Troubleshooting Guide TB37

Troubleshooting
Guide
diesel - gasoline - LPG
P.O. Box 1160 St. Joseph, MO 64502-1160

P/N 0172021 1-800-255-0317 Fax: 816-360-9379
June 1999 www.snorkelusa.com
GENERAL INFORMATION
This manual contains procedures for locating and correcting the majority of problems which may
develop on the “Snorkelift” TB 37 Aerial Platform.
Since the majority of malfunctions experienced on equipment in the aerial platform Industry are
associated with the hydraulic and electrical systems, great effort has been made to develop a guide
which 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 each
group covered by an individual section. The Sections are as follows:
1.) Engine Diagnostics 7.) Platform Rotation System Diagnostics

2.) Hydraulic Pump Diagnostics 8.) Platform Leveling System Diagnostics
3.) Steering System Diagnostics 9.) Boom Elevation System Diagnostics
4.) Drive System Diagnostics 10.) Telescope System Diagnostics
5.) Emergency Power System Diagnostics 11.) Fuel System Diagnostics
6.) Swing System Diagnostics 12.) Accessories Diagnostics
NOTES, CAUTIONS AND DANGERS

The 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 or
clearer. Disregarding a NOTE might cause inconvenience, but would not cause equipment damage or
personal injury.
A is provided in a procedure wherever minor personal injury or equipment
damage could result. Disregarding a CAUTION could cause damage to the machine; however serious
personal injury is unlikely.
is the most serious and emphasizes areas where personnel injury and even
death could result from negligence. Permanent mechanical damage is also highly probable. DANGER
signs are to be taken seriously. In some cases, serious injury or death has resulted from disregarding
a DANGER.
NOTE: Engine maintenance and troubleshooting information not contained in this manual may be
found in the engine maintenance manual originally provided with the machine, or from the Engine
Manufacture/Dealer Network.
It should be recognized that every person who performs testing and diagnostic procedures and every
person supervising any of these functions must be properly trained and qualified. If a problem should
occur which is not covered by this manual or which cannot be corrected using the listed corrective
actions, 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 begin
by localizing the problem and defining the symptoms as accurately as possible. When the problem has
been localized, make sure to completely read and comprehend the appropriate flow chart. Do not
attempt to make shortcuts.
1
MANUAL DESIGN
Each symptom described is followed by a list of inspections to be performed. Each inspection is in the
form of a flowchart. A set of detailed checks are then performed at the component and/or related areas
which confirm or decline the outcome. If the inspection is declined the flowchart will refer to the next
step to be performed until the problem is confirmed. The diagnosis then enables a determination.
Example: Problem Solving Procedure
Step 1
Problem Inspect Go to Page
Step 2 OK
Inspect Go to Page
Example: Flowchart Procedure
Inspect
If
Troubleshoot
Yes Go to step
(Identify Problem)
no
Replace or
perform repair
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.
2
SYMPTOM PAGE NUMBER
Section One - Engine Diagnostics

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

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

Machine will not steer 53
3
SYMPTOM PAGE NUMBER
Section Four - Drive System Diagnostics

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

Emergency pump motor non-operational 85
No functions when on emergency power 85
Section Six - Swing System Diagnostics

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

Platform rotate does not operate 109
Platform rotates itself 109
4
SYMPTOM PAGE NUMBER
Section Eight - Platform Leveling System Diagnostics

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

Boom raises but will not stay elevated 129
Boom will not raise from platform control (Ground Control Ok) 129
Boom will not raise from ground control 129
Section Ten - Telescope System Diagnostics

Boom will not retract from ground control 137
Boom will not retract from platform control (Ground Control Ok) 137
Boom will not extend from ground control 137
Boom will not extend from platform control (Ground Control Ok) 138
Boom drifts in 138
Section Eleven - Fuel System Diagnostics

Engine will not start on gasoline, but will start on L.P. 151
Engine will not start on L.P., but will start on gasoline 151
5
SYMPTOM PAGE NUMBER
Section Twelve - Accessories Diagnostics

AC Generator will not function 159
AC Generator has low voltage 159
Machine will not steer 159
6
SECTION ONE:
ENGINE DIAGNOSTICS
SECTION ONE
ENGINE DIAGNOSTICS
Chart 1
Step 1
Engine starter
Inspect Go to Page
fails to operate Battery and Cable Connections 14
(No Electrical)
OK
Step 2
Inspect Go to Page
Power Cables and
Battery Disconnect Switch 14
OK
Step 3
Inspect Go to Page
Ammeter 15
OK
Step 4
Inspect Go to Page
Ground Control
Circuit Breaker (25 Amp) 15
OK
Step 5
Inspect Go to Page
Emergency Stop Switch 16
OK
Step 6
Inspect Go to Page
Ground Master (Key) Switch 16
OK
Step 7
Inspect Go to Page
Ignition/Emergency
Power Switch 17
OK
Step 8
Inspect Go to Page
Ground/Platform
Selector Switch 17
OK
Step 9
Inspect Go to Page
Engine Anti-Restart Relay 18
OK
Step 10
Inspect Go to Page
Engine Starter Relay 18
OK
Step 11
Inspect Go to Page
Starter Solenoid 19
Troubleshooting Guide 9 TB 37
SECTION ONE
ENGINE DIAGNOSTICS
Chart 2
Step 1
Starter
Inspect Go to Page
disengages before Engine Anti-Restart Relay 20
engine starts
OK
Step 2
Inspect Go to Page
Starter Solenoid 20
Chart 3
Step 1
Engine cranks
Inspect Go to Page
over but Ground Master (Key) Switch 21
will not start
OK
Step 2
Inspect Go to Page
Ground/Platform Selector Switch 21
OK
Step 3
Inspect Go to Page
Ignition/Emergency Power Switch 22
OK
Step 4
Inspect Go to Page
Run Relay 22
Step 5 OK
Inspect Go to Page
OK Magnetic Switch
(Ford only) 23
Step 6
Inspect Go to Page
Magnetic Switch
(Deutz only) 23
Step 7 OK
Inspect Go to Page
Run Solenoid
(Deutz only) 24
SECTION ONE
ENGINE DIAGNOSTICS
Chart 4
Step 1
Engine starts
Inspect Go to Page
then shuts down Engine Temperature Gauge 25
after 30 seconds
OK
Step 2
Inspect Go to Page
Engine Oil Pressure Switch 25
Chart 5
Step 1
Engine will not Inspect Go to Page
Throttle Circuit Breaker (15 Amp)
accelerate 26
OK
Step 2
Inspect Go to Page
Medium Throttle Relay
(Ford only) 26
Step 3 OK
Inspect Go to Page
High Throttle Relay
(Ford only) 27
OK
OK Step 4
Inspect Go to Page
Throttle Governor or Controller
(Ford only) 27
Step 5 OK
Inspect Go to Page
Actuator
(Ford only) 28
Step 6
Inspect Go to Page
Throttle Relay
(Deutz only) 28
Step 7 OK
Inspect Go to Page
Throttle Solenoid
(Deutz only) 29
SECTION ONE
ENGINE DIAGNOSTICS
Chart 6
Step 1
Engine over Inspect
Governor
Go to Page
accelerates (Ford only) 30
OK
Step 2
Inspect Go to Page
Actuator
(Ford only) 30
Chart 7
Step 1
Engine will not
Inspect Go to Page
start from Ground/Platform Selector Switch 31
platform control
OK
Step 2
Inspect Go to Page
Platform Control
Circuit Breaker (20 Amp) 31
OK
Step 3
Inspect Go to Page
Emergency Stop Switch 32
Step 4 OK
Inspect Go to Page
Foot Switch 32
Step 5 OK
Inspect Go to Page
Platform Start Switch 32
Step 6 OK
Inspect Go to Page
Ignition/Emergency Power Switch 33
SECTION ONE
ENGINE DIAGNOSTICS
Chart 8
Engine starts while Step 1

cranking, then dies Inspect Go to Page
Run Solenoid
when key switch is 34
released Step 2 OK
Inspect Go to Page
Murphy Switch 34
OK
Step 2
Inspect Go to Page
Vacuum Switch
(Ford only) 35
SECTION ONE
ENGINE DIAGNOSTICS
Engine starter fails to

operate (No Electrical)
Batteries omit hydrogen Recharge or

and oxygen elements that replace
can combine explosively. battery(s)
Do not smoke or permit If low or no voltage
open flames or sparks Using a meter

Inspect If 12V
when checking batteries set to read
Batteries
voltage, check Check battery
each battery for connections
12 volts while
under load If
If loose
corroded
Clean all Tighten all

connections connections
Step 1
Step 2
Inspect Using a meter set to
Power Cables and read voltage, measure
Battery Disconnect voltage entering
Switch Battery Disconnect Switch
Should read 12-12.7 volts
If
If 12-12.7V
Battery Disconnect
Switch in Off Using a meter set to
Position read voltage, turn
Battery Disconnect Switch
Then
to On position, measure
Reset Battery voltage coming out of
Disconnect Switch Battery Disconnect Switch
to On Position If Should read 12-12.7 volts
12-12.7V
If low or no reading
Go to step 3 Repair or replace

and/or
wiring
SECTION ONE
ENGINE DIAGNOSTICS
Inspect Using a meter set to read

Ammeter voltage, measure voltage
between
1.Battery Disconnect
Switch and Ammeter (+)
on wire # 57
2.Ammeter (-) and Circuit
Breaker on wire #1A
Should read 12-12.7 volts
If
12-12.7V
Repair or replace
Circuit Breaker
and/or
Go to step 4 Circuit Breaker wiring
Step 3
Step 4
Ground Control voltage, turn Battery
Circuit Breaker Disconnect Switch to
(25 Amp) On position,
measure voltage entering
If
Emergency Stop Switch
Circuit breaker is Should read 10-12 volts
open If low or no reading
Then
Check for voltage between
Reset Circuit If
Circuit Breaker and
breaker 10-12V Emergency Stop Switch
on wire #1A
Should read 12 volts
Repair or replace
Circuit Breaker
and/or
Go to step 5 Circuit Breaker wiring
SECTION ONE
ENGINE DIAGNOSTICS
Inspect Using a meter

Emergency Stop set to read voltage, pull
Switch Emergency Stop Switch
If
out and measure
voltage between
Emergency Stop Emergency Stop Switch
Switch is off and Battery side of
(pushed in) Ground Master
Then
(Key) Switch.
Should read 10-12 volts
Pull Emergency If
10-12V If low or no reading
Stop Switch (out)
to the On position Replace
and/or
Go to step 6 wiring
Step 5
Step 6
Ground Master voltage, activate engine
(Key) Switch starter and measure
voltage between Battery
post side of Ground
Master Switch and start
side of Ground
Master Switch.
If
Go to step 7 10-12V Should read 10-12 volts
Repair or replace
Ground Master Switch
and/or
wiring
SECTION ONE
ENGINE DIAGNOSTICS

Ignition/Emergency read voltage, activate
Power Switch engine starter and
measure voltage
between
Ground Master Switch and
Ignition/Emergency Power
If
Switch
Replace
Switch and/or
Switch wiring
Step 7
Step 8
Inspect Set Selector Switch to
Ground/Platform Ground position. Using a
Selector Switch meter set to read voltage,
If
activate starter and
measure voltage between
Ground/Platform Ignition/Emergency Power
Selector Switch is Switch and Ground/
in Platform position Platform Selector Switch
Then
Return Ground/ If low or no reading
Platform Selector If
Switch to Ground 10-12V Replace
position Ground/Platform Selector
Switch and/or
Ground/Platform Selector
Go to step 9 Switch wiring
SECTION ONE
ENGINE DIAGNOSTICS

Engine Anti- read voltage, activate
Restart Relay engine starter and
measure voltage
Replace between Ground Control
wiring to If low Switch and Anti-Restart
or no Relay on wire #5C.
Engine Anti reading
Restart Relay Should read 10-12 volts
If 10-12v
Measure voltage at
If
Go to step 10 10-12v wire #5B.
Check Adjustable Resistor

Replace If still between Terminal
does
Engine Anti- not 164 and 164B, Adjust as
Restart Relay engage needed for starter to
engage.
Step 9
Step 10
Engine Starter read voltage, activate
Relay engine starter and measure
voltage from
Check ground If
1. wire #5B to Starter
continuity 10-12V Relay.
2. wire from Starter
No continuity
Relay to Ground
Continuity Replace Should read 10-12 volts
Engine Starter
Relay
Replace
Go to step 11 Engine Starter Relay wiring
SECTION ONE
ENGINE DIAGNOSTICS

Starter Solenoid read voltage, activate
engine starter and measure
voltage from
Check ground If 1. wire #5A to Starter
continuity 10-12V
Solenoid
No continuity
2. Starter Solenoid to
Ground
Starter Solenoid If low or no reading
Replace
Return to step 1 Starter Solenoid wiring
Step 11
SECTION ONE
ENGINE DIAGNOSTICS
Starter disengages
before engine starts
Inspect Continuity
Engine Anti-
Restart Relay Adjust resistor for longer
cranking time, until engine
starts and alarm shuts off.
Open field in alternator (approx. 30 seconds)
Locate the adjustable

Disconnect wire 164B resistor between terminals
from Alternator. Check #164 and #164B, remove
continuity between post the plastic covering.
and alternator case. While activating the starter,
slowly slide adjuster until
No continuity cranking time is sufficient
for starting engine.
Repair or replace Replace the plastic
Alternator covering.
Step 1
Step 2
Starter Solenoid read voltage, activate
engine starter and measure
voltage from
Check ground If 1. wire #5A to Starter
continuity 10-12V
Solenoid
No continuity
2. Starter Solenoid to
Ground
Starter Solenoid If low or no reading
Replace
Return to step 1 Starter Solenoid wiring
SECTION ONE
ENGINE DIAGNOSTICS
Engine cranks over

but will not start
Ground Master voltage, activate engine
(Key) Switch starter and measure
voltage between Battery
post side of Ground Master
Switch and ignition side of
If
Ground Master Switch.
No reading
If reading
is low
Repair or replace
and/or
wiring
Check Battery
Step 1
Step 2
Ground/Platform Ground position. Using a
activate starter and
If measure voltage between
Ground/Platform Switch and Ground/
Selector Switch Platform Selector Switch
is in Should read 10-12 volts
Platform position
No reading
If
Then If
reading
10-12V Replace is low
Return Ground/ Ground/Platform Selector
Platform Selector Switch and/or
Switch to Ground Ground/Platform Selector
position Switch wiring
Go to step 3 Check Battery
SECTION ONE
ENGINE DIAGNOSTICS
Inspect Ignition/ Using a meter set to

Emergency Power read voltage,
Switch measure voltage
entering Ignition/
If Emergency Power Switch
Check voltage on diode

Replace wire between Ignition/
Ignition/Emergency Emergency Power Switch
Power Switch and/ If low and Ground/Platform
or or no Switch. Replace diode wire
reading
Ignition/Emergency if faulty. Measure voltage
Power Switch entering Run Relay
wiring (wire #4A)
Step 3
Step 4
Run Relay read voltage,
measure voltage
Go to step 5 between Run Relay and
(Ford) If Murphy Switch (B Post)
Go to step 6 10-12V wire #164
(Deutz) Should read 10-12 volts
Replace
Switch and/or
Switch wiring
SECTION ONE
ENGINE DIAGNOSTICS

Magnetic Switch voltage, measure voltage
( Ford only) on wire
1. at post NC of
Magnetic Switch
2. on wire 80 between
Replace Magnetic Switch and
Engine Spark If Ok Engine Spark Module
Module Should read 10-12 volts
Replace
Magnetic Switch and/or
Magnetic Switch wiring
Step 5
Step 6
Magnetic Switch read voltage,
( Deutz only) measure voltage on wire
#8D at post NC of
Magnetic Switch
Go to step 7 If Ok Should read 10-12 volts
Replace
Magnetic Switch and/or
Magnetic Switch wiring
SECTION ONE
ENGINE DIAGNOSTICS

Run Solenoid read voltage,
( Deutz only) measure voltage at wire
#8D to Run Solenoid
Note: Check continuity
If low
to ground on white
Repair Wire or no jumper wire
reading
If Ok
Replace
Run Solenoid
Step 7
SECTION ONE
ENGINE DIAGNOSTICS
Engine starts then shuts

down after 30 seconds

Engine read ohms,
Temperature Check continuity on wire
Gauge between Murphy Switch
(Black wire at S post) and
If low
Repair Wire or no Chassis ground
reading
If resistance is shown
Allow time for Engine to

cool down
Then
Replace
Murphy Engine
Temperature Gauge
Step 1
Step 2
Inspect Remove wire #3C from Oil
If oil level
Engine Oil is adequate
Pressure Switch.
Pressure Switch Restart engine
If If engine still dies
Engine oil Using a meter set to read

pressure is due to ohms, check for continuity
inadequate oil level from wire #3C to Ground
Then If engine Should not read continuity
now ok If no
If continuity exists continuity
Fill to proper level
with oil Repair Wire
Return to step 1
Replace
Engine Oil Pressure Switch
SECTION ONE
ENGINE DIAGNOSTICS
Engine will not

Inspect Using meter set to read
accelerate Throttle Circuit voltage, measure voltage
Breaker (15 Amp) Ford: entering either
If
Medium Throttle Relay wire
#55A or High Throttle
Circuit breaker is Relay wire #55B
open Deutz: on wire #55A
Then between Throttle Relay
and Throttle Solenoid
Reset Circuit
breaker
Check continuity on wire

Go to step 2 If #55 between Throttle
(Ford) continuity
does Circuit Breaker and
Go to step 6 exists Medium Throttle Relay or
(Deutz)
High Throttle Relay
If continuity does not exists
Repair or replace
Circuit Breaker and/or
Circuit Breaker wiring
Step 1
Step 2
Using a meter set to
Inspect
read voltage,
Medium Throttle
measure voltage
Relay
on wire #55A to
(Ford only)
Throttle Controller
If Should read 10-12 volts
10-12V
Go to step 3 If low or no reading

between Medium Throttle
Relay and Throttle
Controller
Then
Repair or replace
wiring from
Medium Throttle Relay
to Throttle Controller
SECTION ONE
ENGINE DIAGNOSTICS
Inspect Using meter set to

High Throttle read voltage,
Relay measure voltage
(Ford only) on wire #55B to
If Throttle Controller
10-12V
Go to step 4 If low or no reading

between High Throttle
Relay and Throttle
Controller
Then
Repair or replace
wiring from
High Throttle Relay
to Throttle Controller
Step 3
Step 4
Electronic read voltage,
Governor measure voltage
(Ford only) on wire #55A and #55B
If going into the
10-12V
Electronic Governor
Go to step 5
Repair or replace
wiring to
Electronic Governor
SECTION ONE
ENGINE DIAGNOSTICS

Actuator read voltage,
measure voltage,
on wire #A1
and #A2 between the
Repair or replace Electronic Governor
If
Electronic 10-12V
and Solenoid
Governor Should read 10-12 volts
Repair or replace
Electronic Governor
and/or wiring
Step 5
Step 6
Inspect read voltage,
Throttle Relay measure voltage
(Deutz only) on wire #55A between
If Throttle Circuit Breaker
10-12V and Throttle Solenoid
Go to step 7 Should read 10-12 volts

between Throttle
Circuit Breaker
If no continuity
Repair or replace
wiring between
Throttle Circuit Breaker
SECTION ONE
ENGINE DIAGNOSTICS

Throttle Solenoid voltage, measure voltage
(Deutz) 1. on wire #55A going
into Throttle Solenoid
2. on wire #55A between
Throttle Solenoid and
ground
Repair or replace
Throttle Solenoid
and/or
Throttle Solenoid wiring
If problem still exists
Adjust Throttle Solenoid

Step 7
SECTION ONE
ENGINE DIAGNOSTICS
Engine over
accelerates

Electronic read voltage,
Governor measure voltage,
on wire #55A and #55B
going into the
Electronic Governor
If
Go to step 2 10-12V
Repair or replace
Ford: wiring to
Electronic Governor
Step 1
Step 2
Actuator read voltage,
measure voltage
on wire #A1
and #A2 between the
Repair or replace Electronic Governor
If
Electronic 10-12V and Actuator
Governor Should read 10-12 volts
Repair or replace
Electronic Governor
and/or wiring
SECTION ONE
ENGINE DIAGNOSTICS
Engine will not start

from platform control

Ground/Platform Platform position. Using a
If activate starter and
Ground/Platform Ignition/Emergency Power
Selector Switch is Switch and Ground/
in Ground position Platform Selector Switch
Then Should read 10-12 volts
Return Ground/ If low or no reading

Platform Selector
Switch to Platform Replace
position Ground/Platform Selector
Switch and/or
Go to step 2 If Switch wiring
10-12V
Step 1
Step 2
Platform Control voltage, turn Ground/
Circuit Breaker Platform Switch to Platform
(20 Amp) position, measure voltage
If on wire #1 and #2
entering Platform Control
Circuit Breaker is Circuit Breaker
open Should read 10-12 volts
Then
If 10-12V
If low
Reset or no
Circuit Breaker Check for voltage on reading
wire #1B to Emergency

If
Go to step 3 10-12V
Stop Switch
If low
or no
Replace reading Repair or replace
Circuit Breaker Wire #1 and/or #2
SECTION ONE
ENGINE DIAGNOSTICS

Emergency Stop voltage, pull Emergency
Switch Stop Switch out and
If
Emergency Stop and Battery side of
Switch is off Platform Master Switch.
(pushed in) Should read 10-12 volts
Then If low or no reading
Pull Emergency Replace

Stop Switch (out) Emergency Stop Switch
to the on position and/or
If
Go to step 4 10-12V
wiring
Step 3
Step 4
Inspect
Make sure Foot Switch is
Foot Switch and
not activated
Wiring
If activated
If Deactivate Foot Switch

not
activated
Using a meter set to read
voltage, measure voltage
on wire #10 going into
Foot Switch and
wire #8 coming out
of Foot Switch
If Should be 10-12 volts
Go to step 5 10-12V
If low or no voltage
Repair or replace
Foot Switch
and/or wiring
SECTION ONE
ENGINE DIAGNOSTICS

Platform Start read voltage, activate
Switch Platform Start Switch and
measure voltage on
wire #5 between
Platform Start Switch and
Platform Emergency Power
Switch
If
Replace
Platform Start Switch
and/or
Platform Start Switch
wiring
Step 5
Step 6
Inspect
read voltage, activate
Ignition/Emergency
engine starter and
Power Switch
measure voltage
on wire #5 between
Platform Master Switch
and Ignition/Emergency
Power Switch
If
Return to step 1 10-12V
Replace
Switch and/or
Switch wiring
SECTION ONE
ENGINE DIAGNOSTICS
Engine starts while

cranking, then dies when
key switch is released

Run Relay read voltage,
measure voltage
at Murphy Switch wire
#164, B post of
Murphy Switch
Go to step 2 10-12V
Repair or replace
Run Relay
and/or
Run Relay wiring
Step 1
Step 2
Murphy Switch voltage, measure voltage
on wire
Ford: on wire #80 to
Spark Module
Ford If Deutz: #8D between Run
Go to step 3 10-12V Solenoid and Murphy
Switch
Note: Check continuity
to ground on white
jumper wire
Replace
Murphy Switch
SECTION ONE
ENGINE DIAGNOSTICS
Inspect Check continuity on wire

Vacuum Switch between Ignition and
(Ford only) Solenoid when switch is in
normally closed position
If no continuity
Replace
Vacuum Switch
Step 3
SECTION TWO:
HYDRAULIC DIAGNOSTICS
SECTION TWO
HYDRAULICS DIAGNOSTICS
Chart 1
Hydraulic system Step 1

functions on Inspect Go to Page
Main Hydraulic Pump
emergency power 42
only Step 2 OK
Inspect Go to Page
Sense Line Dump Valve 42
OK
Step 3
Inspect Go to Page
Sense Line check Valve 43
Chart 2
Step 1
Hydraulic pump Inspect Go to Page
Pump Compensator
stays on stroke 44
Chart 3
Step 1
Hydraulic oil
Inspect Go to Page
overheats Functions Valve 44
during operation
SECTION TWO
Chart 4
Step 1
Hydraulic functions Inspect Go to Page
Engine RPM
are sluggish 45
OK
Step 2
Inspect Go to Page
Pump Pressure 45
OK
Step 3
Inspect Go to Page
Accumulator 46
OK
Step 4
Inspect Go to Page
Flow from Pump 46
Chart 5
Step 1
Hydraulic pump will Inspect Go to Page
Pump Compensator Valve
not build pressure 47
OK
Step 2
Inspect Go to Page
Pump Coupling 47
Chart 6
Step 1
Hydraulic pump
Inspect Go to Page
will not build Pump Compensator Valve 48
enough pressure
OK
Step 2
Inspect Go to Page
Senseline Dump Valve 48
Chart 7
Step 1
Flow from Inspect Go to Page
hydraulic pump Flow Adjustment on Main Hydraulic
49
Pump
is too low
SECTION TWO
Chart 8
Flow from Step 1

hydraulic pump Inspect
Flow Adjustment on
Go to Page
is too high Main Hydraulic Pump 49
(kills engine)
SECTION TWO
Hydraulic system
functions on emergency
power only
Inspect Install 1000 psi pressure

Main Hydraulic gauge to hydraulic pump
Pump test plug. Set engine for
idle and measure
Remove gauge differential/standby
If
and 300 psi pressure.
Go to step 2 Should read 300 psi
If reading is abnormal
Replace
Main Hydraulic
Pump and/or Pump If Check
mal-
Coupling and/or functioning Main Hydraulic Pump,
Pump Pump Coupling and
Compensator Pump Compensator
Step 1
Step 2
Sense Line Dump voltage, activate Ground
Valve Control Switch and
measure voltage
1.on wire #28B between
Check seals on Terminal Strip
If
Sense Line Dump 10-12V in Junction Box and
Valve Sense Line Dump Valve
If bad
2.on wire # 28B at
Sense Line Dump Valve
Repair or replace Should read 10-12 volts
Ok
Sense Line Dump If low or no reading
Valve
Repair or replace
Go to step 3 and/or wiring
SECTION TWO
Inspect Remove and inspect Sense

Sense Line Check Line Check Valve from
Valve Main Hydraulic Valve
Valve should operate
freely.
If Ok
If not
Replace
Return to step 1 Sense Line Check Valve
Step 3
SECTION TWO
Hydraulic pump
stays on stroke
Inspect Remove hose from

Pump compensator. Recheck
Compensator pressure on Pump.
Valve If
goes If stays on stroke
off
Check seals on stroke Repair or replace
Sense Line Dump Pump Compensator
Valve
If bad
Repair or replace
Step 1
Step 1
Switch
Inspect
Manual Overrides
Functions Valve
Hydraulic oil to the On position
overheats Heating stops
during operation Heating

continues
Repair or replace
Functions Valve
Repair or replace
Hosing
SECTION TWO
Hydraulic functions
are sluggish
Inspect Use a Tachometer to

Engine RPM measure Engine RPM
Should read:
Ford - 1050 RPM at Low
2100 RPM at Mid
2800 RPM at High
Deutz -1200 RPM at Low
If correct 2800 RPM at High
Go to step 2 RPM
If not
Adjust
Throttle Actuator
Step 1
Step 2
Inspect Install 1000 psi
Pump Pressure pressure gauge at
Test Port.
Set engine for idle
Remove gauge and measure standby
If
and 300 psi
pressure.
Go to step 3 Should read 300 psi
Adjust
Pump Compensator
SECTION TWO
Inspect
Measure the charge
Accumulator
on the Accumulator
Should be 750 to 800 psi
If
750 to 800 psi If low or no reading
Recharge
Go to step 4 Accumulator
Step 3
Step 4
Inspect With chassis raised
Flow from Pump (all wheels off the ground)
and adequately supported,
1.Install a Flowmeter on
the discharge side of
pump.
2.Install a 1000 psi
pressure gauge at Test
Port on Accumulator.
Start engine and turn
Throttle Switch to high.
Activate drive function
full on.
Flowmeter should read
Remove gauges If 12 to 14 gpm and
12 to
and 14 gpm
pressure gauge should
Return to step 1 and read 300 psi
300 psi
Adjust
Flow Ajustment
SECTION TWO
Hydraulic pump will

not build pressure
Remove hoses from

Inspect
Pump
to Compensator Valve
Compensator
and reattach to
Valve
Pressure Line. Using a
5000 psi pressure gauge
If low check pressure.
Go to step 2 or no Should read 2800 psi
reading
If 2800 psi
Remove gauge and

check seals on
If bad
Repair or replace
Step 1
Step 2
Inspect Remove
Pump Coupling Main Hydraulic Pump
visually check
Pump Coupling
If bad
Ok Repair or replace
Pump Coupling
Repair or replace
Compensator
and/or
Main Hydraulic Pump
SECTION TWO
Hydraulic pump will not

build enough pressure
Inspect Remove hoses from

Pump Sense Line Dump Valve
Compensator to Compensator Valve
Valve and reattach to
Pressure Line. Using a
If low 5000 psi pressure gauge
Go to step 2 or no check pressure.
reading
Should read 2800 psi
If 2800 psi
Remove gauge and

check seals on
If bad
Repair or replace
Step 1
Step 2
Sense Line Dump voltage, activate Ground
Valve Control Switch and
measure voltage
1. On wire #28B between
Check seals on
If Terminal Strip in
Sense Line Dump 10-12V Junction Box and
Valve
If bad 2. On wire # 28B at
Sense Line Dump
Repair or replace
Valve
Sense Line Dump
Valve
Repair or replace
wiring
SECTION TWO
Flow from hydraulic

pump is too low
Inspect Visually check Flow

Flow Adjustment Adjustment Screw on Main
on Main Hydraulic Hydraulic Pump
Pump Screw should extend
between 3/4" and 7/8"
from face of pump
Reset
Flow Adjustment on Main
Hydraulic Pump
Step 1
Step 1
Inspect Visually check Flow
Flow Adjustment Adjustment Screw on Main
Flow from on Main Hydraulic Hydraulic Pump
hydraulic pump Pump Screw should extend
between 3/4" and 7/8"
is too high from face of pump
(kills engine) Reset

Flow Adjustment on Main
Hydraulic Pump
SECTION THREE:
STEERING SYSTEM DIAGNOSTICS
SECTION THREE
Chart 1
Step 1
Machine will not Inspect
Switch for Blocking Valve
Go to Page
steer Ground Signal (at steer Switch) 54
OK
Step 2
Inspect Go to Page
Blocking Valve Relay and Relay
Wiring 54
OK
Step 3
Inspect Go to Page
Blocking Valve 55
OK
Step 4
Inspect Go to Page
Steer Switch (Right) 55
OK
Step 5
Inspect Go to Page
Steer Switch (Left) 56
Step 6 OK
Inspect Go to Page
Steer Control Valve 56
Step 7 OK
Inspect Go to Page
Center Post 57
Step 8 OK
Inspect Go to Page
Tow Package Float Valve 57
SECTION THREE
Machine will not steer
Note: Inspect Using a meter set to read

At this point the manual Switch for Blocking continuity, activate Steer
override may also be Valve Ground Switch and check
use to isolate Signal (at steer for ground
the solenoid, however Switch) 1. on wire #100 between
use caution as the Steer Switch and
machine will be moving. Junction Box
2. at wire #100 in
Junction Box
Should show continuity to
If
Go to step 2 continuity ground
If no continuity
Replace
Steer Switch
and/or
Steer Switch wiring
Step 1
Step 2
Using a meter set to read
Inspect continuity, activate Steer
Blocking Valve Switch and
Relay and Wires check for ground
1. on wire #100 between
If Terminal Strip in
Go to step 3 continuity Junction Box and
Relay
2. on wire #100 entering
Relay
If no continuity
Repair or replace
Blocking Valve Relay
and/or
Blocking Valve Relay wiring
SECTION THREE
Note:
At this point the manual
override may also be
use to isolate
the solenoid, however
use caution as the
machine will be moving.
Inspect Visually check Blocking

Blocking Valve Valve Cartridge for
binding
Should normally be open.

If
Ok If stuck
Repair or replace
Go to step 4 Blocking Valve Cartridge
Step 3
Step 4
Inspect
Steer Switch
read voltage, activate
(Right)
Steer Switch Right and
measure voltage
Steer Switch and Steer
Control Valve
2. on wire #20 at Steer
Control Valve
Go to step 5 10-12V
Replace
Steer Switch (Solenoid)
and/or
Steer Micro (Solenoid)
wiring
SECTION THREE

Steer Switch (Left) read voltage, activate
Steer Switch Left and
During activation of
measure voltage
steering function the
machine will be moving.
Steer Switch (Left) and
Steer Control Valve
2. on wire #19 at Steer
If
Control Valve
Replace
and/or
wiring
Step 5
Step 6
Inspect Activating
Steer Control Manual Overrides and
Valve check pressure
Should be 1500 psi

If approx.
1500 psi
If lower than 1500 psi
Readjust to 1500 psi

Go to step 7
SECTION THREE
During activation of
steering function the
machine will be moving. Remove hoses leading
Inspect
Center Post to Steer Cylinder Plug
hoses and
Repair or replace cap the Steer Cylinder.
Steer Cylinder While activating
If
Note: Machines reading steering function,
with optional is check for 1500 psi at
normal
Tow Package the pump pressure Test
go to step 8 Port
If reading is abnormal
Repair or replace
Center Post
Step 7
Step 8
Inspect
Refer to Chapter 12
Tow Package Float
Accessories Diagnostics
Valve
SECTION FOUR:
DRIVE SYSTEM DIAGNOSTICS
SECTION FOUR
Chart 1
Drive system is not Step 1

operational with Inspect Go to Page
Foot Switch
controller in either 65
direction Step 2 OK
Inspect Go to Page
Drive Circuit Breaker (3 amp) 65
Step 3 OK
Inspect Go to Page
Controller Circuit Board and S1
Micro Switch Wiring 66
Step 4 OK
Inspect Go to Page
S1 Micro-Switch (in Controller) 66
Step 5 OK
Inspect Go to Page
Controller Circuit Board 67
Step 6 OK
Inspect Go to Page
Potentiometer 67
Step 7 OK
Inspect Go to Page
S2 Micro-Switch (in Controller) 68
OK
Step 8
Inspect Go to Page
Drive Solenoid 68
Step 9 OK
Inspect Go to Page
Drive Control Valve 69
Step 10 OK
Inspect Go to Page
Center Post 69
OK
Step 11
Inspect Go to Page
Shuttle Valve Portion of Dual
Counterbalance Valve 70
SECTION FOUR
Chart 2
Step 1
No forward drive Inspect
S2 Micro-Switch
Go to Page
(reverse ok) (in Drive Controller) 71
OK
Step 2
Inspect Go to Page
Drive Controller Circuit Board 71
OK
Step 3
Inspect Go to Page
Solenoid
(Drive Forward on Control Valve) 72
OK
Step 4
Inspect Go to Page
Dual Counterbalance Cartridge 72
Chart 3
Step 1
No reverse drive Inspect
S2 Micro-Switch
Go to Page
(forward ok) (in Drive Controller) 73
OK
Step 2
Inspect Go to Page
Drive Controller Circuit Board 73
OK
Step 3
Inspect Go to Page
Solenoid Valve
(Drive reverse on Control Valve) 74
OK
Step 4
Inspect Go to Page
Dual Counterbalance Cartridge 74
SECTION FOUR
Chart 4
Step 1
Drive high range Inspect Go to Page
Drive Low/High Range Switch
not operating 75
OK
Step 2
Inspect Go to Page
Boom Position and/or
Boom Limits Switch 75
OK
Step 3
Inspect Go to Page
Range Valve 76
OK
Step 4
Inspect Go to Page
Selector Spool in Transmission
Package 76
OK
Step 5
Inspect Go to Page
Power to R Terminal 77
Chart 5
Machine drives at Step 1

full speed with Inspect Go to Page
Boom Limits Switch
platform raised 78
and/or extended Step 2 OK
Inspect Go to Page
Range Valve 78
Chart 6
Step 1
Brakes will not Inspect Go to Page
Brake Pressure
release 79
SECTION FOUR
Chart 7
Step 1
Only one wheel
Inspect Go to Page
turns Case Drain 80
(2 wheel drive)
OK
Step 2
Inspect Go to Page
Flow Divider 80
Chart 8
Step 1
One wheel turns
Inspect Go to Page
faster than other Case Drain 81
(2 wheel drive)
OK
Step 2
Inspect Go to Page
Flow Divider 81
SECTION FOUR
Drive system is
non-operational
with controller in
either direction
Foot switch read voltage, activate
Foot Switch and
measure voltage
If 1. on wire #9 between
Go to step 2 10-12V Foot Switch and Drive
Circuit Breaker
2. at 3 amp Drive
Circuit Breaker
Replace
Foot Switch and/or
Foot Switch wiring
Step 1
Step 2
Drive Circuit read voltage, activate
Breaker (3 amp) Foot Switch and
measure voltage
If 1. on wire #69 between
Go to step 3 10-12V Circuit Breaker and
Drive Controller
2. at positive (+) post of
Drive controller
Replace
Foot Switch and/or
Foot Switch wiring
SECTION FOUR

Controller Circuit read voltage, activate
Board and S1 Foot Switch and
Micro-Switch measure voltage
Wiring 1. on red wire from
Circuit Board to
S1 Micro-Switch
2. at red wire of
S1 Micro-Switch
Go to step 4 10-12V
Replace
Circuit Board
and/or
S1 Micro-Switch wiring
Step 3
Step 4
Inspect Move controller handle in
S1 Micro-Switch either direction and
(in Controller) observe red LED on
If lit Circuit Board Controller
If not lit
Go to step 5
read voltage, step on
Foot Switch and
activate Controller,
Replace
measure voltage
S1 Micro-Switch
If low 1. on black wire between
(in Controller) or no S1 Micro-Switch and
and/or voltage
Controller Circuit Board
S1 Micro-Switch
2. at point where black
wiring
wire from S1 Switch
enters Controller Circuit
Board
Go to step 5 If Should read 10-12 volts
10-12V
SECTION FOUR

Controller Circuit read voltage, step on
Board Foot Switch and
activate Controller,
measure voltage
If 1. on green wire to
Go to step 6 10-12V Potentiometer from
2. on wire between
and Potentiometer
Replace
and/or
wiring
Step 5
Step 6
Inspect Using a meter set to ohms,
Potentiometer measure reading across
1. green wire and purple
wire between Controller
Go to step 7
Circuit Board and
Potentiometer
2. green wire and orange
wire between Controller
Circuit Board and
Potentiometer
continuity
Reading should vary
according to Controller
movement
If no reading
Replace
Potentiometer
and/or Check continuity on wire
No
Potentiometer continuity between Controller Circuit
wiring Board and Potentiometer
SECTION FOUR

S2 Micro-Switch read voltage, step on
(in Controller) Foot Switch and activate
Controller, perform the
following:
Check continuity 1. While activating
on blue wire and controller in forward
on white wire If no mode measure
Machine function will be reading
between Controller proportional voltage at
moving when manual
Circuit Board and Controller Circuit Board
override is activated.
S2 Micro-Switch where white wire enters
No Continuity from S2 Micro-Switch
2. While activating
Continuity Replace Controller in reverse
S2 Micro-Switch mode measure
and/or proportional voltage at
S2 Micro-Switch Controller Circuit Board
wiring where blue wire enters
from S2 Micro-Switch
Go to step 8
Reading should vary
according to amount of
reverse movement
Step 7
Step 8
Inspect Push Manual Override
Drive Solenoid while activating various
If controller functions and
functions check operation.
Go to step 9 are
normal
If functions are abnormal or erratic
Replace
Drive Section
Control Valve
SECTION FOUR
Inspect Remove hoses from drive

Drive Control section of Control Valve.
Valve Plug the hoses and cap
valve. Install a 5000 psi
Remove gauge pressure gauge to
If functions
and are normal Pump Test Port.
Go to step 10 While activating drive
control function, check
pressure.
(while activating function)
If functions are abnormal or erratic
Replace
Valves on Drive Section
of Control Valve
Step 9
Step 10
Inspect Remove hoses at V1 and
Center Post V2 ports of Dual
Counterbalance Valve.
Plug hoses and cap valve.
Install a 5000 psi pressure
Remove gauge
If pressures test gauge to
and are normal Pump Test Port
Go to step 11
While activating drive
control function, check
pressure.
(while activating function)
If pressures are abnormal or erratic
Repair or replace
Center Post
SECTION FOUR
Inspect Install a 5000 psi pressure

Shuttle Valve test gauge to BR port of
Portion of Dual Dual Counterbalance
Counterbalance Valve. Note if pressure is
Valve equal to drive pressure.
unequal pressure
equal pressure
Replace
Shuttle Valve (in Dual
Return to step 1 Counterbalance Valve)
Step 11
SECTION FOUR
No forward drive
(Reverse Ok)

S2 Micro-Switch read voltage, activate
(in Drive function and measure
Controller) proportional voltage at
If
Go to step 2 normal at point where blue wire
from S2 Micro-Switch
enters.
Reading should vary
according to controller
movement.
Replace
S2 Micro-Switch Check continuity on blue
and/or wire between S2 Micro-
no continuity
S2 Micro-Switch Switch and Controller
wiring Circuit Board
Step 1
Step 2
Drive Controller read voltage, activate drive
Circuit Board function and measure
proportional voltage at
If
Go to step 3 normal Terminal A of
Circuit Board.
Reading should vary
movement.
If no or erratic reading
Replace
Drive Controller Circuit
Board
SECTION FOUR

Solenoid Valve voltage. While activating
(Drive forward forward function, measure
on Control Valve) proportional voltage at wire
Machine function will be #17 on Drive section of
moving when manual Control Valve.
override is activated. Reading should vary
movement.
If no reading
Try manual override
Override allows operation

Override
does not Replace
allow
operation Drive Forward Solenoid
Valve and/or
Drive Forward Solenoid
Go to step 4 Valve wiring
Step 3
Step 4
Inspect Using a 5000 psi pressure
Dual test gauge activate drive
Counterbalance function and check system
Valve Cartridge pressure at hose entering
port M1 on Counterbalance
Valve
If no pressure reading
Replace the
Dual Counterbalance Valve
Cartridge tested
SECTION FOUR
No reverse drive
(Forward Ok)

S2 Micro-Switch read voltage, activate
(in Drive reverse function and
Controller) measure proportional
voltage at Controller
If
Go to step 2 normal Circuit Board at point
where white wire from
S2 Micro-Switch enters.
Reading should vary
movement.
Replace
S2 Micro-Switch Check continuity on white
and/or No continuity
wire between S2 Micro-
S2 Micro-Switch Switch and Controller
wiring Circuit Board
Step 1
Step 2
Drive Controller read voltage, activate
Circuit Board reverse function
and measure
If proportional voltage at
Go to step 3 normal Terminal B of
Reading should vary
movement
If no or erratic reading
Replace
Drive Controller Circuit
Board
SECTION FOUR

Solenoid Valve voltage. While activating
(Drive reverse on reverse function,
Control Valve) measure proportional
voltage at wire #18 on
Machine function will be Drive section of
moving when manual Control Valve.
override is activated. Reading should vary
movement.
If no reading
Try manual override
Override allows operation

Override
does not Replace
allow
operation Drive Reverse
Solenoid Valve and/or
Drive Reverse Solenoid
Go to step 4 Valve wiring
Step 3
Step 4
Inspect
Dual Using pressure test gauge
Counterbalance activate drive function and
Valve Cartridge check system pressure at
hose entering port M2 on
Counterbalance Valve
If no pressure reading
Replace the
Dual Counterbalance Valve
Cartridge tested
SECTION FOUR
Drive high range

not operating Inspect Using a meter set to
Drive Low/High read voltage, measure
Range Switch voltage on wire #16A going
into the Low/High Drive
If low Range Switch
Go to step 2 or no Should read 10-12 volts
reading
If 10-12V
Measure voltage on
wire #11 coming out of
the Low/High Drive
Range Switch.
Go to step 3 If 10-12V Should read 10-12 volts
Replace
Drive Low/High Range
Switch and/or
Drive Low/High Range
Switch wiring
Step 1
Step 2
Inspect Booms are not positioned
Boom Position for High Range speed
and/or operations
Boom Limit Switch Boom Limit Switch are
not Adjusted
Repair or replace Position Booms to fully

Boom Extend Limit retracted and down
Switch and/or position. Adjust Boom
wiring Retract/Down Limit Switch
If no
voltage
still not operating
Repair or replace
Boom Up Limit Check for 10-12 volts at
Switch and/or wire #70A at Boom
wiring Extend Limit Switch
If no If 10-12V
Repair or replace voltage
Wiring to Drive Check for 10-12 volts on
Low/High Range wire #16A at Boom Up
Switch If 10-12V
Limit Switch
SECTION FOUR

Range Valve voltage, measure voltage
at Range Valve wire #34.
If no reading
If Repair or replace
10-12V
Wiring to Range Valve
Using a 5000 psi pressure

Check for
If gauge, measure pressure
blockage in Drive pressure on hose between Range
Range Valve is low
Valve and Center Post.
and/or hoses
Should read Drive Pressure
If Ok
Go to step 4
Step 3
Step 4
Inspect Verify that Selector Spool is
Selector Spool in shifting by checking
Transmission drive speed.
Package Should be 1-1.5 mph.
If speeds
are deactivated
reached and 2-3 mph. activated.
Go to step 5 and
(3 mph = 100 ft in 22 sec)
Selector
Spool
is shifting If speeds are 1-1.5 and
Selector Spool is not shifting
Repair or replace
Selector Spool in
Transmission Package
SECTION FOUR
Inspect With Boom retracted and

Power to R lowered, use a meter set
Terminal to read voltage, measure
voltage at the R Terminal
Check connection If of Drive Controller
low
on Boom Wire Should read 10-12 volts
between Boom
If no reading If
Switches and 10-12V
Platform Return to step 2
Adjust High Speed Trim Pot

on controller to get
3 mph + 100 ft in 22 sec.
Step 5
SECTION FOUR
Machine drives at full

speed with platform
raised and/or extended
Inspect Boom Limits Switch are

Boom Limits sticking or not properly
Switch Adjusted
problem Repair, replace or readjust

Go to step 2 still
exists Boom Limits Switch
Step 1
Step 2
Inspect Using a 5000 psi pressure
Range Valve gauge, measure pressure
on hose between Range
Valve and Center Post
Should read 0 psi
If Drive pressure
If
0 psi
Repair or replace
Range Valve
Check for stuck

Selector Valve on
Transmission Package
SECTION FOUR
Brakes will not

release
Inspect 1. Install a 5000 psi

Brake Pressure pressure gauge in BR
Port on Motion Control
Valve
2. Take pressure reading
at Pump Compensator
Readings should be
similar
Repair or replace
Brake Shuttle Valve
Step 1
SECTION FOUR
Only one wheel turns

(2 wheel drive)
Note:
Make sure Hubs are engaged.
Inspect Disconnect existing hose,

Case Drain install a flowmeter
between existing hose
and Drive Motor.
If less Should be no more than
Go to step 2 than .5 gpm while driving
.5 gpm
If more than .5 gpm
Repair or replace
Drive Motor
Step 1
Step 2
Inspect Remove Flow Divider from
Flow Divider Drive Control Valve.
Visually check for broken
Repair or replace If Ok springs
as needed
If bad
Repair or replace Relief

Valve in Drive Control
Valve
SECTION FOUR
One wheel turns faster

than other (2 wheel drive)
Inspect Disconnect existing hose,

Case Drain install a flowmeter
between existing hose
and Drive Motor.
If less Should be no more
Go to step 2 than than .5 gpm
.5 gpm
If more than .5 gpm
Repair or replace
Drive Motor
Step 1
Step 2
Inspect Remove Flow Divider from
Flow Divider Drive Control Valve.
Visually check for broken
Repair or replace If Ok springs
as needed
If bad
Repair or replace Relief

Valve in Drive Control
Valve
SECTION FIVE:
EMERGENCY POWER SYSTEM DIAGNOSTICS
SECTION FIVE
Chart 1
Step 1
Emergency pump
Inspect Go to Page
motor non- Battery and Cable Connections 86
operational
Step 2 OK
Inspect Go to Page
Emergency Power Switch 86
OK
Step 3
Inspect Go to Page
Emergency Power Solenoid
and Wiring 87
OK
Step 4
Inspect Go to Page
Emergency Power Unit 87
Chart 2
Step 1
No functions when
Inspect Go to Page
on emergency Battery and Cable Connections 88
power
Step 2 OK
Inspect Go to Page
Emergency Power Pump 88
OK
Step 3
Inspect Go to Page
Blocking Valve 89
SECTION FIVE
Emergency
pump motor
non-operational
Batteries omit hydrogen

and oxygen elements that Recharge or
can combine explosively. replace
Do not smoke or permit battery(s)
open flames or sparks
when checking batteries
If 12V
Batteries set to read
12 volts while
under load If
If loose
corroded

Step 1
Step 2
Emergency Power read voltage, activate
Switch Emergency Power and
measure voltage
If 1. on wire #6 of
Go to step 3 10-12V Emergency Power
Switch
2. at Emergency Power
Solenoid
Should be 10-12 volts
Repair or Replace If no reading
Emergency Power
Check continuity
Switch Terminal
wiring (wire #6)
Emergency Power
and/or
Switch and Terminal
Emergency Power
Strip in Control Box
Solenoid wiring
2. between wire #6 of
(wire #6A)
Terminal Strip in
and/or
Junction Box and wire
Emergency Power
#6A at Emergency
Switch
Power Solenoid
No continuity
SECTION FIVE

Emergency Power voltage, measure voltage
Solenoid 1. at Emergency Power
and Wiring Solenoid and from
Battery Disconnect
If Switch
Go to step 4 10-12V 2. activate Emergency
Power Switch and
measure voltage at
Emergency Pump
Motor
If no reading
Repair or Replace
Wiring from Battery Check continuity
Disconnect Switch 1. on wire between
to Emergency Battery Disconnect
Power Solenoid Switch and Emergency
No
and/or continuity Power Solenoid
Emergency Power 2. on wire between
Unit wiring and/or Emergency Power
Emergency Power Solenoid and Pump
Solenoid Motor
Step 3
Step 4
Inspect If previous checks have
Emergency Power been performed and found
Unit to be normal, check
Emergency Pump Motor
for internal grounding
condition
Repair or Replace
Emergency Pump Motor
SECTION FIVE
No functions when on
emergency power
Recharge or
Batteries omit hydrogen replace
and oxygen elements that battery(s)
can combine explosively. If low or no voltage
Do not smoke or permit
open flames or sparks If 12V
Batteries set to read
when checking batteries
12 volts while
under load If
If loose
corroded

Step 1
Step 2
Inspect Attach 5000 psi pressure
Emergency Power gauge to discharge
Pump side of Emergency Power
Pump, activate
Emergency Power Pump
Remove gauge and Ground Control Switch
If
and Ok or Foot Switch.
Go to step 3 Should read 3000 psi.
If reading is abnormal or erratic
Repair or Replace
Emergency Power Pump
Unit
SECTION FIVE
Inspect With Ground Control

Blocking Valve Switch activated, use a
meter set to read voltage
and measure voltage
Refer back to on wire #100B to
If
Chapter 3, Chart 1 no voltage Blocking Valve Solenoid
Step 3 Should be 10 to 12 volts
If 10 to 12V
Repair or replace
Blocking Valve Cartridge
Step 3
SECTION SIX:
SWING SYSTEM DIAGNOSTICS
SECTION SIX
Chart 1
Step 1
Swings only in Inspect Go to Page
Swing Control Signal Wire
one direction 96
OK
Step 2
Inspect Go to Page
Swing Control Valve 96
Chart 2
No response from
swing when Step 1
platform controls Inspect Go to Page
Foot Switch
are activated 97
(Ground Step 2 OK
Controls Ok) Inspect Go to Page

Swing Switch 97
Chart 3
Step 1
No response from Inspect Go to Page
swing when ground Ground Control Switch
98
and Wiring
control is activated
OK
Step 2
Inspect Go to Page
Swing Switch 98
OK
Step 3
Inspect Go to Page
Swing Valve 99
OK
Step 4
Inspect Go to Page
Swing Motor and Gear Box 99
SECTION SIX
Chart 4
Step 1
Swings erratically Activate Go to Page
Manual Override
in either direction 100
Step 2 OK
Inspect Go to Page
Solenoid 100
Step 3 OK
Inspect Go to Page
Switch 101
Step 4 OK
Inspect Go to Page
Swing Brake 101
Chart 5
Step 1
Swings faster one Inspect Go to Page
Crossover Relief Valve
way than other 102
OK
Step 2
Inspect Go to Page
Solenoid 102
Chart 6
Step 1
Swing Brake Inspect Go to Page
Swing Brake
will not hold 103
SECTION SIX
Chart 7
Step 1
Activate Go to Page
Swings too slow Manual Override 104
OK
Step 2
Inspect Go to Page
Solenoid 104
Step 3 OK
Inspect Go to Page
Lift/Swing Speed Dial and Valve 105
OK
Step 4
Inspect Go to Page
Swing Brake Release 105
SECTION SIX
Swings only in
one direction Inspect Using meter set to read
Swing Control voltage, perform the
Signal Wire following:
1. while activating
When the turn table Replace Swing If no platform in ccw
Switch voltage
rotates clockwise (cw) it direction, measure
will be moving toward you. If no reading voltage on wire #23 at
Make sure you have room the Terminal Strip in
to step backward. Check continuity on the Platform Box
1. wire #23 between 2. while activating
Terminal Strip in the platform in cw direction,
Platform Box and measure voltage on
Swing Control Valve wire #24 at the
Machine function will be 2. wire #24 between Terminal Strip at
moving when manual Terminal Strip in the Platform Box
override is activated. Platform Box and Should be 10-12 volts
Swing Control Valve
Repair or Replace
If Ok
Swing Control Valve
Go to step 2 wiring
Step 1 No continuity
Step 2
Inspect Manually operate
Swing Control Swing Control Valve
Valve
If functioning If functioning properly
improperly
Repair or Replace Repair or Replace
Swing Control Swing Control Valve
Valve Solenoid
SECTION SIX
No response from swing when

platform controls are activated
(Ground Controls Ok)

Foot Switch read voltage, while
stepping on the Foot
Switch, measure voltage
on wire # 9 at
Swing Switch
If
If no reading
Repair or Replace
Foot Switch and/or
Foot Switch wiring
Step 1
Step 2
Swing Switch read voltage, while
activating function, check
voltage on Swing Switch to
Junction Box
(wire #23 when swing
is moving in a
counterclockwise direction,
wire #24 when swing
is moving in a
Check connection clockwise direction)
If no reading
in Junction Box Should be 10-12 volts
If no reading
Repair or Replace
Swing Switch
and/or
Swing Switch wiring
SECTION SIX
No response from swing

when ground controls are
activated

When the turn table
Ground Control voltage, activate swing
rotates clockwise (cw) it
Switch and Wiring function, measure voltage
will be moving toward you.
from Ground Control
Make sure you have room
Switch to Ground Swing
to step backward.
Switch
If
Go to step 2 10-12V
If no reading
Repair or Replace
Ground Control Switch
and/or
Ground Control Switch
wiring
Step 1
Step 2
Swing Switch read voltage, while
activating function, check
voltage on Swing Switch to
Swing Valve
If (wire #23 when swing
Go to step 3 10-12V is moving in a
wire #24 when swing
is moving in a
clockwise direction)
If no reading
Repair or Replace
Swing Switch and/or
Swing Switch wiring
SECTION SIX
Inspect Remove hoses from

Swing Valve Swing Drive Motor.
Plug hoses and cap
motor. While activating
swing function, check
pressure at
Pump Compensator
Pressure should read
If
Go to step 4 2500 psi
2500 psi
If reading is low or erratic
Go to page 104
Step 3
Step 4
Inspect If previous steps have
Swing Motor and been made and Swing
Gear Box Valve checks ok,
If
2500 psi check pressure.
Return to step 1 If low
Replace
Swing Motor and/or
Gear Box
SECTION SIX
Swings erratically in
either direction
Machine function will be

moving when manual
Push in on Manual
Activate Override and observe
Manual Override swing operation
If still swings erratically
If ok
Go to step 4
Go to step 2
Step 1
Step 2
Inspect Supply 12 volts to
Solenoid Solenoid, check if swing is
operating smoothly
If still swings erratically

If ok
Replace Solenoid
Go to step 3

SECTION SIX
Inspect
Swing Switch
read voltage, while
When the turn table activating function, check
rotates clockwise (cw) it voltage on Swing Switch to
will be moving toward you. Swing Valve
Make sure you have room (wire #23 when swing
to step backward. is moving in a
wire #24 when swing
is moving in a
clockwise direction)
If no reading
Repair or Replace
Swing Switch
and/or
Swing Switch wiring
Step 3
Step 4
Swing Brake gauge into Swing Brake
Line, while activating
function, check pressure.
Should maintain steady
pressure above 350 psi
If ok
Repair or replace
Swing Brake and/or
Gear Box

SECTION SIX
Swings faster one way

than other
When the turn table

rotates clockwise (cw) it
will be moving toward you.
Make sure you have room
to step backward.
Inspect Swap Crossover Relief

Crossover Relief Valves, check for problem
Valve in opposite direction
If still swings faster
If ok Repair or replace
Crossover Relief Valve
Go to step 2
Step 1
Step 2
operating equally
If still swings faster
Replace Solenoid

SECTION SIX
Swing brake will

not hold
Inspect Visually check

Swing Brake Swing Brake
If damaged If Ok
Repair or replace
Install 5000 psi pressure
Swing Brake
gauge into Swing Brake
Check Spools on If 0 psi
Line, check pressure.
Control Valve for Should be 0 psi
blocked ports If above 0 psi
If blocked
Inspect Counter Balance
If Ok
Repair or replace If Cartridge for proper
as needed damaged operation and/or damage
If blocked to O-rings
Check return Line

and filter for
blockage
Step 1

SECTION SIX
Swings too slow

moving when manual
Activate Push in on Manual

Manual Override Override and observe
swing function for faster
movement
If
Swings If still swings slow
faster
Go to step 3
Go to step 2
Step 1
Step 2
If still operating normally
swings slow
If swing is normal
Go to step 3
Repair or replace
Wiring to Valve

SECTION SIX
Inspect Visually check Speed Dial

Lift/Swing Speed in platform Control Box for
Dial and Valve fast speed.
Dial should be set to fast
If Ok
If no
Replace Dial voltage While activating swing
function, use a meter set to
Repair or replace read voltage, measure
as needed voltage on wire #108B at
If bad
Speed Dial.
Remove Valve, If 10-12V
visually check to
insure that it is While activating Swing
moving when function, measure voltage
power is applied
If 10-12V on wire #108 at Lift/Swing
and that O'Rings Speed Valve.
are ok. Should read 10-12 volts
If Ok If no voltage
Go to step 4 Repair wire to Valve

Step 3
Step 4
Swing Brake gauge into Swing Brake
Release Line, while activating
function check pressure.
Should maintain steady
pressure above 350 psi
If still swings slow
If ok
Return to step 1
Repair or replace Swing

Brake

SECTION SEVEN:
PLATFORM ROTATION SYSTEM DIAGNOSTICS
SECTION SEVEN
Chart 1
Step 1
The platform rotate Inspect Go to Page
Platform Rotate Switch
does not operate 110
OK
Step 2
Inspect Go to Page
Platform Rotator Motor 110
Chart 2
Step 1
Platform rotates Inspect Go to Page
Platform Actuator
itself 111
OK
Step 2
Inspect Go to Page
Holding Valves 111

SECTION SEVEN
Platform rotate
does not
operate Platform Rotate voltage, perform the
Switch following:
1. While activating
platform in ccw
If
Go to step 2 10-12V
direction, measure
voltage on wire #26 at
the Rotation Control
If no reading Valve
2. While activating
Check continuity on platform in cw direction,
1. wire #26 between measure voltage on
Terminal Strip in the wire #27 at the Rotation
Junction Box and Control Valve
Platfrom Rotation Motor Should read 10-12 volts
2. wire #27 between
Terminal Strip in the Repair or replace
Junction Box and Platform Rotate Switch
Platfrom Rotation Motor and/or wiring
No continuity
Step 1
Step 2
Platform Rotator ohms, check for continuity
Motor through wire on Motor
If
continuity Should show continuity
does not
exists If continuity does exists
Change Platform
Rotator Motor Check for ground on
Platfrom Rotator Switch
Repair or replace
as needed

SECTION SEVEN
Platform rotates itself
Inspect Check Key by removing the

Platform Actuator coverplate on Actuator.
Visually check for damage
If damaged
If no damage
Repair or replace
Go to step 2 Platform Actuator
Step 1
Step 2
Inspect Visually inspect
Holding Valves Holding Valves
Repair or replace
as needed

SECTION EIGHT:
PLATFORM LEVELING SYSTEM DIAGNOSTICS
SECTION EIGHT
Chart 1
Platform will not Step 1

maintain level as Inspect Go to Page
Hydraulic Oil Temperature
boom 117
raises or lowers Step 2 OK
Inspect Go to Page
Holding Valves 117
Chart 2
Step 1
Platform will not Inspect Go to Page
maintain level with Holding Valves in
118
Slave Level Cylinder
machine off
Chart 3
Step 1
Platform level will
Inspect Go to Page
not work from Ground Control Switch 119
ground control
OK
Step 2
Inspect Go to Page
Level Switch 119
OK
Step 3
Inspect Go to Page
Blocking Valve Relay 120
OK
Step 4
Inspect Go to Page
Blocking Valve 120

SECTION EIGHT
Chart 4
Platform level will Step 1

not work from Inspect Go to Page
Platform Level Switch
platform control 121
(Ground Control Ok)
Chart 5
Step 1
Platform level
Activate Go to Page
up function is Manual Override 122
inoperative
OK
Step 2
Inspect Go to Page
OK
Solenoid Valve 122
Step 3
Inspect Go to Page
Pressure to Cylinder 123
Chart 6
Step 1
Platform level
Inspect Go to Page
down function is Manual Override 124
inoperative
OK
Step 2
Inspect Go to Page
OK Solenoid Valve 124
Step 3
Inspect Go to Page
Pressure to Cylinder 125

SECTION EIGHT
The platform does not

maintain level as boom
raises or lowers
Inspect
Hydraulic Oil is cold
Hydraulic Oil
Temperature
If cold
Cycle the boom a few

If problem
Go to step 2 still exists times to warm up the
hydraulic oil
Step 1
Step 2
Inspect
Holding Valves With platform level and
between Master boom fully down, remove
Level Cylinder the hoses to Level Control
and Tank Valve and cap
Valve and plug hoses.
Raise boom 5 ft. and note
the Platform Leveling
System.
If Level System performs normally

If Level System
performs
abnormally Repair or replace
Holding Valves in Control
Package
Repair or replace
Seals in Master Leveling
System

SECTION EIGHT
The platform will not

maintain level with
machine off
Inspect Place a safe work load

Holding Valves in in platform and
Slave Level remove the hoses to
Cylinder Slave Level Cylinder
Observe the Platform.
If oil leaks and platform drifts
If no oil leaks
but platform Repair or replace
still drifts
Holding Valves
Repair or replace
Level Cylinder
Step 1

SECTION EIGHT
Platform level will not

work from ground control

Ground Control voltage, activate Ground
Switch Control Switch and
measure voltage on
Go to step 2
If wire #28 entering Platform
10-12V
Level Switch
Repair or replace
If no reading
Ground Control
Switch Check continuity on wire
and/or No #28 between Ground
Ground Control continuity Control Switch and
Switch wiring Platform Level Switch
Step 1
Step 2
Level Switch voltage, activate
Level Down and measure
voltage on
wire #13 at Junction Box
If
If no reading
Repair or replace
and/or
wiring to Junction Box

SECTION EIGHT
Inspect While activating Level,

Blocking Valve Switch check for continuity
Relay to ground on wire 100
No
continuity Continuity
Repair or replace
Level Switch Check for continuity on
wire 100 from
Level Switch to
Go to step 4 Continuity Blocking Valve Relay
No continuity
Repair or replace
Wire #100
Step 3
Step 4
Blocking Valve read voltage, measure
voltage on wire #100B to
Blocking Valve
If 10-12V Should read 0 volts
Replace
Blocking Valve If 0 volts
Relay
Remove Blocking Valve
from Control Valve, visually
check Valve.
Valve should be open.
If bad
Replace
Blocking Valve

SECTION EIGHT
Platform level will not work

(Ground Control Ok)
Platform Level set to read voltage,
Switch measure voltage on
wire #9 entering
Replace If low Platform Level Switch
or no
Foot Switch voltage Should read 10-12 volts
If 10-12V
Measure voltage on wires

#12 and #13 leaving
Replace If low Platform Level Switch
or no
Level Switch voltage
If 10-12V
If Using a meter set to read

Replace continuity
does not
ohms, check for continuity
Switch exists on wire #108B to ground
If continuity exists
If Check for continuity on

continuity
Repair Wire does not wire #108B to Lower
exists Control Box
If continuity exists
Return to step 1
Step 1

SECTION EIGHT
Platform level up
function is inoperative

moving when manual
Activate Push in on Manual

Platform level up function
If problem If ok
still exists
Go to step 2
Go to step 3
Step 1
Step 2
Solenoid Valve set to read voltage,
measure voltage on wire
#13 between Level Switch
and Solenoid Valve
If no reading
If
10-12V
Repair or replace
wire #13
Repair or replace
Solenoid Valve

SECTION EIGHT

Pressure to gauge at Port 2 of Slave
Cylinder Level Cylinder. Activate
function and measure
pressure to Slave Level
Cylinder.
Repair or replace when fully extended.
Slave Level
Cylinder
If
2000 psi Remove hose from Port 1
on Slave Level Cylinder,
plug hose and cap Slave
Level Cylinder.
Repair or replace If low
Recheck pressure
Relief Valve in or no Should read 2000 psi
reading
Control Valve when fully extended.
Step 3

SECTION EIGHT
Platform level down

function is inoperative

moving when manual
Inspect Push in on Manual

Platform Level down
function
If problem If ok
still exists
Go to step 2
Go to step 3
Step 1
Step 2
Solenoid Valve set to read voltage,
measure voltage on wire
#12 between Level Switch
and Solenoid Valve
If no reading
If
10-12V
Repair or replace
Wire #12
Repair or replace
Solenoid Valve

SECTION EIGHT

Pressure to gauge at Port 1 of Slave
Cylinder Level Cylinder. Activate
function and measure
pressure to Slave Level
Cylinder.
when fully retracted.
Repair or replace If low or no reading
Slave Level
Cylinder Remove hose from Port 2
If on Slave Level Cylinder,
2000 psi
plug hose and cap Slave
Level Cylinder.
Repair or replace If low Recheck pressure
Relief Valve in or no
reading
Control Valve when fully retracted.
Step 3

SECTION NINE:
BOOM ELEVATION SYSTEM DIAGNOSTICS
SECTION NINE
Chart 1
Step 1
Boom raises but
Inspect Go to Page
will not stay Manual Bleed Down 130
elevated
OK
Step 2
Inspect Go to Page
Holding Valve 130
OK
Step 3
Inspect Go to Page
Seals in Cylinder 131
Chart 2
Boom will not

Step 1
raise from
Inspect Go to Page
platform control Boom Lift Switch 132
(Ground Control
OK
Ok) Step 2
Inspect Go to Page
Lift/Swing Speed Valve 132
Chart 3
Step 1
Boom will not
Inspect Go to Page
raise from Boom Lift Switch 133
ground control
OK
Step 2
Inspect Go to Page
Lift/Swing Speed Valve 133
OK
Step 3
Inspect Go to Page
Lift Control Valve 134

SECTION NINE
Boom raises but will

not stay elevated
Inspect Turn Manual Bleed Down

Manual Bleed Valve clockwise until
Down valve is closed
Problem still exist
Raise boom approximately

Repair or replace 2 ft. and mark Lift Cylinder.
Manual Bleed Leakage Remove hose from port #4
Down on Lift Cylinder. Observe oil
leakage.
Problem still exist
Go to step 2
Step 1
Step 2
Inspect Raise boom approximately
Holding Valve 2 ft, remove hose to
#2 port on Lift Cylinder,
Go to step 3 Problem observe for leakage
still exist
Leakage
Replace
Holding Valve and/or
Seal Kit

SECTION NINE
Inspect Remove steel tube on

Seals in Cylinder Cylinder, check if oil is
leaking from upper port
If leaking
Repair or replace
Cylinder
Step 3

SECTION NINE
Boom will not raise

(Ground Control Ok)

Boom Lift Switch read voltage, measure
voltage on wire #22
If 10 to 12V Should read 10 to 12 volts
Check continuity
on wire between If no reading
Lift Switch and Measure voltage on wire

Junction Box #28 to Lift Switch
No continuity Should read 10 to 12 volts
Repair or replace If no reading
Wire #22 Repair or replace

Lift Switch
Step 1
Step 2
Inspect Visually check Speed Dial
Lift/Swing Speed in platform Control Box for
Dial and Valve fast speed.
Dial should be set to fast
If Ok
If no
Replace Dial voltage While activating swing
function, use a meter set to
Repair or replace read voltage, measure
as needed voltage on wire #108B at
If bad
Speed Dial.
Remove Valve, If 10-12V
visually check to
insure that it is While activating Lift
moving when function, measure voltage
power is applied If 10-12V on wire #108 at Lift/Swing
and that O'Rings Speed Valve.
are ok. Should read 10-12 volts
If Ok If no voltage
Go to step 4 Repair wire to Valve

SECTION NINE
Boom will not raise

from ground control

Boom Lift Switch read voltage, measure
voltage on wire #22
Check continuity If 10 to 12V Should read 10 to 12 volts
on wire between If no reading
Lift Switch and Lift
If 10 to 12V
Valve Measure voltage on wire
#28 to Lift Switch
No continuity
Should read 10 to 12 volts
Repair or replace If no reading
Wire #22 and retry
function Repair or replace
Lift Switch
If still no function
Go to step 2
Step 1
Step 2
Lift/Swing Speed read voltage, measure
Valve voltage on wire #108B to
Lift/Swing Speed Valve
Repair If no
voltage Should read 10-12 volts
Switch and/or Wire
If 10-12V
Remove Lift/Swing Speed

Valve from Control Valve,
If valve
Replace Valve is stuck visually check for proper
operation.
Valve is normally closed
If Ok
Go to step 3

SECTION NINE

moving when manual Inspect Activate manual override
override is activated. Lift Control Valve on Valve, observe boom
If boom movement
operates
Replace
Lift Solenoid If boom does not move
Install a 5000 psi pressure

gauge on test port,
operate function and
check pressure.
Repair or replace If low reading
Lift Cylinder
If boom
operates Remove hose from #2 Port
of Lift Cylinder, plug hose
Reset Lift/Swing and cap cylinder. Recheck
If low
Relief Valve reading pressure
Step 3

SECTION TEN:
TELESCOPE SYSTEM DIAGNOSTICS
SECTION TEN
Chart 1
Step 1
Boom will not
Activate Go to Page
retract from Manual Override 139
ground control
OK
Step 2
Inspect Go to Page
Extend and Retract Switch 139
OK
Step 3
Inspect Go to Page
Retract Solenoid 140
Chart 2
Boom will not Step 1

retract from Activate Go to Page
Manual Override
(Ground Control Ok) Step 2 OK
Inspect Go to Page
OK
Step 3
Inspect Go to Page
Wiring in Hose Carrier 142
Chart 3
Step 1
Boom will not
Activate Go to Page
extend from Manual Override 143
ground control
OK
Step 2
Inspect Go to Page
OK
Step 3
Inspect Go to Page
Extend Solenoid 144
OK
Step 4
Inspect Go to Page
Extend/Retract Valve 144

SECTION TEN
Chart 4
Boom will not Step 1

extend from Activate Go to Page
Manual Override
(Ground Control Ok) Step 2 OK
Inspect Go to Page
OK
Step 3
Inspect Go to Page
Wiring in Hose Carrier 146
Chart 5
Step 1
Activate Go to Page
Boom drifts in Holding Valves for Extend 147
OK
Step 2
Inspect Go to Page
Cylinder for Internal Leakage 147

SECTION TEN
Boom will not retract

from ground control

moving when manual
Activate Activate Ground Control

Manual Override Switch, push in on
Manual Override and
If no
Go to step 4 movement observe boom movement
If retracting
Go to step 2
Step 1
Step 2
Extend and voltage, measure voltage
Retract Switch at wire #15 at
Extend and Retract
Switch
Go to step 3
10-12V
If no reading
Repair or replace
Extend and
Retract Switch

SECTION TEN
Using meter set to read

Inspect
voltage, activate function
Retract Solenoid
and measure voltage on
wire #15 to Retract
Replace Solenoid
Retract Solenoid If 10-12V
If no reading
Repair or replace
Wire to Valve
Step 3
Step 4
Extend/Retract gauge on test port,
Valve operate function and
check pressure.
If low or no pressure
Repair or replace Remove hose from Retract

Extend Cylinder If Port of Control Valve, plug
pressure
and/or Holding Ok hose and cap valve.
Valve Recheck pressure
Adjust 1500 psi Relief in

Control Valve

SECTION TEN
Boom will not retract

(Ground Control Ok)

moving when manual

Manual Override and
observe boom movement
If retracting
Go to step 2
Step 1
Step 2
Extend and Retract
Switch
Go to step 3 If Should read 10-12 volts
12V
If no reading
Repair or replace
Extend and
Retract Switch

SECTION TEN

Wiring in Hose voltage, activate function
Carrier and measure voltage at
wire #15 in
Ground Control Box
If no reading
Repair or replace
Wiring in Hose Carrier
Step 3

SECTION TEN
Boom will not extend

from ground control
(Platform Control Ok)

moving when manual

Manual Override and
If extending
Go to step 2
Step 1
Step 2
Extend and Retract
Switch
Go to step 3 12V
If no reading
Repair or replace
Extend and
Retract Switch

SECTION TEN

Inspect
voltage, activate function
Extend Solenoid
and measure voltage on
wire #14 to Extend
Replace Solenoid
Extend Solenoid If 10-12V
If no reading
Repair or replace
Wire to Valve
Step 3
Step 4
Extend/Retract gauge on test port,
Valve operate function and
check pressure.
Remove hose from Extend

Repair or replace If Port of Control Valve, plug
pressure
Extend Cylinder Ok hose and cap valve.
Recheck pressure
Adjust 1500 psi Relief in

Control Valve

SECTION TEN
Boom will not extend

(Ground Control Ok)

moving when manual

Manual Override and
If extending
Go to step 2
Step 1
Step 2
Extend and Retract
Switch
Go to step 3 12V
If no reading
Repair or replace
Extend and
Retract Switch

SECTION TEN

Wiring in Hose voltage, activate function
Carrier and measure voltage on
wire #14 in
Ground Control Box
If no reading
Repair or replace
Wiring in Hose Carrier
Step 3

SECTION TEN
Boom drifts in
Inspect
Visually check for blown
Holding Valves for
O-Rings
Extend
If Ok
If stuck and/or blown

Go to step 2
Repair or replace
Holding Valves
and/or
O-rings
Step 1
Step 2
Inspect Raise boom and extend
Seals in Extend boom 2 ft., remove hoses
Cylinder from Extend Control Valve.
Observe oil leakage
Leakage from Port 1
Leakage of Extend Cylinder
from Port 2
of Extend Repair or replace
Cylinder
Seals in Extend Cylinder
Repair or replace
Holding Valve

SECTION ELEVEN:
FUEL SYSTEM DIAGNOSTICS
SECTION ELEVEN
Chart 1
Engine will not

start on Gasoline, Inspect Go to Page
Fuel Level
but will start 152
on L.P. OK
Inspect Go to Page
Dual Fuel Switch 152
OK
Inspect Go to Page
Fuel Shutoff Valve 153
Chart 2
Engine will not

start on L.P., Inspect Go to Page
L.P. Gauge
but will start on 154
Gasoline. OK
Inspect Go to Page
Dual Fuel Switch 154
OK
Inspect Go to Page
L.P. Filter Lock 155

SECTION ELEVEN

on Gasoline, but will
start on L.P.
Inspect Visually check Fuel

Fuel Level Gauge to verify an
adequate amount of fuel
is in tank
If yes If not
Go to step 2 Fill tank with Gasoline

Step 1
Step 2
Dual Fuel Switch voltage, measure voltage
1. on wire #77A at the
Dual Fuel Switch
2. on wire #78 coming
out of Dual Fuel Switch
Go to step 3 10-12V
If no reading
Repair or replace
Dual Fuel Switch

SECTION ELEVEN
Inspect
Fuel Shutoff
voltage, measure voltage
Valve
on wire #78 at the
Fuel Shutoff Valve
Repair If no
reading Should read 10-12 volts
wire to Valve
If 10-12V
Repair or replace
Fuel Shutoff Valve
Step 3

SECTION ELEVEN

on L.P., but will start
on Gasoline.
Inspect Visually check

L.P. Gauge L.P. Gauge to verify an
adequate amount of
fuel is in tank
If yes If not
Go to step 2 Fill tank with L.P.

Step 1
Step 2
Dual Fuel Switch voltage, measure voltage
1. on wire #77A at the
Dual Fuel Switch
2. on wire #77B coming
out of Dual Fuel Switch
If
Go to step 3 10-12V
If no reading
Repair or replace
Dual Fuel Switch

SECTION ELEVEN

L.P. Filter Lock voltage, measure voltage
1. on wire #77B at the
L.P. Filter Lock
2. on wire #78 coming
Repair If no out of Dual Fuel Switch
wire to Valve reading Should read 10-12 volts
If 10-12V
Repair or replace
L.P. Filter Lock
Step 3

SECTION TWELVE:
ACCESSORIES DIAGNOSTICS
SECTION TWELVE
Chart 1
Step 1
AC Generator Inspect
Power to Generator Switch
Go to Page
will not function at Platform 160
OK
Step 2
Inspect Go to Page
Generator Solenoid 160
Chart 2
Step 1
AC Generator has Inspect Go to Page
AC Voltage from Generator
low voltage 161
Chart 3
Step 1
Machine will not Inspect Go to Page
Tow Package Float Valve
steer 162

SECTION TWELVE
AC Generator will
not function

Power to voltage, measure voltage
Generator Switch at wire #169 when
at Platform switch is activated to
Generator position
If
10-12V If no reading
Repair or replace
Generator Switch at
Go to step 2 Platform
Step 1
Step 2
Generator voltage, measure voltage
Solenoid on Generator Solenoid
wire #169
If
10-12V
If no reading
Repair or replace Repair or replace

Solenoid Valve Wire from Platform

SECTION TWELVE
AC Generator has
low voltage
Inspect
AC Voltage from Using meter set to read
Generator voltage, measure voltage
at Generator
Should read 130 volts AC
If no reading
Adjust Speed Control

Valve on Hydraulic
Generator Valve
counterclockwise to
increase voltage
Step 1

SECTION TWELVE
Machine will
not steer
Inspect Visually inspect Tow

Tow Package Package Float Valve
Float Valve to insure valve is in
operational position
No
Check decal for correct

positioning
Step 1

Troubleshooting Guide TB37

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Troubleshooting

diesel - gasoline - LPG

P.O. Box 1160  St. Joseph, MO 64502-1160

1.) Engine Diagnostics 7.) Platform Rotation System Diagnostics

NOTES, CAUTIONS AND DANGERS

Example: Problem Solving Procedure

Problem Inspect Go to Page

Example: Flowchart Procedure

Section One - Engine Diagnostics

Section Two - Hydraulic Diagnostics

Section Three - Steering System Diagnostics

Section Four - Drive System Diagnostics

Section Five - Emergency Power System Diagnostics

Section Six - Swing System Diagnostics

Section Seven - Platform Rotation System Diagnostics

Section Eight - Platform Leveling System Diagnostics

Section Nine - Boom Elevation System Diagnostics

Section Ten - Telescope System Diagnostics

Section Eleven - Fuel System Diagnostics

Section Twelve - Accessories Diagnostics

Engine starts while Step 1

Engine starter fails to

Batteries omit hydrogen Recharge or

open flames or sparks Using a meter

Clean all Tighten all

Go to step 3 Repair or replace

Inspect Using a meter set to read

Inspect Using a meter

Inspect Using a meter set to

Return Ground/ If low or no reading

Inspect Using a meter set to

Check Adjustable Resistor

Inspect Using a meter set to

Locate the adjustable

Engine cranks over

Go to step 3 Check Battery

Inspect Ignition/ Using a meter set to

Check voltage on diode

Inspect Using a meter set to read

Inspect Using a meter set to

Engine starts then shuts

Inspect Using a meter set to

Allow time for Engine to

If If engine still dies

Engine oil Using a meter set to read

Engine will not

Check continuity on wire

Check continuity on wire

Inspect Using meter set to

Check continuity on wire

Inspect Using a meter set to

Check continuity on wire

Inspect Using meter set to read

Adjust Throttle Solenoid

Inspect Using a meter set to

Engine will not start

Inspect Set Selector Switch to

Return Ground/ If low or no reading

wire #1B to Emergency

P.O. Box 1160 St. Joseph, MO 64502-1160