Serial Number Range:
From SN 100 to 2000
Rev March-April 2018
Content for Service Manual:
Introduction
Important Information
Find a Manual for this Model
Serial Number Legend
Section 1. Safety Rules
General Safety Rules
Section 2. Specifications
Machine Specifications
Performance Specifications
Hydraulic Specification
Hydraulic Component Specifications
Deutz BF4L 2011 Engine Specifications
Deutz TD2011L04i Engine Specifications
Cummins B4.5L Engine Specifications
Cummins B3.3T Engine Specifications
Perkins 1104C-44 Engine Specifications
Perkins 804D-33T Engine Specifications
Machine Torque Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure
SAE and Metric Fasteners Torque Charts
Section 3. Repair Procedures
Introduction
Platform Controls
Platform Controls
1-1 Platform Circuit Board
How to Remove the LED Circuit Board
1-2 Membrane Decal
1-3 Joysticks - How to Calibrate a Joystick
How to Reset a Proportional Valve Coil Default
How to Set the Function Thresholds and Default Functions Speeds
How to Adjust the Function Speeds
How to Adjust the Function Ramp Rate Setting
Platform Components
2-1 Platform Leveling Cylinder
2-2 Platform Rotator
How to Bleed the Platform Rotator
2-3 Platform Level Sensor - How to Calibrate the Platform Level Sensor
2-4 Platform Overload System (if equipped)
Jib Boom Components
3-1 Jib Boom Cable Track
How to Repair the Cable Track
3-2 Jib Boom
3-3 Jib Boom Lift Cylinder
3-4 Jib Boom Level Cylinder
3-5 Jib Boom Extension Cylinder
3-6 Jib Boom Bellcrank Angle Sensor
How to Calibrate the Jib Boom Bellcrank Angle Sensor
Boom Components
4-1 Primary Boom Cable Track
How to Repair the Primary Boom Cable Track
4-2 Secondary Boom Cable Track
How to Repair the Secondary Boom Cable Track
4-3 Primary Boom
4-4 Primary Boom Lift Cylinder
4-5 Secondary Boom Lift Cylinder
4-6 Primary Boom Extension Cylinder
4-7 Secondary Boom Extension Cylinders
4-8 Primary Boom Angle Sensor
How to Calibrate the Primary Boom Angle Sensor
4-9 Secondary Boom Angle Sensor
How to Calibrate the Secondary Boom Angle Sensor
Engines
5-1 RPM Adjustment
5-2 Flex Plate
How to install a Type A Flex Plate
How to install a Type B Flex Plate
Ground Controls
6-1 Bypass/Recovery Key Switch
How to Use the Recovery Mode
6-2 Circuit Boards
6-3 Membrane Decal
6-4 Full Machine Calibration
Display Module
Hydraulic Pumps
7-1 Function Pump
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
7-2 Drive Pump
How to Prime the Drive Pump
Manifolds
8-1 Function Manifold - (before serial number 440)
8-2 Function Manifold - (after serial number 439)
8-3 Valve Adjustments - Function Manifold
How to Adjust the System Relief Valve
How to Adjust the Primary Boom Extend Relief Valve
8-4 Platform Manifold
8-5 Jib Boom Manifold
8-6 Flow Control Mainfold
8-7 Function Enable Valve
8-8 Turntable Rotation Manifold
8-9 Steer and Axle Manifold
8-10 Valve Adjustments - Steer and Axle Manifold
8-11 Traction Manifold
8-12 Valve Adjustments - Traction Manifold
8-13 Drive Oil Diverter Manifold (welder option)
8-14 Valve Coils
Turntable Rotation Components
9-1 Turntable Rotation Assembly
How to Adjust the Turntable Rotation Gear Backlash
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor
Axle Components
10-1 Steer Sensors
How to Calibrate a Replacement Steer Sensor
How to Calibrate All Steer Sensors
10-2 Steer Cylinders
10-3 Axle Extension Cylinders
10-4 Axle Angle Sensors
How to Calibrate the Axle Angle Sensors
Section 4. Fault Codes
Introduction
Control System Fault Codes
Fault Matrix
Section 5. Schematics
Introduction
Wire Circuit Legend
Wire Color Legend
Limit Switches and Angle Sensors
Circuit Connector Legend
Drive Chassis and Platform Controller Pin Legend
Safety Controller Pin Legend
Turntable Controller Pin Legend
Engine Relay and Fuse Panel Legend - Deutz BF4L 2011, TD2011L04i, Perkins 1104C-44 and 804D-33T
Engine Relay and Fuse Panel Legend - Cummins B4.5L and B3.3T
Electrical Symbols Legend
Hydraulic Symbols Legend
Perkins 1104C-44 and 804D-33T Engine Electrical Schematic
Cummins B4.5L and B3-3.3T Engine Electrical Schematic
Generator Wiring Schematic
Hydraulic Generator (Welder Option)
Hydraulic Schematic (before serial number 180, except for serial number 102)
Hydraulic Schematic (serial number 102 and from serial number 180 to 534)
Hydraulic Schematic (from serial number 535)
Electrical Schematic
----------------------
Content for Parts List Manual:
How to Read Your Serial Number
Parts Stocking List
How to Order Parts
Service Parts Fax Order Form
100 Decals
101.1 Word Decals
102.1 Symbol Decals
200 Drive Chassis
201.1 Top View
202.1 Steer Yoke, Wheel Drive and Motor
203.1 Steer Sensor and Steer Cylinder
204.1 Chassis Components, Yellow Triangle Side
205.1 Chassis Components, Blue Triangle Side
300 Turntable Components
301.1 Tank Side Covers
302.1 Engine Side Covers
303.1 Engine Compartment Components
304.1 Hydraulic Tank Side Components
305.1 Ground controls
306.1 Turntable Center Components
307.1 Secondary Boom Lift Cylinder
308.1 Wire Harness Diagram
400 Engine Components
401.1 Cummins B4. 5L Engine, View 1 (to SN 950)
401.2 Cummins B3.3T Engine, View 1 (from SN 951)
402.1 Cummins B4.5L Engine, View 2 (to SN 950)
402.2 Cummins B3.3T Engine, View 2 (fromSN 951)
403.1 Deutz BF4L 2011 / TD2011L04i Engine, View 1
404.1 Deutz BF4L 2011 / TD2011L04i Engine, View 2
405.1 Perkins 1104C-44 Engine, View 1 (to SN 952)
405.2 Perkins 804D-33T Engine, View 1 (from SN 953)
406.1 Perkins 1104C-44 Engine, View 2 (to SN 952)
406.2 Perkins 804D-33T Engine, View 2 (from SN 953)
500 Boom Components
501.1 Secondary Boom Tube Reference
502.1 Secondary Boom Tube 1 (to SN 1853)
502.2 Secondary Boom Tube 1 (from SN 1854)
503.1 Secondary Boom Tube 2
504.1 Secondary Boom Tube 3
505.1 Secondary Boom Tube 4
506.1 Secondary Boom Extension Cylinders
507.1 Secondary Boom Cable Track and Pull Tube
508.1 Secondary Boom Cable and Hose Clamps, Front View
509.1 Secondary Boom Cable and Hose Clamps, Rear View
510.1 Primary Boom Link, Lever and Lift Cylinder (to SN 359)
510.2 Primary Boom Link, Lever and Lift Cylinder (from SN 360)
511.1 Primary Boom Angle Sensor and Retract Limit Switch (to SN 1853)
511.2 Primary Boom Angle Sensor and Retract Limit Switch (from SN 1854)
512.1 Primary Boom Cable Track
513.1 Primary Boom Bearings and Wear Pads
514.1 Primary Extension Boom
515.1 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder (to SN 1853)
515.2 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder (from SN 1854)
516.1 Jib Boom Cable Track
517.1 Jib Boom Extension and Platform Level Cylinders
518.1 Jib Boom Tubes and Wear Pads
519.1 Platform Rotator
600 Platform Components
601.1 Platform Mount
602.1 Platform Configurations
603.1 Platform Control Box, View 1
604.1 Platform Control Box, View 2
605.1 Toggle Switch Lid Option
606.1 Joysticks
700 Hydraulic Components
701.1 Traction Manifold, View 1
702.1 Traction Manifold, View 2
703.1 Steer/Axle Manifold
704.1 Jib Manifold
705.1 Function Manifold, View 1 (to SN 439)
705.2 Function Manifold, View 1 (from SN 440)
706.1 Function Manifold, View 2 (to SN 439)
706.2 Function Manifold, View 2 (from SN 440)
707.1 Function Enable Valve and Platform Rotator Manifold
708.1 Platform Manifold
709.1 Hydraulic Hoses and Fittings, Drive System
710.1 Hydraulic Hoses and Fittings, Steering System
711.1 Hydraulic Hoses and Fittings, Turntable Components
712.1 Hydraulic Hoses and Fittings, Boom Components
713.1 Hydraulic Hoses and Fittings, Platform Components
714.1 Pumps
800 Accessories
801.1 Platform Accessories
802.1 Hostile Enviroment Option - Secondary Boom Wipers
802.2 Hostile Enviroment Option - Primary and Jib Boom Wipers, Cable Track Covers
803.1 Hostile Enviroment Option - Bellows Installation
804.1 Load Sense
805.1 Belt Driven Generator, Deutz Models
806.1 Belt Driven Generator, Cummins Models
807.1 Belt Driven Generator,Perkins Models
808.1 Air Line to Platform
809.1 Circuit Board Heater Option
810.1 Hostile Environment Option - Engine Air Cleaners (to SN 952)
810.2 Hostile Environment Option - Engine Air Cleaners (from SN 953)
811.1 Cold Start Package
812.1 Welder Option - Chassis Components
813.1 Welder Option - Platform Components
814.1 Welder Option - Hydraulic Hoses and Fittings
815.1 Welder Option - Generator Components
816.1 Hydraulic Generator Option
817.1 Hydraulic Hoses and Fittings, Hydraulic Generator Option
818.1 Boom Latch Kit
819.1 Aircraft Protection Package (from 1071)
820.1 Operator Protection Structure
821.1 Fall Arrest Bar
Indices
Part Number Index
Part Description Index
Cross References
Fittings Cross Reference
Serial Number Range:
From SN 100 to 2000
Rev March-April 2018
Content for Service Manual:
Introduction
Important Information
Find a Manual for this Model
Serial Number Legend
Section 1. Safety Rules
General Safety Rules
Section 2. Specifications
Machine Specifications
Performance Specifications
Hydraulic Specification
Hydraulic Component Specifications
Deutz BF4L 2011 Engine Specifications
Deutz TD2011L04i Engine Specifications
Cummins B4.5L Engine Specifications
Cummins B3.3T Engine Specifications
Perkins 1104C-44 Engine Specifications
Perkins 804D-33T Engine Specifications
Machine Torque Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure
SAE and Metric Fasteners Torque Charts
Section 3. Repair Procedures
Introduction
Platform Controls
Platform Controls
1-1 Platform Circuit Board
How to Remove the LED Circuit Board
1-2 Membrane Decal
1-3 Joysticks - How to Calibrate a Joystick
How to Reset a Proportional Valve Coil Default
How to Set the Function Thresholds and Default Functions Speeds
How to Adjust the Function Speeds
How to Adjust the Function Ramp Rate Setting
Platform Components
2-1 Platform Leveling Cylinder
2-2 Platform Rotator
How to Bleed the Platform Rotator
2-3 Platform Level Sensor - How to Calibrate the Platform Level Sensor
2-4 Platform Overload System (if equipped)
Jib Boom Components
3-1 Jib Boom Cable Track
How to Repair the Cable Track
3-2 Jib Boom
3-3 Jib Boom Lift Cylinder
3-4 Jib Boom Level Cylinder
3-5 Jib Boom Extension Cylinder
3-6 Jib Boom Bellcrank Angle Sensor
How to Calibrate the Jib Boom Bellcrank Angle Sensor
Boom Components
4-1 Primary Boom Cable Track
How to Repair the Primary Boom Cable Track
4-2 Secondary Boom Cable Track
How to Repair the Secondary Boom Cable Track
4-3 Primary Boom
4-4 Primary Boom Lift Cylinder
4-5 Secondary Boom Lift Cylinder
4-6 Primary Boom Extension Cylinder
4-7 Secondary Boom Extension Cylinders
4-8 Primary Boom Angle Sensor
How to Calibrate the Primary Boom Angle Sensor
4-9 Secondary Boom Angle Sensor
How to Calibrate the Secondary Boom Angle Sensor
Engines
5-1 RPM Adjustment
5-2 Flex Plate
How to install a Type A Flex Plate
How to install a Type B Flex Plate
Ground Controls
6-1 Bypass/Recovery Key Switch
How to Use the Recovery Mode
6-2 Circuit Boards
6-3 Membrane Decal
6-4 Full Machine Calibration
Display Module
Hydraulic Pumps
7-1 Function Pump
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
7-2 Drive Pump
How to Prime the Drive Pump
Manifolds
8-1 Function Manifold - (before serial number 440)
8-2 Function Manifold - (after serial number 439)
8-3 Valve Adjustments - Function Manifold
How to Adjust the System Relief Valve
How to Adjust the Primary Boom Extend Relief Valve
8-4 Platform Manifold
8-5 Jib Boom Manifold
8-6 Flow Control Mainfold
8-7 Function Enable Valve
8-8 Turntable Rotation Manifold
8-9 Steer and Axle Manifold
8-10 Valve Adjustments - Steer and Axle Manifold
8-11 Traction Manifold
8-12 Valve Adjustments - Traction Manifold
8-13 Drive Oil Diverter Manifold (welder option)
8-14 Valve Coils
Turntable Rotation Components
9-1 Turntable Rotation Assembly
How to Adjust the Turntable Rotation Gear Backlash
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor
Axle Components
10-1 Steer Sensors
How to Calibrate a Replacement Steer Sensor
How to Calibrate All Steer Sensors
10-2 Steer Cylinders
10-3 Axle Extension Cylinders
10-4 Axle Angle Sensors
How to Calibrate the Axle Angle Sensors
Section 4. Fault Codes
Introduction
Control System Fault Codes
Fault Matrix
Section 5. Schematics
Introduction
Wire Circuit Legend
Wire Color Legend
Limit Switches and Angle Sensors
Circuit Connector Legend
Drive Chassis and Platform Controller Pin Legend
Safety Controller Pin Legend
Turntable Controller Pin Legend
Engine Relay and Fuse Panel Legend - Deutz BF4L 2011, TD2011L04i, Perkins 1104C-44 and 804D-33T
Engine Relay and Fuse Panel Legend - Cummins B4.5L and B3.3T
Electrical Symbols Legend
Hydraulic Symbols Legend
Perkins 1104C-44 and 804D-33T Engine Electrical Schematic
Cummins B4.5L and B3-3.3T Engine Electrical Schematic
Generator Wiring Schematic
Hydraulic Generator (Welder Option)
Hydraulic Schematic (before serial number 180, except for serial number 102)
Hydraulic Schematic (serial number 102 and from serial number 180 to 534)
Hydraulic Schematic (from serial number 535)
Electrical Schematic
----------------------
Content for Parts List Manual:
How to Read Your Serial Number
Parts Stocking List
How to Order Parts
Service Parts Fax Order Form
100 Decals
101.1 Word Decals
102.1 Symbol Decals
200 Drive Chassis
201.1 Top View
202.1 Steer Yoke, Wheel Drive and Motor
203.1 Steer Sensor and Steer Cylinder
204.1 Chassis Components, Yellow Triangle Side
205.1 Chassis Components, Blue Triangle Side
300 Turntable Components
301.1 Tank Side Covers
302.1 Engine Side Covers
303.1 Engine Compartment Components
304.1 Hydraulic Tank Side Components
305.1 Ground controls
306.1 Turntable Center Components
307.1 Secondary Boom Lift Cylinder
308.1 Wire Harness Diagram
400 Engine Components
401.1 Cummins B4. 5L Engine, View 1 (to SN 950)
401.2 Cummins B3.3T Engine, View 1 (from SN 951)
402.1 Cummins B4.5L Engine, View 2 (to SN 950)
402.2 Cummins B3.3T Engine, View 2 (fromSN 951)
403.1 Deutz BF4L 2011 / TD2011L04i Engine, View 1
404.1 Deutz BF4L 2011 / TD2011L04i Engine, View 2
405.1 Perkins 1104C-44 Engine, View 1 (to SN 952)
405.2 Perkins 804D-33T Engine, View 1 (from SN 953)
406.1 Perkins 1104C-44 Engine, View 2 (to SN 952)
406.2 Perkins 804D-33T Engine, View 2 (from SN 953)
500 Boom Components
501.1 Secondary Boom Tube Reference
502.1 Secondary Boom Tube 1 (to SN 1853)
502.2 Secondary Boom Tube 1 (from SN 1854)
503.1 Secondary Boom Tube 2
504.1 Secondary Boom Tube 3
505.1 Secondary Boom Tube 4
506.1 Secondary Boom Extension Cylinders
507.1 Secondary Boom Cable Track and Pull Tube
508.1 Secondary Boom Cable and Hose Clamps, Front View
509.1 Secondary Boom Cable and Hose Clamps, Rear View
510.1 Primary Boom Link, Lever and Lift Cylinder (to SN 359)
510.2 Primary Boom Link, Lever and Lift Cylinder (from SN 360)
511.1 Primary Boom Angle Sensor and Retract Limit Switch (to SN 1853)
511.2 Primary Boom Angle Sensor and Retract Limit Switch (from SN 1854)
512.1 Primary Boom Cable Track
513.1 Primary Boom Bearings and Wear Pads
514.1 Primary Extension Boom
515.1 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder (to SN 1853)
515.2 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder (from SN 1854)
516.1 Jib Boom Cable Track
517.1 Jib Boom Extension and Platform Level Cylinders
518.1 Jib Boom Tubes and Wear Pads
519.1 Platform Rotator
600 Platform Components
601.1 Platform Mount
602.1 Platform Configurations
603.1 Platform Control Box, View 1
604.1 Platform Control Box, View 2
605.1 Toggle Switch Lid Option
606.1 Joysticks
700 Hydraulic Components
701.1 Traction Manifold, View 1
702.1 Traction Manifold, View 2
703.1 Steer/Axle Manifold
704.1 Jib Manifold
705.1 Function Manifold, View 1 (to SN 439)
705.2 Function Manifold, View 1 (from SN 440)
706.1 Function Manifold, View 2 (to SN 439)
706.2 Function Manifold, View 2 (from SN 440)
707.1 Function Enable Valve and Platform Rotator Manifold
708.1 Platform Manifold
709.1 Hydraulic Hoses and Fittings, Drive System
710.1 Hydraulic Hoses and Fittings, Steering System
711.1 Hydraulic Hoses and Fittings, Turntable Components
712.1 Hydraulic Hoses and Fittings, Boom Components
713.1 Hydraulic Hoses and Fittings, Platform Components
714.1 Pumps
800 Accessories
801.1 Platform Accessories
802.1 Hostile Enviroment Option - Secondary Boom Wipers
802.2 Hostile Enviroment Option - Primary and Jib Boom Wipers, Cable Track Covers
803.1 Hostile Enviroment Option - Bellows Installation
804.1 Load Sense
805.1 Belt Driven Generator, Deutz Models
806.1 Belt Driven Generator, Cummins Models
807.1 Belt Driven Generator,Perkins Models
808.1 Air Line to Platform
809.1 Circuit Board Heater Option
810.1 Hostile Environment Option - Engine Air Cleaners (to SN 952)
810.2 Hostile Environment Option - Engine Air Cleaners (from SN 953)
811.1 Cold Start Package
812.1 Welder Option - Chassis Components
813.1 Welder Option - Platform Components
814.1 Welder Option - Hydraulic Hoses and Fittings
815.1 Welder Option - Generator Components
816.1 Hydraulic Generator Option
817.1 Hydraulic Hoses and Fittings, Hydraulic Generator Option
818.1 Boom Latch Kit
819.1 Aircraft Protection Package (from 1071)
820.1 Operator Protection Structure
821.1 Fall Arrest Bar
Indices
Part Number Index
Part Description Index
Cross References
Fittings Cross Reference
