troubleshooting guide - · pdf fileeach symptom described is followed by a list of inspections...

P/N 0172021June 1999

diesel - gasoline - LPG

P.O. Box 1160 St. Joseph, MO 64502-11601-800-255-0317 Fax: 816-360-9379

www.snorkelusa.com

TroubleshootingGuide

1

GENERAL INFORMATIONThis manual contains procedures for locating and correcting the majority of problems which maydevelop on the “Snorkelift” TB 37 Aerial Platform.

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 disregardinga DANGER.

NOTE: Engine maintenance and troubleshooting information not contained in this manual may befound 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 related areaswhich confirm or decline the outcome. If the inspection is declined the flowchart will refer to the nextstep 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) 9Starter disengages before engine starts 10Engine cranks over but will not start 10Engine starts then shuts down after 30 seconds 11Engine will not accelerate 11Engine over accelerates 12Engine will not start from platform control 12Engine starts while cranking, then dies when key switch is released 13

Section Two - Hydraulic DiagnosticsHydraulic system functions on emergency power only 39Hydraulic pump stays on stroke 39Hydraulic oil overheats during operation 39Hydraulic functions are sluggish 40Hydraulic pump will not build pressure 40Hydraulic pump will not build enough pressure 40Flow from hydraulic pump is too low 40Flow from hydraulic pump is too high (kills engine) 41

Section Three - Steering System DiagnosticsMachine will not steer 53

4

SYMPTOM PAGE NUMBER

Section Four - Drive System DiagnosticsDrive system is not operational with controller in either direction 61No forward drive (Reverse OK) 62No reverse drive (Forward Ok) 62Drive high range not operating 63Machine drives at full speed with platform raised and/or extended 63Brakes will not release 63Only one wheel turns (2 wheel drive) 64One wheel turns faster than other (2 wheel drive) 64

Section Five - Emergency Power System DiagnosticsEmergency pump motor non-operational 85No functions when on emergency power 85

Section Six - Swing System DiagnosticsSwings only in one direction 93No response from swing when platform controls are activated (Ground Controls Ok) 93No response from swing when ground controls are activated 93Swings erratically in either direction 94Swings faster one way than other 94Swing brake will not hold 94Swings too slow 95

Section Seven - Platform Rotation System DiagnosticsPlatform rotate does not operate 109Platform rotates itself 109

5

SYMPTOM PAGE NUMBER

Section Eight - Platform Leveling System DiagnosticsPlatform will not maintain level as boom raises or lowers 115Platform will not maintain level with machine off 115Platform level will not work from ground control 115Platform level will not work from platform control (Ground Control Ok) 116Platform level up function is inoperative 116Platform level down function is inoperative 116

Section Nine - Boom Elevation System DiagnosticsBoom raises but will not stay elevated 129Boom will not raise from platform control (Ground Control Ok) 129Boom will not raise from ground control 129

Section Ten - Telescope System DiagnosticsBoom will not retract from ground control 137Boom will not retract from platform control (Ground Control Ok) 137Boom will not extend from ground control 137Boom will not extend from platform control (Ground Control Ok) 138Boom drifts in 138

Section Eleven - Fuel System DiagnosticsEngine will not start on gasoline, but will start on L.P. 151Engine will not start on L.P., but will start on gasoline 151

6

SYMPTOM PAGE NUMBER

Section Twelve - Accessories DiagnosticsAC Generator will not function 159AC Generator has low voltage 159Machine will not steer 159

SECTION ONE:ENGINE DIAGNOSTICS

SECTION ONEENGINE DIAGNOSTICS

Troubleshooting Guide 9 TB 37

InspectStarter Solenoid

InspectPower Cables and

Battery Disconnect Switch

InspectGround Control

Circuit Breaker (25 Amp)

InspectEmergency Stop Switch

InspectGround Master (Key) Switch

InspectEngine Starter Relay

InspectIgnition/Emergency

Power Switch

InspectGround/PlatformSelector Switch

InspectEngine Anti-Restart Relay

Engine starterfails to operate(No Electrical)

Go to Page14

InspectBattery and Cable Connections

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

InspectAmmeter

Go to Page15

OKStep 3



Starterdisengages before

engine startsGo to Page

20Inspect

Engine Anti-Restart Relay

Engine cranksover but

will not startGo to Page

21Inspect

Ground Master (Key) Switch

Go to Page21

InspectGround/Platform Selector Switch

Go to Page22

InspectIgnition/Emergency Power Switch

Go to Page22

InspectRun Relay

Go to Page23

InspectMagnetic Switch

(Ford only)

Go to Page23

InspectMagnetic Switch

(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 will notaccelerate

Go to Page26

InspectThrottle Circuit Breaker (15 Amp)

Go to Page26

InspectMedium Throttle Relay

(Ford only)

Go to Page27

InspectHigh Throttle Relay

(Ford only)

Go to Page27

InspectThrottle Governor or Controller

(Ford only)

Go to Page28

InspectActuator

(Ford only)

OK

OK

OK

OK

Chart 5

Step 1

Step 2

Step 3

Step 4

Step 5

Go to Page28

InspectThrottle Relay(Deutz only)

Go to Page29

InspectThrottle Solenoid

(Deutz only)

OK

Step 6

Step 7

OK

Engine startsthen shuts downafter 30 seconds

Go to Page25

InspectEngine Temperature Gauge

Go to Page25

InspectEngine Oil Pressure Switch

OK

Chart 4

Step 1

Step 2



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

InspectPlatform Control

Circuit Breaker (20 Amp)

Go to Page32

InspectEmergency Stop Switch

Go to Page32

InspectFoot Switch

Go to Page32

InspectPlatform Start Switch

OK

OK

OK

Chart 7

Go to Page31

InspectGround/Platform Selector Switch

OK

Go to Page33

InspectIgnition/Emergency Power Switch

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

InspectMurphy Switch

OKStep 2

Go to Page35

InspectVacuum Switch

(Ford only)

OKStep 2



Engine starter fails tooperate (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

Position

If 12-12.7V

Using a meter set toread voltage, turn

Battery Disconnect Switchto On position, measure

voltage coming out ofBattery Disconnect SwitchShould read 12-12.7 volts

Reset BatteryDisconnect Switch

to On Position

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 for12 volts while

under load

Recharge orreplace

battery(s)

Check batteryconnections

If loose

If low or no voltage

Clean allconnections

Tighten allconnections

Ifcorroded

If 12V

Step 1Step 2

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



Using a meter set to readvoltage, turn BatteryDisconnect Switch to

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

Step 3

Step 4Inspect

Ground ControlCircuit Breaker

(25 Amp)

Circuit breaker isopen If low or no reading

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


Repair or replaceCircuit Breaker

and/orCircuit Breaker wiringGo to step 4

If12-12.7V



Step 5Step 6

InspectGround 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 10-12 voltsGo to step 7

Repair or replaceGround Master Switch

and/orGround Master Switch

wiring

If10-12V


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 readingPull Emergency

Stop Switch (out)to the On position

If

ReplaceEmergency Stop Switch

and/orEmergency Stop Switch

wiringGo to step 6

If10-12V

Then



Step 7Step 8


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

activate starter andmeasure voltage betweenIgnition/Emergency Power

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

Ground/PlatformSelector Switch isin Platform position

Return Ground/Platform SelectorSwitch to Ground

position

Then

If

Go to step 9


ReplaceGround/Platform Selector

Switch and/orGround/Platform Selector

Switch wiring

If10-12V


Power Switch

Using a meter set toread voltage, activate

engine starter andmeasure voltage

betweenGround Master Switch andIgnition/Emergency Power

SwitchShould read 10-12 voltsGo to step 8 If

10-12V


ReplaceIgnition/Emergency Power

Switch and/orIgnition/Emergency Power

Switch wiring



Step 9Step 10

InspectEngine Starter

Relay


engine starter and measurevoltage from

1. wire #5B to StarterRelay.

2. wire from StarterRelay to Ground


Check groundcontinuity

If10-12V


ReplaceEngine Starter

Relay

No continuity

ReplaceEngine Starter Relay wiringGo 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

If10-12v

If lowor no

reading

If stilldoesnot

engage



Step 11




1. wire #5A to StarterSolenoid

2. Starter Solenoid toGround



If10-12V


ReplaceStarter Solenoid

No continuity

ReplaceStarter Solenoid wiringReturn to step 1

Continuity



Disconnect wire 164Bfrom Alternator. Checkcontinuity between post

and alternator case.

InspectEngine Anti-

Restart Relay

Repair or replaceAlternator

Open field in alternator

No continuity

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 time, until enginestarts and alarm shuts off.

(approx. 30 seconds)

Starter disengagesbefore engine starts

Step 1

Continuity




1. wire #5A to StarterSolenoid

2. Starter Solenoid toGround



If10-12V


ReplaceStarter Solenoid

No continuity

ReplaceStarter Solenoid wiringReturn to step 1

Continuity

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 ignition side of

Ground Master Switch.Should read 10-12 voltsGo to step 2

Repair or replaceGround Master Switch

and/orGround Master Switch

wiring

If10-12V

No reading

Check Battery

If reading is low

Engine cranks overbut will not start

Step 2Inspect

Ground/PlatformSelector Switch

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



Ground/PlatformSelector Switch

is inPlatform position

Return Ground/Platform SelectorSwitch to Ground

position

Then

If

Go to step 3

No reading



Switch wiring

Check Battery

Ifreading is low

If10-12V



Step 3Step 4

Inspect Ignition/Emergency Power

Switch

Go to step 4

ReplaceIgnition/EmergencyPower Switch and/

orIgnition/Emergency

Power Switchwiring

Check voltage on diodewire between Ignition/

Emergency Power Switchand Ground/Platform

Switch. Replace diode wireif faulty. Measure voltage

entering Run Relay(wire #4A)


Using a meter set toread voltage,

measure voltageentering Ignition/

Emergency Power SwitchShould read 10-12 volts


InspectRun Relay


measure voltage 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

If10-12V

If lowor no

reading



Step 5Step 6

Inspect Magnetic Switch

( Ford only)


on wire1. at post NC ofMagnetic Switch

2. on wire 80 betweenMagnetic Switch andEngine Spark Module


ReplaceMagnetic Switch and/or Magnetic Switch wiring


Inspect Magnetic Switch

( Deutz only)


measure voltage on wire#8D at post NC of Magnetic Switch


ReplaceMagnetic Switch and/or Magnetic Switch wiring


If OkReplace

Engine SparkModule

If OkGo to step 7



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

If Ok

If lowor no

readingRepair Wire



Step 1Step 2

Engine starts then shutsdown after 30 seconds

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

ReplaceEngine Oil Pressure Switch

InspectEngine Oil

Pressure Switch

Engine oilpressure is due to

inadequate oil level

Using a meter set to readohms, check for continuityfrom wire #3C to Ground

Should not read continuityThen

If oil levelis adequate

Fill to proper levelwith oil

Remove wire #3C from OilPressure Switch.Restart engine

If If engine still dies

If enginenow ok

If lowor no

readingRepair Wire

Repair Wire

If continuity existsIf no

continuity

Return to step 1



Step 1Step 2

Engine will notaccelerate Inspect

Throttle CircuitBreaker (15 Amp)

Using meter set to readvoltage, measure voltage

Ford: entering eitherMedium Throttle Relay wire

#55A or High ThrottleRelay wire #55B

Deutz: on wire #55Abetween Throttle Relayand Throttle Solenoid


Circuit breaker isopen


Check continuity on wire#55 between ThrottleCircuit Breaker and

Medium Throttle Relay orHigh Throttle Relay

Reset Circuitbreaker

Then

If

Repair or replaceCircuit Breaker and/orCircuit Breaker wiring

Go to step 2(Ford)

Go to step 6(Deutz)

If continuity does not exists

InspectMedium Throttle

Relay(Ford only)


measure voltageon wire #55A to

Throttle ControllerShould read 10-12 volts


Check continuity on wirebetween Medium Throttle

Relay and ThrottleController

Repair or replacewiring from

Medium Throttle Relayto Throttle Controller

Then

Go to step 3

Ifcontinuity

doesexists

If10-12V



Step 3Step 4

InspectHigh Throttle

Relay(Ford only)

Using meter set toread voltage,

measure voltageon wire #55B to

Throttle ControllerShould read 10-12 volts


Check continuity on wirebetween High Throttle

Relay and ThrottleController

Repair or replacewiring from

High Throttle Relayto Throttle Controller

Then

Go to step 4

InspectElectronicGovernor

(Ford only)


measure voltageon wire #55A and #55B

going into theElectronic Governor



Repair or replacewiring to

Electronic Governor

Go 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 voltageon wire #55A betweenThrottle Circuit Breakerand Throttle Solenoid



Check continuity on wirebetween ThrottleCircuit Breaker

and Throttle Solenoid

Repair or replacewiring between

Throttle Circuit Breakerand Throttle Solenoid

If no continuity

Go to step 7

If10-12V



Step 7

Inspect Throttle Solenoid

(Deutz)

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

into Throttle Solenoid2. on wire #55A between

Throttle Solenoid andground

Should read 10-12 voltsIf low or no reading

Repair or replace Throttle Solenoid

and/or Throttle Solenoid wiring

If problem still exists

Adjust Throttle Solenoid



Step 1Step 2

Engine overaccelerates

InspectElectronicGovernor


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

going into theElectronic Governor



Repair or replaceFord: wiring to

Electronic Governor

Go to step 2 If10-12V

InspectActuator


measure voltageon 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 1Step 2

Engine will not startfrom platform control

InspectPlatform ControlCircuit Breaker

(20 Amp)

Using a meter set to readvoltage, turn Ground/

Platform Switch to Platformposition, 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


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



Ground/PlatformSelector Switch isin Ground position

Return Ground/Platform SelectorSwitch to Platform

position

Then

If





Switch wiring

ReplaceCircuit Breaker

If lowor no

reading

If lowor no

reading

If 10-12V

If10-12V



Step 3Step 4

InspectFoot Switch and

Wiring

Make sure Foot Switch isnot activated

Deactivate Foot SwitchIfnot

activatedUsing 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 activated

InspectEmergency Stop

Switch

Using a meter set to readvoltage, pull Emergency

Stop Switch out andmeasure voltage betweenEmergency Stop Switch

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

Emergency StopSwitch is off(pushed in)


Pull EmergencyStop Switch (out)to the on position

Then

If

ReplaceEmergency Stop Switch

and/orEmergency Stop Switch

wiringGo to step 4 If10-12V


Repair or replaceFoot Switchand/or wiring

If10-12VGo to step 5



Step 5


Power Switch



on wire #5 betweenPlatform Master Switchand Ignition/Emergency

Power SwitchShould read 10-12 voltsReturn to step 1 If

10-12V


ReplaceIgnition/Emergency Power

Switch and/orIgnition/Emergency Power

Switch wiring

Step 6

InspectPlatform Start

Switch


Platform Start Switch andmeasure voltage on

wire #5 betweenPlatform Start Switch and

Platform Emergency PowerSwitch

Should read 10-12 voltsGo to step 6 If10-12V


ReplacePlatform Start Switch

and/orPlatform Start Switch

wiring



Step 1

Engine starts whilecranking, then dies whenkey switch is released

InspectRun Relay


measure voltageat Murphy Switch wire

#164, B post ofMurphy Switch



Repair or replaceRun Relay

and/orRun Relay wiring

Step 2


InspectMurphy Switch


on wireFord: on wire #80 to

Spark ModuleDeutz: #8D between Run

Solenoid and MurphySwitch

Should read 10-12 voltsNote: Check continuity

to ground on whitejumper wire


ReplaceMurphy Switch

FordGo to step 3

If10-12V



InspectVacuum Switch

(Ford only)

Check continuity on wirebetween Ignition and

Solenoid when switch is innormally closed position

If no continuity

ReplaceVacuum Switch

Step 3

SECTION TWO:HYDRAULIC DIAGNOSTICS

SECTION TWOHYDRAULICS DIAGNOSTICS


Hydraulic systemfunctions on

emergency poweronly

Go to Page42

InspectMain Hydraulic Pump

Go to Page42

InspectSense Line Dump Valve

Hydraulic pumpstays on stroke

Go to Page44

InspectPump Compensator

Chart 1

Chart 2

OK

Step 1

Step 2

Step 1

Go to Page43

InspectSense Line check Valve

OKStep 3

Hydraulic oiloverheats

during operationGo to Page

44Inspect

Functions Valve

Chart 3

Step 1



Hydraulic functionsare sluggish

Go to Page45

InspectEngine RPM

Go to Page45

InspectPump Pressure

Go to Page46

InspectAccumulator

Go to Page46

InspectFlow from Pump

Chart 4

OK

OK

OK

Step 1

Step 2

Step 3

Step 4

Hydraulic pump willnot build pressure

Go to Page47

InspectPump Compensator Valve

Chart 5

Step 1

Hydraulic pumpwill not build

enough pressureGo to Page

48Inspect

Pump Compensator Valve

Go to Page48

InspectSenseline Dump Valve

Chart 6

OK

Step 1

Step 2

Flow fromhydraulic pump

is too lowGo to Page

49Inspect

Flow Adjustment on Main HydraulicPump

Chart 7

Step 1

Go to Page47

InspectPump Coupling

OKStep 2



Flow fromhydraulic pump

is too high(kills engine)

Go to Page49

InspectFlow Adjustment on

Main Hydraulic Pump

Chart 8

Step 1



Inspect Main Hydraulic

Pump

Remove gaugeand

Go to step 2

CheckMain Hydraulic Pump,Pump Coupling andPump Compensator

Install 1000 psi pressuregauge to hydraulic pumptest plug. Set engine for

idle and measuredifferential/standby

pressure.Should read 300 psi

If reading is abnormalReplaceMain Hydraulic

Pump and/or PumpCoupling and/or

PumpCompensator

Ifmal-

functioning

Hydraulic systemfunctions on emergencypower only

Step 1Step 2

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 voltage

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

2.on wire # 28B atSense Line Dump Valve



Repair or replaceSense Line Dump

Valve

If bad

Ok

Go to step 3

If300 psi



Step 3

InspectSense Line Check

Valve

Return to step 1Replace

Sense Line Check Valve

Remove and inspect SenseLine Check Valve fromMain Hydraulic ValveValve should operate

freely.

If notIf Ok



Hydraulic pumpstays on stroke

Step 1

InspectPump

CompensatorValve


Valve

Repair or replacePump Compensator

Remove hose fromcompensator. Recheck

pressure on Pump.

If stays on stroke


Hydraulic oiloverheatsduring operation

InspectFunctions Valve

Repair or replaceFunctions Valve

SwitchManual Overridesto the On position

Heating stops

Heatingcontinues

Repair or replaceHosing

Step 1

Ifgoesoff

stroke

If bad



Step 1

Step 2

Hydraulic functionsare sluggish

InspectEngine RPM

AdjustThrottle 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 correctRPM

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.Install 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 to 14 gpm and

pressure gauge shouldread 300 psi


Remove gaugesand

Return to step 1

If12 to

14 gpmand

300 psi



Step 1Step 2

Hydraulic pump willnot build pressure

InspectPump

CompensatorValve

Go to step 2

Remove hoses fromSense Line Dump Valveto Compensator Valve

and reattach toPressure Line. Using a

5000 psi pressure gaugecheck pressure.

Should read 2800 psiIf lowor no

reading

Remove gauge andcheck seals on

Sense Line Dump Valve


If bad

InspectPump Coupling

Repair or replacePump Coupling

RemoveMain Hydraulic Pump

visually checkPump Coupling

If bad

Ok

Repair or replaceCompensator

and/orMain Hydraulic Pump

If 2800 psi



Step 1Step 2

Hydraulic pump will notbuild enough pressure

Inspect Sense Line Dump

Valve


Valve

If10-12V


wiring

Using meter set to readvoltage, activate Ground

Control Switch andmeasure voltage

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

2. On wire # 28B atSense Line DumpValve



Repair or replaceSense Line Dump

Valve

If bad

InspectPump

CompensatorValve

Go to step 2

Remove hoses fromSense Line Dump Valveto Compensator Valve

and reattach toPressure Line. Using a

5000 psi pressure gaugecheck pressure.

Should read 2800 psi

If lowor no

reading

Remove gauge andcheck seals on

Sense Line Dump Valve


If bad

If 2800 psi



Step 1Step 1

Flow from hydraulicpump is too low

Flow fromhydraulic pumpis too high(kills engine)

InspectFlow Adjustment

on Main HydraulicPump

Visually check FlowAdjustment Screw on Main

Hydraulic PumpScrew should extendbetween 3/4" and 7/8"

from face of pump

ResetFlow Adjustment on Main

Hydraulic Pump

InspectFlow Adjustment

on Main HydraulicPump

Visually check FlowAdjustment Screw on Main

Hydraulic PumpScrew should extendbetween 3/4" and 7/8"

from face of pump

ResetFlow Adjustment on Main

Hydraulic Pump

SECTION THREE:STEERING SYSTEM DIAGNOSTICS

SECTION THREESTEERING SYSTEM DIAGNOSTICS


Machine will notsteer

Go to Page54

InspectSwitch for Blocking Valve

Ground Signal (at steer Switch)

Go to Page54

InspectBlocking Valve Relay and Relay

Wiring

Go to Page55

InspectSteer Switch (Right)

Go to Page56

InspectSteer Switch (Left)

Go to Page56

InspectSteer Control Valve

Go to Page57

InspectCenter Post

OK

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 4

Step 5

Step 6

Step 7

Go to Page55

InspectBlocking Valve

OKStep 3

Go to Page57

InspectTow Package Float Valve

OKStep 8



InspectSwitch for Blocking

Valve GroundSignal (at steer

Switch)

Go to step 2 Ifcontinuity

ReplaceSteer Switch

and/orSteer Switch wiring

Using a meter set to readcontinuity, activate Steer

Switch and checkfor ground

1. on wire #100 betweenSteer Switch andJunction Box

2. at wire #100 inJunction Box

Should show continuity toground

If no continuity

Machine will not steer

Step 1Step 2

Note:At this point the manualoverride may also beuse to isolatethe solenoid, howeveruse caution as themachine will 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

Switch andcheck for ground

1. on wire #100 betweenTerminal Strip inJunction Box andRelay

2. on wire #100 enteringRelay

If no continuity

Ifcontinuity



Step 3Step 4

InspectSteer Switch

(Right)


ReplaceSteer Switch (Solenoid)

and/orSteer Micro (Solenoid)

wiring


Steer Switch Right andmeasure voltage

1. on wire #20 betweenSteer Switch and SteerControl Valve

2. on wire #20 at SteerControl Valve




Go to step 4Repair or replace

Blocking Valve Cartridge

Visually check BlockingValve Cartridge for

binding

Should normally be open.

If stuckIf

Ok

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



Step 5

Step 6Inspect

Steer ControlValve

Go to step 7 Readjust to 1500 psi

ActivatingManual Overrides and

check pressure

Should be 1500 psi

If lower than 1500 psi

If approx.1500 psi

InspectSteer Switch (Left)


ReplaceSteer Switch (Solenoid)

and/orSteer Switch (Solenoid)

wiring

Using a meter set toread voltage, activateSteer Switch Left and

measure voltage1. on wire #19 between

Steer Switch (Left) andSteer Control Valve

2. on wire #19 at SteerControl Valve



During activation ofsteering function themachine will be moving.



Step 7

InspectCenter Post

Repair or replaceSteer Cylinder

Note: Machineswith optionalTow 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

If reading is abnormal

InspectTow Package Float

Valve

Refer to Chapter 12Accessories Diagnostics

During activation ofsteering function themachine will be moving.

Step 8

SECTION FOUR:DRIVE SYSTEM DIAGNOSTICS

SECTION FOURDRIVE SYSTEM DIAGNOSTICS


Drive system is notoperational with

controller in eitherdirection

Go to Page65

InspectFoot Switch

Go to Page65

InspectDrive Circuit Breaker (3 amp)

Go to Page66

InspectController Circuit Board and S1

Micro Switch Wiring

Go to Page66

InspectS1 Micro-Switch (in Controller)

Go to Page67

InspectController Circuit Board

Go to Page67

InspectPotentiometer

Go to Page68

InspectS2 Micro-Switch (in Controller)

Go to Page68

InspectDrive Solenoid

Go to Page69

InspectDrive Control Valve

Go to Page69

InspectCenter Post

Go to Page70

InspectShuttle Valve Portion 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 Page71

InspectS2 Micro-Switch

(in Drive Controller)

Go to Page71

InspectDrive Controller Circuit Board

Go to Page72

InspectSolenoid

(Drive Forward on Control Valve)

Go to Page72

InspectDual Counterbalance Cartridge

No reverse drive(forward ok)

Go to Page73


(in Drive Controller)

Go to Page73

InspectDrive Controller Circuit Board

Go to Page74

InspectSolenoid Valve

(Drive reverse on Control Valve)

Go to Page74

InspectDual Counterbalance Cartridge

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



InspectSelector Spool in Transmission

Package

Drive high rangenot operating

Go to Page75

InspectDrive Low/High Range Switch

Go to Page75

InspectBoom Position and/orBoom Limits Switch

Go to Page76

InspectRange Valve

Go to Page76

Machine drives atfull speed withplatform raised

and/or extended

Go to Page78

InspectBoom Limits Switch

Go to Page78

InspectRange Valve

OK

OK

OK

OK

Chart 4

Chart 5

Brakes will notrelease

Go to Page79

InspectBrake Pressure

Chart 6

Step 1

Step 2

Step 3

Step 4

Step 1

Step 2

Step 1

InspectPower to R Terminal

Go to Page77

OKStep 5



Only one wheelturns

(2 wheel drive)Go to Page

80Inspect

Case Drain

Go to Page80

InspectFlow Divider

One wheel turnsfaster than other(2 wheel drive)

OK

Chart 7

Chart 8

Step 1

Step 2

Go to Page81

InspectCase Drain

Go to Page81

InspectFlow Divider

OK

Step 1

Step 2



InspectFoot switch


Foot Switch andmeasure voltage

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 controller ineither direction

Step 1Step 2

InspectDrive Circuit

Breaker (3 amp)



1. on wire #69 betweenCircuit Breaker andDrive Controller

2. at positive (+) post ofDrive controller



ReplaceFoot Switch and/orFoot Switch wiring




Step 3Step 4

InspectController Circuit

Board and S1Micro-Switch

Wiring



1. on red wire fromCircuit Board toS1 Micro-Switch

2. at red wire ofS1 Micro-Switch



ReplaceCircuit Board

and/orS1 Micro-Switch wiring



(in Controller)

Using a meter set toread voltage, step on

Foot Switch andactivate Controller,measure voltage

1. on black wire betweenS1 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 controller handle ineither direction andobserve red LED on

Circuit Board Controller

If not lit

If lit

If lowor no

voltage




Step 5Step 6


Foot Switch andactivate Controller,measure voltage

1. on green wire toPotentiometer fromController Circuit Board

2. on wire betweenController Circuit Board

and PotentiometerShould read 10-12 volts


ReplaceController Circuit Board

and/orController Circuit Board

wiring


InspectController Circuit

Board

InspectPotentiometer

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

wire between ControllerCircuit Board andPotentiometer

2. green wire and orangewire between ControllerCircuit Board andPotentiometerReading should vary

according to Controllermovement

If no reading

Check continuity on wirebetween Controller CircuitBoard and Potentiometer

Go to step 7

continuity

ReplacePotentiometer

and/orPotentiometer

wiring

Nocontinuity



Step 7Step 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 continuityon blue wire and

on white wirebetween ControllerCircuit Board andS2 Micro-Switch

If noreading

ReplaceS2 Micro-Switch

and/orS2 Micro-Switch

wiring

No Continuity

Go to step 8

Continuity

Push Manual Overridewhile activating variouscontroller functions and

check operation.

If functions are abnormal or erratic

Replace Drive Section Control Valve

Go to step 9

InspectDrive Solenoid

Machine function will bemoving when manualoverride is activated.

Iffunctions

arenormal



Step 9Step 10

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

pressure gauge toPump Test Port.

While activating drivecontrol function, check


(while activating function)

If functions are abnormal or erratic

ReplaceValves on Drive Section

of Control Valve

Remove gaugeand

Go to step 10

InspectDrive Control

Valve

InspectCenter Post

Remove hoses at V1 andV2 ports of Dual

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

test gauge toPump Test Port

While activating drivecontrol function, check


(while activating function)

If pressures are abnormal or erratic

Repair or replaceCenter Post

Remove gaugeand

Go to step 11

If functionsare normal

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

InspectShuttle Valve

Portion of DualCounterbalance

Valve

equal pressure



Step 1Step 2

No forward drive(Reverse Ok)

InspectDrive Controller

Circuit Board

Using a meter set toread voltage, activate drive

function and measureproportional voltage at

Terminal A ofCircuit Board.

Reading should varyaccording to controller

movement.

If no or erratic reading

ReplaceDrive Controller Circuit

Board

Go to step 3 Ifnormal


(in DriveController)


Check continuity on bluewire between S2 Micro-Switch and Controller

Circuit Board

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

from S2 Micro-Switchenters.


movement.

If low or no readingReplaceS2 Micro-Switch

and/orS2 Micro-Switch

wiringno continuity



Step 3Step 4

Replace theDual Counterbalance Valve

Cartridge tested

InspectDual

CounterbalanceValve Cartridge

Using a 5000 psi pressuretest gauge activate drive

function 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

Override allows operation

Overridedoes not

allowoperation




Step 1Step 2

No reverse drive(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 erratic reading

ReplaceDrive Controller Circuit

Board



(in DriveController)


Check continuity on whitewire between S2 Micro-Switch and Controller

Circuit Board

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

S2 Micro-Switch enters.Reading should vary

according to controllermovement.

If low or no readingReplace

S2 Micro-Switchand/or

S2 Micro-Switchwiring

No continuity



Step 3Step 4

Replace theDual Counterbalance Valve

Cartridge tested

InspectDual

CounterbalanceValve Cartridge

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 proportionalvoltage at wire #18 on

Drive section ofControl Valve.


movement.

If no reading

Override allows operationOverridedoes not

allowoperation




Position Booms to fullyretracted and down

position. Adjust BoomRetract/Down Limit Switch

InspectBoom Position

and/orBoom Limit Switch

Booms are not positionedfor High Range speed

operationsBoom Limit Switch are

not Adjusted

Step 1Step 2

Drive high rangenot operating Inspect

Drive Low/HighRange Switch

Go to step 2If lowor no

reading


voltage on wire #16A goinginto the Low/High Drive

Range SwitchShould read 10-12 volts


ReplaceDrive Low/High Range

Switch and/orDrive Low/High Range

Switch wiring

Check for 10-12 volts atwire #70A at BoomExtend Limit Switch

still not operating

Repair or replaceBoom Extend Limit

Switch and/orwiring

Check for 10-12 volts onwire #16A at Boom Up

Limit Switch

Measure voltage onwire #11 coming out of

the Low/High DriveRange Switch.


If 10-12V

Go to step 3 If 10-12V

If 10-12V

If novoltage

Repair or replaceBoom Up LimitSwitch and/or

wiring

If novoltage

If 10-12V

Repair or replaceWiring to Drive

Low/High RangeSwitch



Step 3Step 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 Drive Pressure

If no reading

Repair or replaceWiring to Range Valve

Go to step 4

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

If10-12V

If Ok

Ifpressure

is low

Repair or replaceSelector Spool in

Transmission Package

InspectSelector Spool in

TransmissionPackage

Go to step 5

Verify that Selector Spool isshifting by checking

drive speed.Should be 1-1.5 mph.

deactivatedand 2-3 mph. activated.

(3 mph = 100 ft in 22 sec)

If speeds are 1-1.5 andSelector Spool is not shifting

If speedsare

reachedand

SelectorSpool

is shifting



Step 5

Return to step 2

InspectPower to RTerminal

Adjust High Speed Trim Poton controller to get

3 mph + 100 ft in 22 sec.

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 connectionon Boom Wirebetween BoomSwitches and

Platform

Iflow



Step 1Step 2

Machine drives at fullspeed with platformraised and/or extended

InspectBoom Limits

Switch

Boom 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 Drive pressure

Repair or replaceRange Valve

Check for stuckSelector Valve on

Transmission Package

If0 psi

Go to step 2problem

stillexists



Brakes will notrelease

Step 1

InspectBrake Pressure

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

2. Take pressure readingat Pump Compensator

Readings should besimilar

Repair or replaceBrake Shuttle Valve



Step 1Step 2

Only one wheel turns(2 wheel drive)

InspectCase Drain

Disconnect existing hose,install a flowmeter

between existing hoseand Drive Motor.

Should be no more than.5 gpm while driving

If more than .5 gpm

Repair or replaceDrive Motor

Go to step 2

InspectFlow Divider

Remove Flow Divider fromDrive Control Valve.

Visually check for brokenspringsRepair or replace

as neededIf Ok

Repair or replace ReliefValve in Drive Control

Valve

If bad

Note:Make sure Hubs are engaged.

If lessthan

.5 gpm



Step 1

Step 2

One wheel turns fasterthan other (2 wheel drive)

InspectCase Drain

Disconnect existing hose,install a flowmeter

between existing hoseand Drive Motor.

Should be no morethan .5 gpm

If more than .5 gpm

Repair or replaceDrive Motor

Go to step 2If lessthan

.5 gpm

InspectFlow Divider

Remove Flow Divider fromDrive Control Valve.

Visually check for brokenspringsRepair or replace

as neededIf Ok

Repair or replace ReliefValve in Drive Control

Valve

If bad

SECTION FIVE:EMERGENCY POWER SYSTEM DIAGNOSTICS

SECTION FIVEEMERGENCY POWER SYSTEM DIAGNOSTICS


Emergency pumpmotor non-operational

Go to Page86

InspectEmergency Power Switch

Go to Page87

InspectEmergency Power Solenoid

and Wiring

Go to Page87

InspectEmergency Power Unit

No functions whenon emergency

power

Go to Page88

InspectEmergency Power Pump

OK

OK

Chart 1

Chart 2

Step 2

Step 3

Step 4

Step 2

Go to Page86


OK

Step 1

Go to Page88


OK

Step 1

Go to Page89


OKStep 3



Repair or ReplaceEmergency PowerSwitch Terminalwiring (wire #6)

and/orEmergency Power

Solenoid wiring(wire #6A)

and/orEmergency 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 voltage

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 continuity

InspectBatteries



under load

Recharge orreplace

battery(s)


If loose




Ifcorroded

If 12V




Step 3

Repair or ReplaceEmergency Pump Motor


Unit

If previous checks havebeen performed and found

to be normal, checkEmergency Pump Motor

for internal groundingcondition

Repair or ReplaceWiring from BatteryDisconnect Switch

to EmergencyPower Solenoid

and/or Emergency PowerUnit wiring and/orEmergency Power

Solenoid


Solenoidand Wiring

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. activate EmergencyPower Switch andmeasure voltage atEmergency PumpMotor


If no reading

If10-12V

Step 4

Nocontinuity



Step 1

No functions when onemergency power

Step 2

InspectBatteries



under load

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, activate

Emergency Power Pumpand Ground Control Switch

or Foot Switch.Should read 3000 psi.

If reading is abnormal or erratic

Remove gaugeand

Go to step 3

IfOk



Step 3


Refer back toChapter 3, Chart 1

Step 3

Repair or replaceBlocking Valve Cartridge

With Ground ControlSwitch activated, use a

meter set to read voltageand measure voltage

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

If 10 to 12V

Ifno voltage

SECTION SIX:SWING SYSTEM DIAGNOSTICS

SECTION SIXSWING SYSTEM DIAGNOSTICS


No response fromswing when

platform controlsare activated

(GroundControls Ok)

Go to Page97

InspectFoot Switch

Go to Page97

InspectSwing Switch

Go to Page99

InspectSwing Valve

Go to Page99

InspectSwing Motor and Gear Box

OK

OK

OK

Chart 2

Step 1

Step 2

Step 3

Step 4

Swings only inone direction

Go to Page96

InspectSwing Control Signal Wire

Go to Page96

InspectSwing Control Valve

OK

Chart 1

Step 1

Step 2

No response fromswing when groundcontrol is activated

Go to Page98

InspectGround Control Switch

and Wiring

Go to Page98

InspectSwing Switch

OK

Chart 3

Step 1

Step 2



Swings faster oneway than other

Go to Page102

InspectCrossover Relief Valve

Go to Page102

InspectSolenoid

OK

Chart 5

Step 1

Step 2

Swings erraticallyin either direction

Go to Page100

ActivateManual Override

Go to Page100

InspectSolenoid

Go to Page101

InspectSwitch

Go to Page101

InspectSwing Brake

OK

OK

OK

Chart 4

Step 1

Step 2

Step 3

Step 4

Swing Brakewill not hold

Go to Page103

InspectSwing Brake

Chart 6

Step 1



Swings too slow Go to Page104


Go to Page104

InspectSolenoid

Go to Page105

InspectLift/Swing Speed Dial and Valve

Go to Page105

InspectSwing Brake Release

OK

OK

OK

Chart 7

Step 1

Step 2

Step 3

Step 4



Step 1Step 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 inthePlatform Box

2. while activatingplatform in cw direction,measure voltage onwire #24 at theTerminal Strip atPlatform BoxShould be 10-12 volts

Replace SwingSwitch

If novoltage

No continuity

Swings only inone direction

If no reading

Repair or ReplaceSwing Control Valve

Solenoid

InspectSwing Control

Valve

Manually operateSwing Control Valve

If functioning properlyIf functioningimproperly

Repair or ReplaceSwing Control

Valve

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


Go to step 2

If Ok



Step 2

No response from swing whenplatform controls are activated(Ground Controls Ok)

Repair or ReplaceFoot Switch and/orFoot Switch wiring

InspectFoot Switch

Go to step 2

Using a meter set toread voltage, while

stepping on the FootSwitch, measure voltage

on wire # 9 atSwing Switch


If no reading

If10-12V

Step 1

InspectSwing Switch


activating function, checkvoltage on Swing Switch to

Junction 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

If no readingCheck connection

in Junction Box



Repair or ReplaceGround Control Switch

and/orGround Control Switch

wiring


Switch and Wiring

Go to step 2

Using a meter set to readvoltage, activate swing

function, measure voltagefrom Ground ControlSwitch to Ground Swing

Switch Should be 10-12 volts

If no reading

If10-12V

No response from swingwhen ground controls areactivated

Step 1Step 2


InspectSwing Switch


activating function, checkvoltage on Swing Switch to

Swing Valve(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 3Step 4

Go to page 104

InspectSwing Valve

Remove hoses fromSwing Drive Motor.Plug hoses and cap

motor. While activatingswing function, check

pressure atPump Compensator

Pressure should read2500 psi

If reading is low or erratic

Go to step 4 If2500 psi

ReplaceSwing Motor and/or

Gear Box

InspectSwing Motor and

Gear Box

If previous steps havebeen made and Swing

Valve checks ok,check pressure.

If lowReturn to step 1

If2500 psi



Step 1

Step 2

Go to step 4

Push in on ManualOverride and observe

swing operation


Go to step 2

If still swings erratically

If ok

Swings erratically ineither direction

Replace Solenoid

Supply 12 volts toSolenoid, check if swing is

operating smoothly

InspectSolenoid

Go to step 3

If still swings erraticallyIf ok




Step 3Step 4

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/or

Gear Box

If ok


InspectSwing Switch Using a meter set to

read voltage, whileactivating function, check

voltage on Swing Switch toSwing Valve

(wire #23 when swingis moving in a

counterclockwise direction,wire #24 when swing

is moving in aclockwise direction)


If no reading

Repair or ReplaceSwing Switch

and/orSwing Switch wiring



Step 1Step 2

Swings faster one waythan other

Replace Solenoid


operating equally

InspectSolenoid

If still swings faster

Repair or replaceCrossover Relief Valve

Swap Crossover ReliefValves, check for problem

in opposite direction

InspectCrossover Relief

Valve

Go to step 2

If still swings faster

If ok




Step 1

Repair or replaceSwing Brake

Visually checkSwing Brake

InspectSwing Brake

If Ok

Swing brake willnot hold

If damaged

Install 5000 psi pressuregauge into Swing BrakeLine, check pressure.

Should be 0 psiCheck Spools onControl Valve for

blocked ports

If 0 psi

Check return Lineand filter for

blockage

If blocked

Repair or replaceas needed

If Ok

If blocked

If above 0 psi

Inspect Counter BalanceCartridge for proper

operation and/or damageto O-rings

Ifdamaged



Go to step 3

Step 1

Step 2

Swings too slow

Go to step 3


swing function for fastermovement


Go to step 2

If still swings slowIf

Swingsfaster

Repair or replaceWiring to Valve


operating normally

InspectSolenoid

If swing is normal


If stillswings slow



Step 3Step 4

While activating swingfunction, use a meter set to

read voltage, measurevoltage on wire #108B at

Speed Dial.Should read 10-12 volts

Visually check Speed Dialin platform Control Box for

fast speed.Dial should be set to fast

InspectLift/Swing SpeedDial and Valve

Replace Dial

If Ok

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 still swings slowIf ok

If novoltage

If 10-12V

While activating Swingfunction, measure voltageon wire #108 at Lift/Swing

Speed Valve.Should read 10-12 volts

If no voltage

Repair wire to Valve

If 10-12V

Remove Valve,visually check toinsure that it ismoving when

power is appliedand that O'Rings

are ok.

If Ok

Go to step 4

If bad


SECTION SEVEN:PLATFORM ROTATION SYSTEM DIAGNOSTICS

SECTION SEVENPLATFORM ROTATION SYSTEM DIAGNOSTICS


The platform rotatedoes not operate

Go to Page110

InspectPlatform Rotate Switch

Go to Page110

InspectPlatform Rotator Motor

OK

Chart 1

Step 1

Step 2

Platform rotatesitself

Go to Page111

InspectPlatform Actuator

Chart 2

Step 1

Go to Page111

InspectHolding Valves

OKStep 2



Repair or replacePlatform Rotate Switch

and/or wiring

InspectPlatform Rotate

Switch

Check continuity on1. wire #26 between

Terminal Strip in theJunction Box andPlatfrom Rotation Motor

2. wire #27 betweenTerminal Strip in theJunction Box andPlatfrom Rotation Motor

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 1Step 2

If no reading

No continuity


InspectPlatform Rotator

Motor

Check for ground onPlatfrom Rotator Switch

Using meter set to readohms, check for continuity

through wire on MotorShould show continuity

If continuity does existsChange Platform

Rotator Motor

Ifcontinuitydoes not

exists



Platform rotates itself

Step 1

InspectPlatform Actuator

Repair or replacePlatform Actuator

Check Key by removing thecoverplate on Actuator.

Visually check for damage

If damaged

Step 2

Go to step 2

If no damage



Visually inspectHolding Valves

SECTION EIGHT:PLATFORM LEVELING SYSTEM DIAGNOSTICS

SECTION EIGHTPLATFORM LEVELING SYSTEM DIAGNOSTICS


Platform will notmaintain level as

boomraises or lowers

Go to Page117

InspectHydraulic Oil Temperature

Go to Page117


Platform will notmaintain level with

machine offGo to Page

118

InspectHolding Valves in

Slave Level Cylinder

OK

Chart 1

Chart 2

Step 1

Step 2

Step 1

Platform level willnot work fromground control

Go to Page119

InspectGround Control Switch

Go to Page119

InspectLevel Switch

OK

Chart 3

Step 1

Step 2

Go to Page120

InspectBlocking Valve Relay

OKStep 3

Go to Page120


OKStep 4



Platform level willnot work from

platform control(Ground Control Ok)

Go to Page121

InspectPlatform Level Switch

Chart 4

Step 1

Platform levelup function is

inoperativeGo to Page

122Activate

Manual Override

Go to Page122


Go to Page123

InspectPressure to Cylinder

Platform leveldown function is

inoperativeGo to Page

124Inspect

Manual Override

Go to Page124


Go to Page125

InspectPressure to Cylinder

OK

OK

Chart 5

Chart 6

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 does notmaintain level as boomraises or lowers

Step 1Step 2

InspectHolding Valvesbetween MasterLevel Cylinder

and Tank

Repair or replaceHolding Valves in Control

Package

With platform level andboom fully down, remove

the hoses to Level ControlValve and cap

Valve and plug hoses.Raise boom 5 ft. and note

the Platform LevelingSystem.

If Level System performs normallyIf Level System

performsabnormally

Repair or replaceSeals in Master Leveling

System

If problemstill existsGo to step 2



The platform will notmaintain level withmachine off

Step 1

InspectHolding Valves in

Slave LevelCylinder

Repair or replaceHolding Valves

Place a safe work loadin platform and

remove the hoses toSlave Level Cylinder

Observe the Platform.If oil leaks and platform drifts

If no oil leaksbut platform

still drifts

Repair or replaceLevel Cylinder



Step 1

Platform level will notwork from ground control

Step 2


Switch

Check continuity on wire#28 between GroundControl Switch and

Platform Level Switch

Using meter set to readvoltage, activate Ground

Control Switch andmeasure voltage on

wire #28 entering PlatformLevel Switch


If no readingRepair or replaceGround Control

Switchand/or

Ground ControlSwitch wiring


Nocontinuity

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





Relay

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 toBlocking Valve Relay

Step 3

ContinuityGo to step 4

No continuity

Repair or replaceWire #100

Nocontinuity

Step 4Inspect

Blocking Valve

ReplaceBlocking Valve

Relay


voltage on wire #100B toBlocking Valve

Should read 0 volts

If 0 volts

Remove Blocking Valvefrom Control Valve, visually

check Valve.Valve should be open.

If bad

ReplaceBlocking Valve

If 10-12V



Measure voltage on wires#12 and #13 leaving

Platform Level SwitchShould read 10-12 volts

If lowor no

voltage

ReplaceLevel Switch

Using a meterset to read voltage,measure voltage on

wire #9 enteringPlatform Level Switch


InspectPlatform Level

Switch

Platform level will not workfrom platform control(Ground Control Ok)

If 10-12V

ReplaceFoot Switch

If lowor no

voltage

Using a meter set to readohms, check for continuityon wire #108B to ground


exists

Replace Switch

If 10-12V

Check for continuity onwire #108B to Lower

Control Box

If continuity exists


existsRepair Wire

Return to step 1

If continuity exists

Step 1



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 readingIf

10-12V

Repair or replaceSolenoid Valve

Step 1Step 2

Platform level upfunction is inoperative

Go to step 2


Platform level up function


Go to step 3

If okIf problemstill exists




Step 3

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

pressure to Slave LevelCylinder.

Should read 2000 psiwhen fully extended.

InspectPressure to

Cylinder


Remove hose from Port 1on Slave Level Cylinder,plug hose and cap Slave

Level Cylinder.Recheck pressure

Should read 2000 psiwhen fully extended.

Repair or replaceRelief Valve inControl Valve

Repair or replaceSlave Level

Cylinder

If lowor no

reading

If2000 psi



Step 1Step 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 readingIf10-12V


Go to step 2

Push in on ManualOverride and observePlatform Level down

function

InspectManual Override

Go to step 3

If okIf problemstill exists




Step 3

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

pressure to Slave LevelCylinder.

Should read 2000 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 2000 psiwhen fully retracted.

Repair or replaceRelief Valve inControl Valve

Repair or replaceSlave Level

Cylinder

If lowor no

reading

If2000 psi

SECTION NINE:BOOM ELEVATION SYSTEM DIAGNOSTICS

SECTION NINEBOOM ELEVATION SYSTEM DIAGNOSTICS


Boom raises butwill not stay

elevatedGo to Page

130Inspect

Manual Bleed Down

Go to Page130

InspectHolding Valve

Boom will notraise from

ground controlGo to Page

133Inspect

Boom Lift Switch

Boom will notraise from

platform control(Ground Control

Ok)

Go to Page132

InspectBoom Lift Switch

Go to Page132

InspectLift/Swing Speed Valve

OK

OK

Chart 1

Chart 2

Chart 3

Step 1

Step 2

Step 1

Step 2

Step 1

InspectSeals in Cylinder

OKStep 3

Go to Page131

Go to Page134

InspectLift Control Valve

OKStep 3

Go to Page133

InspectLift/Swing Speed Valve

OKStep 2



Boom raises but willnot stay elevated

Step 1Step 2

Go to step 2

InspectManual Bleed

Down

Turn Manual Bleed DownValve clockwise until

valve is closed

Problem still exist

ReplaceHolding Valve and/or

Seal Kit

InspectHolding Valve

Raise boom approximately2 ft, remove hose to

#2 port on Lift Cylinder,observe for leakage

Leakage

Go to step 3

Raise boom approximately2 ft. and mark Lift Cylinder.Remove hose from port #4on Lift Cylinder. Observe oil

leakage.

Problem still exist

Repair or replaceManual Bleed

DownLeakage

Problemstill exist



Step 3

Repair or replaceCylinder

InspectSeals in Cylinder

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

If leaking



Step 1Step 2

Boom will not raisefrom platform control(Ground Control Ok)

Measure voltage on wire#28 to Lift Switch

Should read 10 to 12 volts


Using meter set toread voltage, measure

voltage on wire #22Should read 10 to 12 volts

If no reading

If 10 to 12VCheck continuityon wire betweenLift Switch andJunction Box

If no reading

Repair or replace Lift Switch

No continuity


While activating swingfunction, use a meter set to

read voltage, measurevoltage on wire #108B at

Speed Dial.Should read 10-12 volts

Visually check Speed Dialin platform Control Box for

fast speed.Dial should be set to fast

InspectLift/Swing SpeedDial and Valve

Replace Dial

If Ok

If novoltage

If 10-12V

While activating Liftfunction, measure voltageon wire #108 at Lift/Swing

Speed Valve.Should read 10-12 volts

If no voltage

Repair wire to Valve

If 10-12V

Remove Valve,visually check toinsure that it ismoving when

power is appliedand that O'Rings

are ok.

If Ok

Go to step 4

If bad




Boom will not raisefrom ground control

Step 1

Measure voltage on wire#28 to Lift Switch

Should read 10 to 12 volts


Using meter set toread voltage, measure

voltage on wire #22Should read 10 to 12 volts

If no reading

If 10 to 12VCheck continuityon wire between

Lift Switch and LiftValve

If no reading

Repair or replace Lift Switch

No continuity

Repair or replaceWire #22 and retry

function


voltage on wire #108B toLift/Swing Speed ValveShould read 10-12 volts

InspectLift/Swing Speed

Valve

RepairSwitch and/or Wire

If novoltage

If 10-12V

Remove Lift/Swing SpeedValve from Control Valve,visually check for proper

operation.Valve is normally closed

If Ok

Go to step 3

If valveis stuckReplace Valve

If 10 to 12V

If still no function

Go to step 2

Step 2



Step 3

Install a 5000 psi pressuregauge on test port,

operate function andcheck pressure.


InspectLift Control Valve

Activate manual overrideon Valve, observe boom

movement

If boom does not move

If boomoperatesReplace

Lift Solenoid

If low reading

Remove hose from #2 Portof Lift Cylinder, plug hoseand cap cylinder. Recheck

pressureReset Lift/Swing

Relief ValveIf low

reading

If boomoperates

Repair or replaceLift Cylinder


SECTION TEN:TELESCOPE SYSTEM DIAGNOSTICS

SECTION TENTELESCOPE SYSTEM DIAGNOSTICS


Chart 1

Boom will notretract from

ground controlActivate

Manual Override

InspectExtend and Retract Switch

InspectRetract Solenoid

OK

OK

Step 1

Step 2

Step 3

Boom will notretract from




InspectWiring in Hose Carrier

OK

OK

Step 1

Step 2

Step 3

Boom will notextend from

ground controlActivate

Manual Override


InspectExtend Solenoid

OK

OK

Step 1

Step 2

Step 3

Chart 2

Chart 3

Go to Page139

Go to Page139

Go to Page140

Go to Page141

Go to Page141

Go to Page142

Go to Page143

Go to Page143

Go to Page144

InspectExtend/Retract Valve

OKStep 4

Go to Page144



Boom will notextend from


Go to Page145


Go to Page145


Go to Page146

InspectWiring in Hose Carrier

OK

OK

Step 1

Step 2

Step 3

Chart 4

Boom drifts in Go to Page147

ActivateHolding Valves for Extend

Step 1

Chart 5

Go to Page147

InspectCylinder for Internal Leakage

OKStep 2



Boom will not retractfrom ground control

Step 1Step 2

Go to step 2

Activate Ground ControlSwitch, push in on

Manual Override andobserve boom movement


If retracting


Repair or replaceExtend and

Retract Switch

InspectExtend and

Retract Switch


at wire #15 atExtend and Retract

SwitchShould read 10-12 volts

If no reading


Go to step 4 If nomovement



Step 3

Repair or replaceWire to Valve

InspectRetract Solenoid

Using meter set to readvoltage, activate functionand measure voltage on

wire #15 to RetractSolenoid


If no reading

If 10-12VReplace

Retract Solenoid




InspectExtend/Retract

Valve

Repair or replaceExtend Cylinderand/or Holding

Valve

If low or no pressure

Remove hose from RetractPort of Control Valve, plug

hose and cap valve.Recheck pressure

Ifpressure

Ok

Adjust 1500 psi Relief inControl Valve


Step 4



Boom will not retractfrom platform control(Ground Control Ok)

Step 1

Step 2


Go to step 2




If retracting

Go to step 3 If12V


Retract Switch

InspectExtend and

Retract Switch




If no reading



Step 3

Repair or replaceWiring in Hose Carrier

InspectWiring in Hose

Carrier

Using meter set to readvoltage, activate functionand measure voltage at

wire #15 inGround Control Box


If no reading



Boom will not extendfrom ground control(Platform Control Ok)

Step 1Step 2


Go to step 2




If extending

Go to step 3 If12V


Retract Switch

InspectExtend and

Retract Switch




If no reading



Step 3

Repair or replaceWire to Valve

InspectExtend Solenoid


wire #14 to ExtendSolenoid


If no reading

If 10-12VReplace

Extend Solenoid




InspectExtend/Retract

Valve

Repair or replaceExtend Cylinder


Remove hose from ExtendPort of Control Valve, plug

hose and cap valve.Recheck pressure

Ifpressure

Ok

Adjust 1500 psi Relief inControl Valve


Step 4



Boom will not extendfrom platform control(Ground Control Ok)

Step 1Step 2


Go to step 2




If extending

Go to step 3 If12V


Retract Switch

InspectExtend and

Retract Switch




If no reading



Step 3

Repair or replaceWiring in Hose Carrier

InspectWiring in Hose

Carrier


wire #14 inGround Control Box


If no reading



Boom drifts in

Step 1

Repair or replaceHolding Valves

and/orO-rings

Visually check for blownO-Rings

If stuck and/or blown

Repair or replaceSeals in Extend Cylinder

Raise boom and extendboom 2 ft., remove hoses

from Extend Control Valve.Observe oil leakage

InspectSeals in Extend

Cylinder

Leakage from Port 1of Extend Cylinder

Repair or replaceHolding Valve

Leakagefrom Port 2of ExtendCylinder

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 Page152

InspectFuel Level

Go to Page152

InspectDual Fuel Switch

Engine will notstart on L.P.,

but will start onGasoline.

Go to Page154

InspectL.P. Gauge

Go to Page154


Chart 2

Chart 1

OK

OK

Go to Page153

InspectFuel Shutoff Valve

OK

Go to Page155

InspectL.P. Filter Lock

OK



Engine will not starton Gasoline, but willstart on L.P.

Step 1Step 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 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 voltsGo to step 3 If

10-12V

If no reading



Step 3

Repair or replaceFuel Shutoff Valve

InspectFuel Shutoff

Valve


on wire #78 at theFuel Shutoff Valve

Should read 10-12 voltsRepairwire to Valve

If noreading

If 10-12V



Engine will not starton L.P., but will starton Gasoline.

Step 1Step 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 replaceDual Fuel Switch


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

Dual Fuel Switch2. on wire #77B coming

out of Dual Fuel SwitchShould read 10-12 voltsGo to step 3 If

10-12V

If no reading



Step 3

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

out of Dual Fuel SwitchShould read 10-12 volts

Repairwire to Valve

If noreading

If 10-12V

SECTION TWELVE:ACCESSORIES DIAGNOSTICS

SECTION TWELVEACCESSORIES DIAGNOSTICS


Machine will notsteer

Go to Page162

InspectTow Package Float Valve

Step 1

Chart 3

AC Generator haslow voltage

Go to Page161

InspectAC Voltage from Generator

Step 1

Chart 2

AC Generatorwill not function

Go to Page160

InspectPower to Generator Switch

at Platform

Go to Page160

InspectGenerator Solenoid

OK

Step 1

Step 2

Chart 1



AC Generator willnot function

Step 1Step 2

Repair or replaceGenerator Switch at

Platform

InspectPower to

Generator Switchat Platform


at wire #169 whenswitch is activated toGenerator position


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 Generator haslow voltage

Adjust Speed ControlValve on HydraulicGenerator Valve

counterclockwise toincrease 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 correctpositioning

InspectTow PackageFloat Valve

Visually inspect TowPackage Float Valveto insure valve is inoperational position

No

troubleshooting guide - · pdf fileeach symptom described is followed by a list of inspections...

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