Rev E2, June 2015 Serial Number Range from Z60-4001 Content: INTRODUCTION Important Information Revision History Serial Number Legend Section 1. Safety Rules General Safety Rules Section 2. Specifications Machine Specifications Performance Specifications Hydraulic Oil Specifications Hydraulic Component Specifications Manifold Component Specifications Ford LRG-425 EFI Engine Specifications Ford DSG-423 EFI Engine Specifications Ford MSG-425 EFI Engine Specifications Deutz F4L-1011F Engine Specifications Deutz F3L-1011F Engine Specifications Deutz F3L-2011/Deutz D2011L03i Engine Specifications Perkins 404C-22 Engine Specifications Machine Torque Specifications Hydraulic Hose and Fitting Torque Specifications SAE and Metric Fasteners Torque Charts Section 3. Scheduled Maintenance Procedures Introduction Pre-Delivery Preparation Maintenance Inspection Report Checklist A Procedures A-1 Inspect the Manuals and Decals A-2 Perform Pre-operation Inspection A-3 Perform Function Tests A-4 Perform Engine Maintenance - All Models A-5 Perform 30 Day Service A-6 Check the High Pressure Hydraulic Filter Condition Indicator A-7 Perform Engine Maintenance - Deutz and Ford Models A-8 Perform Engine Maintenance - Perkins Models A-9 Inspect the Fuel Filter/Water Separator - Deutz Models A-10 Perform Engine Maintenance - Ford Models A-11 Grease the Turntable Rotation Bearing and Rotate Gear A-12 Perform Engine Maintenance - Deutz 1011 F Models A-13 Replace the Drive Hub Oil A-14 Perform Engine Maintenance - Ford Models Checklist B Procedures B-1 Inspect the Battery B-2 Inspect the Electrical Wiring B-3 Inspect the Air Filter B-4 Test the Key Switch B-5 Perform Engine Maintenance - Deutz and Perkins Models B-6 Check the Exhaust System B-7 Check the Oil Cooler and Cooling Fins - Deutz Models B-8 Inspect the Tires, Wheels and Lug Nut Torque B-9 Check the Drive Hub Oil Level and Fastener Torque B-10 Confirm the Proper Brake Configuration B-11 Test the Engine Idle Select B-12 Test the Fuel Select Operation - Ford Models B-13 Test the Ground Control Override B-14 Check the Directional Valve Linkage B-15 Test the Platform Self-leveling B-16 Test the Drive Brakes B-17 Test the Drive Speed - Stowed Position B-18 Test the Drive Speed - Raised or Extended Position B-19 Perform Hydraulic Oil Analysis B-20 Test the Alarm Package (if equipped) and the Descent Alarm B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems B-22 Perform Engine Maintenance - Ford Models Checklist C Procedures C-1 Perform Engine Maintenance - Deutz and Perkins Models C-2 Grease the Platform Overload Mechanism (if equipped) C-3 Test the Platform Overload Mechanism (if equipped) C-4 Replace the Air Filter Element - Deutz and Perkins Models C-5 Replace the Fuel Inline Strainer- Deutz Models C-6 Check and Adjust the Engine RPM C-7 Perform Engine Maintenance - Ford Models Checklist D Procedures D-1 Check the Boom Wear Pads D-2 Check the Turntable Rotation Bearing Bolts D-3 Check the Free-wheel Configuration D-4 Replace the Drive Hub Oil D-5 Perform Engine Maintenance - Deutz and Perkins Models D-6 Replace the Hydraulic Filter Elements D-7 Inspect for Turntable Bearing Wear Checklist E Procedures E-1 Test or Replace the Hydraulic Oil E-2 Grease the Steer Axle Wheel Bearings, 2WD Models E-3 Perform Engine Maintenance - Deutz 1011F and Perkins Models E-4 Perform Engine Maintenance - Deutz and Perkins Models E-5 Perform Engine Maintenance - Ford Models E-6 Perform Engine Maintenance - Deutz 2011 Models E-7 Perform Engine Maintenance - Deutz 2011 Models E-8 Perform Engine Maintenance - Deutz 2011 Models Section 4. Repair Procedures Introduction Platform Controls 1-1 ALC-500 Circuit Board 1-2 Joysticks Platform Components 2-1 How to Remove the Platform 2-2 Platform Leveling Slave Cylinder 2-3 Platform Rotator 2-4 Platform Overload System Jib Boom Components 3-1 Jib Boom 3-2 Jib Boom Lift Cylinder Primary Boom Components 4-1 Cable Track 4-2 Primary Boom 4-3 Primary Boom Lift Cylinder 4-4 Primary Boom Extension Cylinder 4-5 Platform Leveling Master Cylinder Secondary Boom Components 5-1 Secondary Boom 5-2 Secondary Boom Lift Cylinders Engines 6-1 RPM Adjustment 6-2 Flex Plate 6-3 Engine Fault Codes - Ford Models Hydraulic Pumps 7-1 Function Pump 7-2 Drive Pump Manifolds 8-1 Function Manifold Components - View 1 (before serial number 4461) 8-2 Function Manifold Components - View 2 (before serial number 4461) 8-3 Function Manifold Components (from serial number 4461) 8-4 Valve Adjustments - Function Manifold 8-5 Jib Boom / Platform Rotate Manifold Components (before serial number 4461) 8-6 Jib Boom / Platform Rotate Manifold Components (from serial number 4461 to serial number 10425) 8-7 Jib Boom / Platform Rotate Manifold Components (from serial number 10426 to serial number 11003) 8-8 Jib Boom / Platform Rotate Manifold Components (from serial number 11004 to 11477) 8-9 Jib Boom / Platform Rotate Manifold Components (from serial number 11478) 8-10 Brake/Two-Speed Manifold Components (before serial number 4461) 8-11 Brake/Two-Speed Manifold Components (from serial number 4461) 8-12 2WD Drive Manifold Components (before serial number 4551) 8-13 2WD Drive Manifold Components (from serial number 4551) 8-14 4WD Traction Manifold Components (before serial number 10154) 8-15 4WD Traction Manifold Components (from serial number 10154) 8-16 Valve Adjustments, Traction Manifolds 8-17 Directional Valve Manifold Components 8-18 Directional Valve Linkage 8-19 Valve Adjustments, Oscillate Directional Valve 8-20 Turntable Rotation Manifold Components 8-21 Oil Diverter Manifold (welder option) 8-22 Valve Coils Turntable Rotation Components 9-1 Turntable Rotation Assembly Axle Components 10-1 Hub and Bearings, 2WD Models 10-2 Oscillate Cylinders Generators 11-1 Valve Adjustment, Hydraulic Generator Section 5. Fault Codes Introduction Fault Code Chart - Control System Fault Code Chart - Ford LRG-425 EFI Engine Fault Code Chart - Ford DSG-423 EFI Engine Fault Code Chart - Ford MSG-425 EFI Engine Section 6. Schematics Introduction Wire Connector Legend Electrical Symbols Legend Hydraulic Symbols Legend Electrical Abbreviations Legend Ford DSG-423 EFI Engine Relay Layout Ford MSG-425 EFI Engine Relay Layout Diesel Electrical Schematic, (before serial number 4496) Diesel Electrical Schematic, (from serial number 4496 to serial number 5325) Diesel Electrical Schematic, (from serial number 5326 to serial number 9798) Diesel Electrical Schematic ANSI/CSA, (from serial number 9799 to serial number 10387) Diesel Electrical Schematic ANSI/CSA, (from serial number 10388) Diesel Electrical Schematic CE, (from serial number 9799 to serial number 10387) Diesel Electrical Schematic CE, (from serial number 10388) Diesel Ground Control Box Wiring Diagram, (before serial number 5716) Diesel Ground Control Box Wiring Diagram, (from serial number 5716 to serial number 9798) Diesel Ground Control Box Wiring Diagram, (from serial number 9799) Diesel Platform Control Box Wiring Diagram, (before serial number 7227) Diesel Platform Control Box Wiring Diagram, (from serial number 7227 to serial number 9065) Diesel Platform Control Box Wiring Diagram, (from serial number 9066 to serial number 9696) Diesel Platform Control Box Wiring Diagram, (from serial number 9697) Ford Electrical Schematic, (before serial number 4546) Ford Electrical Schematic, (from serial number 4546 to serial number 5715) Ford Electrical Schematic, (from serial number 5716 to serial number 6315) Ford Electrical Schematic, (from serial number 6316 to serial number 7226) Ford Electrical Schematic, (from serial number 7227 to serial number 10387) Ford Electrical Schematic, ANSI/CSA, (from serial number 10388 to serial number 11788) Ford Electrical Schematic, ANSI/CSA, (from serial number 11789) Ford Electrical Schematic, CE, (from serial number 10388 to serial number 11788) Ford Electrical Schematic, CE, (from serial number 11789) Ford Ground Control Box Wiring Diagram, before serial number 4546) Ford Ground Control Box Wiring Diagram, (from serial number 4546 to serial number 5715) Ford Ground Control Box Wiring Diagram, (from serial number 5716 to serial number 7226) Ford Ground Control Box Wiring Diagram, (from serial number 7227 to serial number 9798) Ford Ground Control Box Wiring Diagram, (from serial number 9799) Ford Platform Control Box Wiring Diagram, (before serial number 7227) Ford Platform Control Box Wiring Diagram, (from serial number 7227 to serial number 9065) Ford Platform Control Box Wiring Diagram, (from serial number 9066 to serial number 9798) Ford Platform Control Box Wiring Diagram, (from serial number 9799 to serial number 11788) Ford Platform Control Box Wiring Diagram, (from serial number 11789) Engine Wire Harness, Ford LRG-425 EFI Models Engine Wire Harness, Ford DSG-423 EFI Models (before serial number 6810) Engine Wire Harness, Ford DSG-423 EFI Models (from serial number 6810 to 11788) Engine Wire Harness, Ford MSG-425 EFI Models (from serial number 11789) Electrical Schematic, CTE Option (before serial number 9697) Electrical Schematic, CTE Option (from serial number 9697) Joystick Connector Diagram Hydraulic Generator Options (from serial number 10283) Electrical Schematic, Welder Option Hydraulic Schematic, Welder Option Hydraulic Schematic, 2WD Models(before serial number 4461) Hydraulic Schematic, 2WD Models (from serial number 4461 to 10282) Hydraulic Schematic, 2WD Models (from serial number 10283 to serial number 11003) Hydraulic Schematic, 2WD Models (from serial number 11004 to 11477) Hydraulic Schematic, 2WD Models (from serial number 11478) Hydraulic Schematic, 4WD Models (before serial number 4461) Hydraulic Schematic, 4WD Models (from serial number 4461to serial number 10282) Hydraulic Schematic, 4WD Models (from serial number 10283 to serial number 11003) Hydraulic Schematic, 4WD Models (from serial number 11004 to 11477) Hydraulic Schematic, 4WD Models (from serial number 11478)