit Inoperative.” 2. DownValve 4H-11 notshitting 2. Cleanvalveand reassemble. It defec- tive replace. 3. Down Valve 2H-11 not shifting, 3. Check valve, it defective replace. Outriggers 1. Electrical malfunction. 4, RetertoElectrical Troubleshooting inoperative ‘Outrigger Inoperative.” 2. Outrigger Valve 4H-612, 4H-712, AH-812, 4H-912, 44-1012, 4H-1112, 4H-1212 oF 4H-1312 not shitting. 3. Outrigger Pressure SwitchS-1324, §-1424, S-1524, and S-1624 not holding pressure. 2. Cleanattectedvaive, and reassemble If detective replace 3. Check pressure switch, itdetective replace. 412