Repair Manual 120SE&100SEC

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
This document has been printed from my e doc
MANITOU BF
Head office: 430, Rue de l’Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou
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de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que
l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation exprès et formelle. Tous
droits réservés.
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part
or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization
that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil
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antedicho puede acarrear condenas civiles y penales. Los logotipos y la identidad visual de la empresa son propiedad de MANITOU
BF y no pueden utilizarse sin su autorización expresa y formaL. Reservados todos los derechos.
Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione,
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diritti sono riservati.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Group 00 (General characteristics and safety) 1-1
AXLE ASSEMBLY - AXLE

Group 30 (Axle) 2-1
BRAKE
Group 40 (Brake) 3-1
FRONT ARMS
Group 55 (Jib - Access platform) 4-1
HYDRAULIC
Group 70 (Hydraulic) 5-1
ELECTRICITY
Group 80 (Electricity) 6-1
00
GENERAL CHARACTERISTICS AND SAFETY
- GENERAL INSTRUCTIONS AND SAFETY

NOTICE
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TECHNICAL DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REPAIRS PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
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2 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
GENERAL INSTRUCTIONS
• This section lists the safety instructions that must be followed when conducting repairs to a lifting
platform.
• Any maintenance or repairs other than those detailed in Part 3 - MAINTENANCE in the INSTRUCTIONS
MANUAL for the lifting platform must be performed by duly qualified personnel (contact your dealer)
and under optimum safety conditions to maintain the health of the operator and others and to
prevent damage to the lifting platform.
• • Provided that the lifting platform’s manufacturer does not proceed to check the maintenance or
repair operations directly, the operator or the enterprise’s manager is responsible for the safety for
these processes.
WARNING ABOUT LEAKS – Diesel or hydraulic oil escaping under high pressure can pierce the
skin and cause severe injuries. If anyone is injured by a jet of high-pressure fluid, call a doctor
immediately.
• The FRONT and rear details are shown in the Figures to aid their comprehension.
As a reminder:
TYPE LIFTING PLATFORM front REAR

ARTICULATED Counterweight Basket
SCISSORS Steering axle Steps
VERTICAL MAST Counterweight Basket
LIFTING PLATFORM ON CARRIER Truck cab Basket
TELESCOPIC Basket extension Steps
• Our policy is to seek constantly to improve our products; we may therefore introduce certain modifications
into our range of lifting platforms without the requirement to notify our valued customers.
00-00-M219EN (01/05/2013)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 3
00
REPLACEMENT PARTS
• Our lifting platforms must only be serviced using MANITOU original parts. By authorising the use of
non-original parts, YOU RISK:
– From a legal point of view, being liable in the event of an accident.

– From a technical point of view, causing malfunctions and reducing the lifting platform’s service life.
• The use of counterfeit parts or components not approved by the manufacturer rescinds the benefits
of the contractual warranty. BY USING MANITOU ORIGINAL PARTS IN YOUR SERVICING OPERATIONS:
YOU BENEFIT from KNOW-HOW through its network, MANITOU provides the operator with:
– Know-how and skills

– Guaranty of the quality of the work performed
– Original replacement parts
– Assistance in preventive maintenance
– Effective diagnostic assistance
– Improvements from feedback of experiences
– Operating personnel training
– Only the MANITOU network knows the lifting platform’s design in detail and therefore has the best
technical capabilities for servicing it.
• FOR THE COMMERCIAL COMPONENTS (CYLINDERS, ELECTRIC PUMP, VARIABLE SPEED DRIVE,
CHARGER, ENGINE, ETC...) AND DURING THE LIFTING PLATFORM’S WARRANTY PERIOD:
– Removal of components AUTHORISED

– Removal of components FORMALLY PROHIBITED UNDER PAIN OF LOSS OF WARRANTY
• Original replacement parts are only distributed by MANITOU and its dealer network.
• The dealer network list is available on the MANITOU site : www.manitou.com
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00
TECHNICAL DOCUMENTATION
• READ and thoroughly UNDERSTAND the contents of the lifting platform’s instructions manual (this
manual must be stored in the black storage compartment in the lifting platform’s basket). In particular,
carefully comply with the contents of Section 1 – SAFETY INSTRUCTIONS AND ADVICE and the items
marked by a danger symbol.
• READ and thoroughly UNDERSTAND the safety instructions and/or advice on the stickers affixed to
the lifting platform.
• Before starting any procedure in the repairs manual, READ the procedure completely and fully
understand it.
00-00-M219EN (01/05/2013)
00
REPAIRS PROCEDURES
GENERAL
• SET the lifting platform on a clean, totally uncluttered, horizontal working area and sweep it. If these
conditions cannot be met (the lifting platform is on a work site, in a refrigeration unit, etc.), chock the
wheels, sweep the lifting platform and be aware of the environment-related dangers.
• SWITCH OFF THE LIFTING PLATFORM with the battery cut-off before starting any procedure (unless
otherwise instructed).
• As soon as the weight of a component or an assembly exceeds 20kg, the procedure indicates this
and it is advisable to use HOLDING EQUIPMENT for its removal so that the characteristics (indicated
on the manufacturer’s or taring plates) match the operation to be performed.
• To clean them, use the non-inflammable solvents approved for this purpose.
• When removing or refitting a component, scrupulously follow the procedure step by step; always
complete each step before starting the next.
• If you feel any resistance when removing a component, do not force it. Check that the nuts, screws,
and cables have been removed and that no nearby component is interfering.
• The most important factor in maintaining the lifting platform’s service life is to maintain a high level
of cleanliness for its vital components.
• When not specified, the re-installation operations consist of performing the removal actions in the
reverse order.
MECHANICAL ENGINEERING
• Use screws with the same characteristics as those of the original screws and of an appropriate length.
• When the procedures do not state a value for the tightening torques to be applied to the nuts and bolts,
you should use the standard values appropriate for the characteristics of the particular components.
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HYDRAULIC COMPONENTS
• Some hydraulic lines are under VERY HIGH PRESSURE, even when the lifting platform is not running.
To prevent an accident:
– Follow the hydraulic lines’ pressure relieving procedure before performing any work on one of their
components.
• Some cylinders are fitted with valves used to put the lifting platform in Safe mode as soon as the
movements cease by retaining hydraulic pressure in the cylinder’s chambers. Consequently, a
removed cylinder may still have VERY HIGH PRESSURE in its chambers (over 100 bars, especially in
the tilt compensation circuit). It is therefore advisable:
– To follow the procedures for releasing the pressure in the cylinder to be removed.
– To eliminate the pressure in its chambers before removing a cylinder.
• Before working on a hydraulic component, clean the immediate surrounding area, provide receptacles
or cloths for catching any oil that may escape during removal operations; also provide stoppers and
covers to plug the apertures and prevent any foreign bodies from getting into the circuit.
• The cowls, hatches, seals and filters are designed to keep the hydraulic oil clean and prevent any
foreign bodies from getting into the circuit. On these components, therefore, you must periodically:
– Check that there is no damage or deterioration.

– Keep them properly clean.
• Cloudy oil is the sign of the presence of a significant amount of humidity causing oxidisation /
corrosion of the circuit’s metal components: bleed and empty the whole circuit and then refill the
circuit with fresh oil.
• If it should transpire that the circuit is polluted with foreign bodies (metal, rubber, etc.), bleed the
complete circuit, clean it thoroughly and refill it with fresh oil.
• It is not recommended to mix oils of different types or brands if it is not guaranteed that they are
equivalent in composition and viscosity.
• Please refer to Section 3 - MAINTENANCE in the INSTRUCTIONS MANUAL to select the appropriate oil
to use in the lifting platform.
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00
SYMBOLS
GENERAL
The related text must be read and understood before continuing with
DANGER OF ANY KIND
the procedure.
ELECTRICAL DANGER
the procedure.
HEAT DANGER
the procedure.
HYDRAULIC PRESSURE DANGER
the procedure.
Indicated during removal procedures; this enables you to select the

MINIMUM WEIGHT
appropriate handling equipment.
 647367EN Please refer to Instructions Manual No 647367EN.
 647367C Please refer to Spare Parts Catalogue No 647367.
 80-07-M.219EN Please refer to Section No 80-07-M.219EN in this Repairs Manual.
§B-1 Please refer to Paragraph B - 1 in this Section
(A1-1) (Figure A1 - Rep 1)
Mark the anchoring points or support surfaces (for lift truck forks) to be
used during removal operations.
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EQUIPMENT REQUIRED
• Tool box.
• MANITOU hydraulic kit: Specific reference to be selected according to the type of lifting platform in
catalogue 647382.
• Male and female stoppers for plugging the hoses and hydraulic connectors.
• Calibrator: Specific reference according to the type of lifting platform; see the section concerned.
• Multimeter.
00-00-M219EN (01/05/2013)
AXLE
- AXLE REMOVAL
30
AXLE REMOVAL
30
pages
STEER AXLE COMPONENTS

– YOKE AND DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– STEER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– STEER BELLCRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2 AXLE REMOVAL
Yoke and Drive Motor 7 Tag, disconnect and plug the hydraulic hoses
on the drive motor. Cap the fittings on the drive
motor.
How to Remove the Yoke
and Drive Motor Assembly 8 Support and secure the yoke assembly to an
appropriate lifting device.
When removing a hose assembly or fitting, the
9 Remove the retaining fastener from the steer
fitting and/or hose end must be torqued to
link at the yoke assembly.
specification during installation.
Note: While removing the retaining fasteners, take
note of the quantity and location of the spacers
1 Block the non-steer wheels. when disconnecting the steer link from the yoke
2 Remove the cotter pin from the wheel castle assembly.
30
nut.
10 Remove the retaining fastener from the top of
Note: Always replace the cotter pin with a new one the yoke pivot shaft.
when removing the castle nut.
Note: The pivot shaft retaining fastener is located
3 Loosen the wheel castle nut. Do not remove it. above the main deck.
4 Center a lifting jack under the drive chassis at 11 Lower the yoke assembly out of the chassis.
the steer end of the machine.
5 Raise the machine approximately
6 inches / 15 cm. Place blocks under the
chassis for support.
6 Remove the wheel castle nut. Remove the
wheel.
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AXLE REMOVAL 3
How to Remove a Drive Motor Steer Cylinder

1 Block the non-steer wheels.
How to Remove the
2 Remove the cotter pin from the wheel castle nut
of the motor to be removed.
Steer Cylinder
Note: Always replace the cotter pin with a new one When removing a hose assembly or fitting, the
when removing the castle nut. O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
3 Loosen the wheel castle nut. Do not remove it. installation.
4 Center a lifting jack under the drive chassis at 1 Block the non-steer wheels.
the steer end of the machine.
2 Remove the pin retaining fasteners from the
30
5 Raise the machine approximately rod-end pivot pin. Remove the pivot pin.
2 inches / 5 cm. Place blocks under the chassis
for support. Note: While removing the pin retaining fasteners,
take note of the quantity and location of the
6 Remove the wheel castle nut. Remove the spacers when removing the pivot pin.
wheel.
3 Remove the pin retaining fasteners from the
7 Tag, disconnect and plug the hydraulic hoses barrel-end pivot pin. Remove the pin.
on the drive motor. Cap the fittings on the drive
motor. Note: While removing the pin retaining fasteners,
take note of the quantity and location of the
8 Remove the drive motor mounting fasteners. spacers when removing the pin.
Remove the motor.
4 Remove the steer cylinder from the machine.
Torque specifications
5 Tag, disconnect and plug the hydraulic hoses
Drive motor mounting fasteners, dry 75 ft-lbs from the steer cylinder. Cap the fittings on the
101.7 Nm cylinder.
Drive motor mounting fasteners, lubricated 56 ft-lbs
76.3 Nm
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4 AXLE REMOVAL
Steer Bellcrank
How to Remove the Steer

Bellcrank
1 Remove the steer cylinder. See How to
Remove the Steer Cylinder.
2 Remove the retaining fasteners from the steer
links at each end of the bellcrank.
Note: While removing the retaining fasteners, take
note of the quantity and location of the spacers
30
between the bellcrank and the steer links.

3 Center a lifting jack under the drive chassis at
the steer end. Note: While removing the bellcrank from the
4 Raise the machine approximately machine, take note of the quantity and location of
14 inches / 36 cm. Place blocks under the the spacers between the bellcrank and the steer
chassis for support. links.
5 Turn the yokes to the side so the bellcrank can Note: Before re-installing the steer bellcrank onto
be removed. the machine, apply a small amount of Loctite onto
the threads of the fasteners. Torque the fasteners
6 Remove the bellcrank from the machine. to 31 ft-lbs / 42 Nm.
30-06-M212EN (31/10/2012)
BRAKE
- BRAKE REMOVAL
40
BRAKE REMOVAL
pages
40
NON-STEER AXLE COMPONENTS
– DRIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BRAKE RELEASE AND PUMP COMPONENTS
– BRAKE RELEASE HAND PUMP COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2 BRAKE REMOVAL
Drive Brake 9 Tag, disconnect and plug the hydraulic hose

from the brake. Cap the fitting on the brake.
How to Remove a Drive Brake 10 Place a lifting jack under the brake for support.
When removing a hose assembly or fitting, the 11 Remove the fasteners that attach the brake to
fitting and/or hose end must be torqued to the drive chassis. Remove the brake.
Brake mounting fasteners, dry 75 ft-lbs

1 Support and secure the entry ladder to an 102 Nm
appropriate lifting device. Brake mounting fasteners, lubricated 56 ft-lbs
2 Remove the entry ladder mounting fasteners. 76 Nm
Remove the entry ladder from the machine.
3 Block the steer wheels.
4 Remove the cotter pin from the wheel castle
nut.
40
Note: Always replace the cotter pin with a new one

when removing the castle nut.
5 Loosen the wheel castle nut. Do not remove it.
the non-steer end.
2 inches / 5 cm. Place blocks under the chassis
for support.
8 Remove the wheel castle nut. Remove the
wheel.
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BRAKE REMOVAL 3
Brake Release Hand Pump Components

The brake release hand pump manifold is mounted behind the entry ladder.
Index Schematic
No. Description Item Function Torque
1 Hand pump ....................................... L ............... Manual brake release .............................. 30 ft-lbs / 41 Nm
2 Needle valve ..................................... M ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm
40
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4 BRAKE REMOVAL
40
40-06-M212EN (31/10/2012)
BOOM
- JIB - ACCESS PLATFORM REMOVAL
55
JIB - ACCESS PLATFORM REMOVAL
pages
PLATFORM COMPONENTS
– PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCISSOR COMPONENTS
55
– SCISSOR ASSEMBLY, 78 SEC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– SCISSOR ASSEMBLY, 100 SEC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– SCISSOR ASSEMBLY, 120 SE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GROUND CONTROLS
– MANUAL PLATFORM LOWERING CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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2 JIB - ACCESS PLATFORM REMOVAL
Platform 8 Models with air line to platform option:

Disconnect the air line from the platform. Pull
the air line free of the platform.
How to Remove the Platform
9 Support the platform with a forklift at the
Perform this procedure with the platform extension non-steer end. Do not apply any lifting
fully retracted and locked in position. pressure.
1 Raise the platform to approximately 3 ft / 1 m. 10 Attach a strap from the lanyard anchorage point
2 Remove the retaining fasteners securing the on the platform railings to the carriage on the
platform to the platform mount at the steer end forklift to help support the platform.
of the machine. 11 78 SEC 2 : Lift the steer end
3 Lower the platform to the stowed position. of the platform slightly to clear the platform
mount and slide the platform towards the non-
4 Disconnect the battery packs from the machine. steer end of the machine until the platform slide
blocks at the non-steer end of the machine are
5 Disconnect the platform controls from the
visible through the access holes in the bottom
control cable at the platform.
of the platform.
6 Remove the cover from the AC outlet. Tag and
All other models: Lift the steer end of the
disconnect the wiring from the outlet.
platform slightly to clear the platform mount and
slide the platform towards the steer end of the
machine until the platform slide blocks at the
7 Disconnect the wiring from the platform and pull non-steer end of the machine are visible
the wiring free of the platform. through the access holes in the bottom of the
platform.
55
12 Carefully lift the platform off of the machine and

place it on a structure capable of supporting it.
Note: Take notice of the wear pad position before
the platform is removed. Correct wear pad position
is essential for proper platform functionality.
7 Disconnect the wiring from the platform and pull

the wiring free of the platform.
55-06-M212EN (31/10/2012)
JIB - ACCESS PLATFORM REMOVAL 3
Platform Extension 7 Remove the platform roller wheels from the

machine.
How to Remove the 8 Carefully slide the platform extension out from
the platform and place it on a structure capable
Platform Extension of supporting it.
1 Lower the platform to the stowed position.
How to Replace the Platform
2 Extend the platform approximately 3 feet / 1 m. Extension Wear Pads
3 Remove the platform controls from the platform
1 Remove the Platform Extension. See, How
and lay them off to the side of the machine.
to Remove the Platform Extension.
4 Support the platform extension with a forklift at
2 Drill out the rivets which hold the wear pads in
the steer end of the machine. Do not apply any
place.
lifting pressure.
3 Install the new wear pads using new rivets.
5 Attach a strap from the platform extension
When installing the new rivets, make sure the
railings to the carriage on the forklift to help
rivet heads are not above the surface of the
support the platform extension.
wear pad.
6 Remove the two retaining fasteners from each
platform extension roller bracket assembly.
Remove each assembly from the machine.
Note: Do not remove the platform roller bolt.
55
a roller bracket assembly
b assembly retaining fastener
c platform roller bolt
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78 SEC 2
55
)5217 5($5
1 Number 5 pivot pin 12 Number 4 inner arm
2 Number 4 center pivot pin (2 pins) 13 Number 4 outer arm
3 Number 4 pivot pin (steer end) 14 Number 4 pivot pin (non-steer end)
4 Number 3 center pivot pin (2 pins) 15 Number 3 inner arm
5 Lift cylinder rod-end pivot pin 16 Number 3 outer arm
8 Number 2 pivot pin (steer end) 19 Number 2 outer arm
9 Number 1 center pivot pin (2 pins) 20 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 21 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin 22 Number 1 outer arm
55-06-M212EN (31/10/2012)
Scissor Assembly, 4 Lower the platform onto the safety arm.
78 SEC 2 5 At the ground control, turn the key switch to the

off position and push in the red Emergency
Stop button to the off position.
How to Disassemble the
6 Disconnect the battery pack from the machine.
Scissor Assembly,
7 Remove the fasteners securing the platform
78 SEC 2 height sensor cover to the large platform height
sensor bracket.
O-ring on the fitting and/or hose end must be 8 Remove the platform height sensor cover.
replaced and then torqued to specification during 9 Tag and disconnect the platform height sensor
installation. from the platform height sensor harness.
10 Remove the fastener securing the platform
1 Turn the key switch to ground control and pull height sensor assembly to the number 1 inner
out the red Emergency Stop button to the on arm.
position at both the ground and platform
controls. 11 Remove the platform height sensor assembly
from the number 1 pivot pin.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
12 Remove the plastic nut securing the squeeze
3 Lift the safety arm, move it to the center of the connector to the large platform height sensor
scissor arm and rotate down to a vertical bracket.
position.
55
13 Remove the squeeze connector from the large
platform height sensor bracket.
14 Remove the fasteners securing the large
platform height sensor bracket to the number 1
inner arm pivot bracket.
15 Remove the large platform height sensor
bracket from the number 1 inner arm pivot
bracket.
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16 Install the fasteners removed in 14 to the

number 1 inner arm pivot bracket and chassis.
17 Connect the battery pack to the machine.
18 Turn the key switch to the ground control
position.
19 Press and hold the ground control scroll up and
scroll down buttons.
20 Pull out the red Emergency Stop button to the
on position at the ground controls.
21 Using the ground control menu buttons,
navigate to Service Override Mode. Select
Service Override Mode.
Note: The machine must be in Service Override
Mode to raise the platform. While in Service 78 SEC 2
Override Mode, only the GCON will operate with
limited functionality. The platform will raise a
predetermined amount of time and stop.
Cable bridge and platform height sensor
22 Raise the platform and return the safety arm to legend
the stowed position.
a cable bridge 4
23 Fully lower the platform to the stowed position. b cable bridge 3
55
c cable bridge 2
d cable bridge 1
e platform height sensor
24 Remove the platform.

25 Remove the cables from the number 4 outer
arm (index #13) at the ground controls side.
26 Remove the cables from the number 4 cable

bridge and lay them off to the side.
55-06-M212EN (31/10/2012)
27 Attach a lifting strap from an overhead crane to 36 Remove the cables from the number 3 cable
the number 4 outer arm (index #13). bridge and lay them off to the side.
28 Remove the external snap rings and retaining 37 Remove the number 3 cable bridge mounting
fasteners from the number 4 center pivot pins fasteners and remove the cable bridge from the
(index #2). machine.
29 Use a soft metal drift to remove the number 4 38 Attach a lifting strap from an overhead crane to
center pivot pins (index #2). the number 3 outer arm (index #4) at the
30 Remove the retaining fasteners from the ground controls side.
number 4 pivot pin (index #14) at the non-steer 39 Remove the external snap rings and retaining
end of the machine. fasteners from the number 3 center pivot pins
31 Use a soft metal drift to remove the number 4 (index #4).
pivot pin (index #14) from the non-steer end of 40 Use a soft metal drift to remove the number 3
the machine. Remove the number 4 outer arm center pivot pin (index #4) at the ground control
(index #13) from the machine. side.
32 Remove the number 4 cable bridge mounting 41 Remove the retaining fasteners from the
fasteners and remove the cable bridge from the number 3 pivot pin (index #17) at the non-steer
machine. end of the machine.
33 Attach a lifting strap from an overhead crane to 42 Use a soft metal drift to tap the number 3 pivot
the number 4 inner arm (index #12). pin (index #17) halfway out at the non-steer end
of the machine. Remove the number 3 outer
34 Remove the retaining fasteners from the
55
arm (index #16) at the ground controls side
number 4 pivot pin (index #3).
from the machine.
35 Use a soft metal drift to remove the number 4
pivot pin (index #3) at the steer end. Remove
the number 4 inner arm (index #12) from the
machine.
(31/10/2012) 55-06-M212EN
43 Attach a lifting strap from an overhead crane to 51 Remove the retaining fasteners from the
the number 3 outer arm (index #16) at the number 3 pivot pin (index #6) at the steer end.
battery pack side.
44 Use a soft metal drift to remove the number 3 pivot pin (index #6). Remove the number 3
center pivot pin (index #4) at the battery pack inner arm (index #15) from the machine.
side of the machine.
45 Use a soft metal drift to tap the number 3 pivot bridge and lay them off to the side.
pin (index #17) in the other direction. Remove
54 Remove the external snap rings and retaining
the number 3 outer arm (index #16) from the
fasteners from the number 2 center pivot pin
battery pack side of the machine.
(index #7) at the ground controls side.
46 Remove the number 3 pivot pin (index #17)
55 Remove the number 2 cable bridge mounting
from the non-steer end of the machine.
fasteners and remove the cable bridge from the
47 Attach a lifting strap from an overhead crane to machine.
the lug on the rod end of the lift cylinder for
56 Attach a lifting strap from an overhead crane to
support. Do not apply any lifting pressure.
the number 2 outer arm (index #19) at the
48 Remove the pin retaining fasteners from the lift ground controls side.
cylinder rod-end pivot pin (index #5). Use a soft 57 Use a soft metal drift to remove the number 2
metal drift to remove the pin. center pivot pin (index #7) at the ground
49 Lower the cylinder onto the number 1 inner arm controls side.
(index #9).
55
50 Attach a lifting strap from an overhead crane to number 2 pivot pin (index #20) at the non-steer
the number 3 inner arm (index #15). end of the machine.
55-06-M212EN (31/10/2012)
59 Use a soft metal drift to tap the number 2 pivot 64 Remove the number 3 pivot pin (index #17)
pin (index #20) halfway out at the non-steer end from the non-steer end of the machine.
of the machine. Remove the number 2 outer
arm (index #19) from the ground controls side
the number 2 inner arm (index #18).
of the machine.
number 2 pivot pin (index #8) at the steer end
the number 2 outer arm (index #19) at the
of the machine.
battery pack side.
pivot pin (index #8). Remove the number 2
fasteners from the number 2 center pivot pin
inner arm (index #18) from the machine.
(index #7) at the battery pack side.
62 Use a soft metal drift to remove the number 2 68 Remove the safety arm from the number 2 inner
center pivot pin (index #7) at the battery pack arm (index #18) that was just removed.
side. 69 Attach a lifting strap from an overhead crane to
the number 1 inner arm (index #10).
63 Use a soft metal drift to tap the number 2 pivot
pin at the non-steer end (index #20) in the other 70 Raise the number 1 inner arm (index #10)
direction. Remove the number 2 outer arm approximately 2 feet / 60 cm and install the
(index #19) from the battery pack side of the safety arm between the number 1 inner arm
machine. (index #10) and the number 1 outer arm (index
#22) at the non-steer end of the machine.
Lower the scissor arms onto the safety arm.
55
the lug on the rod end of the lift cylinder
(index #5). Raise the lift cylinder approximately
3 ft / 1 m.
(31/10/2012) 55-06-M212EN
72 Tag, disconnect and plug the hydraulic hoses 77 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m
on the lift cylinder. Cap the fittings on the long block across both sides of the chassis
cylinder. under the number 1 center pivot pin
(index #11).
73 Tag and disconnect the wires and manual
lowering cable from the solenoid valve on the 78 Attach a lifting strap from an overhead crane to
cylinder. the number 1 inner arm (index #10) at the non-
steer end. Raise the number 1 inner arm and
74 Tag and disconnect the wire harness from the remove the safety arm. Lower the number 1
platform overload pressure transducer. inner arm (index #10) onto the block that was
placed across the chassis.
Note: After replacing the scissor assembly, the 79 Remove the cables from the number 1 cable
platform overload system must be calibrated. bridge and lay them off to the side.
Refer to Repair Procedure, How to Calibrate
the Platform Overload System . 80 Support and secure the entry ladder to an
75 Raise the lift cylinder to a vertical position.
81 Remove the fasteners from the entry ladder and
76 Remove the pin retaining fasteners from the lift remove the entry ladder from the machine.
cylinder barrel-end pin (index #21). Use a soft
metal drift to remove the pin. Remove the lift 82 Attach a lifting strap from an overhead crane to
cylinder from the machine. the number 1 outer arm (index #22). Do not
apply any lifting pressure.
fasteners from the number 1 center pivot pins
55
(index #11).
55-06-M212EN (31/10/2012)
84 Remove the number 1 cable bridge from the How to Replace the Scissor Arm
machine.
Wear Pads
center pivot pins (index #9). Note: Machines equipped with a Platform Height
Sensor, begin at step 1. Machines without a
86 Slide the number 1 outer arm (index #22) to the Platform Height Sensor, begin at step 24.
non-steer end and remove it from the machine.
1 Turn the key switch to ground control and pull
87 Attach the strap from an overhead crane to the out the red Emergency Stop button to the on
number 1 inner arm (index #10). Do not lift it. position at both the ground and platform
controls.
88 Remove the upper fasteners securing the
number 1 inner arm pivot bracket to the end of 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
the chassis. Loosen the lower fasteners.
3 Lift the safety arm, move it to the center of the
89 Remove the number 1 inner arm (index #10) scissor arm and rotate down to a vertical
from the machine. position.
4 Lower the platform onto the safety arm.
5 At the ground control, turn the key switch to the

55
height sensor cover to the large platform height
sensor bracket.
8 Remove the platform height sensor cover.
(31/10/2012) 55-06-M212EN
9 Tag and disconnect the platform height sensor 20 Pull out the red Emergency Stop button to the
from the platform height sensor harness. on position at the ground controls.
10 Remove the fastener securing the platform 21 Using the ground control menu buttons,
height sensor assembly to the number 1 inner navigate to Service Override Mode. Select
arm. Service Override Mode.
11 Remove the platform height sensor assembly Note: The machine must be in Service Override
from the number 1 pivot pin. Mode to raise the platform. While in Service
connector to the large platform height sensor
bracket.
13 Remove the squeeze connector from the large 22 Raise the platform and return the safety arm to
platform height sensor bracket. the stowed position.
23 Fully lower the platform to the stowed position.
platform height sensor bracket to the number 1 24 Remove the platform. See, How to
inner arm pivot bracket. Remove the Platform.
15 Remove the large platform height sensor 25 Support and secure the entry ladder to an
bracket from the number 1 inner arm pivot appropriate lifting device.
bracket.
16 Install the fasteners removed in 14 to the remove the entry ladder from the machine.
55
27 Secure the ends of the scissor arms together at

17 Connect the battery pack to the machine. the steer end of the machine with a strap or
18 Turn the key switch to the ground control other suitable device.
position. 28 Secure the ends of the scissor arms together at
19 Press and hold the ground control scroll up and the non-steer end of the machine with a strap or
scroll down buttons. other suitable device.
17 Connect the battery pack to the machine. 29 Remove the retaining fasteners securing the
chassis mount bracket to the chassis at the
18 Turn the key switch to the ground control steer end of the machine.
position.
55-06-M212EN (31/10/2012)

the scissor arm assembly.
31 Raise the scissor arm assembly at the steer
end with the overhead crane until the chassis
mount bracket will clear the level sensor.
32 Remove the scissor assembly from the
machine just enough to access both wear pads.
33 Remove both old wear pads.
34 Install two new wear pads.
35 Slide the scissor assembly back into the drive
chassis.
36 Lower the scissor assembly into position and
install the chassis mount bracket onto the
chassis. Securely install and tighten the
fasteners. Do not over tighten.
55
(31/10/2012) 55-06-M212EN
12
2
13
3 14
4 15
5 16
6 17
18
7
19
8 20
9 21
10 22
11
100 SEC 2
55
)5217 5($5
5 Lift cylinder rod end pivot pin 16 Number 3 outer arm
8 Number 2 pivot pin (steer end) 19 Number 2 outer arm
9 Number 1 center pivot pin (2 pins) 20 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 21 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin 22 Number 1 outer arm
55-06-M212EN (31/10/2012)
Scissor Assembly, 4 Lower the platform onto the safety arm.
100 SEC 2 5 At the ground control, turn the key switch to the
Scissor Assembly,
100 SEC 2 7 Remove the fasteners securing the platform
When removing a hose assembly or fitting, the sensor bracket.
O-ring on the fitting and/or hose end must be
installation. 9 Tag and disconnect the platform height sensor
from the platform height sensor harness.
out the red Emergency Stop button to the on 10 Remove the fastener securing the platform
position at both the ground and platform height sensor assembly to the number 1 inner
controls. arm.
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 11 Remove the platform height sensor assembly
scissor arm and rotate down to a vertical 12 Remove the plastic nut securing the squeeze
position. connector to the large platform height sensor
bracket.
55
bracket.
(31/10/2012) 55-06-M212EN

position.
Mode to raise the platform. While in Service 100 SEC 2
limited functionality. The platform will raise a Cable bridge and platform height sensor
predetermined amount of time and stop. legend
22 Raise the platform and return the safety arm to a cable bridge 4
the stowed position. b cable bridge 3A
c cable bridge 3B
55
23 Fully lower the platform to the stowed position. d cable bridge 2A

e cable bridge 2B
f cable bridge 1
g platform height sensor
24 Remove the platform. See, How to

Remove the Platform.
25 Support and secure the entry ladder to an
remove the entry ladder from the machine.
55-06-M212EN (31/10/2012)
28 Disconnect the number 4 cable bridge from the 37 Remove the retaining fasteners from the
number 4 outer arm (index #13) and remove number 4 center pivot pin (index #2) at the
the cable bridge from the machine. battery side.
29 Remove the retaining fasteners from the 38 Place a rod through the number 4 center pivot
number 5 pivot pin (index #1). pin at the battery side (index #2) and twist to
remove the pin.
pivot pin (index #1). Remove the platform 39 Remove the number 4 outer arm (index #13)
mount bracket from the machine. from the machine.
31 Attach a lifting strap from an overhead crane to 40 Attach a lifting strap from an overhead crane to
the number 4 outer arm at the ground control the number 4 inner arm (index #12). Raise the
side (index #13). arm to a vertical position.
32 Remove the retaining fasteners from the 41 Remove the retaining fasteners from the
number 4 center pivot pin (index #2) at the number 4 pivot pin at the steer end of the
ground control side. machine (index #3).
33 Place a rod through the number 4 center pivot 42 Use a soft metal drift to remove the number 4
pin at the ground control side (index #2) and pivot pin (index #3) from the steer end of the
twist to remove the pin. machine. Remove the number 4 inner arm
(index #12) from the machine.
number 4 pivot pin (index #15) at the non-steer 43 Remove the cables from the number 3A and 3B
end. cable bridge and lay them off to the side.
55
pivot pin (index #14) from the non-steer end of
the machine. Remove the number 4 outer arm
at the ground control side (index #13) from the
machine.
the number 4 outer arm at the battery side
(index #13).
(31/10/2012) 55-06-M212EN
44 Disconnect the number 3A and 3B cable 52 Place a rod through the number 3 center pivot
bridges from the scissor linkset and remove pin at the battery side (index #4) and twist to
both cable bridges from the machine. remove the pin.
45 Attach a lifting strap from an overhead crane to 53 Remove the number 3 outer arm (index #16)
the number 3 outer arm at the ground control from the machine.
side (index #16).
46 Remove the retaining fasteners from the the lug of the rod end of the lift cylinder.
number 3 center pivot pin (index #4) at the
ground control side. 55 Remove the retaining fasteners from the lift
cylinder rod end pivot pin (index #5).
47 Place a rod through the number 3 center pivot
pin at the ground control side (index #4) and 56 Use a soft metal drift to remove the lift cylinder
twist to remove the pin. rod end pivot pin (index #5) from the machine.
48 Remove the retaining fasteners from the 57 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block

number 3 pivot pin (index #17) at the non-steer onto the number 1 inner arm cylinder plate
end. (index #10).
49 Use a soft metal drift to remove the number 3 58 Lower the cylinder onto the block.
the number 3 inner arm (index #15). Raise the
arm to a vertical position.
machine.
55

(index #16).
battery side.
55-06-M212EN (31/10/2012)
60 Remove the retaining fasteners from the 68 Use a soft metal drift to remove the number 2
number 3 pivot pin at the steer end of the pivot pin (index #20) from the non-steer end of
machine (index #6). the machine. Remove the number 2 outer arm
machine.
pivot pin (index #6) from the steer end of the
machine. Remove the number 3 inner arm 69 Attach a lifting strap from an overhead crane to
(index #15) from the machine. the number 2 outer arm at the battery side
(index #19).
62 Remove the cables from the number 2A and 2B
cable bridge and lay them off to the side. 70 Remove the retaining fasteners from the
63 Disconnect the number 2A and 2B cable number 2 center pivot pin (index #7) at the
bridges from the scissor linkset and remove battery side.
both cable bridges from the machine. 71 Place a rod through the number 2 center pivot
64 Attach a lifting strap from an overhead crane to pin at the battery side (index #7) and twist to
the number 2 outer arm at the ground control remove the pin.
side (index #19). 72 Remove the number 2 outer arm (index #19)
65 Remove the retaining fasteners from the from the machine.
ground control side.
pin at the ground control side (index #7) and
twist to remove the pin.
55
number 2 pivot pin (index #20) at the non-steer
end.
(31/10/2012) 55-06-M212EN
73 Attach a lifting strap from an overhead crane to 81 Tag, disconnect and plug the hydraulic hose on
the number 2 inner arm (index #18). Raise the the lower lift cylinder. Cap the fittings on the
arm to a vertical position. cylinder.
74 Remove the retaining fasteners from the 82 Tag and disconnect the wire harness from the
number 2 pivot pin at the steer end of the solenoid valve on the cylinder.
machine (index #8).
83 Tag and disconnect the wires and manual
75 Use a soft metal drift to remove the number 2 lowering cable from the solenoid valve on the
pivot pin (index #8) from the steer end of the cylinder.
machine. Remove the number 2 inner arm
(index #18) from the machine. 84 Tag and diconnect the wire harness from the
platform overload pressure transducer.
the number 1 inner arm (index #10). Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
77 Raise the number 1 inner arm (index #10) Refer to Repair Procedure, How to Calibrate
approximately 2 feet / 60 cm. the Platform Overload System .
78 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 m 85 Raise the lift cylinder to a vertical position.
long block across both sides of the chassis
under the number 1 center pivot pin (index #9). 86 Remove the pin retaining fasteners from the lift
cylinder barrel-end pivot pin (index #21). Use a
79 Lower the scissor arms onto the block that was soft metal drift to remove the pin. Remove the
placed across the chassis. lift cylinder from the machine.
55
the lug of the rod end of the lower lift cylinder.
55-06-M212EN (31/10/2012)
87 Remove the cables from the number 1 cable How to Replace the Scissor Arm
Wear Pads
88 Disconnect the number 1 cable bridge from the
number 1 outer arm (index #22) and remove Note: Machines equipped with a Platform Height
the cable bridge from the machine. Sensor, begin at step 1. Machines without a
Platform Height Sensor, begin at step 24.
the number 1 inner arm (index #10). 1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
90 Raise the arm slightly and remove the block. position at both the ground and platform
91 Lower the arm to the stowed position. controls.
the steer end of the machine with a strap or 3 Lift the safety arm, move it to the center of the
other suitable device. scissor arm and rotate down to a vertical
position.
the non-steer end of the machine with a strap or 4 Lower the platform onto the safety arm.
other suitable device.
94 Remove the retaining fasteners securing the off position and push in the red Emergency
chassis mount bracket to the chassis. Stop button to the off position.
95 Remove the linkset from the machine 6 Disconnect the battery pack from the machine.
55
sensor bracket.
(31/10/2012) 55-06-M212EN
9 Tag and disconnect the platform height sensor 20 Pull out the red Emergency Stop button to the
from the platform height sensor harness. on position at the ground controls.
10 Remove the fastener securing the platform 21 Using the ground control menu buttons,
height sensor assembly to the number 1 inner navigate to Service Override Mode. Select
arm. Service Override Mode.
11 Remove the platform height sensor assembly Note: The machine must be in Service Override
from the number 1 pivot pin. Mode to raise the platform. While in Service
bracket.
13 Remove the squeeze connector from the large 22 Raise the platform and return the safety arm to
platform height sensor bracket. the stowed position.
platform height sensor bracket to the number 1 24 Remove the platform. See, How to
inner arm pivot bracket. Remove the Platform.
15 Remove the large platform height sensor 25 Support and secure the entry ladder to an
bracket from the number 1 inner arm pivot appropriate lifting device.
bracket.
16 Install the fasteners removed in 14 to the remove the entry ladder from the machine.
55

17 Connect the battery pack to the machine. the steer end of the machine with a strap or
18 Turn the key switch to the ground control other suitable device.
position. 28 Secure the ends of the scissor arms together at
19 Press and hold the ground control scroll up and the non-steer end of the machine with a strap or
scroll down buttons. other suitable device.
17 Connect the battery pack to the machine. 29 Remove the retaining fasteners securing the
18 Turn the key switch to the ground control steer end of the machine.
position.
55-06-M212EN (31/10/2012)

chassis.
55
(31/10/2012) 55-06-M212EN
2 16
3 17
4 18
19
5
20
6
21
7
8 22
9 23
10 24
25
11
26
12 27
13 28
55
14 29
15
120 SE 2
FRONT REAR
3 Upper lift cylinder rod-end pivot pin 18 Number 5 pivot pin (non-steer end)
4 Number 5 pivot pin (steer end) 19 Number 4 inner arm
7 Number 3 outer arm 22 Upper lift cylinder barrel-end pivot pin
9 Lower lift cylinder rod-end pivot pin 24 Number 3 pivot pin (non-steer end)
10 Number 3 pivot pin (steer end) 25 Number 2 inner arm
13 Number 1 center pivot pin (2 pins) 28 Lower lift cylinder barrel-end pivot pin
14 Number 1 inner arm 29 Number 1 outer arm
15 Number 1 pivot pin (steer end) (2 pins)
55-06-M212EN (31/10/2012)
Scissor Assembly, 3 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
6( position.
Scissor Assembly, 5 At the ground control, turn the key switch to the
6( Stop button to the off position.
When removing a hose assembly or fitting, the 6 Disconnect the battery pack from the machine.
installation.
sensor bracket.
out the red Emergency Stop button to the on 9 Tag and disconnect the platform height sensor
position at both the ground and platform from the platform height sensor harness.
controls.
10 Remove the fastener securing the platform
2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. height sensor assembly to the number 1 inner
arm.
11 Remove the platform height sensor assembly
55
bracket.
(31/10/2012) 55-06-M212EN

bracket.
position.
navigate to Service Override Mode. Select 120 SE 2
Note: The machine must be in Service Override Cable bridge and platform height sensor
Mode to raise the platform. While in Service
55
legend
a cable bridge 5
b cable bridge 4A
predetermined amount of time and stop. c cable bridge 4B
d cable bridge 3A
22 Raise the platform and return the safety arm to e cable bridge 3B
the stowed position. f cable bridge 2A
g cable bridge 2B
23 Fully lower the platform to the stowed position. h cable bridge 1
i platform height sensor
24 Remove the platform. See, How to

Remove the Platform.
55-06-M212EN (31/10/2012)
26 Remove the fasteners from the entry ladder and 35 Use a soft metal drift to remove the number 5
remove the entry ladder from the machine. pivot pin (index #18) from the non-steer end of
27 Remove the cables from the number 5 cable at the ground control side (index #17) from the
bridge and lay them off to the side. machine.
28 Disconnect the number 5 cable bridge from the
number 5 outer arm (index #17) and remove
the cable bridge from the machine.
(index #17).
number 6 pivot pin (index #1).
30 Use a soft metal drift to remove the number 6 battery side.
pivot pin (index #1). Remove the platform
mount bracket from the machine.
pin at the battery side (index #2) and twist to
31 Attach a lifting strap from an overhead crane to remove the pin.
the number 5 outer arm at the ground control
39 Remove the number 5 outer arm (index #17)
side (index #17).
from the machine.
arm to a vertical position.
pin at the ground control side (index #2) and
55
end.
(31/10/2012) 55-06-M212EN
41 Remove the retaining fasteners from the 47 Attach a lifting strap from an overhead crane to
number 5 pivot pin at the steer end of the the lug of the rod end of the upper lift cylinder.
machine (index #4).
48 Remove the retaining fasteners from the upper
42 Use a soft metal drift to remove the number 5 lift cylinder rod end pivot pin (index #3).
49 Use a soft metal drift to remove the upper lift
cylinder rod end pivot pin (index #3) from the
machine.
43 Tag, disconnect and plug the hydraulic hose on
the upper lift cylinder. Cap the fittings on the 50 Lower the cylinder onto the linkset.
cylinder. 51 Attach a lifting strap from an overhead crane to
the number 4 outer arm at the ground control
44 Tag and disconnect the wire harness from the
side (index #20).
solenoid valve on the cylinder.
45 Remove the cables from the number 4A and 4B
cable bridges and lay them off to the side.
46 Disconnect the number 4A and 4B cable
bridges from the scissor linkset and remove 53 Place a rod through the number 4 center pivot
both cable bridges from the machine. pin at the ground control side (index #5) and
end.
55

machine.
55-06-M212EN (31/10/2012)
56 Attach a lifting strap from an overhead crane to 63 Remove the cables from the number 3A and 3B
the number 4 outer arm at the battery side cable bridges and lay them off to the side.
(index #20).
57 Remove the retaining fasteners from the bridges from the scissor linkset and remove
number 4 center pivot pin (index #5) at the both cable bridges from the machine.
battery side.
58 Place a rod through the number 4 center pivot the number 3 outer arm at the ground control
pin at the battery side (index #5) and twist to side (index #7).
remove the pin.
59 Remove the number 4 outer arm (index #20) number 3 center pivot pin (index #8) at the
from the machine. ground control side.
60 Attach a lifting strap from an overhead crane to 67 Place a rod through the number 3 center pivot
the number 4 inner arm (index #19). Raise the pin at the ground control side (index #8) and
arm to a vertical position. twist to remove the pin.
number 4 pivot pin at the steer end of the number 3 pivot pin (index #24) at the non-steer
machine (index #6). end.
62 Use a soft metal drift to remove the number 4 69 Use a soft metal drift to remove the number 3
pivot pin (index #6) from the steer end of the pivot pin (index #24) from the non-steer end of
machine. Remove the number 4 inner arm the machine. Remove the number 3 outer arm
(index #19) from the machine. at the ground control side (index #7) from the
55
machine.
(31/10/2012) 55-06-M212EN
70 Attach a lifting strap from an overhead crane to 77 Attach a lifting strap from an overhead crane to
the number 3 outer arm at the battery side the lug of the rod end of the lower lift cylinder.
(index #7).
78 Remove the retaining fasteners from the lower
71 Remove the retaining fasteners from the lift cylinder rod end pivot pin (index #9).
79 Use a soft metal drift to remove the lower lift
battery side.
cylinder rod end pivot pin (index #9) from the
72 Place a rod through the number 3 center pivot machine.
pin at the battery side (index #8) and twist to
80 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block
remove the pin.
onto the number 1 inner arm cylinder plate
73 Remove the number 3 outer arm (index #7) (index #14).
from the machine.
81 Lower the cylinder onto the block.
the lug of the rod end of the upper lift cylinder.
75 Raise the lift cylinder to a vertical position. arm to a vertical position.
76 Remove the pin retaining fasteners from the lift 83 Remove the retaining fasteners from the
cylinder barrel-end pivot pin (index #22). number 3 pivot pin at the steer end of the
Remove the lift cylinder from the machine. machine (index #10).
55
55-06-M212EN (31/10/2012)
85 Remove the cables from the number 2A and 2B 92 Attach a lifting strap from an overhead crane to
cable bridges and lay them off to the side. the number 2 outer arm at the battery side
(index #26).
bridges from the scissor linkset and remove 93 Remove the retaining fasteners from the
both cable bridges from the machine. number 2 center pivot pin (index #11) at the
battery side.
the number 2 outer arm at the ground control 94 Place a rod through the number 2 center pivot
side (index #26). pin at the battery side (index #11) and twist to
remove the pin.
number 2 center pivot pin (index #11) at the 95 Remove the number 2 outer arm (index #26)
ground control side. from the machine.
89 Place a rod through the number 2 center pivot 96 Attach a lifting strap from an overhead crane to
pin at the ground control side (index #11) and the number 2 inner arm (index #25). Raise the
twist to remove the pin. arm to a vertical position.
number 2 pivot pin (index #27) at the non-steer number 2 pivot pin at the steer end of the
end. machine (index #12).
55
machine.
(31/10/2012) 55-06-M212EN
98 Use a soft metal drift to remove the number 2 105 Tag and disconnect the wire harness from the
pivot pin (index #12) from the steer end of the solenoid valve on the cylinder.
106 TagDQGGLVFRQQHFWWKHZLUHKDUQHVVIURPWKH
SODWIRUPRYHUORDGSUHVVXUHWUDQVGXFHU
the number 1 inner arm (index #14). Note: After replacing the scissor assembly, the
platform overload system must be calibrated.
100 Raise the number 1 inner arm (index #14) Refer to Repair Procedure, How to Calibrate
approximately 2 feet / 60 cm. the Platform Overload System .
101 Place a 4 x 4 x 48 inch / 10 cm x 10 cm x 1.2 107 Raise the lift cylinder to a vertical position.
m long block across both sides of the
chassis under the number 1 center pivot 108 Remove the pin retaining fasteners from the
pin (index #13). lift cylinder barrel-end pivot pin (index #28).
Use a soft metal drift to remove the pin.
102 Lower the scissor arms onto the block that Remove the lift cylinder from the machine.
was placed across the chassis.
103 Attach a lifting strap from an overhead crane bridge and lay them off to the side.
to the lug of the rod end of the lower lift
cylinder. 110 Disconnect the number 1 cable bridge from
the number 1 outer arm (index #29) and
104 Tag, disconnect and plug the hydraulic hose remove the cable bridge from the machine.
on the lower lift cylinder. Cap the fittings on
the cylinder. 111 Attach a lifting strap from an overhead crane
to the number 1 inner arm (index #14).
55
112 Raise the arm slightly and remove the block.
55-06-M212EN (31/10/2012)
113 Lower the arm to the stowed position. How to Replace the Scissor Arm
114 Secure the ends of the scissor arms together Wear Pads
at the steer end of the machine with a strap or
other suitable device. Note: Machines equipped with a Platform Height
Sensor, begin at step 1. Machines without a
115 Secure the ends of the scissor arms together Platform Height Sensor, begin at step 24.
at the non-steer end of the machine with a
strap or other suitable device. 1 Turn the key switch to ground control and pull
116 Remove the retaining fasteners securing the position at both the ground and platform
chassis mount bracket to the chassis. controls.
117 Remove the linkset from the machine. 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
position.
55
sensor bracket.
. 8 Remove the platform height sensor cover.
(31/10/2012) 55-06-M212EN
9 Tag and disconnect the platform height sensor 19 Press and hold the ground control scroll up and
from the platform height sensor harness. scroll down buttons.
10 Remove the fastener securing the platform 20 Pull out the red Emergency Stop button to the
height sensor assembly to the number 1 inner on position at the ground controls.
arm.
11 Remove the platform height sensor assembly navigate to Service Override Mode. Select
from the number 1 pivot pin. Service Override Mode.
12 Remove the plastic nut securing the squeeze Note: The machine must be in Service Override
connector to the large platform height sensor Mode to raise the platform. While in Service
bracket. Override Mode, only the GCON will operate with
22 Raise the platform and return the safety arm to
inner arm pivot bracket. 23 Fully lower the platform to the stowed position.
15 Remove the large platform height sensor 24 Remove the platform. See, How to
bracket from the number 1 inner arm pivot Remove the Platform.
bracket.
16 Install the fasteners removed in 14 to the appropriate lifting device.
55

17 Connect the battery pack to the machine. remove the entry ladder from the machine.
18 Turn the key switch to the ground control 27 Secure the ends of the scissor arms together at
position. the steer end of the machine with a strap or
17 Connect the battery pack to the machine. the non-steer end of the machine with a strap or
position.
55-06-M212EN (31/10/2012)
29 Remove the retaining fasteners securing the

steer end of the machine.
chassis.
55
(31/10/2012) 55-06-M212EN
Manual Platform Lowering Cable Skip to step 8 if the measurement is correct.

6 To adjust, loosen the upper lock nut on the
The manual platform lowering cable lowers the cable mounting bracket at the cylinder. Turn the
platform in the event of a main power failure. The lower lock nut clockwise to decrease the
manual platform lowering cable is attached to the distance or counterclockwise to increase the
barrel end of the lift cylinder and is activated next distance. Tighten the upper lock nut.
to the ground controls.
How to Adjust the Manual a
Platform Lowering Cable

b
c
position.
d
4 Pull the handle of the manual platform lowering
e
cable out until considerable resistance is felt.
Release the handle.
5 Measure the distance between the base of the f
handle and cable mounting nut.
55
Result: The measurement should be no greater

than 1/8 inch / 3 mm. Y7 N g
a manual lowering cable sheath

b upper lock nut
c cable mounting bracket
d lower lock nut
e cable mounting nut
f end of the lowering cable
g manual lowering valve
(hydraulic schematic item N)
7 Repeat this procedure beginning with step 4.

8 Raise the platform and rotate the safety arm to
Platform manual lowering cable specification 9 Pull the manual lowering handle at the ground
controls 2 to 3 times to ensure it is functioning
Gap, lowering handle to mounting nut 0 to 1/8 inch
0 to 3 mm
correctly.
55-06-M212EN (31/10/2012)
HYDRAULIC
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC CONTROL AND ADJUSTMENT
- HYDRAULIC COMPONENTS REMOVAL
70
HYDRAULIC SCHEMATIC DIAGRAMS
pages
HYDRAULIC SCHEMATICS
– 78 SEC 2 (FROM SERIAL NUMBER 910662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– 100 SEC 2 (FROM SERIAL NUMBER 917098) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– 120 SE 2 (FROM SERIAL NUMBER 915526) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70
(31/10/2012) 70-02-M212EN
2 HYDRAULIC SCHEMATIC DIAGRAMS
78 SEC 2 (from serial number 910662)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
LEFT RIGHT
LIFT CYLINDER
A (ALL MODELS)
BRAKE RELEASE BRAKE
A
PRESSURE
370 to 450 psi
MANUAL
26 to 31 bar M
PLATFORM 0.037 inch
N RELEASE
OVERLOAD 0.94 mm HAND

(CE&AUS MODELS) Y7 PUMP
BRAKE
C O RELEASE
C
0.037 inch MANIFOLD L
0.94 mm RIGHT
R B1 LEFT
DRIVE DRIVE
THE ORIFICE IS LOCATED MOTOR
UNDERNEATH THE STEER STEER P MOTOR
HOSE FITTING ON THE LEFT RIGHT 4.75 CU. IN.
LIFT CYLINDER 78 cc
FORWARD
REVERSE
E E
L V S1 S2 HP B AC M1 M4
Y4 Y3
G G
0.25 gpm
0.95 L/min Y6 Y5
D E
10 psi
1500 psi
I 103 bar
0.7 bar I
A 0.75 gpm
H 2.8 L/min
TP G
70
Y8
K C FUNCTION MANIFOLD K
0.25 gpm @ 1800 to 3700 psi
0.95 L/min @ 124 to 255 bar
I
0.25 gpm @ 3700 psi
0.95 L/min @ 255 bar
P T
200 psi
13.8 bar
M S M
10 MICRON WITH
M 25 psi / 1.7 bar
4 gpm @ 2500 psi BYPASS
POWER UNIT 15 L/min @ 172 bar
HYDRAULIC TANK
O ABBREVIATION LEGEND
O
Item Description Location
A Test port 3I
B Check valve, steer circuit 12G
C Relief valve, lift 9K
D Check valve, brake circuit 16I
E Drive forward/reverse 19I
F Steer left/right 10G
Q Q
G Flow regulator/relief valve 13I
H Platform up 6I
I Relief valve, system 6K
L Hand pump, manual brake release 15C
M Needle valve, manual brake release 13A
N Platform lowering valve 9A
O Orifice, platform down circuit 8C
S P Accumulator 15C S
R Pressure transducer 4C
S Check valve, drive circuit 11M
70-02-M212EN (31/10/2012)
HYDRAULIC SCHEMATIC DIAGRAMS 3

120 SE 2 (from serial number 915526)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
BRAKE RELEASE LEFT RIGHT

PLATFORM LIFTCYLINDER PRESSURE
A OVERLOAD (ALLMODELS) 370 to 450 psi BRAKE
A
(CE&AUS MODELS) 26 to 31 bar
M MANUAL
RELEASE
0.037 inch N
0.94 mm HAND
Y7 PUMP
R
C O BRAKE C
THE ORIFICE IS LOCATED 0.059 inch RELEASE
UNDERNEATH THE HOSE 1.5 mm MANIFOLD L
FITTING ON THE LIFT CYLINDER B1
STEER STEER P LEFT RIGHT
LEFT RIGHT 4.75 CU. IN. DRIVE DRIVE
78 cc MOTOR MOTOR
UPPER LIFTCYLINDER
(120 SE 2)
FORWARD
REVERSE
E Y9 E
N
V S1 S2 HP B AC M1 M3 M2 M4
O
0.037 inch
0.94 mm
AC
Q Y4 Y3
2500 psi maximum AE
G 172 bar maximum G
Y1
THE ORIFICE IS LOCATED UNDERNEATH THE PLUG
OPPOSITE THE HOSE INLET OF THE LIFT CYLINDER
AD
L
0.25 gpm Y6 Y5
0.95 L/min
AG
I 1500 psi
103 bar
I
AI
AA 0.75 gpm
2.8 L/min AF
TP AH 50 psi
3.4 bar
70
K Y8 AJ FUNCTION MANIFOLD K
0.25 gpm @ 1800 to 3700 psi
0.95 L/min @ 124 to 255 bar
AB
0.25 gpm @ 3700 psi
0.95 L/min @ 255 bar
P T
AK
M M
M
ABBREVIATION LEGEND
POWER UNIT
4 gpm @ 2500 psi 10 MICRON WITH Item Description Location
15 L/min @ 172 bar 25 psi / 1.7 bar
BYPASS AA Test port 4I
AB Relief valve, system 6K
AC Steer left/right 11G
O HYDRAULIC TANK AD Check valve, lift (120 SE 2 equipped 12G
O
with load sense only)
AE Check valve, steer circuit 19G
AF Drive speed 16I
AG Relief valve, brake release 19I
AH Drive forward/reverse 13I
AI Flow regulator/relief valve 7I
Q AJ Platform up 9K Q
AK Relief valve, lift 4M
L Hand pump, manual brake release 15C
M Needle valve, manual brake release 13A
N Platform lowering valve 9A/4E
O Orifice, platform down circuit 8C/6E
P Accumulator 15C
S Q Relief valve, platform down 4G S

R Pressure switch, platform overload 4C
(31/10/2012) 70-02-M212EN
4 HYDRAULIC SCHEMATIC DIAGRAMS
70
70-02-M212EN (31/10/2012)
HYDRAULIC CONTROL AND ADJUSTMENT
pages
HYDRAULIC PUMP
– FUNCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MANIFOLDS
– FUNCTION MANIFOLD COMPONENTS -78 SEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– FUNCTION MANIFOLD COMPONENTS- 100 SEC AND 120 SE. . . . . . . . . . . . . . . . . . . . . . 6
– CHECK VALVE MANIFOLD COMPONENTS - 78 SEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– VALVE ADJUSTMENTS - FUNCTION MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
70
(31/10/2012) 70-04-M212EN
2 HYDRAULIC CONTROL AND ADJUSTMENT
70
70-04-M212EN (31/10/2012)
HYDRAULIC CONTROL AND ADJUSTMENT 3
Function Pump 4 Activate the platform up function from the

ground controls.
The hydraulic pump is attached to the motor which Result: If the pressure gauge reads
makes up the hydraulic power unit. 3200 psi / 221 bar, immediately stop. The pump
is good.
How to Test the Hydraulic Pump
Result: If pressure fails to reach
When removing a hose assembly or fitting, the 3200 psi / 221 bar, the pump is bad and will
fitting and/or hose end must be torqued to need to be serviced or replaced.
specification during installation. 5 Remove the pressure gauge and reconnect the
1 Tag, disconnect and plug the high pressure hydraulic hose. Torque to specification.
hydraulic hose from the hydraulic pump.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the pump.
controls.

gauge to the high pressure port on the pump.
controls.
70
(31/10/2012) 70-04-M212EN
Function Manifold Components -

6(&
The function manifold is mounted under the machine, between the module trays.
Index Schematic
— Coil nut (item F) .................................................................................................................... 4-5 ft-lbs / 5-7 Nm
— Coil nut (items E and H) ....................................................................................................... 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... A ......................... Testing
2 Check disc ................................................. B ......................... Steer circuit ............................ 18 ft-lbs / 24 Nm
3 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. C ......................... Lift relief .................................. 20 ft-lbs / 27 Nm
4 Check valve, 10 psi / 0.7 bar ..................... D ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm
5 Solenoid valve, 3 position 4 way ............... E ......................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
6 Solenoid valve, 3 position 4 way ............... F ......................... Steer left/right ......................... 25 ft-lbs / 34 Nm
7 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar ...................................... G ......................... Steer circuit ............................ 26 ft-lbs / 35 Nm
8 Solenoid valve, 2 position 4 way ............... H ......................... Platform up ............................. 25 ft-lbs / 34 Nm
9 Relief valve,
3700 psi / 255 bar maximum ..................... I .......................... System relief ........................... 20 ft-lbs / 27 Nm
70
How to Install a Valve Cartridge

1 Dip the cartridge in clean oil to lube the O-rings.
2 Screw the cartridge in by hand until the top
O-ring is met, then torque to specification.
3 If required, install the valve coil(s) onto the
valve stem. Install the coil nut onto the valve
stem and torque to specification.
70-04-M212EN (31/10/2012)
70
(31/10/2012) 70-04-M212EN
Function Manifold Components -

6(&6(
The function manifold is mounted behind an inspection door on the ground control side of the machine.
Index Schematic
— Coil nut (item AC) ................................................................................................................. 4-5 ft-lbs / 5-7 Nm
— Coil nut (items AE, AG and AI) ............................................................................................. 5-7 ft-lbs / 7-9 Nm
1 Diagnostic nipple ....................................... AA ...................... Testing
2 Relief valve,
3700 psi / 255 bar maximum ..................... AB ...................... System relief ........................... 20 ft-lbs / 27 Nm
3 Solenoid valve, 3 position 4 way ............... AC ...................... Steer left/right ......................... 25 ft-lbs / 34 Nm
4 Check valve (6(&
with load sense installed) .......................... AD ...................... Lift ........................................... 23 ft-lbs / 31 Nm
5 Check disc ................................................. AE ...................... Steer circuit ............................ 18 ft-lbs / 24 Nm
6 Solenoid valve, 2 position 4 way ............... AF ....................... Drive speed select circuit ....... 25 ft-lbs / 34 Nm
7 Relief valve ................................................ AG ...................... Brake release ......................... 20 ft-lbs / 27 Nm
8 Solenoid valve, 3 position 5 way ............... AH ...................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm
9 Flow regulator and relief valve,
0.75 gpm / 2.8 L/min,
1500 psi / 103 bar ...................................... AI ........................ Steer circuit ............................ 26 ft-lbs / 35 Nm
10 Solenoid valve, 2 position 4 way ............... AJ ....................... Platform up ............................. 25 ft-lbs / 34 Nm
11 Relief valve,
1800 to 3700 psi / 124 to 255 bar ............. AK ...................... Lift relief .................................. 20 ft-lbs / 27 Nm
70

70-04-M212EN (31/10/2012)
70
(31/10/2012) 70-04-M212EN
Check Valve Manifold Components -

6(&
The check valve manifold is mounted on the function manifold.
Index Schematic
1 Check valve, 200 psi / 13.8 bar ................. S ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm
70

70-04-M212EN (31/10/2012)
Valve Adjustments - 6 Move and hold the joystick fully in either

direction while observing the pressure reading
Function Manifold on the pressure gauge. Note the pressure.
Refer to Section Specifications.
How to Adjust the 7 Turn the machine off. Hold the system relief
System Relief Valve valve with a wrench and remove the cap
(schematic item I, AB or DB).
Perform this test from the ground with the platform
controls. Do not stand in the platform. 8 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
Be sure that the hydraulic oil level is at the FULL decrease the pressure.
mark on the hydraulic tank.
9 Install the relief valve cap.
1 Locate the system relief valve on the function
manifold (schematic item I). 10 Repeat steps 5 and 6 to confirm the relief valve
pressure.
2 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the function a b
manifold (schematic item A, AA or DA).
3 Chock both sides of the wheels at the steer end
of the machine.
4 Remove the platform controls from the platform.
5 Turn the key switch to platform control and pull
controls. d
70
6(&6(
a test port
b system relief valve
c steer relief valve
d lift relief valve
6(&
(31/10/2012) 70-04-M212EN
How to Adjust the 6 Move and hold the joystick fully in either
direction while observing the pressure reading
Platform Lift Relief Valve on the pressure gauge. Note the pressure.
Perform this test from the ground with the platform 7 Turn the machine off. Hold the system relief
controls. Do not stand in the platform. valve with a wrench and remove the cap
(hydraulic schematic item I, AB or DB).
Be sure that the hydraulic oil level is at the FULL
mark on the hydraulic tank. 8 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
1 Locate the system relief valve on the function decrease the pressure.
manifold (item I).
2 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the function 10 Repeat steps 5 and 6 to confirm the relief valve
manifold (schematic item A, AA or DA). pressure.
3 Chock both sides of the wheels at the steer end 11 Place maximum rated load into the platform.
of the machine. Secure the load to the platform.
a b
controls.
d
70
6(&6(
a test port
d lift relief valve
6(&
a test port
c lift relief valve
70-04-M212EN (31/10/2012)

controls.
13 Hold the lift relief valve with a wrench and
remove the cap (schematic item C).
14 While activating the platform up function, adjust
the internal hex socket clockwise, just until the
platform fully raises.
15 Fully lower the platform.
16 Add an additional 50 pounds / 22.7 kg to the
platform. Secure the additional weight.
17 Attempt to raise the platform.
Result: The power unit should not be able to lift
the platform.
Result: If the power unit lifts the platform, adjust
the internal hex socket counterclockwise until
the platform will not raise.
19 Remove the weight from the platform.
20 Bleed the hydraulic system by raising the
platform to full height. If the pump cavitates or
the platform fails to reach full height, add
hydraulic oil until the pump is functioning
70
correctly. Do not overfill the hydraulic tank.
(31/10/2012) 70-04-M212EN
How to Adjust the Steer Relief 5 Activate the function enable switch and press
and hold the steer thumb rocker switch to the
Valve right. Allow the wheels to completely turn to the
Perform this test from the ground with the platform right. Continue holding the switch while
controls. Do not stand in the platform. observing the pressure reading on the pressure
gauge. Note the pressure.
Be sure that the hydraulic oil level is at the FULL
6 Press and hold the steer thumb rocker switch to
mark on the hydraulic tank.
the left. Allow the wheels to completely turn to
1 Locate the steer relief valve on the function the left. Continue holding the switch while
manifold (schematic item G). observing the pressure reading on the pressure
gauge.
gauge to the test port (schematic item A, AA or 7 Turn the machine off. Hold the steer relief valve
DA) on the function manifold. with a wrench and remove the cap (schematic
item G, AH or DH).
8 Adjust the internal hex socket. Turn it clockwise
4 Turn the key switch to platform control and pull to increase the pressure or counterclockwise to
out the red Emergency Stop button to the on decrease the pressure.
controls. 9 Install the relief valve cap.
10 Repeat steps 5 through 6 to confirm the relief
valve pressure.
a b
70
c
6(&
6(&6(
a test port
b steer relief valve a test port
d lift relief valve
70-04-M212EN (31/10/2012)
HYDRAULIC COMPONENTS REMOVAL
pages
SCISSOR COMPONENTS
– LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC PUMP
– FUNCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC TANK
– HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
70
(31/10/2012) 70-06-M212EN
2 HYDRAULIC COMPONENTS REMOVAL
Lift Cylinder
How to Remove the Lift Cylinder

78 SEC 2:

controls.
position.
a lift cylinder
b orifice (schematic item O)
c connector fitting
d hydraulic hose
e pressure transducer (schematic R)
f manual lowering cable
g solenoid valve (schematic item N)
h cable mount bracket

5 Using a suitable lifting device, support the link
70
stack at the steer end of the machine.
70-06-M212EN (31/10/2012)
HYDRAULIC COMPONENTS REMOVAL 3
6 At the ground control, turn the key switch to the 14 Remove the retaining fasteners from the lift
off position and push in the red Emergency cylinder rod-end pivot pin. Use a soft metal drift
Stop button to the off position. to remove the pin.
7 Disconnect the battery pack from the machine. 15 Lower the cylinder onto the number 2 inner arm.
8 Tag and disconnect the wiring from the solenoid 16 Attach a lifting strap from an overhead crane or
valve coil at the barrel end of the lift cylinder. similar lifting device to the barrel end of the lift
cylinder for support.
9 If equipped, tag and disconnect the three-pin
connector from the pressure transducer 17 Remove the retaining fasteners from the lift
harness. To remove the pressure transducer cylinder barrel-end pivot pin. Use a soft metal
refer to Repair Procedure , How to Remove drift to remove the pin.
the Pressure Transducer .
18 Support and secure the lift cylinder to an
10 Loosen the adjustment nuts on the solenoid appropriate lifting device.
valve and disconnect the manual lowering cable
19 Remove the lift cylinder through the scissor
from the valve.
arms at the steer end of the machine.
Note: During assembly, the manual platform
20 Install new cylinder, fittings, hoses and pressure
lowering cable needs to be properly adjusted.
transducer .
See, How to Adjust the Manual Platform
Lowering Cable.
11 Remove the fasteners securing the manual
lowering cable mount bracket to the cylinder.
Remove the bracket from the cylinder.
on the lift cylinder. Cap the fittings on the
cylinder.
70
the rod end of the lift cylinder for support.
(31/10/2012) 70-06-M212EN
Torque specification 100 SEC 2 :

Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
(schematic item N) 27 Nm
Coil nut 5 ft-lbs 1 Turn the key switch to ground control and pull
7 Nm
Pressure transducer 27 ft-lbs position at both the ground and platform
(schematic item R) 37 Nm controls.
21 Remove the lifting device supporting the link 1
3 Turn thesafety
Lift the key switch to ground
arm, move control
it to the and
center ofpull
the
stack at the steer end of the machine. out
scissor arm and rotate down to a vertical on
the red Emergency Stop button to the
position
position.at both the ground and platform
22 Connect the battery pack to the machine. controls.
23 Turn the key switch to the ground control 2 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
position.
24 Press and hold the ground control scroll up and scissor arm and rotate down to a vertical
scroll down buttons. position.
70

Note: Calibrate the Platform Overload System.
Refer to Repair Procedure,
How to Calibrate the Platform Overload System.
70-06-M212EN (31/10/2012)

8 Tag and disconnect the wiring from the solenoid
valve coil at the barrel end of the lift cylinder.
9 If equipped, tag and disconnect the three-pin
connector from the pressure transducer
harness. To remove the pressure transducer
refer to Repair Procedure, How to Remove
the Pressure Transducer .
10 Loosen the adjustment nuts on the solenoid
valve and disconnect the manual lowering cable
from the valve.
Note: During assembly, the manual platform
Lowering Cable.
a lift cylinder
b orifice (schematic item O) 12 Tag, disconnect and plug the hydraulic hoses
c connector fitting
d hydraulic hose on the lift cylinder. Cap the fittings on the
e pressure transducer (schematic R) cylinder.
70
(31/10/2012) 70-06-M212EN
13 Attach a lifting strap from an overhead crane to 20 Install new cylinder, fittings, hoses and pressure
the rod end of the lift cylinder for support. transducer .
14 Remove the retaining fasteners from the lift Torque specification
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. Solenoid valve, 2 position 2 way N.C. 20 ft-lbs
15 Lower the cylinder onto the number 1 inner arm
cylinder plate. Coil nut 5 ft-lbs
7 Nm
16 Attach a lifting strap from an overhead crane or
Pressure transducer 27 ft-lbs
similar lifting device to the barrel end of the lift
(schematic item R) 37 Nm
cylinder for support.
17 Remove the retaining fasteners from the lift
cylinder barrel-end pivot pin. Use a soft metal 21 Remove the lifting device supporting the link
drift to remove the pin. stack at the steer end of the machine.
18 Support and secure the lift cylinder to an 22 Connect the battery pack to the machine.
appropriate lifting device. 23 Turn the key switch to the ground control
19 Remove the lift cylinder through the scissor position.
arms at the steer end of the machine. 24 Press and hold the ground control scroll up and
70

Note: Models with a pressure transducer, calibrate
the Platform Overload System. Refer to Repair
Procedure, How to Calibrate the Platform
Overload System .
70-06-M212EN (31/10/2012)
6(:

controls.
position.
a lift cylinder
b orifice (schematic item O)
c connector fitting
d hydraulic hose
e pressure transducer (schematic R)
70
(31/10/2012) 70-06-M212EN
7 Disconnect the battery pack from the machine. 13 Attach a lifting strap from an overhead crane to
the rod end of the lift cylinder for support.
Note: At the lower lift cylinder, install the orifice
fitting with the small opening of the orifice fitting 14 Remove the retaining fasteners from the lift
closest to the supply hose. cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
8 Tag and disconnect the wiring from the solenoid
valve coil at the barrel end of the lift cylinder. 15 Lower the cylinder to a horizontal position.
Skip to step 13 if removing the upper cylinder. 16 Attach a lifting strap from an overhead crane or
similar lifting device to the barrel end of the lift
9 If equipped, tag and disconnect the three-pin cylinder for support.
connector from the pressure transducer
harness. To remove the pressure transducer 17 Remove the retaining fasteners from the lift
refer to Repair Procedure, How to Remove cylinder barrel-end pivot pin. Use a soft metal
the Pressure Transducer . drift to remove the pin.
10 Loosen the adjustment nuts on the solenoid 18 Support and secure the lift cylinder to an
valve and disconnect the manual lowering cable appropriate lifting device.
from the valve. 19 Remove the lift cylinder through the scissor
Note: During assembly, the manual platform arms at the steer end of the machine.
Lowering Cable.
on the lift cylinder. Cap the fittings on the
cylinder.
70
70-06-M212EN (31/10/2012)
20 Install new cylinder, fittings, hoses and pressure 21 Remove the lifting device supporting the link
transducer (if equipped). stack at the steer end of the machine.
position.
Upper Lift Cylinder
a lift cylinder 27 Raise the platform and return the safety arm to
b orifice fitting (schematic item O) the stowed position.
c connector fitting
d hydraulic hose 28 Fully lower the platform to the stowed position.
e solenoid valve (schematic item N)
f relief valve (schematic item Q) Note: &alibrateWKH3ODWIRUP2YHUORDG6\VWHP
Refer to Repair3URFHGXUH
Note: At the upper lift cylinder, install the orifice How to Calibrate the Platform 2YHUORDG6\VWHP
fitting with the small opening of the orifice fitting
closest to the supply hose.
70
Torque specification
Solenoid valve, 2 position 2 way N.C. 20 ft-lbs

Relief valve 20 ft-lbs

(schematic item Q) 27 Nm
Coil nut 5 ft-lbs

7 Nm
Pressure transducer 27 ft-lbs

(schematic item R) 37 Nm
(31/10/2012) 70-06-M212EN
How to Remove the 6 Tag, disconnect and plug the high pressure
hose at the pump. Cap the fitting on the pump.
Hydraulic Pump
7 Remove the hydraulic power unit from the
machine.
replaced and then torqued to specification during 8 Remove the pump mounting bolts. Carefully
installation. remove the pump.

2 Tag and disconnect the hydraulic power unit
cables at the motor controller.
3 Disconnect the filter head from the filter head
mounting bracket. Rotate the filter out and away
from the hydraulic power unit.
4 Remove the hydraulic power unit retaining
fasteners.
5 Tag, disconnect and plug the hydraulic hard line
from the pump. Cap the fitting on the pump.
70
70-06-M212EN (31/10/2012)
Hydraulic Tank 2 Tag and disconnect the hydraulic tank return

hard line from the filter. Remove the hard line
The primary functions of the hydraulic tank are to from the machine. Cap the fitting on the filter
cool and deaerate the hydraulic fluid during head.
operation. It utilizes internal suction strainers for 3 Tag and disconnect the hydraulic tank hard line
the pump supply lines and has an external return from the pump. Remove the hard line from the
line filter. machine. Cap the fitting on the pump.
How to Remove the 4 Remove the hydraulic tank retaining fasteners

and remove the hydraulic tank from the
Hydraulic Tank machine.
When removing a hose assembly or fitting, the 5 Remove the hydraulic tank cap and drain the
fitting and/or hose end must be torqued to tank into a suitable container.
Perform this procedure with the platform in the
stowed position. Hydraulic tank retaining fasteners, dry 35 in-lbs
4 Nm
Hydraulic tank retaining fasteners, lubricated 26 in-lbs
2.9 Nm
70
(31/10/2012) 70-06-M212EN
70
70-06-M212EN (31/10/2012)
ELECTRIC
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL CONTROL AND ADJUSTMENT
- ELECTRICAL TROUBLESHOOTING
80
ELECTRICAL SCHEMATIC DIAGRAMS
pages
LEGENDS
– INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– ELECTRICAL COMPONENT LEGEND
78 SEC 2 (FROM SN 910662)
100 SEC 2 (FROM SN 917098)
120 SE 2 (FROM SN 915526) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– WIRE COLOR LEGEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– WIRING DIAGRAM - GROUND AND PLATFORM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 6
– LIMIT SWITCH LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– ELECTRICAL SYMBOLS LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL SCHEMATIC
– 78 SEC 2 (FROM SN 910662)
80
100 SEC 2 (FROM SN 917098)
120 SE 2 (FROM SN 915526)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(31/10/2012) 80-02-M212EN
2 ELECTRICAL SCHEMATIC DIAGRAMS
About This Section

There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
General Repair Process
Observe and Obey:

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
80
80-02-M212EN (31/10/2012)
ELECTRICAL SCHEMATIC DIAGRAMS 3
Electrical component legend


B5 Battery pack 24V DC, 4 each 6V DC O3
C1 Connector - Anderson connector Q8
C2 Connector - PCON cable connector A24
C3 Connector - PCON coil cord connector A29
C4 Connector - Power control (J1) G16
C5 Connector - Sensors and switches (J3) G22
C6 Connector - Function manifold (J2) M22
C7 Connector - Sensor power bus E26
C8 Connector - Sensor ground bus K25
C9 Connector - Pot hole limit switch I28
C10 Connector - Down limit switch I33
C11 Connector - Level sensor K35
C12 Connector - Function manifold ground bus Q24
C13 Connector - Drive reverse coil O27
C14 Connector - Drive forward coil Q28
C15 Connector - Steer right coil Q30
C16 Connector - Steer left coil O31
C17 Connector - Platform up coil Q32
C18 Connector - Platform down coil O33
C19 Connector - Load sense cable O37
C20 Connector - Platform height cable M39
C21 Connector - Load sense ground bus K22
80
C22 Connector - Parallel coil O29
C23 Connector - Platform height sensor M39
C24 Connector - Platform overload pressure transducer O37
C41 Connector - Platform control bus C17
C43 Connector - Key switch, platform mode K9
C44 Connector - Key switch, emergency stop K7
C45 Connector - Automotive style horn + G32
C46 Connector - Emergency stop K6
C47 Connector - GCON alarm + G34
C48 Connector - Circuit breaker, MTR V+ O5
C49 Connector - Emergency stop, ECM driver V+ K4
C50 Connector - Circuit breaker, ECM driver V+ O4
C51 Connector - Key switch, ground mode K9
C52 Connector - GCON alarm - G34
C53 Connector - Automotive style horn - G32
C70 Connector - Platform down coil + (100 SEC 2 - 120 SE 2) O35
C71 Connector - Platform down coil - (100 SEC 2 - 120 SE 2) O35
CB2 Circuit breaker 7A M6
D1 Diode - Motor controller enable -, 3A S25
(31/10/2012) 80-02-M212EN

D2 Diode - Motor controller enable +, 3A Q19
EN1 Enclosure - Platform control box E32
EN4 Enclosure - AC outlet box A17
F6 Fuse 275A O6
FB Flashing beacons G36
H1 Horn or alarm A39
H2 Automotive style horn G33
H5 Multifunction alarm G35
J1 Connector plug - Power control (U5) G17
J2 Connector plug - Function manifold (U5) M21
J3 Connector plug - Sensors and switches (U5) G21
J5 Connector plug - PCON coil cord platform controls PC board A34
J6 Connector plug - PCON emergency stop and alarm to platform control PC board A36
J7 Connector plug - Joystick to platform controls PC board E36
JC9 Joystick controller E40
K1 Contactor, motor controller power, NOHC O10
KS1 Key switch K8
LS6 Limit switch - Platform down G34
LS7 Limit switch - Pothole I30
LS8 Limit switch - Pothole I30
M5 Hydraulic power unit O13
P1 Power switch - Emergency stop button at ground controls K5
P2 Power switch - Emergency stop button at platform controls A39
PT15 Pressure transducer - Platform overload (option) Q38
QD16 Connector - AC outllet box A15
QD30 Connector - AC outllet box A7
R30 Resistor 20 Ohm 10W S26
S7 Sensor - Level sensor K36
80
S14 Sensor - Platform height sensor O38

U3 Electronic component - PCON printed circuit board C37
U5 Electronic component - Electronic control module K17
U6 Electronic component - Motor controller O11
U9 Electronic component - Battery charger Q5
U13 Electronic component - Voltage inverter (option) O6
Y1 Valve coil - Parallel (100 SEC 2 - 120 SE 2) O29
Y3 Valve coil - Steer right Q30
Y4 Valve coil - Steer left O31
Y5 Valve coil - Drive reverse O27
Y6 Valve coil - Drive forward Q28
Y7 Valve coil - Platform down O33
Y8 Valve coil - Platform up Q32
Y9 Valve coil - Platform down (100 SEC 2 - 120 SE 2) O35
80-02-M212EN (31/10/2012)
Wire color legend
Wire color legend Wire color legend

Color Description Color Description
BK Black LB Light blue
BK/RD Black/Red OR Orange
BL Blue OR/BK Orange/Black
BL/BK Blue/Black OR/RD Orange/Red
BL/OR Blue/Orange OR/WH Orange/White
BL/WH Blue/White RD Red
BR Brown RD/BK Red/Black
GR Green RD/WH Red/White
GR/BK Breen/Black WH White
GR/WH Green/White WH/BK White/Black
GR/YL Green/Yellow YL Yellow
80
(31/10/2012) 80-02-M212EN
Wiring Diagram
Ground and Platform Controls
80
80-02-M212EN (31/10/2012)
Limit Switch Legend
78 SEC 100 SEC

120 SE
80
Limit Switch Legend
a down limit switch LS6

b pothole switches LS7, LS8
(31/10/2012) 80-02-M212EN
Electrical Symbols Legend
Limit switch
Motor controller Key switch
Wire with Emergency Stop button

description or color
Motor Solenoid valve
with diode
Circuit breaker
Circuits crossing
no connection
Level sensor
Fuse
Battery charger
Diode
Horn or alarm
Deutsch connector
Circuit connection 6V or 12v DC battery

Flashing beacon
Pressure transducer
Resistor
Platform height sensor
80
Contactor
80-02-M212EN (31/10/2012)
ELECTRICAL SCHEMATIC - 78 SEC 2 (from serial number 910662) ELECTRICAL SCHEMATIC DIAGRAMS 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
QD30 QD16 AC
H1
J5 J6 ALARM +
GN 1 1 GR GR 1 1 GR/YL OUTLET C2 C3 1 1
BK 2 2 BK BK 2 2 BK
A RD 1 1 PCON V + RD 1 1 PCON V + RD 2 2 RD - A
WH 3 3 WH WH 3 3 LT BL
AC INPUT WH 2 2 E-STOP WH 2 2 E-STOP WH 3 3 BK
POWER TO PLATFORM BL 3 3 DATA LINK + BL 3 3 DATA LINK + BL 4 4 WH E-STOP +
(110V-240V AC) EN4 GND OR 4 4 DATA LINK - OR 4 4 DATA LINK - OR 5 5 WH E-STOP -
AC
BR 5 5 PCON V - BR 5 5 PCON V - BR 6 6
OUTLET GROUND
STUD 6 6 6 6 7
P2
BOX EMERGENCY
8 STOP
U3
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1 YL JOYSTICK AXIS 1
C 2 C
3 BK STEER SWITCH COM
C41 4 YL DRIVE ENABLE COM
RD 1 1 RD 5 WH DRIVE ENABLE
WH 2 2 WH 6 BL STEER LEFT
GR 3 3 BL 7 GR STEER RIGHT
OR 4 4 OR 8 RD JOYSTICK 5V DC
BR 5 5 BR
9
6 6
10 BK JOYSTICK GND
11
E
EN1 12 BK CHASSIS GND E
C7 PLATFORM J7 JOYSTICK JC9
12
10
CONTROLLER CONTROLLER
9
11 RD
3 RD
5 RD
8 RD
6 RD
7 RD
1 RD C47
J3
G J1 GREEN C5 2 RD H5 G
C4 GRAY 4 RD ALARM
1
C52 FB
RD ECM LOGIC V+ RD 1 2 BL ALARM OUT C45 H2 FLASHING
RD PCON V+ OUT RD 2 3 RD SENSOR V+ OUT AUTO-STYLE BEACONS
WH E-STOP WH 3 4 WH AUTO HORN OUT HORN (OPTION)
GR GR 4 RD BK
C53 (OPTION) LS6
DATA LINK+ 5 OR/RD POTHOLE LIMIT SW
2 N.C.H.O. DOWN
OR DATA LINK- OR 5 6 BR GROUND RD 1 1 BK LIMIT
BR PCON V- OUT BR 6 7 OR DOWN LIMIT SW LS7 SWITCH
- NOTE - ECM V- BR 7 8 RD/BK LEVEL SENSOR 1
POTHOLE
PLATFORM MODE BK 8 GUARD C10 LOW TEMPERATURE
9 WH N.C.H.O.
MACHINE SHOWN IN THE GROUND MODE WH 9
BL/WH CYL PRESSURE
SWITCH CUT-OUT MODULE
10 OR/WH PLAT HEIGHT OR/RD C9
I STOWED POSITION WITH E-STOP WH/BK 10 3 OR 2 2 WH
(OPTION) I
11 WH WH BK BK/RD BR
THE POWER OFF 11 12 BK LOAD SENSOR GND N.C.H.O. WH
RD ECM DRIVER V+ RD 12 BK
LS8 BK/RD
POTHOLE BR
4
GUARD
C8 OR/RD BK
P1 8 SWITCH RD A A RD V+
EMERGENCY KS1 7
BR RD/BK C C WH SIG
STOP KEY SWITCH
U5 1
BR BR B B BK V-
PCON 1 C43 ELECTRONIC 5
BR LEVEL
CONTROL C21 2 NOT CONNECTED WITH LOW C11 S7 SENSOR
K C49 C46 C44 OFF MODULE
BR TEMP. CUT-OUT OPTION K
2 1 BK
3
WH WH BR
1 2 B 2 BK 4
BR
3 C51 3 BK
6
BR SENSOR V-
GCON 4
J2
BLACK C6
1 OR PLATFORM UP COIL
XX
A C B
2 OR/BK PLATFORM DOWN COIL OR
C20
3 BL/BK STEER LEFT COIL A C B
M CB2 4 BL STEER RIGHT COIL M
5 RD/WH PARALLEL COIL
WH
7A
RD
BK
CIRCUIT 6 WH DRIVE FORWARD COIL
BREAKER 7
8 GR/WH MOTOR CONTROLLER ENABLE WH 1 3 2
WH 100 SEC 2 C23
RD 9
RD RD WH 120 SE 2 120 SE 2 1 3 2
RD C48 10 WH/BK DRIVE REVERSE COIL ONLY ONLY
C50 D1 C22 C16 C18 C70
WH
C13
RD
11 GR MOTOR CONTROLLER THROTTLE
BK
M5 12 Y5 Y1 Y4 Y7 Y9
M5 DRIVE PARALLEL STEER PLATFORM PLATFORM A C B
V- SIG V+
U13 RD MOTOR REVERSE LEFT DOWN DOWN C19
O DC/AC INVERTER K1 A C B
O
(OPTION) Contactor A1
BK N.O.H.C.
BK GR/WH
RD
BK
S14
BL
U6 RD PLATFORM
F6 + - BR MOTOR
HEIGHT
CONTROLLER GR GR C71 A C B
B5 275A FUSE
GR/WH GR/WH C14 C15 C17 C24 SENSOR
4-6V B+ M A C B
RD RD
BATTERY
RD D2 3A Y6 Y3 Y8 BK
RD A2 3
RD
WH
DRIVE STEER PLATFORM
BK
FORWARD RIGHT UP
U9 BK B- 1 V+ SIG V-
BATTERY
C1 (+) PT15
Q CHARGER
WH
PRESSURE Q
RD TRANDUCER
BR
C12
BK
5 BR
(-) 7 BR
2 BR
BK 6 BR
BK 3 BR
BK 4 BN
1 BR BR
Motor Controller BLACK AND WHITE WIRES CUT POWER 8
TO MOTOR CONTROLLER WHEN THE
S Power Cut-off Option CHARGER ISPLUGGED IN (OPTION) MANIFOLD V- BR BR
S
SENSOR V- BR
BR D1 R30
RD
3A 200Ω 10w
(30/09/2012) 80-02-M212EN
XX
80-02-M212EN (30/09/2012)
ELECTRICAL CONTROL AND ADJUSTMENT
pages
PLATFORM CONTROLS
– OPERATIONAL INDICATOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– PLATFORM CONTROLS ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– PLATFORM EMERGENCY STOP BUTTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SCISSOR COMPONENTS
– PLATFORM OVERLOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GROUND CONTROLS
– GROUND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– SOFTWARE REVISION LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– MACHINE SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
80
– DISPLAY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– LEVEL SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MANIFOLDS
– VALVE COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
(01/05/2013) 80-04-M212EN
2 ELECTRICAL CONTROL AND ADJUSTMENT
The platform controls are used to operate the Operational Indicator Codes
machine from the platform.
These codes are generated by the electrical
Activating a function button sends a signal to the system to indicate machine operating status.
Electronic Control Module (ECM). When the ECM During normal operation a code will appear in the
is in the function mode, the platform controls are platform controls LED readout if a condition such
used to operate the various machine functions. as off-level, overload cutout, chassis mode
The platform controls consist of an Emergency operation or pothole guards stuck occurs.
Stop button, electronic circuit board, proportional If the platform controls LED readout displays an
control handle, drive/steer enable switch, alarm, operational indicator code such as LL, the fault
function buttons and LED display. condition must be repaired or removed before
For further information or assistance, consult the resuming machine operation. Push in and pull out
Service Department. the red Emergency Stop button to reset the
system.
Platform Controls LED Readout
Code Condition
LL Off-Level
OL Platform Overloaded
CH Chassis Mode Operation
PHS Pothole Guard Stuck

a red Emergency Stop button P2
b platform controls circuit board U3 nd No Drive (option)
c proportional control handle and
drive/steer enable switch JC9
d alarm H1
80
Note: A code and a description of a code can also

be viewed at the ground controls LCD display.
80-04-M212EN (01/05/2013)
ELECTRICAL CONTROL AND ADJUSTMENT 3
Circuit Board 9 Carefully remove the platform controls circuit

board fasteners.
How to Remove the Platform 10 Carefully remove the platform controls circuit
board from the platform control box.
Controls Circuit Board
11 Remove the transparent caps from the platform
1 Push in the red Emergency Stop button to the controls circuit board and save.
off position at both the ground and platform
controls. Circuit board fastener torque specifications
2 Disconnect the platform controls from the Hand tighten until screw seats < 5 in-lbs
control cable at the platform. < 0.6 Nm
control box to the platform control bracket. Note: Before installing a circuit board, place the
transparent caps removed in step 11, over the
4 Remove the fasteners securing the bottom
circuit board buttons.
cover to the platform control box. Open the
control box. Note: After installing the circuit board, check for
5 Remove the ties securing the wire harness. proper button operation. Excessive torque of the
circuit board fasteners will cause the buttons to
6 Disconnect the red and black wires from the bind. Moderate torque of the circuit board fasteners
alarm. will not allow the buttons to engage.
7 Carefully remove the alarm from the platform
control box.
8 Carefully disconnect all wire harness
connectors from the platform controls circuit
board.
80
(01/05/2013) 80-04-M212EN
Joystick Platform Controls Alarm
How to Remove the Joystick How to Remove the Platform

1 Push in the red Emergency Stop button to the Controls Alarm
off position at both the ground and platform 1 Push in the red Emergency Stop button to the
controls. off position at both the ground and platform
2 Disconnect the platform controls from the controls.
control cable at the platform. 2 Disconnect the platform controls from the
3 Remove the fasteners securing the platform control cable at the platform.
control box to the platform control bracket. 3 Remove the fasteners securing the platform
4 Remove the fasteners securing the bottom control box to the platform control bracket.
cover to the platform control box. Open the 4 Remove the fasteners securing the bottom
control box. cover to the platform control box. Open the
5 Remove the ties securing the joystick wire control box.
harness. 5 Disconnect the red and black wires from the
6 Carefully disconnect the joystick wire harness alarm.
from the platform controls circuit board. 6 Carefully remove the alarm from the platform
7 Carefully remove the joystick fasteners. control box.
8 Carefully remove the joystick from the platform

control box.
Joystick fasteners 9 in-lbs
1 Nm
80
80-04-M212EN (01/05/2013)
Platform Emergency Stop Button 6 Carefully remove the Emergency Stop base
from the Emergency Stop button.
How to Remove the Platform 7 Carefully remove the retaining ring from the
Emergency Stop button.
Controls Emergency Stop Button
8 Carefully remove the Emergency Stop button
1 Push in the red Emergency Stop button to the from the platform control box.
off position at both the ground and platform
controls.
2 Disconnect the platform controls from the
control cable at the platform.
control box to the platform control bracket.
4 Remove the fasteners securing the bottom
cover to the platform control box. Open the
control box.
5 Disconnect the white wires from the Emergency
Stop base.
80
(01/05/2013) 80-04-M212EN
Platform Overload System Note: To calibrate the platform overload system,

follow the menu structure indicated on the ground
control LCD display.
How to Calibrate the Platform
Overload System Full Load Calibration: Part 1
1 Fully charge the batteries and check the
Perform this procedure with the machine in the
hydraulic fluid level.
stowed position and on a firm, level surface that is
free of obstructions. Note: The hydraulic fluid level must be between the
FULL and ADD marks on the hydraulic tank.
Perform this procedure in an environment that
allows the platform to be fully raised. Models rated 2 Apply a thin layer of dry film lubricant to the
for inside use only, can only be calibrated inside a area of the chassis and platform, where the
facility with enough ceiling height to fully raise the scissor arm wear pads make contact.
platform.
3 Chock both sides of the wheels at the steer end
Perform this procedure after confirming that the of the machine.
platform height sensor is not damaged and
4 Using a suitable lifting device, place a test
functions correctly.
weight corresponding to the machine maximum
There are two options to the platform overload load, in the center of the platform deck. Secure
calibration procedure in this section, Full Load the weight to the platform. Refer to the chart
Calibration and No Load Calibration. Full Load below.
Calibration has two steps requiring calibration with
6(& kg
and without rated load in the platform. No Load
Calibration does not require rated load in the 6(& 227 kg
platform.
6( 317 kg
Note: No Load Calibration can be completed
stand alone to fulfill the C-2 overload calibration
requirements, if the machine has completed the
Full Load Calibration procedure.
Note: If a new Ground Controller is installed on a

machine, the Full Load Calibration procedure is
required to maintain rated load platform capacity.
If a No Load Calibration is performed, machine
80
lifting performance will be significantly reduced.

Note: Ambient temperature must be above
32°F / 0°C before calibrating the Platform Overload
System.
a number 1 inner arm

b fastener
(platform height sensor assembly)
c number 1 pivot pin
d lever arm retaining screw
e squeeze connector
f lever arm
g platform height sensor harness
connection
h platform height sensor
i fastener
a fasteners (platform height sensor (large platform height sensor bracket)
cover) j fastener (platform height sensor)
b platform height sensor cover k platform height sensor assembly
80-04-M212EN (01/05/2013)
5 Turn the key switch to ground control. 18 At the ground controls, press and hold the
Function Enable and Platform Up buttons until
6 At the ground controls, press and hold the
the platform reaches maximum height.
Menu Up and Menu Down buttons.
19 When the platform reaches maximum height,
7 While pressing both buttons down, pull out the
press the ground controls 2. button. Allow
red Emergency Stop Button.
the ground controls to gather data.
8 Release the Menu Up and Menu Down buttons
20 When prompted, press and hold the
after the ground controller powers up.
Function Enable and Platform Down buttons.
9 Use the Menu Up or Menu Down buttons to The platform will lower, then automatically stop
scroll to, Select Option. Press the 2. button. at a predetermined point to gather data. Allow
the ground controls to gather data.
10 Use the Menu Up or Menu Down buttons to
scroll to Platform Overload. 21 Continue pressing the Function Enable and
Platform Down buttons throughout the lowering
11 Press the 2. button to select Platform and data gathering sequence. The machine will
Overload. stop to gather data and lower several times
12 Use the Menu Up or Menu Down buttons to before the machine reaches the stowed
scroll to Platform Overload Calibrate. position. When the platform reaches the stowed
position, press the 2. button.
13 Press the 2. button to select Platform
Overload Calibrate. Note: If the machine is switched to PCON mode
to drive the machine to an area for weight removal,
14 Confirm the Platform Overload Calibrate step 3 and steps 5 through 14 will have to be
selection by pressing the 2. button again. repeated before Full Load Calibration: Part 2 is
15 Use the Menu Up or Menu Down buttons to performed. Additionally, the CO25 fault will appear.
select Full Load calibration. This is expected and the data collected in Full
Load Calibration: Part 1 has not been lost.
16 Press the 2.button to select Full Load
calibration. 22 Using a suitable lifting device, remove the test
weight from the platform deck.
17 Press the 2. button to confirm rated load is
in the platform. 23 After the weight is removed from the platform
deck, press the 2. button to confirm the
weight has been removed.
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Full Load Calibration: Part 2

24 At the ground controls, press and hold the
Function Enable and Platform Up buttons until
the platform reaches maximum height.
25 When the platform reaches maximum height,
press the 2. button. Allow the ground
controls to gather data.
26 When prompted, press and hold the
Function Enable and Platform Down buttons
to lower the platform. The platform will move
down, then automatically stop at a
predetermined point to gather data. Allow the
ground controls to gather data.
27 Continue pressing the Function Enable and
Platform Down buttons throughout the lowering
and data gathering sequence. The machine will
stop to gather data and lower several times
before the machine reaches the stowed
position. When the platform reaches the stowed
position, press the 2. button.
28 When prompted, push the red Emergency Stop
button in to complete the Platform Overload
Calibration procedure.
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80-04-M212EN (01/05/2013)
The ground controls, used to operate the machine

from the ground, can also be used to tune the
performance of the machine.
The ground controls consist of an Electronic
Control Module (ECM), emergency stop button,
key switch and circuit breaker.
Activating the function enable button and the up

or down at the same time, sends a signal to the
(ECM). This allows the platform to be raised or
lowered at the ground controls.
Note: Steer and drive functions are not available at

the ground controls.
When the ECM is in the set up mode, the ground
controls are used to adjust the function speed
parameters, machine models, or machine options.
a machine setup, escape button
For further information or assistance, consult the b machine setup, scroll up button
c LCD readout
Service Department. d machine setup, scroll down button
e machine setup, 2. button
f key switch KS1
g red Emergency Stop P1
h circuit breaker CB2
i ECM U5
j platform down button
k lift function enable button
l platform up button
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Software Revision Level 2 Press the ground control scroll down button.
Result: The ground control LCD display will
How to Determine the indicate the software revision and hour meter
information. After 5 seconds, the ground
Software Revision Level controls LCD display will display machine
The machine software revision level is displayed at model and hour meter information again.
the ground controls LCD display. See example below.
1 Turn the key switch to the ground controls or

platform controls position. Pull out the red
Emergency Stop button to the on position at
both ground and platform controls.
Result: The display at the platform controls will 3 Push in the red Emergency Stop button to the
show "CH". See example below. off position at both the ground and platform
controls and turn the key switch to the off
position.
Result: The display at the ground controls will

show the machine model and hour meter
information. After 3 seconds, the machine
model will not show on the display. See
example below.
a ground control LCD display

b ground control scroll down button
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80-04-M212EN (01/05/2013)
Machine Setup 1 Turn the key switch to the ground controls

position and pull out the red Emergency Stop
button to the on position at the platform
How to Setup the Machine from controls.
Ground Controls
The ground controls can be used to setup the scroll down buttons.
machine parameters from the ground. Features
that can be adjusted from the ground controls
include machine Model, Options and Speed setup.
This menu can only be entered from ground
controls with the key switch in the ground controls
position.
Note: Select a test area that is firm, level and free
of obstructions.
Ground Control Menu Buttons
a scroll down button

b enter button
c scroll up button
d escape button
e LCD display

Result: The ground controls LCD display will
show the following:
4 Use the ground control menu buttons to select
80
machine Model, Options and Speed Setup
parameters. Follow the menu structure
indicated on the ground control LCD display.
(01/05/2013) 80-04-M212EN
e a
80
c b
Ground control menu buttons
a scroll down button

b enter button
c scroll up button
d escape button
e LCD display
Note : for matching your platform in the display menu see table below
Display ref. Elevating platform

GS-1932 78 SEC 2
GS-2632 100 SEC 2
GS-3246 120 SE 2
80-04-M212EN (01/05/2013)
MAIN MENU STRUCTURE
BLANK SCREEN
(POWER UP MACHINE)
+ These screens are only displayed if the Keypad Security

Option is enabled.
MACHINE LOCKED See Keypad Security Option - LOCK/UNLOCK
S
Flowchart for details.
F
ENTER PIN:****
Correct PIN
PIN ACCEPTED
MACHINE UNLOCKED Auto Transition

after 1 second.
LIFT SETUP+TEST
SELECT MODEL
LIFT SETUP+TEST
SELECT OPTION
LIFT SETUP + TEST
SET PARAMS
SERVICE OVERRIDE
See Machine Branding for next steps
MODE
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MACHINE BRANDING
SERVICE OVERRIDE
MODE
Hold for 5 seconds
CHANGE MACHINE
BRANDING
SET BRAND BRAND IS
TO GENIE NOW GENIE
Auto transition
after 1 second
SET BRAND BRAND IS
TO MANITOU NOW MANITOU
Auto transition
after 1 second
Notes:
1. Service Tool Branding - Depending upon the machine brand selected, the
service tool shall settings shall change as well. This entails the service tool images,
colors and machine models.
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MACHINE MODEL SETUP MENU - MANITOU BRANDED
Auto Transition
after 1 second.
GOING BACK TO LIFT SETUP+TEST

GOING BACK TO
MAIN MENU SELECT MODEL Auto Transition
Auto Transition after 1 s
after 1 second.
MAIN MENU
CURRENT MODEL
<Displays Current Model>
CHANGE MODEL
YES? ; NO?
SELECT MODEL SELECT 78 SEC MODEL SELECTED
78 SEC YES? ; NO? 78 SEC
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Blanck Screen Select Option is only available if a Tune speed is only available if a
(Power up Machine) Model has been Selected. Model has been Selected.
Auto Transition after 1 second. This should be coded in the software. This should be coded in the software.
+
GOING BACK TO LIFT SETUP+TEST LIFT SET-UP+TEST
MAIN MENU SELECT MODEL SELECT OPTION
CURRENT MODEL
<Displays Current Model> LIFT SET-UP+TEST
TUNE SPEEDS
GOING BACK TO
CHANGE MODEL MAIN MENU Auto Transition after 1 second.
YES? NO?
SELECT MODEL SELECT GRC-10 MODEL SELECTED

GRC-10 YES? NO? GRC-10
SELECT MODEL SELECT GR-12 MODEL SELECTED

GR-12 YES? NO? GR-12
SELECT MODEL SELECT GRC-15 MODEL SELECTED

GRC-15 YES? NO? GRC-15
SELECT MODEL SELECT GR-20 MODEL SELECTED

GR-20 YES? NO? GR-20
SELECT MODEL SELECT GS-1530 MODEL SELECTED

GS-1530 YES? NO? GS-1530

GS-1532 YES? NO? GS-1532

GS-1930 YES? NO? GS-1930

GS-1932 YES? NO? GS-1932
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GS-2032 YES? NO? GS-2032

GS-2046 YES? NO? GS-2046

GS-2632 YES? NO? GS-2632

GS-2646 YES? NO? GS-2646

GS-3232 YES? NO? GS-3232

GS-3246 YES? NO? GS-3246
80-04-M212EN (01/05/2013)
MACHINE OPTION SETUP MENU STRUCTURE

Notes:
1. Outrigger Option - If GS3232 is selected in machine model Setup, the outrigger option is automatically turned on.
The user cannot turn this option off if GS3232 is selected.
2. Platform Overload and Down Delay Option - If GS1532 and GS1932 are selected in Machine Model Setup, the platform overload
and down delay options are automatically turned on. The user cannot turn this option off if GS1532 or GS1932 are selected.
3. Steer Sensor Option - If RTxx69DC is selected in Machine Model Setup, the steer sensor option is automatically
turned on. The user cannot turn this option off if RTxx69DC is selected.
GOING BACK TO Auto Transition LIFT SETUP+TEST
MAIN MENU after 1 second. SELECT OPTION
SELECT OPTION Model==GRXX or See GS Platform Overload

NO
PLAT. OVERLOAD Model==GSXX69DC Flowchart for next steps
YES
PLAT. OVERLOAD PLAT. OVERLOAD

IS<CS>.TURN<!CS>? IS NOW <!CS>
2
Auto Transition after 1 second.
SELECT OPTION DOWN DELAY DOWN DELAY

DOWN DELAY IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION MOTION ALARM MOTION ALARM

MOTION ALARM IS<CS>.TURN<!CS>? IS NOW <!CS>
1
SELECT OPTION See Outrigger Flowchart

OUTRIGGER for next steps.
SELECT OPTION PWR EXT DECK PWR EXT DECK

PWR EXT DECK IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION POWER SAVE MODE POWER SAVE MODE

POWER SAVE MODE IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION FOOTSWITCH FOOTSWITCH

FOOTSWITCH IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION LOW VOLTAGE INT LOW VOLTAGE INT
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LOW VOLTAGE INT IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION QSTOCK RETAIL QSTOCK RETAIL

QSTOCK RETAIL IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION AUTOMOTIVE HORN AUTOMOTIVE HORN

AUTOMOTIVE HORN IS<CS>.TURN<!CS>? IS NOW <!CS>
SELECT OPTION DRIVE /STEER CUT DRIVE /STEER CUT

DRIVE /STEER CUT IS<CS>.TURN<!CS>? IS NOW <!CS>
3
SELECT OPTION See Steer Sensor Flowchart

STEER SENSOR for next steps.
SELECT OPTION See Charger Interlock

CHARGER ILOCK Flowchart for next steps.
SELECT OPTION See Pump Calibration

PUMP EFFICIENCY Flowchart for next steps.
SELECT OPTION ALL FUNCTION CUT ALL FUNCTION CUT

ALL FUNCTION CUT IS<CS>.TURN<!CS>? IS NOW <!CS>
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GOING BACK TO LIFT SETUP+TEST NOTES:

MAIN MENU TUNE SPEED VALUE% = Current Value pulled from application
LSL Max = Maximum Low Speed Lift Elevate
Scroll Up = Increase Value%
Scroll Down = Decrease Value%
[1 - MAX] = This is the maximum adjustable value and is dependent upon the machine
model. See UC glossary for the maximum value.
If Scroll Up or Scroll Down are pressed for 2 seconds, the Value% shall increase or
decrease at a rate of 2 digits per 100ms.
TUNE SPEED PCON ELEVATED DRIVE ELEVATED DRIVE

ELEVATED DRIVE [1MAX] VALUE% SPEED TEST
TUNE SPEED PCON HI STOWED DRIVE HI STOWED DRIVE

HI STOWED DRIVE [1-100] VALUE% SPEED TEST
TUNE SPEED PCON LO STOWED DRIVE LO STOWED DRIVE

LO STOWED DRIVE [1-100] VALUE% SPEED TEST
TUNE SPEED PCON NEUTRAL STEER NEUTRAL STEER

NEUTRAL STEER [1-100] VALUE% SPEED TEST
TUNE SPEED PCON HI SPEED LIFT HI SPEED LIFT

HI SPEED LIFT [1-100] VALUE% SPEED TEST
TUNE SPEED PCON LO SPEED LIFT LO SPEED LIFT

LO SPEED LIFT [1-100] VALUE% SPEED TEST
TUNE SPEED GCON LIFT UP GCON LIFT

GCON LIFT UP [1-100] VALUE% SPEED TEST
RESTORE DEFAULT SPEEDS ALL DEFAULT

80
DEFAULT SPEEDS YES? NO? SPEED RESTORED
RESTORE
DEFAULT SPEEDS Auto Transition after 1 second.
80-04-M212EN (01/05/2013)
Level Sensors If you are not installing a new level sensor,

proceed to step 15.
The Electronic Control Module (ECM) is 7 Turn the key switch to the off position and push
programmed to deactivate the lift and drive in the red Emergency Stop button to the off
functions and activate an alarm when a signal is position at the ground controls.
received from the level sensor.
8 Tag and disconnect the level sensor wire
The tilt alarm sounds when the incline of the harness from the chassis wire harness.
chassis exceeds 1.5° to the side and 3° to the front
or rear. Note: The wire harness connection is located next
to the level sensor, on top of the chassis at the
How to Install and Calibrate the steer end of the machine.
1.5° Level Sensor 9 Remove the level sensor retaining fasteners.
Remove the level sensor from the machine.
1 Move the machine to an area that has a firm,
level surface and is free of obstructions. 10 Tag and disconnect the level sensor wires from
the level sensor connector plug.
11 Securely install the wires of the new level
sensor into the level sensor connector plug.
position at both the ground and platform 12 Place the new level sensor onto the level
controls. sensor mount bracket with the "X" on the level
sensor base closest to the long side of the level
sensor mount, and the "Y" on the level sensor
5 Lift the safety arm, move it to the center of the base closest to the short side of the level
scissor arm and rotate down to a vertical sensor mount.
position.
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13 Install the level sensor retaining fasteners Steer end

through the level sensor and springs, and into
the mount bracket. Tighten the fasteners and
a
measure the distance between the level sensor
and the level sensor mount bracket.
f b
Y
Result: The measurement should be X
approximately 3/8 inch / 10 mm. e

c
14 Connect the chassis wire harness to the level
sensor wire harness.
15 Turn the key switch to the ground control and
d
pull out the red Emergency Stop button to the
16 Adjust the level sensor retaining fasteners until
the bubble at the top of the level sensor is
centered in the circles.
Result: The tilt sensor alarm should not sound.
17 Raise the platform slightly.
18 Return the safety arm to the stowed position.
20 Center a lifting jack under the drive chassis at Non-steer end
the ground controls side of the machine.
a limit switch
21 Raise the machine approximately b level sensor mount bracket
2 inches / 5 cm. c level sensor S7
d alarm H5
e level sensor retaining fastener
f scissor chassis
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22 6(&: Place a 0.68 x 6 x 6 31 6(&: Place a 0.83 x 6 x 6

inch / 17.2 mm x 15 cm x 15 cm thick steel inch / 21.1 mm x 15 cm x 15 cm thick steel
block under both wheels at the ground controls block under both wheels at the battery pack
side of the machine. side of the machine.
6(&: Place a 6(&: Place a
0.66 x 6 x 6 inch / 16.8 mm x 15 cm x 15 cm 0.8 x 6 x 6 inch / 20.3 mm x 15 cm x 15 cm
thick steel block under both wheels at the thick steel block under both wheels at the
ground controls side of the machine. battery pack side of the machine.
6(: 6(:
Place a 1 x 6 x 6 inch / 25.4 mm x 15 cm x 15 Place a 1.22 x 6 x 6 inch / 31 mm x 15 cm x 15
cm thick steel block under both wheels at the cm thick steel block under both wheels at the
ground controls side of the machine. battery pack side of the machine.
23 Lower the machine onto the blocks. 32 Lower the machine onto the blocks.
24 Raise the platform 7 to 8 feet / 2.1 to 2.4 m. 33 Raise the platform 7 to 8 feet / 2.1 to 2.4 m.
Result: The level sensor alarm should not Result: The platform should stop, an alarm
sound. should sound and fault code LL appears in the
diagnostic display.
Result: The level sensor alarm does sound and
fault code LL appears in the diagnostic display. Result: The platform does not stop or the level
Adjust the level sensor retaining fasteners just sensor alarm does not sound. Adjust the level
until the level sensor alarm does not sound. sensor until the alarm just begins to sound OR
the down limit switch may need to be adjusted.
2 inches / 5 cm.
position.
27 Remove the blocks from under both wheels.
35 Lower the scissor arms onto the safety arm.
28 Lower the machine and remove the jack.
37 Return the safety arm to the stowed position.
the battery pack side of the machine.
2 inches / 5 cm. 39 Raise the machine approximately
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2 inches / 5 cm.
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O S
Valve Coils Valve Coil Resistance

Specification
How to Test a Coil
Note: The following coil resistance specifications
A properly functioning coil provides an are at an ambient temperature of 68°F / 20°C. As
electromagnetic force which operates the solenoid valve coil resistance is sensitive to changes in air
valve. Critical to normal operation is continuity temperature, the coil resistance will typically
within the coil. Zero resistance or infinite increase or decrease by 4% for each 18°F / -7.7°C
resistance indicates the coil has failed. that your air temperature increases or decreases
from 68°F / 20°C.
Since coil resistance is sensitive to temperature,
resistance values outside specification can Valve Coil Resistance Specifications
produce erratic operation. When coil resistance
decreases below specification, amperage Description Specification
increases. As resistance rises above specification,
Solenoid valve, 3 position 4 way 27.2Ω
voltage increases.
20V DC with diode (schematic items F, AC and DC)
While valves may operate when coil resistance is Solenoid valve, 3 position 4 way 19Ω
outside specification, maintaining coils within 20V DC with diode (schematic item E)
specification will help ensure proper valve function
over a wide range of operating temperatures. Solenoid valve, 2 position 4 way 19Ω
20V DC with diode (schematic item H, AI and DI)
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing Solenoid valve, 2 position 2 way N.C. 25Ω
this test. 20V DC with diode (schematic item N)
Solenoid valve, 2 position 4 way 19Ω

1 Tag and disconnect the wiring from the coil to
20V DC with diode (schematic items AE and DE)
be tested.
Solenoid valve, 3 position 5 way 19Ω
2 Test the coil resistance using a multimeter set
20V DC with diode (schematic item AG and DG)
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table. Solenoid valve, 2 position 2 way 27.2Ω
20V DC with diode (schematic item CA, CB, CC
Result: If the resistance is not within the and CD)
adjusted specification, plus or minus 10%,
replace the coil. Solenoid valve, 3 position 4 way 19Ω
20V DC with diode (schematic item BA)
80
Proportional solenoid valve, 2 position 2 way 23.9Ω

20V DC with diode (schematic item DO)
80-04-M212EN (01/05/2013)
How to Test a Coil Diode

,ncorporates spike suppressing diodes in all
of its coils. Properly functioning coil diodes protect
the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
1 Test the coil for resistance. See How to
Test a Coil.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the a multimeter
b 9V DC battery
other end of the resistor to a terminal on the c 10Ω resistor
coil. d coil
Note: The battery should read 9V DC or more Note: Dotted lines in illustration indicate a reversed
when measured across the terminals. connection as specified in step 6
Ω
Resistor, 10Ω 5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
3 Set a multimeter to read DC amperage.
6 At the battery or coil terminals, reverse the
Note: The multimeter, when set to read DC connections. Note and record the current
amperage, should be capable of reading up to reading.
800 mA.
Result: Both current readings are greater than
4 Connect the negative lead to the other terminal 0 mA and are different by a minimum of 20%.
on the coil. The coil is good.
Note: If testing a single-terminal coil, connect the Result: If one or both of the current readings are
negative lead to the internal metallic ring at either 0 mA, or if the two current readings do not differ
end of the coil. by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
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replaced.
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ELECTRICAL TROUBLESHOOTING
pages
DIAGNOSTICS
– INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– GROUND CONTROLS I/O WITH LOAD SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– INDICATION/FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– FAULT INSPECTION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FAULT CODES
– TYPE "HXXX" FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– TYPE "PXXX" FAULTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– TYPE "UXXX" FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– TYPE "FXXX" FAULTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– TYPE "CXXX" FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2 ELECTRICAL TROUBLESHOOTING
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropriate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting short cuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
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ELECTRICAL TROUBLESHOOTING 3
About This Section Definitions

When a malfunction is discovered, the fault code DS - Diagnostic System
charts in this section will help a service
professional pinpoint the cause of the problem. ECM - Electronic Control Module
To use this section, basic hand tools and certain GCON - Ground Controls
pieces of test equipment are required —
voltmeter, ohmmeter, pressure gauges. PCON - Platform Controls
OIC - Operational Indicator Codes

General Repair Process
DTC - Diagnostic Trouble Codes
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GCON LCD Diagnostic Readout Diagnostic6\VWHP

This machine is equipped with the
Diagnostic System (DS). The
DS indicates a machine malfunction has
happened by displaying Operational Indicator
Codes (OIC) and Diagnostic Trouble Codes
The diagnostic readout displays alpha numeric (DTC). These codes are displayed at the
codes that provide information about the machine Platform Controls and the Ground Controls.
operating status and about malfunctions. The Ground Controls will display a brief
The codes listed in the Diagnostic Trouble Code description of the code at the LCD display as
Charts describe malfunctions and can aid in well.
troubleshooting the machine by pinpointing the Refer to the GCON I/O Maps, Operational
area or component affected. Indicator Codes (OIC) and Diagnostic Trouble
Codes (DTC) in this section, to assist in
troubleshooting faults.
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Rear of Ground
Controls ECM
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Operational Indicator Codes Diagnostic Trouble Codes (DTC)

(OIC) These codes are generated by the system to
These codes are generated by the electrical indicate that a device or circuit malfunction has
system to indicate machine operating status been detected in the electrical system.
such as Off-level, Overload Cutout, Chassis The types of Diagnostic Trouble Codes that may
Mode Operation and Pothole Guard Stuck, occur are explained below.
during normal operation. Type "HXXX" - Indicate a malfunction
These codes are not indicators of a device associated with devices that control hydraulic
malfunction in the electrical system. functions in the electrical system. The "HXXX"
faults are divided into short circuit battery
Code Condition negative, short circuit to battery positive, open
LL Off-Level circuit and generic shorts. Example of these
devices are solenoid controlled hydraulic valves
OL Platform Overloaded and motor controller.
CH Chassis Mode Operation Type "PXXX" - Indicate a malfunction associated
with power type devices in the electrical system.
PHS Pothole Guard Stuck
The "PXXX" faults are divided into short circuit to
battery negative, short circuit to battery positive,
open circuit and generic shorts. Example of
these devices are horns, sensor power and
alarms.
Type "UXXX" - Indicate a malfunction associated

with user interface devices in the electrical
system. The "UXXX" faults are divided into short
circuit to battery negative, short circuit to battery
positive, open circuit and generic shorts.
Example of these devices are GCON up and
down switches and PCON drive joystick.
Type "FXXX" - Indicate a malfunction associated
with machine feedback devices in the electrical
system. The "FXXX" faults are divided into short
circuit to battery negative, short circuit to battery
80
positive, open circuit and generic shorts.

Example of these devices are limit switches,
height sensors and pressure transducers.
Type "CXXX" - Indicate a malfunction associated

with controls devices in the electrical system.
Example of these devices are platform controls
and ground controls ECM.
80-08-M212EN (01/05/2013)
Troubleshooting "HXXX" and "PXXX" Faults

The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX and PXXX".
Diagnostic Chart
No Good
1 Check the fault device for a short or open circuit. Replace faulted device.
Good
No Good
Check short or open circuit of the harness or Repair or replace harness and/or connector.
2 connector between Ground Controls and faulted device.
Good
No Good
3 Check GCON Electronic Control Module (ECM). Replace ECM.
Wiring Diagram
The wiring diagram shown below illustrates how fault type "HXXX" or "PXXX" devices are typically wired.
The signal to these types of devices originates at the Ground Controls and terminates at system ground.
Signal Side Return Side
GCON Signal Wire Return Wire

Electronic Control Module DEVICE
(ECM)
In order to successfully troubleshoot "HXXX" or "PXXX" type faults, the entire faulted out circuit needs to
be investigated.
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Fault Inspection Procedure

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Type "HXXX" Faults

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Type "PXXX" Faults
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Type "UXXX" Faults

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Type "FXXX" Faults

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Type "CXXX" Faults

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Repair Manual 120SE&100SEC

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Repair Manual 120SE&100SEC

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REPAIR MANUAL

This document has been printed from my e doc

AXLE ASSEMBLY - AXLE

- GENERAL INSTRUCTIONS AND SAFETY

TYPE LIFTING PLATFORM front REAR

– From a legal point of view, being liable in the event of an accident.

– Know-how and skills

– Removal of components AUTHORISED

– Check that there is no damage or deterioration.

Indicated during removal procedures; this enables you to select the

 647367EN Please refer to Instructions Manual No 647367EN.

 647367C Please refer to Spare Parts Catalogue No 647367.

 80-07-M.219EN Please refer to Section No 80-07-M.219EN in this Repairs Manual.

§B-1 Please refer to Paragraph B - 1 in this Section

(A1-1) (Figure A1 - Rep 1)

STEER AXLE COMPONENTS

How to Remove a Drive Motor Steer Cylinder

How to Remove the Steer

between the bellcrank and the steer links.

Drive Brake 9 Tag, disconnect and plug the hydraulic hose

Brake mounting fasteners, dry 75 ft-lbs

Note: Always replace the cotter pin with a new one

Brake Release Hand Pump Components

- JIB - ACCESS PLATFORM REMOVAL

Platform 8 Models with air line to platform option:

12 Carefully lift the platform off of the machine and

7 Disconnect the wiring from the platform and pull

Platform Extension 7 Remove the platform roller wheels from the

Scissor Assembly, 4 Lower the platform onto the safety arm.

78 SEC 2 5 At the ground control, turn the key switch to the

16 Install the fasteners removed in 14 to the

24 Remove the platform.

26 Remove the cables from the number 4 cable

5 At the ground control, turn the key switch to the

27 Secure the ends of the scissor arms together at

30 Attach a lifting strap from an overhead crane to

Scissor Assembly, 4 Lower the platform onto the safety arm.

16 Install the fasteners removed in 14 to the

23 Fully lower the platform to the stowed position. d cable bridge 2A

24 Remove the platform. See, How to

48 Remove the retaining fasteners from the 57 Place a 4 x 4 x 10 inch / 10 x 10 x 25 cm block

the number 3 outer arm at the battery side

the lug of the rod end of the lower lift cylinder.

27 Secure the ends of the scissor arms together at

30 Attach a lifting strap from an overhead crane to

14 Remove the fasteners securing the large

24 Remove the platform. See, How to

55 Use a soft metal drift to remove the number 4

(index #23) from the machine.

112 Raise the arm slightly and remove the block.

26 Remove the fasteners from the entry ladder and

29 Remove the retaining fasteners securing the

Manual Platform Lowering Cable Skip to step 8 if the measurement is correct.

How to Adjust the Manual a

Platform Lowering Cable

Result: The measurement should be no greater

a manual lowering cable sheath

7 Repeat this procedure beginning with step 4.

- HYDRAULIC SCHEMATIC DIAGRAMS

- HYDRAULIC CONTROL AND ADJUSTMENT

- HYDRAULIC COMPONENTS REMOVAL

78 SEC 2 (from serial number 910662)

OVERLOAD 0.94 mm HAND