Service Manual (ANSI/CSA)

This manual is based on Serial Number: SJ 68XXRT 37 004 671 & Above

Content:
Section 1. SCHEDULED MAINTENANCE
Operators Responsibility for Maintenance
Service and Maintenance
Tables
Table 1.1 Owners Annual Inspection Record
Table 1.2 Pre-Delivery / Maintenance Inspection Checklist
Service and Maintenance Inspections
Scheduled Maintenance Inspections
Function Tests

Section 2. MAINTENANCE TABLES AND DIAGRAMS
Table 2.1 Specifications and Features
Table 2.2 Floor Loading Pressure
Table 2.3 Maximum Platform Capacities (Evenly Distributed)
Table 2.6 Torque Specifications for Fasteners (Imperial)
Table 2.7 Torque Specifications for Fasteners (Metric)
Table 2.8 Torque Specifications for Hydraulic Couplings & Hoses

Section 3. SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Charts
3.1. Hydraulic Symbol Chart
3.2. Electrical Symbol Chart
3.3 AC Cord Color Code
Parts List
3.4 Hydraulic Schematic Parts List
3.5 Electrical Parts List
Diagrams and Schematics
3.6a Hydraulic Schematic S/N 37006450 & above
3.6b Hydraulic Schematic S/N 37006449 & below
3.7 Hydraulic Manifold Valve Port Identification
3.8 Control Box Wiring Diagram
3.9 Outrigger / Hydraulic Generator Control Console Wiring Diagram
3.10 Scissor Arm Control Cable Wiring Diagram
3.11 Main Manifold Valve Harness Wiring Diagram
3.12a Kubota Engine Wiring Diagram - Dual Fuel System - S/N 37009728 & Below
3.12b Kubota Engine Wiring Diagram - Dual Fuel System - S/N 37009729 & Above
3.13 Kubota Engine Wiring Diagram (Diesel Fuel System)
3.14 Outrigger Harness Wiring Diagram
3.15 Hydraulic Generator Electrical Panel Assembly
3.16 All Motion Alarm Electrical Panel Diagram
3.17 Telematics Harness Wiring Diagram
3.18a Electrical Panel Wiring Diagram S/N 37000235 & above
3.18b Electrical Panel Wiring Diagram S/N 37000234 & below
3.19a Electrical Panel Diagram with Positive Air Shut Off Option S/N 37000235 & above
3.19b Electrical Panel Diagram with Positive Air Shut Off Option S/N 37000234 & below
3.20 Positive Air Shut Off Harness Wiring Diagram - Diesel Engine
3.21a Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000235 & above
3.21b Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000234 & below
3.22a Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000235 & above
3.22b Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000234 & below
3.23a Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000235 & above
3.23b Electrical Schematic (All Option with Kubota Diesel Engine) 37000234 & below

Section 4. TROUBLESHOOTING INFORMATION
Introduction
Electrical System
4.1-1 All Controls Inoperative
4.1-2 No Power To Platform
4.1-3 All Functions Inoperative from The Platform
4.1-4 Engine Does not Crank from Platform or Base Control Console
4.1-5 Engine Cranks But Does not Start - Kubota Diesel
4.1-6 Engine Cranks But Does not Start - Kubota Dual Fuel
4.1-7 Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models)
4.1-8 Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel)
4.1-9 High Throttle Inoperative
4.1-10 High Throttle On Demand Inoperative (Kubota Dual Fuel)
4.1-11 Drive and Steer Inoperative (Machines without outriggers option)
4.1-12 Drive and Steer Inoperative (Machines with outriggers option)
4.1-13 Brakes Does not Release
4.1-14 Steer Right Inoperative
4.1-15 Steer Left Inoperative
4.1-16 Reverse Drive Inoperative
4.1-17 Forward Drive Inoperative
4.1-18 First Drive Speed and Steering Inoperative
4.1-19 Second Drive Speed Inoperative
4.1-20 Third Drive Speed Inoperative
4.1-22 High Drive Speed Inoperative
4.1-21 Up Circuit Inoperative from Platform
4.1-22 Up Circuit Inoperative from Base Control Console
4.1-23 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers)
4.1-24 Platform does not Lift from Platform or Base Control Console with Outriggers Retracted (Lift Operates
Correctly with Outriggers Extended)
4.1-25 Platform does not Lift from Platform or Base Control Console with Outriggers Extended
4.1-26 Platform does not Lift from Platform or Base Control Console with Outriggers Extended or Retracted
4.1-27 Down Circuit Inoperative from Platform
4.1-28 Down Circuit Inoperative from Base
4.1-29 Hydraulic Generator Inoperative
4.1-30 Hydraulic Generator does not Shut Off from Generator Switch
4.1-31 All Outriggers Inoperative (Auto-Level and Manual)
4.1-32 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)
4.1-33 All Outriggers Inoperative (Base Controls only)
4.1-34 All Outriggers Inoperative (Auto Level only)
4.1-35 All Outriggers Inoperative (Auto Level only)
4.1-36 Left Front Outrigger Inoperative Manually
4.1-37 Right Front Outrigger Inoperative Manually
4.1-38 Right Rear Outriggers Inoperative Manually
4.1-39 Left Rear Outriggers Inoperative Manually
4.1-40 Individual Outrigger Functions Inoperative (Auto-Level)
4.1-41 Auto-Level Inoperative
4.1-42 Auto All Up Inoperative (Retract)
Hydraulic System
4.2-1 All Functions Inoperative
4.2-2 Steering Inoperative
4.2-3 Lift, Steer and First Drive Speed Inoperative
4.2-4 Second Drive Speed Inoperative
4.2-5 Drive Inoperative
4.2-6 Drive Sluggish
4.2-7 Reverse Drive Inoperative
4.2-8 Forward Drive Inoperative
4.2-9 Drive Inoperative When in Low Drive
4.2-10 Drive Inoperative When in High Drive
4.2-11 Brakes Does not Release
4.2-12 Up Circuit Inoperative
4.2-13 Down Circuit Inoperative
4.2-14 Hydraulic Generator Inoperative
4.2-15 All Outriggers Inoperative
4.2-16 Left Front Outriggers Inoperative
4.2-17 Right Front Outriggers Inoperative
4.2-18 Right Rear Outriggers Inoperative
4.2-19 Left Rear Outriggers Inoperative
4.2-20 Outriggers Drift In

Section 5. PROCEDURES
General
Safety and Workmanship
Base
5.1-2 Wheel Bolt / Nut Inspection and Torquing Procedure
5.1-3 Wheel Reinstallation and Torquing Procedure
5.1-4 Reconnecting the Platform Control Box for Use from the Ground
5.1-5 Tightening and Torque Recommendations for Hydraulic Couplings and Hoses
5.1-6 Checking the Holding Valve
5.1-7 System Pressure Setting
5.1-8 Lift Pressure Setting
5.1-9 Grease Points
5.1-7 Electronic Tilt Switch Setup Procedure
Engine
5.2-1 Kubota Dual Fuel (DF972 / WG752) Resistance Checks
5.2-2 Fan Belt Replacement and Adjustment
5.2-3 Kubota Dual Fuel (DF972 / WG752) Engine Throttle Setting
5.2-4 Kubota Diesel (D902) Engine Throttle Setting
5.2-5 Replacing the Air Cleaner Element
5.2-6 Replacing the Fuel Filter Element (Kubota D902)
5.2-7 Bleeding the Fuel System of Air (Kubota D902)
5.2-8 Replacing the Oil Filter Cartridge
5.2-9 Changing the Oil
5.2-10 Checking and Replenishing the Radiator Coolant Level
5.2-11 Draining and Refilling the Radiator
Outriggers
5.3-1 Auto-Leveling Outrigger PC Board Layout
5.3-2 Outrigger Mechanical Limit Switch Wiring Diagram
5.3-3 Auto-Leveling Outrigger Settings and Error Codes
5.3-4 Auto-Leveling Outrigger Error Code Breakdown
5.3-5 Hand Held Calibration/Diagnostic Tool Key Functions
5.3-6 Outrigger Control Module Instructions
5.3-7 Auto-Leveling Outrigger Control Module Pin Reference Chart
5.3-8 Outrigger Upper Limit Switch (LS61, LS62, LS63, LS64) Replacement and Adjustment
5.3-9 Outrigger Lower Limit Switch (LS65, LS66, LS67, LS68) Replacement and Adjustment
Scissors
5.4-1 High Speed Cutout Limit Switch (LS5) Replacement and Adjustment
Platform
5.5-1 Gate Springe Hinge Adjustment.