Maintenance & Troubleshooting Manual
HB-P527
SUPO-643
REV A
2
TABLE OF CONTENTS
SECTION 1 | SAFETY ...............................................................................................................6
1.1 | SAFETY SYMBOLS ..................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS ............................................................................... 6
1.3 | SAFETY GUIDELINES ................................................................................................................ 7
SECTION 2 | MAINTENANCE ................................................................................................8
2.1 | BATTERY MAINTENANCE ....................................................................................................... 8
2.2 | BATTERY MAINTENANCE WET CELL BATTERIES .......................................................... 8
2.3 | CHARGING THE BATTERY ..................................................................................................... 8
2.4 | LUBRICATION ........................................................................................................................... 10
2.5 | COMPONENTS REQUIRING ADJUSTMENT ..................................................................... 10
2.6 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ............ 10
2.7 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ................................................ 10
2.8 | STORAGE ................................................................................................................................... 10
2.9 | MAJOR ALTERATIONS OR REPAIRS .................................................................................... 10
SECTION 3 | MAINTENANCE CHECKLISTS ........................................................................11
3.1 | PRE-START INSPECTION CHECKLIST ................................................................................. 12
3.2 | FREQUENT INSPECTION CHECKLIST ................................................................................ 13
3.3 | FREQUENT INSPECTION CHECKLIST ................................................................................ 14
SECTION 4 | TECHNICAL REFERENCES .............................................................................16
4.1 | HYDRAULIC SCHEMATIC ....................................................................................................... 17
4.2 | ELECTRICAL SCHEMATIC ...................................................................................................... 19
SECTION 5 | WIRING DIAGRAMS .........................................................................................20
5.1 | WIRING DIAGRAM .................................................................................................................... 20
5.2 | UPPER CONTROL WIRING DIAGRAM ............................................................................... 22
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS .........................................................24
6.1 | TROUBLESHOOTING FLOWCHART: POWER .................................................................. 24
6.2 | TROUBLESHOOTING FLOWCHART: ELEVATING .......................................................... 27
6.3 | TROUBLESHOOTING FLOWCHART: LOWERING ........................................................... 28
SECTION 7 | PARTS DIAGRAMS ............................................................................................30
7.1 | SAFETY CONTROL DECALS ................................................................................................... 30
7.2 | MAIN POWER/SAFETY CIRCUIT ........................................................................................... 31
7.3 | ELEVATE/LOWER CIRCUIT PARTS ....................................................................................... 32
7.4 | WHEELS/BREAKS ...................................................................................................................... 34
7.5 | COVERS/OTHER ....................................................................................................................... 35
SECTION 8 | WARRANTY .......................................................................................................36
