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P.O. Box 1160St. Joseph, MO 64502-1160

Phone: (816) 364-0317Fax: (816) 390-9379

www.snorkelusa.comP/N 074446Sept. 1998

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1

GENERAL INFORMATIONThis manual contains procedures for locating and correcting the majority of problems which may

develop on the “Snorkelift” TB 42/50 Aerial Platform built after June 1997.

Since the majority of malfunctions experienced on equipment in the aerial platform Industry areassociated with the hydraulic and electrical systems, great effort has been made to develop a guidewhich insures that procedures regarding these areas are given the fullest possible attention and detail.As a result of these efforts, the aerial platform has been divided into twelve distinct groups with eachgroup covered by an individual section. The Sections are as follows:

1.) Engine Diagnostics 7.) Platform Rotation System Diagnostics2.) Hydraulic Pump Diagnostics 8.) Platform Leveling System Diagnostics3.) Steering System Diagnostics 9.) Boom Elevation System Diagnostics4.) Drive System Diagnostics 10.) Telescope System Diagnostics5.) Emergency Power System Diagnostics 11.) Fuel System Diagnostics6.) Swing System Diagnostics 12.) Accessories Diagnostics

NOTES, CAUTIONS AND DANGERSThe terms NOTE, CAUTION, and DANGER appear throughout this manual and have specific mean-ings.

A NOTE provides additional or special information to make a step or procedure easier orclearer. Disregarding a NOTE might cause inconvenience, but would not cause equipment damage orpersonal injury.

A is provided in a procedure wherever minor personal injury or equipmentdamage could result. Disregarding a CAUTION could cause damage to the machine; however seriouspersonal injury is unlikely.

is the most serious and emphasizes areas where personnel injury and evendeath could result from negligence. Permanent mechanical damage is also highly probable. DANGERsigns are to be taken seriously. In some cases, serious injury or death has resulted from disregarding

a DANGER.

NOTE: Engine maintenance and troubleshooting information not contained in this manual may be

found in the engine maintenance manual originally provided with the machine, or from the EngineManufacture/Dealer Network.

It should be recognized that every person who performs testing and diagnostic procedures and everyperson supervising any of these functions must be properly trained and qualified. If a problem shouldoccur which is not covered by this manual or which cannot be corrected using the listed correctiveactions, technically qualified guidance from the Service Department of Snorkel International Inc.,should be obtained prior to proceeding further. Tel: (816) 364-0317

NOTE: Diagnostic procedures basically consist of a logical process of elimination. For this reason,it is very important that the steps be performed in the order in which they are presented. Always beginby localizing the problem and defining the symptoms as accurately as possible. When the problem hasbeen localized, make sure to completely read and comprehend the appropriate flow chart. Do notattempt to make shortcuts.

2

MANUAL DESIGN

Each symptom described is followed by a list of inspections to be performed. Each inspection is in theform of a flowchart. A set of detailed checks are then performed at the component and/or relatedareas which confirm or decline the outcome. If the inspection is declined the flowchart will refer to thenext step to be performed until the problem is confirmed. The diagnosis then enables a determination.

Problem Go to PageInspect

Go to PageInspect

OK

Step 1

Step 2

Example: Problem Solving Procedure

Inspect

Troubleshoot(Identify Problem)

Replace orperform repair

If

Go to step

no

Yes

Example: Flowchart Procedure

EQUIPMENT NEEDED:Multimeter: A meter designed to read voltage, amperage and resistance.

Pressure Test Gauge: A pressure gauge rated for 0 - 1000 psi.

A pressure gauge rated for 0 - 5000 psi.

Tachometer: A meter designed to measure engine RPM on gas and/or diesel.

(Photo Tachometer is recommended)

Flowmeter: A meter designed to measure fluid flow.

Stopwatch: A tool designed to measure time.

3

SYMPTOM PAGE NUMBER

Section One - Engine DiagnosticsEngine starter fails to operate (No Electrical) 9

Starter disengages before engine starts 10

Engine cranks over but will not start 10

Engine starts then shuts down after 30 seconds 11

Engine will not accelerate 11

Engine over accelerates 12

Engine will not start from platform control 12

Engine starts while cranking, then dies when key switch is released 13

Section Two - Hydraulic DiagnosticsHydraulic system functions on emergency power only 39

Hydraulic pump stays on stroke 39

Hydraulic oil overheats while idling 39

Hydraulic oil overheats during operation 40

Hydraulic functions are sluggish 40

Hydraulic pump will not build pressure 40

Hydraulic pump will not build enough pressure 41

Flow from hydraulic pump is too low 41

Flow from hydraulic pump is too high (kills engine) 41

Section Three - Steering System DiagnosticsMachine will not steer 55

4

SYMPTOM PAGE NUMBER

Section Four - Drive System DiagnosticsDrive system is not operational with controller in either direction 63

No forward drive (Reverse OK) 64

No reverse drive (Forward Ok) 64

Drive high range not operating 65

Machine drives at full speed with platform raised and/or extended 65

Brakes will not release 65

Only one wheel turns (2 wheel drive) 66

One wheel turns faster than other (2 wheel drive) 66

Section Five - Emergency Power System DiagnosticsEmergency pump motor non-operational 87

No functions when on emergency power 87

Section Six - Swing System DiagnosticsSwings only in one direction 95

No response from swing when platform controls are activated 95

No response from swing when ground controls are activated 96

Swings erratically in either direction 96

Swings faster one way than other 96

Swing brake will not hold 97

Swings too slow 97

Section Seven - Platform Rotation System DiagnosticsPlatform rotate does not operate 113

Platform rotates too fast 113

Platform rotates too slow 113

Platform rotates itself 113

5

SYMPTOM PAGE NUMBER

Section Eight - Platform Leveling System DiagnosticsPlatform will not maintain level as boom raises or lowers 121

Platform will not maintain level with machine off 121

Platform bleeds down 121

Platform level will not work from ground control 121

Platform level will not work from platform control 122

Platform level up function is inoperative 122

Platform level down function is inoperative 122

Section Nine - Boom Elevation System DiagnosticsBoom raises but will not stay elevated 135

Boom will not raise from platform control 135

Boom will not raise from ground control 135

Boom raises slow from platform 135

Section Ten - Telescope System DiagnosticsBoom will not retract from ground control (Platform Control Ok) 143

Boom will not retract from platform control (Ground Control Ok) 143

Boom will not extend from ground control (Platform Control Ok) 143

Boom will not extend from platform control (Ground Control Ok) 144

Boom drifts in 144

Section Eleven - Fuel System DiagnosticsEngine will not start on gasoline, but will start on L.P. 157

Engine will not start on L.P., but will start on gasoline 157

6

SYMPTOM PAGE NUMBER

Section Twelve - Accessories DiagnosticsAC Generator will not function 165

AC Generator has low voltage 165

Machine will not steer 165

SECTION ONE:ENGINE DIAGNOSTICS

SECTION ONEENGINE DIAGNOSTICS

Troubleshooting Guide Flowchart 9 TB 42/50

InspectStarter Solenoid

InspectPower Cables and

Battery Disconnect Switch

InspectGround Contro l

Circui t Breaker (25 Amp)

InspectEmergency Stop Swi tch

InspectGround Master (Key) Swi tch

InspectEngine Starter Relay

InspectIgni t ion/Emergency

Power Swi tch

InspectGround/Plat formSelector Switch

InspectEngine Ant i -Restart Relay

Engine starterfails to operate(No Electrical)

Go to Page14

InspectBat tery and Cable Connect ions

Go to Page14

Go to Page15

Go to Page16

Go to Page16

Go to Page17

Go to Page17

Go to Page18

Go to Page18

Go to Page19

OK

OK

OK

OK

OK

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

Step 11

InspectAmmete r

Go to Page15

OKStep 3



Starterdisengages before

engine starts

Go to Page20

InspectEngine Ant i -Restart Relay

Engine cranksover but

will not start

Go to Page21

InspectGround Master (Key) Swi tch

Go to Page21

InspectGround/Plat form Selector Switch

Go to Page22

InspectIgni t ion/Emergency Power Swi tch

Go to Page22

InspectRun Relay

Go to Page23

InspectMurphy (Magnet ic) Swi tch

(Ford only)

Go to Page23

InspectMurphy (Magnet ic) Swi tch

(Deutz only)

OK

OK

OK

OK

Chart 2

Chart 3

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 1

Go to Page20


OKStep 2

Go to Page24

InspectRun Solenoid(Deutz only)

OKStep 7

OK



Engine startsthen shuts downafter 30 seconds

Go to Page25

InspectEngine Temperature Gauge

Go to Page25

InspectEngine Oi l Pressure Switch

Engine will notaccelerate

Go to Page26

InspectThrott le Circui t Breaker (15 Amp)

Go to Page26

InspectMedium Throt t le Relay

(Ford only)

Go to Page27

InspectHigh Thrott le Relay

(Ford only)

Go to Page27

InspectThrott le Governor or Control ler

(Ford only)

Go to Page28

InspectActuator

(Ford only)

OK

OK

OK

OK

OK

Chart 4

Chart 5

Step 1

Step 2

Step 1

Step 2

Step 3

Step 4

Step 5

Go to Page28

InspectThrott le Relay(Deutz only)

Go to Page29

InspectThrott le Solenoid

(Deutz only)

OK

Step 6

Step 7

OK



Chart 6

Engine overaccelerates

Go to Page30

Inspect Governor(Ford only)

Go to Page30

InspectActuator

(Ford only)

OK

Step 1

Step 2

Engine will notstart from

platform control

Go to Page31

InspectPlat form Control

Circui t Breaker (20 Amp)

Go to Page32

InspectEmergency Stop Swi tch

Go to Page32

InspectFoot Swi tch

Go to Page32

InspectPlat form Start Switch

OK

OK

OK

Chart 7

Go to Page31

InspectGround/Plat form Selector Switch

OK

Go to Page33

InspectIgni t ion/Emergency Power Swi tch

OK

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6



Engine starts whilecranking, then dieswhen key switch is

released

Go to Page34

InspectRun Solenoid

Step 1

Chart 8

Go to Page34

InspectRun Relay

OKStep 2

Go to Page35

InspectVacuum Swi tch

(Ford only)

OKStep 2



Engine starterfails to operate(No Electrical)

InspectPower Cables andBattery Disconnect

Switch

Using a meter set toread voltage, measure

voltage enteringBattery Disconnect SwitchShould read 12-12.7 volts

Battery DisconnectSwitch in Off

Posit ion

If 12-12.7V

Using a meter set toread voltage, turn

Battery Disconnect Switchto On posit ion, measure

voltage coming out ofBattery Disconnect SwitchShould read 12-12.7 voltsReset Battery

Disconnect Switchto On Posit ion

If

Repair or replaceBattery Disconnect Switch

and/orBattery Disconnect Switch

wiring

If low or no reading

Go to step 3

If12-12.7V

Then

InspectBatteries

Using a meterset to read

voltage, checkeach battery for

12 volts whileunder load

Recharge orreplace

battery(s)

Check batteryconnect ions

If loose

If low or no voltage

Clean allconnect ions

Tighten allconnect ions

Ifcorroded

If 12V

Step 1

Step 2

Batteries omit hydrogenand oxygen elements thatcan combine explosively.Do not smoke or permitopen f lames or sparkswhen checking batteries



Using a meter set to readvoltage, turn BatteryDisconnect Switch to

On posit ion,measure voltage enteringEmergency Stop SwitchShould read 10-12 volts

Step 3

Step 4Inspect

Ground ControlCircuit Breaker

(25 Amp)

Circuit breaker isopen


Check for voltage betweenCircuit Breaker and

Emergency Stop Switchon wire #1A

Should read 12 volts

Reset Circuitbreaker

Then

If

Repair or replaceCircuit Breaker

and/orCircuit Breaker wiring


Go to step 5

If10-12V

InspectAmmeter

Using a meter set to readvoltage, measure voltage

between1. Battery Disconnect

Switch and Ammeter (+)on wire # 57

2.Ammeter (-) and CircuitBreaker on wire #1A

Should read 12-12.7 volts



and/orCircuit Breaker wiring

Go to step 4

If12-12.7V



Step 5

Step 6Inspect

Ground Master(Key) Switch

Using a meter set to readvoltage, activate engine

starter and measurevoltage between Battery

post side of GroundMaster Switch and start

side of GroundMaster Switch.

Should read 12 voltsGo to step 7

Repair or replaceGround Master Switch

and/orGround Master Switch

wiring

If12V


InspectEmergency Stop

Switch

Using a meterset to read voltage, pullEmergency Stop Switch

out and measurevoltage between

Emergency Stop Switchand Battery side of

Ground Master(Key) Switch.

Should read 10-12 volts

Emergency StopSwitch is off(pushed in)

If low or no readingPul l Emergency

Stop Switch (out)to the On posit ion

If

ReplaceEmergency Stop Switch

and/orEmergency Stop Switch

wiringGo to step 6

If10-12V

Then



Step 7

Step 8Inspect

Ground/PlatformSelector Switch

Set Selector Switch toGround posit ion. Using ameter set to read voltage,

activate starter andmeasure voltage betweenIgnit ion/Emergency Power

Switch and Ground/Platform Selector SwitchShould read 10-12 volts

Ground/PlatformSelector Switch isin Platform posit ion

Return Ground/Platform SelectorSwitch to Ground

posit ion

Then

If

Go to step 9


ReplaceGround/Platform Selector

Switch and/orGround/Platform Selector

Switch wiring

If10-12V

InspectIgnit ion/Emergency

Power Switch

Using a meter set toread voltage, activate

engine starter andmeasure vol tage

betweenGround Master Switch andIgnit ion/Emergency Power

SwitchShould read 10-12 volts

Go to step 8 If10-12V


ReplaceIgnit ion/Emergency Power

Switch and/orIgnit ion/Emergency Power

Switch wiring



Step 9

Step 10Inspect

Engine StarterRelay


engine starter and measurevoltage from

1. wire #5B to StarterRelay.

2. wire from StarterRelay to Ground

Should read 10-12 voltsCheck ground

continuityIf

10-12V


ReplaceEngine Starter

Relay

No cont inui ty

ReplaceEngine Starter Relay wiring

Go to step 11

Continuity

Go to step 10

InspectEngine Anti-

Restart Relay



between Ground ControlSwitch and Anti-Restart

Relay on wire #5C.Should read 10-12 volts

Measure voltage atwire #5B.


ReplaceEngine Anti-

Restart Relay


Replacewiring to

Engine AntiRestart Relay

Check Adjustable Resistorbetween Terminal

164 and 164B,Adjust asneeded for starter to

engage.

If 10-12v

If lowor no

reading

If10-12v

If stilldoesnot

engage



Step 11




1. wire #5A to StarterSolenoid

2. Starter Solenoid toGround


continuityIf

10-12V


ReplaceStarter Solenoid

No cont inui ty


wiring

Return to step 1

Continui ty



Disconnect wire 164Bfrom Alternator. Check

continuity between postand alternator case.

InspectEngine Anti-

Restart Relay

Repair or replaceAlternator

Open field in alternator

No cont inui ty

Locate the adjustableresistor between terminals#164 and #164B, remove

the plastic covering.While activating the starter,

slowly slide adjuster untilcranking time is sufficient

for starting engine.Replace the plastic

covering.

Adjust resistor for longercranking t ime, unti l enginestarts and alarm shuts off.

(approx. 30 seconds)

Starterdisengagesbefore enginestarts

Step 1

Continuity




1. wire #5A to StarterSolenoid

2. Starter Solenoid toGround


continuityIf

10-12V



No cont inui ty


wiring

Return to step 1

Continui ty

Step 2



Step 1

InspectGround Master

(Key) Switch

Using a meter set to readvoltage, activate engine

starter and measurevoltage between Battery

post side of Ground MasterSwitch and ignit ion side of

Ground Master Switch.Should read 10-12 volts

Go to step 2

Repair or replaceGround Master Switch

and/orGround Master Switch

wiring

If10-12V

No reading

Check Battery

If reading is low

Engine cranksover butwill not start

Step 2Inspect


Set Selector Switch toGround posit ion. Using ameter set to read voltage,

activate starter andmeasure vol tage betweenIgnit ion/Emergency Power



is inPlatform posit ion

Return Ground/Platform SelectorSwitch to Ground

posit ion

Then

If

Go to step 3

No reading



Switch wiring

Check Battery

If reading is low

If10-12V



Step 3

Step 4

Inspect Ignition/

Emergency PowerSwitch

Go to step 4

ReplaceIgnition/

Emergency PowerSwitch and/or

Ignition/Emergency Power

Switch wiring

Check voltage on diodewire between Ignit ion/

Emergency Power Switchand Ground/Platform

Switch. Replace diode wireif faulty. Measure voltage

entering Run Relay(wire #4A)


Using a meter set toread voltage,

measure vol tageentering Ignition/

Emergency Power SwitchShould read 10-12 volts



If10-12V

InspectRun Relay


measure vol tage between Run Relay andMurphy Switch (B Post)

wire #164Should read 10-12 volts

Go to step 5(Ford)

Go to step 6(Deutz)

If10-12V




Switch wiring



Step 5

Step 6

InspectMurphy Magnetic

Switch( Ford only)


measure voltage on wire 1. at post NC of

Murphy Magnetic Switch2. on wire 80A betweenMurphy Magnetic Switch

and Governor Should read 10-12 volts

ReplaceMurphy Magnetic Switch

and/orMurphy Magnetic Switch

wiring


InspectMurphy Magnetic

Switch( Deutz only)


measure voltage on wire#8D at post NC of

Murphy Magnetic Switch Should read 10-12 volts

ReplaceMurphy Magnetic Switch

and/orMurphy Magnetic Switch

wiring




Step 7

InspectRun Solenoid( Deutz only)


measure voltage at wire#8D to Run Solenoid

Should read 10-12 voltsNote: Check continuity

to ground on whitejumper wire

ReplaceRun Solenoid




Step 1

Step 2

Engine startsthen shutsdown after 30seconds

InspectEngine

TemperatureGauge

Using a meter set toread ohms,

Check continuity on wirebetween Murphy Switch

(Black wire at S post) andChassis ground

Allow time for Engine tocool down

If resistance is shown

Then

ReplaceMurphy Engine

Temperature Gauge

Return to step 1

InspectEngine Oil

Pressure Switch

Engine oilpressure is due to

inadequate oil levelReplace

Engine Oil Pressure SwitchThen

If oil levelis adequate

Fill to proper levelwith oil

With the engine off,use a meter set to readohms, check continuitybetween wire #3C and

Ground wire at Engine OilPressure Switch

If

I f resistance is shownIf noresistanceis shown



Step 1

Step 2

Enginewill notaccelerate

InspectThrottle Circuit

Breaker (15 Amp)

Using meter set toread voltage,

measure vol tageFord: entering either

Medium Thrott le Relaywire #55A or

High Thrott le Relaywire #55B

Deutz: on wire #55Abetween Thrott le Relayand Thrott le Solenoid


Circuit breaker isopen


Check continuity on wire#55 between Thrott leCircuit Breaker and

Medium Thrott le Relay orHigh Thrott le Relay

Reset Circuitbreaker

Then

If


and/orCircuit Breaker

wiring

Go to step 2(Ford)

Go to step 6(Deutz)

Then

InspectMedium Thrott le

Relay(Ford only)


measure vol tageon wire #55A to

Throttle ControllerShould read 10-12 volts


Check continuity on wirebetween Medium Thrott le

Relay and Thrott leController

Repair or replacewiring from

Medium Thrott le Relayto Throttle Controller

Then

Go to step 3

If

If10-12V



Step 3

Step 4

InspectHigh Thrott le

Relay(Ford only)

Using meter set toread voltage,

measure vol tageon wire #55B to

Throttle ControllerShould read 10-12 volts


Check continuity on wirebetween High Thrott le

Relay and Thrott leController

Repair or replacewiring from

High Thrott le Relayto Throttle Controller

Then

Go to step 4

InspectElectronicGovernor

(Ford only)


measure vol tageon wire #55A and #55B

going into theElectronic Governor



Repair or replacewiring to

Electronic GovernorGo to step 5

If10-12V

If10-12V



Step 5

InspectActuator


measure voltage,on wire #A1

and #A2 between theElectronic Governor

and SolenoidShould read 10-12 volts


Repair or replaceElectronicGovernor

If10-12V

Repair or replace Electronic Governor

and/or wiring

Step 6

InspectThrottle Relay(Deutz only)


measure vol tageon wire #55A betweenThrottle Circuit Breakerand Thrott le Solenoid



Check continuity on wirebetween Thrott leCircuit Breaker

and Thrott le Solenoid

Repair or replacewiring between

Throttle Circuit Breakerand Thrott le Solenoid

If no continuity

Go to step 7

If10-12V



Step 7

Inspect Thrott le Solenoid

(Deutz)

Using meter set to readvoltage, measure voltage1. on wire #55A going

into Throttle Solenoid2. on wire #55A between

Thrott le Solenoid andground



Repair or replace Thrott le Solenoid

and/or Throttle Solenoid wiring

If problem sti l l exists

Adjust Thrott le Solenoid



Step 1

Step 2

Engine overaccelerates

InspectElectronicGovernor


measure voltage,on wire #55A and #55B

going into theElectronic Governor



Repair or replaceFord: wiring to

Electronic Governor


InspectActuator


measure vol tageon wire #A1

and #A2 between theElectronic Governor

and ActuatorShould read 10-12 volts


Repair or replaceElectronicGovernor

If10-12V

Repair or replaceElectronic Governor

and/or wiring



Circuit Breaker isopen

Step 1

Step 2

Engine will notstart fromplatform control

InspectPlatform ControlCircuit Breaker

(20 Amp)

Using a meter set to readvoltage, turn Ground/

Platform Switch to Platformposit ion, measure voltage

on wire #1 and #2entering Platform Control

Circuit BreakerShould read 10-12 volts

Check for voltage onwire #1B to Emergency

Stop SwitchShould read 10-12 volts

ResetCircuit Breaker

Then

If

Repair or replaceWire #1 and/or #2

Go to step 3

If10-12V

InspectGround/PlatformSelector Switch

Set Selector Switch toPlatform posit ion. Using ameter set to read voltage,

activate starter andmeasure vol tage betweenIgnit ion/Emergency Power


Ground/PlatformSelector Switch isin Ground posit ion

Return Ground/Platform SelectorSwitch to Platform

posit ion

Then

If





Switch wiring

ReplaceCircuit Breaker

If lowor no

reading

If lowor no

reading

If 10-12V



Step 3

Step 4Inspect

Foot Switch andWir ing

Make sure Foot Switch isnot activated

Deactivate Foot SwitchIfnot

act ivated

Using a meter set to readvoltage, measure voltage

on wire #10 going intoFoot Switch and

wire #8 coming outof Foot Switch

Should be 10-12 volts

If act ivated

InspectEmergency Stop

Switch

Using a meter set to readvoltage, pul l Emergency

Stop Switch out andmeasure vol tage betweenEmergency Stop Switch

and Battery side ofPlatform Master Switch.Should read 10-12 volts

Emergency StopSwitch is off(pushed in)

If low or no readingPul l Emergency

Stop Switch (out)to the on posit ion

Then

If

ReplaceEmergency Stop Switch

and/orEmergency Stop Switch

wiringGo to step 4 If

10-12V


Repair or replaceFoot Switch

and/or wiring

If10-12VGo to step 5



Step 5

InspectIgnit ion/Emergency

Power Switch



on wire #4 betweenPlatform Master Switchand Ignit ion/Emergency

Power SwitchShould read 10-12 volts

Return to step 1 If10-12V


ReplaceIgnit ion/Emergency Power

Switch and/orIgnit ion/Emergency Power

Switch wiring

Step 6

InspectPlatform Start

Switch


Platform Start Switch andmeasure voltage onwire #4C between

Platform Start Switch andPlatform Emergency Power




ReplacePlatform Start Switch

and/orPlatform Start Switch

wiring



Step 1

Engine startswhile cranking,then dies whenkey switch isreleased

InspectRun Relay


measure vol tageat Murphy Switch wire

#164, B post ofMurphy Switch



Repair or replaceRun Relay

and/orRun Relay wiring

Step 2


InspectRun Solenoid


measure vol tageon wire #8D between RunSolenoid Murphy SwitchShould read 10-12 voltsNote: Check continuity

to ground on whitejumper wire


ReplaceRun Solenoid

and/orRun Solenoid wir ing




InspectVacuum Switch

(Ford only)

Check continuity on wirebetween Ignit ion and

Solenoid when switch is innormally closed posit ion

If no continuity

ReplaceVacuum Switch

Step 3

SECTION TWO:HYDRAULIC DIAGNOSTICS

SECTION TWOHYDRAULICS DIAGNOSTICS


Hydraulic systemfunctions on

emergency poweronly

Go to Page42

InspectMain Hydraul ic Pump

Go to Page42

InspectSense L ine Dump Valve

Hydraulic pumpstays on stroke

Go to Page44

InspectCompensator Valve

Chart 1

Chart 2

OK

Step 1

Step 2

Step 1

Go to Page43

InspectBlocking Valve Relay and Wir ing

OKStep 3

Go to Page43

InspectBlocking Valve

OKStep 4

Hydraulic oiloverheats

while idling

Go to Page45


Chart 3

Step 1

Go to Page45

InspectSteer Level Valve

OKStep 2



Hydraulic oiloverheats

during operation

Go to Page46

InspectFunct ions Valve

Hydraulic functionsare sluggish

Go to Page47

InspectEng ine RPM

Go to Page47

InspectPump Pressure

Go to Page48

InspectAccumulator

Go to Page48

InspectF low f rom Pump

Chart 4

Chart 5

OK

OK

OK

Step 1

Step 2

Step 3

Step 4

Step 1

Hydraulic pump willnot build pressure

Go to Page49


Chart 6

Step 1



Flow fromhydraulic pump

is too low

Go to Page51

InspectHydrau l ic Pump Compensator

Flow fromhydraulic pump

is too high(kills engine)

Go to Page51

InspectFlow Adjustment on

Main Hydraul ic Pump

Chart 8

Chart 9

Step 1

Step 1

Hydraulic pumpwill not build

enough pressure

Go to Page50


Go to Page50

InspectSensel ine Dump Valve

Chart 7

OK

Step 1

Step 2



Inspect Main Hydraulic

Pump

Remove gaugeand

Go to step 2

CheckMain Hydraul ic Pump,

Pump Coupl ing andPump Compensator

Install 1000 psi pressuregauge to hydraul ic pumptest plug. Set engine for

idle and measuredifferential/standby

pressure.Should read 350 psi

If reading is abnormal

ReplaceMain Hydraul ic Pump

and/orPump Coupl ing

and/orPump Compensator

If malfunct ioning

Hydraulicsystemfunctions onemergencypower only

Step 1

Step 2

If350 psi

Inspect Sense Line Dump

Valve

Check seals onSense Line Dump

Valve

If10-12V

Repair or replaceSense Line Dump Valve

and/or wiring

Using a meter set to readvoltage, activate Ground

Control Switch andmeasure vol tage

1.on wire #28B betweenTerminal Stripin Junction Box andSense Line Dump Valve

2.on wire # 28B atSense Line Dump Valve




If bad

O k

Go to step 3



Step 3

Step 4


Relay and Wires

Go to step 4

Repair or replaceBlocking Valve Relay

and/orBlocking Valve Relay wiring

Using a meter set to readcontinuity , activate Steer

Micro-Switch andcheck for ground

1. on wire #100 betweenTerminal Strip inJunct ion Box andRelay

2. on wire #100 enteringRelay

If no continuity

Ifcontinuity


Return to step 1Repair or replace

Blocking Valve Cartr idge

Visually check BlockingValve Cartridge for

binding

Should normally be open.

If stuckIf

O k



Hydraulicpump stays onstroke

Step 1

InspectCompensator

Valve


Valve

Ifgoes

offs t roke

Repair or replaceCompensator

Remove hose f romcompensator

Recheck pressure onPump

If stays on stroke

Repair or replaceSense Line Dump

Valve

If bad



Step 1

Step 2

Hydraulic oiloverheatswhile idling

InspectSteer Level Valve

Repair or replaceSteer Level Valve

Manually depressoverrides to center the

spools

If stuck


Go to step 2Repair or replace



binding


If stuckIf

O k

Machine function wil l bemoving when manualoverride is activated.



Hydraulic oiloverheatsduringoperation

Step 1

InspectFunctions Valve

Repair or replaceFunctions Valve

SwitchManual Overr idesto the On posit ion

Heat ing stops

Heat ingcont inues

Repair or replaceHosing



Step 1

Step 2

Hydraulicfunctions aresluggish

InspectEngine RPM

AdjustThrott le Actuator

Use a Tachometer tomeasure Engine RPM

Should read:Ford - 1050 RPM at Low 2100 RPM at Mid 2800 RPM at HighDeutz -1200 RPM at Low 2800 RPM at High

If not

Go to step 2 If correctR P M

InspectPump Pressure

AdjustPump Compensator

Install 1000 psipressure gauge at

Test Port.Set engine for idle

and measure standbypressure.

Should read 300 psi


Remove gaugeand

Go to step 3

If300 psi



Step 3

Step 4

InspectAccumulator

RechargeAccumulator

Measure the chargeon the Accumulator

Should be 750 to 800 psi


Go to step 4

If750 to 800 psi

InspectFlow from Pump

AdjustFlow Ajustment

With chassis raised(all wheels off the ground)and adequately supported,

1.Instal l a Flowmeter onthe discharge side ofpump.

2.Install a 1000 psipressure gauge at TestPort on Accumulator.Start engine and turnThrottle Switch to high.Activate drive functionfull on.

Flowmeter should read12 to14 gpm and

pressure gauge shouldread 300 psi


Remove gaugesand

Return to step 1

If12 to

14 gpmand

300 psi



Step 1

Step 2

Hydraulic pumpwill not buildpressure Inspect

CompensatorValve

Go to step 2

Remove hoses f romSense Line Dump Valveto Compensator Valve

and reattach toPressure Line. Using a

5000 psi pressure gaugecheck pressure.

Should read 2500 psi


Remove gauge andcheck seals on

Sense Line Dump Valve


If bad

If 2500 psi

InspectPump Coupl ing

Repair or replacePump Coupl ing

RemoveMain Hydraul ic Pump

visually checkPump Coupl ing

If bad

O k

Repair or replaceCompensator

and/orMain Hydraul ic Pump



Step 1

Step 2

Hydraulic pumpwill not buildenough pressure Inspect

CompensatorValve

Go to step 2

Remove hoses f romSense Line Dump Valveto Compensator Valve

and reattach toPressure Line. Using a

5000 psi pressure gaugecheck pressure

Should read 2500 psi


Remove gauge andcheck seals on

Sense Line Dump Valve


If bad

If 2500 psi

Inspect Sense Line Dump

Valve


Valve

If10-12V


wiring

Using meter set to readvoltage, activate Ground

Control Switch andmeasure vol tage

1. On wire #28B betweenTerminal Strip inJunction Box andSense Line Dump Valve

2. On wire # 28B atSense Line DumpValve




If bad



Step 1

Step 1

Inspect Hydraul ic Pump

Compensator

Adjust Differential/StandbyAdjustment on Pump

compensator to 300 psi

Install 1000 psi pressuregauge to actuator test plug.

Set engine for idle andmeasure differential/

standby pressure.Should read 300 psi

If reading is to low

ReplacePump Compensator

and/orPump Coupl ing

Wil l not adjust or errat ic

Flow fromhydraulicpump istoo low

Flow fromhydraulicpump istoo high(kills engine)

InspectFlow Adjustment

on Main HydraulicPump

Visually check FlowAdjustment Screw on Main

Hydraul ic PumpScrew should extend

between 3/4" and 7/8" from face of pump

ResetFlow Adjustment on Main

Hydraul ic Pump

SECTION THREE:STEERING SYSTEM DIAGNOSTICS

SECTION THREESTEERING SYSTEM DIAGNOSTICS


Machine will notsteer

Go to Page56

InspectMicro-Switch for Blocking Valve

(at steer control ler)

Go to Page56

InspectBlocking Valve Solenoid and

Solenoid Wir ing

Go to Page57

InspectSteer Micro Switch (Right)

Go to Page58

InspectSteer Micro Switch (Left)

Go to Page58

InspectSteer Control Valve

Go to Page59

InspectCenter Post

OK

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 4

Step 5

Step 6

Step 7

Go to Page57


OKStep 3

Go to Page59

InspectTow Package Float Valve

OKStep 8



InspectMicro-Switch forBlocking Valve

(at steer controller)

Go to step 2 Ifcontinuity

ReplaceSteer Micro Switch

and/orSteer Micro Switch wiring

Using a meter set to readcontinuity, activate SteerMicro-Switch and check

for ground1. on wire #100 between

Steer Micro-Switch andJunction Box

2. at wire #100 inJunct ion Box

Should show continuity toground

If no continuity

Machine willnot steer

Step 1

Step 2

Note:At this point the manualoverride may also beuse to isolatethe solenoid, howeveruse caution as themachine wil l be moving.


Relay and Wires

Go to step 3

Repair or replaceBlocking Valve Relay

and/orBlocking Valve Relay wiring

Using a meter set to readcontinuity , activate Steer

Micro-Switch andcheck for ground

1. on wire #100 betweenTerminal Strip inJunct ion Box andRelay

2. on wire #100 enteringRelay

If no continuity

Ifcontinuity



Step 3

Step 4Inspect

Steer Micro-Switch(Right)


ReplaceSteer Micro-Switch

(Solenoid)and/or

Steer Micro-Switch(Solenoid) wiring


Steer Right Switch andmeasure vol tage

1. on wire #20 betweenSteer Micro-Switch(Right) and SteerControl Valve

2. on wire #20 at SteerControl Valve




Go to step 4Repair or replace



binding


If stuckIf

O k

Note:At this point the manualoverride may also beuse to isolatethe solenoid, howeveruse caution as themachine wil l be moving.



Step 5

Step 6Inspect

Steer ControlValve

Go to step 7 ReplaceSteer Control Valve

ActivatingManual Overr ides and

check pressure

Should be 1500 psi

If lower than 1500 psi

I f approx.1500 ps i

InspectSteer Micro-Switch

(Left)


ReplaceSteer Micro-Switch

(Solenoid)and/or

Steer Micro-Switch(Solenoid) wiring


Steer Right Switch andmeasure vol tage

1. on wire #19 betweenSteer Micro-Switch(Left) and Steer ControlValve

2. on wire #19 at SteerControl Valve



During activation ofsteering function themachine wil l be moving.



Step 7

InspectCenter Post

Repair or replaceSteer Cylinder

Note: Machineswith optional

Tow Packagego to step 8

Ifreading

isnormal

Repair or replaceCenter Post

Remove hoses leading to Steer Cylinder Plug

hoses andcap the Steer Cylinder.

While activatingsteering function,

check for 1500 psi atthe pump pressure Test

Port


InspectTow Package Float

Valve

Refer to Chapter 12Accessories Diagnostics

During activation ofsteering function themachine wil l be moving.

Step 8

SECTION FOUR:DRIVE SYSTEM DIAGNOSTICS

SECTION FOURDRIVE SYSTEM DIAGNOSTICS


Drive system is notoperational with

controller in eitherdirection

Go to Page67

InspectFoot Swi tch

Go to Page67

InspectDrive Circui t Breaker (3 amp)

Go to Page68

InspectControl ler Circui t Board and S1

Micro Swi tch Wir ing

Go to Page68

InspectS1 Micro-Switch ( in Control ler)

Go to Page69

InspectControl ler Circui t Board

Go to Page69

InspectPotent iometer

Go to Page70

InspectS2 Micro-Switch ( in Control ler)

Go to Page70

InspectDr ive Solenoid

Go to Page71

InspectDrive Control Valve

Go to Page71

InspectCenter Post

Go to Page72

InspectShutt le Valve Port ion of Dual

Counterbalance Valve

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

Step 11



No forward drive(reverse ok)

Go to Page73

InspectS2 Micro-Swi tch

(in Drive Control ler)

Go to Page73

InspectDrive Control ler Circui t Board

Go to Page74

Solenoid(Drive Forward on Control Valve)

Go to Page74

InspectDual Counterbalance Cartr idge

No reverse drive(forward ok)

Go to Page75

InspectS2 Micro-Swi tch

(in Drive Control ler)

Go to Page75

InspectDrive Control ler Circui t Board

Go to Page76

InspectSolenoid Valve

(Drive reverse on Control Valve)

Go to Page76

InspectDual Counterbalance Cartr idge

OK

OK

OK

OK

OK

OK

Chart 2

Chart 3

Step 1

Step 2

Step 3

Step 4

Step 1

Step 2

Step 3

Step 4



InspectPower to R Terminal

Drive high rangenot operating

Go to Page77

InspectDr ive Low/High Range Swi tch

Go to Page77

InspectBoom Posi t ion and/orBoom Limi ts Swi tch

Go to Page78

InspectRange Valve

Go to Page78

Machine drives atfull speed withplatform raised

and/or extended

Go to Page80

InspectBoom Limi ts Swi tch

Go to Page80

InspectRange Valve

OK

OK

OK

OK

Chart 4

Chart 5

Brakes will notrelease

Go to Page81

InspectBrake Pressure

Chart 6

Step 1

Step 2

Step 3

Step 4

Step 1

Step 2

Step 1

InspectSelector Spool in Transmission

Package

Go to Page79

OKStep 5



Only one wheelturns

(2 wheel drive)

Go to Page82

InspectCase Drain

Go to Page82

InspectSelector Valve

One wheel turnsfaster than other(2 wheel drive)

OK

Chart 7

Chart 8

Step 1

Step 2

Go to Page83

InspectCase Drain

Go to Page83


OK

Step 1

Step 2



InspectFoot switch


Foot Switch andmeasure vol tage

1. on wire #9 betweenFoot Switch and DriveCircuit Breaker

2. at 3 amp DriveCircuit Breaker



ReplaceFoot Switch

and/orFoot Switch wiring


Drive system isnon-operationalwith controllerin eitherdirection

Step 1

Step 2Inspect

Drive CircuitBreaker (3 amp)



1. on wire #69 betweenCircuit Breaker andDrive Controller

2. at positive (+) post ofDrive controller



ReplaceFoot Switch





Step 3

Step 4

InspectController Circuit

Board and S1Micro-Switch

Wir ing



1. on red wire fromCircuit Board toS1 Micro-Switch

2. at red wire ofS1 Micro-Switch



ReplaceCircuit Board

and/orS1 Micro-Switch wiring


InspectS1 Micro-Switch

(in Controller)

Using a meter set toread voltage, step on

Foot Switch andactivate Controller,

measure vol tage1. on black wire between

S1 Micro-Switch andController Circuit Board

2. at point where blackwire from S1 Switchenters Controller CircuitBoard


ReplaceS1 Micro-Switch

(in Controller)and/or

S1 Micro-Switchwiring

Go to step 5


Move control ler handle ineither direction andobserve red LED on

Circuit Board Controller

If not litIf lit



Step 5

Step 6


Foot Switch andactivate Controller,

measure vol tage1. on green wire to

Potent iometer fromController Circuit Board

2. on wire betweenController Circuit Board

and Potent iometerShould read 10-12 volts


ReplaceController Circuit Board

and/orController Circuit Board

wiring



Board

InspectPotent iometer

Using a meter set to ohms,measure reading across1. green wire and purple

wire between Control lerCircuit Board andPotent iometer

2. green wire and orangewire between Control lerCircuit Board andPotent iometerReading should vary

according to Controllermovement

If no reading

Check continuity on wirebetween Controller CircuitBoard and Potent iometer

Go to step 7

continuity

ReplacePotent iometer

and/orPotent iometer

wiring

No cont inui ty



Step 7

Step 8


(in Controller)


Foot Switch and activateController, perform the

following:1. While activating

controller in forwardmode measureproportional voltage atController Circuit Boardwhere white wire entersfrom S2 Micro-Switch

2. While activatingController in reversemode measureproportional voltage atController Circuit Boardwhere blue wire entersfrom S2 Micro-Switch

Reading should varyaccording to amount of

reverse movement

Check continuity on bluewire and on white wire

between Controller CircuitBoard and S2 Micro-Switch



No Cont inui ty

Go to step 8

If no reading

Continui ty

Push Manual Overr idewhile activating variouscontroller functions and

check operation.

If funct ions are abnormal or errat ic

Replace Drive Section Control Valve

Go to step 9

InspectDrive Solenoid

If functionsare normal




Step 9

Step 10

Remove hoses from dr ivesection of Control Valve.Plug the hoses and capvalve. Install a 5000psi

pressure gauge toPump Test Port.

While activating drivecontrol function, check


(while activating function)

If funct ions are abnormal or errat ic

ReplaceValves on Drive Section

of Control Valve

Remove gauge andGo to step 10

InspectDrive Control

Valve

If functionsare normal

InspectCenter Post

Remove hoses at V1 andV2 ports of Dual

Counterbalance Valve.Plug hoses and cap valve.Instal l a 5000psi pressure

test gauge toPump Test Port

While activating drivecontrol function, check


(while activating function)

If pressures are abnormal or errat ic

Repair or replaceCenter Post

Remove gauge andGo to step 11

If pressuresare normal



Step 11

Install a 5000 psi pressuretest gauge to BR port of

Dual CounterbalanceValve. Note if pressure isequal to drive pressure.

unequal pressure

ReplaceShuttle Valve (in Dual

Counterbalance Valve)

Return to step 1

equalpressure

InspectShutt le Valve

Portion of DualCounterbalance

Valve



Step 1

Step 2

No forwarddrive(Reverse Ok)

InspectDrive Controller

Circuit Board

Using a meter set toread voltage, activate drive

funct ion and measureproportional voltage at

Terminal A ofCircuit Board.

Reading should varyaccording to controller

movement .

If no or errat ic reading

ReplaceDrive Controller Circuit

Board

Go to step 3 Ifnormal


(in DriveController)


Check continuity on bluewire between S2 Micro-

Switch and Control lerCircuit Board

Using a meter set toread voltage, activatefunct ion and measureproportional voltage atController Circuit Boardat point where blue wire

from S2 Micro-Switchenters.


movement .




no cont inuity



Step 3

Step 4

Replace theDual Counterbalance Valve

Cartr idge tested

InspectDual

CounterbalanceValve Cartr idge

Using a 5000psi pressuretest gauge activate drive

funct ion and check systempressure at hose entering

port M1 on CounterbalanceValve

If no pressure reading

ReplaceDrive Forward Solenoid

Valve and/orDrive Forward Solenoid

Valve wiring

InspectSolenoid Valve(Drive forward

on Control Valve)

Go to step 4

Try manual override

Using a meter set to readvoltage. While activating

forward function, measureproportional voltage at wire

#17 on Drive section ofControl Valve.


movement .

If no reading

Overr ide al lows operat ion

Overr idedoes not

al lowoperat ion




Step 1

Step 2

No reversedrive(Forward Ok)

InspectDrive Controller

Circuit Board


reverse functionand measure

proportional voltage atTerminal B of

Controller Circuit BoardReading should vary

according to controllermovement

If no or errat ic reading

ReplaceDrive Controller Circuit

Board



(in DriveController)


Check continuity on whitewire between S2 Micro-

Switch and Control lerCircuit Board

Using a meter set toread voltage, activatereverse function andmeasure proport ionalvoltage at ControllerCircuit Board at pointwhere white wire from

S2 Micro-Switch enters.Reading should vary

according to controllermovement .




No cont inui ty



Step 3

Step 4

Replace theDual Counterbalance Valve

Cartr idge tested

InspectDual

CounterbalanceValve Cartr idge

Using pressure test gaugeactivate drive function andcheck system pressure athose entering port M2 on

Counterbalance Valve

If no pressure reading

ReplaceDrive Reverse

Solenoid Valve and/orDrive Reverse Solenoid

Valve wiring


(Drive reverse onControl Valve)

Go to step 4

Try manual override

Using a meter set to readvoltage. While activating

reverse function,measure proport ionalvoltage at wire #18 on

Drive section ofControl Valve.


movement .

If no reading

Overr ide al lows operat ionOverr idedoes not

al lowoperat ion




Posit ion Booms to ful lyretracted and down

posit ion

Adjust Boom Retract/DownLimit Switch

InspectBoom Posit ion

and/orBoom Limit Switch

Booms are not posit ionedfor High Range speed

operations

Boom Limit Switch arenot Adjusted

Step 1

Step 2

Drive highrange notoperating

InspectDrive Low/HighRange Switch


Using a meter set to readvoltage, measure voltage1. on wire #4C going into

the Low/High DriveRange Switch

2. on wire #11 coming outof the Low/High DriveRange Switch.



ReplaceDrive Low/High Range

Switchand/or

Drive Low/High RangeSwitch wiring

Check for 10-12volts at wire #11A

at Boom LimitSwitch

stillnot

operat ing

Repair or replaceBoom Limit Switch

If no voltage

Go to step 3

If10-12V



Step 3

Step 4

InspectRange Valve

Check forblockage in Drive

Range Valveand/or hoses

Using a 5000 psi pressuregauge, measure pressureon hose between RangeValve and Center Post.Should read 2500 psi

If no reading

Repair or replaceRange Valve

Go to step 4

Ifpressure

is low

Return to step 2

InspectPower to R

Terminal

Go to step 5

With Boom retracted andlowered, use a meter setto read voltage, measurevoltage at the R Terminal

of Drive ControllerShould read 10-12 volts

If no reading If10-12V

Check connect ionon Boom Wirebetween BoomSwitches and

Platform

Iflow

Using meter set to readvoltage, measure voltageat Range Valve wire #34.Should read 10-12 volts

If10-12V

If 2500 psi



Step 5

Repair or replaceSelector Spool in

Transmission Package

InspectSelector Spool in

TransmissionPackage

Return to step 1

Verify that Selector Spoolis shift ing by checking

drive speed.Should be 1 mph.

deact ivated and 3 mph.activated.

(3 mph = 100 ft in 22 sec)

If speeds are not reachedSelector Spool is not shif t ing

I f speeds arereached

Selector Spoolis shift ing



Step 1

Step 2

Machinedrives at fullspeed withplatformraised and/orextended

InspectBoom Limits

SwitchBoom Limits Switch aresticking or not properly

Adjusted

Repair, replace or readjustBoom Limits Switch

InspectRange Valve

Using a 5000 psi pressuregauge, measure pressureon hose between RangeValve and Center Post

Should read 0 psi

If 2500 psi

Repair or replaceRange Valve

Check for stuckSelector Valve on

Transmission Package

If0 psi

Go to step 2prob lem

stillexists



Brakes will notrelease

Step 1

InspectBrake Pressure

1. Install a 5000psipressure gauge in BRPort on Motion ControlValve

2. Take pressure readingat Pump Compensator

Readings should besimilar

Repair or replaceBrake Shutt le Valve



Step 1

Step 2

Only onewheel turns(2 wheel drive)

InspectCase Drain

Disconnect exist ing hose,install a f lowmeter

between exist ing hoseand Drive Motor.

Should be no morethan .5 gpm

If morethan .5 gpm

Repair or replaceDrive Motor

Go to step 2

If lessthan

.5 gpm


Visually check for oilleakage around Pilot Block

and Main Block.

ReplaceO'rings

Ifb lown

Inspect Quad Rings onSelector Spool

Remove Pi lot Block andinspect O'rings on Pilot

spool

If leakage exist

I f O'r ings Ok

ReplaceQuad Rings

Ifb lown

Check rel ief Valve onTransmission Valve

If Quad Rings Ok

Adjust Relief Valvefor 2500 psi

IfO k

Check f low control acrossFlow Divider Combiner


Adjust FlowControl for proper

operation

IfO k

Note:I f machine is equippedwith Tow Package Optionmake sure Hubs areengaged.



Step 1

Step 2

One wheelturns fasterthan other(2 wheel drive)

InspectCase Drain

Disconnect exist ing hose,install a f lowmeter

between exist ing hoseand Drive Motor.

Should be no morethan .5 gpm

If morethan .5 gpm

Repair or replaceDrive Motor

Go to step 2

If lessthan

.5 gpm


Visually check for oilleakage around Pilot Block

and Main Block.

ReplaceO'rings

Ifb lown

Inspect Quad Rings onSelector Spool

Remove Pi lot Block andinspect O'rings on Pilot

spool

If leakage exist

I f Ok

ReplaceQuad Rings

Ifb lown

Check rel ief Valve onTransmission Valve

If Quad Rings Ok

Adjust Relief Valvefor 2500 psi

IfO k

Check f low control acrossFlow Divider Combiner


Adjust FlowControl for proper

operation

IfO k

SECTION FIVE:EMERGENCY POWER SYSTEM DIAGNOSTICS

SECTION FIVEEMERGENCY POWER SYSTEM DIAGNOSTICS


Emergency pumpmotor non-operational

Go to Page88

InspectEmergency Power Swi tch

Go to Page89

InspectEmergency Power Solenoid

and Wir ing

Go to Page89

InspectEmergency Power Uni t

No functions whenon emergency

power

Go to Page90


OK

OK

Chart 1

Chart 2

Step 2

Step 3

Step 4

Step 2

Go to Page88


OK

Step 1

Go to Page90


OK

Step 1

Go to Page91

InspectEmergency Power Pump

OKStep 3



Repair or ReplaceEmergency Power SwitchTerminal wiring (wire #6)

and/orEmergency Power

Solenoid wiring (wire #6A)and/or

Emergency Power Switch

InspectEmergency Power

Switch

Go to step 3

Check continuity1. on wire #6 between

Emergency PowerSwitch and TerminalStrip in Control Box

2. between wire #6 ofTerminal Strip inJunction Box and wire#6A at EmergencyPower Solenoid


Emergency Power andmeasure vol tage

1. on wire #6 ofEmergency PowerSwitch

2. at Emergency PowerSolenoidShould be 10-12 volts

If no reading

If10-12V

Step 1

Step 2

Emergencypump motornon-operational

No cont inui ty

InspectBatteries




Recharge orreplace

battery(s)


If loose




Ifcorroded

If 12V




Step 3

Repair or ReplaceEmergency Pump Motor


Unit

I f previous checks havebeen performed and found

to be normal, checkEmergency Pump Motor

for internal groundingcondit ion

Repair or ReplaceWiring from Battery

Disconnect Switch toEmergency Power

Solenoid and/or Emergency Power Unit

wiring and/orEmergency Power

Solenoid


Solenoidand Wir ing

Go to step 4

Check continuity1. on wire between

Battery DisconnectSwitch and EmergencyPower Solenoid

2. on wire betweenEmergency PowerSolenoid and PumpMotor

Using a meter set to readvoltage, measure voltage1. at Emergency Power

Solenoid and fromBattery DisconnectSwitch

2. act ivate EmergencyPower Switch andmeasure voltage atEmergency PumpMotor


If no reading

If10-12V

No cont inui ty

Step 4



Step 1

No functionswhen onemergencypower

Step 2

InspectBatteries




Recharge orreplace

battery(s)


If loose




Ifcorroded

If 12V


Repair or ReplaceEmergency Power Pump

Unit


Pump

Attach 5000 psi pressuregauge to discharge

side of Emergency PowerPump, act ivate

Emergency Power Pumpand Ground Control Switch

or Foot Switch.Should read

2500-2750 psi.

If reading is abnormal or errat ic

Remove gaugeand

Go to step 3

IfO k



Step 3


Refer back toChapter 3, Chart 1

Step 3

Repair or replaceBlocking Valve Cartr idge

With Ground ControlSwitch activated, use a

meter set to read voltageand measure vol tage

on wire #100B toBlocking Valve SolenoidShould be 10 to 12 volts

If 10 to 12V

Ifno vol tage

SECTION SIX:SWING SYSTEM DIAGNOSTICS

SECTION SIXSWING SYSTEM DIAGNOSTICS


No response fromswing when

platform controlsare activated

(GroundControls Ok)

Go to Page99

InspectFoot Swi tch

Go to Page99

InspectSwing Circui t Breaker (3 amp)

Go to Page100

InspectControl ler Circui t Board

Go to Page100

InspectControl ler S1 Micro Switch

Go to Page101

InspectControl ler Potent iometer

Go to Page101

InspectControl ler S2 Micro Switch

Go to Page102

InspectSwing Valve

Go to Page102

InspectSwing Motor and Gear Box

OK

OK

OK

OK

OK

OK

OK

Chart 2

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Swings only inone direction

Go to Page98

InspectSwing Contro l Signal Wire

Go to Page98

InspectSwing Contro l Valve

OK

Chart 1

Step 1

Step 2



No response fromswing when groundcontrol is activated

(PlatformControl Ok)

Go to Page103

InspectGround Contro l Swi tch

and Wir ing

Go to Page103

InspectSwing Swi tch

OK

Chart 3

Step 1

Step 2

Swings erraticallyin either direction

Go to Page104

Act ivateManual Overr ide

Go to Page104

InspectSolenoid

Go to Page105

InspectControl ler

Go to Page105

InspectSwing Brake

OK

OK

OK

Chart 4

Step 1

Step 2

Step 3

Step 4

Swings faster oneway than other

Go to Page106

InspectCrossover Rel ief Valve

Go to Page106

InspectSolenoid

OK

Chart 5

Step 1

Step 2



Swing Brakewill not hold

Go to Page107

InspectSwing Brake

Chart 6

Step 1

Swings too slow Go to Page108


Go to Page108

InspectSolenoid

Go to Page109

InspectSwing Valve

Go to Page109

InspectSwing Brake Release

OK

OK

OK

Chart 7

Step 1

Step 2

Step 3

Step 4



Step 1

Step 2

Repair or ReplaceSwing Control Valve

wiring

Inspect Swing Control

Signal Wire

Check continuity on1. wire #23 between

Terminal Strip in thePlatform Box andSwing Control Valve

2. wire #24 betweenTerminal Strip in thePlatform Box andSwing Control Valve

Using meter set to readvoltage, perform the

following:1. while activating

platform in ccwdirection, measurevoltage on wire #23 atthe Terminal Strip inthe Platform Box

2. while activatingplatform in cw direction,measure voltage onwire #24 at theTerminal Strip atPlatform BoxShould be 7-8 volts

Go to step 2 If7-8 volts

No cont inui ty

Swings only inone direction

I f no reading

Repair or ReplaceSwing Control Valve

Solenoid

InspectSwing Control

ValveManually operate

Swing Control Valve

If functioning properlyIf functioningimproper ly

Repair or ReplaceSwing Control

Valve

When the turn tablerotates clockwise (cw) itwil l be moving toward you.Make sure you have roomto step backward.




Step 2

No responsefrom swingwhen platformcontrols areactivated(GroundControls Ok)

Repair or ReplaceFoot Switch


InspectFoot Switch

Go to step 2

Check continuity on wire#9 between Foot Switch

and Swing Circuit Breaker

Using a meter set toread voltage, while

stepping on the FootSwitch, measure voltage

on wire # 9 atSwing Circuit Breaker


If no reading

No cont inui ty

If10-12V

Step 1

Repair or ReplaceSwing Circuit Breaker

and/orSwing Circuit Breaker

wiring

InspectSwing Circuit

Breaker (3 amp)

Go to step 3

Check continuityon wire between CircuitBreaker and posit ive (+)post on Swing Control ler


stepping on the FootSwitch, measure voltage at

posit ive (+) post onSwing Control ler


If no reading

No cont inui ty

If10-12V



Step 3

Step 4

Repair or ReplaceCircuit Board

and/orCircuit Board wiring


Board

Go to step 4

Check continuityon red wire to S1 Micro

Switch (at Controller)


stepping on the FootSwitch, measure voltageon red wire to S1 Micro

Switch (at Controller)Should read 10-12 volts

If no reading

No cont inui ty

If10-12V

Repair or ReplaceS1 Micro Switch

(at Controller)and/or

Control ler S1 MicroSwitch wiring

InspectControl ler S1Micro Switch

Go to step 5

Check continuityon black wire from S1

Micro Switch (at Controller)to the Circuit Board


stepping on the FootSwitch, activate Controllerand measure vol tage onblack wire running from

S1 Micro Switch toController Circuit BoardShould read 10-12 volts

and red LED should be l i t

I f no reading

If10-12V

No cont inui ty



Step 5

Step 6

Repair or ReplacePotent iometer

and/orPotentiometer wir ing

InspectController

Potent iometer

Check continuityon wir ing between

Potentiometer and CircuitBoard


stepping on the FootSwitch, activate Controllerand measure proport ional

voltage on wire runningfrom Potentiometer to

Circuit BoardVoltage should vary

according to Controllermovement

If no reading

No cont inui ty


Repair or ReplaceS2 Micro Switch

and/orS2 Micro Switch wiring

InspectControl ler S2 Micro

Switch

Check continuity on1. Wire (white) from S2

Controller Micro Switchto Controller CircuitBoard

2. Wire (blue) from S2Controller Micro Switchto Controller CircuitBoard


stepping on the FootSwitch, activate Controller

and measureproportional voltage on

1. wire (white) from S2Controller Micro Switchto Controller CircuitBoard (with swing inccw Direction)

2. wire (blue) from S2Controller Micro Switchto Controller CircuitBoard (with swing in cwDirection)

Voltage readings shouldvary according to

Control ler movementNo cont inui ty

I f no reading

Go to step 7

If normal



Step 7

Step 8

ReplaceSwing Section Control

Valve

InspectSwing Valve

Remove hoses f romSwing Drive Motor.Plug hoses and cap

motor. While activatingswing function, check

pressure atPump Compensator

Pressure should read2500 psi

If reading is low or errat ic

Go to step 8 If2500 ps i

ReplaceSwing Motor

and/or Gear Box

InspectSwing Motor and

Gear Box

If previous stepshave been madeand Swing Valve

checks ok,check pressure.

If low

Return to step 1

If2500 ps i



Repair or ReplaceGround Control Switch

and/orGround Control Switch

wiring

InspectGround Control

Switch and Wir ing

Go to step 2

Using a meter set to readvoltage, activate swing

function, measure voltagefrom Ground Control

Switch to Ground SwingSwitch


If no reading

If10-12V

No response fromswing whenground controlsare activated(PlatformControls Ok)

Step 1

Step 2


InspectSwing Switch


activating function, checkvoltage on Swing Switch to

Junct ion Box(wire #23 when swing

is moving in acounterclockwise direction,

wire #24 when swingis moving in a

clockwise direction)Should be 10-12 volts

If no reading

Repair or ReplaceSwing Switch

and/orSwing Switch wiring



Step 1

Step 2

Go to step 4

Push in on ManualOverr ide and observe

swing operation

ActivateManual Overr ide

Go to step 2

If sti l l swings erratically

If ok

Swingserratically ineither direction

Replace Solenoid

Supply 12 volts toSolenoid, check if swing is

operating smoothly

InspectSolenoid

Go to step 3

If sti l l swings erratically

If ok




Step 3

Step 4

Replace Control ler

Swap functions with aworking function

InspectController

If swing is ok

Install 5000 psi pressuregauge into Swing Brake

Line, while activatingfunction, check pressure.Should maintain steadypressure above 350 psi

InspectSwing Brake

Repair or replaceSwing Brake

and/orGear Box

If ok




Step 1

Step 2

Swings fasterone way thanother

Replace Solenoid


operating equally

InspectSolenoid

If st i l l swings faster

Repair or replaceCrossover Relief Valve

SwapCrossover Relief Valves,

check for problem inopposite direction

InspectCrossover Relief

Valve

Go to step 2

If st i l l swings faster

If ok




Step 1

Repair or replaceSwing Brake

Visually checkSwing Brake

InspectSwing Brake

Swing brakewill not hold



Go to step 3

Step 1

Step 2

Swings tooslow

Go to step 4


swing function for fastermovement


Go to step 2

If st i l l swings slow

IfSwingsfaster

Replace Solenoid


operating normally

InspectSolenoid

If st i l l swings slowIf swing isnormal




Step 3

Step 4

Set for proper speed

Turn speed adjustmentscrew counterclockwise

1 turn.Recheck swing speed

InspectSwing Valve

Go to step 4

If swings faster

If no

Return to step 1

Install 5000 psi pressuregauge into Swing Brake

Line, while activatingfunction check pressure.Should maintain steadypressure above 350 psi

InspectSwing Brake

Release

Repair or replace SwingBrake

If st i l l swings slow

If ok

SECTION SEVEN:PLATFORM ROTATION SYSTEM DIAGNOSTICS

SECTION SEVENPLATFORM ROTATION SYSTEM DIAGNOSTICS


The platform rotatedoes not operate

Go to Page114

InspectPlat form Rotate Switch

Go to Page114

InspectRotat ion Control Valve

Go to Page115

InspectPlat form Rotator

Platform rotatestoo fast

Go to Page116

InspectFlow Control

Platform rotatestoo slow

Go to Page116

InspectFlow Control

OK

OK

Chart 1

Chart 2

Chart 3

Step 1

Step 2

Step 3

Step 1

Step 1

Platform rotatesitself

Go to Page117

InspectHolding Valves

Chart 4

Step 1



Repair or replacePlatform Rotate Switch

wiring

InspectPlatform Rotate

Switch

Check continuity on1. wire #26 between

Terminal Strip in theJunction Box andRotation Control Valve

2. wire #27 betweenTerminal Strip in theJunction Box andRotation Control Valve

Using meter set to readvoltage, perform the

following:1. While activating

platform in ccwdirection, measurevoltage on wire #26 atthe Rotation ControlValve

2. While activatingplatform in cw direction,measure voltage onwire #27 at the RotationControl Valve



Platform rotatedoes notoperate

Step 1

Step 2

I f no reading

No cont inui ty

Repair or replaceSolenoids on

Rotation Control Valve

InspectRotation Control

Valve

While act ivat ing GroundControl Switch or Foot

Switch, depress ManualOverride

Go to Step 3

Ifp lat formrotates

If platformdoes not rotates




Step 3

InspectPlatform Rotator

Repair or ReplacePlatform Rotator

Remove hose f romRotator. Plug hoses and

cap Rotator. Using gauge,activate platform rotate

function and test pressureat Pump Compensator

System pressure shouldread 1500 psi

(while activated)


Return to step 1 If1500 ps i

Reconnect hoses toPlatform Rotator

Then



Platform rotatestoo fast

Step 1

Step 1

InspectFlow Control

ReplaceFlow Control Cartr idge

Use a stop watch to t imeplatform rotation speed

from fully clockwiseposition to fully

counterclockwise posit ion.Should be between

16 to 20 seconds

If proper speed is not maintained

Platform rotatestoo slow

InspectFlow Control

ReplaceFlow Control Cartr idge

Use a stop watch to t imeplatform rotation speed

from fully clockwiseposition to fully

counterclockwise posit ion.Should be between

16 to 20 seconds

If proper speed is not maintained



Platform rotatesitself

Step 1


Repair or replaceHolding Valves

and/orO-rings

Visually check for stuckValve or blown O-Rings

If stuck and/or blown

SECTION EIGHT:PLATFORM LEVELING SYSTEM DIAGNOSTICS

SECTION EIGHTPLATFORM LEVELING SYSTEM DIAGNOSTICS


Platform will notmaintain level as

boomraises or lowers

Go to Page123

InspectHydraul ic Oi l Temperature

Go to Page123

InspectRel ief Valves

Platform will notmaintain level with

machine off

Go to Page124

InspectHolding Valves in

Slave Level Cyl inder

OK

Chart 1

Chart 2

Step 1

Step 2

Step 1

Platform bleedsdown

Go to Page124

InspectHolding Valve

Chart 3

Step 1

Platform level willnot work fromground control

(PlatformControl Ok)

Go to Page125

InspectGround Contro l Swi tch

Go to Page125

InspectLevel Switch

OK

Chart 4

Step 1

Step 2

Go to Page126

InspectPlat form Blocking Valve

Circuit

OKStep 3



Platform level willnot work from

platform control(Ground Control Ok)

Go to Page127

InspectPlat form Level Switch

Chart 5

Step 1

Platform levelup function is

inoperative

Go to Page128


Go to Page129


Go to Page130

InspectPressure to Cyl inder

Platform leveldown function is

inoperative

Go to Page131

InspectManual Overr ide

Go to Page131


Go to Page132

InspectPressure to Cyl inder

OK

OK

Chart 6

Chart 7

Step 1

Step 2

Step 3

Step 1

Step 2

Step 3

OK

OK



InspectHydraulic OilTemperature

Cycle the boom a fewtimes to warm up the

hydraulic oil

Hydraulic Oil is cold

If cold

The platform doesnot maintain levelas boom raises orlowers

Step 1

Step 2Inspect

Holding Valvesbetween MasterLevel Cylinder

and Tank


With platform level andboom ful ly down, remove

the hoses from dualHolding Valve to LevelControl Valve and cap Dual Holding Valve.

Raise boom 5ft. and notethe Platform Leveling

System.

If Level System performs normal lyI f Level System

per formsabnormal ly

Repair or replaceSeals in Master Leveling

System



The platform willnot maintainlevel withmachine off

Step 1

InspectHolding Valves in

Slave LevelCylinder


Place a safe work loadin platform and

remove the hoses toSlave Level Cylinder

Observe the Platform.

If oi l leaksand platform dr i f ts

If no oi l leaksbut p lat form

stil l drifts

Repair or replaceLevel Cylinder



Step 1

Platformbleeds down



and/orO-rings

Visually check for stuckValve or blown O-rings




Step 1

Platform levelwill not workfrom groundcontrol(PlatformControl Ok)

Step 2

InspectGround Control

Switch

Check continuity on wire#28 between Ground

Control Switch andPlatform Level Switch

Using meter set to readvoltage, activate Ground

Control Switch andmeasure voltage on

wire #28 entering PlatformLevel Switch


If no reading

Repair or replaceGround Control Switch

and/orGround Control Switch

wiring


No cont inui ty

InspectLevel Switch

Using meter set to readvoltage, activate

Level Down and measurevoltage on

wire #13 at Junction BoxShould read 10-12 volts

If no reading

Repair or replacePlatform Level Switch

and/orPlatform Level Switchwiring to Junction Box





Circuit

Repair or replaceLevel Switch

While activating Level,Switch check for continuity

to ground on wire 100

Continuity

Check for continuity onwire 100 from

Level Switch toJunct ion Box

Step 3

Nocontinuity

ContinuityReturn to Step 1

No cont inui ty

Repair or replaceWire #100



Measure voltage on wires#12 and #13 leaving

Platform Level SwitchShould read 10-12 volts


Step 1

ReplaceLevel Switch

Using a meterset to read voltage,measure voltage on

wire #9 enteringPlatform Level Switch


InspectPlatform Level

Switch

Platform levelwill not workfrom platformcontrol(GroundControl Ok)

I f 10-12V

ReplaceFoot Switch

If lowor no

vol tage



Repair or replacewire #13

Using a meterset to read voltage,

measure voltage on wire#13 between Level Switch

and Solenoid ValveShould be 10-12 volts


If no reading

If10-12V

Repair or replaceSolenoid Valve

Step 1

Step 2

Platform level upfunction is inoperative

Go to step 2


Platform level up function


Go to step 3

If ok

I f problemstil l exists




Step 3

Install 5000 psi pressuregauge at Port 2 of SlaveLevel Cylinder. Activatefunct ion and measure

pressure to Slave LevelCylinder.

Should read 1500 psiwhen ful ly extended.

InspectPressure to

Cylinder


Remove hose from Port 6on Slave Level Cylinder,plug hose and cap Slave

Level Cylinder.Recheck pressure

Should read 1500 psiwhen ful ly extended.

Repair or replaceRelief Valve in

Reduced PressureManifold

Repair or replaceSlave Level

Cylinder

If lowor no

reading

If1500 ps i

Return to Step 1If lowor no

reading



Step 1

Step 2

Platform level downfunction is inoperative


Using a meterset to read voltage,

measure voltage on wire#12 between Level Switch

and Solenoid ValveShould be 10-12 volts


If no reading

If10-12V


Go to step 2

Push in on ManualOverr ide and observePlatform Level down

function

InspectManual Overr ide

Go to step 3

If ok

I f problemstil l exists




Step 3

Install 5000 psi pressuregauge at Port 1 of SlaveLevel Cylinder. Activatefunct ion and measure

pressure to Slave LevelCylinder.

Should read 1500 psiwhen fully retracted.

InspectPressure to

Cylinder


Remove hose from Port 2on Slave Level Cylinder,plug hose and cap Slave

Level Cylinder.Recheck pressure

Should read 1500 psiwhen fully retracted.

Repair or replaceRelief Valve in

Reduced PressureManifold

Repair or replaceSlave Level

Cylinder

If lowor no

reading

If1500 ps i

Return to Step 1If lowor no

reading

SECTION NINE:BOOM ELEVATION SYSTEM DIAGNOSTICS

SECTION NINEBOOM ELEVATION SYSTEM DIAGNOSTICS


Boom raises butwill not stay

elevated

Go to Page136

InspectManual B leed Down

Go to Page136


Boom will notraise from

ground control

Go to Page139

InspectBoom Li f t Swi tch

Boom will notraise from

platform control

Go to Page138

InspectVoltage on Control ler

Go to Page138

InspectBoom Contro l Wire

OK

OK

Chart 1

Chart 2

Chart 3

Step 1

Step 2

Step 1

Step 2

Step 1

InspectSeals in Cyl inder

OKStep 3

Go to Page137

Boom raises slowfrom Platform

Go to Page140


Go to Page140

InspectVoltage on Control ler

OK

Chart 4

Step 1

Step 2



Boom raisesbut will notstay elevated

Step 1

Step 2

Go to step 2

InspectManual Bleed

Down

Turn Manual Bleed DownValve clockwise unti l

valve is closed

Problem st i l l exist

ReplaceHolding Valve

and/orSeal Kit


Raise boom approximately2ft, remove hose to

#2 port on Lift Cylinder,observe for leakage

LeakageGo to step 3

Prob lemstil l exist

Raise boom approximately2ft. and mark Lift Cylinder.Remove hose from port#4

on Lift Cylinder. Observe oilleakage.

Problem st i l l exist

Repair or replaceManual Bleed

Down

Leakage



Step 3

Repair or replaceCylinder

InspectSeals in Cylinder

Remove steel tube onCylinder, check if oil isleaking from upper port

If leaking



Repair or replaceController

InspectVoltage onController

Using meter set toread voltage, measure

voltage on wire #22B Terminal ofLift Controller

Should read 5 to 6 volts

If no reading

Go to step 2 If5 to 6V

Step 1

Step 2

Boom will not raisefrom platform control(Ground Control Ok)

Repair or replaceBoom Control Wire

InspectBoom ControlWire at BaseJunction Box

Using meter set toread voltage, measurevoltage on wire #22B


If no reading



Boom will not raisefrom ground control(Platform Control Ok)

Step 1

Measure voltage on wire#28 to Lift Switch


InspectBoom Lift Switch


voltage on wire #22Should read 10 to 12 volts

If no readingIf 10 to 12V

Check continuityon wire betweenLift Switch andJunction Box

If no reading

Repair or replace Lift Switch

No cont inui ty




Step 1

Step 2

Boom raises slowfrom platform

Go to step 2


boom function for fastermovement


If Ok

AdjustController

InspectVoltage onController


voltage on wire #22B Terminal ofLift Controller


If no reading


SECTION TEN:TELESCOPE SYSTEM DIAGNOSTICS

SECTION TENTELESCOPE SYSTEM DIAGNOSTICS


Chart 1

Boom will notretract from

ground control (Platform

Control Ok)


InspectExtend and Retract Switch

InspectWir ing to Junct ion box

OK

OK

Step 1

Step 2

Step 3

Boom will notretract from




InspectWir ing in Hose Carr ier

OK

OK

Step 1

Step 2

Step 3

Boom will notextend from

ground control(Platform

Control Ok)



InspectWir ing to Junct ion box

OK

OK

Step 1

Step 2

Step 3

Chart 2

Chart 3

Go to Page145

Go to Page145

Go to Page146

Go to Page147

Go to Page147

Go to Page148

Go to Page149

Go to Page149

Go to Page150



Boom will notextend from


Go to Page151


Go to Page151


Go to Page152

InspectWir ing in Hose Carr ier

OK

OK

Step 1

Step 2

Step 3

Chart 4

Boom drifts in Go to Page153

ActivateHolding Valves for Extend

Step 1

Chart 5

Go to Page153

InspectCyl inder for Internal Leakage

OKStep 2



Boom will not retractfrom ground control(Platform Control Ok)

Step 1

Step 2

Go to step 2

Activate Ground ControlSwitch, push in on

Manual Overr ide andobserve boom movement


If retracting

Go to step 3 If12V

Repair or replaceExtend and

Retract Switch

InspectExtend and

Retract Switch

Using meter set to readvoltage, measure voltage

at wire #15 atExtend and Retract


If no reading




Step 3

Repair or replaceWire to Junction Box

InspectWire to Junction

BoxUsing meter set to read

voltage, activate functionand measure vol tage onwire #15 to Junction BoxShould read 10-12 volts

If no reading



Go to step 2

Activate Foot Switch, pushin on Manual Override andobserve boom movement


If retracting


Boom will notretract fromplatform control(Ground Control Ok)

Step 1

Step 2


Retract Switch

InspectExtend and

Retract Switch


on wire #15 atExtend and Retract


If no reading




Step 3

Repair or replaceWiring in Hose Carrier

InspectWir ing in Hose

Carrier

Using meter set to readvoltage, activate functionand measure voltage at

wire #15 inJunct ion Box


If no reading



Boom will not extendfrom ground control(Platform Control Ok)

Step 1

Step 2

Go to step 2

Activate Ground Controlswitch, push in on Manual

Overr ide and observeboom movement


If extending



Retract Switch

InspectExtend and

Retract Switch


at wire #14 atExtend and Retract


If no reading




Step 3

Repair or replaceWire to Junction Box

InspectWire to Junction

BoxUsing meter set to read

voltage, activate functionand measure vol tage onwire #14 to Junction BoxShould read 10-12 volts

If no reading




Boom will notextend fromplatform control(Ground Control Ok)

Step 1

Step 2

Go to step 2

Activate Foot Switch, pushin on Manual Override andobserve boom movement


If retracting


Retract Switch

InspectExtend and

Retract Switch


on wire #14 atExtend and Retract


If no reading




Step 3

Repair or replaceWiring in Hose Carrier

InspectWir ing in Hose

Carrier

Using meter set to readvoltage, activate functionand measure vol tage on

wire #14 inJunct ion Box


If no reading



Boom drifts in

Step 1


and/orO-rings

Visually check for blownO-Rings


Repair or replaceHolding Valves for Retract

and/orSeals in Extend Cylinder

Raise boom and extendboom 2ft . , remove hoses

from Extend Control Valve.Observe oi l leakage

InspectSeals in Extend

Cylinder

Leakage f rom Por t 1of Extend Cyl inder

Repair or replaceHolding Valves for Extend

and/orSeals in Extend Cylinder

Leakagefrom Port 2of ExtendCyl inder

ReplaceSeals in Extend Cylinder

No leakage, boomcontinues to retract

Step 2

Go to step 2

If Ok

InspectHolding Valves for

Extend

SECTION ELEVEN: FUEL SYSTEM DIAGNOSTICS

SECTION ELEVENFUEL SYSTEM DIAGNOSTICS


Engine will notstart on Gasoline,

but will starton L.P.

Go to Page158

InspectFuel Level

Go to Page158

InspectFuel Shutoff Valve

Engine will notstart on L.P.,

but will start onGasoline.

Go to Page160

InspectL.P. Gauge

Go to Page160

InspectL.P. Fi l ter Lock

Chart 2

Chart 1

OK

OK

Go to Page159

InspectDual Fuel Switch

Go to Page159


OK

OK

Go to Page161


Go to Page161


OK

OK



Engine will notstart onGasoline, butwill start onL.P.

Step 1

Step 2

Fill tank with Gasoline

InspectFuel Level

Visually check FuelGauge to verify an

adequate amount of fuelis in tank

If not

Go to step 2

If yes

Repair or replaceFuel Shutoff Valve

InspectFuel Shutoff

ValveUsing meter set to read

voltage, measure voltageon wire #78A at the

Fuel Shutoff ValveShould read 10-12 voltsGo to step 3 If no

reading

If 10-12V



Step 3

Step 4




If no continuity


Repair or replaceDual Fuel Switch


Using meter set to readvoltage, measure voltage1. on wire #77A at the

Dual Fuel Switch2. on wire #78 coming

out of Dual Fuel SwitchShould read 10-12 volts


If no reading



Engine will notstart on L.P.,but will starton Gasoline.

Step 1

Step 2

Fill tank with L.P.

InspectL.P. Gauge

Visually checkL.P. Gauge to verify an

adequate amount of fuel is in tank

If not

Go to step 2

If yes

Repair or replaceL.P. Filter Lock

InspectL.P. Filter Lock

Using meter set to readvoltage, measure voltage1. on wire #77B at the

L.P. Filter Lock2. on wire #78 coming


Go to step 3 If noreading

If10-12V



Step 3

Step 4




If no continuity


Repair or replaceDual Fuel Switch


Using meter set to readvoltage, measure voltage1. on wire #77A at the

Dual Fuel Switch2. on wire #77B coming



If no reading

SECTION TWELVE:ACCESSORIES DIAGNOSTICS

SECTION TWELVEACCESSORIES DIAGNOSTICS


AC Generatorwill not function

Go to Page166

InspectPower to Generator Swi tch

at Plat form

Go to Page16

InspectGenerator Solenoid

AC Generator haslow voltage

Go to Page167

InspectAC Vol tage f rom Generator

OK

Step 1

Step 1

Step 2

Chart 1

Chart 2

Machine will notsteer

Go to Page168

InspectTow Package Float Valve

Step 1

Chart 3



AC Generatorwill notfunction

Step 1

Step 2

Repair or replaceGenerator Switch at

Platform

InspectPower to

Generator Switchat Platform


at wire #169 whenswitch is activated to

Generator posit ionShould read 10-12 volts

If no reading

Go to step 2

If10-12V

Repair or replaceWire from Platform

InspectGeneratorSolenoid


on Generator Solenoidwire #169


If no reading


If10-12V



Step 1

AC Generatorhas lowvoltage

Adjust Speed ControlValve on Hydraulic

Generator Valvecounterclockwise to

increase voltage

InspectAC Voltage from

GeneratorUsing meter set to read

voltage, measure voltageat Generator

Should read 130 volts AC

If no reading



Step 1

Machine willnot steer

Check decal for correctposit ioning

InspectTow Package

Float ValveVisually inspect TowPackage Float Valveto insure valve is inoperational posit ion

No

€¦ · 4 symptom page number section four - drive system diagnostics drive system is not...

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