HR21 (SP64) Hybrid AWD Service Manual - Niftylift · Ensure battery posts are always protected and...

info

@n

ifty

lift

.co

m.c

om

Heightrider/SPService Manual

MODEL HR21 (SP64) HYBRID SERIESAWD

Manufactured by:Niftylift Limited

Fingle DriveStonebridge

Milton KeynesMK13 0ER

England

www.niftylift.come-mail: [email protected]: +44 (0)1908 223456Fax: +44 (0)1908 312733M50430/01

HR21/SP64 Hybrid Series Service Manual

English / USA – 05/12 1

Table of Contents

1 Introduction and General Information 5

1.1 FOREWORD .................................................................................... 5

1.2 WARRANTY .................................................................................... 5

1.3 SCOPE ............................................................................................ 6

1.4 GENERAL MAINTENANCE INFORMATION ........................................ 6

1.4.1 Pre-maintenance checks ...................................................... 6

1.4.2 Maintenance information ...................................................... 7

1.5 MAINTENANCE SAFETY INFORMATION ........................................... 8

1.5.1 Personal injury prevention .................................................... 8

1.5.2 Machine damage prevention ................................................ 8

1.5.3 Electrical safety.................................................................... 8

1.5.4 Hydraulic safety ................................................................... 9

1.5.5 Environmental awareness .................................................... 9

2 Specifications 10

2.1 ENGINE SPECIFICATIONS.............................................................. 10

2.2 GEARBOX SPECIFICATIONS .......................................................... 10

2.3 FUNCTION SPEEDS ....................................................................... 11

2.4 FLUID PROPERTIES ...................................................................... 12

2.4.1 Fluid volumes .................................................................... 12

2.4.2 Engine oil specifications ..................................................... 12

2.4.3 Gearbox oil specifications .................................................. 12

2.4.4 Hydraulic oil specifications ................................................. 12

2.4.5 Engine coolant specifications ............................................. 12

2.4.6 Tyre specifications ............................................................. 13

2.4.7 Hydraulic pressure settings ................................................ 13

2.5 TORQUE SETTINGS....................................................................... 14

2.6 HYDRAULIC HOSE AND FITTING TORQUE SPECIFICATIONS .......... 15

3 Preventative Maintenance 17

3.1 ENGINE ......................................................................................... 17

3.1.1 Engine maintenance procedures and intervals .................... 17

3.1.2 Engine oil level check ......................................................... 18

3.1.3 Engine oil replacement ....................................................... 19



3.1.4 Engine oil filter replacement ............................................... 19

3.1.5 Engine coolant level check ................................................. 20

3.1.6 Changing coolant ............................................................... 21

3.1.7 Checking coolant hoses and clamp bands .......................... 21

3.1.8 Air filter element maintenance ............................................ 22

3.1.9 In-line fuel filter (tank) replacement .................................... 23

3.1.10 Checking fuel pipes.......................................................... 23

3.1.11 Cleaning the fuel filter container ....................................... 24

3.1.12 Bleeding air from the fuel system ..................................... 24

3.1.13 Exhaust system check ..................................................... 25

3.1.14 Fan belt check (Every 100 hours) ..................................... 25

3.2 Drive Hub Gearbox ........................................................................ 26

3.2.1 Oil Replacement ................................................................ 26

3.2.2 Bleeding air from the braking circuit ................................... 26

3.3 Batteries ....................................................................................... 27

3.3.1 Condition check (Daily) ...................................................... 27

3.3.2 Condition check (Weekly) .................................................. 27

3.4 Hydraulic Oil ................................................................................. 28

3.4.1 Level check (Weekly) ......................................................... 28

3.4.2 Filter check (Monthly) ........................................................ 28

3.4.3 Hydraulic oil renewal .......................................................... 28

3.5 Telescopic Boom .......................................................................... 30

3.5.1 Wear Pad Check (Monthly) ................................................ 30

3.5.2 Hose Trunking and Energy Chain Check (Weekly) .............. 30

3.5.3 Chain Inspection ................................................................ 31

3.6 Boom Rotation Gear ...................................................................... 32

3.6.1 Rotation Pinion Engagement Check (Monthly) .................... 32

3.6.2 Rotation Ring Lubrication (Yearly) ...................................... 32

4 Repair Procedures 33

4.1 General ......................................................................................... 33

4.1.1 FUSES ............................................................................... 33

4.2 Platform/Cage ............................................................................... 34

4.2.1 JOYSTICK .......................................................................... 34

4.2.2 FOOTSWITCH .................................................................... 34

4.2.3 SiOPSTM - Load Sensing Console ....................................... 35

4.2.4 ELECTRONIC LOAD CELL (IF FITTED) ................................ 37



4.2.5 TOUGHCAGE FLOOR.......................................................... 39

4.2.6 TOUGHCAGE FRAME ......................................................... 40

4.3 Booms .......................................................................................... 41

4.3.1 LIFT CYLINDER .................................................................. 41

4.3.2 LUFFING CYLINDER ........................................................... 42

4.3.3 LEVELLING CYLINDERS ..................................................... 43

4.3.4 FLYBOOM CYLINDER ......................................................... 45

4.3.5 BOOM ROTATION PINION GEARBOX .................................. 46

4.3.6 ENERGY CHAIN ................................................................. 47

4.4 Power Tray ................................................................................... 48

4.4.1 CENTRIFUGAL CLUTCH ..................................................... 48

4.4.2 DIESEL ENGINE THROTTLE SOLENOID .............................. 49

4.4.3 RADIATOR ......................................................................... 50

4.4.4 EXHAUST .......................................................................... 51

4.5 Chassis......................................................................................... 52

4.5.1 DRIVE HUB MOTOR ........................................................... 52

4.5.2 DRIVE HUB GEARBOX ....................................................... 52

4.5.3 SUSPENSION CYLINDER .................................................... 54

4.5.4 STEER CYLINDER .............................................................. 54

4.5.5 HYDRAULIC VALVE BLOCKS ............................................. 55

5 Hybrid System Overview 60

5.1 Introduction .................................................................................. 60

5.2 Hybrid Operation ........................................................................... 60

5.3 Boom System ............................................................................... 62

5.4 Drive System ................................................................................ 62

5.5 Charging System and Batteries ...................................................... 63

5.6 System Overview .......................................................................... 64

5.7 Load Sensing Pump ...................................................................... 65

5.8 Main Control Valve ........................................................................ 65

5.9 Diff-lock Valve and Freewheeling Valves ........................................ 65

5.10 Brake Release ............................................................................... 66

5.11 Suspension and Steer ................................................................... 66

5.12 Boom Control Valve and Pilot Joystick ........................................... 66

5.13 Electrical Control System Overview ............................................... 67

5.14 Control Logic ................................................................................ 67



5.15 Motor/Generator ........................................................................... 67

5.16 Controller ...................................................................................... 68

5.17 Curtis Hand Held Unit .................................................................... 69

6 Troubleshooting guide 71

6.1 TROUBLE SHOOTING INFORMATION ............................................ 71

6.2 PLATFORM FUNCTION FAULT FINDING ......................................... 71

6.3 ENGINE FAULT FINDING ................................................................ 72

6.4 GEARBOX FAULT FINDING ............................................................ 74

Appendix A 75



1 Introduction and General Information 1.1 FOREWORD

The purpose of these manuals is to provide the owner, service engineer or technician with information to service and maintain the Niftylift.

Prior to carrying out any maintenance or operating the Niftylift the operator's manual should be read and fully understood.

The manufacturer has no direct control over machine application and use, therefore conformance with good safety practices is the responsibility of the user and his operating personnel.

All information in these manuals is based on the use of the machine under proper operating conditions. Alteration and/or modification of the machine are strictly forbidden.

One of the most important facts to remember is that any equipment is only as safe as those who operate it.

DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS AND NOTICE Any place these topics may appear, either in this manual or on the machine, are defined as follows:

DANGER: If not correctly followed there is a high probability of serious injury or death to personnel.

WARNING OR CAUTION: If not correctly followed there is some possibility of serious injury or death to personnel.

THE 'SAFETY ALERT' SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS THAT MAY LEAD TO SERIOUS INJURY OR DEATH, IF IGNORED.

IMPORTANT AND INSTRUCTIONS: Denotes procedures essential to safe operation and prevention of damage to or destruction of the machine.

NOTICE: Indicates general safety rules and/or procedures relating to the machine.

It is the owner's/user's responsibility to know and comply with all applicable rules, regulations, laws, codes and any other requirements applicable to the safe use of this equipment.

1.2 WARRANTY

Consult Niftylift prior to carrying out any corrective maintenance on your machine. If work is carried out without Niftylift consent your warranty will be invalidated.



1.3 SCOPE

Please note at the time of going to press all information, illustrations, details and descriptions contained herein are valid. Niftylift reserves the right to change, alter, modify or improve its products without any obligations to install them on previously manufactured machines.

If information is found to be either incorrect or missing Niftylift encourage you to send in suggestions which will aid our continuous product improvement.

If After reading this manual you require further information please do not hesitate to contact us at your nearest office.

Niftylift Ltd, Fingle Drive, Stonebridge, Milton Keynes MK13 0ER, Great Britain Tel: +44 (0) 1908 223456 Fax: +44 (0) 1908 312733

Niftylift Inc, 32 Concourse Way, Greer, SC 29651 USA Tel: +01 864 968 8881 Fax: +01 864 968 8836

Nifty Pty Ltd, 265 King Street, Newcastle, NSW 2300, Australia Tel: +61 (0) 2 4929 6700 Fax: +61 (0) 2 4925 2570

1.4 GENERAL MAINTENANCE INFORMATION

Any maintenance work must be carried out by a competent qualified person.

Manufacturer’s safety rules and instructions must be obeyed at all times.

FAILURE TO PERFORM PREVENTATIVE MAINTENANCE AT THE REQUIRED INTERVALS WILL RESULT IN A NIFTYLIFT THAT IS NOT SAFE TO USE WHICH COULD CAUSE INJURY OR POSSIBLE DEATH

Regular inspections ensure the machine operates efficiently and economically. Regular maintenance will assure you that the machine will perform satisfactorily with minimal service or repair thus down time is reduced.

1.4.1 Pre-maintenance checks

Ensure machine is parked on even, firm and level ground.

Ensure machine is in transport mode, i.e. all booms lowered, cage level and perpendicular to booms.

Ensure wheels are chocked, if applicable parking brake applied and any lockouts must be engaged.

Ignition must be turned off with key removed and hydraulic system pressure relieved.

Machine must be allowed to cool down before maintenance.

Power to the machine must be disconnected prior to maintenance.

Before replacing electrical components ensure batteries are disconnected.



1.4.2 Maintenance information

Ensure maintenance is being carried out in suitable workshop facilities with appropriate tools and suitable lifting equipment.

Components which require replacement must be replaced with parts which are identical or equivalent. If unsure contact your nearest Niftylift dealer for advice.

Inspect all parts prior to reassembly and replace if necessary. Do not fit faulty, used, or worn parts to a Niftylift.

Replace all o-rings, seals and gaskets at reassembly.

Replace any parts with damaged threads; replace all roll pins, self locking fittings and circlips.

If any part resists removal check all fasteners, hydraulic lines, electrical wires and interferences before continuing.

Keep all new parts in container until they are to be fitted, inspect before fitment.

Mark or tag all hydraulic lines before removal to avoid confusion and error. Never leave hydraulic lines open or open them in a contaminated area. Always use plugs or caps.

Use only recommended lubricants. Refer to Section 2.4.

In general, assembly of components can be completed by reversing the disassembly process and instructions.

Please refer to the following documents for further details.

Document Number

Hydraulic Schematic D81325

Electric Schematic D81392

Control Logic Diagram D81393

Machine Wiring Diagram D81397

Operating and Safety Instructions M50371

Parts Manual M50370

Chain Inspection Manual M50280

Engine Operators Manual M50291

For easy access to any of the above documents go to www.niftylift.com, register in the 'My Nifty Registration' section, then navigate to the ‘My Nifty’ section and enter the machine Serial Number.

http://www.niftylift.com/



1.5 MAINTENANCE SAFETY INFORMATION

1.5.1 Personal injury prevention

CORRECT PPE (PERSONAL PROTECTION EQUIPMENT) MUST BE WORN FOR ALL MAINTENANCE OPERATIONS CARRIED OUT ON YOUR NIFTYLIFT ACCESS PLATFORM

Do not wear jewellery whilst carrying out maintenance. Restrain long hair and do not wear loose clothing.

Ensure the work area is well ventilated and well lit.

Never work under an elevated boom. Boom must be restrained from movement by blocking, using overhead slings or fitting a safety prop.

Ensure all stepping surfaces, hand holds and anti-slip surfaces are free from oil, dirt, fuel and ice. Do not step on parts of machine which are not intended for this.

Use caution when checking hot pressurised systems such as hydraulic and engine coolant.

Use correct tools and equipment, broken or damaged tools and equipment should be replaced/repaired.

1.5.2 Machine damage prevention

Never reset a pressure relief valve to a value higher than that stated by the manufacturer.

Ensure no tools, equipment or other objects have been left on machine.

Measures to be taken prior to welding on the Niftylift, please contact your nearest Niftylift dealer prior to carrying out any welding.

1.5.3 Electrical safety

Ensure sparks, flames or lighted tobacco are kept away from batteries as they emit explosive gases.

Keep metallic objects (tools, etc.) well clear from battery posts.

Ensure battery posts are always protected and caps are fitted and in good condition.

Never connect a discharged battery in series with a fully charged battery as this creates a risk of explosion. Always use batteries that are charged/discharged to the same level.



1.5.4 Hydraulic safety

Relieve system pressure before removing any hydraulic connections, undo fittings slowly to make sure there is no residual pressure. If pressure is detected, allow it to be released slowly before completely removing hose.

Fluid leaks may not be visible to the naked eye. Use a piece of cardboard to check for leaks, not your hand.

Never install hydraulic lines or components which are damaged.

Ensure all connections are correctly tightened (Refer to Section 2.6).

1.5.5 Environmental awareness

When draining fluids, ensure they are collected in a suitable container and spillages avoided.

Used batteries must be disposed of in the correct manner as waste is harmful to the environment.

Consumables such as oil containers, rags and gloves should also be disposed of correctly as waste is harmful to the environment.



2 Specifications Information correct at time of print, refer to serial number of machine.

2.1 ENGINE SPECIFICATIONS

FEATURE KUBOTA D722

Type Water cooled, 3-cycle diesel engine

Fuel Diesel fuel, No. 2-D

Engine Oil See Section 2.4.2

Spark Plug N/A

Mass (Dry weight) 63.1kg 139 lbs

Displacement 719cm3

Net power 14kW/18.8hp @ 3600rpm

Net torque N/A

Oil capacity 3.8 L 1 US Gal

Fuel capacity 45 L 11.9 US Gal (Tank in Chassis)

Coolant capacity 3.1 L 0.82 US Gal

Spark plug gap N/A

Idle speed 800 – 900rpm

Valve clearance 0.145 - 0.185mm

2.2 GEARBOX SPECIFICATIONS

TYPE COMER PGWF401

MASS 49.2kg 108lbs

OIL CAPACITY 0.5 L 1.1 US Pints

OIL TYPE See Section 2.4.3



2.3 FUNCTION SPEEDS

Speed, (Seconds)

Function Up/Right/Out Down/Left/In

Slew (180) 68±10 68±10

Links 22±5 27±2

Luffing (Telescope out) 37±5 27±5

Fly 15±3 20±4

Telescope (Luffing down) 23±5 33±5

Low revs High revs

Engine speed 2100 ±25 rpm 3800 ±25 rpm

Electric Motor speed 2200 ±25 rpm 3600 ±25 rpm

Machine drive speed FWD/REV

1 Km/h (0.62 mph)

4.5 Km/h (2WD) - 2.8 mph

2.25 Km/h (AWD) - 1.4 mph

40s (+4/ -4) 8s ±2

Tortoise 21s (+4/-4)

Machine FWD/REV drive speed must be measured over a 10 meter (33 feet) distance to check PWM current setting in conjunction with engine revs.

All measurements carried out with 225kg in cage (including operator) and operated from cage.

Machine must be at full working temperature before testing, i.e. Hydraulic oil must be above 100°F (38°C).

Function speeds may vary depending on ambient air temperature (e.g. extreme cold).



2.4 FLUID PROPERTIES

2.4.1 Fluid volumes

FLUID VOLUMES HYDRAULIC OIL TANK 80 L (21.1 US gal)

FUEL TANK 45 L (11.9 US gal)

ENGINE OIL 3.8 L (8 US Pints)

COOLANT 4 L (8.45 US Pints)

2.4.2 Engine oil specifications

AMBIENT TEMPERATURE OIL TYPE

ABOVE 0°C SAE30 OR

SAE 10W/30

SAE 10W/40

0°C / +25°C SAE20 OR

SAE 10W/30 Standard fitment

SAE 10W/40

BELOW 0°C SAE10W OR

SAE 10W/30

SAE 10W/40

2.4.3 Gearbox oil specifications

AMBIENT TEMPERATURE OIL TYPE

SAE STANDARD

-20°C / +30°C SAE 80W/90 (Standard fitment)

+10°C / +45°C SAE 85W/140

2.4.4 Hydraulic oil specifications

ISO VG 22 oil is fitted as standard, for other climates or harsh operating conditions please contact your local Niftylift dealer.

2.4.5 Engine coolant specifications

If the ambient temperature is likely to remain above 0°C then no anti-freeze is required in the engine coolant. If the ambient temperature is likely to fall below 0°C then anti-freeze is required.

Use permanent type (PT) for the Kubota D722 engine.

When anti-freeze is mixed with water, the ratio must be less than 50%, see table below.

Volume % Anti-freeze Freezing Point Boiling Point

°C °F °C °F 40 -24 -12 106 222

50 -37 -34 108 226



2.4.6 Tyre specifications

Standard tyre fitment: Solideal Safety Master 33x12-20.

DO NOT REPLACE TYRES WITH ANYTHING OTHER THAN ABOVE SPECIFICATION. CONSULT NIFTYLIFT PRIOR TO REPLACEMENT.

2.4.7 Hydraulic pressure settings

Refer to hydraulic schematic as supplied with machine noting serial number of machine.



2.5 TORQUE SETTINGS

BOLT QUALITY/SIZE Tightening torque in ft-lbs (Nm)

Plated Unplated

Grade 8.8 10.9 12.9 8.8 10.9 12.9

M 6 5 (7) 8 (10) 9 (12) 6 (8) 8 (11) 10 (13)

M 8 13 (17) 18 (25) 22 (29) 14 (19) 20 (27) 23 (32)

M 10 25 (34) 36 (49) 43 (58) 27 (37) 40 (54) 46 (63)

M 12 43 (58) 63 (85) 73 (99) 47 (63) 69 (93) 80 (108)

M 14 68 (93) 100 (135) 117 (158) 74 (101) 109 (148) 127 (172)

M 16 106 (143) 154 (209) 180 (245) 115 (156) 168 (228) 197 (267)

M 20 212 (288) 301 (408) 352 (477) 224 (304) 328 (445) 384 (521)

M24 362 (491) 515 (698) 602 (806) 383 (519) 561 (760) 656 (889)

WHEEL NUTS 111ft lbs (150 Nm)

WHEEL GEARBOX NUTS 100ft lbs (135 Nm)

SLEW RING BOLTS 221ft lbs (300 Nm)

This torque chart is based on the following assumptions:

Bolts to ISO 898-1 "Mechanical properties of fasteners made of carbon steel and alloy steel"

For "unplated" bolts, all grades:

Hex head bolts Black oxide steel bolt with a rolled & oiled thread, no finish on steel nut Prevailing torque includes Nylock (minimum prevailing torque figure assumed) Medium Clearance holes to ISO 273 Bolt tightening condition = Yield factor of 75%

For "plated" bolts, all grades:

Hex head bolts Zinc plated oiled (rolled or cut) steel external thread with no finish on steel internal thread Prevailing torque includes Nylock (minimum prevailing torque figure assumed) Medium Clearance holes to ISO 273 Bolt tightening condition = Yield factor of 75%

Figures quoted in Nm have been calculated in Nm and then rounded to the nearest whole number. Figures quoted in ft-lbs have been calculated in Nm, converted using a factor of 0.737561 and then rounded.



2.6 HYDRAULIC HOSE AND FITTING TORQUE SPECIFICATIONS

BSP (Solid Back Nut)

O-Ring Seal Female (ISO 8434) Soft Seal Positional/Banjo/Block Fittings (ISO 6149 & 1179)

Size Thread Torque ft-lbs (Nm) Size Thread Torque ft-lbs (Nm)

4 1/4" - 19 18 (25) 4 1/4" - 19 30 (40)

6 3/8" - 19 26 (35) 6 3/8" - 19 55 (75)

8 1/2" - 14 41 (55) 8 1/2" - 14 74 (100)

10 5/8" 14 48 (65) 10 5/8" - 14 96 (130)

12 3/4" - 14 74 (100) 12 3/4" - 14 140 (190)

16 1" - 11 92 (125) 16 1" - 11 221 (300)

20 1"1/4" - 11 140 (190) 20 1"1/4" - 11 243 (330)

24 1"1/2" - 11 184 (250) 24 1"1/2" - 11 339 (460)

32 2" - 11 295 (400) 32 2" - 11 N/A

Elastomeric Seal Male (ISO 1179)

Size

Thread

Torque ft-lbs (Nm)

Steel Aluminium

4 1/4" - 19 44 (60) 22 (30)

6 3/8" - 19 66 (90) 33 (45)

8 1/2" - 14 96 (130) 48 (65)

10 5/8" 14 N/A N/A

12 3/4" - 14 148 (200) 74 (100)

16 1" - 11 221 (300) 111 (150)

20 1"1/4" - 11 369 (500) 184 (250)

24 1"1/2" - 11 443 (600) 221 (300)

32 2" - 11 N/A N/A



Metric (S-Series)

Soft Seal Positional/Banjo/Block Fittings

(ISO 6149 & 1179)

Elastomeric Seal Male (9974/3869)

Thread

Torque ft-lbs (Nm)

Thread Torque ft-lbs (Nm) Steel Aluminium

M12 x 1.5 26 (35) M12 x 1.5 30 (40) 15 (20)

M14 x 1.5 33 (45) M14 x 1.5 44 (60) 22 (30)

M16 x 1.5 41 (55) M16 x 1.5 59 (80) 30 (40)

M18 x 1.5 52 (70) M18 x 1.5 70 (95) 33 (45)

M20 x 1.5 59 (80) M20 x 1.5 103 (140) 52 (70)

M22 x 1.5 74 (100) M22 x 1.5 111 (150) 55 (75)

M27 x 2.0 133 (180) M27 x 2.0 148 (200) 74 (100)

M30 x 2.0 N/A M30 x 2.0 280 (380) 140 (190)

M42 x 2.0 243 (330) M42 x 2.0 354 (480) 177 (240)

UNF Male with O ring

Connector Male SAE UNF with O.R ISO 11926 Ports

Thread Torque ft-lbs (Nm)

7/16" 16 (21)

1/2" 20 (27)

9/16" 30 (40)

3/4" 58 (78)

7/8" 81 (110)

1" 1/16 133 (180)

1" 3/16 170 (230)

1" 5/16 210 (285)

1" 5/8 236 (320)



3 Preventative Maintenance 3.1 ENGINE

3.1.1 Engine maintenance procedures and intervals

EV

ERY

50

HOU

RS

EVER

Y 10

0 H

OURS

EVER

Y 20

0 H

OURS

EVER

Y 1

M

ONTH

EVER

Y 50

0 H

OURS

EVER

Y YE

AR

EVER

Y 2

YEAR

S

ENGINE OIL ● ENGINE OIL FILTER ● AIR FILTER @ ▲◊ ▲ ● ENGINE COOLANT @ ■ ● COOLANT HOSES AND CLAMP BANDS ▲ ●

FUEL FILTER ● IN-LINE FUEL FILTER ● WATER SEPARATOR ■ FUEL TANK ■ FUEL HOSES AND CLAMP BANDS @ ▲ ● BATTERY ▲ ▲ ● FAN BELT ▲ ● AIR INTAKE LINE @ ● ELECTRICAL WIRING/CONNECTIONS ▲

▲ Check

■ Cleaning

● Replacement

First time procedure

◊ This must be carried out when the work environment contains high levels of dust

@ Emission critical component



3.1.2 Engine oil level check

ENSURE ENGINE IS OFF BEFORE DRAINING THE ENGINE OIL

WHEN DRAINING ENGINE OIL, PLACE A CONTAINER UNDERNEATH THE ENGINE AND DISPOSE ACCORDING TO LOCAL REGULATIONS

DO NOT DRAIN OIL AFTER RUNNING THE ENGINE, ALLOW ENGINE TO COOL DOWN SUFFICIENTLY

1) Check engine oil level before starting or more

than 5 minutes after stopping the engine.

2) Remove item A oil level dip-stick; note the

location of the oil filling port.

3) Remove oil level dip-stick once again and

check oil level. If low add correct specification

oil to the oil filling port shown above until the

upper limit of the dip-stick is reached.

4) After adding oil, wait for 5 minutes and re-

check oil level.

MAX

MIN

A



3.1.3 Engine oil replacement

1) Remove the drain plug located on the underside

of the engine and drain the oil into a suitable

container. Note; This will be easier if the oil is

warm. Dispose of waste oil in accordance with

local environmental policies.

2) Renew engine oil to the upper limit of the oil

level gauge. Oil type and quantities can be

found from the oil specification table in Section

2.4.2.

3) Re-check oil level at least 5 minutes after filling

engine.

3.1.4 Engine oil filter replacement

1) Using a filter wrench or strap, remove the old

filter.

2) Apply oil film to the seal of the new filter.

Ensure filter is marked with the machines hours

and date of filter change.

3) Screw filter onto engine by hand. When seal

contacts the seal surface, tighten the filter

enough by hand. Do not tighten with filter

wrench.

4) Once filter is replaced run engine for a short

period and check oil level and check for leaks.



3.1.5 Engine coolant level check

DO NOT STOP ENGINE SUDDENLY, IDLE ENGINE FOR 5 MINUTES BEFORE STOPPING

WORK SHOULD BE CARRIED OUT AFTER LETTING THE ENGINE AND RADIATOR COOL OFF COMPLETELY (A MINIMUM OF 30 MINUTES AFTER STOPPING ENGINE)

DO NOT REMOVE RADIATOR CAP WHILST ENGINE COOLANT IS HOT AND PRESSURISED. WHEN COOL TO TOUCH, ROTATE CAP TO THE FIRST STOP TO ALLOW EXCESS PRESSURE TO ESCAPE, THEN REMOVE CAP COMPLETELY

IF OVERHEATING SHOULD OCCUR, STEAM MAY GUSH FROM THE RADIATOR OR RESERVE TANK RESULTING IN SEVERE BURNS

1) Remove the radiator cap after the engine has

completely cooled. Ensure the coolant level

reaches the supply port.

2) Ensure coolant level is sufficient on the reserve

tank. The level should be between the full and

low marks.

3) Ensure both drain plugs are fitted; one to the

lower part of the radiator (2) and the other is on

the side of the crank case (1).

4) If coolant levels are low, top-up using the

correct specification fluid. Refer to

Section 2.4.5.

Important;

• If the radiator cap has to be removed follow the caution label and securely retighten the cap.

• If coolant should leak, consult your local Kubota dealership.

• Make sure contaminated or sea water does not enter the coolant system.

• Use clean, fresh water with 50% anti-freeze to fill the header tank.

• Do not refill reserve tank with coolant higher than the “FULL” level mark.

• Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak out and quickly decrease the coolant level



3.1.6 Changing coolant

DO NOT STOP ENGINE SUDDENLY, IDLE ENGINE FOR 5 MINUTES BEFORE STOPPING

WORK SHOULD BE CARRIED OUT AFTER LETTING THE ENGINE AND RADIATOR COOL OFF COMPLETELY (MORE THAN 30 MINUTES AFTER STOPPING ENGINE)

DO NOT REMOVE RADIATOR CAP WHILST ENGINE COOLANT IS HOT AND PRESSURISED. WHEN COOL TO TOUCH ROTATE CAP TO THE FIRST STOP TO ALLOW EXCESS PRESSURE TO ESCAPE. THEN REMOVE CAP COMPLETELY

IF OVERHEATING SHOULD OCCUR, STEAM MAY GUSH FROM THE RADIATOR OR RESERVE TANK RESULTING IS SEVERE BURNS

1) Open both drain plugs and simultaneously open

the radiator cap. This must be removed to allow

a full coolant drain.

2) Remove the overflow pipe from the radiator

pressure cap to drain the reserve tank.

3) See fluid specifications in Section 2.4.5 for

coolant quantities and specification.

3.1.7 Checking coolant hoses and clamp bands

BE SURE TO CHECK RADIATOR HOSES AND CLAMPS PERIODICALLY. IF RADIATOR HOSE IS DAMAGED OR COOLANT LEAKS, OVERHEATING OR SEVERE BURNS MAY OCCUR

1) Check radiator hoses are securely fixed every

200 hours of operation or 6 months, whichever

comes first.

2) If hose clamps are loose or water leaks,

retighten hose clamps securely.

3) If hoses are swollen, hardened or cracked they

must be replaced along with clamps. Clamps

must be tightened securely.



3.1.8 Air filter element maintenance

DO NOT APPLY OIL TO THE AIR FILTER; YOUR MACHINE IS FITTED WITH A DRY TYPE AIR FILTER. AVOID TOUCHING THE ELEMENT EXCEPT WHEN CLEANING

1) Open the evacuator valve once a week under

ordinary conditions, daily when used in a dust

rich environment. This allows dirt and dust to

be removed from the air filter.

2) To remove air filter, release spring clips and

remove cover. The air filter element will now

slide out of the air filter body.

3) Wipe inside the air cleaner with cloth if found to

be dirty or wet.

4) When dry dust adheres to the element, blow

compressed air from the inside out whilst

rotating the filter. Air pressure must be no more

than 686kPa (7kgf/cm2, 99psi).

5) When carbon or oil adheres to the filter, soak

the filter in detergent for 15 minutes, and then

wash it several times in water. Rinse with clean

water and allow to dry naturally.

6) After filter is fully dried, inspect the inside with a

flashlight for damage. Refer to instructions on

the label attached to the filter.

7) Insert filter back into air filter body, refit cover

and secure spring clips.

8) Replace filter element every year or after 6

cleanings. This is in standard operating

conditions; dust enriched operating

environments will require shorter intervals.



3.1.9 In-line fuel filter (tank) replacement

1) Remove 4 screws securing the access panel at

the rear of the machine.

2) Locate fuel filter and clamp the feed pipe from

tank.

3) Loosen jubilee clips and remove fuel pipes.

4) Attach pipes to new filter ensuring the arrow on

the filter points in the direction of fuel flow (tank

to engine).

5) Remove old filter and dispose of in an

appropriate and safe manner.

6) Remove clamp from feed hose ensuring filter

refills with fuel.

7) If required, refer to Section 3.1.12 for bleeding

of air from the fuel system.

3.1.10 Checking fuel pipes

1) Fuel pipes and clamps should be checked every

50 hours of engine operation.

2) If clamp bands are found to be loose, apply oil

to screw of the band and tighten securely.

3) If rubber fuel pipes are found to be worn,

replace immediately.

4) When fuel pipes are not installed, ensure they

are capped to prevent dirt entering. This could

lead to fuel injection pump malfunction.



3.1.11 Cleaning the fuel filter container

1) Close the fuel filter tap (1).

2) Remove the top cap and rinse out container (3)

with diesel fuel.

3) After cleaning, re install the fuel filter, ensuring

it does not come into contact with any dust or

dirt.

4) Refer to section below for bleeding of air from

the fuel system before attempting to start the

engine.

3.1.12 Bleeding air from the fuel system

DO NOT BLEED A HOT ENGINE. FUEL COULD SPILL ON TO THE EXHAUST MANIFOLD CREATING A FIRE RISK.

This procedure is required if;

• the fuel filter and hoses have been detached and refitted

• the fuel tank has become empty

• the machine has been in prolonged storage.

1) Fill the fuel tank. Open the fuel filter tap (1) as shown above.

2) Loosen air vent plug (2) by a few turns.

3) Retighten plug once air bubbles are no longer present in container (3).

4) Open the air vent plug on the fuel injection pump.

5) Retighten plug once bubbles are no longer present in container (3).



3.1.13 Exhaust system check

DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING. BEWARE OF HOT ENGINE COMPONENTS.

1) Remove the engine tray retaining bolt.

2) Swing the engine tray away from the superstructure.

3) Inspect the exhaust components for signs of cracks and

leaks; i.e. carbon build up around joints and seams.

4) Swing engine tray back in to position. Insert retaining bolt

and retighten (Refer to Section 2.5 for torque).

3.1.14 Fan belt check (Every 100 hours)

1) Ensure engine is switched OFF.

2) Apply moderate pressure to belt

using your thumb in area shown

on diagram. If dimension A does

not fall in the range 7 to 9mm

(0.28 to 0.35in), loosen the

alternator mounting bolts and

adjust accordingly until the belt

deflection falls within these limits.

3) If belt is damaged, replace

immediately.



3.2 Drive Hub Gearbox

3.2.1 Oil Replacement

1) Manufacturer specifications require this

procedure to be carried out after the first 50 to

100 hours, then every 2500 hours or once a

year. Depending on the operating cycle this

frequency may vary.

2) Select the drive hub to be serviced. Manoeuvre

machine until either plug is at its lowest

possible position.

3) Remove both plugs and drain the oil into a

suitable container. Dispose of waste oil in

accordance with local environmental policies.

4) Manoeuvre machine until one plug (A) is at the

highest point (see diagram). Fill gearbox until oil

level is even with bottom of plug hole B. Refer

to Section 2.4.3 for oil specifications.

5) Refit plugs and securely fasten.

6) Repeat for remaining gearboxes.

3.2.2 Bleeding air from the braking circuit

1) Connect the hydraulic couplings to the brake ports on the gearbox.

2) Pressurise the hydraulic circuit, then slightly loosen the hose on the inlet port and wait for the

air to bleed. Fully retighten once oil is flowing through.



3.3 Batteries

3.3.1 Condition check (Daily)

1) Check that the batteries are fully charged. Batteries should be recharged at the end of each

working day or shift. See manufacturer’s Operating Manual for correct battery charging

procedure.

2) Check batteries for evidence of leaks or spilt battery acid. If material is released or spilled, lime

or soda ash may be used to neutralise, or flush with large volumes of water. Dispose of waste

in accordance with local regulations for acid and lead scrap. Use approved respiratory

protection, rubber gloves, and splash-proof safety goggles. Use rubber boots and acid-proof

clothing for major spills. Renew any defective batteries.

3) Check the condition of battery cables and link wires. Ensure that the insulation is intact along

the length of each cable. Renew any defective battery cables or link wires. Use insulated

spanners on battery terminals. Do not lay tools or other metal objects on the batteries.

4) Check that all battery cables and link wires are securely fastened to the battery terminals and

lubricated. Remove any corrosion from battery terminals and clamps. Ensure all surfaces are

clean and free of lubrication. Secure battery terminals using an insulated spanner. Once

tightened and secure, lubricate battery clamps with petroleum jelly to prevent corrosion.

3.3.2 Condition check (Weekly)

1) Carry out all procedures listed above in Daily checks.

2) Remove all battery cell caps and check the fluid level in each cell in each battery. The level

should be sufficient to cover the plates. Top-up each battery cell as necessary using distilled

water, do not overfill. Replace and tighten battery cell caps and put batteries on charge. Leave

batteries to stabilise for one hour before proceeding with further checks.

3) Using a hydrometer, check the specific gravity of the battery fluid in each cell in each battery

(Target 1.26-1.27 for DYNO Batteries when fully charged). If the specific gravity is not within

the serviceable range, battery de-sulphate fluid may be used to restore batteries.

4) Replace all battery cell caps and clean any liquid from the top surface of the batteries.

Contact with concentrated sulphuric acid results in rapid destruction of body tissue via burns. If inhaled, seek fresh air and immediate medical attention. In the event of skin or eye contact, flush with large volumes of water and seek immediate medical attention. In the event of ingestion, do not induce vomiting and seek immediate medical attention.



3.4 Hydraulic Oil

3.4.1 Level check (Weekly)

Ensure that the machine is on level ground with the platform stowed. Check that the oil level is

between the minimum and maximum marks on the gauge. Top-up the tank with oil if the level is

below the minimum mark. Use the same oil grade as indicated on the label attached to the

hydraulic tank. If the oil level is above the MAX mark, drain as required. Refer to Section 3.4.3.

3.4.2 Filter check (Monthly)

With the machine running and the oil temperature at 40°C, operate the telescope out function and observe the filter condition indicator (Located under Control Canopy). If the needle is in the red zone, the filter cartridge should be replaced once the oil has cooled sufficiently.

3.4.3 Hydraulic oil renewal

Renew the Hydraulic oil after the first 500 hours of operation, then every 2000 hours or two years (whichever comes first) thereafter.

Replacement or testing of the hydraulic oil is essential for optimum machine performance. Contaminated oil and filters may cause poor performance and continued use may cause component damage. Depending upon the operating environment, more regular oil changes may be required.

1) Ensure that the machine is on level ground with the platform stowed and the oil temperature is

not above 40°C.

2) Loosen the filler cap to relieve pressure. Caution must be taken when removing the tank cap as

the hydraulic tank is pressurised.

3) Place a suitable container under the hydraulic

tank. Remove the drain plug located on the

underside of the tank. Refer to capacity

specifications in Section 2.4.1. Dispose of waste

oil in accordance with local environmental

policies.

4) Disconnect the suction strainer pipe on the RH

side of tank. Remove strainer and clean with mild

solvent or renew if necessary. Reconnect suction

pipe and retighten (Refer to Section 2.6 for

torque value).



5) Locate the return filter underneath the base

control canopy. Place a suitable container

underneath the filter. Remove the filter cartridge

using a strap wrench if necessary.

6) Install a new cartridge and rubber seal. Tighten

fully by hand. Dispose of waste oil as detailed

previously.

7) Refit drain plug in tank. Refill tank with oil

(Refer to Section 2.4.1 for capacity) until level

is between MIN and MAX on gauge.



3.5 Telescopic Boom

3.5.1 Wear Pad Check (Monthly)

1) With the links and luffing boom down and the telescope boom fully retracted, check that there

are no loose, missing, or defective components in the superstructure end of the telescope

boom. This includes wear pads, shims, spacers, and fasteners.

2) Fully extend the telescope boom. It may be necessary to raise luffing boom slightly to avoid the

platform hitting the floor. Check that there are no loose, missing, or defective components in

the platform end of the telescope boom. This includes wear pads, shims, spacers, fasteners,

wear screws and locking nuts.

3) Check the clearance between each wear screw and

the inner telescope boom section. In each case this

should be no more than the following limits:

• Red Wear Screws (side of section) - 1mm

• Black Wear Screws (top of section) - 2mm

If adjustment is required, release the locking nut and tighten each wear screw until it makes contact with the inner telescope boom section. Then back-off each wear screw by the following amounts before retightening the locking nuts.

• Red Wear Screws - 1/6th turn (0.5mm)

• Black Wear Screws - 1/3rd turn (1.0mm)

4) Check that the underside of the inner telescope boom section is adequately lubricated and free

from scoring or rubbing marks. If lubrication is necessary use Hycote White Grease or

equivalent.

3.5.2 Hose Trunking and Energy Chain Check (Weekly)

1) Examine the hose trunking and check that there are no loose, missing, or defective

components.

2) Check that the hose trunking does not make contact with or “snag” on the boom structure at

any point over its range of travel.

3) With the telescope section fully extended, check that the trunking system adequately supports

the weight of the hose bundle. The upper section of aluminium trunking should be

approximately parallel with the top surface of the boom.



4) Check the condition of the energy chain, paying particular attention to the condition of the links

at both ends, as this is where the highest loads and wear rates occur. If any links require

replacement please refer to Section 4.2.5.

5) Check that the energy chain is free from debris or any abrasive material that could cause

damage to the hydraulic hoses. Remove & dispose of any debris in accordance with local

environmental policies.

3.5.3 Chain Inspection

After every 6 months of operation (more frequent in hostile environments), the leaf chains should

be inspected and lubricated. Please refer to Chain Inspection Manual (M50280) for further

information.



3.6 Boom Rotation Gear

3.6.1 Rotation Pinion Engagement Check (Monthly)

1) Rotate the superstructure around until the slew pinion is as close as possible to the three teeth

with painted tips (this marks the area of maximum eccentricity of the gear teeth).

2) With the telescope boom fully extended, manually push the booms from side-to-side. Check the

play between the rotation ring and pinion. A small amount of play is permissible.

3) Rotate the machine through a full revolution and check that there are no tight spots where the

machine struggles to rotate.

4) If adjustment is required, loosen the

securing bolts (5 off) on the rotation

pinion gearbox and slacken off the

locking nuts on the adjustment bolts.

Screw in adjustment bolts to increase

pinion engagement and screw out the

adjustment bolts to reduce pinion

engagement. Tighten the locking nuts

and retighten the rotation pinion

gearbox securing bolts to a torque of

120Nm (89lb ft).

5) Rotate the machine through a full revolution and check that there are no tight spots where the

machine struggles to rotate. If necessary reduce pinion engagement.

3.6.2 Rotation Ring Lubrication (Yearly)

1) Locate both grease nipples on the inside of the rotation ring and attach grease gun.

2) Pump the grease gun two to three times as required. Use lithium based (Ep) grease

corresponding to DIN 51825 K2K – 20 and ISO L-X-BCHA2. It is also permissible to use

equivalent grease with a working temperature between -20°C and +120°C.

3) Apply grease to the teeth of the rotation gear as required.



4 Repair Procedures 4.1 General 4.1.1 FUSES

There are three replaceable fuses on the machine.

325A - Battery Power Circuit, 125A - Diesel Engine (Starter Motor and Alternator) and 1A - Battery Controller. Refer to diagram below for their location.



4.2 Platform/Cage

4.2.1 JOYSTICK

The joystick is used to drive and steer the machine in forward and reverse directions.

Removal

1) Isolate machine from power supply

(Disconnect Anderson).

2) Remove the four securing screws (A)

from the cage control panel and carefully

lift clear of the console.

3) Disconnect the joystick plug connector.

4) Remove the four securing screws (B)

from the joystick.

5) Carefully remove the joystick by feeding

it back through the control panel.

6) Install replacement joystick using steps 1 to 5 in reverse order.

4.2.2 FOOTSWITCH

The footswitch is used to provide power to the machine controls.

Removal

1) Isolate machine from power supply (Disconnect

Anderson).

2) Remove the outer cover from the footswitch.

3) Disconnect wiring from contact switch.

4) Remove the two securing bolts from the footswitch

base.

5) Unscrew and remove cable gland from footswitch

base. Retain for reuse when installing new footswitch.

6) Install replacement footswitch using steps 1 to 5 in reverse order.



Contact Switch Replacement

1) Isolate machine from power supply (Disconnect

Anderson).

2) Remove the outer cover from the footswitch.

3) Disconnect wiring from contact switch.

4) Remove the clamp screws and the two securing

screws from the switch.

5) Remove the contact switch.

6) Install replacement switch using steps 1 to 5 in reverse order. Ensure contact screw is adjusted as shown.

4.2.3 SiOPSTM - Load Sensing Console

The load sensing console senses if the operator has been pushed or has fallen against the console, upon which the footswitch will be disabled reducing the possibility of sustained involuntary operation.

Proximity Switch Replacement

1) Remove the four securing screws (A) from the cage control panel.

2) Carefully lift the control panel clear of the console.

3) Locate the relevant switch cable and disconnect from the control panel. (RH Switch is SB1.

LH switch is SB2).

4) Remove the retaining screw

securing the plastic cover on the

side of the console and remove

cover.

5) Remove the two securing screws

from the proximity switch.

6) Remove cable tie-wraps and

carefully remove the switch and

cable from the console.

7) Install replacement proximity

switch using steps 1 to 6 in

reverse order.



Proximity Switch Adjustment

1) Remove the plastic cover from the side of the

console.

2) Carefully insert the top part of the cover between the

console and cage frame as shown.

3) Adjust the bolt head until it just makes contact with

the cage frame.

4) Replace cover and repeat process on opposite side of

console.



4.2.4 ELECTRONIC LOAD CELL (IF FITTED)

The Load Cell monitors weight in the platform/cage of the machine. If pre-configured values are exceeded, warnings are activated.

THE ELECTRONIC LOAD CELL IS A SAFETY CRITICAL COMPONENT, THEREFORE, THE FOLLOWING PROCEDURES SHOULD ONLY BE CARRIED OUT BY A NIFTYLIFT SERVICE ENGINEER OR NIFTYLIFT APPROVED DEALER.

Removal

1) Machine must be in the stowed position with a level cage, parked in a suitable location allowing sufficient access around the cage to carry out step 6.

2) Isolate machine from power supply (Disconnect Anderson).

3) Remove the four securing screws from the cage control panel and lift clear of the console.

4) Locate cable from load cell and disconnect from control panel.

5) Remove cable tie-wraps then carefully extract the cable from the console and cage.

6) Using a suitable lifting device, support the weight of the cage.

7) Remove the M12 safety bolts (2 off).

8) Remove the M16 bolts (8 off) securing the load cell to the cage and extender bracket, remove

the load cell from the machine.

Replacement

1) Ensure the M16 bolts removed from load cell are in good condition.

Renew if necessary.

2) Apply a low strength threadlocker (equivalent to Loctite 222) to the

fixing bolt threads.

3) Offer up the new load cell to the underside of the cage ensuring it is in

its correct orientation (See illustration).

4) Re-insert the fixing bolts and tighten diagonally up to a torque of

205 Nm (151 ft-lbs).



5) Re-insert the two M12 safety bolts and fixings. Do not fully tighten nut. Ensure that there is a

gap of 2-3mm between bolt head and washer.

6) Feed cable through cage and console, fit new tie-wraps and

reconnect to cage control panel.

7) Assemble control panel to console and reconnect power supply

isolator.

8) Proceed to 'Calibration' section below.

Calibration (New Load Cell)

1) Ensure the replacement load cell is mounted correctly (see 'Replacement' section above) and

fully connected.

2) Activate machine by turning the key switch to Ground (Centre) position.

3) Ensure the cage is not in contact with the ground and free from any

additional weight.

4) Remove the dust protection cap.

5) Connect the 'Teach in' handset to the load cell. Take care to ensure

locating peg is correctly aligned with locating hole.

6) After a few seconds, during which the handset carries out a system

check, the 'T' on the handset will flash with a frequency of 5Hz.

Note; if the 'T' stays on constant this indicates an error. Disconnect handset, switch off machine and repeat steps 2 to 6. Contact Niftylift if an error re-occurs.

7) Press and hold the '4' button for four seconds, the 'T' will now display a constant light.

8) Carefully place weights in the platform/cage until the Safe Working Load (SWL) has been

exceeded by 10%, the 'T' will now flash with a frequency of 1Hz.

9) Remove the additional weight to achieve SWL (225KG, 500lbs), now

press and hold the '4' button for four seconds, the 'T' will now display a

constant light.

10) Disconnect the handset and re-insert the dust protection cap.

11) Remove a small amount of weight (10%), wait four seconds then

reload the additional weights to exceed SWL. The overload alarm will

now activate.

12) Remove all weight from cage and check orange LED on load cell is on.

13) Calibration procedure is now complete.



Calibration (Existing Load Cell)

1) Ensure the load cell is mounted correctly and fully connected.

2) Activate machine by turning the key switch to Ground (Centre) position.

3) Ensure the cage is not in contact with the ground and free from any additional weight.

Note; if orange LED on load cell is lit, calibration is not required. If orange LED is off continue with step 4).

4) Remove the dust protection cap.

5) Connect the 'Teach in' handset to the load cell. Take care to ensure locating peg is correctly

aligned.

6) After a few seconds, during which the handset carries out a system check, the 'T' on the

handset will flash with a frequency of 5Hz.

Note; if the 'T' stays on constant this indicates an error. Disconnect handset, switch off machine and repeat steps 2 to 6. Contact Niftylift if an error re-occurs.

7) Press and hold the '4' button for four seconds, the 'T' will now display a constant light.

8) Disconnect the handset.

9) Check that orange LED on load cell is lit. If LED is off, repeat steps 5 to 9.

10) Re-insert the dust protection cap. Calibration procedure is now complete.

4.2.5 TOUGHCAGE FLOOR

Replacement (2 Person Task)


2) Disconnect and remove footswitch from platform (Refer to Section 4.2.2).

3) Disconnect Load Cell cable from Control Panel (Refer to Section 4.2.4).

4) Locate the six bolts on the underside of the toughcage floor. (Four on spider bracket, two at either side).

5) Carefully remove bolts and 'shake-proof' washers. If

any pair of washers has been separated, ensure they

are reassembled correctly with wide spaced ridges

placed together. (Refer to diagram).



6) Position one person at either side of the cage frame and carefully ease the frame out of the floor, enabling the floor to be pulled clear of the machine.

7) Install replacement floor using steps 1 to 6 in reverse order. Ensure floor is in correct orientation with the step cut-out underneath the cage gate. Tighten securing bolts to 59ft-lbs (80Nm).

8) Ensure any decals are replaced in their correct locations.

4.2.6 TOUGHCAGE FRAME

Replacement (2 Person Task)


2) Disconnect and remove footswitch from platform (Refer to Section 4.2.2).

3) Disconnect Load Cell cable from Control Panel (Refer to Section 4.2.4).

4) Remove SiOPSTM covers (Refer to Section 4.2.3).

5) Remove the two M12 bolts that secure the console to the cage frame.

6) Position one person at either side of the cage console, carefully lift the console clear of the cage and lay to one side.

7) Locate the six bolts on the underside of the toughcage floor. (Four on spider bracket, two at either side).

8) Carefully remove bolts and 'shake-proof' washers. If any pair of washers have been separated,

ensure they are reassembled correctly with wide spaced ridges placed together. (Refer to

Section 4.2.5).

9) Position one person at either side of the cage frame and carefully ease the frame out of the

floor.

10) Install replacement frame using steps 1 to 9 in reverse order.

11) Ensure cage gate is refitted and any decals are replaced in their correct locations.



4.3 Booms

4.3.1 LIFT CYLINDER

The Lift Cylinder raises and lowers the links boom sections.

Removal (2 Person Task)

1) Ensure the machine is in its stowed position.

2) Using the ground control levers, raise the telescopic boom sufficiently to allow access to pivot

pin (1) that secures the lift cylinder to Link 4.

3) Place a suitable support (e.g. wooden block) between the telescopic boom and the boom rest.

4) Place a suitable container underneath the cylinder valve block to ensure collection of any

hydraulic oil. Carefully remove hosing from the cylinder valve block by slowly loosening fittings

to allow pressure to dissipate.

5) Locate and remove the two swing bolt securing screws (M10) at both ends of the cylinder.

6) Remove the swing bolts.

7) Using a hammer and suitable size soft metal drift, remove pivot pin

(1). The cylinder will be supported on the inside of Link 4 once pin

has been fully removed.

8) Repeat step 7 on lower pivot pin (2). However, ensure pin is only

partially removed, far enough to allow the rod end of cylinder to

be lowered out of its location.

9) Person 1 and 2 can now carefully remove cylinder from machine.

Note; Cylinder weight is >25kg (55lbs)

10) Install replacement cylinder using steps 2 to 9 in reverse order.

11) After installation, operate the links function through a complete cycle, check hydraulic oil level

and top up with appropriate grade of oil if necessary (Refer to Section 3.4.1).



4.3.2 LUFFING CYLINDER

The Luffing Cylinder raises and lowers the telescopic boom.


1) Using the base controls, lower the telescopic boom on to the boom rest into the stowed

position.

2) Locate the two swing bolt securing screws (M10) at both ends of the cylinder and remove.

3) Using a hammer and soft metal drift, tap the swing bolts to rotate both pivot pins into a suitable

position enabling complete removal of the

swing bolt. Note; Use of penetrating oil (e.g.

WD-40) on pivot pins may be required.

4) Ensure the cylinder is correctly supported

using a strap or wooden supports.

5) Using a hammer and suitable size soft metal

drift, remove the pivot pin at the rod end of

the cylinder by knocking it through from the

opposite side to the swing bolt.

6) Fully retract cylinder using the base controls.

7) Remove hosing from valve block on underside of cylinder. Insert bungs to prevent oil loss.

Retain plugs from side of valve for insertion into replacement cylinder.

8) Using a hammer and suitable size soft metal drift, remove the pivot pin at the knuckle end of the

cylinder. Ensure plastic washers (2 off) are retained for reuse.

9) Carefully remove the cylinder from the machine.

10) Ensure pivot pin holes in replacement cylinder are free from paint and debris.

11) Replace temporary plugs in side of new cylinder valve block with plugs removed from old

cylinder in step 7.

12) Person 1 must now hold the cylinder in position to align the pivot pin holes with the knuckle.

Person 2 re-inserts the two plastic washers (retained in step 8), pivot pin and swing bolt.

13) Re-assemble remainder of cylinder using steps 2 to 7 in reverse order.

14) After installation, operate the luffing function through a complete cycle, check hydraulic oil level

and top up with appropriate grade of oil if necessary (Refer to Section 3.4.1).



4.3.3 LEVELLING CYLINDERS

The levelling cylinders enable the cage/platform floor to maintain a horizontal state when raising and lowering the booms.

Slave Cylinder Removal (2 port - Flyboom)


2) Using the base controls, extend the

telescopic boom out to reveal the pivot pin

(1) that secures the levelling cylinder to the

inner boom section.

3) Using a suitable lifting device, support the

weight of the cage/platform.

4) Remove circlip on pivot pin (2) that secures

the cylinder (rod end) to the flyboom

knuckle.

5) Using a hammer and suitable size soft metal

drift, remove pivot pin 2.

6) Use the base controls cage/platform levelling function to fully close the cylinder.

7) Remove circlip on pivot pin (1).

8) Using a hammer and suitable size soft metal drift, remove pivot pin 1.

9) Carefully remove cylinder, insert metal drift through hole for pivot pin (2) in flyboom knuckle.

Thread the rod end of cylinder onto metal drift then push drift through other side of flyboom

knuckle, allowing the cylinder to hang freely on the drift.

10) Using the ground controls, cycle the cage/platform levelling function back and forth slightly to

relieve pressure in the hydraulic circuit. Carefully remove the hosing from the cylinder. Note;

the oil may still be under pressure, so place a suitable container under cylinder to

capture any oil spillage.

11) Remove check valve, associated fittings and metal tube from old cylinder.

12) Hang replacement cylinder on metal drift as described in Step 9.

13) Re-assemble items removed in step 11 to new cylinder. Note; ensure tapered fitting at rod

end of cylinder securing the metal tube is renewed and a low strength threadlocker

(equivalent to Loctite 222) is applied.




15) After installation, operate the levelling function through a complete cycle, check hydraulic oil

level and top up with appropriate grade of oil if necessary (Refer to Section 3.4.1).

Master Cylinder Removal (4 port - Links Knuckle)


2) Using the ground controls, cycle the cage/platform levelling function back and forth slightly to

relieve pressure in the hydraulic circuit. Carefully remove the hosing from the cylinder. Insert

plugs and cap to prevent oil loss. Note; the oil may still be under pressure, so place a

suitable container under cylinder to capture any oil spillage.

3) Locate the two swing bolt securing screws (M10) at both ends of the cylinder and remove.

4) Remove both swing bolts.

5) Insert a suitable metal rod through the hole in the end of the pivot pins and using a twist and

pull motion remove both pins.

6) Carefully remove the cylnder from the machine.


8) After installation, operate the levelling function through a complete cycle, check hydraulic oil

level and top up with appropriate grade of oil if necessary (Refer to Section 3.4.1).



4.3.4 FLYBOOM CYLINDER

The flyboom cylinder raises and lowers the platform by using the flyboom function.

Removal


2) Using a suitable lifting device, support the weight of the cage/platform.

3) Using the ground controls, cycle the

flyboom function back and forth slightly

to relieve pressure in the hydraulic

circuit. Place a suitable container under

cylinder to capture any oil spillage.

Carefully remove the hosing from the

cylinder. Insert plugs and cap to prevent

oil loss.

4) Remove all four roll pins from pivot pins

1 and 2 (Refer to diagram).

5) Using a hammer and suitable size soft

metal drift, partially remove pivot pin 1,

ensure pin is far enough to allow the rod

end of cylinder to drop out of its

location, but still retained in one side of

the cage mounting bracket and its

associated flyboom arm. (Refer to lower diagram)

6) Repeat step 5 for pivot pin 2.

7) Carefully remove the cylnder from the machine.

8) Install replacement cylinder using steps 3 to 6 in

reverse order.

9) After installation, operate the flyboom function

through a complete cycle, check hydraulic oil

level and top up with appropriate grade of oil if

necessary (Refer to Section 3.4.1).



4.3.5 BOOM ROTATION PINION GEARBOX

The boom rotation pinion gear rotates the upper half of the machine around from 0 to 3550.

Removal

ENSURE SLEW LOCKING PIN IS FULLY ENGAGED (DOWN) BEFORE CARRYING OUT THIS PROCEDURE.


2) Open the ground control canopy.

3) Disconnect battery and remove from machine.

4) Remove upper RH bolt from hand pump (Refer to diagram).

5) Remove battery support plate securing bolts (4 off), remove plate from machine.

6) Remove pinion gear adjustment bolts (2 off). Refer to diagram in Section 3.6.1.

7) Remove securing screws (2 off) from the gearwheel guard.

8) Rotate guard anti-clockwise around gearwheel and remove from machine.

9) Remove gearbox securing bolts (5 off). Refer to diagram in Section 3.6.1.

10) Carefully remove the hosing from the gearbox motor. Insert plugs and cap to prevent oil loss.

11) Lift gearbox vertically and remove from machine. Note; Approximate weight of gearbox assembly is 20kg.

12) Install the replacement gearbox assembly using steps 3 to 11 in reverse order.



4.3.6 ENERGY CHAIN

Link Removal

1) Insert a small flat screwdriver into the

slots on the energy chain bridge

section (See diagram).

2) Carefully prise the bridge section out

of the chain.

3) Repeat steps 1 and 2 on the opposite

side of chain.

4) The damaged/worn link section can

now be removed.



4.4 Power Tray

4.4.1 CENTRIFUGAL CLUTCH

The centrifugal clutch engages the Diesel engine to the Electric motor.

Removal


2) Open the Engine (Right Hand) canopy.

3) Remove the engine tray

retaining bolt. Refer to

Section 3.1.13.

4) Swing the engine tray out

from the superstructure.

5) Remove transmission covers

(2 off).

6) Remove the inertia disc grub

screw (M6).

7) Remove the flexible coupling

bolts (3 off - M10) securing

it to the inertia disc.

8) Using a lever and mallet,

carefully tap the inertia disc towards the electric motor until it just comes into contact with the

motor mounting bolts.

9) Using the 8mm Allen key adapter (Part no. P24806) with a 19mm spanner, loosen the flexible

coupling bolts (3 off - M10) securing it to the clutch, enabling the coupling and clutch to be

separated.

10) Release the bolts (5 off - M8), that secure the clutch to the engine flywheel.

11) Slide the clutch assembly slightly towards the front of machine and remove from the power

tray.

12) Install the replacement clutch assembly using steps 3 to 11 in reverse order. Note; the securing

bolts (6 off) removed from the coupling in steps 7 and 9 MUST be renewed (Part No. P24805)

Apply a small amount of grease under bolt head then torque to 50Nm, 37 ft-lbs). The bolts

have a special coating applied that requires a curing time of 4 - 5 hours at 20°C (15 minutes at

70°C) after assembly. DO NOT OPERATE THE COUPLING DURING THE CURING PERIOD.



4.4.2 DIESEL ENGINE THROTTLE SOLENOID

The throttle solenoid controls the engine speed.

Removal


2) Carefully disconnect wiring from solenoid.

3) Cut cable tie-wrap securing rubber boot (Refer to diagram).

4) Remove securing bolts (2 off).

5) Solenoid can now be removed from its shaft.

Note; In almost all cases the existing shaft will be reusable and simplifies the replacement of a non-functioning solenoid unit. If complete solenoid needs replacement refer to set up procedure below.

6) Install the replacement solenoid using steps 1 to 5 in reverse order. Ensure a new cable tie-

wrap is secured around rubber boot.

Set-up procedure

1) Once solenoid arm is assembled, ensure that spring length is approximately 11mm when

solenoid is fully engaged by pressing

on the bolt as shown and Arm 1

should move freely.

2) Copper grease should be applied

along full length of bolt and Loctite

243 applied as shown below.

3) Spring length when solenoid is

disengaged should be approximately

20 mm.



4.4.3 RADIATOR

Removal



3) Drain coolant from radiator. Refer to Section 3.1.6.

4) Remove the upper and lower hoses.

5) Remove the cooling fan guard and place to one side for reuse.

6) Remove securing bolts (4 off, 2 each side) from upper mounting brackets and remove brackets from mounting frame.

7) Radiator can now be removed from the mounting frame.

8) Install the replacement radiator using steps 1 to 7 in reverse order. Ensure cooling fan guard retained in step 5 is refitted.

9) Refill with coolant. Refer to Section 2.4 for quantity and specification.



4.4.4 EXHAUST

Removal

DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING. BEWARE OF HOT ENGINE COMPONENTS.


2) Remove the engine tray retaining bolt. Refer to Section 3.1.13.

3) Swing the engine tray away from the

superstructure.

4) Remove the retaining bolts (4 off) securing the exhaust assembly to the manifold.

5) Remove the retaining bolts (2 off) securing the exhaust assembly to the front mounting bracket.

6) Remove exhaust assembly from machine.

7) Fit a new exhaust pipe on the replacement exhaust assembly or remove and refit pipe from old assembly if in a satisfactory condition.

8) Install the replacement exhaust assembly using steps 1 to 5 in reverse order. Ensure a new gasket is installed between the exhaust assembly and the engine manifold.



4.5 Chassis

4.5.1 DRIVE HUB MOTOR

Removal


2) Place a suitable container (i.e. drip tray) underneath the drive hub assembly requiring a

replacement motor to capture any oil spillage.

3) Carefully remove the hydraulic hoses (3 off) from the motor by slowly loosening fittings to

allow pressure to dissipate. Insert plugs and cap to prevent oil loss.

4) Remove the cap head bolts (4 off) securing

the motor to the drive gearbox.

5) Remove the motor from the machine.

6) Install replacement motor using steps 3 to 5 in

reverse order. Note; Ensure small plastic seal

(around drive shaft) and large 'O' Ring are

replaced/renewed upon installation. Also

ensure the four bushes DU1215 (Niftylift Part

No. P10523) are replaced/renewed inside

drive motor securing holes.

7) If necessary, top-up gearbox oil as described in Section 3.2.1.

4.5.2 DRIVE HUB GEARBOX



2) Slightly loosen the wheel nuts on the drive gearbox requiring replacement.

3) Using a suitable lifting device, raise the axle until the relevant wheel is clear of the ground.

4) Place a suitable supporting device underneath the axle if replacing a front wheel drive hub, or

underneath the chassis if replacing a rear wheel drive hub.



5) Fully remove wheel nuts and remove wheel from machine.

THE WHEEL AND TYRE WEIGHT IS 133KG (293lbs). A SUITABLE SUPPORT/LIFTING DEVICE IS RECOMMENDED FOR THIS PROCEDURE.

6) Place a suitable container (i.e. drip tray) underneath the drive hub assembly to capture any oil

spillage.

7) Carefully remove the hydraulic hoses (3 off) from the drive motor and the brake hose (1 off)

from the drive gearbox by slowly loosening fittings

to allow pressure to dissipate. Insert plugs and cap

to prevent oil loss.

8) Remove the cap head bolts (8 off) securing the

drive gearbox to the axle.

9) Remove the complete drive hub assembly from the

axle.

Note; drive hub assembly weight is >55kg

(121lbs). A suitable hoist/lifting device is

recommended for this procedure.

10) Stand the assembly on its end with the gearbox wheel studs on the ground, enabling access to

the drive motor securing bolts (refer to diagram).

11) Position the replacement drive gearbox adjacent to

this assembly in the same orientation.

12) Remove the cap head bolts (4 off) securing the drive

motor.

13) Remove the motor from the old gearbox and place it

on to the replacement gearbox ensuring both seals

are correctly positioned (Refer to Section 4.5.1).

14) Apply a threadlocker (equivalent to Loctite 243) to the

securing bolts. Refit the bolts and washers to the motor and torque to 140Nm (103 ft-lbs).

15) Refit the complete drive hub assembly to the axle.

Note; Drive hub assembly weight is >55kg (121lbs). A suitable hoist/lifting device is recommended for this procedure.

16) Apply a threadlocker (equivalent to Loctite 243) to the cap head bolts (M14- 8 off). Refit the

bolts and washers, tighten diagonally and torque to 220Nm (162 ft-lbs).



17) Refit the wheel to the machine and lower it down onto the ground.

18) Fill gearbox with correct grade of oil. Refer to Sections 2.4.3 and 3.2.1.

4.5.3 SUSPENSION CYLINDER

Removal


2) Carefully remove the hydraulic hoses (2 off) from the cylinder by slowly loosening fittings to allow pressure to dissipate. Insert plugs and cap to prevent oil loss.

3) Remove the roll pin from the upper pivot pin.

4) The cylinder can now be removed from the rear axle.

5) Install replacement cylinder using steps 2 to 4 in reverse order. Ensure plastic washer is in position between cylinder and chassis.

4.5.4 STEER CYLINDER

Removal


2) Remove the cover attached to the front axle allowing access to the steer cylinder.

3) Carefully remove the hydraulic hoses (2 off) from the cylinder by slowly loosening fittings to allow pressure to dissipate. Insert plugs and cap to prevent oil loss.

4) Remove the roll pins from the steer rod arms as shown.

5) Remove the four steer cylinder securing screws.

6) The cylinder can now be removed from the front axle.


8) After installation, operate the steer function through a complete cycle, check hydraulic oil level and top up with appropriate grade of oil if necessary (Refer to Section 3.4.1).



4.5.5 HYDRAULIC VALVE BLOCKS

Main Control Valve

This valve is a multi-sectional valve block comprising of three sections and two end sections. It is located in the rear end of the chassis on the Hydraulic tray.

Refer to the diagram below.

Section 1 controls flow to the boom function valves and drive steer.

Section 2 controls the brake enable function, brake pressure and the elevated drive limiter.

Section 3 controls the drive function (forward and reverse).

Individual sections can be replaced by removing the three securing screws at either end, removing the end section then removing the appropriate valve section. Take note of orientation markings on top of valve section.

Ensure seals are renewed between any sections that have been disassembled. Fit the new section ensuring orientation markings are correct way round, taking care to align square to the existing valve. Re-attach end section with the three securing screws and tighten to a maximum torque of 30Nm in three steps (6Nm then 16Nm and finally 30Nm).



Main Control Valve

Port Description Function Torque

CT12 Directional valve Flow limiter - Elevated Drive

60Nm 44ft-lbs

CT13 Pressure Reducing Cartridge Brake Release 45-50Nm 33-37ft-lbs

CT14 Directional valve Coil Nut

Brake Release

27 - 33Nm 20-24ft-lbs 6Nm 4-5ft-lbs

Refer to Section 5.8 for further details.

Suspension Valve

Located on the Hydraulic tray in the rear end of the chassis.

Port Description Function Torque

CT1 Pressure Reducing Cartridge 60Nm 44ft-lbs

CT2 Solenoid Cartridge Coil Nut

20Nm 15ft-lbs 3-4Nm 2-3ft-lbs

CT3 Check valve 45Nm 33ft-lbs



4WD Bypass Valve

Located in the front end of the chassis.

Ref Description Function Torque

1 Solenoid Cartridge 30Nm 22ft-lbs



Freewheel Valve



1 Banjo bolt 100Nm 74ft-lbs

2 Solenoid Cartridge 22-24Nm 16-18ft-lbs

3 Coil Nut 5-6Nm 3-5ft-lbs



Brake Release Valve



1 Solenoid Cartridge 30Nm 22ft-lbs

2 Coil Nut 3-4Nm 2-3ft-lbs



5 Hybrid System Overview 5.1 Introduction

The main hardware for this system consists of an IC engine, centrifugal clutch, motor/generator, variable displacement pump and a motor/generator controller. The system is a self contained autonomous system that can run either in electric or hybrid mode (diesel only mode for emergency operation).

When used in hybrid mode the power train can provide an equivalent of 27kW power to the pump, 13kW from motor and 14kW from diesel engine. This allows the machine to work as a full performance 4WD machine when required but keeping the energy consumption and noise levels as low as possible when performing lower duty operations. When in electric only mode the machine enables machine performance with reduced noise and zero emissions.

IC ENGINE14kW

Cen

trifu

gal C

lutc

h

Generator/Motor13kW

Variable Displacement Load Sensing Pump

315 Bar/18CC

Generator/Motor Controller48VDC

350A RMS

Figure 5.1 Power Train

5.2 Hybrid Operation

In hybrid mode the system operates around two preset RPM values (which here after are called upper limit and lower limit). If the RPM is above the upper limit, the engine will charge the batteries (regen) while performing the required function. If it falls below the upper limit then charging stops to provide full engine power for the required function. If the RPM drops below the lower limit then the electric motor supports the shaft (boost) to keep the RPM above the lower limit. Figure 4.2 below explains the working principle. During boost, the system demand is always monitored such that if boost is not required it will stop supplying electric power.



Current (Negative, Boosting)

Max RegenCurrent

Max BoostCurrent

Regen ZoneBoost Zone

Upper LimitRegen Cut-Off

Lower LimitBoost Turn-On

RPM

`

Current (Positive, Charging)

Boost Monitoring

Figure 5.2 Regen – Boost Operation

The table below shows the RPM settings for various operating modes.

Mode of Operation Engine Preset

RPM (No Load)

Upper Limit Regen Cut-Off

RPM

Lower Limit Boost Turn-On

RPM

Boom / Low Speed Drive 2100 1810 1800

High Speed Drive 3800 3510 3500

Table 5.1 Hybrid Operating Points



5.3 Boom System

The boom system uses a maximum of 25L/min from the pump. Functions can be operated proportionally and simultaneously until the demand reaches 25L/min. If the demand exceeds 25L/min then the flow is shared between the functions with priority given to the function with the lowest operating pressure.

Electric Only Mode

The electric motor is set to run at 2200RPM during booms operation. Booms have full functionality in electric only mode with no limitations with regard to speed or load.

Hybrid Mode

In Hybrid mode the engine is set to run at 2100 RPM in a no load condition. The engine can be loaded either by battery charging or by operating the booms. If the revs drops below 1810 RPM, battery charging stops temporarily and the engine then supplies full power to lift the booms, if it drops further then the electric motor will support the shaft to keep the revs above 1800 RPM. Once load is taken off the engine, revs will recover above 1810 RPM and charging will start automatically. Charging current constantly varies depending on the excess power available.

If the electric system fails to function (controller failure, motor failure, etc) the booms can be operated in diesel only mode. However, this mode is only for low duty functions and for assisting to recover the booms back to the transport position. Full boom function performance is only available in electric only or hybrid modes.

5.4 Drive System

The drive system uses 60L/min maximum flow from the pump. One of the novel features of the machine is having a switchable 2WD and 4WD system. 2WD mode is configured to be front wheel drive which provides good slab performance and the lowest energy consumption for efficiency. 4WD mode engages all 4 wheels and locks them hydraulically to provide good traction and gradeablity. When used in 2WD mode the rear wheels are connected in such a way that they freewheel with minimum drag to the system. If the machine is driven on slopes exceeding 100 it automatically reverts to 4WD (Low speed) until the joystick is released. Table 4.2 below describes the available driving modes.

Driving Mode Speed

KPH Gradeablity

% Configuration Traction

(Diff-lock)

Hare 5 20 2WD OFF

Tortoise 2 20 2WD OFF

Off Road 2.5 40 4WD ON

Elevated (Hare/Tortoise) 1 20 2WD OFF

Elevated Off Road 0.5 40 4WD ON

Table 5.2 Driving Modes



Electric only mode

All the listed driving modes are available in electric only operation. Available power is reduced to 13kW and hence performance is reduced. It is advisable to switch to hybrid mode when high power demand is required e.g. off road driving.

Hybrid Mode

In hybrid mode a full 27kW of combined power is available for machine functions. In this mode the machine consumes battery power to support the engine when required and regenerates battery power when the function duty is low. Under continued high duty function for long periods (for example continued 4x4 off road driving with diff-lock engaged) the battery levels will be significantly reduced to support the high power requirement. Under such conditions it will be normal to have to recharge the battery levels prior to electric only use.

5.5 Charging System and Batteries

Charging System

As standard all machines are fitted with a 25A variable input intelligent charger. The machine can be left on charge over an infinite period or can be used whilst on charge.

Engine charge or “regen” will charge the batteries at differing rates depending on the mode of operation as shown in the table below.

Operating Mode Maximum Charge Current

Engine idling 60A

Boom operation, Low speed drive, Elevated drive 35A

High speed drive 15A

Two charge modes can be combined to give 85A maximum current. The machine is designed to allow this function and will recharge fully discharged batteries quickly to a charged state. If used frequently battery water levels should be monitored and topped up as required. With regular use of this function as a means of charging it is essential that regular and thorough maintenance of the batteries is performed.

The alternator charges the start battery when the engine is running which keeps the battery at 14.4V. A step-down unit is fitted to all machines to convert 48V to 14.4V, which provides control system voltage and keeps the start battery in a charged state. This system also helps keep 48V batteries and the 12V battery in good condition regardless of the operating mode.

Batteries

350 AH DYNO Batteries are fitted as standard. The Niftylift charger and battery management system are tuned to provide the best performance with DYNO batteries. If alternative batteries are used the charger and battery management system must be reconfigured to suit the replacement batteries. Contact Niftylift for further information.



5.6 System Overview

A simplified version of the hydraulic system is shown below in block diagram format. Brief descriptions of the operation of individual blocks are given below. Component details, valve arrangement and connections are shown in the hydraulic schematic D81325. Please refer to D81325 in conjunction with the electric schematic D81392 for in-depth understanding of the complete system.

Variable Displacement

PumpMain Control Valve

Suspension Valve Steering Valve

Boom Control Valve

Pilot Joystick

Difflock ValveFree-wheeling Valves

Wheel MotorsFront

Wheel MotorsRear

Brake Release Rear

Hand Pump

Brake Release (Front)

Figure 5.3 Hydraulic System Concept



5.7 Load Sensing Pump

The machine is fitted with an 18CC variable displacement pump (open loop load sensing). Standby pressure and maximum pressure are set to 17 bar and 315 bar. The load sense signal is obtained either from the boom control valve or from the drive control valve. The tank is pressurised up to 1.3 bar (absolute) to allow positive head at the suction port. Note that if any maintenance is carried out on the hydraulic system, undo the filler cap on top of the tank to remove the pressure from the tank, this will reduce leakage from the tank ports. The pump runs at fixed preset speeds and swash angle/pressure varies according to the flow demand and load pressure.

5.8 Main Control Valve

This main control valve is the main distribution hub of the hydraulic system. Flow to each function valve is provided through the main control valve. The table below describes the main functions of the valves and related cartridges (refer to D81325 for more details).

Function Description Related Cartridges

Drive Controls drive forward and backward. Provides proportional speed control for both directions.

CT2

Brake Release Supplies 30 bar of pressure to the front brakes, supplies the pressure feed to the rear brake release valve.

CT14/CT13

Steer Enables 3.5 L/min flow to the steer valve and enables pressure compensation.

CT1-a

Elevated Drive Flow Limiter

Maximum flow is limited to 11 L/min for elevated drive. This is done by creating a fixed restriction to the load sense line which then acts as a flow regulator in conjunction with the load sensing pump. Full flow is enabled for high speed drive.

CT11/CT12

Booms Enables 25 L/min maximum flow to booms valve. CT1-b

Load sense control

Decays the load sense to tank and shuts the decay line when not in use.

CT17/CT18

Table 5.3 Functions of the Main Control Valve

5.9 Diff-lock Valve and Freewheeling Valves

The diff-lock valve divides/combines the flow to all four wheels equally when in operation. Bypass restrictors are fitted to help with cornering manoeuvres. A 30 bar pressure is supplied from the main drive valve for pilot valve operation.

As with all diff-lock systems, power consumption is increased with the diff-lock engaged, steering whilst diff-lock is engaged further increases power consumption.

In 2WD mode diff-lock is not operable. Flow is free to go to either of the two front wheels. In this mode ports A/B of the rear wheels are connected together via the freewheeling valves to allow free movement.



5.10 Brake Release

The front brakes are released using the BRV valve in the main control valve. This is energised when operating stationery steer function or when driving. Rear brakes are released (Item 38 of D81325) only when driving. Pressure to the rear brake release valve is supplied from the BRV port of the main valve. If stationery steer is used in an emergency condition (with hand pump operation) the front gearboxes must be disengaged mechanically. Refer to decal or section 5.5.1 in the Operating & Safety Manual (M50371)

5.11 Suspension and Steer

Suspension Valve

Drive pressure is supplied to the suspension valve from the main control valve. Maximum pressure to the cylinders is limited to 75 bar using a pressure reducing valve. Once booms are raised out of the transport position the cylinders are connected to the tank line and no suspension is available.

Steer Valve

When steer is activated, steer flow is supplied from the main drive valve via the steer enable valve. This controls the flow to the steer valve and connects the load sense signal to the pump to allow simultaneous operation of drive and steer. Steer valve (Item 9) controls the direction of steer. A pressure switch is fitted to the main drive valve at the steer enable port to limit the maximum pressure on the steer line to 180 Bar. This will disable steer when the cylinder reaches the end of stroke.

5.12 Boom Control Valve and Pilot Joystick

Boom Control Valve

This is a proportional load sensing valve designed to operate all boom functions simultaneously. Flow to each function is compensated and metered by the spool. Where necessary, anti-shock valves are fitted to the work ports. For all main boom functions both manual operation and hydraulic pilot operation is possible. For steer and cage level functions only manual operation is possible.

This valve also provides hydraulic supply to the cage control valve (pilot Joystick). Pilot supply pressure is limited to 50 Bar and controlled by a solenoid fitted to the boom control valve.

Pilot Joystick

This is a 6 section pilot joystick valve block designed to control the main valve remotely. A pilot pressure of 50 bar is supplied to the inlet from the boom control valve. For each joystick section two proportional pressure reducing valves are fitted. Depending on the position of the joystick the pressure on the port is varied. The boom valve is designed to work between 6 bar and 18 bar. At 6 bar the spool starts opening and at 18 bar it is fully open.



5.13 Electrical Control System Overview

Cage Control

Cage User Inputs

Cage Weigh

Base Control

Safety Inputs

Base User Inputs

Outputs to Valves

Motor Controller Motor

Engine

48V Supply

12V Supply

SIOPS

Figure 5.4 Control System Concept

5.14 Control Logic

Many parts of the control system are common with the Niftylift HR21 range. Control logic diagram D81393 explains the operational logic in detail. Component level details and connections are provided in the Electric Schematic D81392.

5.15 Motor/Generator

As previously highlighted, a 48V AC 3 phase motor/generator is fitted to the power train. The motor is equipped with a temperature and speed sensor which feed information to the controller. Current supplied to the motor is controlled by the motor controller. The motor can operate at full power (13kW output) for 20 minutes continuously. If the motor overheats the controller will reduce the current supply and operate in a low power mode. Using the full available 350A line current, the motor can provide 60NM torque and 13kW shaft power.



5.16 Controller

Motor/Generator Control

The Motor Controller has a current rating of 350A. It can supply a maximum power of 15 KW to the motor (power input to the motor). High voltage safety functions are controlled within the motor controller. If a fault is detected in the power supply, motor controller or motor; a main contactor will shut-off the power to the controller. Under this condition a fault code will be displayed on the motor controller status display. Under normal working conditions the yellow LED of the controller status indicator flashes continuously. In a fault condition the yellow and red LED will flash in a particular pattern as shown below.

“X” denotes a flash

RED YELLOW RED YELLOW X XXX XX XXXX

First Digit (3) Second Digit (4)

This represents a fault code of “34”.

Table 5.4 Fault Display Format

Refer to Appendix A for the list of numerical codes and relevant fault descriptions.

If overheating occurs the controller will reduce power accordingly and protect the internal electronics.



Drive Speed Control

In addition to motor control, the controller adjusts the analogue voltage output for drive speed control. Drive joystick output from cage is connected to the motor controller and the output from the motor controller is modified for different drive modes (Hare/Tortoise/Elevated). This can be adjusted using an OEM level hand held unit. This analogue signal is then fed back to the proportional valve driver which converts it to a PWM current.

5.17 Curtis Hand Held Unit

This unit can be used to monitor the operation of the controller and for troubleshooting. Access levels are controlled within the unit. The monitor menu provides useful information for troubleshooting. Figure 5.5 below shows the menu of the HR21AWD HYBRID controller with the latest software as seen on a user level hand held unit (Only the relevant information is shown). More parameters can be accessed with an OEM level hand held unit.

Parameters under the program menu are adjustable (providing you have access, “*” in front of the value says you don’t have sufficient access to modify the parameter). Parameters under monitor menu are for information only and are not adjustable.

Under the fault menu existing faults (if applicable) and previous faults are shown.



Program Software Version E10006 002 20AUG2010

Niftylift

Niftylift

Fan Off 40CFan Control

Mode 2 3600RPM

Shaft Speed Mode 1 2200RPM

Battery I 0.0A

RPM 2200RPMShaft Speed

Max Charge Volt 59V

Constant V 57V

Charge MaxA 0ARegen Control

Fan On 45C

Monitor

CV OFF

Regen ON

Damped Batt V 0.00V

Battery Monitor

Regen Monitor

Battery V 0.00V

Damped Batt I 0.0A

Fan OFFFan Monitor

Master I Limit 0A

Regen I Limit 350A

Set Charge I 0.0A

Drive Monitor Analog Input 0.00V

Analog Output 0.00V

System Faults XXXXXXXXXXXFault

XXXXXXXXXXXFault History

Figure 5.5 Curtis Hand Held Unit – User Level Menu



6 Troubleshooting guide 6.1 TROUBLE SHOOTING INFORMATION

This guide is designed to help machine faults be found and rectified more easily. Known faults are listed below. Your specific machine fault may not be listed here, if not please contact your local Niftylift dealer in order for the guide to be continually improved and updated.

6.2 PLATFORM FUNCTION FAULT FINDING

PROBLEM CAUSE/TEST SOLUTION

Machine will not drive

Check that power is reaching the solenoids on the drive block

Replace main PCB

Check main PCB for signal in from joystick and out to drive block

Check joystick Replace joystick if faulty (Refer to Section 4.2.1)

No functions, but engine operates correctly

Coupling failure Re-fit coupling. Replace any damaged parts (Refer to Section 4.4.1)

Footswitch fault Contact switch may need replacement (Refer to Section 4.2.2)

Machine inactive, engine will not start

Anderson connecter disconnected Reconnect

Check main fuse If fuse blown, renew with direct replacement (Refer to Section 4.1.1)

Batteries discharged Recharge batteries

E-stops activated Ensure e-stops are pulled out, at base controls and cage controls

Cage weigh activated or micro switch faulty

Remove weight from cage, or replace switch if problem persists



6.3 ENGINE FAULT FINDING


Engine difficult to start

Fuel is thick and doesn’t flow

Check the fuel tank and fuel filter. Remove water, dirt and other impurities

As all fuel will be filtered by the filter, if there should be water or other foreign matters on the filter, clean the filter with diesel

Air or water mixed in fuel system

If air is in the fuel filter or injection lines, the fuel pump will not work properly. To attain proper fuel injection pressure, check carefully for loosened fuel line couplings, loose cap nuts etc

Loosen joint bolt at top of fuel filter and air vent screws of fuel injection pump to eliminate all the air in the fuel system

Thick carbon deposits on orifice of injection nozzle

This is caused when water or dirt is mixed in the fuel. Clean the nozzle injection piece, being careful not to damage the orifice

Check to see if nozzle is working properly. If not, install a new nozzle

Valve clearance is incorrect Adjust valve clearance to 0.145 to 0.185mm (0.0057 to 0.0072in.) when the engine is cold

Leaking valves Grind valves

Fuel injection timing is wrong Adjust injection timing

The injection timing 0.3 rad (18°) before top dead centre

Engine oil becomes thick in cold weather and engine cranks slow

Change grade of oil appropriate to the ambient temperature

Low compression Bad valve or excessive wear of rings, pistons and liners cause insufficient compression. Replace with new parts

Battery is discharged and the engine will not crank

Charge battery

In winter, always remove battery from machine, charge fully and keep indoors. Install on machine when required




Engine output insufficient

Carbon stuck around orifice of injection nozzle piece

Clean orifice and needle valve, being careful not to damage the nozzle orifice

Check nozzle for condition. Replace if necessary

Inadequate compression.

Leaking valves

Bad valve or excessive wear of rings, pistons and liners cause insufficient compression. Replace with new parts

Grind valves

Fuel supply is deficient Check fuel system

Moving parts overheating

Check lubricating oil system

Check lubricating oil filter is functioning correctly

Filter element deposited with impurities will cause poor lubrication. Replace element

Check clearance of bearings are within factory specs

Check ignition timing

Valve clearance is wrong Adjust valve clearance to 0.145 to 0.185mm (0.0057 to 0.0072in.) when the engine is cold

Air cleaner is dirty Clean the air filter every 100 hours of operation

Fuel injection pressure is incorrect

Adjust to correct pressure. 13.7 Mpa (140kgf/cm2, 1991psi)

Injection pump wear

Do not use poor quality fuel as it will cause excessive pump wear. Only use No 2-D fuel

Check the fuel injection pump element and delivery valve assembly and replace if necessary

Engine cutting out due to low fuel level

Fuel level too low Re-fill fuel tank if problem persists see above for 'Air or water mixed in fuel system'

Fuel line crushed Release fuel line and replace if damaged

Lift pump not functioning correctly

Replace lift pump



6.4 GEARBOX FAULT FINDING


Oil leakage from seals

Hardening of the seals due to prolonged storage

Clean area and check for leakage after a few days

Seals damaged or worn Contact nearest assistance centre

Too much lubricant Check oil level (Refer to Section 3.2.1)

Vibrations and/or excessive noise

Wheel gear is not correctly installed

Check the fixing

Internal anomaly Contact nearest assistance centre

Bearings badly lubricated or faulty Contact nearest assistance centre

Dented or chipped teeth Contact nearest assistance centre

Low oil level Check oil level, top-up if necessary

The parking disc brake fails to disengage

Low pressure in the braking circuit Check the brake connection

Discs stuck due to prolonged storage

Apply pressure to the brake and turn the wheel by turning the motor on

Parking disc brake does not engage

Residual pressure in the circuit Check hydraulic circuit

Discs worn Contact nearest assistance centre

The wheel gear does not turn when the motor is running

Incorrect mounting of motor Check coupling between motor and wheel gear

Brakes seized Check the braking system

Internal anomaly Contact nearest assistance centre

Wheel gear disengaged See the DISENGAGE section

Over-heating

Either too much or too little oil Check the oil level

Unsuitable lubricant Check the lubricant type and condition

Bearings badly lubricated or faulty Contact an assistance centre

Multiple-disc brake not opening completely

Check brake opening pressure

High thermal power Contact an assistance centre



Appendix A Code Programmer LCD Display

Effect of fault Possible Cause Set/Clear Conditions

12 Controller Overcurrent ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake;

1. External short of phase U,V, or W motor connections. 2. Motor parameters are mis-tuned. 3. Controller defective.

Set: Phase current exceeded the current measurement limit.

Clear: Cycle KSI.

13 Current Sensor Fault ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake;

1. Leakage to vehicle frame from phase U, V, or W (short in motor stator). 2. Controller defective.

Set: Controller current sensors have invalid offset reading. Clear: Cycle KSI.

14 Precharge Failed ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake;

1. External load on capacitor bank (B+ connection terminal) that prevents the capacitor bank from charging.

2. See 1311 Monitor menu » Battery: Capacitor Voltage.

Set: Precharge failed to charge the capacitor bank to the KSI voltage. Clear: Cycle Interlock input or use VCL function Precharge().

15 Controller Severe Undertemp ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake;

1. See 1311 Monitor menu » Controller: Temperature.

2. Controller is operating in an extreme environment.

Set: Heatsink temperature below -40°C. Clear: Bring heatsink temperature above -40°C, and cycle interlock or KSI.

16 Controller Severe Overtemp ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

1. See 1311 Monitor menu » Controller: Temperature.


3. Excessive load on vehicle. 4. Improper mounting of controller.

Set: Heatsink temperature above +95°C. Clear: Bring heatsink temperature below +95°C, and cycle interlock or KSI.

17 Severe Undervoltage Reduced drive torque.

1. Battery Menu parameters are misadjusted.

2. Non-controller system drain on battery. 3. Battery resistance too high. 4. Battery disconnected while driving. 5. See 1311 Monitor menu »

Battery: Capacitor Voltage. 6. Blown B+ fuse or main contactor

did not close.

Set: Capacitor bank voltage dropped below the Severe Undervoltage limit with FET bridge enabled. Clear: Bring capacitor voltage above Severe Undervoltage limit.

18 Severe Overvoltage

ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle; FullBrake;

1. Battery Menu parameters are misadjusted.

2. Battery resistance too high for given regen current

3. Battery disconnected while regen braking

4. See 1311 Monitor menu » Battery: Capacitor Voltage.

Set: Capacitor bank voltage exceeded the Severe Overvoltage limit with FET bridge enabled.

Clear: Bring capacitor voltage below Severe Overvoltage limit then cycle KSI.



Code Programmer LCD Display Effect of fault

Possible Cause Set/Clear Conditions

21 Controller Undertemp Cutback

None, unless a fault action is programmed in VCL.

1. Controller is performance limited at this temperature.

2. Controller is operating in an extreme environment

3. See 1311 Monitor menu » Controller: Temperature

Set: Heatsink temperature d r o ppe d below -25°C.

Clear: Bring heatsink temperature above -25°C.

22 Controller Overtemp Cutback

Reduced drive and brake torque.

1. Controller is performance limited at this temperature.


3. Excessive load on vehicle. 4. Improper mounting of controller. 5. See 1311 Monitor menu » Controller:

Temperature

Set: Heatsink temperature ex ce e de d 85°C. Clear: Bring heatsink temperature below 85°C.

23 Undervoltage Cutback

Reduced drive torque.

1. Normal operation. Fault shows that the batteries need recharging. Controller is performance limited at this voltage.

2. Battery parameters are misadjusted. 3. Non-controller system drain on

battery. 4. Battery resistance too high. 5. Battery disconnected while driving. 6. See 1311 Monitor menu »

Battery: Capacitor Voltage. 7. Blown B+ fuse or main contactor did

not close.

Set: Capacitor bank voltage dropped below the Undervoltage limit with FET bridge enabled.

Clear: Bring capacitor voltage above Undervoltage limit.

24 Overvoltage Cutback

Reduced brake torque.

1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking. Controller is performance limited at this voltage.

2. Battery parameters are misadjusted. 3. Battery resistance too high for given

regen current. 4. Battery disconnected while regen

braking. 5. See 1311 Monitor menu » Battery:

Capacitor Voltage

Set: Capacitor bank voltage exceeded the Overvoltage limit with FET bridge enabled. Clear: Bring capacitor voltage below the Overvoltage limit.

25 +5V Supply Failure


1. External load impedance on the +5V supply (pin26) is too low.

2. See 1311 Monitor menu » Outputs: 5 Volts and Ext Supply Current.

Set:+5V supply (pin26) outside the +5V ±10% range. Clear: Bring voltage within range.





26 Digital Out 6 Overcurrent

Digital Output 6 driver will not turn on.

1. External load impedance on Digital Output 6 driver (pin19) is too low.

Set: Digital output 6 (pin19) current exceeded 15 mA. Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

27 Digital Out 7 Overcurrent

Digital Output 7 driver will not turn on.

1. External load impedance on Digital Output 7 driver (pin20) is too low.

Set: Digital output 7 (pin20) current exceeded 15 mA.

Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

28 Motor Temp Hot Cutback

Reduced drive torque.

1. Motor temperature is at or above the programmed Temperature hot setting and the requested current is being cut back.

2. Motor Temperature Control Menu parameters are mis-tuned.

3. See 1311 Monitor menu » Motor: Temperature and Monitor » Inputs: Analog2

4. If the application doesn't use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off.

Set: Motor temperature is at or above the Temperature Hot parameter setting. Clear: Bring the motor temperature within range.

29 Motor Temp Sensor Fault

MaxSpeed reduced (LOS, Limited Operating Strategy) and motor temperature cutback is disabled.

1. Motor thermistor is not connected properly.

2. If the application doesn't use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off.

3. See 1311 Monitor menu » Motor: Temperature and Monitor » Inputs: Analog2.

Set: Motor thermistor input (pin8) is at the voltage rail (0 or 10V).

Clear: Bring the motor thermistor input voltage within range.

31 Coil1 Driver Open/Short

ShutdownDriver1.

1. Open or short on driver load. 2. Dirty connector pins. 3. Bad crimps or faulty wiring.

Set: Driver 1 (pin6) is either open or shorted.

Clear: Correct open or short, and cycle driver.

31 Main Open/Short ShutdownDriver1; ShutdownMotor; ShutdownEMBrake;


Set: Main contactor driver (pin6) is either open or shorted.







ShutdownDriver2.




32 EM Brake Open/Short ShutdownDriver2; ShutdownThrottle; FullBrake;


Set: Electromagnetic brake driver (pin5) is either open or shorted.



ShutdownDriver3.





ShutdownDriver4.




35 PD Open/Short

ShutdownPD.


Set: Proportional driver (pin2) is either open or shorted.


36 Encoder Fault

Control Mode changed to (LOS, Limited Operating Strategy)

1. Motor encoder failure. 2. Bad crimps or faulty wiring. 3. See 1311 Monitor menu » Motor:

Motor RPM.

Set: Proportional driver (pin2) is either open or shorted.

Clear: Cycle KSI.

37 Motor Open ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake;

1. Motor phase is open.

2. Bad crimps or faulty wiring.

Set: Motor phase U, V or W detected open.

Clear: Cycle KSI.

38 Main Contactor Welded ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake;

1. Main contactor tips are welded closed.

2. Motor phase U is disconnected or open.

3. An alternate voltage path (such as an external precharge resistor) is providing a current to the capacitor bank (B+ connection terminal)

Set: Just prior to the main contactor closing, the capacitor bank voltage (B+ connection terminal) was loaded for a short time and the voltage did not discharge.

Clear: Cycle KSI.

39 Main Contactor did not Close ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake;

1. Main contactor did not close. 2. Main contactor tips are oxidized,

burned or not making good contact. 3. External load on capacitor bank (B+

connection terminal) that prevents capacitor bank from charging.

4. Blown B+ fuse.

Set: With the main contactor commanded closed, the capacitor bank voltage (B+ connection terminal) did not charge to B+.

Clear: Cycle KSI.





41 Throttle Wiper High

Shutdown Throttle.

1. Throttle pot wiper voltage too high. 2. See 1311 Monitor menu » Inputs:

Throttle Pot

Set: Throttle pot wiper (pin16) voltage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring throttle pot wiper voltage below the fault threshold.

42 Throttle Wiper Low

Shutdown Throttle.


Set: Throttle pot wiper (pin16) voltage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring throttle pot wiper voltage above the fault threshold.

43 Brake Wiper High

FullBrake.


Set: Brake pot wiper (pin17) voltage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring brake pot wiper voltage below the fault threshold.

44 Brake Wiper Low

FullBrake.


Set: Brake pot wiper (pin17) voltage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring brake pot wiper voltage above the fault threshold.

45 Pot Low Overcurrent

ShutdownThrottle; FullBrake.

1. Combined pot resistance connected to pot low is too low..

2. See 1311 Monitor menu »Outputs: Pot Low

Set: Pot low (pin18) current exceeds 10mA

Clear: Clear pot low overcurrent condition and cycle KSI.

46 EEPROM Failure ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake.

1. Failure to write to EEPROM memory. This can be caused by EEPROM memory writes initiated by VCL, by the CAN bus, by adjusting parameters with the 1311, or by loading new software into the controller.

Set: Controller operating system tried to write to EEPROM memory and failed.

Clear: Download the correct software (OS) and matching parameter default settings into the controller and cycle KSI.

47 HPD/Sequencing Fault ShutdownThrottle;

1. KSI, interlock, direction and throttle inputs applied in incorrect sequence.

2. Faulty wiring, crimps or switches at KSI, interlock, direction or throttle inputs.

3. See 1311 Monitor menu » Inputs.

Set: HPD (High Pedal Disable) or sequencing fault caused by incorrect sequence of KSI, interlock, direction and throttle inputs.

Clear: Reapply inputs in correct sequence.





47 Emer Rev HPD ShutdownThrottle; ShutdownEMBrake;

1. Emergency Reverse operation has concluded, but the throttle, forward and reverse inputs and interlock have not been returned to neutral.

Set: At the conclusion of Emergency Reverse, the fault was set because various inputs were not returned to neutral.

Clear: If EMR_Interlcok = On, clear the interlock, throttle and direction inputs.

If EMR_Interlock = Off, clear the throttle and direction inputs.

49 Parameter Change Fault ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake;

1. This is a safety fault caused by a change in certain 1311 parameter settings so that the vehicle will not operate until KSI is cycled.

For example, if a user changes the Throttle type this fault will appear and require cycling KSI before the vehicle can operate.

Set: Adjustment of a parameter setting that requires cycling of KSI.

Clear: Cycle KSI.

51-67 OEM Faults

(See OEM Documentation)

1. These faults can be defined by the OEM and are implemented in the application specific VCL code. See OEM documentation.

Set: See OEM documentation.

Clear: See OEM documentation.

68 VCL Runtime Error ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake.

1. VCL code encountered a runtime VCL error.

2. See 1311 Monitor menu » Controller: VCL Error Module and VCL Error. This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

Set: Runtime VCL code error condition.

Clear: Edit VCL application software to fix this error condition; flash the new compiled software and matching parameter defaults; cycle KSI.

69 External Supply out of Range


1. External load on the 5V and 12V supplies draws either too much or too little current.

2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mis-tuned.

3. See 1311 Monitor menu » Outputs: Ext Supply Current.

Set: The external supply current (combined current used by the 5V supply (pin26) and 12V supply (pin25) is either greater than the upper current threshold or lower than the lower current threshold. The two thresholds are defined by the Ext Supply Max and Ext Supply Min parameter settings (Page 52).

Clear: Bring the external supply current within range.





71 OS General ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake.

1. Internal controller fault. Set: Internal controller fault detected.

Clear: Cycle KSI.

72 PDO Timeout ShutdownInterlock; CAN NMT State set to Pre-operational

1. Time between CAN PDO messages received exceeded the PDO Timeout Period.

Set: Time between CAN PDO messages received exceeded the PDO Timeout Period.

Clear: Cycle KSI.

73 Stall Detect

Control Mode changed to LOS, (Limited Operating Strategy)

1. Stalled motor. 2. Motor encoder failure. 3. Bad crimps or faulty wiring. 4. Problem with power supply for the

motor encoder. 5. See 1311 Monitor menu » Motor:

Motor RPM.

Set: No motor encoder movement detected.

Clear: Either cycle KSI, or detect valid motor encoder signals while operating in LOS mode and return Throttle Command = 0 and Motor RPM = 0.

87 Motor Characterization Fault ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle;

1. Motor characterization failed because of an Overvoltage or Undervoltage fault, Motor Temperature Sensor fault or Motor_Temperature > 150°C during the characterization process.

Set: Motor characterization failed during the motor characterization process.

Clear: Cycle KSI.

88 Encoder Characterization Fault ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle; Encoder_Steps set to value = 31

1. Encoder characterization failed during the motor characterization process.

2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr)

Set: During the motor characterization process, encoder pulses were detected but the Encoder_Steps were not detected as 32, 48, 64 or 80 ppr.

Clear: Manually set Encoder_Steps to the correct value for the motor encoder and cycle KSI.





89 Motor Type Fault ShutdownMainContactor; ShutdownMotor; ShutdownEMBrake; ShutdownThrottle;

1. The Motor_Type parameter value is out of range.

Set: Motor_Type parameter is set to an illegal value.

Clear: Set Motor_Type to correct value and Cycle KSI.

92 EM Brake Failed to Set

Enter Position Hold.

1. Vehicle movement sensed after the EM Brake has been commanded to set.

2. EM Brake will not hold the motor from rotating.

Set: After the EM Brake was commanded to set and time has elapsed to allow the brake to fully engage, vehicle movement has been sensed.

Clear: Activate the throttle.

93 Limited Operating Strategy (LOS)

Enter LOS Control mode.

1. Limited Operating Strategy (LOS) control mode has been activated as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

2. Motor encoder failure. 3. Bad crimps or faulty wiring. 4. Vehicle is stalled.

Set: Encoder Fault (Code 36) or a Stall Detect Fault (Code 73) was activated and Brake or Interlock has been applied to activate LOS control mode allowing limited motor control.

Clear: Cycle KSI or if the LOS mode was activated by the Stall Fault, clear LOS by ensuring encoder senses proper operation, Motor RPM = 0 and Throttle Command = 0

HR21 (SP64) Hybrid AWD Service Manual - Niftylift · Ensure battery posts are always protected and...

Documents

Transcript of HR21 (SP64) Hybrid AWD Service Manual - Niftylift · Ensure battery posts are always protected and...