Troubleshooting Guide - · PDF fileSECTION ONE ENGINE DIAGNOSTICS Troubleshooting Guide 12 UNO...

P/N 0153180July 1999

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

www.snorkelusa.com

TroubleshootingGuide

1

GENERAL INFORMATIONThis manual contains procedures for locating and correcting the majority of problems which maydevelop on the “Snorkelift” UNO 33 and 41 4x4 Aerial Platforms.

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

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

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

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

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

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

NOTE: Engine maintenance and troubleshooting information not contained in this manual may befound in the engine maintenance manual originally provided with the machine, or from the EngineManufacture/Dealer Network.

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

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

2

MANUAL DESIGN

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

Problem Go to PageInspect

Go to PageInspect

OK

Step 1

Step 2

Example: Problem Solving Procedure

Inspect

Troubleshoot(Identify Problem)

Replace orperform repair

If

Go to step

no

Yes

Example: Flowchart Procedure

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

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

A pressure gauge rated for 0 - 5000 psi.

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

(Photo Tachometer is recommended)

Flowmeter: A meter designed to measure fluid flow.

Stopwatch: A tool designed to measure time.

3

SYMPTOM PAGE NUMBER

Section One - Engine DiagnosticsEngine starter fails to operate (No Electrical) 9Starter disengages before engine starts (Ford only) 10Engine cranks over but will not start 10Engine starts then shuts down after 30 seconds 11Engine will not accelerate (Ford only) 11Engine will not accelerate (Kubota only) 11Engine over accelerates (Ford only) 12Engine will not start from platform control 12Engine starts while cranking, then dies when key switch is released 13

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

Section Three - Steering System DiagnosticsMachine will not steer 51

4

SYMPTOM PAGE NUMBER

Section Four - Drive System DiagnosticsDrive system is not operational with controller in either direction 57No forward drive (reverse ok) 58No reverse drive (forward ok) 58Drive high range not operating (mid speed ok) 59Drive mid range not operating (low speed ok) 59Wheel on one side rotate faster than wheels on other side 59One wheel rotates slower than others 60Brakes will not release 60

Section Five - Emergency Power System DiagnosticsEmergency pump motor non-operational 83No functions when on emergency power 83

Section Six - Swing System DiagnosticsSwings only in one direction 89No response from swing when platform controls are activated (ground controls ok) 89No response from swing when ground controls are activated (platform controls ok) 89Swings erratically in either direction 90Swings faster one way than other 90Swing brake will not hold 90Swings too slow 91

Section Seven - Boom Functions DiagnosticsNo boom functions from ground control 107No boom functions from platform control 107

5

SYMPTOM PAGE NUMBER

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

Section Nine - Boom Elevation System DiagnosticsBoom raises but will not stay elevated (Bottom/Middle/Top) 127Bottom boom will not raise from platform control (ground control ok) 127Middle boom will not raise from platform control (ground control ok) (Uno 41 only) 127Top boom will not raise from platform control (ground control ok) 127Bottom boom will not raise from ground control 128Middle boom will not raise from ground control (Uno 41 only) 128Top boom will not raise from ground control 128

Section Ten - Telescope System DiagnosticsBoom will not retract from ground control 143Boom will not retract from platform control (ground control ok) 143Boom will not extend from ground control 144Boom will not extend from platform control (ground control ok) 144Boom drifts in 144

Section Eleven - Fuel System DiagnosticsEngine will not start on gasoline, but will start on L.P. 159Engine will not start on L.P., but will start on gasoline 159

6

SYMPTOM PAGE NUMBER

Section Twelve - Accessories DiagnosticsAC Generator will not function 167AC Generator has low voltage 167Machine will not steer 167

SECTION ONE:ENGINE DIAGNOSTICS

SECTION ONEENGINE DIAGNOSTICS

Troubleshooting Guide 9 UNO 33/ 41 4X4

InspectStarter Solenoid

InspectPower Cables and

Battery Disconnect Switch

InspectGround Control

Circuit Breaker (25 Amp)

InspectEmergency Stop Switch

InspectGround Master (Key) Switch

InspectEngine Starter Relay

InspectIgnition/Emergency

Power Switch

InspectGround/PlatformSelector Switch

InspectEngine Anti-Restart Relay

(Ford Only)

Engine starterfails to operate(No Electrical)

Go to Page13

InspectBattery and Cable Connections

Go to Page13

Go to Page14

Go to Page15

Go to Page15

Go to Page16

Go to Page16

Go to Page17

Go to Page17

Go to Page18

OK

OK

OK

OK

OK

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

Step 11

InspectAmmeter

Go to Page14

OKStep 3



Starterdisengages before

engine starts(Ford Only)

Go to Page19

InspectEngine Anti-Restart Relay

Engine cranksover but

will not startGo to Page

20Inspect

Ground Master (Key) Switch

Go to Page20

InspectGround/Platform Selector Switch

Go to Page21

InspectIgnition/Emergency Power Switch

Go to Page21

InspectRun Relay

Go to Page22

InspectMagnetic Switch

(Ford only)

Go to Page22

InspectMagnetic Switch

(Kubota only)

OK

OK

OK

OK

Chart 2

Chart 3

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 1

Go to Page19


OKStep 2

Go to Page23

InspectRun Solenoid(Kubota only)

OKStep 7

OK



Engine will notaccelerate(Ford Only)

Go to Page26

InspectThrottle Circuit Breaker (15 Amp)

Go to Page26

InspectMedium Throttle Relay

Go to Page27

InspectHigh Throttle Relay

Go to Page27

InspectThrottle Governor or Controller

Go to Page28

InspectActuator

OK

OK

OK

OK

Chart 5

Step 1

Step 2

Step 3

Step 4

Step 5

Go to Page29

InspectThrottle Relay

Go to Page30

InspectThrottle Solenoid

OK

Step 6

Step 7

Engine startsthen shuts downafter 30 seconds

Go to Page24

InspectEngine Temperature Gauge

Go to Page24

InspectEngine Oil Pressure Switch

(Ford Only)

OK

Chart 4

Step 1

Step 2

Go to Page25

InspectEngine Oil Pressure Switch

(Kubota Only)

OKStep 3

Engine will notaccelerate

(Kubota Only)

Chart 6

Go to Page29

InspectFuse (10 Amp)

OK

Step 1



Chart 7

Engine overaccelerates(Ford Only)

Go to Page31

Inspect Governor

Go to Page31

InspectActuator

OK

Step 1

Step 2

Engine will notstart from

platform control

Go to Page32

InspectPlatform Control

Circuit Breaker (20 Amp)

Go to Page33

InspectEmergency Stop Switch

Go to Page33

InspectFoot Switch

Go to Page34

InspectPlatform Start Switch

OK

OK

OK

Chart 8

Go to Page32

InspectGround/Platform Selector Switch

OK

Go to Page34

InspectIgnition/Emergency Power Switch

OK

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Engine starts whilecranking, then dieswhen key switch is

released

Go to Page35

InspectRun Solenoid

Step 1

Chart 9

Go to Page35

InspectRun Relay

OKStep 2



Engine starter fails tooperate (No Electrical)

InspectPower Cables andBattery Disconnect

Switch

Using a meter set toread voltage, measure

voltage enteringBattery Disconnect SwitchShould read 12-12.7 volts

Battery DisconnectSwitch in Off

Position

If 12-12.7V

Using a meter set toread voltage, turn

Battery Disconnect Switchto On position, measure

voltage coming out ofBattery Disconnect SwitchShould read 12-12.7 volts

Reset BatteryDisconnect Switch

to On Position

If

Repair or replaceBattery Disconnect Switch

and/orBattery Disconnect Switch

wiring

If low or no reading

Go to step 3

If12-12.7V

Then

InspectBatteries

Using a meterset to read

voltage, checkeach battery for12 volts while

under load

Recharge orreplace

battery(s)

Check batteryconnections

If loose

If low or no voltage

Clean allconnections

Tighten allconnections

Ifcorroded

If 12V

Step 1Step 2

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



Using a meter set to readvoltage, turn BatteryDisconnect Switch to

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

Step 3

Step 4Inspect

Ground ControlCircuit Breaker

(25 Amp)

Circuit breaker isopen If low or no reading

Check for voltage betweenCircuit Breaker and

Emergency Stop Switchon wire #1A

Should read 12 volts

Reset Circuitbreaker

Then

If

Repair or replaceCircuit Breaker

and/orCircuit Breaker wiring


Go to step 5

If10-12V

InspectAmmeter

Using a meter set to readvoltage, measure voltage

between1.Battery Disconnect

Switch and Ammeter (+)on wire # 57

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

Should read 12-12.7 volts


Repair or replaceCircuit Breaker

and/orCircuit Breaker wiringGo to step 4

If12-12.7V



Step 5Step 6

InspectGround Master(Key) Switch

Using a meter set to readvoltage, activate engine

starter and measurevoltage between Battery

post side of GroundMaster Switch and start

side of GroundMaster Switch.

Should read 10-12 volts

FordGo to step 7

KubotaGo to step 8

Repair or replaceGround Master Switch

and/orGround Master Switch

wiring

If10-12V


InspectEmergency Stop

Switch

Using a meterset to read voltage, pullEmergency Stop Switch

out and measurevoltage between

Emergency Stop Switchand Battery side of

Ground Master(Key) Switch.


Emergency StopSwitch is off(pushed in)

If low or no readingPull Emergency

Stop Switch (out)to the On position

If

ReplaceEmergency Stop Switch

and/orEmergency Stop Switch

wiringGo to step 6

If10-12V

Then



Step 7Step 8


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

activate starter andmeasure voltage betweenIgnition/Emergency Power

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

Ground/PlatformSelector Switch isin Platform position

Return Ground/Platform SelectorSwitch to Ground

position

Then

If

FordGo to step 9

KubotaGo to step 7


ReplaceGround/Platform Selector

Switch and/orGround/Platform Selector

Switch wiring

If10-12V


Power Switch

Using a meter set toread voltage, activate

engine starter andmeasure voltage

betweenGround Master Switch andIgnition/Emergency Power

SwitchShould read 10-12 volts


ReplaceIgnition/Emergency Power

Switch and/orIgnition/Emergency Power

Switch wiring

FordGo to step 8

KubotaGo to step 10

If10-12V



Step 9Step 10

InspectEngine Starter

Relay


engine starter and measurevoltage from

1. Ford: wire #5B toStarter Relay.Kubota: wire #5A toStarter Relay.

2. wire from Starter Relay to Ground


Check groundcontinuity

If10-12V


ReplaceEngine Starter

Relay

No continuity

ReplaceEngine Starter Relay wiring

Go to step 11

Continuity

Go to step 10

InspectEngine Anti-

Restart Relay(Ford only)



between Ground ControlSwitch and Anti-Restart

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

Measure voltage atwire #5B.


ReplaceEngine Anti-

Restart Relay


Replacewiring to

Engine AntiRestart Relay

Check Adjustable Resistorbetween Terminal

164 and 164B. Adjust asneeded for starter to

engage.

If 10-12v

If10-12v

If lowor no

reading

If stilldoesnot

engage



Step 11




1. Ford: wire #5A toStarter Solenoid

Kubota: wire #165 toStarter Solenoid

2. Starter Solenoid toGround



If10-12V


ReplaceStarter Solenoid

No continuity

ReplaceStarter Solenoid wiringReturn to step 1

Continuity



Disconnect wire 164Bfrom Alternator. Checkcontinuity between post

and alternator case.

InspectEngine Anti-

Restart Relay

Repair or replaceAlternator

Open field in alternator

No continuity

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

the plastic covering.While activating the starter,slowly slide adjuster untilcranking time is sufficient

for starting engine.Replace the plastic

covering.

Adjust resistor for longercranking time, until enginestarts and alarm shuts off.

(approx. 30 seconds)

Starter disengagesbefore engine starts(Ford only)

Step 1

Continuity




1. wire #5A to StarterSolenoid

2. Starter Solenoid toGround



If10-12V


ReplaceStarter Solenoid

No continuity

ReplaceStarter Solenoid wiringReturn to step 1

Continuity

Step 2



Step 1

InspectGround Master(Key) Switch

Using a meter set to readvoltage, activate engine

starter and measurevoltage between Battery

post side of Ground MasterSwitch and ignition side of

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

Repair or replaceGround Master Switch

and/orGround Master Switch

wiring

If10-12V

No reading

Check Battery

If reading is low

Engine cranks overbut will not start

Step 2Inspect

Ground/PlatformSelector Switch

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



Ground/PlatformSelector Switch

is inPlatform position

Return Ground/Platform SelectorSwitch to Ground

position

Then

If

Go to step 3

No reading



Switch wiring

Check Battery

Ifreading is low

If10-12V



Step 3Step 4

Inspect Ignition/Emergency Power

Switch

Go to step 4

ReplaceIgnition/EmergencyPower Switch and/

orIgnition/Emergency

Power Switchwiring

Check voltage on diodewire between Ignition/

Emergency Power Switchand Ground/Platform

Switch. Replace diode wireif faulty. Measure voltage

entering Run Relay(wire #4A)


Using a meter set toread voltage,

measure voltageentering Ignition/

Emergency Power SwitchShould read 10-12 volts


InspectRun Relay


measure voltage between Run Relay andMurphy Switch (B Post)

wire #164Should read 10-12 volts

Go to step 5(Ford)

Go to step 6(Kubota)

If10-12V




Switch wiring

If10-12V

If lowor no

reading



Step 5Step 6

Inspect Magnetic Switch

( Ford only)


on wire1. at post NC ofMagnetic Switch

2. on wire 80A betweenMagnetic Switch and

Governor Should read 10-12 volts

ReplaceMagnetic Switch and/or Magnetic Switch wiring


Inspect Magnetic Switch

( Kubota only)


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


ReplaceMagnetic Switch and/or Magnetic Switch wiring




Step 7

InspectRun Solenoid( Kubota only)


measure voltage at wire#8D to Run Solenoid

Should read 10-12 voltsNote: Check continuity

to ground on whitejumper wire

ReplaceRun Solenoid




Step 1Step 2

Engine starts then shutsdown after 30 seconds

InspectEngine Temp.

Gauge

Using a meter set toread ohms,

Check continuity on wirebetween Murphy Switch

(Black wire at S post) andChassis ground

Allow time for Engine tocool down

If resistance is shown

Then

ReplaceMurphy Engine

Temperature Gauge

Return to step 1

InspectEngine Oil

Pressure Switch(Ford only)

Engine oilpressure is due to

inadequate oil level ReplaceEngine Oil Pressure SwitchThen

If oil levelis adequate

Fill to proper levelwith oil

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

Ground wire at Engine OilPressure SwitchIf

If resistance is shownIf noresistanceis shown

FordGo to step 2

KubotaGo to step 3




Step 3Return to step 1

InspectEngine Oil

Pressure Switch(Kubota only)

Engine oilpressure is due to

inadequate oil level

ReplaceEngine Oil Pressure Switch

Then


Fill to proper levelwith oil

Jump wire #3A from EngineOil Pressure Switch toground, start engine

If If engine starts and stay running

If enginedoes not

start



Step 1Step 2

Engine will notaccelerate(Ford only)

InspectThrottle Circuit

Breaker (15 Amp)

Using meter set to readvoltage, measure voltage

Ford: entering eitherMedium Throttle Relay wire

#55A or High ThrottleRelay wire #55B

Deutz: on wire #55Abetween Throttle Relayand Throttle Solenoid


Circuit breaker isopen


Check continuity on wire#55 between ThrottleCircuit Breaker and

Medium Throttle Relay orHigh Throttle Relay

Reset Circuitbreaker

Then

If

Repair or replaceCircuit Breaker and/orCircuit Breaker wiring

Go to step 2(Ford)

Go to step 6(Deutz)

If continuity does not exists

InspectMedium Throttle

Relay(Ford only)


measure voltageon wire #55A to

Throttle ControllerShould read 10-12 volts


Check continuity on wirebetween Medium Throttle

Relay and ThrottleController

Repair or replacewiring from

Medium Throttle Relayto Throttle Controller

Then

Go to step 3

Ifcontinuity

doesexists

If10-12V



Step 3Step 4

InspectHigh Throttle

Relay(Ford only)

Using meter set toread voltage,

measure voltageon wire #55B to

Throttle ControllerShould read 10-12 volts


Check continuity on wirebetween High Throttle

Relay and ThrottleController

Repair or replacewiring from

High Throttle Relayto Throttle Controller

Then

Go to step 4

InspectElectronicGovernor

(Ford only)


measure voltageon wire #55A and #55B

going into theElectronic Governor



Repair or replacewiring to

Electronic Governor

Go to step 5

If10-12V

If10-12V



Step 5

InspectActuator


measure voltage,on wire #A1

and #A2 between theElectronic Governor

and SolenoidShould read 10-12 volts


Repair or replaceElectronicGovernor

If10-12V

Repair or replace Electronic Governor

and/or wiring



InspectThrottle Relay(Kubota only)


on wire #13D betweenFuse and Throttle RelayShould read 10-12 volts

If 10-12VRepair or replacewiring between

Fuse and ThrottleRelay Activate Ground Control

Switch and measurevoltage on wire #140 to

Throttle SolenoidShould read10-12 volts

If lowor no

reading

Step 1Step 2

Engine will not accelerate(Kubota only)

InspectFuse (10 Amp)

Verify if fuse is blown

Replace Fuse

If blownIf10-12V

Go to step 2

Go to step 3

If Ok

If lowor no

readingReplace Relay



InspectThrottle Solenoid


voltage on wire #14D intoThrottle Solenoid



Repair or replaceThrottle Solenoid and/orThrottle Solenoid wiring

Step 3



Step 1Step 2

Engine over accelerates(Ford only)

InspectElectronicGovernor


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

going into theElectronic Governor



Repair or replaceFord: wiring to

Electronic Governor

Go to step 2 If10-12V

InspectActuator


measure voltageon wire #A1

and #A2 between theElectronic Governor

and ActuatorShould read 10-12 volts


Repair or replaceElectronicGovernor

If10-12V

Repair or replaceElectronic Governor

and/or wiring



Circuit Breaker isopen

Step 1Step 2

Engine will not startfrom platform control

InspectPlatform ControlCircuit Breaker

(20 Amp)

Using a meter set to readvoltage, turn Ground/

Platform Switch to Platformposition, measure voltage

on wire #1 and #2entering Platform Control

Circuit BreakerShould read 10-12 volts

Check for voltage onwire #1B to Emergency

Stop SwitchShould read 10-12 volts

ResetCircuit Breaker

Then

If

Repair or replaceWire #1 and/or #2

Go to step 3


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



Ground/PlatformSelector Switch isin Ground position

Return Ground/Platform SelectorSwitch to Platform

position

Then

If





Switch wiring

ReplaceCircuit Breaker

If lowor no

reading

If lowor no

reading

If 10-12V

If10-12V



Step 3Step 4

InspectFoot Switch and

Wiring

Make sure Foot Switch isnot activated

Deactivate Foot SwitchIfnot

activatedUsing a meter set to readvoltage, measure voltage

on wire #10 going intoFoot Switch and

wire #8 coming outof Foot Switch

Should be 10-12 volts

If activated

InspectEmergency Stop

Switch

Using a meter set to readvoltage, pull Emergency

Stop Switch out andmeasure voltage betweenEmergency Stop Switch

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

Emergency StopSwitch is off(pushed in)


Pull EmergencyStop Switch (out)to the on position

Then

If

ReplaceEmergency Stop Switch

and/orEmergency Stop Switch

wiringGo to step 4 If10-12V


Repair or replaceFoot Switchand/or wiring

If10-12VGo to step 5



Step 5


Power Switch



on wire #5 betweenPlatform Master Switchand Ignition/Emergency

Power SwitchShould read 10-12 voltsReturn to step 1 If

10-12V


ReplaceIgnition/Emergency Power

Switch and/orIgnition/Emergency Power

Switch wiring

Step 6

InspectPlatform Start

Switch


Platform Start Switch andmeasure voltage on

wire #5 betweenPlatform Start Switch and

Platform Emergency PowerSwitch

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


ReplacePlatform Start Switch

and/orPlatform Start Switch

wiring



Step 1

Engine starts whilecranking, then dies whenkey switch is released

InspectRun Relay


measure voltageat Murphy Switch wire

#164, B post ofMurphy Switch



Repair or replaceRun Relay

and/orRun Relay wiring

Step 2


InspectRun Solenoid

Using a meter set to readvoltage, measure voltageon wire #8D between RunSolenoid Murphy SwitchShould read 10-12 voltsNote: Check continuity

to ground on whitejumper wire


ReplaceRun Solenoid

and/orRun Solenoid wiring

SECTION TWO:HYDRAULIC DIAGNOSTICS

SECTION TWOHYDRAULICS DIAGNOSTICS


Hydraulic systemfunctions on

emergency poweronly

Go to Page41

InspectMain Hydraulic Pump

Go to Page41

InspectSense Line Dump Valve

Hydraulic pumpstays on stroke

Go to Page42

InspectPump Compensator

Chart 1

Chart 2

OK

Step 1

Step 2

Step 1

Hydraulic functionsare sluggish

Go to Page43

InspectEngine RPM

Go to Page43

InspectPump Pressure

Go to Page44

InspectAccumulator

Go to Page44

InspectFlow from Pump

Chart 3

OK

OK

OK

Step 1

Step 2

Step 3

Step 4

Hydraulic pump willnot build pressure

Go to Page45

InspectPump Compensator Valve

Chart 4

Step 1

Go to Page45

InspectPump Coupling

OKStep 2



Hydraulic pumpwill not build

enough pressureGo to Page

46Inspect

Pump Compensator Valve

Go to Page46

InspectSenseline Dump Valve

Chart 5

OK

Step 1

Step 2

Flow fromhydraulic pump

is too lowGo to Page

47

InspectFlow Adjustment on

Main Hydraulic Pump

Chart 6

Step 1

Flow fromhydraulic pump

is too high(kills engine)

Go to Page47

InspectFlow Adjustment on

Main Hydraulic Pump

Chart 7

Step 1



Inspect Main Hydraulic

Pump

Remove gaugeand

Go to step 2

CheckMain Hydraulic Pump,Pump Coupling andPump Compensator

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

idle and measuredifferential/standby

pressure.Should read 250-300 psi

If reading is abnormalReplaceMain Hydraulic

Pump and/or PumpCoupling and/or

PumpCompensator

Ifmal-

functioning

Hydraulic system functionson emergency power only

Step 1Step 2

Inspect Sense Line Dump

Valve

Check seals onSense Line Dump

Valve

If10-12V

Repair or replaceSense Line Dump Valve

and/or wiring

Using a meter set to readvoltage, activate Ground

Control Switch andmeasure voltage

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

2.on wire # 28B atSense Line Dump Valve



Repair or replaceSense Line Dump

Valve

If bad

Ok

Go to step 3

If250-300 psi



Hydraulic pumpstays on stroke

Step 1

InspectPump

CompensatorValve


Valve

Repair or replacePump Compensator

Remove hose fromcompensator. Recheck

pressure on Pump.

If stays on stroke


Ifgoesoff

stroke

If bad



Step 1

Step 2

Hydraulic functionsare sluggish

InspectEngine RPM

Adjust Throttle Actuatoror Solenoid

Use a Tachometer tomeasure Engine RPM

Should read:Ford - 1050 RPM at Low 2100 RPM at Mid 2800 RPM at HighKubota -1500-1800 RPM at

Low 3200 RPM at High

If not

Go to step 2 If correctRPM

InspectPump Pressure

AdjustPump Compensator

Install 1000 psipressure gauge at

Test Port.Set engine for idle

and measure standbypressure.

Should read 250-300 psi


Remove gaugeand

Go to step 3

If300 psi



Step 3

Step 4

InspectAccumulator

RechargeAccumulator

Measure the chargeon the Accumulator

Should be 750 to 800 psi


Go to step 4

If750 to 800 psi

InspectFlow from Pump

AdjustFlow Ajustment

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

1.Install a Flowmeter onthe discharge side ofpump.

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

Flowmeter should read12 to 14 gpm and

pressure gauge shouldread 300 psi


Remove gaugesand

Return to step 1

If12 to

14 gpmand

300 psi



Step 1Step 2

Hydraulic pump willnot build pressure

InspectPump

CompensatorValve

Go to step 2

Remove hoses fromSense Line Dump Valveto Compensator Valve

and reattach toPressure Line. Using a

5000 psi pressure gaugecheck pressure.

Should read 2400 psiIf noreading

Remove gauge andcheck seals on

Sense Line Dump Valve


If bad

InspectPump Coupling

Repair or replacePump Coupling

RemoveMain Hydraulic Pump

visually checkPump Coupling

If bad

Ok

Repair or replaceCompensator

and/orMain Hydraulic Pump

If 2800 psi



Step 1Step 2

Hydraulic pump will notbuild enough pressure

Inspect Sense Line Dump

Valve


Valve

If10-12V


wiring

Using meter set to readvoltage, activate Ground

Control Switch andmeasure voltage

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

2. On wire # 28B atSense Line DumpValve



Repair or replaceSense Line Dump

Valve

If bad

InspectPump

CompensatorValve

Go to step 2

Remove hoses fromSense Line Dump Valveto Compensator Valve

and reattach toPressure Line. Using a

5000 psi pressure gaugecheck pressure.

Should read 2800 psi

If noreading

Remove gauge andcheck seals on

Sense Line Dump Valve


If bad

If 2800 psi

If lowreadingAdjust

CompensatorValve



Step 1Step 1

Flow from hydraulicpump is too low

Flow fromhydraulic pumpis too high(kills engine)

InspectFlow Adjustment

on Main HydraulicPump

Visually check FlowAdjustment Screw on Main

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

from face of pump

ResetFlow Adjustment on Main

Hydraulic Pump

InspectFlow Adjustment

on Main HydraulicPump

Visually check FlowAdjustment Screw on Main

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

from face of pump

ResetFlow Adjustment on Main

Hydraulic Pump

SECTION THREE:STEERING SYSTEM DIAGNOSTICS

SECTION THREESTEERING SYSTEM DIAGNOSTICS


Machine will notsteer

Go to Page52

InspectSteer Switch

Go to Page52

Inspect3 Way Valve

Go to Page53

InspectSteer Control Valve

Go to Page54

InspectCenter Post

Go to Page54

InspectTow Package Float Valve

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 4

Step 5

Step 6

Go to Page53

InspectBoom Speed Dial

OKStep 3



Machine will not steer

Step 1Step 2

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

InspectSteer Switch


ReplaceSteer Switch

and/orSteer Switch wiring

Using a meter set to readvoltage, activate Steer

Right Switch and measurevoltage on wire #20

between Steer Switch andSteer Control Valve.

Activate Steer Left Switchand measure voltage on

wire #19.Should read 10-12 volts


InspectBlocking Valve

Go to step 3Repair or replace

Blocking Valve Cartridge

Visually check BlockingValve Cartridge for

binding

Should normally be closed.

If stuckIf

Ok

Using a meter set to readvoltage, activate Steerfunction and measurevoltage on wire #160

between Steer Switch and3-Way Valve


If 10-12V

Repair or replaceSwitch and/or

wiring

If lowor no

reading



Step 3Step 4

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


Turn to full speed

Remove wire #16B fromBy-Pass Coil on Main

Hydraulic Valve and retryfunction

Visually checkSpeed Dial for full speed

If full speed

If notfull speed

Remove By-Pass Valvefrom Main Valve and

inspect. Valve is normallyclosed

If no change

If steerok

ReplaceSpeed Dial in

Platform

Activate Manual Overrideon Valve while activating

Steer function

If Ok

Replace Valve If stuck

Go to step 4 If Ok

Go to step 5

If function does not operate

InspectSteer Control

Valve

Repair or replaceSteer Control

Valve or Solenoid Go to Step 5

ActivatingManual Overrides and

check pressureShould be 2400 psi

If lower than 2400 psi

If approx.2400 psi



Step 5

InspectCenter Post

Repair or replaceSteer Cylinder

Note: Machineswith optionalTow Packagego to step 6

Ifreading

isnormal

Repair or replaceCenter Post

Remove hoses leading to Steer Cylinder Plug

hoses andcap the Steer Cylinder.

While activatingsteering function,

check for 2400 psi atthe pump pressure Test

Port

If reading is abnormal

InspectTow Package Float

Valve

Refer to Chapter 12Accessories Diagnostics

During activation ofsteering function themachine will be moving.

Step 6

SECTION FOUR:DRIVE SYSTEM DIAGNOSTICS

SECTION FOURDRIVE SYSTEM DIAGNOSTICS


Drive system is notoperational with

controller in eitherdirection

Go to Page61

InspectFoot Switch

Go to Page61

InspectDrive Fuse

Go to Page62

InspectController Circuit Board and S1

Micro Switch Wiring

Go to Page62

InspectS1 Micro-Switch (in Controller)

Go to Page63

InspectController Circuit Board

Go to Page63

InspectPotentiometer

Go to Page64

InspectS2 Micro-Switch (in Controller)

Go to Page64

InspectDrive Solenoid

Go to Page65

InspectDrive Control Valve

Go to Page65

InspectCenter Post

Go to Page66

InspectDual Counterbalance Valve

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

Chart 1

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

Step 11



No forward drive(reverse ok)

Go to Page67

InspectS2 Micro-Switch

(in Drive Controller)

Go to Page67

InspectDrive Controller Circuit Board

Go to Page68

InspectSolenoid

(Drive Forward on Control Valve)

Go to Page68

InspectDual Counterbalance Cartridge

No reverse drive(forward ok)

Go to Page69


(in Drive Controller)

Go to Page69

InspectDrive Controller Circuit Board

Go to Page70

InspectSolenoid Valve

(Drive reverse on Control Valve)

Go to Page70

InspectDual Counterbalance Cartridge

OK

OK

OK

OK

OK

OK

Chart 2

Chart 3

Step 1

Step 2

Step 3

Step 4

Step 1

Step 2

Step 3

Step 4



Inspect3-Way Cartridge Valves in

Transmission Valve

Drive high rangenot operating

(mid speed ok)Go to Page

71Inspect

Drive Range Switch

Go to Page71

InspectBoom Position and/or

Boom Limit Switch

Go to Page72

Inspect2 Wheel Motor Shift Valve

Go to Page72

OK

OK

OK

Chart 4

Step 1

Step 2

Step 3

Step 4

InspectLeft and Right Motor Shift Valves

Drive mid rangenot operating

(low speed ok)Go to Page

73Inspect

Drive Range Switch

Go to Page73

InspectBoom Limit Switch

Go to Page74

InspectSteer Limit Switches

Go to Page74

OK

OK

OK

Chart 5

Step 1

Step 2

Step 3

Step 4

InspectPower to R Terminal on Controller

Go to Page75

OKStep %

Wheels on one siderotate faster than on

other sideGo to Page

76Inspect

Drive Range Switch

Go to Page76


OK

Chart 6

Step 1

Step 2



One wheel rotatesslower than others

Go to Page78

Inspect3-Way Cartridge Valves

Go to Page78

InspectFlow Divider (spool type)

OK

Chart 7

Step 1

Step 2

Brakes will notrelease

Go to Page80

InspectBrake Pressure

Chart 8

Step 1

Go to Page79

InspectWheel Motors

OKStep 2



InspectFoot switch Using a meter set to

read voltage, activateFoot Switch andmeasure voltage

1. on wire #9 betweenFoot Switch and DriveFuse

2. at 3 amp Drive FuseShould read 10-12 volts


ReplaceFoot Switch and/orFoot Switch wiring


Drive system is non-operationalwith controller in either direction

Step 1Step 2

InspectDrive Fuse (3 amp)


Foot Switch andmeasure voltage

1. on wire # betweenDrive Fuse andDrive Controller

2. at positive (+) post ofDrive controller



ReplaceFoot Switch and/orFoot Switch wiring




Step 3Step 4

InspectController Circuit

Board and S1Micro-Switch

Wiring


Foot Switch andmeasure voltage

1. on red wire fromCircuit Board toS1 Micro-Switch

2. at red wire ofS1 Micro-Switch



ReplaceCircuit Board

and/orS1 Micro-Switch wiring



(in Controller)

Using a meter set toread voltage, step on

Foot Switch andactivate Controller,measure voltage

1. on black wire betweenS1 Micro-Switch andController Circuit Board

2. at point where blackwire from S1 Switchenters Controller CircuitBoard


ReplaceS1 Micro-Switch

(in Controller)and/or

S1 Micro-Switchwiring

Go to step 5

Move controller handle ineither direction andobserve red LED on

Circuit Board Controller

If not lit

If lit

If lowor no

voltage




Step 5Step 6


Foot Switch andactivate Controller,measure voltage

1. on green wire toPotentiometer fromController Circuit Board

2. on wire betweenController Circuit Board

and PotentiometerShould read 10-12 volts


ReplaceController Circuit Board

and/orController Circuit Board

wiring


InspectController Circuit

Board

InspectPotentiometer

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

wire between ControllerCircuit Board andPotentiometer

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

according to Controllermovement

If no reading

Check continuity on wirebetween Controller CircuitBoard and Potentiometer

Go to step 7

continuity

ReplacePotentiometer

and/orPotentiometer

wiring

Nocontinuity



Step 7Step 8


(in Controller)


Foot Switch and activateController, perform the

following:1. While activating

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

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

Reading should varyaccording to amount of

reverse movement

Check continuityon blue wire and

on white wirebetween ControllerCircuit Board andS2 Micro-Switch

If noreading

ReplaceS2 Micro-Switch

and/orS2 Micro-Switch

wiring

No Continuity

Go to step 8

Continuity

Push Manual Overridewhile activating variouscontroller functions and

check operation.

If functions are abnormal or erratic

Replace Drive Section Control Valve

Go to step 9

InspectDrive Solenoid

Machine function will bemoving when manualoverride is activated.

Iffunctions

arenormal

If Ok



Step 9Step 10

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

pressure gauge toPump Test Port.

While activating drivecontrol function, check

pressure.Should read 2400 psi

(while activating function)

If functions are abnormal or erratic

ReplaceValves on Drive Section

of Control Valve

Remove gaugeand

Go to step 10

InspectDrive Control

Valve

InspectCenter Post

Remove hoses at V1 andV2 ports of Dual

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

test gauge toPump Test Port

While activating drivecontrol function, check

pressure.Should read 2400 psi

(while activating function)

If pressures are abnormal or erratic

Repair or replaceCenter Post

Remove gaugeand

Go to step 11

If functionsare normal

If pressuresare normal



Step 11

Replace DualCounterbalance Valve, and

retry function

If still no function

Return to step 1

InspectDual

CounterbalanceValve



Step 1Step 2

No forward drive(Reverse Ok)

InspectDrive Controller

Circuit Board

Using a meter set toread voltage, activate drive

function and measureproportional voltage at

Terminal A ofCircuit Board.

Reading should varyaccording to controller

movement.

If no or erratic reading

ReplaceDrive Controller Circuit

Board

Go to step 3 Ifnormal


(in DriveController)


Check continuity on bluewire between S2 Micro-Switch and Controller

Circuit Board

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

from S2 Micro-Switchenters.


movement.

If low or no readingReplaceS2 Micro-Switch

and/orS2 Micro-Switch

wiringno continuity



Step 3Step 4

Replace theDual Counterbalance Valve

Cartridge tested

InspectDual

CounterbalanceValve Cartridge

Using a 5000 psi pressuretest gauge activate drive

function and check systempressure at hose entering

port C2 on CounterbalanceValve


If pressure reading is high

ReplaceDrive Forward Solenoid

Valve and/orDrive Forward Solenoid

Valve wiring

InspectSolenoid Valve(Drive forward

on Control Valve)

Go to step 4

Try manual override

Using a meter set to readvoltage. While activating

forward function, measureproportional voltage at wire

#17 on Drive section ofControl Valve.


movement.If no reading

Override allows operation

Overridedoes not

allowoperation


Return to step 1 If0-500 psi



Step 1Step 2

No reverse drive(Forward Ok)

InspectDrive Controller

Circuit Board


reverse functionand measure

proportional voltage atTerminal B of

Controller Circuit BoardReading should vary

according to controllermovement

If no or erratic reading

ReplaceDrive Controller Circuit

Board



(in DriveController)


Check continuity on whitewire between S2 Micro-Switch and Controller

Circuit Board

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

S2 Micro-Switch enters.Reading should vary

according to controllermovement.

If low or no readingReplace

S2 Micro-Switchand/or

S2 Micro-Switchwiring

No continuity



Step 3Step 4

ReplaceDrive Reverse

Solenoid Valve and/orDrive Reverse Solenoid

Valve wiring


(Drive reverse onControl Valve)

Go to step 4

Try manual override

Using a meter set to readvoltage. While activating

reverse function,measure proportionalvoltage at wire #18 on

Drive section ofControl Valve.


movement.

If no reading

Override allows operationOverridedoes not

allowoperation


Replace theDual Counterbalance Valve

Cartridge tested

InspectDual

CounterbalanceValve Cartridge

Using a 5000 psi pressuretest gauge activate drive

function and check systempressure at hose entering

port C1 on CounterbalanceValve


If pressure reading is high

Return to step 1 If0-500 psi



Position Booms to fullydown position. Adjust BoomRetract/Down Limit Switch

InspectBoom Position

and/orBoom Limit Switch

Booms are not positionedfor High Range speed

operationsBoom Limit Switch are

not Adjusted

Step 1Step 2

Drive high rangenot operating(mid speed ok)

InspectDrive Range

Switch

Go to step 2If lowor no

reading


on wire #70B going into theR Terminal of Drive Controller



ReplaceDrive Range Switch

and/or wiring

still not operating

Check for 10-12 volts onwire #70 at Boom Up Limit

Switch

Measure voltage on wire#170 coming out of the

Drive Range Switch.Should read 10-12 volts

If 10-12V

Repair or replaceBoom Up LimitSwitch and/or

wiringIf 10-12V

Repair or replaceWiring to R Terminal of

Drive Controller

Note: High speed onlyworks in forward direction

Go to step 3

Check Hi Speed Micro-Switch on controller.

should trip at 80% forwardmovement.

Measure voltagefrom Micro Switch

to Drive RangeSwitch.

should read 10-12volts when driving

full forward

If Ok

If 10-12V

If 10-12V

Replace Switch

Adjust Micro-Switch If not


If novoltage



Step 3Step 4

Inspect2 Wheel Motor

Shift Valve

Remove valve andcheck for stuckValve or blown

O'Rings

Using a 5000 psi pressuregauge, measure pressureon hose between 2 Wheel

Motor Shift Valve andCenter Post.

Should read 0 psi

If no reading

Repair or replaceWiring to Shift Coil

Go to step 4

Using meter set toread voltage, measure

voltage at 2 Wheel MotorShift Coil wire #170 .


If10-12V

If Ok

Ifpressureis high

Repair or replace3-Way Cartridge Valve in

Transmission Valve

Inspect3-Way Cartridge

Valve inTransmission

Valve

Go to step 5

Verify that Valves areshifting by Removing valve

and checking formovement.

If not moving

If bad

Repair or replaceas needed

If Ok



Step 1

Step 2

Drive mid range notoperating (low speed ok)

InspectDrive Range

Switch


on wire #11 on DriveRange Switch

Should read 0 voltswith switch in Mid Speed

If voltage

ReplaceSwitch with

Part # 302-0017 only

Go to step 2 If 0V


With booms down, use ameter set to read voltage,measure voltage on wire#34 of Boom Limit Switch

Should read 0 voltsGo to step 3 If 0V

Repair, replace or adjustBoom Limit Switch

If voltage



Step 3Step 4

InspectSteer LimitSwitches

With tires straight, checkswitches on steering toverify if activated or not

activatedSwitches should not be

activated

If not activated

Using a meter set to readvoltage, measure voltageon wire 34L on left Motor

Shift Valve and on 34R onright Motor Shift Valve

Should read 0 volts

Readjust Switches Ifactivated

InspectLeft and Right

Motor Shift Valves

Install a 5000 psi pressuregauge in line with Port B1(for right) or B2 (for left) of

Drive Shift Valve.Should read same pressure

as on compensator ofPump or Drive Pressure

Go to step 5 If Ok

Repair, replace Motor Shift Valves

If low or no pressure

If voltage

Repair or replaceSteer Switches

Go to step 4 Ifactivated



Step 5

Return to step 1

InspectPower to RTerminal

Adjust High Speed Trim Poton controller to get

3 mph = 100 ft in 22 sec.

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

of Drive ControllerShould read 10-12 volts

If no reading If10-12V

Check connectionon Boom Wirebetween BoomSwitches and

Platform

Iflow



Step 1Step 2

Wheels on one side rotatefaster than other side

Note:In mid and high only.

InspectSteer LimitSwitches

With tires straight, checkswitches on steering toverify if activated or not

activatedSwitches should not be

activated

If not activated

Using a meter set to readvoltage, measure voltageon wire 34L on left Motor

Shift Valve and on 34R onright Motor Shift Valve

Should read 0 volts

Readjust Switches Ifactivated

If voltage

Repair or replaceSteer Switches

Go to step 2 Ifactivated

InspectLeft and Right

Motor Shift Valves

Install a 5000 psi pressuregauge in line with Port B1(for right) or B2 (for left) of

Drive Shift Valve.Should read same pressure

as on compensator ofPump or Drive Pressure

Repair, replace Motor Shift Valves


Go to step 3 If Ok



Step 3

InspectWheel Motor

Remove Case Drain Hosefrom slow motor, install

flowmeter in line.Drive machine and read

flowmeter.Should read less than

.5 gpm

If more than .5 gpm

ReplaceMotor

Go to Chart 8If lessthan

.5 gpm



Step 1Step 2

One wheel rotates slowerthan others

Note:In mid range forward only.

Inspect3-Way Cartridge

Valves

If Front Left Wheel or RearRight Wheel

Remove 3-way CartridgeValves from Right

Transmission Valve.Inspect for shifting or blown

o'rings

If Front Right Wheel orRear Left Wheel

Remove 3-way CartridgeValves from Left

Transmission Valve.Inspect for shifting or blown

o'rings

If bad


Go to step 2 If Ok

Inspectflow Divider(Spool type)

If Front Left Wheel orRear Right Wheel, remove

Flow Divider from rightTransmission Valve.

Inspect for broken springsor scratches on Valve

If Front Right Wheel orRear Left Wheel, remove

Flow Divider from leftTransmission Valve.

Inspect for broken springsor scratches on Valve


If bad

Go to step 3 If Ok



Step 3

InspectWheel Motor

Remove Case Drain Hosefrom slow motor, install

flowmeter in line.Drive machine and read

flowmeter.Should read less than

.5 gpm

If more than .5 gpm

ReplaceMotor

Go to Chart 8If lessthan

.5 gpm



Brakes will notrelease

Step 1

InspectBrake Pressure

1. Install a 5000 psipressure gauge inBrake Port Drive Motor

2. Take pressure readingat Pump Compensator

Readings should besimilar

Repair or replaceBrake Orifice located in

Bulk Head Fitting going toBrake

SECTION FIVE:EMERGENCY POWER SYSTEM DIAGNOSTICS

SECTION FIVEEMERGENCY POWER SYSTEM DIAGNOSTICS


Emergency pumpmotor non-operational

Go to Page84

InspectEmergency Power Switch

Go to Page85

InspectEmergency Power Solenoid

and Wiring

Go to Page85

InspectEmergency Power Unit

No functions whenon emergency

power

Go to Page86

InspectEmergency Power Pump

OK

OK

Chart 1

Chart 2

Step 2

Step 3

Step 4

Step 2

Go to Page84


OK

Step 1

Go to Page86


OK

Step 1



Repair or ReplaceEmergency PowerSwitch Terminalwiring (wire #6)

and/orEmergency Power

Solenoid wiring(wire #6A)

and/orEmergency Power

Switch

InspectEmergency Power

Switch

Go to step 3

Check continuity1. on wire #6 between

Emergency PowerSwitch and TerminalStrip in Control Box

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


Emergency Power andmeasure voltage

1. on wire #6 ofEmergency PowerSwitch

2. at Emergency PowerSolenoidShould be 10-12 volts

If no reading

If10-12V

Step 1

Step 2

Emergencypump motornon-operational

No continuity

InspectBatteries



under load

Recharge orreplace

battery(s)


If loose




Ifcorroded

If 12V


If Ok

Go to step 2



Step 3

Repair or ReplaceEmergency Pump Motor


Unit

If previous checks havebeen performed and found

to be normal, checkEmergency Pump Motor

for internal groundingcondition

Repair or ReplaceWiring from BatteryDisconnect Switch

to EmergencyPower Solenoid

and/or Emergency PowerUnit wiring and/orEmergency Power

Solenoid


Solenoidand Wiring

Go to step 4

Check continuity1. on wire between

Battery DisconnectSwitch and EmergencyPower Solenoid

2. on wire betweenEmergency PowerSolenoid and PumpMotor

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

Solenoid and fromBattery DisconnectSwitch

2. activate EmergencyPower Switch andmeasure voltage atEmergency PumpMotor


If no reading

If10-12V

Step 4

Nocontinuity



Step 1

No functions when onemergency power

Step 2

InspectBatteries



under load

Recharge orreplace

battery(s)


If loose




Ifcorroded

If 12V


Repair or ReplaceEmergency Power Pump

Unit


Pump

Attach 5000 psi pressuregauge to discharge

side of Emergency PowerPump, activate

Emergency Power Pumpand Ground Control Switch

or Foot Switch.Should read 1750 psi.

If reading is abnormal or erratic

Remove gaugeand

Go to step 3

IfOk

If Ok

Go to step 2

SECTION SIX:SWING SYSTEM DIAGNOSTICS

SECTION SIXSWING SYSTEM DIAGNOSTICS


No response fromswing when

platform controlsare activated

(GroundControls Ok)

Go to Page93

InspectFoot Switch

Go to Page93

InspectPlatform Boom Speed Dial

Go to Page94

InspectSwing Switch

Go to Page94

InspectSwing Valve

OK

OK

OK

Chart 2

Step 1

Step 2

Step 3

Step 4

Swings only inone direction

Go to Page92

InspectSwing Control Signal Wire

Go to Page92

InspectSwing Control Valve

OK

Chart 1

Step 1

Step 2

No response fromswing when groundcontrol is activated

(PlatformControl Ok)

Go to Page96

InspectGround Control Switch

and Wiring

Go to Page96

InspectGround Control Boom Speed Dial

OK

Chart 3

Step 1

Step 2

Go to Page95

InspectSwing Motor and Gear Box

OKStep 5

Go to Page97

InspectSwing Switch

OKStep 3



Swings faster oneway than other

Go to Page100

InspectCrossover Relief Valve

Go to Page100

InspectSolenoid

OK

Chart 5

Step 1

Step 2

Swings erraticallyin either direction

Go to Page98

ActivateManual Override

Go to Page98

InspectSolenoid

Go to Page99

InspectSwing Switch

Go to Page99

InspectSwing Brake

OK

OK

OK

Chart 4

Step 1

Step 2

Step 3

Step 4

Swing Brakewill not hold

Go to Page101

InspectSwing Brake

Chart 6

Step 1



Swings too slow Go to Page102


Go to Page102

InspectSolenoid

Go to Page103

InspectSwing Valve

Go to Page103

InspectSwing Brake Release

OK

OK

OK

Chart 7

Step 1

Step 2

Step 3

Step 4



Step 1Step 2

Repair or ReplaceSwing Control Valve

wiring

Inspect Swing Control

Signal Wire

Check continuity on1. wire #23 between

Terminal Strip in thePlatform Box andSwing Control Valve

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

Using meter set to readvoltage, perform the

following:1. while activating

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

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

Go to step 2 If10-12 V

No continuity

Swings only inone direction

If no reading

Repair or ReplaceSwing Control Valve

Solenoid

InspectSwing Control

Valve

Manually operateSwing Control Valve

If functioning properlyIf functioningimproperly

Repair or ReplaceSwing Control

Valve

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




Step 2

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

Repair or ReplaceFoot Switch and/orFoot Switch wiring

InspectFoot Switch

Go to step 2

Check continuity on wire#9 between Foot Switch

and Swing Circuit Breaker

Using a meter set to readvoltage, while stepping onthe Foot Switch, measure

voltage on wire # 9 atSwing Switch


If no reading

No continuity

If10-12V

Step 1

InspectPlatform Boom

Speed Dial

Turn to full speed Remove wire #16 from By-Pass Coil on Main



If full speedIf notfull speed


inspect.Valve is normally closed

If no change


Platform

If Ok


Go to step 3

If swingok



Step 3Step 4

ReplaceSwing Section Control

Valve

InspectSwing Valve

Remove hoses fromSwing Drive Motor.Plug hoses and cap

motor. While activatingswing function, check

pressure atPump Compensator

Pressure should read1100 psi

If reading is low or erratic

Go to step 5 If1100 psi

InspectSwing Switch

Using a meter set toread voltage, while

activating function, checkvoltage on Swing Switch to

Junction Box(wire #23 when swing

is moving in acounterclockwise direction,

wire #24 when swingis moving in a

clockwise direction)Should be 10-12 volts

If no reading

Repair or ReplaceSwing Switch

and/orSwing Switch wiring




Step 5

ReplaceSwing Motor and/or

Gear Box

InspectSwing Motor and

Gear Box

If previous steps havebeen made and Swing

Valve checks ok,check pressure.

If lowReturn to step 1

If2500 psi



Repair or ReplaceGround Control Switch

and/orGround Control Switch

wiring


Switch and Wiring

Go to step 2

Using a meter set to readvoltage, activate swing

function, measure voltagefrom Ground ControlSwitch to Ground Swing

Switch Should be 10-12 volts

If no reading

If10-12V

No response from swing whenground controls are activated(Platform Controls Ok)

Step 1Step 2


InspectGround Boom

Speed Dial

Turn to full speed Remove wire #16A fromBy-Pass Coil on Main



If full speedIf notfull speed


inspect.Valve is normally closed

If no change


Platform

If Ok


Go to step 3

If swingok



InspectSwing Switch

Using a meter set toread voltage, while

activating function, checkvoltage on Swing Switch to

Junction Box(wire #23 when swing

is moving in acounterclockwise direction,

wire #24 when swingis moving in a

clockwise direction)Should be 10-12 volts

If no reading

Repair or ReplaceSwing Switch and/orSwing Switch wiring

Step 3



Step 1

Step 2

Go to step 4

Push in on ManualOverride and observe

swing operation


Go to step 2

If still swings erratically

If ok

Swings erratically ineither direction

Replace Solenoid

Supply 12 volts toSolenoid, check if swing is

operating smoothly

InspectSolenoid

Go to step 3

If still swings erraticallyIf ok




Step 3Step 4

Install 5000 psi pressuregauge into Swing Brake

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

InspectSwing Brake

Repair or replaceSwing Brake and/or

Gear Box

If ok


InspectSwing Switch Using a meter set to

read voltage, whileactivating function, check

voltage on Swing Switch toJunction Box

(wire #23 when swingis moving in a

counterclockwise direction,wire #24 when swing

is moving in aclockwise direction)


If no reading

Repair or ReplaceSwing Switch

and/orSwing Switch wiring



Step 1Step 2

Swings faster one waythan other

Replace Solenoid


operating equally

InspectSolenoid

If still swings faster

Repair or replaceCrossover Relief Valve

Swap Crossover ReliefValves, check for problem

in opposite direction

InspectCrossover Relief

Valve

Go to step 2

If still swings faster

If ok




Step 1

Repair or replaceSwing Brake

Visually checkSwing Brake

InspectSwing Brake

If Ok

Swing brake willnot hold

If damaged

Install 5000 psi pressuregauge into Swing BrakeLine, check pressure.

Should be 0 psiCheck Spools onControl Valve for

blocked ports

If 0 psi

Check return Lineand filter for

blockage

If blocked


If Ok

If blocked

If above 0 psi

Inspect Counter BalanceCartridge for proper

operation and/or damageto O-rings

Ifdamaged



Go to step 3

Step 1

Step 2

Swings too slow

Go to step 4


swing function for fastermovement


Go to step 2

If still swings slowIf

Swingsfaster

Replace Solenoid


operating normally

InspectSolenoid

If still swings slow


If swing isnormal



Step 3Step 4

Set for proper speed

Turn speed adjustmentscrew counterclockwise

1 turn.Recheck swing speed

InspectSwing Valve

Go to step 4

If swings fasterIf no

Return to step 1

Install 5000 psi pressuregauge into Swing Brake

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

InspectSwing Brake

Release

Repair or replace SwingBrake

If still swings slowIf ok

SECTION SEVEN:BOOM FUNCTIONS DIAGNOSTICS

SECTION SEVENBOOM FUNCTIONS DIAGNOSTICS


No boom functionsfrom ground control

Go to Page108


Go to Page108

InspectBy-Pass Valve

OK

Chart 1

Step 1

Step 2

No boom functionsfrom platform

control

Chart 2

Go to Page109

Inspect3-Way Valve

OKStep 3

Go to Page110


Go to Page110


OK

Step 1

Step 2

Go to Page111

Inspect3-Way Valve

OKStep 3



No boom functionsfrom ground control

Step 1Step 2

InspectBy-pass Valve


Turn to full speed

Remove wire #16A fromBy-Pass Coil on Main



If full speed

If notfull speed

Remove By-Pass Valvefrom Main Valve, inspect

for blown O'ringsor stuck Valve.

Valve is normally closed

If no change

If functionok


Platform

Go to step 3

If Ok


Go to step 2



Step 3

Inspect3-Way Valve

Remove Valve and inspectValve is normally closed

With function activated, usea meter set to read voltage,measure voltage on wire#

160C to 3-Way ValveShould read 10-12 volts

If 10-12V

Repair wiring to3-Way Valve

If low orno voltage



No boom functionsfrom platform control

Step 1Step 2

InspectBy-pass Valve


Turn to full speed

Remove wire #16 fromBy-Pass Coil on Main



If full speed

If notfull speed

Remove By-Pass Valvefrom Main Valve, inspect

for blown O'ringsor stuck Valve.

Valve is normally closed

If no change

If functionok


Platform

Go to step 3

If Ok


Go to step 2



Step 3

Inspect3-Way Valve

Remove Valve and inspectValve is normally closed

With function activated, usea meter set to read voltage,measure voltage on wire#

160C to 3-Way ValveShould read 10-12 volts

If 10-12V

Repair wiring to3-Way Valve

If low orno voltage

SECTION EIGHT:PLATFORM LEVELING SYSTEM DIAGNOSTICS

SECTION EIGHTPLATFORM LEVELING SYSTEM DIAGNOSTICS


Platform will notmaintain level as

boomraises or lowers

Go to Page117

InspectHydraulic Oil Temperature

Go to Page117

InspectHolding Valves

Platform will notmaintain level with

machine offGo to Page

118

InspectHolding Valves in

Slave Level Cylinder

OK

Chart 1

Chart 2

Step 1

Step 2

Step 1

Platform level willnot work fromground control

(PlatformControl Ok)

Go to Page119

InspectGround Control Switch

Go to Page119

InspectLevel Switch

OK

Chart 3

Step 1

Step 2

Platform level willnot work from

platform control(Ground Control Ok)

Go to Page120

InspectPlatform Level Switch

Chart 4

Step 1



Platform levelup function is

inoperativeGo to Page

121Activate

Manual Override

Go to Page121


Go to Page122

InspectPressure to Cylinder

Platform leveldown function is

inoperativeGo to Page

123Activate

Manual Override

Go to Page123


Go to Page124

InspectPressure to Cylinder

OK

OK

Chart 5

Chart 6

Step 1

Step 2

Step 3

Step 1

Step 2

Step 3

OK

OK



InspectHydraulic OilTemperature

Cycle the boom a fewtimes to warm up the

hydraulic oil

Hydraulic Oil is cold

If cold

The platform does notmaintain level as boomraises or lowers

Step 1Step 2

InspectHolding Valves inMain Hydraulic

Valve

Repair or replaceHolding Valves and/or

Check Valves

With platform level andboom fully down, remove

the hoses from MainHydraulic Valve, plughoses and cap valve.

Raise boom 5 ft. and notethe Platform Leveling

System.

If Level System performs normallyIf Level Systemperforms

abnormally

Repair or replaceSeals in Master Leveling

System

If problemstill existsGo to step 2



The platform will notmaintain level withmachine off

Step 1

InspectHolding Valves in

Slave LevelCylinder

Repair or replaceHolding Valves

Place a safe work loadin platform and

remove the hoses toSlave Level Cylinder

Observe the Platform.If oil leaks and platform drifts

If no oil leaksbut platform

still drifts

Repair or replaceLevel Cylinder



Step 1

Platform level will notwork from ground control(Platform Control Ok)

Step 2


Switch

Check continuity on wire#28A between Ground

Control Switch andPlatform Level Switch

Using meter set to readvoltage, activate Ground

Control Switch andmeasure voltage on

wire #28A entering PlatformLevel Switch


If no readingRepair or replaceGround Control

Switchand/or

Ground ControlSwitch wiring


Nocontinuity

InspectLevel Switch

Using meter set to readvoltage, activate

Level Down and measurevoltage on

wire #13 at Junction BoxShould read 10-12 volts

If no reading

Repair or replacePlatform Level Switch

and/orPlatform Level Switchwiring to Junction Box



Measure voltage on wires#12 and #13 leaving

Platform Level SwitchShould read 10-12 volts

If lowor no

voltage

Step 1

ReplaceLevel Switch

Using a meterset to read voltage,measure voltage on

wire #9 enteringPlatform Level Switch


InspectPlatform Level

Switch

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

If 10-12V

ReplaceFoot Switch

If lowor no

voltage



Repair or replacewire #13

Using a meterset to read voltage,

measure voltage on wire#13 between Level Switch

and Solenoid ValveShould be 10-12 volts


If no readingIf

10-12V

Repair or replaceSolenoid Valve

Step 1Step 2

Platform level upfunction is inoperative

Go to step 2


Platform level up function


Go to step 3

If okIf problemstill exists




Step 3

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

pressure to Slave LevelCylinder.

Should read 2000 psiwhen fully extended.

InspectPressure to

Cylinder


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

Level Cylinder.Recheck pressure

Should read 2000 psiwhen fully extended.

Repair or replaceRelief Valve in

Reduced PressureManifold

Repair or replaceSlave Level

Cylinder

If lowor no

reading

Return to Step 1If lowor no

reading

If1500 psi



Step 1Step 2

Platform level downfunction is inoperative

Repair or replaceWire #12

Using a meterset to read voltage,

measure voltage on wire#12 between Level Switch

and Solenoid ValveShould be 10-12 volts


If no readingIf10-12V


Go to step 2

Push in on ManualOverride and observePlatform Level down

function


Go to step 3

If okIf problemstill exists




Step 3

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

pressure to Slave LevelCylinder.

Should read 2000 psiwhen fully retracted.

InspectPressure to

Cylinder


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

Level Cylinder.Recheck pressure

Should read 2000 psiwhen fully retracted.

Repair or replaceRelief Valve in

Reduced PressureManifold

Repair or replaceSlave Level

Cylinder

If lowor no

reading

If1500 psi

Return to Step 1If lowor no

reading

SECTION NINE:BOOM ELEVATION SYSTEM DIAGNOSTICS

SECTION NINEBOOM ELEVATION SYSTEM DIAGNOSTICS


Boom raises but willnot stay elevated

(Bottom /Middle/Top)

Go to Page129

InspectManual Bleed Down

Go to Page129

InspectHolding Valve

Bottom boom willnot raise from


Go to Page131

InspectBoom Lift Switch

Go to Page131

InspectLift/Swing Speed Valve

OK

OK

Chart 1

Chart 2

Step 1

Step 2

Step 1

Step 2

InspectSeals in Cylinder

OKStep 3

Go to Page130

Middle boom will notraise from


(Uno 41 only)

Go to Page132


Go to Page132


OK

Chart 3

Step 1

Step 2

Top boom will notraise from


Go to Page133


Go to Page133


OK

Chart 4

Step 1

Step 2



Bottom boom willnot raise fromground control

Go to Page134


Chart 5

Step 1

Go to Page135

Inspect3-Way Valve

OKStep 3

Go to Page134


OKStep 2

Middle boom will notraise from

ground control(Uno 41 only)

Chart 6

Top boom will notraise from

ground control

Chart 7

Go to Page135

InspectLift Control Valve

OKStep 4

Go to Page136


Step 1

Go to Page137

Inspect3-Way Valve

OKStep 3

Go to Page136


OKStep 2

Go to Page137


OKStep 4

Go to Page138


Step 1

Go to Page139

Inspect3-Way Valve

OKStep 3

Go to Page138


OKStep 2

Go to Page139


OKStep 4



Boom raises but will not stayelevated (Bottom /Middle/Top)

Step 1Step 2

Go to step 2

InspectManual Bleed

Down

Turn Manual Bleed DownValve clockwise until

valve is closed

Problem still exist

ReplaceHolding Valve and/or

Seal Kit

InspectHolding Valve

Raise boom approximately2 ft, remove hose to

#2 port on Lift Cylinder,observe for leakage

Leakage

Go to step 3

Raise boom approximately2 ft. and mark Lift Cylinder.Remove hose from port #2on Lift Cylinder. Observe oil

leakage.

Problem still exist

Repair or replaceManual Bleed

DownLeakage

Problemstill exist



Step 3

Repair or replaceCylinder

InspectSeals in Cylinder

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

If leaking



Step 1Step 2

Bottom boom will not raisefrom platform control(Ground Control Ok)

Measure voltage on wire#28 to Lift Switch

Should read 10 to 12 volts



voltage on wire #22Should read 10 to 12 volts

If no reading

If 10 to 12VCheck continuityon wire betweenLift Switch andGround Control

Box

If no reading

Repair or replace Lift Switch

No continuity

Repair or replaceWire #22

While activating boomfunction, use a meter set to

read voltage, measurevoltage on wire #16B at

By-Pass Coil.Should read 0 volts

Visually check Speed Dialin platform Control Box for

fast speed.Dial should be set to fast


Replace Dial

If Ok

If10-12V

If Ok

While activatingLift function,

measure voltageon wire #160C at

3-Way Valve.Should read 10-12

volts

If no voltage

Repair wire toGround Control

Box

Remove Valve, visuallycheck to insure that it ismoving when power is

applied and that O'Ringsare ok.

If bad

Repair or replace asneeded

Go to step 2

If continuityexists

If 0V



Step 1Step 2

Middle boom will not raisefrom platform control(Ground Control Ok)(Uno 41 only)




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


If no reading


Box

If no reading


No continuity

Repair or replaceWire #22B







Replace Dial

If Ok

If10-12V

If Ok




volts

If no voltage


Box



If bad


Go to step 2

If continuityexists

If 0V



Step 1Step 2

Top boom will not raise fromplatform control(Ground Control Ok)




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


If no reading


Box

If no reading


No continuity

Repair or replaceWire #22A







Replace Dial

If Ok

If10-12V

If Ok




volts

If no voltage


Box



If bad


Go to step 2

If continuityexists

If 0V



Bottom boom will not raisefrom ground control

Step 1





voltage on wire #22Should read 10 to 12 volts

If no reading

If 10 to 12VCheck continuityon wire between

Lift Switch and LiftValve

If no reading


No continuity

Repair or replaceWire #22 and retry

function


voltage on wire #16B to By-Pass Valve

Should read 0 volts


RepairSwitch and/or Wire

Ifvoltage

If 0V

Remove Valve from ControlValve, visually check for

proper operation.Valve is normally closed

If Ok

Go to step 3

If valveis stuckReplace Valve

If 10 to 12V


Go to step 2

Step 2



Step 3

Install a 5000 psi pressuregauge on test port,

operate function andcheck pressure.



Activate manual overrideon Valve, observe boom

movement

If boom does not move

If boomoperatesReplace

Lift Solenoid

If low reading

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

pressure

If pressureis Ok

Repair or replaceLift Cylinder


Step 4


voltage on wire #160C at3-Way Valve


Inspect3-Way Valve

Repair or replace Wire to valve

Ifvoltage

If 10-12V

Remove Valve fromControl Valve, visually

check for stuck valve orblown O-rings.

Valve is normally closedIf Ok

Go to step 4

If badReplace Valve



Middle boom will not raisefrom ground control(Uno 41 only)

Step 1




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


If no reading



If no reading


No continuity

Repair or replaceWire #22B andretry function



Should read 0 volts



Ifvoltage

If 0V



If Ok

Go to step 3


If 10 to 12V


Go to step 2

Step 2



Step 3






movement



Lift Solenoid

If low reading


pressure

If pressureis Ok



Step 4




Inspect3-Way Valve


Ifvoltage

If 10-12V




Go to step 4

If badReplace Valve



Top boom will not raisefrom ground control

Step 1




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


If no reading



If no reading


No continuity

Repair or replaceWire #22A andretry function



Should read 0 volts



Ifvoltage

If 0V



If Ok

Go to step 3


If 10 to 12V


Go to step 2

Step 2



Step 3






movement



Lift Solenoid

If low reading


pressure

If pressureis Ok



Step 4




Inspect3-Way Valve


Ifvoltage

If 10-12V




Go to step 4

If badReplace Valve

SECTION TEN:TELESCOPE SYSTEM DIAGNOSTICS

SECTION TENTELESCOPE SYSTEM DIAGNOSTICS


Chart 1

Boom will notretract from

ground controlActivate

Manual Override

InspectExtend and Retract Switch

InspectRetract Solenoid

OK

OK

Step 1

Step 2

Step 3

Boom will notretract from




InspectWiring in Hose Carrier

OK

OK

Step 1

Step 2

Step 3

Chart 2

Go to Page145

Go to Page145

Go to Page146

Go to Page148

Go to Page148

Go to Page149

InspectBoom Speed Dial and Valve

Inspect3-Way Valve

OK

OK

Step 4

Step 5

Go to Page146

Go to Page147

InspectExtend/Retract Valve

OKStep 6

Go to Page147



Boom will notextend from


Go to Page153


Go to Page153


Go to Page154

InspectWiring in Hose Carrier

OK

OK

Step 1

Step 2

Step 3

Chart 4

Boom drifts in Go to Page155

InspectHolding Valves for Extend

Step 1

Chart 5

Go to Page155

InspectCylinder for Internal Leakage

OKStep 2

Boom will notextend from

ground controlActivate

Manual Override


InspectExtend Solenoid

OK

OK

Step 1

Step 2

Step 3

Chart 3

Go to Page150

Go to Page150

Go to Page151

InspectBoom Speed Dial and Valve

OKStep 4

Go to Page151

Inspect3-Way Valve

OKStep 5

Go to Page152

InspectExtend/Retract Valve

OKStep 6

Go to Page152



Boom will not retractfrom ground control

Step 1Step 2

Go to step 2

Activate Ground ControlSwitch, push in on

Manual Override andobserve boom movement


If retracting


Repair or replaceExtend and

Retract Switch

InspectExtend and

Retract Switch


at wire #15 atExtend and Retract


If no reading


Go to step 4 If nomovement



Step 3

Repair or replaceWire to Valve

InspectRetract Solenoid

Using meter set to readvoltage, activate functionand measure voltage on

wire #15 to RetractSolenoid


If no reading

If 10-12VReplace

Retract Solenoid

Step 4Inspect

Boom Speed Dialand Valve

Turn to full speedRemove wire #16B from

By-Pass Coil on MainHydraulic Valve and retry

function


If full speedIf not

full speed



If no change

If retractok


Platform


Steer function

If Ok


Go to step 5 If Ok

Go to step 6




Step 5




InspectExtend/Retract

Valve

Repair or replaceExtend Cylinderand/or Holding

Valve


Remove hose from RetractPort of Control Valve, plug

hose and cap valve.Recheck pressure

Ifpressure

Ok

AdjustPump Main System Relief


Step 6




Inspect3-Way Valve


Ifvoltage

If 10-12V




Go to step 6

If badReplace Valve



Boom will not retractfrom platform control(Ground Control Ok)

Step 1Step 2


Go to step 2




If retracting



Retract Switch

InspectExtend and

Retract Switch




If no reading

Go to Chart 1step 4 and 5

If10-12V



Step 3

Repair or replaceWiring in Hose Carrier

InspectWiring in Hose

Carrier

Using meter set to readvoltage, activate functionand measure voltage at

wire #15 inGround Control Box


If no reading



Boom will not extendfrom ground control

Step 1Step 2


Go to step 2




If extending



Retract Switch

InspectExtend and

Retract Switch




If no reading

Go to step 4 If nomovement



Step 3

Repair or replaceWire to Valve

InspectExtend Solenoid


wire #14 to ExtendSolenoid


If no reading

If 10-12VReplace

Extend Solenoid


and Valve

Turn to full speedRemove wire #16B from

By-Pass Coil on MainHydraulic Valve and retry

function


If full speedIf not

full speed



If no change

If steerok


Platform


Steer function

If Ok


Go to step 5


Step 4



Step 5




InspectExtend/Retract

Valve

Repair or replaceExtend Cylinderand/or Holding

Valve


Remove hose from RetractPort of Control Valve, plug

hose and cap valve.Recheck pressure

Ifpressure

Ok

AdjustPump Main System Relief


Step 6




Inspect3-Way Valve


Ifvoltage

If 10-12V




Go to step 6

If badReplace Valve



Boom will not extendfrom platform control(Ground Control Ok)

Step 1Step 2


Go to step 2




If extending

Go to step 3 If12V


Retract Switch

InspectExtend and

Retract Switch




If no reading

Go to Chart 3step 4 and 5

If10-12V



Step 3

Repair or replaceWiring in Hose Carrier

InspectWiring in Hose

Carrier


wire #14 inGround Control Box


If no reading



Boom drifts in

Step 1

Repair or replaceHolding Valves

and/orO-rings

Visually check for blownO-Rings

If stuck and/or blown

Repair or replaceSeals in Extend Cylinder

Raise boom and extendboom 2 ft., remove hoses

from Extend Control Valve.Observe oil leakage

InspectSeals in Extend

Cylinder

Leakage from Port 1of Extend Cylinder

Repair or replaceHolding Valve

Leakagefrom Port 2of ExtendCylinder

Step 2

Go to step 2

If Ok

InspectHolding Valves for

Extend

SECTION ELEVEN: FUEL SYSTEM DIAGNOSTICS

SECTION ELEVENFUEL SYSTEM DIAGNOSTICS


Engine will notstart on Gasoline,

but will starton L.P.

Go to Page160

InspectFuel Level

Go to Page160

InspectDual Fuel Switch

Engine will notstart on L.P.,

but will start onGasoline.

Go to Page162

InspectL.P. Gauge

Go to Page162


Chart 2

Chart 1

OK

OK

Go to Page161

InspectFuel Shutoff Valve

OK

Go to Page163

InspectL.P. Filter Lock

OK



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

Step 1Step 2

Fill tank with Gasoline

InspectFuel Level

Visually check FuelGauge to verify an

adequate amount of fuelis in tank

If not

Go to step 2

If yes

Repair or replaceDual Fuel Switch


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

Dual Fuel Switch2. on wire #78 coming

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

10-12V

If no reading



Step 3

Repair or replaceFuel Shutoff Valve

InspectFuel Shutoff

Valve


on wire #78 at theFuel Shutoff Valve

Should read 10-12 voltsRepairwire to Valve

If noreading

If 10-12V



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

Step 1Step 2

Fill tank with L.P.

InspectL.P. Gauge

Visually checkL.P. Gauge to verify an

adequate amount of fuel is in tank

If not

Go to step 2

If yes

Repair or replaceDual Fuel Switch


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

Dual Fuel Switch2. on wire #77B coming

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

10-12V

If no reading



Step 3

Repair or replaceL.P. Filter Lock

InspectL.P. Filter Lock

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

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

out of Dual Fuel SwitchShould read 10-12 volts

Repairwire to Valve

If noreading

If 10-12V

SECTION TWELVE:ACCESSORIES DIAGNOSTICS

SECTION TWELVEACCESSORIES DIAGNOSTICS


Machine will notsteer

Go to Page168

InspectTow Package Float Valve

Step 1

Chart 3

AC Generator haslow voltage

Go to Page169

InspectAC Voltage from Generator

Step 1

Chart 2

AC Generatorwill not function

Go to Page168

InspectPower to Generator Switch

at Platform

Go to Page168

InspectGenerator Solenoid

OK

Step 1

Step 2

Chart 1



AC Generator willnot function

Step 1Step 2

Repair or replaceGenerator Switch at

Platform

InspectPower to

Generator Switchat Platform


at wire #169 whenswitch is activated toGenerator position


If no reading

Go to step 2

If10-12V

Repair or replaceWire from Platform

InspectGeneratorSolenoid


on Generator Solenoidwire #169


If no reading


If10-12V



Step 1

AC Generator haslow voltage

Adjust Speed ControlValve on HydraulicGenerator Valve

counterclockwise toincrease voltage

InspectAC Voltage from

GeneratorUsing meter set to read

voltage, measure voltageat Generator

Should read 130 volts AC

If no reading



Step 1

Machine willnot steer

Check decal for correctpositioning

InspectTow PackageFloat Valve

Visually inspect TowPackage Float Valveto insure valve is inoperational position

No

Troubleshooting Guide - · PDF fileSECTION ONE ENGINE DIAGNOSTICS Troubleshooting Guide 12 UNO...

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Transcript of Troubleshooting Guide - · PDF fileSECTION ONE ENGINE DIAGNOSTICS Troubleshooting Guide 12 UNO...