Heightrider

Service Manual
MODEL HR12 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
M50606/01 Fax: +44 (0)1908 312733
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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 Electrical safety ............................................................................................................................6
1.5.5 Hydraulic safety............................................................................................................................6
1.5.6 Environmental awareness .............................................................................................................7
2 SPECIFICATIONS ...........................................................................................................................8
2.1 Engine specifications ............................................................................................................................8
2.2 Gearbox specifications ..........................................................................................................................9
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 Hydraulic pressure settings .........................................................................................................10
2.5 Tyre specifications..............................................................................................................................11
2.6 Torque settings ...................................................................................................................................11
2.6.1 Torque settings - Kubota OC60 and OC95 engines ......................................................................12
2.7 Hydraulic hose and fitting torque specifications ...................................................................................13
3 PREVENTATIVE MAINTENANCE ...................................................................................................15
3.1 Maintenance schedules.......................................................................................................................15
3.1.1 Engine maintenance....................................................................................................................15
3.1.2 Machine maintenance .................................................................................................................17
3.1.3 Engine oil level check..................................................................................................................18
3.1.4 Engine oil replace........................................................................................................................19
3.1.5 Engine oil strainer clean - Diesel..................................................................................................20
3.1.6 Air filter element maintenance .....................................................................................................21
3.1.7 Fuel pipes check .........................................................................................................................21
3.1.8 Fuel filter clean / replace .............................................................................................................22
3.1.9 Spark plug check ........................................................................................................................23
3.1.10 Exhaust system inspect ............................................................................................................23
3.2 Drive hub gearbox...............................................................................................................................24
3.2.1 Oil replace ..................................................................................................................................24
3.2.2 Bleeding air from the braking circuit ............................................................................................25
3.3 Batteries .............................................................................................................................................26
3.3.1 Condition check (daily) ...............................................................................................................26
3.3.2 Condition check (weekly) - excludes AGM batteries.....................................................................26

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3.3.3 Storage ...................................................................................................................................... 27

3.4 Inverter / generator and power to cage options.................................................................................... 28
3.4.1 Condition check (daily)............................................................................................................... 28
3.5 Hydraulic oil ....................................................................................................................................... 29
3.5.1 Level check (weekly) .................................................................................................................. 29
3.5.2 Pressure filter check (weekly) ..................................................................................................... 29
3.5.3 Hydraulic oil and filters replace ................................................................................................... 30
3.6 Telescopic boom................................................................................................................................ 31
3.6.1 Wear pad check (monthly).......................................................................................................... 31
3.6.2 Hose trunking and energy chain check (weekly).......................................................................... 32
3.6.3 Boom pivot bushes lubricate (annually)...................................................................................... 33
3.6.4 Boom pivot pin check (daily) ...................................................................................................... 33
3.7 Boom rotation gear ............................................................................................................................. 34
3.7.1 Slew gear engagement check (monthly) ..................................................................................... 34
3.7.2 Slew ring lubrication (monthly) ................................................................................................... 34
3.7.3 Slew ring bolts check (yearly)..................................................................................................... 35
3.8 Front axle ........................................................................................................................................... 35
3.8.1 Front wheel hub bushes (yearly) ................................................................................................. 35
3.9 Chassis .............................................................................................................................................. 36
3.9.1 Earth strap check (daily)............................................................................................................. 36
3.10 Wheels and tyres.............................................................................................................................. 36
3.10.1 Wheel bolt torque (monthly) ..................................................................................................... 36
4 REPAIR PROCEDURES .................................................................................................................37
4.1 General .............................................................................................................................................. 37
4.1.1 Fuses ......................................................................................................................................... 37
4.2 Platform/Cage .................................................................................................................................... 39
4.2.1 Footswitch - contact switch replace............................................................................................ 39
4.3 Booms ............................................................................................................................................... 40
4.3.1 Energy chain link ........................................................................................................................ 40
4.4 Base Assembly................................................................................................................................... 41
4.4.1 Engine exhaust ........................................................................................................................... 41
4.4.2 Steer cylinder ............................................................................................................................. 42
5 SYSTEM OVERVIEW ....................................................................................................................44
5.1 Introduction ........................................................................................................................................ 44
5.1.1 Power system ............................................................................................................................ 44
5.1.2 DC electric system ..................................................................................................................... 45
5.2 Battery charging ................................................................................................................................. 46
5.2.1 Battery charging - extension leads .............................................................................................. 47
5.3 Bi-energy system ............................................................................................................................... 49
5.3.1 Duty selector.............................................................................................................................. 49
5.4 Boom system ..................................................................................................................................... 49
5.4.1 Boom switch.............................................................................................................................. 49
5.5 Drive system ...................................................................................................................................... 49
5.5.1 Drive Control Valve (DCV)........................................................................................................... 49
5.5.2 Brake Release Valve ................................................................................................................... 49
5.6 Hydraulic system overview ................................................................................................................. 50
5.7 Steering.............................................................................................................................................. 50
5.8 Electrical control system overview ...................................................................................................... 51
5.9 Control logic....................................................................................................................................... 51

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6 TROUBLESHOOTING GUIDE.........................................................................................................52
6.1 Trouble shooting information...............................................................................................................52
6.2 Platform function fault finding..............................................................................................................52
6.3 Engine fault finding..............................................................................................................................53
6.3.1 Diesel engine ..............................................................................................................................53
6.3.2 Petrol engine...............................................................................................................................56
6.4 Gearbox fault finding ...........................................................................................................................57

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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 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 and/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, “Defined maintenance
terms,” on page 2.

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Table 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
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 please do not hesitate to contact us at your
nearest office.
Niftylift Ltd, Chalkdell Drive, Shenley Wood, Milton Keynes MK5 6GF, England
Tel: +44 (0) 1908 223456 Fax: +44 (0) 1908 312733
Nifty Pty Ltd, 111 Kennington Drive, Tomago, NSW 2322, Australia
Tel: +61 (0) 2 4964 9714 Fax: +61 (0) 2 4964 9765

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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.
Manufacturer'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.
FAILURE TO PERFORM PREVENTATIVE MAINTENANCE AT THE REQUIRED
WARNING INTERVALS WILL 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 being 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.
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.

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Mark or tag all hydraulic lines before removal to avoid confusion and error. Never leave hydraulic lines
open or open them in a contaminated area. Always use plugs or caps.
Use only recommended lubricants. See section 2.4.2.
In general, installation of components can be completed by reversing the removal process and
instructions.
Please refer to the following documents for further details.

Document Number

DIESEL PETROL BI-ENERGY DC ELECTRIC

Hydraulic Schematic D80526
Electric Schematic D81632
Operating and Safety M50192
Instructions

Parts Manual M50510

Engine Operators Manual M50290 M50295 - -

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 the manufacturer’s instructions, on a Niftylift:
(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 aerial platform
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) and hydraulic oil as specified by the
manufacturer.
(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.

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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, as provided by Niftylift, 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 YOUR 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.
Please contact your nearest Niftylift approved dealer prior to carrying out any welding.
Never start the engine without the power tray retaining bolt installed.

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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 Electrical safety

During maintenance of the electrical system,
disconnect the start battery negative (-) terminal
(Diesel & Bi-energy machines). To isolate the 24V + -

battery system, pull both battery-disconnect handles & + -

(Anderson).
P18610/01

Ensure sparks, flames or lighted tobacco are kept

away from batteries as they emit explosive gases.
Keep metallic objects (tools, etc.) well clear from
battery posts.
Ensure battery posts are always protected and caps
are installed and in good condition.
Never connect a discharged battery in series with a
fully charged battery as this creates a risk of explosion.
Always use batteries that are charged/discharged to
the same level.

1.5.5 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 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).

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1.5.6 Environmental awareness

When draining fluids, ensure they are collected in a suitable container and spillages 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.

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2 Specifications
Information correct at time of print, refer to serial number of the Niftylift.

2.1 Engine specifications

Diesel

Feature Kubota OC60 Kubota OC95

Type Oil-cooled 4-cycle, 1 cylinder diesel engine

Fuel Diesel fuel No. 2-D

Engine oil See section 2.4.2

Mass (Dry weight) 38kg (84 lbs) 55kg (121 lbs)

Displacement 276cm3 416cm3

Net power 4.2kW/5.6hp @ 3600rpm 7.0kW/9.4hp @ 3600rpm

Oil capacity 1.3 L (0.29 gal) 1.7 L (0.37 gal)

Fuel capacity 3.6 L (0.79 gal) 5.5 L (1.2 gal)

Valve clearance (Cold) 0.14 to 0.18 mm (0.0055 - 0.0071 in.)

Petrol

Feature Honda GX270

Type Air cooled 4-cycle, 1 cylinder OHV petrol engine

Fuel Premium Petrol (Unleaded)

Engine oil See section 2.4.2

Mass (Dry weight) 25.8kg (56.9 lbs)

Displacement 270cm3

Net power 6.6kW/9hp @ 3600rpm

Oil capacity 1.1 L (0.24 gal)

Fuel capacity 5.3 L (1.16 gal)

Spark plug gap 0.70 - 0.80 mm (0.028 - 0.031 in.)

Valve clearance (Cold) Inlet 0.15 ± 0.02 mm (0.0059 ± 0.0007 in.)

Exhaust 0.20 ± 0.02 mm (0.0078 ± 0.0007 in.)

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2.2 Gearbox specifications

Type 425GEARBOX PGWF130/5.75/GWS100

Mass (Dry weight) 21kg (46 lbs)

Oil capacity 0.3 L (0.06 gal)

Oil type See section 2.4.3

2.3 Function times

Function Up/right/out Down/left/in

Time, (Seconds)

Petrol/Diesel Battery Petrol/Diesel Battery

Slew (180°) 41±5 41±5

Boom 2 (Ram 1) 29±5 25±5

Boom 3 (Ram 2) 31±5 30±5

Boom 4 35±5 23±5

Niftylift drive speed FWD/REV Petrol/Diesel Battery

Max hare speed 3.26 km/h - (2.03mph) 2.55 km/h - (1.59 mph)

Max tortoise speed 1.62 km/h - (1.01 mph) 1.27 km/h - (0.79 mph)

Elevated drive 0.46 km/h - (0.29 mph) 0.40 km/h - (0.25 mph)

FWD/REV drive speed must be measured over a 10 metre (33 feet) distance on flat level ground.

All measurements carried out with 200kg (441 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).

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2.4 Fluid properties

2.4.1 Fluid volumes

Fluid volumes
Hydraulic oil tank 19 L (4.2 gal)

Fuel tank OC60 3.6 L (0.79 gal)

OC95 5.5 L (1.20 gal)
GX270 5.3 L (1.16 gal)

Engine oil OC60 1.3 L (0.29 gal)

OC95 1.7 L (0.37 gal)
GX270 1.1 L (0.24 gal)

2.4.2 Engine oil specifications

Engine Ambient temperature Oil type

Kubota OC60 / OC95 ABOVE 25°C (77°F) SAE30 SAE 10W/30
OR SAE 10W/40

0°C / +25°C (32°F / +77°F) SAE20 SAE 10W/30

OR SAE 10W/40

BELOW 0°C (32°F) SAE10W SAE 10W/30

OR SAE 10W/40

Honda GX270 All - SAE 10W/30

2.4.3 Gearbox oil specifications

Ambient temperature Oil type

-20°C (-4°F) to +45°C (113°F) ISO VG 22 (Standard fitment)

2.4.4 Hydraulic oil specifications

ISO VG 22 oil is fitted as standard, for other climates or harsh operating conditions please contact your
nearest Niftylift approved dealer.

2.4.5 Hydraulic pressure settings

Refer to Hydraulic Schematic as supplied with the machine noting the serial number of the Niftylift.

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2.5 Tyre specifications

Standard tyre fitment: Kenda Superturf Tyre 23-10.50-12 6PLY or Grey
non-marking, Trelleborg, 23x10.50-12.
DO NOT REPLACE TYRES WITH ANYTHING OTHER THAN THE ABOVE
WARNING SPECIFICATION. CONSULT NIFTYLIFT PRIOR TO REPLACEMENT.

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 BOLTS 86 Nm (65 lbf·ft)

SLEW RING BOLTS 279 Nm (206 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.

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2.6.1 Torque settings - Kubota OC60 and OC95 engines

Screw and bolt material grades are identified by numbers stamped on the screw/bolt head.

Bolt size Tightening torque in Nm (lbf·ft)

Grade Standard screw/bolt (4) Special screw/bolt (7)

M6 7.9 - 9.3 (5.8 - 6.9) 9.8 - 11.3 (7.2 - 8.3)

M8 17.7 - 20.6 (13.0 - 15.2) 23.5 - 27.5 (17.4 - 20.3)

M10 39.2 - 45.1 (28.9 - 33.3) 48.1 - 55.9 (35.4 - 41.2)

M12 62.8 - 72.6 (46.3 - 53.5) 77.5 - 90.2 (57.1 - 66.5)

Stamped number Screw / bolt material grade

Blank or 4 Standard screw / bolt SS41, S20C

7 Special screw / bolt S34C, S48C (Refined)

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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)

Soft Seal
20 1”1/4 - 11 500 (369) 250 (184)
Positional
24 1”1/2- 11 600 (443) 300 (221)

32 2” - 11 N/A N/A

Elastomeric
(Integrated Seal)

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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

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3 Preventative maintenance
3.1 Maintenance schedules

3.1.1 Engine maintenance

Diesel - Kubota OC60 and OC95

Every 1500
Every 100

Every 500

Every 800
Every Day

Every 25

Every 2
Hours

Hours

Hours

Hours

Hours

Years
Every
Year
Operation

Engine oil ▲ ●a) ●

Oil strainer ■a) ■

Air filter @ ▲ ■b) ●b)

Fuel filter ■ ●

Fuel pipes and clamps ▲ ●

Valve clearance ▲c)

Nozzle injection pressure

▲■c)
and spraying condition @

Battery ▲

▲ 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) Consult a Kubota approved dealer.

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Petrol - Honda GX270

Every 3 Months

Every 6 Months

Every 2 Years
or 100 Hours

or 300 Hours
or 20 Hours

or 50 Hours
First Month
Every Week

Every 1000
Every Year
Every Day

Hours
Operation

Engine oil ▲ ● ●

Air filter ▲ ■a)b) ●b)

Sediment cup ■b)

Spark plug ▲ ●

Spark arrester (where fitted) ■b)

Valve clearance ▲b)

Combustion chamber ■b)

Fuel tank & filter ■b)

Fuel pipe ▲

▲ Check/Inspect
■ Clean
● Replace
a) In arduous conditions (high levels of dust) the air filter must be cleaned and replaced more frequently.
b) Consult a Honda approved dealer.

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3.1.2 Machine maintenance

Every 100 Hours

Every 6 Months
Every Month
Every Week

Every Year
Every Day
Operation

Gearbox oil ●a) ●b)

Battery condition ▲

Battery fluid levels ▲

Hydraulic oil level ▲

Pressure filter ▲

Hydraulic oil and filters ●c)

Telescopic boom wear pads ▲

Hose trunking and energy chain ▲

Boom pivot pin/bushes ▲ **

Slew gear engagement ▲

Slew ring **

Slew ring bolts ** ▲

Wheel bolts ▲

Inverter / generatord) ▲ ▲e)

Cage power supplyd) ▲ ▲e)

Earth strap ▲

▲ Check/Inspect
■ Clean
● Replace
** Lubricate
a) First time procedure.
b) Every 1000 hours or yearly whichever occurs first.
c) In arduous conditions (high levels of dust) the hydraulic oil and filters must be replaced more frequently.
d) Optional equipment.
e) PAT Test (or equivalent) inspection to be carried out.

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3.1.3 Engine oil level check

Diesel
1) Check with the Niftylift on level surface
before starting or more than 5 minutes after
stopping the engine.
2) Remove the oil dipstick (1) and wipe clean.
3) Insert the oil dipstick into the filler neck.
4) Remove the filler cap/dipstick and check the
oil level.
5) If low, add correct specification oil to the oil
filling port.
6) After adding oil, wait for 5 minutes and re-
X
check oil level. Do not overfill. MA
7) Reinstall the filler cap/dipstick and tighten
by hand.

MIN
Petrol
1) Check with the Niftylift on level surface
before starting or more than 5 minutes after
stopping the engine.
2) Remove the oil filler cap/dipstick (1) and
wipe clean.
3) Oil level should be to the upper limit mark
(bottom edge of the oil fill hole).
4) Insert the filler cap/dipstick into the filler
neck, but do not screw it in (see diagram). 1
5) Remove the filler cap/dipstick and check the
oil level.
UPPER LIMIT
6) If low, add correct specification oil to the oil
filling port.
7) After adding oil, wait for 5 minutes and re-
check oil level. Do not overfill.
8) Reinstall the filler cap/dipstick and tighten
by hand.
LOWER LIMIT

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3.1.4 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.

Diesel

1) Remove the oil filler cap (1).

1
2) Remove the drain plug (2) and drain the oil into
a suitable container. Note; This will be easier if
the oil is warm.
3) Replace seal ring and reinstall drain plug.
4) Tighten drain plug. See section 2.6 for torque
settings.
5) Top up engine oil to the upper limit of the
dipstick. See section 2.4 for oil type and
capacity.
6) Reinstall the oil filler cap.
7) Re-check oil level at least 5 minutes after filling 2
engine.

Petrol

1) Remove the filler cap/dipstick (1).

2) Remove the drain plug (2) and drain the oil into
a suitable container. Note; This will be easier if
the oil is warm.
3) Replace seal ring and reinstall drain plug.
4) Tighten drain plug. See section 2.6 for torque
settings.
5) Top up engine oil to the upper limit mark
(bottom edge of the oil fill hole). See section
2.4 for oil type and capacity.
1
6) Re-check oil level at least 5 minutes after filling
engine. 2
7) Reinstall the filler cap/dipstick and tighten by
hand.

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3.1.5 Engine oil strainer clean - Diesel

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE OFF AND COOLED
CAUTION DOWN. BEWARE OF HOT ENGINE COMPONENTS.
DISPOSE ANY WASTE ACCORDING TO LOCAL REGULATIONS.
NOTICE
The engine oil strainer should be cleaned each time the engine oil is changed.

1) With the engine oil drained, remove the engine

oil strainer (1).
2) Clean with mild solvent or replace if necessary.
3) Reinstall engine oil strainer and tighten. See
section 2.6 for torque settings.
4) Replenish engine oil. See section 3.1.4.

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3.1.6 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.

Diesel

1) Undo nut (1) and remove the cover (2).

2) Undo nut (3) and remove the filter 1
element (4).
3) When dry dust adheres to the element, blow
compressed air from the inside out whilst
rotating the element. Air pressure must be
no more than 205kPa (2.1kgf/cm2 30psi).
4) Reinstall the filter element and tighten nut. 4
5) Reinstall the cover and tighten nut. 3
6) Replace the filter element every year or after 2
6 cleanings. This is in standard operating
conditions; dust enriched operating
environments will require shorter intervals.

Petrol
The air filter should be checked weekly, cleaned every 6 months or 100 hours and replaced every year or
300 hours. This is in standard operating conditions; dust enriched operating environments will require
shorter intervals.
Consult a Honda approved dealer.

3.1.7 Fuel pipes check

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE SWITCHED OFF
CAUTION AND COOLED. BEWARE OF HOT ENGINE COMPONENTS.
PETROL IS HIGHLY FLAMMABLE AND EXPLOSIVE. KEEP FLAMES,
WARNING SPARKS AND HEAT SOURCES AWAY FROM PETROL. CLEAN UP ANY
SPILLAGES IMMEDIATELY.

1) Fuel pipes and clamp bands should be checked every day.

2) If clamp bands are found to be loose, replace immediately.
3) If rubber fuel pipes are found to be worn or perished, replace immediately.
4) When fuel pipes are not installed, ensure they are capped to prevent dirt entering.
5) Fuel pipes should be replaced after 2 years.

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3.1.8 Fuel filter clean / replace

FUEL ESCAPE - PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK
WARNING AREA AND DISPOSE FUEL ACCORDING TO LOCAL REGULATIONS.
ENSURE ENGINE IS OFF BEFORE REPLACING THE FUEL FILTER. ALLOW
WARNING ENGINE TO COOL DOWN SUFFICIENTLY.

Diesel
6) Undo the fuel tank drain plug (1) and drain the
fuel. 4
7) Replace the seal ring and reinstall the drain plug.
8) Tighten the drain plug. See section 2.6.1 for 2
torque settings.
3
9) Loosen the clamp band (2) on the fuel pipe (3)
and disconnect from the fuel filter (4).
10) Undo the fuel filter and remove.
11) Wash the fuel filter with clean diesel or replace if
necessary.
12) Observe clean assembly practices to avoid
contamination by dust or dirt.
13) Tighten the filter by hand.
1
14) Reconnect the fuel pipe and reinstall clamp band.
15) Replenish fuel and inspect for leaks.

Petrol
The fuel filter should be checked every 6 months or 100 hours. Consult a Honda approved dealer.

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3.1.9 Spark plug check

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE SWITCHED OFF
CAUTION AND COOLED. BEWARE OF HOT ENGINE COMPONENTS.
TO AVOID POTENTIAL DAMAGE TO THE ENGINE, MAKE SURE THE SPARK
NOTICE PLUG IS INSTALLED AND TIGHTENED TO THE SPECIFIED TORQUE.

1) Open the Engine canopy.

2) Disconnect the ignition coil lead and remove
the spark plug.
3) Remove any carbon deposits from the spark
plug using a wire brush.
4) Visually inspect the spark plug.
5) Replace if damaged, badly fouled or if the
electrode is worn.
6) Check and adjust the electrode gap to 0.7 - 0.8mm
0.7-0.8 mm (0.028-0.031 in) using a (0.028 - 0.031in)
suitable feeler gauge.
7) Reinstall spark plug and tighten by hand, then
tighten a further 1/8 to 1/4 of a turn. Note; where the spark plug is replaced, the new spark plug should
be tightened by hand and then a further 1/2 turn.
8) Connect the ignition coil lead.

3.1.10 Exhaust system inspect

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE SWITCHED OFF
CAUTION AND COOLED. BEWARE OF HOT ENGINE COMPONENTS.

1) Open the Engine canopy.

2) Inspect the exhaust components for signs of cracks and leaks; e.g. carbon build up around joints and
seams.

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3.2 Drive hub gearbox

3.2.1 Oil replace

1) Manufacturer’s specifications require this procedure to be

1
carried out after the first 100 hours, then every 1000 hours or
once a year. Depending on the operating cycle this frequency
may vary.
2) Select the drive hub to be serviced. Manoeuvre the Niftylift
until the drive hub is in position (see diagram).
3) Chock the front wheels.
4) Remove the yellow wheel bolt indicators from the wheel.
5) Loosen each wheel bolt by half a turn.
6) Using a suitable jack raise the rear of the Niftylift until the
wheels are clear of the ground.
2
7) Ensure the Niftylift is supported on suitable blocks or stands,
not the jack.
8) Support the wheel using a suitable wheel jack.
9) Undo the wheel bolts and remove the wheel.
10) Remove level/filler plug (1) and drain plug (2).
11) Drain oil into a suitable container. Dispose of waste oil in accordance with local environmental
policies.
12) Reinstall drain plug and tighten. See section 2.6 for torque settings.
13) Fill gearbox through the level/filler plug hole until oil level reaches bottom of plug hole. See section
2.4.3 and 2.2 for oil specification and capacity.
14) Reinstall level/filler plug and tighten. See section 2.6 for torque settings.
15) Reinstall wheel and partially tighten bolts.
16) Remove supports and lower Niftylift.
17) Tighten wheel bolts and reinstall yellow wheel bolt indicators. See section 3.10.1.
18) Repeat process for remaining gearbox.

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3.2.2 Bleeding air from the braking circuit

ENSURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN WHEN
WARNING OPENING THE HYDRAULIC CIRCUIT.
PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK AREA AND
CAUTION 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.

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3.3 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.

3.3.1 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. Use insulated spanners on
battery terminals. Do not lay tools or other metal objects on the batteries.
4) Check that all battery cables and link wires are securely fastened to the battery terminals and
lubricated. Remove any corrosion from battery terminals and clamps. Ensure all surfaces are clean
and free of lubrication. Secure battery terminals using an insulated spanner. Once tightened and
secure, lubricate battery clamps with petroleum jelly to prevent corrosion.

3.3.2 Condition check (weekly) - excludes AGM batteries

1) Carry out all procedures listed above in Daily checks.

2) Remove all battery cell caps and check the fluid level in each cell in each battery. The level should
be sufficient to cover the plates. Top-up each battery cell as necessary using distilled (deionised)
water, do not overfill. Replace and tighten battery cell caps and put batteries on charge. Leave
batteries to stabilise for one hour before proceeding with further checks.

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3) Using a hydrometer, check the specific gravity of the battery fluid in each cell in each battery (Target
1.26-1.27 for DYNO Batteries when fully charged). If the specific gravity is not within the serviceable
range, battery de-sulphate fluid may be used to restore batteries.
4) Replace all battery cell caps and clean any liquid from the top surface of the batteries.

3.3.3 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.

Lead-acid flooded (wet) batteries

Before placing the Niftylift into storage, ensure batteries are fully charged to 6.37V open circuit voltage
(100% state of charge). Isolate the batteries (See section 1.5.4) and monitor open circuit voltage every
4 - 6 weeks (2 - 4 weeks if stored in temperatures greater than 32°C (90°F)). Batteries in storage should
be charged when they decline to the following state of charge:
• 6.19V (70% 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.

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 the batteries (See section 1.5.4) and 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 the following state of charge:
• 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.

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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.

3.4 Inverter / generator and power to cage options

3.4.1 Condition check (daily)

EXPLOSION HAZARD. DO NOT USE THE INVERTER / GENERATOR IN THE
WARNING VICINITY OF FLAMMABLE FUMES OR GASES. AVOID COVERING THE
VENTILATION OPENINGS. ALWAYS OPERATE UNIT IN AN OPEN AREA.
EXPLOSION HAZARD. DO NOT USE THE INVERTER / GENERATOR IN THE
NOTICE VICINITY OF FLAMMABLE FUMES OR GASES. AVOID COVERING THE
VENTILATION OPENINGS. ALWAYS OPERATE UNIT IN AN OPEN AREA.
Information regarding the operation of the inverter / generator can be found in the Operating and Safety
Instructions Manual supplied with the Niftylift.
If the inverter detects a malfunction, an error code will be displayed on the unit’s digital display.

Checks before and after use

(1) Ensure operation of the inverter / generator is prevented when the E-stop is pressed.
(2) With the E-stop pressed, check that the socket / plug at cage and base are correctly wired (only if
competent to do so) and visually check the terminals for burn marks or staining that may suggest
overheating, to ensure they are not damaged.
(3) Check electrical cable (where visible) is not damaged and has not been repaired with insulating tape
or an unsuitable connector. Damaged cable should be replaced with a new cable of the correct type
and wire gauges, by a competent person.
(4) Check the RCD box is not damaged in any way that will give rise to electrical or mechanical hazards
and visually check the terminals for burn marks or staining that may suggest overheating.
(5) Ensure a PAT test label (or equivalent) is fitted on the RCD box and is up to date and within its next
approval check.
(6) With the E-stop released and the inverter / generator switched on, ensure the RCD works correctly
by pressing the test switch, then reset.
(7) PAT testing (or equivalent) should be completed every 6 months.

PAT Testing (or equivalent)

Due to the high usage of the machine with the power cable running through the booms, a PAT test (or
equivalent) must be carried out on the cable every 6 months by a competent person.
This must be done by disconnecting the inline connector from the inverter / generator to the RCD unit (If
fitted).
A competent person is an individual who can demonstrate they have the necessary knowledge, skills and
experience to carry out a task, that has been trained in PAT testing and holds a certificate of competence
in PAT testing.

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If the test fails, report immediately and attach a “not be used / out of action” warning label to the cage
socket and to the RCD box. Leave the RCD in the OFF position, until the issue has been rectified.
Rectify any defects before placing the Niftylift back into service.

3.5 Hydraulic oil

3.5.1 Level check (weekly)

ALWAYS USE THE SAME OIL GRADE AS INDICATED ON THE LABEL
NOTICE ATTACHED TO THE HYDRAULIC TANK.

Ensure the Niftylift is on level ground with the platform stowed.

Locate the hydraulic tank filler cap underneath the middle
bonnet. Loosen the filler cap to relieve pressure. Caution must
be taken when removing the tank cap as the hydraulic tank is
pressurised.
Check that the oil level is between the minimum and maximum
marks on the dipstick. Top-up the tank with oil if the level is
below the MIN 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 3.5.3. MAX

MIN

3.5.2 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 rear bonnet). If the visual
indicator is red, the pressure filter cartridge should be replaced once the oil has
cooled sufficiently.

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3.5.3 Hydraulic oil and filters replace

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE SWITCHED OFF
CAUTION AND COOLED DOWN. BEWARE OF HOT ENGINE COMPONENTS.
RISK OF BURNS - ALLOW THE HYDRAULIC OIL SUFFICIENT TIME TO COOL
CAUTION BEFORE DRAINING.
DISPOSE ANY WASTE ACCORDING TO LOCAL REGULATIONS.
NOTICE
Replace the Hydraulic oil and filters every year.
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) Locate the hydraulic tank drain plug underneath the Niftylift.
4) Place a suitable container under the hydraulic tank and undo the drain plug.
5) Dispose of waste oil in accordance with local environmental policies.
6) Replace drain plug and tighten to 130Nm (96 lbf·ft).

Return filter
7) Locate the return filter underneath the middle
bonnet.
8) Using a filter wrench or strap, remove the filter (1).
9) Replace the filter, apply a film of clean hydraulic oil
to the filter seal.
10) Screw filter onto housing by hand. When seal
contacts the housing surface, tighten by hand. Do
not tighten with filter wrench.

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Pressure filter
11) Remove the rear bonnet and locate the pressure
filter.
12) Place a suitable container underneath filter
housing.
13) Remove the filter bowl (1) and seal ring (2). 2

14) Remove filter element (3) and seal ring (4).

3
15) Replace seal rings on filter bowl, lubricate with
clean hydraulic oil.
16) Replace filter element.
4
17) Reinstall filter bowl and tighten. DO NOT APPLY 1
EXCESSIVE TIGHTENING TORQUE.
18) Refill tank with oil until level is between MIN and
MAX on the dipstick. See section 2.4.1 for
capacity and 2.4.3 for oil specification.
19) Operate the hydraulic system until oil temperature reaches 40°C (104°F). Check operation and
inspect for leaks.

3.6 Telescopic boom

3.6.1 Wear pad check (monthly)

1) With the links and luffing boom down and the

telescope boom fully retracted, check that there
are no loose, missing, or defective components in
the superstructure end of the telescope boom.
This includes wear pads, shims, spacers and
fasteners.
2) Fully extend the telescope boom.
1
3) It may be necessary to raise boom 3 slightly to
avoid the cage hitting the floor.
4) Check that there are no loose, missing, or 2
defective components in the platform end of the
telescope boom. This includes wear pads, shims,
spacers, fasteners, wear screws and locking nuts.
3

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5) Check the clearance between each wear screw

and the inner telescope boom section. 4
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.
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 is adequately lubricated and free from
scoring or rubbing marks.
9) Connect a grease gun to the grease nipple (3) and
pump the grease gun two to three times as
required.
10) Locate the second grease nipple (4) at the knuckle end of telescope boom and pump the grease gun
two to three times as required.
11) Use Hycote white grease or equivalent.

3.6.2 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.

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3.6.3 Boom pivot bushes lubricate (annually)

At yearly intervals lubricate all DU pivot bushes on the booms and telescope assemblies.

1 1

Use a dry PTFE aerosol lubricant spray such as WD40 W/D44394 or equivalent. Apply lubricant spray and
allow to penetrate at each of the pivot bush joints (1) in the diagram above. Note; with the exception of the
boom knuckle, there are no grease or lubrication nipples on the pivot bushes.

Boom knuckle
Ensure that the Niftylift is on level ground with the
platform stowed.

1) Locate the boom knuckle grease nipple (1).

2) Connect a grease gun to the grease nipple and
pump the grease gun two to three times as
required.
3) Use EP 2 Grease meeting specification DIN
51825: (2004-06) 2K-30 or equivalent.

3.6.4 Boom pivot pin check (daily)

Check the respective locking device is installed and secure on all boom pivot pins.

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3.7 Boom rotation gear

3.7.1 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.

3.7.2 Slew ring lubrication (monthly)

1) Open the base control station access cover.

2) Grease nipples are located 180° apart on the inner slew ring.

3) Connect a flexi-end grease gun through the access hole to the grease nipple.
4) Pump the grease gun two to three times as required. Use lithium based (Ep) grease corresponding
to DIN 51825 K2K - 20 and ISO L-X-BCHA2. It is also permissible to use equivalent grease with a
working temperature between -20°C (68°F) and +120°C (248°F).
5) Using a suitable paint brush, apply grease liberally to the outer slew ring teeth.
6) Close the base control station access cover.

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3.7.3 Slew ring bolts check (yearly)

Tighten the slew ring bolts located on the superstructure. See section 2.6 for torque settings.

3.8 Front axle

3.8.1 Front wheel hub bushes (yearly)

1) Ensure that the Niftylift is on level ground and

the platform stowed.
2) Chock the rear wheels.
3) Using a suitable jack raise the front of the
Niftylift until the wheels are clear of the ground.
4) Ensure the Niftylift is supported on suitable
blocks or stands, not the jack.
5) Rock the wheel by hand and check for
excessive vertical movement between the hub
assembly (1) and axle beams (2). A small
amount of movement is permissible. 2
6) Where movement is excessive, the hub
assembly will need to be removed for further
inspection.

1
2

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3.9 Chassis

3.9.1 Earth strap check (daily)

Check that the earth strap is secure and in contact with the ground.

3.10 Wheels and tyres

3.10.1 Wheel bolt torque (monthly)

1) Ensure that the Niftylift is on level ground and

the wheels are chocked.
2) Remove the yellow wheel bolt indicators. 1
3) Slacken each wheel bolt and tighten to the 4 3
specified torque as per the sequence shown in
the diagram. See section 2.6 for torque
settings. 2 5
4) Reinstall the wheel bolt indicators as shown in
the diagram.
5) Repeat process for each wheel.

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4 Repair procedures
4.1 General

4.1.1 Fuses
There are 3 main replaceable fuses on the Niftylift:
• 225A (x2) - Power Pack,
• 125A - Engine Starter Motor,
• 30A - (Diesel Engine).
In addition to the 3 main fuses, 2 fuses can be found in the Terminal box:
• 5A Blade fuse,
• 3.15A Slow blow glass fuse.
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.
Isolate Niftylift from power supply during maintenance of the electrical system. (See section 1.5.4).
The replacement fuse must always be the same rating as the defective one.
See location diagrams.
Main fuse location

125A

225A

30A

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Terminal box fuse location

5A

3.15A

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4.2 Platform/Cage

4.2.1 Footswitch - contact switch replace

The footswitch is used to provide power to the Niftylift controls.

Remove

1) Isolate the power supply (See section 1.5.4).

2) Remove bolts (1) and (2) and remove the 1
footswitch cover and rubber gasket.
Note; the longer length of bolt (1). 2
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 3.0Nm (2.2 lbf·ft) and bolt (2) to
2.5Nm (1.8 lbf·ft).
10) Connect the power supply (See section 1.5.4).

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4.3 Booms
Booms are safety critical components, contact a 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 prise upwards.
3) Raise the chain bridge until vertical.
4) Carefully prise apart link (2) at the four points
arrowed.
5) Remove link from the chain.
1
Install
6) Replace the link section and click into
position.
7) Lower each chain bridge and click into
position.

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4.4 Base Assembly

4.4.1 Engine exhaust

ONLY CARRY OUT THIS PROCEDURE WITH THE ENGINE OFF AND COOLED
CAUTION DOWN. BEWARE OF HOT ENGINE COMPONENTS.

Exhaust assembly - Diesel

Remove

1) Open the front bonnet. 1 4

2) Remove the 2 nuts from the exhaust clamp (1)
and remove the exhaust pipe (2).
3) Remove 2 retaining bolts (3) securing the exhaust
assembly to the engine.
4) Remove 2 nuts (4) from the exhaust manifold and
remove the exhaust assembly.
5) Remove the exhaust gasket.

Install
6) Replace exhaust gasket. 2 3
7) Replace exhaust assembly and tighten 2 nuts and
2 bolts. See section 2.6.1 for torque settings.
8) Reinstall the exhaust pipe and clamp.
9) Tighten 2 clamp nuts. See section 2.6 for torque settings.
10) Start the engine and check the exhaust.
11) Close the engine canopy.

Exhaust assembly - Petrol

Consult a Honda approved dealer.

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4.4.2 Steer cylinder

PRESSURISED HYDRAULIC OIL CAN PENETRATE AND BURN SKIN.
WARNING SLOWLY LOOSEN HYDRAULIC CONNECTIONS TO ALLOW PRESSURE TO
DISSIPATE. DO NOT ALLOW OIL TO SQUIRT OR SPRAY.
RISK OF BURNS - ALLOW THE HYDRAULIC OIL SUFFICIENT TIME TO
CAUTION COOL BEFORE DRAINING.
ENSURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN WHEN
WARNING OPENING THE HYDRAULIC CIRCUIT.
PLACE A CONTAINER UNDERNEATH THE WORK AREA AND DISPOSE ANY
NOTICE WASTE ACCORDING TO LOCAL REGULATIONS.

Remove

1 2
1) Ensure the Niftylift is in its stowed position.
2) Centre the steering so wheels point straight ahead.
3) Observe clean assembly practices to avoid
contamination by dust or dirt. 3
4) Open or remove the front bonnet (model specific).
5) Carefully remove 2 hydraulic hoses from the steer
cylinder. Slowly loosen fittings to allow pressure to 4
dissipate.
6) Insert plugs and cap to prevent oil loss.
4
7) Remove bolt and spring washer (1).
8) Remove steer pin (2), washer (3) and 2 spacers (4).
9) Chock the rear wheels.
10) Remove the yellow wheel bolt indicators from one of
the front wheels.
11) loosen each wheel bolt by half a turn.
12) Using a suitable jack raise the front of the Niftylift until
the front wheels are clear of the ground.
13) Ensure the Niftylift is supported on suitable blocks or 5
stands, not the jack.
14) Undo the wheel bolts and remove the front wheel.
15) Using a suitable hammer, tap the track rod (5) 6
upwards to release from the front hubs.
16) Remove and retain the washer (6) on each track rod
pin.

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17) Pull the track rod assembly from the Niftylift.

18) Remove one R-clip (7) and washer (8) then remove 9
pin (9).
19) Remove steer cylinder from track rod.

Install
20) Replace steer cylinder.
21) Reinstall pin and washer to track rod.
22) Secure pin with R-clip.
8
23) Reinstall track rod assembly to Niftylift.
7
24) Reinstall washer to track rod pin and tap track rod
downwards into front hub.
25) Reinstall steer pin, spacers and washer.
26) Reinstall spring washer and tighten bolt to steer pin. See section 2.6 for torque settings.
27) Reinstall front wheel.
28) Remove supports and lower Niftylift.
29) Tighten wheel bolts and reinstall yellow wheel bolt indicators. See section 3.10.1.
30) Connect hydraulic hoses and tighten connectors. See section 2.7 for torque settings.
31) Operate the hydraulic system until oil temperature reaches 40°C (104°F). Check operation and inspect
for leaks.
32) Check hydraulic oil level and top up with appropriate grade of oil if necessary. See section 2.4.4.
33) Close or reinstall the front bonnet.

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5 System overview
5.1 Introduction
Power options consist of DC Battery only, petrol or Diesel only, Bi-energy (Engine & Battery).

5.1.1 Power system

The main hardware for this system consists of the following:
(1) Diesel or petrol engine
(2) Coupling
(3) Pump Assembly

3
2

Diesel engine
A Kubota OC60 or OC95 engine, driving a twin bodied pump with direct mounted pump dump valves (one
per section), and integral relief valve on the rear pump. The arrangement allows two speed operation, fast
throttle and automatic relief for ramp climbing.
Petrol engine
A Honda GX 270 engine, driving a single body pump with direct mounted pump dump valve. The engine
is also equipped with a throttle solenoid for two-speed operation.

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5.1.2 DC electric system

The main hardware for this system consists of the following:
(1) 245Ah 6V batteries x8
(2) Power Packs x2 (3kW 24V)

Battery pack
Eight 245Ah 6V batteries wired in parallel supply 24V to both power packs. The on-board battery charger
requires connection to either a 230V or 110V AC power supply. Recharge batteries at the end of every
working day or shift. A step down voltage converter reduces the output voltage from 24V to 12V to supply
the control circuit.
Power packs
The 24V battery system powers x2 3kW 24V power packs. Each has an integral hydraulic pump 1.2CC
(RH power pack) and 2.2CC (LH power pack) providing power to the hydraulic circuit. A step down
regulator reduces the output voltage from 24V to 12V to supply the control circuit and separate battery.
Battery management
Battery condition is permanently monitored by the control circuit, such that when available power has
decreased to 20% of full charge, the battery status circuit begins to restrict the power to the hydraulic
power packs. This function causes the drive system to alternately stop and start, signalling to the operator
that re-charging is necessary. At the same time the Klaxon will begin to sound intermittently re-enforcing
the charge warning. At this point, sufficient power remains to drive to the nearest power point. Should the
operator ignore the on-set of the discharge warning, the "chopping" will continue until the machine is
rendered inoperative. Immediate charging will then be required.
UNDER NO CIRCUMSTANCES SHOULD A MACHINE BE LEFT FULLY
NOTICE DISCHARGED AS SEVERE BATTERY DAMAGE CAN OCCUR IN A
RELATIVELY SHORT TIME.
UNDER NO CIRCUMSTANCES SHOULD BATTERIES BE LEFT ON CHARGE
NOTICE FOR PERIODS IN EXCESS OF 24 HOURS.

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Battery isolation
The battery-disconnect handles (Anderson) are located beneath the rear bonnet and allow the machine
control and power circuits to be isolated from the batteries. In order to isolate the batteries it is necessary
to pull both handles. The left side release handle also incorporates a control circuit connector. Pulling this
handle also disconnects the supply to the PCB control box. Under normal operation, the machine key
switch should be used to isolate the machine, with the battery-disconnect handles only being required for
emergencies, in the event of a short circuit, or during routine maintenance. See section 1.5.4.
Batteries
245 AH DYNO Batteries are fitted as standard. If alternative batteries are used the charger must be
reconfigured to suit the replacement batteries. Contact Niftylift for further information.
As an alternative to the standard 245 Ah DYNO batteries, the Niftylift may be fitted with 245 Ah Absorbent
Glass Mat (AGM) batteries.
These batteries are maintenance free, therefore DO NOT REFILL with distilled (deionised) water.
Irreparable damage will occur.

5.2 Battery charging

Recharge batteries at the end of every working day or shift. Refer to the Operating & Safety Instructions
manual as supplied with the machine for information on battery charging.

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5.2.1 Battery charging - extension leads

Excessive cable lengths from the supply point to the battery charger will result in significant voltage drop,
leading to a reduction in the chargers efficiency. In addition, inadequate sized cable cores will have a
limiting effect on its current carrying capacity, which will again lead to a reduction in the chargers
efficiency. Both of these can result in over-heating of the cable with an increased risk of fire, short circuits,
or damage to the components themselves.
When connecting the on-board battery charger to an earthed AC power supply, use the shortest length
lead possible. Where this is not practicable, observe the following information to ensure effective battery
charging.
EXTENSION LEADS MUST HAVE APPROPRIATE SAFETY APPROVALS FOR
CAUTION THE COUNTRY IN WHICH THEY ARE USED.

Extension leads 230v

EXTENSION LEADS ARE TO BE UNCOILED TO PREVENT OVERHEATING AND
NOTICE MUST BE VISUALLY INSPECTED FOR ANY DEFECTS BEFORE USE.
ONLY USE APPROVED EXTENSION LEADS WITH A PASSED PAT LABEL
NOTICE FITTED.
DO NOT EXCEED THE MAXIMUM LENGTHS WHEN JOINING MULTIPLE
NOTICE LEADS.
ENSURE THE MACHINE IS CONNECTED DIRECTLY TO THE POWER SUPPLY
NOTICE SOURCE AND AVOID THE USE OF SPLITTERS.

230V (UK Only) standard Type G 13A plug maximum extension lead length

Cable core size Connector maximum current Maximum length

1.5mm 13A 15m (49.2ft)

1.5mm 13A RCD protected 25m (82ft)

2.5mm 13A 25m (82ft)

2.5mm 13A RCD protected 45m (147.6ft)

230V 16A rated plug maximum extension lead length

Cable core size Connector maximum current Maximum length

1.5mm 16A 15m (49.2ft)

1.5mm 16A RCD protected 22m (72.2ft)

2.5mm 16A 25m (82ft)

2.5mm 16A RCD protected 35m (114.8ft)

4mm 16A 40m (131.2ft)

4mm 16A RCD protected 55m (180.4ft)

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230V 15A rated plug maximum extension lead length

Cable core size Connector maximum current Maximum length

1.5mm 15A 15m (49.2ft)

1.5mm 15A RCD protected 22m (72.2ft)

2.5mm 15A 25m (82ft)

2.5mm 15A RCD protected 40m (131.2ft)

4mm 15A 40m (131.2ft)

4mm 15A RCD protected 60m (196.9ft)

Extension leads 110v (UK only)

Ensure the supply from the transformer is suitable for the application. It must allow continuous supply
based on the current required in order to allow a complete charge cycle and avoid nuisance tripping.
IF CHARGING A MACHINE WITH A 16A SUPPLY, THE 110V
NOTICE TRANSFORMER MUST HAVE A CONTINUOUS RATING OF 2.25KVA OR
ABOVE.
IF CHARGING A MACHINE WITH A 32A SUPPLY, THE 110V
NOTICE TRANSFORMER MUST HAVE A CONTINUOUS RATING OF 3.5KVA OR
ABOVE.
EXTENSION LEADS ARE TO BE UNCOILED TO PREVENT OVERHEATING
NOTICE AND MUST BE VISUALLY INSPECTED FOR ANY DEFECTS BEFORE USE.
ONLY USE APPROVED EXTENSION LEADS WITH A PASSED PAT LABEL
NOTICE FITTED.
DO NOT EXCEED THE MAXIMUM LENGTHS WHEN JOINING MULTIPLE
NOTICE LEADS.
ENSURE THE MACHINE IS CONNECTED DIRECTLY TO THE POWER
NOTICE SUPPLY SOURCE AND AVOID THE USE OF SPLITTERS.

110V maximum extension lead length

Cable core size Connector maximum current Maximum length

1.5mm 16A 10m (32.8ft)

2.5mm 16A 18m (59.1ft)

4mm 16A 28m (91.9ft)

4mm 32A 14m (45.9ft)

6mm 32A 23m (75.5ft)

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5.3 Bi-energy system

5.3.1 Duty selector

On multiple power option machines, (Bi-Energy) one of the functions on the platform control station will
be a duty selector. This key switch allows the selection of either power option, i.e. from Diesel to Battery
or Petrol to battery, or vice-versa. On other machines this same key switch serves as an "On-Off" control.

5.4 Boom system

5.4.1 Boom switch

The boom switch is located adjacent to the Knuckle, and works from a cam attached to boom 3. This
permits the operator to slightly raise the booms whilst still permitting high-speed drive. This switch
controls both the operation of the tilt alarm sensor, and the speed control function.
With the booms in the stowed position, the tilt alarm sensor is by-passed, allowing the machine to
negotiate slopes in excess of the permissible working angle, without isolating the drive function. At the
same time, "Hi" drive is possible, as is fast throttle on those machines so equipped. When the booms are
raised, the tilt alarm sensor becomes activated, only slow speed operation is possible and only "Lo" 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.

5.5 Drive system

5.5.1 Drive Control Valve (DCV)

The motion control valve comprises several individual components all directly involved in the hydraulic
supply to the wheel drive motors. Principal amongst these are the drive control valves, which electrically
change the drive motor hydraulics supply from series flow to parallel, or vice versa. This control function
is only available when the booms are lowered, and allows the operator to select "Hi" or "Lo" drive. "Hi" drive
gives fast speed of travel, but low gradeability, "Lo" drive gives best gradeability, but slow speed. "Lo" drive
is used for climbing inclines and delicate positioning of the machine.

5.5.2 Brake Release Valve

The motion control valve also incorporates a solenoid operated dump 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. Only when a green "Power Control" push-button is being used (or the Platform
Foot-switch is depressed) will the BRV operate. If the tilt alarm sensor detects an excessive inclination
whilst the booms are raised it is the BRV which is de-energised to isolate the machine. (At the same time
the klaxon tone changes to a continuous tone to indicate this condition).

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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 Schematic D80526. Please refer to D80526 in conjunction with
the Electric Schematics D81632 and D81867 for in-depth understanding of the complete system.

BASE CONTROLS CAGE CONTROLS

HAND WHEEL MOTORS

ENGINE
PUMP REAR

HYDRAULIC DRIVE
PUMP CONTROL VALVE

DUTY
SELECTOR

DC POWER
PACK

BRAKE
BRAKE
RELEASE
OVERRIDE
VALVE

5.7 Steering
Steer system
Steer is activated using the drive joystick on the platform control box. Steer flow is supplied to the steer
cylinder via the cage control valve. Maximum pressure on the steer line is set to 200 Bar (2900 psi).

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5.8 Electrical control system overview

CAGE USER
INPUTS

CAGE
WEIGH CAGE CONTROL SiOPS

24V
SUPPLY
(Bi-ENERGY)

SAFETY
INPUTS
POWER
PACKS

BASE
BASE USER
CONTROL
INPUTS

ENGINE

12V
SUPPLY

OUTPUTS
TO
VALVES

5.9 Control logic

Component level details and connections are provided in the Electric Schematics D81632 and D81867.

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6 Troubleshooting guide
6.1 Trouble shooting 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 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 Check fuse and reset on
Drive Control Valve (DCV) Terminal box
Niftylift will not
drive Return booms to stowed
Tilt alarm activated position and drive Niftylift onto
level ground

Connect coupling. Replace any

No functions, but Coupling failure
damaged parts
engine operates
correctly Contact switch may need
Footswitch fault
replacement (See section 4.2.1)

Reconnect Battery disconnect

Battery disconnect handles (Anderson)
handles (Anderson) (See
Disconnected
section 1.5.4)

If fuse blown, replace with direct

Check main fuses
Niftylift inactive, replacement (See section 4.1.1)
engine will not start
Batteries discharged Recharge batteries

Ensure e-stops are pulled out, at

E-stops activated
base controls and cage controls

Cage weigh activated? Remove weight from cage

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6.3 Engine fault finding

6.3.1 Diesel engine

Problem Cause / Test Solution

No fuel Replenish fuel

Air in the fuel system Vent air

Water in the fuel system Replace fuel and repair or replace fuel system

Fuel pipe clogged Clean

Fuel filter clogged Clean or replace

Excessively high viscosity of

fuel or engine oil at low Use the specified fuel / oil
temperature

Fuel with low cetane number Use the specified fuel

Fuel leak due to loose injection

Tighten nut
pipe retaining nut

Adjust injection timing

OC60 - 0.26 - 0.30 rad (15° - 17°) before top dead

Incorrect injection timing centre (TDC)

OC95 - 0.23 - 0.26 rad (13° - 15°) before top dead

Engine
centre (TDC)
does not start
Fuel camshaft worn Replace

Injection nozzle clogged Clean

Injection pump malfunctioning Replace

Seizure of crankshaft,
camshaft, piston, cylinder lining Replace
or bearing

Compression leak from Replace cylinder head gasket, Tighten cylinder head bolt
cylinder head and nozzle holder

Deficient compression Check and correct valve

Improper valve seat alignment,

valve spring broken, valve Replace
seized

Incorrect valve timing Adjust

Piston ring and liner worn Replace

Excessive valve clearance Adjust

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Problem Cause / Test Solution

Fuel filter clogged or dirty Clean

Air cleaner clogged Clean or replace

Fuel leak due to loose injection

Tighten nut
pipe retaining nut

Engine runs Injection pump malfunctioning Replace

erratically Incorrect nozzle injection
Repair or adjust
pressure

Injection nozzle stuck or

Replace
clogged

Fuel overflow pipe clogged Clean

Governor malfunctioning Repair

Excessive engine oil Reduce to the specified level

Either white or Piston ring and liner worn or
blue exhaust Replace
stuck
smoke is
observed Incorrect injector timing Adjust

Deficient compression Check top clearance and correct valve recessing

Either black or Overload Reduce load

dark grey
exhaust smoke Low grade fuel used Use the specified fuel
is observed Fuel filter clogged Clean or replace

Air cleaner clogged Clean or replace

Incorrect injection timing Adjust

moving parts show signs of

Deficient Repair or replace
seizing
output
Deficient nozzle injection Repair or replace nozzle

Compression leak Repair

Piston ring gaps aligned Space gaps 120° apart

Oil ring worn or stuck Replace

Excessive oil
Piston ring groove worn Replace piston
consumption
Valve stem and guide worn Replace

Oil leak Repair

Fuel mixed into

Injection pump broken Replace pump element or pump
lubricant

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Problem Cause / Test Solution

Engine oil insufficient Replenish

Oil strainer clogged Clean

Relief valve stuck Replace

Relief valve spring weakened or

Replace
broken

Low oil Excessive oil clearance of

Replace
pressure crankshaft bearing

Excessive oil clearance of crank

Replace
pin bearing

Oil gallery clogged Clean

Incorrect oil Use specified oil

Oil pump defective Repair or replace

High oil Incorrect oil Use specified oil

pressure Relief valve defective Replace

Engine oil insufficient Replenish

Overload running Reduce load

Engine
Head gasket defective Replace
overheating
Incorrect injection timing Adjust

Incorrect fuel Use specified fuel

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6.3.2 Petrol engine

Problem Cause / Test Solution

Battery discharged Recharge battery

Fuse blown Replace fuse

Fuel valve OFF Move lever to ON position

Choke OPEN Move lever to CLOSE position unless engine is warm

Engine switch OFF Turn engine switch to ON position

Engine oil level low (Oil Alert

Replenish with specified oil
models)

Engine Insufficient fuel Replenish with specified fuel

does not start Bad fuel; engine stored without
Drain fuel tank and carburettor, replenish with fresh
treating or draining petrol, or
petrol
refuelled with bad petrol

Spark plug faulty, fouled or

Gap or replace spark plug
improperly gapped

Spark plug wet with fuel Dry and reinstall spark plug. Start engine with throttle
(flooded engine) lever in MAX position

Fuel filter restricted, carburettor

Repair or replace faulty components as necessary.
malfunction, ignition
Consult a Honda approved dealer
malfunction, valves stuck etc.

Air filter elements restricted Clean or replace filter elements

Bad fuel; engine stored without

Drain fuel tank and carburettor, replenish with fresh
treating or draining petrol, or
Engine lacks petrol
refuelled with bad petrol
power
Fuel filter restricted, carburettor
Repair or replace faulty components as necessary.
malfunction, ignition
Consult a Honda approved dealer
malfunction, valves stuck etc.

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6.4 Gearbox fault finding

Problem Cause / Test Solution

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 3.2.1)

Wheel gear is not correctly

Check the fixing
installed

Vibrations Internal anomaly Contact a Niftylift approved service centre

and/or
Bearings badly lubricated or
excessive Contact a Niftylift approved service centre
faulty
noise
Dented or chipped teeth Contact a Niftylift approved service centre

Low oil level Check oil level, top-up if necessary (See section 3.2.1)

Low pressure in the braking

The brakes Check the brake connection
circuit
fails to
disengage Brake stuck due to prolonged Apply pressure to the brake and turn the wheel by turning
storage the motor on

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

Over-heating
Bearings badly lubricated or
Contact a Niftylift approved service centre
faulty

High thermal power Contact a Niftylift approved service centre

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