Service Manual: Heightrider

Heightrider
Service Manual
MODEL HR21 MK2 SERIES
.com
Manufactured by:
Niftylift Limited
info@niftylift.com
Chalkdell Drive
Shenley Wood
Milton Keynes
MK5 6GF
England
www.niftylift.com
e-mail: info@niftylift.com
Tel: +44 (0)1908 223456
M50648/01 Fax: +44 (0)1908 312733
HR21 4x4 MK2
Service Manual
1 INTRODUCTION AND GENERAL INFORMATION .............................................................................1

1.1 Foreword ..............................................................................................................................................1
1.1.1 Defined maintenance terms...........................................................................................................1
1.2 Warranty...............................................................................................................................................2
1.3 Scope...................................................................................................................................................2
1.4 General maintenance information ..........................................................................................................3
1.4.1 Pre-maintenance checks...............................................................................................................3
1.4.2 Maintenance information...............................................................................................................3
1.4.3 Frequent inspection.......................................................................................................................4
1.4.4 Annual inspection .........................................................................................................................5
1.5 Maintenance safety information.............................................................................................................5
1.5.1 Personal injury prevention .............................................................................................................5
1.5.2 Machine damage prevention .........................................................................................................5
1.5.3 Diesel system safety.....................................................................................................................6
1.5.4 Hydraulic safety............................................................................................................................6
1.5.5 Environmental awareness .............................................................................................................7
1.5.6 Electrical safety ............................................................................................................................7
2 SPECIFICATIONS ...........................................................................................................................8
2.1 Engine specifications ............................................................................................................................8
2.2 Gearbox specifications ..........................................................................................................................8
2.3 Function times ......................................................................................................................................9
2.4 Fluid properties ...................................................................................................................................10
2.4.1 Fluid volumes .............................................................................................................................10
2.4.2 Engine oil specifications..............................................................................................................10
2.4.3 Gearbox oil specifications ...........................................................................................................10
2.4.4 Hydraulic oil specifications..........................................................................................................10
2.4.5 Engine coolant specifications ......................................................................................................11
2.4.6 Hydraulic pressure settings .........................................................................................................11
2.5 Tyre specifications..............................................................................................................................11
2.6 Torque settings ...................................................................................................................................12
2.7 Hydraulic hose and fitting torque specifications ...................................................................................13
3 PREVENTATIVE MAINTENANCE ...................................................................................................16
3.1 Maintenance schedules.......................................................................................................................16
3.1.1 Engine maintenance....................................................................................................................16
3.1.2 Machine maintenance .................................................................................................................18
3.2 Consumables......................................................................................................................................19
3.2.1 Data, safety and specification......................................................................................................20
3.3 Engine operations ...............................................................................................................................21
3.3.1 Power tray..................................................................................................................................21
3.3.2 Engine oil level check (daily) .......................................................................................................22
3.3.3 Engine oil replace........................................................................................................................23
3.3.4 Engine oil filter replace ................................................................................................................24
3.3.5 Engine coolant level check (daily)................................................................................................26
3.3.6 Coolant replace...........................................................................................................................27
3.3.7 Antifreeze check .........................................................................................................................28
3.3.8 Coolant hoses and clamp bands check .......................................................................................29
3.3.9 Air filter element maintenance .....................................................................................................29
3.3.10 Air filter condition indicator check (daily) ...................................................................................31
3.3.11 In-line fuel filter replace .............................................................................................................32
English 06/17 -4
HR21 4x4 MK2
Service Manual
3.3.12 Fuel filter and water separator clean/replace.............................................................................. 33

3.3.13 Fuel filter (cartridge type) replace .............................................................................................. 34
3.3.14 Bleeding air from the fuel system .............................................................................................. 35
3.3.15 Fuel pipes check....................................................................................................................... 38
3.3.16 Exhaust system check .............................................................................................................. 38
3.3.17 Fan belt check .......................................................................................................................... 39
3.4 Drive hub gearbox .............................................................................................................................. 40
3.4.1 Gearbox disengagement ............................................................................................................. 40
3.4.2 Gearbox oil replace..................................................................................................................... 41
3.4.3 Bleeding air from the braking circuit ............................................................................................ 42
3.5 Batteries............................................................................................................................................. 42
3.5.1 Condition check (daily)............................................................................................................... 42
3.5.2 Storage ...................................................................................................................................... 43
3.6 Hydraulic oil ....................................................................................................................................... 44
3.6.1 Level check (weekly) .................................................................................................................. 44
3.6.2 Return filter check (monthly)....................................................................................................... 44
3.6.3 Pressure filter check (weekly) ..................................................................................................... 44
3.6.4 Hydraulic oil and filters replace ................................................................................................... 45
3.7 Telescopic boom................................................................................................................................ 47
3.7.1 Wear pad check (monthly).......................................................................................................... 47
3.7.2 Hose trunking and energy chain check (weekly).......................................................................... 47
3.7.3 Lubricate boom pivot bushes (annually)...................................................................................... 48
3.7.4 Boom pivot pin check (daily) ...................................................................................................... 48
3.7.5 Boom chain inspection ............................................................................................................... 48
3.8 Boom rotation gear ............................................................................................................................. 48
3.8.1 Slew gear engagement check (monthly) ..................................................................................... 48
3.8.2 Lubricate slew ring (monthly) ..................................................................................................... 49
3.8.3 Slew ring bolts check (annually) ................................................................................................. 49
3.9 Front axle ........................................................................................................................................... 50
3.9.1 Lubricate steer pin (daily) ........................................................................................................... 50
4 REPAIR PROCEDURES .................................................................................................................51
4.1 General .............................................................................................................................................. 51
4.1.1 Fuses ......................................................................................................................................... 51
4.2 Platform/cage..................................................................................................................................... 59
4.2.1 Footswitch - contact switch replace............................................................................................ 59
4.3 Booms ............................................................................................................................................... 60
4.3.1 Energy chain link ........................................................................................................................ 60
4.4 Power tray.......................................................................................................................................... 61
4.4.1 Exhaust ...................................................................................................................................... 61
4.4.2 Fan belt ...................................................................................................................................... 64
4.5 Base assembly ................................................................................................................................... 66
4.5.1 Steer cylinder ............................................................................................................................. 66
4.6 Superstructure.................................................................................................................................... 67
4.6.1 Tilt sensor .................................................................................................................................. 67
4.6.2 Sensor calibration....................................................................................................................... 67
5 SYSTEM OVERVIEW ....................................................................................................................69
5.1 Introduction ........................................................................................................................................ 69
5.1.1 Hybrid system............................................................................................................................ 69
-3 English 06/17
HR21 4x4 MK2
Service Manual
5.1.2 Hybrid terminology .....................................................................................................................70

5.1.3 Battery states..............................................................................................................................70
5.1.4 Power modes .............................................................................................................................70
5.1.5 Operation....................................................................................................................................71
5.2 Diesel system .....................................................................................................................................72
5.3 Boom system .....................................................................................................................................73
5.3.1 Boom switch ..............................................................................................................................73
5.3.2 Telescopic boom switch .............................................................................................................73
5.3.3 Boom enable valve......................................................................................................................73
5.4 Drive system.......................................................................................................................................73
5.4.1 Hybrid & diesel ...........................................................................................................................73
5.5 Charging system and batteries ............................................................................................................74
5.5.1 Charging system - diesel.............................................................................................................74
5.5.2 Charging system - hybrid............................................................................................................74
5.5.3 Absorbent Glass Mat (AGM) batteries..........................................................................................74
5.5.4 Lithium (Li-ion) batteries .............................................................................................................74
5.6 Hydraulic system overview..................................................................................................................75
5.7 Load sensing pump ............................................................................................................................75
5.8 Drive control valve ..............................................................................................................................76
5.9 Four wheel drive (4x4) ........................................................................................................................76
5.10 Brake release ....................................................................................................................................76
5.11 Steering ............................................................................................................................................76
5.12 Suspension.......................................................................................................................................77
5.13 Electrical control system overview.....................................................................................................77
5.14 Control logic .....................................................................................................................................77
5.16 Motor controller ................................................................................................................................78
5.17 Niftylift diagnostics............................................................................................................................79
6 TROUBLESHOOTING GUIDE.........................................................................................................78
6.1 Troubleshooting information................................................................................................................78
6.2 Platform function fault finding..............................................................................................................78
6.3 Engine fault finding..............................................................................................................................79
6.4 Engine fault codes...............................................................................................................................81
6.5 Gearbox fault finding ...........................................................................................................................83
6.6 Error codes.........................................................................................................................................84
6.6.1 Error cause (1st byte) .................................................................................................................84
6.6.2 Error source (2nd byte)...............................................................................................................86
6.6.3 Safety controller..........................................................................................................................89
6.6.4 Application specific error code (3rd byte) ....................................................................................90
6.6.5 Application specific (motor controller) error code (3rd byte) ........................................................94
6.6.6 Error class (4th byte) ................................................................................................................103
English 06/17 -2
HR21 4x4 MK2
Service Manual
Notes
-1 English 06/17
HR21 4x4 MK2
Service Manual
1 Introduction and general information

1.1 Foreword
The purpose of this manual is to provide the owner, service engineer or technician with information to
service and maintain the Niftylift.
Prior to carrying out any maintenance or operating the Niftylift the operator's manual should be read and
fully understood.
The manufacturer has no direct control over the Niftylift’s application and use, therefore conformance with
good safety practices is the responsibility of the user and his operating personnel.
All information in this manual is based on the use of the Niftylift under proper operating conditions.
Alteration or modification of the Niftylift are strictly forbidden.
One of the most important facts to remember is that any equipment is only as safe as those who operate it.
Warnings and Cautions
Any place these topics may appear, either in this manual or on the Niftylift, are defined as follows:
THE 'SAFETY ALERT' SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL

HAZARDS THAT, IF IGNORED, MAY LEAD TO SERIOUS INJURY OR DEATH.
Indicates hazardous situations, which if not avoided, will result in serious injury
DANGER or death.
Indicates potentially hazardous situations, which if not avoided, could result in
WARNING serious injury or death.
Indicates potentially hazardous situations, which if not avoided, could result in
CAUTION minor or moderate injury.
Indicates important information that is not safety related. This includes general
NOTICE safety rules and/or procedures relating to the Niftylift.
IMPORTANT AND INSTRUCTIONS: Denotes procedures essential to safe operation and prevention of
damage to or destruction of the Niftylift.
1.1.1 Defined maintenance terms

Defined maintenance terms used within this manual can be found in the Table 1.1, “Defined Maintenance
Terms,” on page 2.
English 06/17 1
HR21 4x4 MK2
Service Manual
Table 1.1: Defined Maintenance Terms
Term Action
Remove Disconnect and take off component
Install Place component in position ready for use
Replace Remove and discard the original component and put a new component in its place
Secure Install or attach locking device
Reinstall Install the previously removed component
Tighten Apply specified torque
Clean Remove all dirt and deposits
Inspect Determine general condition conforms to required standards
Check Determine a particular condition e.g. completeness, security, position
Adjust Change or move in order to achieve a desired result
Connect Install, engage component
Lubricate Apply lubricant
Disconnect Remove, disengage component
1.2 Warranty
During the warranty period, consult Niftylift prior to carrying out any corrective maintenance on your
Niftylift. If work is carried out without Niftylift consent your warranty will be invalidated.
Clean assembly practices must be observed when carrying out repairs, as seals and other hydraulic
components are sensitive to contamination.
The Niftylift must not have been neglected, misused or modified and must have been regularly maintained.
Failure to comply with these conditions invalidates the warranty.
1.3 Scope
Please note at the time of going to press all information, illustrations, details and descriptions contained
herein are valid. Niftylift reserves the right to change, alter, modify or improve its products without any
obligations to install them on previously manufactured Niftylifts.
If information is found to be either incorrect or missing Niftylift encourage you to send in suggestions
which will aid our continuous product improvement.
If after reading this manual you require further information contact us at your nearest office or see the
My Nifty section on www.niftylift.com.
Niftylift Ltd, Chalkdell Drive, Shenley Wood, Milton Keynes MK5 6GF, England
Tel: +44 (0) 1908 223456 Fax: +44 (0) 1908 312733
2 English 06/17
HR21 4x4 MK2
Service Manual
Nifty Pty Ltd, 11 Kennington Dr, Tomago NSW 2322, Australia

Tel: +61 (0) 2 4964 9765 Fax: +61 (0) 2 4964 9714
1.4 General maintenance information

Any repair or maintenance work on a Niftylift must be undertaken by a competent person with sufficient
training and experience to perform the activity. Basic mechanical, hydraulic, and electrical skills are
required to perform routine maintenance and minor repairs to a Niftylift. However, several procedures
require specialised skills, tools, lifting equipment and a suitable workshop. In these instances, it is
recommend that maintenance and repair be performed by Niftylift or at a Niftylift approved service centre.
Niftylift’s safety rules and instructions must be obeyed at all times.
Refer to “Frequent inspection” on page 4 where the Niftylift has been out of service for a period longer than
3 months. Different time scales may apply, always comply with local or national regulations.
FAILURE TO PERFORM PREVENTATIVE MAINTENANCE AT THE REQUIRED
WARNING INTERVALS MAY RESULT IN A NIFTYLIFT THAT IS NOT SAFE TO USE
WHICH COULD CAUSE INJURY OR POSSIBLE DEATH.
Regular inspections and appropriate maintenance will ensure the Niftylift performs efficiently and
economically with minimal service or repair down time.
1.4.1 Pre-maintenance checks

Perform the following before maintaining the Niftylift:
• Park the Niftylift on firm and level ground,
• Turn off ignition, remove the key, and relieve hydraulic system pressure,
• Ensure the Niftylift is in transport mode, i.e. all booms lowered and slewed parallel to the base, and
cage floor horizontal,
• Ensure wheels are chocked, and, if installed, engage the parking brake,
• Allow the Niftylift to cool down,
• Disconnect power to the Niftylift,
• Disconnect batteries before replacing electrical components.
1.4.2 Maintenance information

Ensure maintenance is carried out in suitable workshop facilities with appropriate tools and suitable lifting
equipment.
Components must be replaced with identical or equivalent parts. If unsure contact your nearest Niftylift
approved dealer for advice.
Inspect all parts prior to reassembly and replace if necessary. Do not install faulty, used, or worn parts to
a Niftylift.
Replace all O-rings, seals and gaskets at reassembly.
Replace any parts with damaged threads; replace all roll pins, self locking fittings and circlips.
English 06/17 3
HR21 4x4 MK2
Service Manual
If any part resists removal check all fasteners, hydraulic lines, electrical wires and interferences before
continuing.
Keep all new parts in their packaging until they are to be installed, carry out inspection before installation.
Mark or tag all hydraulic lines before removal to avoid confusion and errors during reinstallation. Never
leave hydraulic lines open or open them in a contaminated area. Always use plugs or caps.
Use only recommended lubricants. See section 2.4.
In general, installation of components can be completed by reversing the removal process and
instructions.
Please refer to the following documents for further details.
Table 1.2: Technical Documents
Document Number
HYBRID DIESEL
Hydraulic Schematic D82950 D82900
Electric Schematic D81819
Operating & Safety Instructions M50541
Parts Manual M50540
Engine Operator’s Manual M50291 (D902) M50292 (V1505)
Chain Service & Inspection Manual M50280
For easy access to any of the above documents go to www.niftylift.com, register in the 'My Nifty
Registration' section, then navigate to the 'My Nifty' section and enter the Niftylift Serial Number.
1.4.3 Frequent inspection

The owner of the Niftylift shall make sure that a frequent inspection is carried out in accordance
with Niftylift instructions, on a machine:
(1) That was purchased used. This inspection shall be accomplished unless it is determined that the
frequent and annual inspections are current.
(2) That has been in service for three months or 150 hours, whichever comes first.
(3) That has been out of service for a period longer than 3 months.
The inspection must be made by a person qualified as a technician on the specific type of Niftylift or one
having similar design characteristics. The inspection must be in accordance with items specified by the
manufacturer for a frequent Inspection and shall include, but not limited to the following:
(1) All functions and their controls for speed(s), smoothness, and limits of motion.
(2) Lower controls including the provisions for overriding of upper controls.
(3) All chain and cable mechanisms for adjustment and worn or damaged parts.
(4) All emergency and safety devices.
(5) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant
as specified by the manufacturer.
4 English 06/17
HR21 4x4 MK2
Service Manual
(6) Visual inspection of structural components and other critical components such as fasteners, pins,
shafts, and locking devices.
(7) Placards, warnings and control markings.
(8) Items specified by the manufacturer.
(9) Emergency lowering means.
1.4.4 Annual inspection

The owner of the Niftylift shall make sure that an annual inspection is performed no later than
thirteen (13) months from the date of the prior annual inspection.
The inspection must be made by a person qualified as a technician on the specific type of Niftylift or one
having similar design characteristics. The inspection shall include all items included in the frequent
inspection (See section 1.4.3) plus items specified by the manufacturer for an annual inspection, to
include manufacturer's bulletins.
The inspection shall verify that the MEWP (Mobile Elevated Work Platform) is registered with Niftylift and
that any open safety-related bulletins are addressed as part of the inspection. The MEWP shall not be
placed back into service until all malfunctions and problems identified in the inspection have been rectified.
The owner shall maintain on the MEWP a means to identify the date the last annual inspection was
performed and the interval at which annual inspections are required.
1.5 Maintenance safety information
1.5.1 Personal injury prevention

CORRECT PPE (PERSONAL PROTECTION EQUIPMENT) MUST BE WORN
WARNING FOR ALL MAINTENANCE OPERATIONS CARRIED OUT ON A NIFTYLIFT
ACCESS PLATFORM.
Do not wear jewellery whilst carrying out maintenance. Restrain long hair and do not wear loose clothing.
Ensure the work area is well ventilated and well lit.
Never work under an elevated boom. Booms must be restrained from movement by blocking, using
overhead slings or fitting a safety prop.
Ensure all stepping surfaces, hand holds and anti-slip surfaces are free from oil, dirt, fuel and ice. Do not
step on parts of the Niftylift which are not intended for this.
Use caution when checking hot pressurised systems such as hydraulic and engine coolant.
Use correct tools and equipment, broken or damaged tools and equipment should be replaced/repaired.
Where hydraulic or electrical circuits need to be energized e.g. during maintenance or diagnostic
procedures, personnel must be aware of moving parts and position themselves accordingly to avoid being
crushed or injured.
1.5.2 Machine damage prevention

Never reset a pressure relief valve to a value higher than that stated by the manufacturer.
Ensure no tools, equipment or other objects have been left on the Niftylift.
English 06/17 5
HR21 4x4 MK2
Service Manual
Please contact your nearest Niftylift approved dealer prior to carrying out any welding.
Never start the engine without the power tray retaining bolt installed.
1.5.3 Diesel system safety

Escaping fuel under pressure can penetrate the skin causing serious injury. Do not attempt work on the
fuel system without proper training and safety equipment.
Seek immediate medical attention in the event of fuel penetrating the skin.
1.5.4 Hydraulic safety

Hydraulic oil escaping under pressure can penetrate
the skin and cause serious injury. Do not allow
hydraulic oil to squirt or spray.
Seek immediate medical attention in the event of
hydraulic oil penetrating the skin.
Wear chemical-resistant protective gloves and suitable
eye protection when handling hydraulic oil.
Relieve system pressure before removing any
hydraulic connections, undo fittings slowly to make
sure there is no residual pressure. If pressure is
detected, allow it to be released slowly before
completely removing the hose.
Fluid leaks may not be visible to the naked eye. Use a piece of cardboard to check for leaks, not your
hand.
Never install hydraulic lines or components that are damaged.
Ensure all connections are correctly tightened (See section 2.7).
6 English 06/17
HR21 4x4 MK2
Service Manual
1.5.5 Environmental awareness

When draining fluids, ensure they are collected in a suitable container and spillages are avoided.
Used batteries must be disposed of in the correct manner as waste is harmful to the environment.
Consumables such as oils, rags and gloves should also be disposed of correctly in accordance to local
regulations as waste is harmful to the environment.
1.5.6 Electrical safety

During maintenance of the electrical system, isolate the
start battery negative (-) terminal.
Ensure sparks, flames or lighted tobacco are kept away 12v
0v
from batteries as they emit explosive gases.
Keep metallic objects (tools, etc.) well clear from
battery posts.
Never connect a discharged battery in series with a
fully charged battery as this creates a risk of explosion.
Always use batteries that have the same level of 0
charge. - + - +
12
- + - +
P29666/01
To isolate the 48V battery system depress the isolation

switch on Hybrid machines (See diagram).
English 06/17 7
HR21 4x4 MK2
Service Manual
2 Specifications
Information correct at time of print.
2.1 Engine specifications
Kubota D902 Perkins 403D Kubota V1505

Feature
(Hybrid) (Diesel) (Diesel)
Type Water cooled 4-cycle, 3 Water cooled 4-cycle, 3 Water cooled 4-cycle, 4
cylinder diesel engine cylinder diesel engine cylinder diesel engine
Fuel Diesel fuel grade 2-D, EN Diesel fuel grade 2-D, EN Diesel fuel grade 2-D, EN
590 590 590
Engine oil See section 2.4.2 See section 2.4.2 See section 2.4.2
Mass (Dry weight) 72 kg (159 lbs) 197 kg (434 lbs) 110 kg (243 lbs)
Displacement 898cm3 1496cm3 1498cm3
Net power 16.1 kW/21.6hp @ 24.4 kW/32.7hp @ 18.5 kW/24.8hp @

3200rpm 2800rpm 2300rpm
Net torque - 96.0 Nm @ 1800rpm -
Oil capacity 3.8 L (0.8 gal) 6.0 L (1.3 gal) 6.0 L (1.3 gal)
Fuel capacity 42.0 L (9.2 gal) 42.0 L (9.2 gal) 42.0 L (9.2 gal)
Coolant capacity Approx. 3.1 L (0.7 gal) Approx. 9.0 L (2.0 gal) Approx. 8.5 L (1.9 gal)
Valve clearance Cold - 0.16mm (0.0065in.) Hot or cold - 0.20mm Cold 0.145 - 0.185mm
(0.008in.) (0.0057 - 0.0073in.)
2.2 Gearbox specifications
Type I=56.2 REGGIANA GEARBOX
Mass (Dry weight) 43 kg (95 lbs)
Oil capacity 0.5 L (0.11 gal)
Oil type See section 2.4.3
8 English 06/17
HR21 4x4 MK2
Service Manual
2.3 Function times
Function Up/right/out Down/left/in

Time, (Seconds)
Slew (180°) Tele in 51±10 51±10
Slew (180°) Tele out 86±10 86±10
Links 23±5 23±5
Luffing (Boom rest to full height) tele in 26±5 26±5
Luffing (Boom rest to full height) tele out 38±5 38±5
Fly boom 13±5 13±5
Telescope (luffed up) 24±5 24±5
Cage rotate (180°) 13±5 11±5
Machine Speed HYBRID DIESEL
Power source Diesel Electric
Drive speed FWD/REV Hare 6.0 km/h 4.0 km/h 6.0 km/h (3.7 mph)
(3.7 mph) (2.5 mph)
Tortoise 2.0 km/h 1.0 km/h (0.6 2.0 km/h (1.2 mph)
(1.2 mph) mph)
Off-road 3.0 km/h (1.9 2.0 km/h (1.2 3.0 km/h (1.9 mph)
mph) mph)
Elevated 0.7 km/h (0.4 mph) 0.7 km/h (0.4 mph)
FWD/REV drive speed must be measured over a 10 metre (33 feet) distance on flat level ground.
All measurements carried out with 250 kg (551 lbs) in cage (including operator) and operated from cage.
Niftylift must be at full working temperature. Hydraulic oil must be between 30-40°C (86-104°F).
Function speeds may vary depending on ambient air temperature (e.g. extreme cold).
English 06/17 9
HR21 4x4 MK2
Service Manual
2.4 Fluid properties
2.4.1 Fluid volumes
Fluid volumes
Kubota D902 Perkins 403D Kubota V1505
Hydraulic oil tank 75 L (16.5 gal) 75 L (16.5 gal) 75 L (16.5 gal)
Fuel tank 42 L (9.2 gal) 42 L (9.2 gal) 42 L (9.2 gal)
Engine oil 3.8 L (0.8 gal) 6.0 L (1.3 gal) 6.0 L (1.3 gal)
Coolant Approx. 3.1 L (0.7 gal) Approx. 9.0 L (2.0 gal) Approx. 8.5 L (1.9 gal)
2.4.2 Engine oil specifications
Engine Ambient temperature Oil type
Kubota D902a) ABOVE 0°C (32°F) SAE30 SAE 10W/30

OR SAE 10W/40
Kubota V1505a)
0°C (32°F) / +25°C (77°F) SAE20 SAE 10W/30 Standard fitment
OR SAE 10W/40
BELOW 0°C (32°F) SAE10W SAE 10W/30

OR SAE 10W/40
Perkins 403Db) ABOVE 40°C (104°F) SAE 10W/40
-20°C (-4°F) / +40°C (104°F) SAE 10W/30 Standard fitment

a) Oil which conforms to API CF rating or higher must be used.
b) A single or multi grade lubricating oil which conforms to API CG4 / CH4 or ACEA E3 / E5 must be used.
2.4.3 Gearbox oil specifications

ISO VG 150 EP oil is installed as standard.
2.4.4 Hydraulic oil specifications

ISO VG 22 oil is installed as standard, for other climates or harsh operating conditions please contact your
nearest Niftylift approved dealer.
10 English 06/17
HR21 4x4 MK2
Service Manual
2.4.5 Engine coolant specifications

Use permanent type (PT) such as Ethylene Glycol for all engines.
When anti-freeze is mixed with water, the ratio must be less than 50%, see table below.
Freezing Point Boiling Point

Volume % Volume %
Engine
Anti-freeze Water °C °F °C °F
Kubota D902 40 60 -24 -12 106 222
Kubota V1505
50 50 -37 -34 108 226
Perkins 403D 50 50 -36 -33 - -
2.4.6 Hydraulic pressure settings

Refer to hydraulic schematic as supplied with the machine noting the serial number of the Niftylift.
2.5 Tyre specifications

Standard tyre fitment: Solideal Safety Master 33x12-20.
DO NOT REPLACE TYRES WITH ANYTHING OTHER THAN THE ABOVE
WARNING SPECIFICATION. CONSULT NIFTYLIFT PRIOR TO REPLACEMENT.
English 06/17 11
HR21 4x4 MK2
Service Manual
2.6 Torque settings
Bolt quality/size Tightening torque in Nm (lbf·ft)

Plated Unplated
Grade 8.8 10.9 12.9 8.8 10.9 12.9
M6 7 (5) 10 (8) 12 (9) 8 (6) 11 (8) 13 (10)
M8 17 (13) 25 (18) 29 (22) 19 (14) 27 (20) 32 (23)
M10 34 (25) 49 (36) 58 (43) 37 (27) 54 (40) 63 (46)
M12 58 (43) 85 (63) 99 (73) 63 (47) 93 (69) 108 (80)
M14 93 (68) 135 (100) 158 (117) 101 (74) 148 (109) 172 (127)
M16 143 (106) 209 (154) 245 (180) 156 (115) 228 (168) 267 (197)
M20 288 (212) 408 (301) 477 (352) 304 (224) 445 (328) 521 (384)
M24 491 (362) 698 (515) 816 (602) 519 (383) 760 (561) 889 (656)
WHEEL NUTS 225 Nm (166 lbf·ft)
WHEEL GEARBOX NUTS 215 Nm (158 lbf·ft)
SLEW RING BOLTS 295 Nm (218 lbf·ft)

This torque chart is based on the following assumptions:
Bolts to ISO 898-1 “Mechanical properties of fasteners made of carbon steel and alloy steel”
For “unplated” bolts, all grades:
Hex head bolts
Black oxide steel bolt with a rolled & oiled thread, no finish on steel nut
Prevailing torque includes Nylock (minimum prevailing torque figure assumed)
Medium Clearance holes to ISO 273
Bolt tightening condition = Yield factor of 75%
For “plated” bolts, all grades:
Hex head bolts
Zinc plated oiled (rolled or cut) steel external thread with no finish on steel internal thread
Prevailing torque includes Nylock (minimum prevailing torque figure assumed)
Medium Clearance holes to ISO 273
Bolt tightening condition = Yield factor of 75%
Figures quoted in Nm have been calculated in Nm and then rounded to the nearest whole number.
Figures quoted in lbf·ft have been calculated in Nm, converted using a factor of 0.737561 and then rounded.
12 English 06/17
HR21 4x4 MK2
Service Manual
2.7 Hydraulic hose and fitting torque specifications

BSP (solid black nut)
Soft seal positional/banjo/block fittings

O-Ring seal female (ISO 8434)
(ISO 6149 & 1179)
Size Thread Torque Nm (lbf·ft) Size Thread Torque Nm (lbf·ft)
4 1/4” - 19 25 (18) 4 1/4” - 19 40 (30)
6 3/8” - 19 35 (26) 6 3/8” - 19 75 (55)
8 1/2” - 14 55 (41) 8 1/2” - 14 100 (74)
10 5/8 - 14 65 (48) 10 5/8 - 14 130 (96)
12 3/4” - 14 100 (70) 12 3/4” - 14 190 (140)
16 1” - 11 125 (92) 16 1” - 11 300 (221)
20 1”1/4 - 11 190 (140) 20 1”1/4 - 11 330 (243)
24 1”1/2- 11 250 (184) 24 1”1/2- 11 460 (339)
32 2” - 11 400 (295) 32 2” - 11 N/A
Elastomeric seal male (ISO 1179)

Size Thread Torque Nm (lbf·ft)
Steel Aluminium
4 1/4” - 19 60 (44) 30 (22) O-Ring female
6 3/8” - 19 90 (66) 45 (33)
8 1/2” - 14 130 (96) 65 (48)
10 5/8 - 14 N/A N/A
12 3/4” - 14 200 (148) 100 (74)
16 1” - 11 300 (221) 150 (111)
20 1”1/4 - 11 500 (369) 250 (184) Soft Seal

Positional
24 1”1/2- 11 600 (443) 300 (221)
32 2” - 11 N/A N/A
Elastomeric
(Integrated Seal)
English 06/17 13
HR21 4x4 MK2
Service Manual
Metric (S-series)
Soft seal positional/banjo/block

Elastomeric seal male (9974/3869)
fittings (ISO 6149 & 1179)
Torque Nm (lbf·ft)
Thread Torque Nm (lbf·ft) Thread Steel Aluminium
M12 X 1.5 35 (26) M12 X 1.5 40 (30) 20 (15)
M14 X 1.5 45 (33) M14 X 1.5 60 (44) 30 (22)
M16 X 1.5 55 (41) M16 X 1.5 80 (59) 40 (30)
M18 X 1.5 70 (52) M18 X 1.5 95 (70) 45 (33)
M20 X 1.5 80 (59) M20 X 1.5 140 (103) 70 (52)
M22 X 1.5 100 (74) M22 X 1.5 150 (111) 75 (55)
M27 X 2.0 180 (133) M27 X 2.0 200 (148) 100 (74)
M30 X 2.0 N/A M30 X 2.0 380 (280) 190 (140)
M42 X 2.0 330 (243) M42 X 2.0 480 (354) 240 (177)
UNF male with O-ring
Connector male SAE UNF with

O.R ISO 11926 ports
Thread Torque Nm (lbf·ft)
7/16” 21 (16)
1/2” 27 (20)
9/16” 40 (30) Soft Seal

Positional
3/4” 78 (58)
7/8” 110 (81)
1”1/16 180 (133)
1”3/16 230 (170)
1”5/16 285 (210)
1”5/8 320 (236)
Elastomeric
(Integrated Seal) UNF with O-Ring
14 English 06/17
HR21 4x4 MK2
Service Manual
UNF bolts
Dowty seal positional / banjo bolts

Size Thread Torque Nm (lbf·ft)
UNF 9/16” - 18 40 (30)
Dowty Seal
Positional/Banjo
Metric (L-series)
Metric L-series hose tails

FDLORX & MDL (DIN 3852)
AF Size Thread Torque Nm (lbf·ft)
Steel
19MM 10L M16 X 1.5 35 (26) L-Series Hose Tails
English 06/17 15
HR21 4x4 MK2
Service Manual
3 Preventative maintenance
3.1 Maintenance schedules
3.1.1 Engine maintenance

Engine maintenance is required at periodic or hourly intervals whichever occurs first. The engine running
hours are displayed in the menu screen on the cage and ground control display units.
Kubota D902 & Kubota V1505

Every 100
Every 200
Every 400
Every 500
Every 50
Every 2
Hours
Hours
Hours
Hours
Hours
Month
Years
Every
Every
Operation
Year
Engine oil ●a) ● ▲
Engine oil filter ●a) ●
Air filter @ ■b) ●b)c)
Engine coolant ●
Coolant hoses and clamp bands ▲d) ●
Fuel filter & water separator ■ ●
In-line fuel filter ●
Fuel tank ■
Fuel hoses and clamp bands @ ▲ ●e)
Fan belt ▲ ●
Air intake line @ ▲ ●f)
Electrical wiring & connections ▲
▲ Check/inspect
■ Clean
● Replace
@ Emission critical component

a) First time procedure.
b) In arduous conditions (high levels of dust) the air filter must be cleaned and replaced more frequently.
c) After six checks with cleaning or annually; whichever occurs sooner.
d) Every 200 engine running hours or 6 months; whichever occurs sooner.
e) Contact a Kubota approved dealer.
f) Replace if necessary.
16 English 06/17
HR21 4x4 MK2
Service Manual
Perkins 403D
Every 1000
Every 2000
Every 3000
Every 250
Every 500
Hours
Hours
Hours
Hours
Hours
Daily
Operation
Engine oil ▲ ●a)
Engine oil filter ●a)
Air filter condition indicator ▲
Air filter ■a)b)c)
Engine coolant ▲ ●d)
Coolant hoses and clamp bands ▲a)
Fuel filter ●
In-line fuel filter ●
Valve clearance ▲e)
Engine crankcase breather ●e)
Fuel hoses and clamp bands ▲a)
Fan belt ▲f) ●
Fuel injectors ▲e)
▲ Check/inspect
■ Clean
● Replace
a) Every 500 engine running hours or annually; whichever occurs sooner.
b) In arduous conditions (high levels of dust) the air filter must be cleaned and replaced more frequently.
c) After six checks with cleaning or annually; whichever occurs sooner.
d) Every 3000 engine running hours or 2 years; whichever occurs sooner.
e) Contact a Perkins approved dealer.
f) Every 250 engine running hours or 6 months; whichever occurs sooner.
English 06/17 17
HR21 4x4 MK2
Service Manual
3.1.2 Machine maintenance

Machine maintenance is required at periodic or hourly intervals. The total active, booms active, and drive
active hours are displayed in the menu screen on the cage and ground control display units.
Every 500 Hours

Every 6 Months
Every 50 Hours
Every 4 Years
Every Month
Every Week
Every Year
Daily
Operation
Gearbox oil ●a) ●b)
Battery condition ▲
Hydraulic oil level ▲
Return filter ▲
Pressure filter ▲
Hydraulic oil and filters ●a) ●c)
Telescopic boom wear pads ▲
Hose trunking & energy chain ▲
Boom pivot pin/bushes ▲ **
Boom chains ▲**d) ▲e)
Wheel Nuts ▲
Slew gear engagement ▲
Slew ring **
Slew ring bolts ▲
Steer Pin **
▲ Check/inspect
■ Clean
● Replace
** Lubricate
a) First time procedure.

b) Annually or 2500 machine running hours, whichever occurs first.
c) In arduous conditions (high levels of dust) the hydraulic oil and filters must be replaced more frequently.
d) More frequent in hostile environments.
e) Full inspection required.
18 English 06/17
HR21 4x4 MK2
Service Manual
3.2 Consumables
Consumable items required for maintenance can be found in Table 1.
Table 1: Consumables
Type Detail Frequency
Engine oil 10W30 / 15W40
Engine oil filter Spin on filter

See section 3.1.1
Diesel fuel filter Cartridge or filter element
Engine coolant Antifreeze
Hydraulic oil ISO VG 22
Hydraulic oil Pressure filter 10 Micron screen filter
Hydraulic oil Return filter 3 Micron screen filter
Hydraulic oil Suction strainer 90 Micron filter element
White grease Renolit CZ2 See section 3.1.2
Black Grease Multis MS 2
Anti Friction Dry PTFE Lubricant WD 40 Anti Friction Dry PTFE Lubricant
Petroleum jelly Vaseline petroleum jelly
ISO VG 150 Gear oil EP 150
Fuse 125A SIBA 80VDC
Fuse 2A ATO 32VDC
Fuse 5A ATO 32VDC
Fuse 10A ATO 32VDC
Fuse 15A ATO 32VDC
Fuse 2A Mini ATO 58VDC

Replace as required
Fuse 40A J Case 32VDC
Fuse 50A J Case 32VDC
Fuse 1A Ceramic Fuse 250V
Fuse 30A Ceramic Fuse 250V
English 06/17 19
HR21 4x4 MK2
Service Manual
3.2.1 Data, safety and specification

Data, safety and specification details are listed in Table 2.
Table 2: Data and Specification
Type Detail Number
Hydraulic oil ISO VG 22/32 Haydn.pdf
White grease Renolit CZ2 RENOLIT CZ 2_sds.pdf
Black Grease Multis MS 2 msds.pdf
WD 40 W/D44394 aerosol Anti Friction Dry PTFE Lubricant WD-40-Specialist-High-Performance-PTFE-

Lubricant.pdf
Gear oil ISO VG 150 Q8 Goya 150.pdf
Engine oil 10W30 / 15W40 14793.pdf
Engine coolant Antifreeze 11923-1.pdf
Petroleum jelly Vaseline petroleum jelly petroleum_jelly_sds.pdf
Thread locking adhesive Loctite 243 243-EN.pdf
20 English 06/17
HR21 4x4 MK2
Service Manual
3.3 Engine operations
3.3.1 Power tray

Certain procedures require the engine power tray to be swung away from the superstructure. Never start
the engine without the power tray retaining bolt installed.
THE POWER TRAY RETAINING BOLT MUST BE INSTALLED AND TIGHTENED
WARNING TO THE SPECIFIED TORQUE BEFORE STARTING THE ENGINE.
WHEN MOVING THE POWER TRAY BEWARE OF HOT ENGINE
CAUTION COMPONENTS. CONTACT WITH HOT ENGINE AND EXHAUST
COMPONENTS MAY CAUSE BURNS. ALLOW THE ENGINE SUFFICIENT
TIME TO COOL DOWN.
1) Open the engine (right hand) canopy.
2) Remove the power tray retaining bolt and swing the power tray away from the superstructure.
3) Swing power tray back in to position.
4) Reinstall retaining bolt and tighten. See section 2.6 for torque settings.
5) Close the engine canopy.
English 06/17 21
HR21 4x4 MK2
Service Manual
3.3.2 Engine oil level check (daily)

1
Kubota D902
1) Check with the Niftylift on level surface before

starting or more than 5 minutes after stopping
the engine.
2) Remove oil level dipstick (2) and wipe clean.
3) Insert dipstick and remove to check oil level.
4) If low, add correct specification oil to the oil
filling port (1) until the upper limit of the dipstick
is reached.
5) After adding oil, wait for 5 minutes and re-check
oil level. Do not overfill. 2
6) Reinstall the oil filler cap and tighten by hand.
MAX
MIN
Perkins 403D
1) Check with the Niftylift on level surface before
starting or more than 5 minutes after stopping 1
the engine.
4) If low, add correct specification oil to the oil
filling port (1) until the upper limit of the dipstick
is reached.
oil level. Do not overfill.
2
22 English 06/17
HR21 4x4 MK2
Service Manual
Kubota V1505
1) Check with the Niftylift on level surface before 2
starting or more than 5 minutes after stopping the 1
engine.
4) If low, add correct specification oil to the oil filling
port (1) until the upper limit of the dipstick is
reached.
oil level. Do not overfill.
MAX
MIN
3.3.3 Engine oil replace

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE OFF AND COOLED.
CAUTION
WHEN DRAINING ENGINE OIL, PLACE A CONTAINER UNDERNEATH THE
NOTICE ENGINE AND DISPOSE ACCORDING TO LOCAL REGULATIONS.
1) Remove the drain plug located on the underside of the engine and drain the oil into a suitable
container. Note; This will be easier if the oil is warm.
2) Replace seal ring and reinstall drain plug.
3) Tighten drain plug. See section 2.6 for torque settings.
4) Top up engine oil to the upper limit of the dipstick. Oil type and quantities can be found from the oil
specification table. See section 2.4.2.
5) Re-check oil level at least 5 minutes after filling engine.
English 06/17 23
HR21 4x4 MK2
Service Manual
3.3.4 Engine oil filter replace

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE OFF AND
CAUTION COOLED.
PLACE A CONTAINER UNDERNEATH THE ENGINE OIL FILTER AND
NOTICE DISPOSE ANY WASTE ACCORDING TO LOCAL REGULATIONS.
THE POWER TRAY RETAINING BOLT MUST BE INSTALLED AND
WARNING TIGHTENED TO THE SPECIFIED TORQUE BEFORE STARTING THE ENGINE.
Kubota D902
1) Remove the power tray retaining bolt and swing

the power tray away from the superstructure. See
section 3.3.1.
2) Using a filter wrench or strap, remove the engine
oil filter (1).
3) Replace oil filter, apply a film of oil to the seal of
the oil filter. Ensure oil filter is marked with the
Niftylift’s hours and date of filter change.
4) Screw oil filter onto engine by hand. When seal
contacts the seal surface, tighten oil filter by hand.
Do not tighten with filter wrench.
5) Swing power tray back in to position. 1
6) Reinstall retaining bolt and tighten. See section
2.6 for torque settings.
7) Run engine for a short period and check for leaks.
8) Wait 5 minutes and check the oil level.
Perkins 403D
1) Using a filter wrench or strap, remove the engine

oil filter (1).
2) Apply a film of oil to the filter seal and replace.
contacts the seal surface, tighten oil filter by hand.
Do not tighten with filter wrench.
4) Ensure oil filter is marked with the Niftylift’s
engine running hours and replacement date.
1
24 English 06/17
HR21 4x4 MK2
Service Manual
Kubota V1505
1) Using a filter wrench or strap, remove the engine oil

filter (1).
2) Apply a film of oil to the filter seal and replace.
contacts the seal surface, tighten oil filter by hand. Do
not tighten with filter wrench.
4) Ensure oil filter is marked with the Niftylift’s engine
running hours and replacement date.
English 06/17 25
HR21 4x4 MK2
Service Manual
3.3.5 Engine coolant level check (daily)

DO NOT STOP ENGINE SUDDENLY AFTER OPERATING, ALLOW ENGINE TO
NOTICE IDLE BEFORE SWITCHING OFF.
WORK SHOULD BE CARRIED OUT AFTER LETTING THE ENGINE AND
RADIATOR COOL DOWN COMPLETELY (A MINIMUM OF 30 MINUTES
AFTER STOPPING ENGINE).
RISK OF BURNS - DO NOT REMOVE RADIATOR CAP WHILST ENGINE
WARNING COOLANT IS HOT AND PRESSURISED. WHEN COOL TO TOUCH, ROTATE
CAP TO THE FIRST STOP TO ALLOW EXCESS PRESSURE TO ESCAPE,
THEN REMOVE CAP COMPLETELY.
IF OVERHEATING SHOULD OCCUR, STEAM MAY GUSH FROM THE
RADIATOR OR RESERVE TANK RESULTING IN SEVERE BURNS.
1) Remove the radiator cap after the engine has

completely cooled. Ensure the coolant level
reaches the supply port.
2) On Hybrid machines ensure coolant level is
sufficient on the reserve tank. The level should
be between the full and low marks.
3) If coolant levels are low, top-up using the
correct specification fluid. See section 2.4.5
for coolant specifications and 2.4.1 for fluid
volumes.
Important;
• If the radiator cap has to be removed follow the
caution label and securely tighten the cap.
• If coolant should leak, consult your local Kubota or Perkins approved dealer.
• Ensure contaminated or sea water does not enter the coolant system.
• Use clean, fresh water with the correct amount of anti-freeze. See section 2.4.5.
• Periodically check the antifreeze specific gravity for correct freeze protection. See section 3.3.7.
• Do not refill reserve tank with coolant higher than the "FULL" level mark.
• Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak
out and quickly decrease the coolant level. Replace the radiator cap if necessary.
26 English 06/17
HR21 4x4 MK2
Service Manual
3.3.6 Coolant replace

DO NOT STOP ENGINE SUDDENLY AFTER OPERATION, ALLOW ENGINE TO
NOTICE IDLE BEFORE SWITCHING OFF.
WORK SHOULD BE CARRIED OUT AFTER LETTING THE ENGINE AND
RADIATOR COOL OFF COMPLETELY (A MINIMUM OF 30 MINUTES AFTER
STOPPING ENGINE).
CAUTION COOLANT IS HOT AND PRESSURISED. WHEN COOL TO TOUCH, ROTATE
CAP TO THE FIRST STOP TO ALLOW EXCESS PRESSURE TO ESCAPE, THEN
REMOVE CAP COMPLETELY.
IF OVERHEATING SHOULD OCCUR, STEAM MAY GUSH FROM THE
RADIATOR OR RESERVE TANK RESULTING IN SEVERE BURNS.
PLACE A CONTAINER UNDERNEATH THE ENGINE AND DISPOSE ANY
NOTICE WASTE ACCORDING TO LOCAL REGULATIONS.
Kubota D902
1) Open both drain plugs and simultaneously
open the radiator cap. This must be
removed to allow a full coolant drain.
2) Remove the overflow pipe from the radiator
pressure cap to drain the reserve tank.
3) Ensure both drain plugs are installed; one to
the lower part of the radiator (2) and the
other is on the side of the crank case (1). 2
4) See section 2.4.5 for coolant quantities and
fluid specifications.
1
Perkins 403D
1) Open both drain plugs and simultaneously
open the radiator cap. This must be
removed to allow a full coolant drain.
2) Ensure both drain plugs are installed; one to
the lower part of the radiator (2) and the
other is on the side of the crank case (1).
3) See section 2.4.5 for coolant quantities and
fluid specifications.
1 2
English 06/17 27
HR21 4x4 MK2
Service Manual
Kubota V1505
1) Open both drain plugs and simultaneously open 2 1
the radiator cap. This must be removed to allow
a full coolant drain.
2) Ensure both drain plugs are installed; one to the
lower part of the radiator (2) and the other is on
the side of the crank case (1).
3) See section 2.4.5 for coolant quantities and fluid
specifications.
3.3.7 Antifreeze check

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE SWITCHED OFF
CAUTION AND COOLED DOWN.
CAUTION COOLANT IS HOT AND PRESSURISED. WHEN COOL TO TOUCH, ROTATE
CAP TO THE FIRST STOP TO ALLOW EXCESS PRESSURE TO ESCAPE,
THEN REMOVE CAP COMPLETELY.
Periodically the antifreeze specific gravity should be checked to ensure suitable freeze protection.
1) Allow the engine to cool down and carefully remove the radiator cap.
2) Using a suitable antifreeze hydrometer, test the antifreeze specific gravity. See section 2.4.5 for the
appropriate protection level.
3) Replenish coolant if necessary; use a ratio of 1:1 clean water and antifreeze.
4) Reinstall the radiator cap, ensure it is securely fitted.
28 English 06/17
HR21 4x4 MK2
Service Manual
3.3.8 Coolant hoses and clamp bands check

BE SURE TO CHECK RADIATOR HOSES AND CLAMPS PERIODICALLY. IF
CAUTION RADIATOR HOSE IS DAMAGED OR COOLANT LEAKS, OVERHEATING OR
SEVERE BURNS MAY OCCUR.
1) Check radiator hoses are securely fixed every 200 hours of engine operation or 6 months (Kubota
D902 & V1505 engines) or 500 hours of engine operation or annually (Perkins 403D), whichever
occurs first.
2) If hose clamps are loose or water leaks, tighten hose clamps securely.
3) If hoses are swollen, hardened or cracked they must be replaced along with clamps. Clamps must be
tightened securely.
3.3.9 Air filter element maintenance

DO NOT APPLY OIL TO THE AIR FILTER; YOUR NIFTYLIFT IS FITTED WITH
NOTICE A DRY TYPE AIR FILTER. AVOID TOUCHING THE ELEMENT EXCEPT WHEN
CLEANING.
Kubota D902

section 3.3.1.
2) Open the evacuator valve once a week under
ordinary conditions, daily when used in a dust rich
environment. This allows dirt and dust to be
removed from the air filter.
3) Release spring clips and remove cover.
4) Slide out of the air filter body. Filter Element
5) Wipe inside the air cleaner with cloth if found to be Spring Clip
dirty or wet.
6) When dry dust adheres to the element, blow Evacuator valve
compressed air from the inside out whilst rotating
the filter. Air pressure must be no more than
686 kPa (7 kgf/cm2 99 psi).
7) When carbon or oil adheres to the filter, soak the filter in detergent for 15 minutes.
8) Wash it several times in water, rinse with clean water and allow to dry naturally.
9) After filter is fully dried, inspect the inside with a flashlight for damage. Refer to instruction label
attached to the filter.
10) Reinstall filter into the air filter body, reinstall cover and engage spring clips.
English 06/17 29
HR21 4x4 MK2
Service Manual
11) Replace filter element every year or after 6 cleanings. This is in standard operating conditions; dust
enriched operating environments will require shorter intervals.
Perkins 403D
1) Open the evacuator valve (1) once a week under 2

ordinary conditions, daily when used in a dust
rich environment. This allows dirt and dust to be
2) Release spring clips (2) and remove cover.
3) Remove the air filter element (3).
4) Wipe inside the air cleaner with cloth if found to
be dirty or wet. 3
5) When dry dust adheres to the element, blow
compressed air from the inside out whilst rotating
the filter. Air pressure must be no more than 1
207 kPa (2.2 kgf/cm2 30 psi).
6) Reinstall filter into the air filter body, reinstall cover and engage spring clips.
7) Replace filter element after 500 hours of engine operation, annually or after 6 cleanings. This is in
standard operating conditions; dust enriched operating environments will require shorter intervals.
Kubota V1505

section 3.3.1.
2) Open the evacuator valve (1) once a week under
ordinary conditions, daily when used in a dust 4
rich environment. This allows dirt and dust to be
3) Remove bolt (2) and washer (3). 3
4) Slide the filter element (4) out of the air filter body.
1
5) Wipe inside the air cleaner with cloth if found to
be dirty or wet. 2
6) When dry dust adheres to the element, blow
compressed air from the inside out whilst rotating the filter. Air pressure must be no more than
686 kPa (7 kgf/cm2 99 psi).
7) When carbon or oil adheres to the filter, soak the filter in detergent for 15 minutes.
8) Wash it several times in water, rinse with clean water and allow to dry naturally.
30 English 06/17
HR21 4x4 MK2
Service Manual
9) After filter is fully dried, inspect the inside with a flashlight for damage. Refer to instruction label
attached to the filter.
10) Reinstall filter element into the air filter body.
11) Reinstall washer and hand tighten bolt.
12) Replace filter element every year or after 6 cleanings. This is in standard operating conditions; dust
enriched operating environments will require shorter intervals.
3.3.10 Air filter condition indicator check (daily)
Perkins 403D
Observe the air filter condition indicator (located on
the air filter housing). If the visual indicator is red, the
air filter element should be cleaned or replaced as
necessary. To reset, press the button (arrowed) on
the underside.
English 06/17 31
HR21 4x4 MK2
Service Manual
3.3.11 In-line fuel filter replace

FUEL ESCAPE - PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK
WARNING AREA AND DISPOSE FUEL ACCORDING TO LOCAL REGULATIONS.
1) Locate fuel filter under the control (left hand)

canopy. p
e l Pum
To Fu
2) Clamp the feed pipe from tank.
3) Loosen jubilee clips and remove fuel pipes. Fu el Tan
k
From
4) Replace fuel filter ensuring the arrow on the filter
points in the direction of fuel flow (tank to engine).
5) Tighten Jubilee clips. Flow Indicator
Place Clamp Here
6) Remove clamp from feed hose ensuring filter
refills with fuel.
7) Inspect for leaks.
8) Close the control canopy.
9) See section 3.3.14 for bleeding air from the fuel system before attempting to start the engine.
32 English 06/17
HR21 4x4 MK2
Service Manual
3.3.12 Fuel filter and water separator clean/replace

Kubota D902
1) Close the fuel filter tap (1). 2

2) Undo the top ring and remove container and fuel
filter (3).
3) Rinse out container with clean diesel fuel.
4) Wash fuel filter with clean diesel or replace if
necessary.
5) Observe clean assembly practices to avoid 1
contamination by dust or dirt.
OFF/CLOSED
6) Reinstall the container and tighten the top ring by
hand.
7) See section 3.3.14 for bleeding of air from the fuel 3
system before attempting to start the engine.
English 06/17 33
HR21 4x4 MK2
Service Manual
3.3.13 Fuel filter (cartridge type) replace

Perkins 403D
1) Undo bolt (1), remove the fuel filter (2) from the 1
housing.
6
2) Remove the fuel filter from the filter bowl (3).
3) Wash the filter bowl with clean diesel.
4) Replace seals 4 (x2), 5, and 6.
4
5) Replace fuel filter and reinstall filter bowl to 5

housing.
6) Tighten bolt.
2
7) See section 3.3.14 for bleeding of air from the
fuel system before attempting to start the engine.
Kubota V1505
2
1) Locate the fuel filter on the side of the engine and
clamp both the fuel pipes on the filter housing.
2) Using a filter wrench or strap, remove the fuel
filter (1).
3) Replace fuel filter with clean diesel.
4) Screw filter onto filter housing by hand. When
seal contacts the housing surface, tighten by
hand. Do not tighten with filter wrench.
5) Release the pipe clamp from the tank feed pipe 1
first followed by the outlet pipe.
6) See section 3.3.14 for bleeding of air from the fuel system before attempting to start the engine.
34 English 06/17
HR21 4x4 MK2
Service Manual
3.3.14 Bleeding air from the fuel system

DO NOT BLEED A HOT ENGINE. FUEL COULD SPILL ON TO THE EXHAUST
DANGER MANIFOLD CREATING A FIRE RISK.
ENSURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN WHEN
WARNING BLEEDING THE FUEL SYSTEM.
DO NOT OPERATE THE STARTER FOR MORE THAN 15 SECONDS. AFTER 15
NOTICE SECONDS, STOP AND WAIT 30 SECONDS BEFORE OPERATING THE
STARTER.
This procedure is required when;
• the fuel filter and hoses have been removed and installed
• the fuel tank has become empty
• the Niftylift has been in prolonged storage.
Observe the type of fuel filter installed and follow the respective bleed procedure.
Kubota D902
2
1) Fill the fuel tank.
2) Open the fuel filter tap (1).
3) Loosen air vent plug (2).
4) Crank the engine for a maximum of 15 seconds.
5) Tighten plug (2) once air bubbles are no longer
present in container (3). 1
6) Carry out procedure to bleed the fuel injection OFF/CLOSED
pump before attempting to start the engine.
3
Perkins 403D

2) Loosen air vent plug (1) on the fuel filter housing.
1
4) Tighten air vent plug once fuel flows and air
bubbles are no longer present.
5) Carry out procedure to bleed the fuel injection
English 06/17 35
HR21 4x4 MK2
Service Manual
Kubota V1505
2
2) Loosen the air vent plug on the filter housing (2).
3) Crank the engine for a maximum of 15 Seconds.
4) Tighten air vent plug when fuel flows and air
bubbles are no longer present.
5) Carry out procedure to bleed the fuel injection
Fuel injection pump
Kubota D902
1) Fill the fuel tank and bleed fuel filter.

2) Ensure air has been bled from the fuel filter.
1
3) Loosen air vent plug (1) on the fuel injection
pump.
5) Tighten plug once fuel flows and air bubbles are
no longer present.
6) Start the engine and inspect for leaks. If engine
fails to start repeat bleed procedure.
36 English 06/17
HR21 4x4 MK2
Service Manual
Perkins 403D

pump. 1
no longer present.
Kubota V1505

pump. 1
no longer present.
English 06/17 37
HR21 4x4 MK2
Service Manual
3.3.15 Fuel pipes check
1) Fuel pipes and clamps should be checked every 50 hours of engine operation on Hybrid machines
and every 500 hours of engine operation on Diesel machines.
2) If clamp bands are found to be loose, apply oil to screw of the band and tighten securely.
3) If rubber fuel pipes are found to be worn, replace immediately.
When fuel pipes are not installed, ensure they are capped to prevent dirt entering. Failure to cap pipes
could lead to fuel injection pump malfunction.
3.3.16 Exhaust system check

CAUTION AND COOLED DOWN. BEWARE OF HOT ENGINE COMPONENTS.

2) Remove the power tray retaining bolt and swing the power tray away from the superstructure. See
section 3.3.1.
3) Inspect the exhaust components for signs of cracks and leaks; e.g. carbon build up around joints and
seams.
38 English 06/17
HR21 4x4 MK2
Service Manual
3.3.17 Fan belt check

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE OFF AND COOLED.
CAUTION
Kubota D902 & V1505 - Every 100 engine running

hours
1) Ensure engine is switched OFF.

2) Apply moderate pressure to belt using your thumb
in area shown on diagram. If dimension A does 1
not fall in the range 7 to 9mm (0.28 to 0.35in).
3) Loosen the alternator mounting bolts (1) and
adjust accordingly until the belt deflection falls
within these limits. A
4) Tighten alternator mounting bolts. See section 2.6
for torque settings.
5) If belt is damaged, replace immediately.
Perkins 403D - Every 250 engine running hours
1) Ensure engine is switched OFF.

2) Install a suitable belt tension gauge e.g. Burroughs
Gauge at point A. A
3) Check the belt tension; a new belt should be 400 N
(90 lb) to 489 N (110 lb) and a used belt (that has
been in operation for 30 minutes) should be 267 N
(60 lb) to 356 N (80 lb).
2
4) Loosen the alternator mounting bolts (1) and
adjusting bolt (2). 1
5) Adjust until the belt tension falls within the correct
limits.
6) Tighten alternator mounting and adjusting bolts.
See section 2.6 for torque settings.
7) If belt is damaged, replace immediately.
English 06/17 39
HR21 4x4 MK2
Service Manual
3.4 Drive hub gearbox
3.4.1 Gearbox disengagement

When towing or winching it will be necessary to disengage the gearbox drive hubs. Ensure the gearbox
drive hubs are engaged once manoeuvres are complete.
REINSTALL THE COVER PLATE IMMEDIATELY, DO NOT ATTEMPT TO
CAUTION ROTATE THE DRIVE WHEELS OR MOVE THE MACHINE WITH A COVER
PLATE REMOVED.
FAILURE TO ENGAGE THE GEARBOX DRIVE HUBS COULD RESULT IN LOSS
DANGER OF CONTROL OF THE MACHINE. DEATH OR SERIOUS INJURY MAY
OCCUR.
Disengage
1) Ensure the Niftylift is on level ground and the platform is stowed.

2) Chock the steer wheels.
3) Using a suitable jack, raise the rear of the Niftylift until the wheels are clear of the ground.
4) Ensure the Niftylift is supported on suitable stands, not the jack.
5) Remove 2 screws from the cover plate and turn it over.
6) Reinstall screws and tighten to 5 Nm (3.7 lbf·ft).
7) Carry out procedure on the other gearbox; ensure both wheels rotate with minimum effort.
8) Raise the Niftylift and remove the stands.
9) Lower the Niftylift and chock the rear wheels.
10) Using a suitable jack, raise the front of the Niftylift until the wheels are clear of the ground.
11) Repeat steps 4 to 8.
12) Lower the Niftylift, ensure the wheels remain chocked when static.
TYRE GEARBOX ENGAGED

POSITION
WHEEL
GEARBOX DISENGAGED
POSITION
40 English 06/17
HR21 4x4 MK2
Service Manual
Engage
13) Chock the steer wheels.
14) Using a suitable jack, raise the rear of the Niftylift until the wheels are clear of the ground.
15) Ensure the Niftylift is supported on suitable stands, not the jack.
16) Remove 2 screws from the cover plate and turn it over.
17) Reinstall screws and tighten to 5 Nm (3.7 lbf·ft).
18) Carry out procedure on the other gearbox, rotate each wheel to ensure correct engagement.
19) Raise the Niftylift and remove stands.
20) Lower the Niftylift and chock the rear wheels.
21) Using a suitable jack, raise the front of the Niftylift until the wheels are clear of the ground.
22) Repeat steps 15 to 19.
23) Lower the Niftylift and remove the jack.
24) Remove chocks from the rear wheels.
3.4.2 Gearbox oil replace

Manufacturer’s specifications require this procedure to be carried out after the first 50 hours, then every
2500 hours or annually. Depending on the operating cycle this frequency may vary.
1) Select the drive hub to be serviced. Manoeuvre the

1
Niftylift until the drive hub is in position A
(see diagram). A
2) Remove plugs (1) and (2) and drain the oil into a
suitable container. Dispose of waste oil in accordance
with local environmental policies.
3) Manoeuvre the Niftylift until the drive hub is in position
B (see diagram).
4) Fill gearbox through plug hole (1) until oil level reaches
bottom of plug hole (2). See section 2.4.1 and 2.4.3
for oil specifications and capacities. 2
5) Reinstall plugs, tighten to 33 Nm (24 lbf·ft). 1
6) Repeat for remaining gearbox. B
English 06/17 41
HR21 4x4 MK2
Service Manual
3.4.3 Bleeding air from the braking circuit

WARNING OPENING THE HYDRAULIC CIRCUIT.
PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK AREA AND
NOTICE DISPOSE OIL ACCORDING TO LOCAL REGULATIONS.
1) Connect the hydraulic couplings to the brake ports on the gearbox.

2) Pressurise the hydraulic circuit, then carefully loosen the hose union on the inlet port.
3) Tighten the hose union once oil flows and air bubbles are no longer present. See section 2.7 for
hydraulic hose torque settings.
4) Clean any excess oil and inspect for leaks.
3.5 Batteries
MAKE SURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN
WARNING WHEN MAINTAINING THE BATTERIES.
MAKE SURE THERE IS ADEQUATE VENTILATION WHEN CARRYING OUT
MAINTENANCE ON THE BATTERIES.
CONTACT WITH CONCENTRATED SULFURIC ACID RESULTS IN RAPID
WARNING DESTRUCTION OF BODY TISSUE VIA BURNS. IF INHALED, SEEK FRESH
AIR AND IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF SKIN OR
EYE CONTACT, FLUSH WITH LARGE VOLUMES OF WATER AND SEEK
IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF INGESTION, DO NOT
INDUCE VOMITING AND SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES ARE MAINTENANCE FREE AND DO NOT REQUIRE TOPPING
NOTICE UP. IF IGNORED, IRREPARABLE DAMAGE TO THE BATTERY WILL OCCUR.
UNDER NO CIRCUMSTANCES SHOULD A MACHINE BE LEFT FULLY
NOTICE DISCHARGED AS SEVERE BATTERY DAMAGE CAN OCCUR IN A
RELATIVELY SHORT TIME.
3.5.1 Condition check (daily)
1) Check that the batteries are fully charged. Batteries should be recharged at the end of each working
day or shift. See manufacturer's Operating Manual for correct battery charging procedure.
2) Check batteries for evidence of leaks or spilt battery acid. If material is released or spilled, lime or
soda ash may be used to neutralise, or flush with large volumes of water. Dispose of waste in
accordance with local regulations for acid and lead scrap. Use approved respiratory protection,
rubber gloves, and splash-proof safety goggles. Use rubber boots and acid-proof clothing for major
spills. Replace any defective batteries.
3) Check the condition of battery cables and link wires. Ensure that the insulation is intact along the
length of each cable. Replace any defective battery cables or link wires. Where applicable use
insulated spanners on battery terminals. Do not lay tools or other metal objects on the batteries.
42 English 06/17
HR21 4x4 MK2
Service Manual
4) Check that all battery cables, clamps and link wires are securely fastened to the battery terminals.
5) Clean and remove any corrosion from the battery terminals and clamps. For Absorbent Glass Mat
(AGM) batteries, apply petroleum jelly (See section 3.2.1) to the battery clamps and terminals if
necessary.
3.5.2 Storage
Should the Niftylift be unused for a period of time, it will be necessary to fully charge the batteries to prevent
irreversible damage.
IF A BATTERY IS DISCHARGED, ENSURE THAT IT IS CHARGED UP BEFORE
NOTICE BEING LEFT IDLE FOR AN EXTENDED PERIOD OR PUT INTO STORAGE
REGULAR MONITORING AND MAINTENANCE OF BATTERIES IS ESSENTIAL
NOTICE DURING STORAGE OR IDLE PERIODS. IF BATTERIES DISCHARGE BELOW
A CERTAIN VOLTAGE THEY BECOME UNUSABLE AND MUST NOT BE
RECHARGED. BATTERY FAILURE CAUSED BY NEGLECT WILL NOT BE
COVERED UNDER WARRANTY. IT IS THEREFORE IMPERATIVE THAT THE
FOLLOWING INSTRUCTIONS ARE ADHERED TO.
Absorbent Glass Mat (AGM) batteries

Before placing the Niftylift into storage, ensure batteries are fully charged to 6.42V open circuit voltage
(100% state of charge). Isolate batteries (See section 1.5.6). Monitor open circuit voltage every 2 - 3
months (1 - 2 months if stored in temperatures greater than 32°C (90°F)). Batteries in storage should be
charged when they decline to 6.27V (75% state of charge).
Where possible always keep batteries in cool, dry environments. Storage in hot environments can
negatively impact batteries. Avoid direct exposure to heat sources during storage. Batteries self-discharge
faster at high temperatures.
Avoid storing in freezing temperatures, batteries can freeze in cold temperatures (less than 0°C (32°F)) if
they are not fully charged. If batteries are stored in cold environments, it is critical that they be kept at a
high state of charge.
Due to the potential for self-discharge during storage, batteries should be given a full charge prior to
placing back into service.
Lithium (Li-ion) batteries

Before placing the Niftylift into storage, ensure batteries are charged above the minimum storage voltage
of 50.12V (25% state of charge). Isolate batteries (See section 1.5.6).
Ensure that the battery does not drop below 42.0V at any time. If the battery pack is to be left unused for
more than 45 days, it must be checked periodically and if necessary, charged to ensure that the voltage
remains above 50.12V.
Where possible always keep batteries in cool, dry environments. While in storage the temperature should
be less than 70°C (158°F) and greater than -40°C (-40°F). Ideally the temperature should be less than 25°C
(77°F) and greater than 6°C (43°F).
Due to the potential for self-discharge during storage, batteries should be given a full charge prior to
placing back into service.
English 06/17 43
HR21 4x4 MK2
Service Manual
3.6 Hydraulic oil
3.6.1 Level check (weekly)

Ensure the Niftylift is on level ground with the platform stowed. Lift the control (left hand) canopy and
check that the oil level is between the minimum and maximum marks on the gauge. Top-up the tank with
oil if the level is below the minimum mark. Use the same oil grade as indicated on the label attached to
the hydraulic tank. If the oil level is above the MAX mark, drain as required. See section 3.6.4.
3.6.2 Return filter check (monthly)
2 4
40
60
20
1 5
80
87
bar 6
With the Niftylift running and the oil temperature at 40°C (104°F), operate the telescope out function and
observe the return filter condition indicator (located under the control (left hand) canopy). If the needle is
in the red zone, the return filter cartridge should be replaced once the oil has cooled sufficiently.
3.6.3 Pressure filter check (weekly)
With the Niftylift running and the oil temperature at 40°C (104°F), observe the pressure filter condition
indicator (located under the engine (right hand) canopy). If the visual indicator is red, the pressure filter
cartridge should be replaced once the oil has cooled sufficiently.
44 English 06/17
HR21 4x4 MK2
Service Manual
3.6.4 Hydraulic oil and filters replace

Replace the Hydraulic oil and filters after the first 500 hours of machine operation, then annually thereafter.
Replacement or testing of the hydraulic oil is essential for optimum machine performance.
Contaminated oil and filters may cause poor performance and continued use may cause
component damage. Depending upon the operating environment, more regular oil changes may
be required.
Observe clean working practices when servicing the hydraulic system.
1) Ensure that the Niftylift is on level ground with the platform stowed and the oil temperature is not
above 40°C (104°F).
2) Loosen the filler cap to relieve pressure. Caution must be taken when removing the tank cap as the
hydraulic tank is pressurised.
3) Place a suitable container under the hydraulic tank.
4) Remove the drain plug located on the underside of the tank.
5) Dispose of waste oil in accordance with local environmental policies.
Suction filter
6) Locate the suction strainer hose on the hydraulic
tank.
7) Undo clamp bands (1) and remove hose. 1
8) Remove strainer (2) from the hydraulic tank.
9) Clean with mild solvent or replace if necessary.
2
10) Reinstall suction hose and tighten clamp bands.
Return Filter
11) Locate the return filter underneath the control (left
hand) canopy.
12) Remove 3 bolts (1) and remove housing cover. 1
13) Remove seal ring (2). 2

14) Remove filter element (3) from bowl (4). 3
15) Remove seal ring (5). 4
16) Replace filter element and seal ring and lower

bowl into housing. 5
17) Lubricate seal rings with clean hydraulic oil.
18) Replace seal ring and reinstall housing cover.
19) Tighten 3 bolts to 10.0 Nm (7.4 lbf·ft).
English 06/17 45
HR21 4x4 MK2
Service Manual
Pressure Filter
20) Locate the pressure filter on the power tray.
21) Place a suitable container underneath filter
housing. 2
22) Remove the filter bowl (1) and seal ring (2).
23) Remove filter element (3) and seal ring (4). 3
24) Replace seal rings on filter bowl, lubricate with

clean hydraulic oil.
4
25) Replace filter element. 1
26) Reinstall filter bowl, ensure it is tight. DO NOT
OVER TIGHTEN.
27) Reinstall drain plug in hydraulic tank and tighten
to 55 Nm (41 lbf·ft).
28) Refill tank with oil until level is between MIN and MAX on gauge. See section 2.4.1 for capacity and
2.4.4 for oil specification.
29) Operate the hydraulic system until oil temperature reaches 40°C (104°F). Check operation and
inspect for leaks.
46 English 06/17
HR21 4x4 MK2
Service Manual
3.7 Telescopic boom
3.7.1 Wear pad check (monthly)

2
2 2
1) With the links and luffing boom down and the 1
telescope boom fully retracted, check that there 2
are no loose, missing, or defective components in 1 1
the superstructure end of the telescope boom.
This includes wear pads, shims, spacers and
fasteners.
1 1
2) Fully extend the telescope boom.
2
3) It may be necessary to raise luffing boom slightly 2
to avoid the platform hitting the floor. 1
4) Check that there are no loose, missing, or
1
defective components in the platform end of the
telescope boom. This includes wear pads, shims, 2 2
spacers, fasteners, wear screws and locking nuts.
5) Check the clearance between each of the 6 wear screws and the inner telescope boom sections.
6) If adjustment is required, release the locking nut (1) and tighten each wear screw (2) until it makes
contact at the tightest point with the inner telescope boom section.
7) Back-off each wear screw until it no longer touches the inner telescope boom, then tighten the locking
nuts.
8) Check that the underside of the inner telescope boom section is adequately lubricated and free from
scoring or rubbing marks.
9) Lubricate if necessary using white grease. See section 3.2.1.
3.7.2 Hose trunking and energy chain check (weekly)
1) Examine the hose trunking and check that there are no loose, missing, or defective components.
2) Check that the hose trunking does not make contact with or “snag” on the boom structure at any point
over its range of travel.
3) With the telescope section fully extended, check that the trunking system adequately supports the
weight of the hose bundle. The upper section of aluminium trunking should be approximately parallel
with the top surface of the boom.
4) Check the condition of the energy chain, paying particular attention to the condition of the links at both
ends, as this is where the highest loads and wear rates occur. See section 4.3.1 if any links require
replacement.
5) Check that the energy chain is free from debris or any abrasive material that could cause damage to
the hydraulic hoses. Remove & dispose of any debris in accordance with local environmental
policies.
English 06/17 47
HR21 4x4 MK2
Service Manual
3.7.3 Lubricate boom pivot bushes (annually)

Annually lubricate all DU pivot bushes (1) on the Fly boom, Links and Telescope assemblies.
1 1 1
1
1
1
Use a dry PTFE aerosol lubricant spray. See section 3.2.1. Apply lubricant spray and allow to penetrate
at each of the pivot bush joints identified in the diagram above. Note; there are no grease or lubrication
nipples on the pivot bushes.
3.7.4 Boom pivot pin check (daily)

Check the respective locking device on each boom pivot pin is installed and secure.
3.7.5 Boom chain inspection

Every 6 months of operation (more frequent in hostile environments), the leaf chains should be inspected
and lubricated. Every 4 years a full chain inspection must be carried out. Please refer to Chain Service &
Inspection Manual (M50280) for further information.
3.8 Boom rotation gear
3.8.1 Slew gear engagement check (monthly)
1) Check the play between the slew ring and pinion.

2) With the telescope boom fully extended, manually push the booms from side-to-side. A small amount
of play is permissible.
3) Inspect the slew gear for signs of uneven wear, damage or missing teeth.
4) Rotate the machine through a full revolution and check that there are no tight spots where the
superstructure struggles to rotate.
48 English 06/17
HR21 4x4 MK2
Service Manual
3.8.2 Lubricate slew ring (monthly)

DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING.
NOTICE
1) Open the engine (right hand) canopy to gain access.

2) Two grease nipples (1) are located on the side of the superstructure.
3) Pump the grease gun two to three times as required. Use black EP grease (See section 3.2.1).
3.8.3 Slew ring bolts check (annually)

Access the outer slew ring bolts via the aperture in the superstructure. See section 2.6 for torque settings.
English 06/17 49
HR21 4x4 MK2
Service Manual
3.9 Front axle
3.9.1 Lubricate steer pin (daily)
1) Two grease nipples (1) are located on

either side of the front axle.
2) Pump the grease gun two to three times as
required. Use black EP grease (See section
1
3.2.1).
50 English 06/17
HR21 4x4 MK2
Service Manual
4 Repair procedures
4.1 General
4.1.1 Fuses
Main replaceable fuses on the Niftylift:
• 125A SIBA 80V DC - Engine (Hybrid),
• 325A SIBA 80V DC - Engine (Diesel),
• 125A SIBA 80V DC (x2) - Lithium batteries,
• 225A SIBA 80V DC - Descent motor (Hybrid and Diesel),
• 325A SIBA 80V DC - Battery power circuit (Hybrid only).
In addition to the main fuses, fuses can be found in the following locations:
• Ground Controls - Module Box 1 and DC converter,
• Power Tray - Module Box 2 and 3,
• Cage Controls.
Prior to the replacement of any fuse, determine the cause of the fault. Do not replace the fuse until the
cause of the fault has been remedied. When replacing SIBA fuses, tighten the fixing nuts to
16 Nm (12 lbf·ft).
Isolate Niftylift from power supply during maintenance of the electrical system. (See section 1.5.6).
The replacement fuse must always be the same rating as the defective one.
See location diagrams.
Hybrid - AGM batteries
125A
225A
325A
English 06/17 51
HR21 4x4 MK2
Service Manual
Hybrid - Lithium batteries
125A
125A
225A
325A
125A
Diesel
325A
225A
52 English 06/17
HR21 4x4 MK2
Service Manual
DC converter (Hybrid)
30A
DC converter (Diesel V1505)
English 06/17 53
HR21 4x4 MK2
Service Manual
Module box1 - Hybrid Kubota D902, Diesel Perkins 403D and Diesel Kubota V1505
Located under the control (left hand) canopy.
1 6 11 16 21 26
2 7 12 17 22
3 8 13 18 23
4 9 14 19 24
5 10 15 20 25
No. Circuit Type No. Circuit Type

1 Main control system supply 20A Mini ATO 14 PLC Supply outputs 15A Mini ATO
58VDC (VBB4 EX 10) 58VDC
2 Tracker supply 2A Mini ATO 15 PLC Internal relay supply (VBBREL 15A Mini ATO
58VDC EX 51) 58VDC
3 Charging signal input 2A Mini ATO 16 Ground control supply 2A Mini ATO
58VDC 58VDC
4 Chassis 12V- to GND 2A Mini ATO 17 Interface port supply 2A Mini ATO
58VDC 58VDC
5 Converter 0V link 20A Mini ATO 18 Tilt sensor supply 2A Mini ATO
58VDC 58VDC
6 PLC Internal Relay supply (VBB15 2A Mini ATO 19 Boom switch supply 2A Mini ATO
ST 32) 58VDC 58VDC
7 PLC Supply sensor / modules 2A Mini ATO 20 Tele switch supply 2A Mini ATO
(VBBs ST 10) 58VDC 58VDC
8 PLC Supply via relay 15A Mini ATO 21 FUEL LEVEL Supply 2A Mini ATO
(VBBr ST 01) 58VDC 58VDC
9 PLC Supply output 15A Mini ATO 22 FUEL LEVEL signal to 0V 330Ω
(VBBo ST 19) 58VDC
10 Cage E-stop supply 5A Mini ATO 23 Engine control supply 10A Mini ATO
58VDCa) 58VDC
11 PLC Supply outputs 15A Mini ATO 24 CAN connectors supply 5A Mini ATO
(VBB1 EX 19) 58VDC 58VDC
12 PLC Supply outputs 15A Mini ATO 25 Ground key switch supply 2A Mini ATO
13 PLC Supply outputs 15A Mini ATO 26 Hydraulic pressure sensor supply 2A Mini ATO
a) 10A Mini ATO 58VDC is installed on machines with Dual USB charger.
54 English 06/17
HR21 4x4 MK2
Service Manual
Module Box 2 - Hybrid (Kubota D902)

Located under the engine (right hand) canopy.
No. Circuit Rating

1 Motor engine shut down relay 35A/12V Ultra
Micro Relay
2 Ignition relay 35A/12V Ultra

Micro Relay
2 1
3 CAN1&2 BUS resistor 120Ω
4 CAN4 BUS resistor Reserved 3 4 5

5 Motor controller supply 10A Mini ATO
58VDC
Module Box 3 - Hybrid (Kubota D902)

No. Circuit Rating

1 Glow supply 50A J CASE
FUSE 32VDC
2 Starter coil supply 20A J CASE 1

FUSE 32VDC
3 Governor supply 15A Mini ATO 2 3

58VDC
English 06/17 55
HR21 4x4 MK2
Service Manual
Module box 2 - Diesel (Perkins 403D)

No. Circuit Rating

1 Motor Engine shut down relay 35A/12V Ultra
Micro Relay
1
2 CAN4 BUS resistor 120Ω
3 CAN1&2 BUS resistor 120Ω 3 2
Module box 3 - Diesel (Perkins 403D)

No. Circuit Rating

FUSE 32VDC 1
2 Starter coil supply 20A MINI ATO
58VDC 2
56 English 06/17
HR21 4x4 MK2
Service Manual
Module box 2 - Diesel (Kubota V1505)

No. Circuit Rating

1 High rev relay (throttle pull) 35A/12V Ultra
Micro Relay
2 Motor engine shut down relay 35A/12V Ultra
1 2
Micro Relay
3 CAN1&2 BUS resistor 120Ω 3 4
4 Fuel pump & stop hold 5A Mini ATO
solenoid supply 58VDC
Module box 3 - Diesel (Kubota V1505)

No. Circuit Rating

FUSE 32VDC 1 2
2 Starter & stop pull coil supply 40A J CASE
FUSE 32VDC
English 06/17 57
HR21 4x4 MK2
Service Manual
Cage controls PCB

To access the cage control panel fuses, remove 6 screws (1).
1
1
1
1
No. Circuit Rating

1 Main cage supply 5A ATO 32VDC
2 Cage enable 3A ATO 32VDC
3 Cage rotate 3A ATO 32VDC

4
4 Dual USB charger 5A ATO 32VDC
2 1
58 English 06/17
HR21 4x4 MK2
Service Manual
4.2 Platform/cage
4.2.1 Footswitch - contact switch replace

The footswitch is used to provide power to the
Niftylift controls.
Remove 1
1) Isolate Niftylift from power supply. (See section
1.5.6). 2
2) Remove bolts (1) and (2) and remove the
footswitch cover and rubber gasket.
Note; the longer length of bolt (1).
3) Record wiring locations.
4) Disconnect wiring from switch terminals (3).
5) Remove 2 screws (4) from contact switch and
remove.
Install
6) Replace contact switch and tighten 2 screws. 3
7) Connect wiring to contact switch terminals as
observed in step 3.
4
8) Reinstall footswitch cover and rubber gasket
making sure bolts are in the same position as
step 2.
9) Tighten bolt (1) to 3.0 Nm (2.2 lbf·ft) and bolt
(2) to 2.5 Nm (1.8 lbf·ft).
10) Connect the power supply (See section 1.5.6).
English 06/17 59
HR21 4x4 MK2
Service Manual
4.3 Booms
Booms are safety critical components, please contact your nearest Niftylift approved dealer for further
information.
4.3.1 Energy chain link
Remove
1) Operate telescopic boom to access the worn

or damaged link.
2) Insert a small flat screwdriver into chain
bridge (1) and lever upwards.
3) Lift out the chain bridges.
4) Repeat step 2 and step 3 and remove lower
chain bridges.
5) Carefully prise apart link (2) at the four points
arrowed.
6) Remove link from chain.
Install
7) Replace link to chain and click into position.
2
8) Reinstall upper and lower chain bridges and 1
click into position.
60 English 06/17
HR21 4x4 MK2
Service Manual
4.4 Power tray
4.4.1 Exhaust
Kubota D902
Remove
1) Isolate Niftylift from power supply. (See section 4

1.5.6).
3) Remove the power tray retaining bolt. (See section 2
3.3.1).
4) Swing the power tray away from the superstructure.
5) Remove the exhaust clamp (1) from the exhaust
silencer.
6) Remove 4 retaining nuts (2).
7) Remove the exhaust pipe (3) and gasket (4).
1
8) Remove 4 retaining bolts (5) on the radiator bracket. 3
9) Remove exhaust silencer (6). 5
5
Install
10) Replace exhaust silencer.
11) Reinstall 4 retaining bolts to the front mounting
bracket and tighten. See section 2.6 for torque
settings.
12) Replace gasket on manifold.
13) Replace the exhaust pipe and tighten 4 nuts. See 6
section 2.6 for torque settings.
14) Reinstall the exhaust clamp and tighten to 20 Nm (15 lbf·ft).
16) Reinstall power tray retaining bolt and tighten. See section 2.6 for torque settings.
English 06/17 61
HR21 4x4 MK2
Service Manual
Perkins 403D
Remove

2) Remove the power tray retaining bolt. (See section 2 4
3.3.1).
silencer. 3
6) Remove the exhaust pipe (3) and gasket (4).
7) Remove 4 retaining bolts (5).
8) Remove exhaust silencer (6). 1
Install 5
9) Replace exhaust silencer. 5
settings.
12) Replace the exhaust pipe and tighten 4 nuts. See
section 2.6 for torque settings.
13) Reinstall the exhaust clamp and tighten to 6
20 Nm (15 lbf·ft).
62 English 06/17
HR21 4x4 MK2
Service Manual
Kubota V1505
Remove
4
1.5.6).
3) Remove the power tray retaining bolt. (See section 2
3.3.1).
silencer.
7) Remove the exhaust pipe (3) and gasket (4). 1 3
8) Remove 4 retaining bolts (5) on the radiator bracket.
9) Remove exhaust silencer (6).
5
Install
10) Replace exhaust silencer. 5
settings.
13) Replace the exhaust pipe and tighten 4 nuts. See
section 2.6 for torque settings. 6
14) Reinstall the exhaust clamp and tighten to
20 Nm (15 lbf·ft).
English 06/17 63
HR21 4x4 MK2
Service Manual
4.4.2 Fan belt

Kubota D902
Remove
1) Open the engine (right hand) canopy. 1

2) Remove the power tray retaining bolt. (See
section 3.3.1).
3) Swing the power tray away from the
superstructure.
4) Remove 4 bolts (1) and remove fan guard.
5) Loosen the alternator mounting bolts and
remove the fan belt.
Install
6) Replace fan belt.
7) See section 3.3.17 for fan belt adjustment.
8) Reinstall fan guard and tighten 4 bolts. See section 2.6 for torque settings.
Perkins 403D
1
Remove

2) Remove the power tray retaining bolt. (See section
3.3.1).
4) Remove 4 bolts (1) and remove fan guard.
5) Loosen the alternator mounting bolts and remove the
fan belt.
Install
64 English 06/17
HR21 4x4 MK2
Service Manual

Kubota V1505
Remove
1
2) Remove the power tray retaining bolt. (See section
3.3.1).
4) Remove 4 bolts (1) and remove the fan guard.
5) Loosen the alternator mounting bolts and remove the
fan belt.
Install
English 06/17 65
HR21 4x4 MK2
Service Manual
4.5 Base assembly
4.5.1 Steer cylinder

WARNING OPENING THE HYDRAULIC CIRCUIT.
PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK AREA AND
NOTICE DISPOSE OIL ACCORDING TO LOCAL REGULATIONS.
Remove
1
1) Ensure the Niftylift is in its stowed
position.
2) Centre the steering so wheels point 1
straight ahead.
3) Undo 4 bolts and remove the cover
3
attached to the front axle.
4) Observe clean assembly practices to 3
avoid contamination by dust or dirt. 2
5) Carefully remove 2 hydraulic hoses from 2
the steer cylinder. Slowly loosen fittings to
allow pressure to dissipate.
6) Insert plugs and cap to prevent oil loss.
7) Remove and discard 2 roll pins (1) from the steer rod arms.
8) Remove 4 bolts, 8 washers and 4 nuts (2).
9) Remove steer cylinder from front axle.
10) Remove and retain 2 bushes (3) fitted to each eyelet on the steer cylinder.
Install
11) Reinstall 2 bushes retained in step 10 to the steer cylinder eyelets.
12) Replace steer cylinder.
13) Reinstall 4 bolts, 8 washers and 4 nuts.
14) Tighten bolts to 215 Nm (159 lbf·ft).
15) Replace roll pins to the steer rod arms.
16) Connect hydraulic hoses and tighten connectors. See section 2.7 for torque settings.
17) Operate the hydraulic system until oil temperature reaches 40°C (104°F). Check operation and
inspect for leaks.
18) Check hydraulic oil level and top up with appropriate grade of oil if necessary (See section 2.4.4).
19) Reinstall cover to front axle and tighten 4 bolts. See section 2.6 for torque settings.
66 English 06/17
HR21 4x4 MK2
Service Manual
4.6 Superstructure
4.6.1 Tilt sensor
Remove

1.5.6).
2) Locate tilt sensor under the lower booms on the
superstructure.
1
3) Disconnect wiring harness from the tilt sensor.
4) Undo 4 bolts (1) and remove.
Install
5) Apply thread locking adhesive to bolt threads.
(See section 3.2.1).
6) Replace the tilt sensor, hand tighten bolts at this
stage.
7) Tighten 4 bolts to 2.5 Nm (1.8 lbf·ft). DO NOT OVERTIGHTEN.
8) Connect wiring harness to tilt sensor.
4.6.2 Sensor calibration

Under certain conditions or following maintenance, it will be necessary to a perform a sensor calibration.
This is done via the display unit in the ground controls. For further information on the display unit, refer to
the Operating and Safety Instructions Manual supplied with the Niftylift.
To calibrate the sensors, ensure the Niftylift is parked on flat, level ground. Check that the booms are on
the rest, the chassis tilt is ±1 degree of level and if relevant the Niftylift is ±2 degrees of level.
1) Select SENSOR CALIBRATION in the menu. (The

Niftylift will then check the configuration to ensure
calibration is possible).
ok
English 06/17 67
HR21 4x4 MK2
Service Manual
2) The inclination values and boom status are

displayed on the screen, those which do not meet
the calibration requirements will be highlighted.
3) If necessary correct the boom status and
inclination values.
4) Once configuration is correct, contact Niftylift

using the details displayed and quote the
reference number displayed on the screen.
5) Press OK.
6) Enter the four digit reset code supplied by Niftylift

using the arrow keys, then press OK.
7) If the entered code is correct the screen will
display a green tick, and automatically redirect
back to the menu. If the code is incorrect the
screen will display a red cross and automatically
redirect back to the code entry.
68 English 06/17
HR21 4x4 MK2
Service Manual
5 System overview
5.1 Introduction
5.1.1 Hybrid system

The main hardware for this system consists of the following:
(1) 16.1 kW Kubota diesel engine
(2) Centrifugal clutch
(3) Motor/generator
(4) Motor controller
(5) 315 bar (4569 psi) 18cc variable displacement pump.
The hybrid system is self-contained and can run in either electric or hybrid mode.
When used in hybrid mode the power train can provide an equivalent of 30.3 kW power to the pump,
14.2 kW from motor and 16.1 kW from diesel engine. This allows the machine to work as a full
performance 4x4 machine when required but keeping the energy consumption and noise levels as low as
possible when performing lower duty operations. When in electric only mode the machine performs with
reduced noise and zero emissions.
4
1
5
3
2
English 06/17 69
HR21 4x4 MK2
Service Manual
5.1.2 Hybrid terminology
Term Description
Regeneration (Regen) State of the hybrid system during which the batteries are being charged
Boost State of the hybrid system during which the diesel engine is being
supported by power from the electric motor
Battery state Pre determined states of charge where the Niftylift will react differently
dependent on which one is active
Battery Discharge Indicator Indicates the % state of charge of the DC power batteries
(BDI)
5.1.3 Battery states
Battery states Hybrid reaction Electric reaction
Battery full 16% - 100% Full machine performance
Battery warning 11% - 15% Full machine performance - warning on display
Battery low 1% - 10% No boost, limited drive Reduced drive

speed based on power performance
available
Battery critical 0% Maximum regen at all No drive, limited boom

times dependent on function
power available
5.1.4 Power modes

Hybrid has three power modes, diesel only, electric only and hybrid. Modes are dependent on several
factors including battery state and component temperature.
Electric only
The Niftylift will operate using only power from the DC power batteries any time the engine is switched off.
Diesel only
Where the DC power batteries are below 10% of charge, boost will be disabled meaning all surplus power
from the engine is being used to charge (Regen) the DC power batteries.
Hybrid mode
The power option of the Niftylift when the engine is running and the battery state is above 10%, all hybrid
functionality is possible.
70 English 06/17
HR21 4x4 MK2
Service Manual
5.1.5 Operation
Boost
Boost is controlled automatically by monitoring the engine load and deciding whether boost is required
and to what level. It is enabled whilst the battery state is above battery low (10% on the way down and
15% on the way up) level and device temperatures are acceptable. Boost has priority over Regen at all
times except when in a battery low state.
The aim of boost is to maintain the minimum acceptable diesel RPM at all times up to maximum motor
controller current.
If at any point the battery state reaches Battery low <10% boost will only be activated again once the BDI
reaches 15%, this is to prevent erratic changes in performance when battery state is around 10%.
Regen
Regen is controlled automatically by monitoring the engine load and deciding whether there is surplus
power available. Regen is enabled if there has not been a boost demand and there is surplus power
available for a set period of time.
The regen map/charge algorithm consists of a constant current mode and a constant voltage mode which
adapt the level of charge dependent on the battery state.
Each type/manufacturer of battery requires a different algorithm and if batteries are changed an appropriate
algorithm must be used to ensure optimum performance at all times.
The regen level (max 40 Amps) is controlled by a number of variables, battery state and the surplus power
available.
Once the batteries are fully charged the control system will switch off regen until the BDI drops below
100% once again.
English 06/17 71
HR21 4x4 MK2
Service Manual
5.2 Diesel system

The main hardware for this system consists of the following:
(1) Perkins 403D 24.4 kW or Kubota V1505 18.5 kW diesel engine
(2) 315 bar (4569 psi) 28cc variable displacement pump.
Either a Perkins 403D 24.4 kW or a Kubota V1505 18.5 kW diesel engine, driving a 28cc variable
displacement (swash) pump powers the hydraulic system.
Perkins 403D
Kubota V1505
72 English 06/17
HR21 4x4 MK2
Service Manual
5.3 Boom system
5.3.1 Boom switch

Mounted on the links knuckle and operated by the raising of link booms or upper boom, this switch
controls both the operation of the Tilt Sensor, and the speed control function. With the booms in the
stowed position, the Tilt Sensor is by-passed, allowing the machine to negotiate slopes in excess of the
permissible elevated working angle, without isolating the drive function. At the same time, High Speed
drive (Depicted by a Hare Icon) is possible. When the booms are raised the Tilt Sensor is activated and
only Slow Speed drive is permitted. These control functions are of primary importance to safety of the
machine and operator; under no circumstances should this control function be isolated or by-passed.
5.3.2 Telescopic boom switch

Mounted inside the Telescopic Boom, this switch controls the operation of the Tilt Sensor and Speed
Control function as described in 5.3.1.
5.3.3 Boom enable valve

Mounted under the control canopy, this hydraulic valve block enables boom operation.
5.4 Drive system
5.4.1 Hybrid & diesel

The table below describes the available driving mode, speed and gradeability for both hybrid and diesel.
Driving mode Speed Gradeablity %
Diesel Electric
Hare 6.0 km/h (3.7 mph) 4.0 km/h (2.5 mph) 20
Tortoise 2.0 km/h (1.2 mph) 1.0 km/h (0.6 mph) 20
Off road 3.0 km/h (1.8 mph) 2.0 km/h (1.2 mph) 45
Elevated drive 0.7 km/h (0.4 mph) -
Electric only mode

All the listed driving modes are available in electric only operation. Available power is reduced to 14.2 kW
and hence performance is reduced. It is advisable to switch to hybrid mode when high power demand is
required e.g. off road driving.
Hybrid mode
In hybrid mode a full 30.3 kW of combined power is available for machine functions. In this mode the
machine consumes battery power to support the engine when required and regenerates battery power
when the function duty is low. Under continued high duty function for long periods (for example continued
4x4 off road driving) the battery levels will be significantly reduced to support the high power requirement.
Under such conditions it will be normal to have to recharge the battery levels prior to electric only use.
English 06/17 73
HR21 4x4 MK2
Service Manual
5.5 Charging system and batteries
5.5.1 Charging system - diesel

The engine alternator charges the start battery when the engine is running which keeps the battery at
14.4V.
5.5.2 Charging system - hybrid

As standard all Niftylifts are fitted with a 25A variable input intelligent charger. The Niftylift can be left on
charge over an infinite period or can be used whilst on charge.
Engine charge or regen will charge the batteries at differing rates up to a maximum of 40A depending on
the mode of operation.
The engine alternator charges the start battery when the engine is running which keeps the battery at
14.4V. A step-down unit is fitted to all Niftylifts to convert 48V to 14.4V, which provides control system
voltage and keeps the start battery in a charged state. This system also helps keep 48V batteries and the
12V battery in good condition regardless of the operating mode.
5.5.3 Absorbent Glass Mat (AGM) batteries

390 Ah Absorbent Glass Mat (AGM) batteries are fitted as standard. The Niftylift charger is tuned to
provide the best performance with AGM batteries. If alternative batteries are used the charger must be
reconfigured to suit the replacement batteries. Contact Niftylift for further information.
These batteries are maintenance free, therefore DO NOT REFILL with distilled (deionised) water.
Irreparable damage will occur.
5.5.4 Lithium (Li-ion) batteries

As an alternative to standard AGM batteries, two 111 Ah Lithium-Ion (Li-ion) batteries are used. Batteries
are given master and slave status with the master battery located in the control side battery carrier. Both
battery circuits are protected separately by a 125A SIBA fuse located within each battery carrier.
Should batteries require replacement, it will be necessary to programme the battery for master or slave
status. Under no circumstances should two batteries with the same status be installed. When replacing
batteries the open circuit voltage must be within 0.5V of each other before connecting. Alternative
batteries should not be used.
These batteries are maintenance free, therefore DO NOT REFILL with distilled (deionised) water.
Irreparable damage will occur.
Batteries should never be left in a discharged state and charged at the end of each working day or shift.
74 English 06/17
HR21 4x4 MK2
Service Manual
5.6 Hydraulic system overview

A simplified version of the hydraulic system is shown below in block diagram format. Brief descriptions
of the operation of individual blocks are given below. Component details, valve arrangement and
connections are shown in the hydraulic schematics. Please refer to the hydraulic schematics in
conjunction with the electric schematics listed in “Technical Documents” on page 4 for in-depth
understanding of the complete system.
SUSPENSION EMERGENCY
STEER CYLINDER
CYLINDER PUMP
SUSPENSION BOOM
HAND
VALVE CONTROL
PUMP
VALVE
OPEN LOOP BOOM

SWASH DRIVE ENABLE
PUMP CONTROL VALVE
VALVE
BRAKE RELEASE BRAKE RELEASE

REAR FRONT
ANTI
CAVITATION
VALVE
WHEEL MOTORS WHEEL MOTORS

REAR FRONT
5.7 Load sensing pump

The Niftylift is fitted with a variable displacement pump (open loop load sensing). See Pump specifications
table for information. The load sense signal is obtained either from the boom enable valve or from the drive
control valve. The tank is pressurised up to 1.3 bar (18.9 psi) absolute to allow positive head at the suction
port. Note that if any maintenance is carried out on the hydraulic system, undo the filler cap on top of the
English 06/17 75
HR21 4x4 MK2
Service Manual
tank to remove the pressure from the tank, this will reduce leakage from the tank ports. The pump runs at
fixed preset speeds and swash angle/pressure varies according to the flow demand and load pressure.
Pump specifications
HYBRID DIESEL
18cc Open Loop Swash Pump 28cc Open Loop Swash Pump
Standby pressure 17 bar (246.6 psi)
Maximum pressure 315 bar (4569 psi)
5.8 Drive control valve

This valve comprises several individual components all directly involved in the hydraulic supply to the
wheel drive motors. Amongst these are the drive control valves which allow the operator to propel the
machine forward or backward by using the Joystick.
In addition the Brake Release Valve (BRV) is also incorporated into this valve block. It is a solenoid
operated valve, which controls the brake function on the machine. This valve must be energised to allow
the machine to move. If no voltage is present, the wheel motors will not be able to develop drive torque,
whilst at the same time, the parking brakes will remain engaged. The BRV will only operate when a green
power button is being used (or the Platform Foot-switch is depressed) in Drive mode. If the tilt sensor
detects an excessive inclination whilst the booms are raised it is the BRV which is de-energised to isolate
the machine.
Refer to hydraulic schematic listed in Table 1.2 on page 4 for more details.
5.9 Four wheel drive (4x4)

The Anti-Cavitation Valve divides/combines the flow to all four wheels equally. Bypass restrictors are fitted
to help with cornering manoeuvres. 250 bar (3626 psi) pressure is supplied from the DCV.
As with all diff-lock systems, power consumption is increased with the diff-lock engaged, steering whilst
diff-lock is engaged further increases power consumption.
When Tortoise or Off-road speed is selected, the diff-lock is engaged and all four wheels are driven.
Diff-lock is not engaged when Hare speed is selected.
5.10 Brake release

The front and rear brakes are released via the DCV which is energised when driving. In drive condition
30 bar (435 psi) pressure is supplied to the gearboxes.
5.11 Steering
When steer is activated, steer flow is supplied from the DCV to the steer cylinder. Pressure Reduction
Valves fitted to the main DCV limit the maximum pressure on the steer line to 160 Bar (2321 psi). This
will disable steer when the cylinder reaches the end of stroke.
76 English 06/17
HR21 4x4 MK2
Service Manual
5.12 Suspension
Suspension valve
Drive pressure is supplied to the suspension valve from the main DCV. Maximum pressure to the cylinders
is limited to 75 bar (1088 psi).
5.13 Electrical control system overview
CAGE CAGE USER

WEIGH INPUTS SiOPS
48V
SUPPLY
SAFETY
INPUTS
MOTOR
MOTOR
CONTROLLER
BASE
BASE USER
CONTROL
INPUTS
ENGINE
12V
SUPPLY
OUTPUTS
TO
VALVES
5.14 Control logic

Component level details and connections are provided in the Electric Schematics listed in Table 1.2,
“Technical Documents,” on page 4.
English 06/17 77
HR21 4x4 MK2
Service Manual
5.15 Motor generator

As previously highlighted, a 48V AC 3 phase motor/generator is fitted to the power train. The motor is
equipped with a temperature and speed sensor which feeds information to the motor controller. Current
supplied to the motor is controlled by the motor controller. The motor can operate at full power (14.2 kW
output) for 20 minutes continuously. If the motor overheats the motor controller will reduce the current
supply and operate in a low power mode. Using the full available 350A line current, the motor can provide
60 Nm torque and 14.2 kW shaft power.
Curtis diagnostic unit
This unit can be used to monitor the operation of the motor controller and for troubleshooting. Under the
fault menu existing faults (if applicable) and previous faults are shown.
5.16 Motor controller

Motor/generator control
The motor controller has a current rating of 350A. It can supply a maximum power of 14.2 kW to the
motor (power input to the motor). High voltage safety functions are controlled within the motor controller.
If a fault is detected in the power supply, motor controller or motor; a main contactor will shut-off the
power to the motor controller. Under this condition a fault code will be displayed on the motor controller
status display. Under normal working conditions the LED of the motor controller status indicator flashes
orange continuously. In a fault condition the LED will flash red in a particular pattern as shown below.
“X” denotes a flash. A fault code of “23” is represented in the table below.
LED Status Indicator

RED Orange RED Orange
X XX XX XXX
First Digit (2) Second Digit (3)
See section 6.6.5 for the list of numerical flash codes and relevant fault descriptions. If overheating occurs
the motor controller will reduce power accordingly and protect the internal electronics.
78 English 06/17
HR21 4x4 MK2
Service Manual
5.17 Niftylift diagnostics

If the control system detects a malfunction, an error code will be displayed on the cage and ground control
display units. Diagnostic menus can be accessed via the display unit. See section 6.6 for error code and
diagnostic information.
For further information on accessing the diagnostic functions, refer to the Operating and Safety
Instructions Manual supplied with the Niftylift.
English 06/17 79
HR21 4x4 MK2
Service Manual
6 Troubleshooting guide
6.1 Troubleshooting information
This guide is designed to help identify and rectify faults more easily. Known faults are listed below. Your
specific Niftylift fault may not be listed here, if not please contact your local Niftylift approved dealer in
order for the guide to be continually improved and updated.
6.2 Platform function fault finding
Problem Cause / Test Solution

Check that power is reaching the solenoids on the Replace Drive Enable
drive block Relay
Niftylift will not drive Check main PCB for signal in from joystick and out
Loose connector
to drive block
Check joystick Replace joystick if faulty
Connect coupling.
Coupling failure Replace any damaged
No functions, but engine parts
operates correctly Contact switch may need
Footswitch fault replacement (See section
4.2.1)
Battery isolator depressed Release battery isolator
If fuse blown, replace

Check main fuses with direct replacement
(See section 4.1.1)
Niftylift inactive, engine Batteries discharged Recharge batteries

will not start
Ensure e-stops are pulled
E-stops activated out, at ground controls
and cage controls
Remove weight from

Cage weigh activated
cage
78 English 06/17
HR21 4x4 MK2
Service Manual
6.3 Engine fault finding

Check the fuel tank and fuel filter. Remove water, dirt and other
Fuel is thick and does not impurities
flow
If the filter is blocked, clean it with diesel
If air is in the fuel filter or injection lines, the fuel pump will not
work properly. To attain proper fuel injection pressure, check
Air or water mixed in fuel carefully for loosened fuel line couplings, loose cap nuts etc.
system
Loosen joint bolt at top of fuel filter and air vent screws of fuel
injection pump to eliminate all the air in the fuel system
This is caused when water or dirt is mixed in the fuel. Clean the
Thick carbon deposits on nozzle injection piece, being careful not to damage the orifice
orifice of injection nozzle Check to see if nozzle is working properly. If not, install a new
Engine nozzle
difficult
to start Valve clearance is incorrect Adjust valve clearance
leaking valves Grind valves
Fuel injection timing is wrong Adjust injection timing
Engine oil becomes thick in

cold weather and engine Change grade of oil appropriate to the ambient temperature
cranks slow
Bad valve or excessive wear of rings, pistons and liners cause

Low compression
insufficient compression. Replace with new parts
Charge start battery

Battery is discharged and the
engine will not crank In winter, always remove battery from the Niftylift, charge fully
and keep indoors. Install on the Niftylift when required
English 06/17 79
HR21 4x4 MK2
Service Manual

Clean orifice and needle valve, being careful not to damage the
Carbon stuck around orifice nozzle orifice
of injection nozzle piece
Check nozzle for condition. Replace if necessary
Bad valve or excessive wear of rings, pistons and liners cause

Inadequate compression. insufficient compression. Replace with new parts
Leaking valves
Grind valves
Fuel supply is deficient Check fuel system
Check lubricating oil system
Check lubricating oil filter is functioning correctly
Engine Filter element deposited with impurities will cause poor

Moving parts overheating
output lubrication. Replace element
insufficient
Check clearance of bearings are within factory specifications
Check ignition timing
Incorrect valve clearance Adjust valve clearance
Air cleaner is dirty Clean or replace the air filter if necessary
Fuel injection pressure is

Adjust to correct pressure
incorrect
Do not use poor quality fuel as it will cause excessive pump

wear. Use only Grade 2-D / EN 590 diesel
Injection pump wear
Check the fuel injection pump element and delivery valve
assembly and replace if necessary
Re-fill fuel tank if problem persists see above for 'Air or water
Fuel level too low
Engine mixed in fuel system'
cutting out
Fuel line crushed Release fuel line and replace if damaged
due to low
fuel level Lift pump not functioning
Replace lift pump
correctly
80 English 06/17
HR21 4x4 MK2
Service Manual
6.4 Engine fault codes

The engine Electronic Control Module (ECM) is located on the power tray. To access, open the engine
(right hand) canopy and swing the power tray away from the superstructure. See section 3.3.1.
When power is applied, the LED (1) on the ECM will flash once for one second to indicate that the LED is
working. A flashing LED indicates a fault condition, if there are multiple faults, the LED will flash them all
in sequence. Count the flash codes to determine the fault conditions.
See Table 6.1 for descriptions.
If there are no faults, the LED will flash once at reset and from then on indicate the detection of engine
speed. A continuous ON LED indicates that a valid engine speed is being sensed.
The ECM will attempt to shut down for certain faults and will not permit starting after reset with faults 1, 5
and 8.
Table 6.1: Engine ECM fault codes
Flash Engine
Problem Solution
Code Shutdown
1 Unit not calibrated Yes ECM requires calibration, contact a Niftylift approved
service centre
2 Engine speed Yes Check electrical interference

excessive Check wiring and connections
Check ECM ground connections
Check throttle actuator connections and fitment
3 Engine speed Yes Check throttle actuator connections and fitment

unusually low Check machine loading on engine
4 Engine protection input Yes Check engine protection inputs

triggered Check engine protection run time setting
5 Factory calibration lost Yes Contact a Niftylift approved service centre
6 Analogue sensor input No Check throttle actuator wiring

out of range
English 06/17 81
HR21 4x4 MK2
Service Manual
Table 6.1: Engine ECM fault codes
Flash Engine
Problem Solution
Code Shutdown
7 Throttle position / Idle No - may Verify wiring on throttle and IVS
Validation Switch (IVS) restrict Check throttle and IVS parameters
signal mismatch acceleration Check throttle configuration
8 ECM failure Yes Check wiring, shielding and ECM connections

Cycle power to engine
Check electrical interference
Contact a Niftylift approved service centre
9 Excessive throttle No Check throttle actuator wiring

actuator current Check throttle actuator fitment
limiting
10 No engine speed Yes - Non Check speed pick up fitment

signal start Check speed pick up wiring
Check electrical interference on pick up sensor & wiring
Check contamination on sensor
11 Autocrank detects No Check wiring and settings

engine non start Check engine mechanical parts
12 Excessive current draw No Check wiring to output

on auxiliary output Check current draw of lamp, relay etc.
13 Excessive current draw No Check wiring to output

on auxiliary 2 output Check current draw of lamp, relay etc.
14 Throttle actuator Yes Check throttle actuator wiring and fitment

disconnected or open Check electrical interference
circuit Check throttle actuator resistance
(less than 10 ohms)
82 English 06/17
HR21 4x4 MK2
Service Manual
6.5 Gearbox fault finding

Hardening of the seals due to
Clean area and check for leakage after a few days
prolonged storage
Oil leakage from
seals Seals damaged or worn Contact a Niftylift approved service centre
Too much lubricant Check oil level (See section 3.4.2)
Wheel gear is not correctly

Check the fixing
installed
Internal anomaly Contact a Niftylift approved service centre

Vibrations and/or
Bearings badly lubricated or
excessive noise Contact a Niftylift approved service centre
faulty
Dented or chipped teeth Contact a Niftylift approved service centre
Low oil level Check oil level, top-up if necessary (See section 3.4.2)
Low pressure in the braking

Check the brake connection and hydraulic circuit
Brakes fail to circuit
disengage Brake stuck due to prolonged
storage
Brakes do not Residual pressure in the

Check hydraulic circuit
engage circuit
Either too much or too little

Check the oil level
oil
Unsuitable lubricant Check the lubricant type and condition
Bearings badly lubricated or

Over-heating Contact a Niftylift approved service centre
faulty
Multiple-disc brake not

Check brake opening pressure
opening completely
High thermal power Contact a Niftylift approved service centre
English 06/17 83
HR21 4x4 MK2
Service Manual
6.6 Error codes

When an error is detected, an error code will be displayed on the cage and ground control display units.
Upon rectification of any errors the Niftylift should be power cycled. Power the Niftylift down and power
up again to complete a power cycle. Ensure the error code is cleared before returning the Niftylift to
operation.
The error code consists of x4 Hexadecimal values (may contain letters or numbers); see Table 6.2.
Note: The same Hexadecimal value will have a different meaning depending on its position in the error
code.
Table 6.2: Error codes
4th byte 3rd byte 2nd byte 1st byte
ERROR CLASS APPLICATION SPECIFIC ERROR SOURCE ERROR CAUSE

ERROR CODE
## ## ## ##
6.6.1 Error cause (1st byte)

The 1st byte indicates the cause, see Table 6.3 for descriptions.
## ## ## ##
Table 6.3: Error cause (1st byte)
Error Code Description
######00 No error cause or: application specific error
######01 Break
######02 Short
######04 Overload
######05 Undervoltage
######06 Overvoltage
######07 Current control
######08 Safety diagnosis on current input
######09 Safety diagnosis on voltage input
######0A Safety diagnosis on activated output (stuck at 1, cross fault)
######0B Safety diagnosis on safety switch
######0C Safety diagnosis on analogue multiplexer
######0D Safety diagnosis on deactivated output (stuck at 1)
######18 Temperature
84 English 06/17
HR21 4x4 MK2
Service Manual
Table 6.3: Error cause (1st byte)
Error Code Description
######19 Relay contact
######20 Memory test
######21 Address test
######30 Interrupt system
######31 Time base
######32 Command execution
######33 Integer overflow or: division by zero
######38 FPU (Floating Point Unit) underflow
######39 FPU (Floating Point Unit) overflow
######3A FPU (Floating Point Unit) division by Zero
######3B FPU (Floating Point Unit) unspecific error
######70 Communication to coprocessor
######80 CRC (Cyclical Redundancy Checking)
######81 Corrupt data
######82 Memory protection
######83 No data
######90 Watchdog
######91 Trap
######92 Safety core stopped
######93 Assertion failed
######C0 CANsafety
######C2 CAN bus-off
######C3 CANsafety reception error
######C4 CANsafety transmission error
######C5 CANsafety configuration corrupt
######E0 Board link warning (ExtendedController)
######E1 Board link error (ExtendedController)
######F0 Serial number
######F1 Runtime system expired
######F8 Wrong parameter
English 06/17 85
HR21 4x4 MK2
Service Manual
6.6.2 Error source (2nd byte)
## ## ## ##
The 2nd byte indicates the source, these can be application-specific (Table 6.4) or generic (Table 6.5).
For applicable pin identification see Table 6.4 and “Safety controller” on page 89.
Table 6.4: Error source (2nd byte) - application-specific

Input Pin Input Pin
2nd byte Description 2nd byte Description
Number ST Number EX
####10## 55 Booms Switch NC ####20## 55 -
####11## 36 Keyswitch Base ####21## 36 Glow Switch
####12## 54 Telescope Switch NC ####22## 54 Fuel Level
####13## 35 Cage E-Stop NC ####23## 35 Start Switch
####14## 53 Machine Active ####24## 53 -
####15## 34 Override Cage Switch NC ####25## 34 Override Base Switch NO
####16## 52 Base E-Stop NC ####26## 52 Debug
####17## 33 Cage Weigh PCB Alarm ####27## 33 Keypad ID OK
####18## 24 Booms Switch NO ####28## 24 -
####19## 41 Keyswitch Cage ####29## 41 -
####1A## 23 Telescope Switch NO ####3A## 23 Water Temperature
####1B## 40 Cage E-Stop NO ####3B## 40 Alternator L
####1C## 22 Base E-Stop NO ####3C## 22 Oil Pressure Switch
####1D## 39 Override Cage Switch NO ####3D## 39 Charger Feedback
####1E## 21 Hydraulic Pressure Sensor ####3E## 21 -
####1F## 38 Cage Weigh PCB Enable ####3F## 38 -
86 English 06/17
HR21 4x4 MK2
Service Manual
Table 6.4: Error source (2nd byte) - application-specific
Output Pin Output Pin

Number ST Number EX
####40## 18 Rear Brake Release ####50## 18 Cage Hydraulics Down Valve
####41## 17 Booms Enable Valve ####51## 17 Engine Glow
####42## 16 Steer Left Valve ####52## 16 Slew Left Valve
####43## 15 Steer Right Valve ####53## 15 Engine Start
####44## 14 Pump Dump Valve ####54## 14 Luffing Up Valve
####45## 13 Drive Forward Valve ####55## 13 Telescope Out Valve
####46## 12 Drive Backward Valve ####56## 12 Diff Valve
####47## 11 - ####57## 11 Slew Right Valve
####48## 02 Elevated Drive ####58## 02 Cage Hydraulics Up Valve
####49## 03 Motor/Engine Shutdown ####59## 03 Suspension Valve
####4A## 04 - ####5A## 04 Links Up Valve
####4B## 05 Front Brake Release ####5B## 05 -
####4C## 06 - ####5C## 06 Base Sounder
####4D## 07 - ####5D## 07 Luffing Down Valve
####4E## 08 Sounder Relay Action ####5E## 08 Telescope In Valve
####4F## 09 Load Sense Dump ####5F## 09 Links Down Valve
####60## 25 Auxiliary Cage
####61## 26 Motion Beacon
####62## 27 -
####63## 28 Generator Valve
####64## 29 Ignition
####65## 30 Horn
####66## 31 -
####67## 50 -
####68## 42 -
####69## 43 Descent LED
####70## 44 Warning LED
####71## 45 Power LED
####6C## 46 -
####6D## 47 -
####6E## 48 Low Displacement Valve
####6F## 49 -
English 06/17 87
HR21 4x4 MK2
Service Manual
Table 6.5: Error source (2nd byte) - generic

No error cause or: application specific

####00## ####9C## VBB2 (extended side)
error
####01## CPU ####9D## VBB3 (extended side)
####02## Peripheral Processor ####9E## VBB4 (extended side)
####03## Coprocessor ####A0## Analogue Multiplexer
####04## Safety Core ####A1## Analogue reference
####05## Safety Core (code) ####B0## Internal Flash
####06## Safety Core (trap) ####B1## External Flash
####80## CAN 1 ####B2## Internal Ram
####81## CAN 1 ####B3## External Ram
####82## CAN 1 ####C0## Code Startupper
####83## CAN 1 ####C1## Code Bootloader
####90## Relay Voltage VBBo (standard side) ####C2## Code Runtime System
####91## Relay Voltage VBBr (standard side) ####C3## Data Peripheral Processor
####92## VBBo (standard side) ####C4## Boot Project
####93## VBBr (standard side) ####C5## Code Application Program
####94## VBBs (standard side) ####C6## Scratchpad RAM
####95## Terminal 15 ####C7## Code Peripheral Processor
####96## Relay Voltage VBB1 (extended side) ####E0## System Data
####97## Relay Voltage VBB2 (extended side) ####E1## System Settings
####98## Relay Voltage VBB3 (extended side) ####E2## System Information
####99## Relay Voltage VBB4 (extended side) ####E3## Calibration Data
####9A## VBBRel (extended side) ####E4## FRAM/MRAM (User’s Area)
####9B## VBB1 (extended side)
88 English 06/17
HR21 4x4 MK2
Service Manual
6.6.3 Safety controller

The Safety controller has two connectors; the Standard (ST) side connector and the Extended (EX)
connector. Table 6.4, “Error source (2nd byte) - application-specific,” on page 86 should be used in
conjunction with the pin locations shown below.
EX
ST
19
55 37
50 32
12
44 26
38 20
1
English 06/17 89
HR21 4x4 MK2
Service Manual
6.6.4 Application specific error code (3rd byte)

The 3rd byte represents the application specific error code, for descriptions and troubleshooting actions
see Table 6.6.
## ## ## ##
Table 6.6: Application specific error code (3rd byte)
Error code Description Action
##00#### No error cause or: application specific error -
Ensure contact blocks are securely in

There is a problem with the signals from the
position.
##A1#### normally closed and normally open contacts of
Check Keyswitch wiring from the switch
the Keyswitch to the PLC
contacts to the PLC

position.
Check Base E-Stop wiring from the switch
the Base E-Stop to the PLC
contacts to the PLC

position.
Check Cage E-Stop wiring from the switch
the Cage E-Stop to the PLC
contacts to the PLC
Check the Load Sensing PCB is functioning

There is an error with the signals from the Load and EN and ALM are opposite.
##A4####
Sensing system Check wiring from the Load Sensing PCB to
the PLC

Check Booms Down Switch wiring from the
switch contacts to the PLC
the Booms Down Switch to the PLC

Check Telescope Switch wiring from the
switch contacts to the PLC
the Telescope Switch to the PLC
Check the wiring from the Mode Select Switch

##A7#### There is a problem with the Mode Select Switch to the Cage Node.
Replace the Mode Select Switch
The Cage Rotate Switch is sending Left and Check the Cage Rotate switch wiring.
##A8####
Right signals at the same time Replace the Cage Rotate switch
Check the wiring from the Override Switch to

##A9#### There is a problem with the Override Switch the PLC
Replace the Override Switch
The steer switch is sending a left and right Check the wiring to the Drive Joystick.
##AA####
signal at the same time Replace the Drive Joystick
Check the wiring from the Pressure

Transducer to the PLC
The pressure transducer is reporting a value
##AB#### Ensure the pressure transducer is securely
that is lower than its allowable range
installed into the valve block and the electrical
connector is plugged in
90 English 06/17
HR21 4x4 MK2
Service Manual
The pressure transducer is reporting a value

##AC#### Check the wiring to the Pressure Transducer
that is greater than its allowable range
Avoid sharp changes of direction.

##AD#### The drive pressure in elevated mode is too high
Return the Links Paddle to the neutral position

The Links Paddle was out of the neutral
and release the Green Button and Footswitch.
##B1#### position before the Green Button or Footswitch
Press the Green Button or Footswitch and
was pressed
then move the Links Paddle to operate Links
Return the Luffing Paddle to the neutral

position and release the Green Button and
The Luffing Paddle was out of the neutral
Footswitch.
##B2#### position before the Green Button or Footswitch
was pressed
then move the Luffing Paddle to operate
Luffing
Return the Slew Paddle to the neutral position

The Slew Paddle was out of the neutral position
##B3#### before the Green Button or Footswitch was
pressed
then move the Slew Paddle to operate Slew
Return the Telescope Paddle to neutral and

release the Green Button and Footswitch.
The Telescope Paddle was out of the neutral
then move the Telescope Paddle to operate
##B4#### position too long before the Green Button or
Telescope.
Footswitch was pressed
Check the paddle returns to the neutral
position when released. If not, replace the
paddle
Return the Fly Paddle to the neutral position

The Fly Paddle was out of the neutral position
##B5#### before the Green Button or Footswitch was
pressed
then move the Fly Paddle to operate Fly
Return the Drive Joystick to the neutral

The Drive Joystick was out of the neutral position and release the Green Button and
##B6#### position before the Green Button or Footswitch Footswitch.
was pressed Press the Green Button or Footswitch and
then move the Drive Joystick to operate drive
Ensure Joystick is plugged in.

##C2#### The Joystick and PLC are not communicating Check power and CAN Bus connections to the
Drive Joystick
Ensure Cage Node is plugged in

The Cage Node and PLC are not
##C3#### Check power supply and CAN Bus
communicating
connections to the Cage Node
Ensure the Motor Controller is plugged in.

The Motor Controller and PLC are not
communicating
connections to the Motor Controller
Check power supply and CAN Bus

##C5#### The Engine and PLC are not communicating
connections to the Engine Node
English 06/17 91
HR21 4x4 MK2
Service Manual
Ensure screen is plugged in.

The Cage Screen and PLC are not
communicating
connections to the Cage Screen
Ensure screen is plugged in.

The Base Screen and PLC are not
communicating
connections to the Base Screen
Ensure Chassis Inclination Sensor is plugged

The Chassis Inclination Sensor and PLC are not in.
##CF####
communicating Check power supply and CAN Bus
connections to the Chassis Inclination Sensor
Release the Base Green Button, Cage Green

There is potentially a fault with the Footswitch,
##D1#### Button, and Footswitch and ensure they are
Base Green Button, Cage Green Button
clear from obstructions. Check the wiring
Hold trigger for only a few seconds prior to

The drive joystick trigger is: being held too long
requesting motion. Remove objects that are
##D2#### before motion is requested; obstructed; or it
obstructing the trigger. Replace the drive
has failed
joystick
The Chassis Inclination Sensor is at an angle Move the machine to firm level ground (e.g.
##D3#### side to side across the machine that is too Concrete factory floor) before entering the
great to allow the zero to be set code to zero the Chassis Inclination Sensor
The Chassis Inclination Sensor is at an angle Move the machine to firm level ground (e.g.
##D4#### between the front and rear of the machine that Concrete factory floor) before entering the
is too great to allow the zero to be set code to zero the Chassis Inclination Sensor
The Chassis Inclination sensor requires Calibrate the inclination sensors using the
##D5####
calibration (X) machine screen in the base control position
The Chassis Inclination sensor requires Calibrate the inclination sensors using the
##D6####
calibration (Y) machine screen in the base control position
Calibrate the steer angle sensor using the

##D7#### The Steer position sensor requires calibration
machine screen in the base control position
Return the Links Paddle to neutral and attempt

to operate Links again.
There is a problem with the signal from the
##E1#### Check the connector to the Links Paddle is
Links Paddle in the Cage
secure.
Replace the Links Paddle
Return the Luffing Paddle to neutral and

attempt to operate Luffing again.
##E2#### Check the connector to the Luffing Paddle is
Luffing Paddle in the Cage
secure.
Replace the Luffing Paddle
Return the Slew Paddle to neutral and attempt

to operate Slew again.
##E3#### Check the connector to the Slew Paddle is
Slew Paddle in the Cage
secure.
Replace the Slew Paddle
92 English 06/17
HR21 4x4 MK2
Service Manual
Return the Telescope Paddle to neutral and

attempt to operate Telescope again.
##E4#### Check the connector to the Telescope Paddle
Telescope Paddle in the Cage
is secure.
Replace the Telescope Paddle
Return the Fly Paddle to neutral and attempt to

operate Fly again.
There is a problem with the signal from the Fly
##E5#### Check the connector to the Fly Paddle is
Paddle in the cage
secure.
Replace the Fly Paddle
Return the Drive Joystick to neutral and

attempt to operate the Joystick again.
##E6#### Check the connector to the Drive Joystick is
Drive Joystick in the cage
secure.
Replace the Drive Joystick
Investigate the flashing LED on the Motor

##F1#### There is a problem with the Motor Controller
Controller for further diagnosis
##F2#### A software parameter is missing or not valid Cycle the power to the machine
Check the machine serial plate.

##F3#### The serial number of the machine is incorrect
Move the Test Jumper in the Main Control Box

##F4#### The PLC is set to download
to 0 V (Zero volts)
This could be because the fuel level is low, the

##F5#### The engine has gone into a protect state oil pressure is low or the coolant temperature
is too high
##F6#### The Hybrid battery pack temperature is too high Allow the machine to cool
Power cycle the machine and if the problem

Main hydraulic power has been disabled due to
##FA#### persists, contact a Niftylift approved service
a safety related error
centre.
Power cycle the machine and if the problem

Auxiliary hydraulic power has been disabled
##FB#### persists, contact a Niftylift approved service
due to a safety related error
centre.
Check the auxiliary motor contactor and

There is an error with the Auxiliary pump
##FC#### wiring. If the problem persists, contact a
contactors
Niftylift approved service centre.
Check the auxiliary battery pack wiring and

The Auxiliary pump battery system voltage is
##FD#### charge levels. If the problem persists, contact
outside of its allowable range
a Niftylift approved service centre.
There is an error with the Charge Algorithm Contact a Niftylift approved service centre for
##FE####
selected with the charger assistance.
English 06/17 93
HR21 4x4 MK2
Service Manual
6.6.5 Application specific (motor controller) error code (3rd byte)

For error codes, descriptions and troubleshooting the motor controller application see Table 6.7.
See section 5.16 for information on the motor controller flash codes.
## ## ## ##
Table 6.7: Motor controller specific error code (3rd byte)
Flash
Error code Description Possible Cause Set/Clear Conditions
Code
1. External short of
Controller Overcurrent phase U,V, or W motor
Set: Phase current
ShutdownMotor; connections.
exceeded the current
ShutdownMainContactor; 2. Motor parameters are
##47#### measurement limit. 12
ShutdownEMBrake; mis-tuned.
ShutdownThrottle; 3. Controller defective.
Clear: Cycle KSI.
FullBrake. 4. Speed encoder noise
problems.
Current Sensor Fault

1. Leakage to vehicle Set: Controller current
ShutdownMotor;
frame from phase U, V, sensors have invalid
ShutdownMainContactor;
##60#### or W (short in motor offset reading. 13
ShutdownEMBrake;
stator).
ShutdownThrottle;
2. Controller defective. Clear: Cycle KSI.
FullBrake.
1. See Monitor menu» Set: Precharge failed to

Precharge Failed Battery: Capacitor charge the capacitor
ShutdownMotor; Voltage. bank to the KSI voltage.
ShutdownMainContactor; 2. External load on
##46#### 14
ShutdownEMBrake; capacitor bank (B+ Clear: Cycle Interlock
ShutdownThrottle; connection terminal) that input or use VCL
FullBrake. prevents the capacitor function Enable_
bank from charging. Precharge().
Set: Heatsink
Controller Severe
temperature below -
Undertemp 1. See Monitor menu»
40°C.
ShutdownMotor; Controller: Temperature.
##57#### ShutdownMainContactor; 2. Controller is operating 15
Clear: Bring heatsink
ShutdownEMBrake; in an extreme
temperature
ShutdownThrottle; environment.
above -40°C, and cycle
FullBrake.
interlock or KSI.
Set: Heatsink
Controller Severe 1. See Monitor menu» temperature above
Overtemp Controller: Temperature. +95°C (194°F).
ShutdownMotor; 2. Controller is operating
##58#### ShutdownMainContactor; in an extreme Clear: Bring heatsink 16
ShutdownEMBrake; environment. temperature
ShutdownThrottle; 3. Excessive load on below +95°C (194°F),
FullBrake. vehicle. and cycle interlock or
KSI.
94 English 06/17
HR21 4x4 MK2
Service Manual
Flash
Code
1. See Monitor menu»

Battery: Keyswitch Set: When below
Voltage. Brownout Voltage (20V)
2. Non-controller system for 2 seconds.
Severe B+ Undervoltage
##43#### drain on battery/KSI 17
Reduced drive torque.
circuit wiring. Clear: Bring KSI voltage
3. KSI disconnected above Brownout
while driving. Voltage.
4. Blown KSI fuse.

Battery: Capacitor Set: Capacitor bank
Voltage. voltage exceeded the
Severe B+ Overvoltage
2. Battery Menu Severe Overvoltage limit
ShutdownMotor;
parameters are with FET bridge
##44#### misadjusted. enabled. 18
ShutdownEMBrake;
3. Battery resistance too Clear: Bring capacitor
ShutdownThrottle;
high for given regen voltage below Severe
FullBrake.
current. Overvoltage limit, and
4. Battery disconnected then cycle KSI.
while regen braking.

Controller: Temperature
2. Controller is
Set: Heatsink
performance limited at
temperature e x c e e d e d
Controller Overtemp this temperature.
85°C (185°F).
Cutback 3. Controller is operating
##56#### 22
Reduced drive and brake in an extreme
Clear: Bring heatsink
torque. environment.
temperature below
4. Excessive load on
85°C (185°F).
vehicle.
5. Improper mounting of
controller.
1. Normal operation.
Fault shows that the
batteries need
recharging. Controller is
this voltage.
2. Battery parameters
Set: Capacitor bank
are misadjusted.
voltage dropped below
3. Non-controller system
B+ Undervoltage the Undervoltage limit
drain on battery.
##54#### Cutback with FET bridge enabled. 23
4. Battery resistance too
Reduced drive torque. Clear: Bring capacitor
high.
voltage above
5. Battery disconnected
Undervoltage limit.
while driving.
Battery: Capacitor
Voltage.
7. Blown B+ fuse or
main contactor did not
close.
English 06/17 95
HR21 4x4 MK2
Service Manual
Flash
Code
1. Normal operation.
Fault shows that regen
braking currents elevated
the battery voltage
during regen braking.
Controller is
Set: Capacitor bank
B+ Overvoltage Cutback voltage exceeded the
this voltage.
Reduced brake torque. Overvoltage limit with
2. Battery parameters
##55#### Note: This fault is declared FET bridge enabled. 24
are misadjusted.
only when the controller is Clear: Bring capacitor
3. Battery resistance too
running in regen. voltage below the
high for given regen
Overvoltage limit.
current.
4. Battery disconnected
while regen braking.
Battery: Capacitor
Voltage.
1. External load
Set:+5V supply (pin 26)
impedance on the +5V
+5V Supply Failure outside the +5V ±10%
supply (pin 26) is too
None, unless a fault range.
##64#### low. 25
action is programmed in
VCL. Clear: Bring voltage within
Outputs: 5 Volts and Ext
range.
Supply Current.
Set: Digital output 6

(pin 19) current
exceeded 15 mA.
1. External load
Digital Out 6 Open/Short
impedance on Digital
##5E#### Digital Output 6 driver will not Clear: Remedy the 26
Output 6 driver (pin 19) is
turn on. overcurrent cause and
too low.
use the VCL function
Set_DigOut() to turn the
driver on again.
Set: Digital output 7

(pin 20) current exceeded
15 mA.
1. External load
Digital Out 7 Open/Short
impedance on Digital
##5F#### Digital Output 7 driver will not Clear: Remedy the 27
Output 7 driver (pin 20)
turn on. overcurrent cause and
is too low.
use the VCL function
Set_DigOut() to turn the
driver on again.
96 English 06/17
HR21 4x4 MK2
Service Manual
Flash
Code
1. Motor temperature is
at or above the
programmed
Temperature Hot setting,
and the requested
current is being cut back.
Set: Motor temperature is
2. Motor Temperature
at or above the
Control Menu
Temperature Hot
parameters are mis-
Motor Temp Hot Cutback parameter setting.
##61#### tuned. 28
Reduced drive torque.
Clear: Bring the motor
Motor: Temperature
temperature within
and » Inputs: Analog2.
range.
4. If the application
doesn't use a motor
thermistor, Temp
Compensation and Temp
Cutback should be
programmed Off.
1. Motor thermistor is
not connected properly.
2. If the application Set: Motor thermistor
Motor Temp Sensor Fault doesn't use a motor input (pin 8) is at the
MaxSpeed reduced (LOS, thermistor, Temp voltage rail (0 or 10V).
##4B#### Limited Operating Strategy) Compensation and Temp 29
and motor temperature Cutback should be Clear: Bring the motor
cutback is disabled. programmed Off. thermistor input voltage
3. See Monitor menu» within range.
Motor: Temperature
and » Inputs: Analog2.
Set: Driver 1 (pin 6) is

1. Open or short on either open or shorted.
driver load. This fault can be set only
Coil1 Driver Open/Short
##59#### 2. Dirty connector pins. when Main Enable = 31
ShutdownDriver1.
3. Bad crimps or faulty Off.
wiring. Clear: Correct open or
short, and cycle driver.
Set: Main contact driver

Main Open/Short
1. Open or short on (pin 6) is either open or
ShutdownMotor;
driver load. shorted. This fault can be
##45#### 2. Dirty connector pins. set only when Main 31
ShutdownEMBrake;
3. Bad crimps or faulty Enable = On.
ShutdownThrottle;
FullBrake.

1. Open or short on either open or shorted.
driver load. This fault can be set only
Coil2 Driver Open/Short
##5A#### 2. Dirty connector pins. when EM Brake Type = 32
ShutdownDriver2.
3. Bad crimps or faulty 0.
English 06/17 97
HR21 4x4 MK2
Service Manual
Flash
Code
Set: Electromagnetic brake

driver (pin 5) is either
1. Open or short on
EM Brake Open/Short open or shorted. This
driver load.
ShutdownEMBrake; fault can be set only
##5D#### 2. Dirty connector pins. 32
ShutdownThrottle; when EM Brake Type >
3. Bad crimps or faulty
FullBrake. 0.
wiring.
Clear: Correct open or
1. Open or short on
driver load.
Coil4 Driver Open/Short either open or shorted.
##5B#### 2. Dirty connector pins. 34
ShutdownDriver4. Clear: Correct open or
3. Bad crimps or faulty
wiring.
1. Open or short on Set: Proportional driver

driver load. (pin 2) is either open or
PD Open/Short
##5C#### 2. Dirty connector pins. shorted. 35
ShutdownPD.
3. Bad crimps or faulty Clear: Correct open or
wiring. short, and cycle driver.
1. Motor encoder failure.

Encoder Fault 2. Bad crimps or faulty Set: Motor encoder phase
##4C#### ShutdownEMBrake; wiring. failure detected. 36
ShutdownThrottle. 3. See Monitor menu» Clear: Cycle KSI.
Motor: Motor RPM.
Motor Open
ShutdownMotor;
1. Motor phase is open. Set: Motor phase U, V or W
##48#### 2. Bad crimps or faulty detected open. 37
ShutdownEMBrake;
wiring. Clear: Cycle KSI.
ShutdownThrottle;
FullBrake.
1. Main contactor tips

are welded closed. Set: Just prior to the main
Main Contactor Welded 2. Motor phase U or V is contactor closing, the
ShutdownMotor; disconnected or open. capacitor bank voltage (B+
ShutdownMainContactor; 3. An alternate voltage connection terminal) was
##40#### 38
ShutdownEMBrake; path (such as an external loaded for a short time and
ShutdownThrottle; precharge resistor) is the voltage did not
FullBrake. providing a current to the discharge.
capacitor bank (B+ Clear: Cycle KSI.
connection terminal).
1. Main contactor did not

close.
2. Main contactor tips
Main Contactor did not
are oxidized, burned or Set: With the main contactor
Close
not making good commanded closed, the
ShutdownMotor;
contact. capacitor bank voltage (B+
##41#### ShutdownMainContactor; 39
3. External load on connection terminal) did not
ShutdownEMBrake;
capacitor bank (B+ charge to B+.
ShutdownThrottle;
connection terminal) that Clear: Cycle KSI.
FullBrake.
prevents capacitor bank
from charging.
4. Blown B+ fuse.
98 English 06/17
HR21 4x4 MK2
Service Manual
Flash
Code
Set: Pot2 wiper (pin 17)

voltage is higher than the
high fault threshold (can be
changed with the VCL
Pot2 Wiper High Inputs: Pot2 Raw.
##52#### function 43
FullBrake. 2. Pot2 wiper voltage too
Setup_Pot_Faults()).
high.
Clear: Bring Pot2 wiper
voltage below the fault
threshold.
Set: Brake pot wiper

(pin 17) voltage is lower
than the low fault threshold
(can be changed with the
Pot2 Wiper Low Inputs: Pot2 Raw.
##51#### VCL function 44
FullBrake. 2. Pot2 wiper voltage too
Setup_Pot_Faults()).
low.
Clear: Bring pot2 wiper
voltage above the fault
threshold.
1. See Monitor menu» Set: Pot low (pin 18)

Pot Low Overcurrent Outputs: Pot Low. current exceeds 10mA.
##50#### ShutdownThrottle; 2. Combined pot Clear: Clear pot low 45
FullBrake. resistance connected to overcurrent condition
pot low is too low. and cycle KSI.
EEPROM Failure
1. Failure to write to
ShutdownMotor;
EEPROM memory. This Set: Controller operating
can be caused by system tried to write to
ShutdownEMBrake;
EEPROM memory writes EEPROM memory and
ShutdownThrottle;
initiated by VCL, by the failed.
ShutdownInterlock;
##53#### CAN bus, by adjusting Clear: Download the correct 46
ShutdownDriver1;
parameters with the software (OS) and matching
ShutdownDriver2;
Niftylift Diagnostic Unit, parameter default settings
ShutdownDriver3;
or by loading new into the controller and cycle
ShutdownDriver4;
software into the KSI.
ShutdownPD;
controller.
FullBrake.
1. KSI, interlock,
direction and throttle
Set: HPD (High Pedal
inputs applied in
Disable) or sequencing fault
incorrect sequence.
caused by incorrect
HPD/Sequencing Fault 2. Faulty wiring, crimps
##42#### sequence of KSI, interlock, 47
ShutdownThrottle; or switches at KSI,
direction and throttle inputs.
interlock, direction or
Clear: Reapply inputs in
throttle inputs.
correct sequence.
Inputs.
English 06/17 99
HR21 4x4 MK2
Service Manual
Flash
Code
Set: At the conclusion of

Emergency Reverse, the
fault was set because
1. Emergency Reverse various inputs were not
operation has concluded, returned to neutral.
Emer Rev HPD
but the throttle, forward Clear: If EMR_Interlcok
##67#### ShutdownThrottle; 47
and reverse inputs and = On, clear the
ShutdownEMBrake;
interlock have not been interlock, throttle and
returned to neutral. direction inputs.
If EMR_Interlock = Off,
clear the throttle and
direction inputs.
1. This is a safety fault

caused by a change in
certain parameter
Parameter Change Fault settings so that the
ShutdownMotor; machine will not operate Set: Adjustment of a
ShutdownMainContactor; until KSI is cycled. parameter setting that
##62#### 49
ShutdownEMBrake; For example, if a user requires cycling of KSI.
ShutdownThrottle; changes the Throttle Clear: Cycle KSI.
FullBrake. Type this fault will appear
and require cycling KSI
before the machine can
operate.
VCL Run Time Error 1. VCL code

ShutdownMotor; encountered a runtime
Set: Runtime VCL code
ShutdownMainContactor; VCL error.
error condition.
ShutdownEMBrake; 2. See Monitor menu»
Clear: Edit VCL
ShutdownThrottle; Controller: VCL Error
application software to
ShutdownInterlock; Module and VCL Error.
##63#### fix this error condition; 68
ShutdownDriver1; This error can then be
flash the new compiled
ShutdownDriver2; compared to the runtime
software and matching
ShutdownDriver3; VCL module ID and error
parameter defaults;
ShutdownDriver4; code definitions found in
cycle KSI.
ShutdownPD; the specific OS system
FullBrake. information file.
Set: The external supply

current (combined current
1. External load on the used by the 5V supply
5V and 12V supplies (pin 26) and 12V supply
draws either too much or (pin 25) is either greater
External Supply out of too little current. than the upper current
Range 2. Fault Checking Menu threshold or lower than the
##4A#### None, unless a fault parameters Ext Supply lower current threshold. The 69
action is programmed in Max and Ext Supply Min two thresholds are defined
VCL. are mis-tuned. by the Ext Supply Max and
3. See Monitor menu» Ext Supply Min parameter
Outputs: Ext Supply settings.
Current. Clear: Bring the external
supply current within
range.
100 English 06/17

HR21 4x4 MK2
Service Manual
Flash
Code
OS General
ShutdownMotor;
ShutdownEMBrake;
ShutdownThrottle;
Set: Internal controller fault
ShutdownInterlock;
##65#### 1. Internal controller fault. detected. 71
ShutdownDriver1;
Clear: Cycle KSI.
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
Set: Time between CAN

PDO Timeout 1. Time between CAN PDO messages received
ShutdownThrottle; PDO messages received exceeded the PDO Timeout
##66#### 72
CAN NMT State set to exceeded the PDO Period.
Pre-operational Timeout Period. Clear: Cycle KSI or receive
CAN NMT message.
1. Stalled motor. Set: No motor encoder

2. Motor encoder failure. movement detected.
Stall Detected
3. Bad crimps or faulty Clear: Either cycle KSI,
ShutdownEMBrake;
wiring. or detect valid motor
ShutdownThrottle;
##4E#### 4. Problems with power encoder signals while 73
Control Mode changed to
supply for the motor operating in LOS mode
LOS, (Limited Operating
encoder. and return Throttle
Strategy).
5. See Monitor menu» Command = 0 and
Motor: Motor RPM. Motor RPM = 0.
Supervisor Fault
ShutdownMotor; 1. The Supervisor has
ShutdownMainContactor; detected a mismatch in Set: Mismatched redundant
ShutdownEMBrake; redundant readings. readings; damaged
ShutdownThrottle; 2. Internal damage to Supervisor; illegal switch
ShutdownInterlock; Supervisor inputs.
##69#### 77
ShutdownDriver1; microprocessor. Clear: Check for noise
ShutdownDriver2; 3. Switch inputs allowed or voltage drift in all
ShutdownDriver3; to be within upper and switch inputs; check
ShutdownDriver4; lower thresholds for over connections; cycle KSI.
ShutdownPD; 100 milliseconds.
FullBrake.
Supervisor Incompatible
ShutdownMotor;
ShutdownEMBrake;
ShutdownThrottle; Set: Incompatible software.
ShutdownInterlock; 1. The main OS is not Clear: Load properly
##6D#### ShutdownDriver1; compatible with the matched OS code or 78
ShutdownDriver2; Supervisor OS. update the Supervisor
ShutdownDriver3; code; cycle KSI.
ShutdownDriver4;
ShutdownPD;
FullBrake.
English 06/17 101

HR21 4x4 MK2
Service Manual
Flash
Code
Driver Supply
ShutdownMotor;
1. Internal controller fault Set: Internal controller fault
##6E#### in the voltage supply for detection. 83
ShutdownEMBrake;
the driver circuits. Clear: Cycle KSI.
ShutdownThrottle;
FullBrake.
Encoder Pulse Count

Fault
ShutdownMotor; Set: Motor lost IFO
ShutdownMainContactor; control and accelerated
ShutdownEMBrake; without throttle
1. Encoder Steps
ShutdownThrottle; command.
parameter does not
##4F#### ShutdownInterlock; Clear: Ensure the 88
match the actual motor
ShutdownDriver1; Encoder Steps
encoder.
ShutdownDriver2; parameter matches the
ShutdownDriver3; actual encoder; cycle
ShutdownDriver4; KSI.
ShutdownPD;
FullBrake.
Motor Type Fault Set: Motor_Type

ShutdownMotor; parameter is set to an
1. The Motor_Type
ShutdownMainContactor; illegal value.
##68#### parameter value is out of 89
ShutdownEMBrake; Clear: Set Motor_Type to
range.
ShutdownThrottle; correct value and cycle
FullBrake. KSI.
VCL/OS Mismatch
Set: VCL and OS
ShutdownMotor;
software do not match;
when KSI cycles, a
ShutdownEMBrake;
check is made to verify
ShutdownThrottle; 1. The VCL software in
that they match and a
ShutdownInterlock; the controller does not
##6A#### fault is issued when 91
ShutdownDriver1; match the OS software in
they do not.
ShutdownDriver2; the controller.
Clear: Download the
ShutdownDriver3;
correct VCL and OS
ShutdownDriver4;
software into the
ShutdownPD;
controller.
FullBrake.
Set: Encoder Fault

(Code 36) or a Stall Detect
1. Limited Operating Fault (Code 73) was
Strategy (LOS) control activated, and Brake or
mode has been Interlock has been applied
activated, as a result of to activate LOS control
Encoder LOS (Limited either an Encoder Fault mode, allowing limited
##4D#### Operating Strategy) (Code 36) or a Stall motor control. 93
Enter LOS Control mode. Detect Fault (Code 73). Clear: Cycle KSI or if the
2. Motor encoder failure. LOS mode was activated
3. Bad crimps or faulty by the Stall Fault, clear
wiring. by ensuring encoder
4. Vehicle is stalled. senses proper operation,
Motor RPM = 0 and
Throttle Command = 0
102 English 06/17

HR21 4x4 MK2
Service Manual
Flash
Code
1. Emergency Reverse Set: Emergency Reverse

was activated and was activated and ran until
Emer Rev Timeout concluded because the the EMR Timeout timer
##6B#### ShutdownEMBrake; EMR Timeout timer has expired. 94
ShutdownThrottle. expired. Clear: Turn the
2. The emergency emergency reverse
reverse input is stuck On. input Off.
Set: Illegal Model_Number

variable; when KSI cycles a
Illegal Model Number 1. Model_Number
check is made to confirm a
ShutdownMotor; variable contains illegal
legal Model_Number, and a
ShutdownMainContactor; value.
##6C#### fault is issued if one is not 98
ShutdownEMBrake; 2. Software and
found.
ShutdownThrottle; hardware do not match.
Clear: Download
FullBrake. 3. Controller defective.
appropriate software for
your controller model.
6.6.6 Error class (4th byte)

The 4th byte represents the error class, for descriptions see Table 6.8.
Information is only applicable when input TEST = FALSE.
## ## ## ##
Table 6.8: Error class (4th byte)

4th byte Description
00###### No error
General error, not safety related

01###### >Error flag, error code
>Error reset possible
Serious error, component error

>Error flag, error code
02######
Safe state (Safety Controller: keep-alive possible)
Critical error
>Error code
03###### >Application program interrupted temporarily
>Safe state
Fatal error
>Error code
04###### >Application program aborted
>Safe state
>>Power cycle required
Fatal errors are only visible in the application if the TEST input was active when the error occurred. Fatal errors
normally lead to a STOP of the controller; however, this will not be the case with an active TEST input.
English 06/17 103

Service Manual: Heightrider

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: Heightrider

Uploaded by

Copyright:

Available Formats

Heightrider

1 INTRODUCTION AND GENERAL INFORMATION .............................................................................1

3.3.12 Fuel filter and water separator clean/replace.............................................................................. 33

5.1.2 Hybrid terminology .....................................................................................................................70

1 Introduction and general information

THE 'SAFETY ALERT' SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL

1.1.1 Defined maintenance terms

Table 1.1: Defined Maintenance Terms

Install Place component in position ready for use

Secure Install or attach locking device

Reinstall Install the previously removed component

Tighten Apply specified torque

Clean Remove all dirt and deposits

Inspect Determine general condition conforms to required standards

Check Determine a particular condition e.g. completeness, security, position

Adjust Change or move in order to achieve a desired result

Connect Install, engage component

Lubricate Apply lubricant

Disconnect Remove, disengage component

Nifty Pty Ltd, 11 Kennington Dr, Tomago NSW 2322, Australia

1.4 General maintenance information

1.4.1 Pre-maintenance checks

1.4.2 Maintenance information

Table 1.2: Technical Documents

Hydraulic Schematic D82950 D82900

Electric Schematic D81819

Operating & Safety Instructions M50541

Parts Manual M50540

Engine Operator’s Manual M50291 (D902) M50292 (V1505)

Chain Service & Inspection Manual M50280

1.4.3 Frequent inspection

1.4.4 Annual inspection

1.5 Maintenance safety information

1.5.1 Personal injury prevention

1.5.2 Machine damage prevention

1.5.3 Diesel system safety

1.5.4 Hydraulic safety

1.5.5 Environmental awareness

1.5.6 Electrical safety

To isolate the 48V battery system depress the isolation

2.1 Engine specifications

Kubota D902 Perkins 403D Kubota V1505

Displacement 898cm3 1496cm3 1498cm3

Net power 16.1 kW/21.6hp @ 24.4 kW/32.7hp @ 18.5 kW/24.8hp @

Net torque - 96.0 Nm @ 1800rpm -

2.2 Gearbox specifications

Type I=56.2 REGGIANA GEARBOX

Mass (Dry weight) 43 kg (95 lbs)

Oil capacity 0.5 L (0.11 gal)

Oil type See section 2.4.3

2.3 Function times

Function Up/right/out Down/left/in

Slew (180°) Tele in 51±10 51±10

Slew (180°) Tele out 86±10 86±10

Links 23±5 23±5

Luffing (Boom rest to full height) tele in 26±5 26±5

Luffing (Boom rest to full height) tele out 38±5 38±5

Fly boom 13±5 13±5

Telescope (luffed up) 24±5 24±5

Cage rotate (180°) 13±5 11±5

Machine Speed HYBRID DIESEL

Power source Diesel Electric

Elevated 0.7 km/h (0.4 mph) 0.7 km/h (0.4 mph)