SERVICE MANUAL ARTICULATING BOOMS MODELS SJ46AJ SJ51AJ

Transcription

1 SERVICE MANUAL ARTICULATING BOOMS MODELS SJ46AJ SJ5AJ AD February 7

2 This manual is based on Serial Number(s): SJ46AJ & SJ5AJ: & Above Please refer to the website ( for older Serial Numbers. Skyjack Service Center 345 Swenson Ave. St. Charles, Illinois, 6074 USA Phone: Toll Free: Fax: Parts (North America) Toll Free: Toll Free Fax: Skyjack Australia Pty Ltd. 4 Coates Place Wetherill Park New South Wales 264 Australia Tel: +6 (0) Fax: +6(0) Parts & Service (Europe) Unit Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY0 8NN UK Phone: Fax: info@skyjackeurope.co.uk Skyjack Brasil Alameda Júpiter, 70 Loteamento American Park Empresarial Indaiatuba, SP, Brasil Tel:

3 SERVICE AND MAINTENANCE Table of Contents Section - Scheduled Maintenance Table of Contents Section 2 - Maintenance Tables Table of Contents Section 3 - System Component Identification and Schematics Table of Contents Section 4 - Troubleshooting Table of Contents Section 5 - Procedures Table of Contents December 07 Page 3

4 The Safety Alert Symbol identifies important safety messages on aerial platforms, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. This Safety Alert Symbol means attention! Become alert! Your safety is involved. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which, if not followed, may result in a malfunction or damage to the aerial platform. Page 4 December 07

5 Section SCHEDULED MAINTENANCE Table of Contents Operator s Responsibility for Maintenance Aerial Platform Definition...6 Purpose of Equipment...6 Use of Equipment...6 Manuals...6 Service Policy and Warranty...6 Operator Safety Reminders, Warnings, and Precautions...6 Maintenance and Inspection Schedule...7 Owner s Annual Inspection Record...7 Replacement Parts...7 Maintenance and Service Safety Tips...7 Hydraulic System & Component Maintenance and Repair...8 Maintenance Hints...8 Service and Maintenance About this Section...9 Service Bulletins...9 Maintenance and Inspection...9 Maintenance Instructions...9 Tables Table. Owner s Annual Inspection Record...0 Table.2 Pre-Delivery/Maintenance Inspection Checklist... Scheduled Maintenance Inspections and Function Tests. Scheduled Maintenance Inspections Function Tests...23 December 07 Page 5

6 Operator s Responsibility for Maintenance Section - Scheduled Maintenance SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications and dimensions are subject to change without notice. Aerial Platform Definition A mobile device that has an adjustable position platform supported from ground level by a structure. Purpose of Equipment The SKYJACK (Models SJ 46A, 46AJ, & 5AJ) aerial platform is designed to transport and raise personnel, tools and materials to overhead work areas Use of Equipment The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level, compacted surface. It can be driven over uneven terrain only when the platform is fully lowered. Manuals Operating The operating manual is considered a fundamental part of the aerial platform. It is a very important way to communicate necessary safety information to users and operators. A complete and legible copy of this manual must be kept in the provided weather-resistant storage compartment on the aerial platform at all times. Service & Maintenance The purpose of this is to provide the customer with the servicing and maintenance procedures essential for the promotion of proper machine operation for its intended purpose. All information in this manual should be read and understood before any attempt is made to service the machine. The updated copy of the manuals are found on the company s website: Service Policy and Warranty SKYJACK warrants each new SJT series work platform to be free of defective parts and workmanship for the first 24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor. Contact SKYJACK Service Department for warranty statement extensions or exclusions. Operator Safety Reminders, Warnings, and Precautions Operator safety is SKYJACK s priority. The operator should comply with all applicable safety-related reminders, warnings and precautions found in the Operating Manual. They should be read and understood completely before operating the aerial platform. Page 6 December 07

7 Section - Scheduled Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the maintenance schedule. The inspection points covered in Table.2. Maintenance and lnspection Checklist, indicates the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed. Owner s Annual Inspection Record It is the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform. Table.. Owner s Annual lnspection Record is to be used for recording the date of the inspection, owner s name, and the person responsible for the inspection of the work platform. Replacement Parts Use only original replacement parts. Parts such as batteries, wheels, railings, etc. with weight and dimensions different from original parts will affect stability of the aerial platform and must not be used without manufacturer s consent. All replacement tires must be of the same size and load rating as originally supplied tires; to maintain safety and stability of aerial platform. Consult SKYJACK s Service Department for optional tires specifications and installation. WARNING Any unit that is damaged or not operating properly must be immediately tagged and removed from service until proper repairs are completed. Operator s Responsibility for Maintenance Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform. All maintenance and service procedures should be performed in a well lighted and well ventilated area. Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual. All tools, supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins. Work area should be kept clean and free of debris to avoid contaminating components while servicing. All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment. Keep sparks and flames away from all flammable or combustible materials. Properly dispose of all waste material such as lubricants, rags, and old parts according to the relative law provisions obtaining in the country. Before attempting any repair work, turn Battery Disconnect Switch to off position. Preventive maintenance is the easiest and least expensive type of maintenance. December 07 Page 7

8 Operator s Responsibility for Maintenance Hydraulic System & Component Maintenance and Repair The following points should be kept in mind when working on the hydraulic system or any component: WARNING Escaping fluid from a hydraulic pressure leak can damage your eyes, penetrate the skin and cause serious injury. Use proper personal preotection at all times.. Any structure has limits of strength and durability. To prevent failure of structural parts of hydraulic components, relief valves which limit pressure to safe operating values are included in the hydraulic circuits. 2. Tolerance of working parts in the hydraulic system is very close. Even small amounts of dirt or foreign materials in the system can cause wear or damage to components, as well as general faulty operation of the hydraulic system. Every precaution must be taken to assure absolute cleanliness of the hydraulic oil. 3. Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles or foreign materials in the system, drain and flush the entire system and replace the filter cartridges. A complete change of oil must be performed under these circumstances. 4. Whenever the hydraulic system is drained, check the magnets in the hydraulic reservoir for metal particles. If metal particles are present, flush the entire system and add a new change of oil. The presence of metal particles also may indicate the possibility of imminent component failure. A very small amount of fine particles is normal. 5. All containers and funnels used in handling hydraulic oil must be absolutely clean. Use a funnel when necessary for filling the hydraulic oil reservoir, and fill the reservoir only through the filter opening. The use of cloth to strain the oil should be avoided to prevent lint from getting into the system. Section - Scheduled Maintenance 7. All hydraulic components must be disassembled in spotlessly clean surroundings. During disassembly, pay particular attention to the identification of parts to assure proper reassembly. Clean all metal parts in a clean mineral oil solvent. Be sure to thoroughly clean all internal passages. After the parts have been dried thoroughly, lay them on a clean, lint-free surface for inspection. 8. Replace all O-rings and seals when overhauling any component. Lubricate all parts with clean hydraulic oil before reassembly. Use small amounts of petroleum jelly to hold O-rings in place during assembly. 9. Be sure to replace any lost hydraulic oil when completing the installation of the repaired component, and bleed any air from the system when required. 0. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit the oil to leak out or air to be drawn into the system. Air in the system can cause damage to the components and noisy or erratic system operation. Maintenance Hints Three simple maintenance procedures have the greatest effect on the hydraulic system performance, efficiency and life. Yet, the very simplicity of them may be the reason they are so often overlooked. They are simply these:. Change filters annually. The filters will need to be changed more often depending on the operating conditions. Dirty, dusty, high moisture environments may cause the hydraulic system to be contaminated more quickly. 2. Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir. 3. Keep all connections tight. 6. When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components. Page 8 December 07

9 Section - Scheduled Maintenance About this Section This section contains the maintenance and inspection schedule that is to be performed. References are made to the procedures in Section 5 that outline detailed step-by-step instructions for checks and replacements. Service Bulletins Before performing any scheduled maintenance inspection procedure, refer to service bulletins found in our web site: for updates related to service and maintenance of this aerial platform. Maintenance and Inspection Death or injury can result if the aerial platform is not kept in good working order. Inspection and maintenance should be performed by competent personnel who are trained and qualified on mantenance of this aerial platform. WARNING Failure to perform each procedure as presented and scheduled may cause death, serious injury or substantial damage. NOTE Preventive maintenance is the easiest and least expensive type of maintenance. Unless otherwise specified, perform each maintenance procedure with the aerial platform in the following configuration: - Aerial platform parked on a flat and level surface - Disconnect the battery by turning the main power disconnect switch to off position. Service and Maintenance Maintenance Instructions This manual consists of four schedules to be done for maintaining on an aerial platform. Inspection schedule frequency is shown below: Inspection Schedule PDI / Frequent B Annual B + C Additional * B - Perform PDI prior to each delivery, or Frequent Inspection every 3 months or 50 hours. C - Perform Scheduled Maintenance Inspections every year. * - Perform at time sensitive maintenance intervals. Make copies of the maintenance and inspection checklist to be used for each inspection. Check the schedule on the checklist for the type of inspection to be performed. Place a check in the appropriate box after each inspection procedure is completed. Use the maintenance and inspection checklist and step-by-step procedures in Section to perform these inspections. If any inspection receives a fail, tag and remove the aerial platform from service. If any aerial platform component(s) has been repaired, an inspection must be performed again before removing the tag. Place a check in the repair column. Legend P = Pass F = Fail R = Repaired N/A = Not applicable Repair any damaged or malfunction components before operating aerial platform. Keep records on all inspections. December 07 Page 9

10 Service and Maintenance Section - Scheduled Maintenance Table. Owner s Annual Inspection Record Model Number: Serial Number: * ** 00AB This decal is located on the control compartment cowling. It must be completed after an annual inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 6 months. * Pictorial Description Inspection Date ** Inspector Signature Page 0 December 07

11 Section - Scheduled Maintenance Service and Maintenance Pre-Delivery/Maintenance Inspection Checklist Articulating Booms & Telescopic Booms Serial Number: Product Owner: Model: Hourmeter Reading: Product User: Date/Time: Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to the applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection Intervals, etc.). Inspection Type Schedule PDI B B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 50 hrs. For further details refer to Service P - Pass Frequent B & Operating Manuals. F - Fail Annual B + C C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals. R - Repaired Additional * * - Perform time sensitive maintenance intervals. Refer to the Service Manual. N/A - Not Applicable Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided. Items for Inspection P F R N/A Items for Inspection P F R N/A Refer to skyjack.com for the latest service bulletins. B, C Fuel Tank Leaks. Tight fittings and hoses & no damage or B Ensure Annual Inspection has been completed within the leaks. B last 3 months. Base Weldment. No cracks or deformation. B Manuals & Required Documents. In storage box, in good condition & legible. Labels. In place, secure & legible. Limit Switches. Secured & no obstructions or damage. B B B B Main Power Disconnect Switch. Cables secure & in Oscillating Cylinder Assembly. Secure & no missing working order. parts. Tight fittings and hoses & no leaks. B, C Battery. No damage, tight connections, adequate fluid Steer Cylinder Assembly. Secure & no missing parts. B levels. Clean terminals and cable ends. Tight fittings and hoses & no leaks. B Swing Drive Motor. Tight fittings, hoses & bolts. No Pins & Bushings. No damage/wear, or loose or missing B, C damage, missing parts or leaks. parts. B Turret Rotation Gear. No damage or missing parts. B, C Steer Linkage. No damage/wear or missing parts. B Rotary Manifold. Tight fittings & hoses, & no leaks. B Wheel/Tire Assembly. Check all tires for damage, wear High Pressure Filter. Secure & no damage or leaks. B, C & proper alignment. Lug nuts torqued as recommended. B, C Hydraulic Pumps. Tight fittings, hoses & bolts. No Platform Assembly. No damage or missing parts. B B damage, missing parts or leaks. Raillings and Gate. Secure & no damage or missing parts. B Muffler and Exhaust. Secure & no damage. B Lanyard Attachment Anchorage. Attachment rings Engine Pivot Tray. Secure & no damage or missing parts. B secure & no damage. B Engine Oil. Level in the "safe" zone. Ensure oil change Platform Control Console. Switches in neutral position & B interval has not been exceeded. secure. No damage or missing parts. B Engine Air Filter. No damage or missing parts. B, C Rotary Actuator. No damage or missing parts. Tight B Engine Fuel Leaks. No damage or leaks from tank, fittings, hoses and bolts & no leaks. B, C shutoff valve & hoses and fittings. Jib. No damage or missing parts. Tight hoses and bolts & B Engine Fuel Filter. No damage, missing parts or leaks. B, C no leaks. Base Control Console. Switches in neutral position & no Boom. No damage or missing parts. No deformation or B damage or missing parts. cracks in welds. Tight hoses and bolts & no leaks. B Hydraulic Tank. Filler cap secure & no damage or leaks. Hydraulic Oil. Level between min. & max. marks. B *, B Control Cables and Hoses. No damage or missing parts. No spring gaps. Ensure Inspection Interval has not been *, B Hydraulic Filter. Secure & no damage, missing parts or exceeded. B, C leaks. Riser. Secure & no damage/deformation or missing parts. B Brake & Main Manifolds. Tight fittings and hoses & no Cylinders. Secure & no damage or leaks. B B, C leaks. Tight wire connections. Wear Pads. No damage or missing parts. Bolts tightened. B Emergency Power Unit. Tight fittings and hoses & no Cable Carrier. No damage or missing parts. B leaks. Tight wire connections & no damage or missing B Special Options and Approved Attachments. Secure & parts. no damage or missing parts. Fuel Tank. Filler cap is secure & no damage or leaks. B, C Function Tests (Refer to your corresponding Serial #'s Operating Manual for information on running these tests.) Comments: Turret Transportation Lock. Unlocked & no damage or missing parts. Drive Axle. Secure & no missing parts. Tight fittings and hoses & no leaks. B B, C PASS FAIL The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner. Furthermore, the undersigned confirms that all discrepancies have been corrected prior to using this machine. Owner: / / Print Name Signature Date (DD/MM/YY) User: / / Print Name Signature Date (DD/MM/YY) Note: Visit skyjack.com for a printable copy of this form AA December 07 Page

12 Scheduled Maintenance Inspections Section - Scheduled Maintenance Manual Box Platform Assembly. Scheduled Maintenance Inspections Begin the visual and daily maintenance inspections by checking each item in sequence for the conditions listed in this section. WARNING To avoid injury, do not operate an aerial platform until all malfunctions have been corrected. WARNING To avoid possible injury, ensure aerial platform power is off during your visual and daily maintenance inspections. Electrical Maintaining electrical components is essential to good performance and service life of aerial platform. Perform a visual inspection around the following areas: boom to platform cable harness engine compartment electrical panel engine wiring harness rotary manifold wiring Hydraulic Maintaining hydraulic components is essential to good performance and service life of the aerial platform. Perform a visual inspection around the following areas: hydraulic tank filter, fittings, hoses, emergency power unit and turret/base surface engine compartment fittings, hoses, main pump, filter and turret/base surface all hydraulic cylinders all hydraulic manifolds the underside of the turret the underside of the base ground area under the aerial platform.- Manuals & Required Documents(B) Ensure a copy of the operating manual and other important documents are enclosed in the manual storage box. Check to be sure manual storage box is present and in good condition. Ensure manuals are legible and in good condition. Always return manuals to the manual storage box after use..-2 Labels (B) Refer to the labels section in the operating manual and ensure that all labels are in place and are legible. Page 2 December 07

13 Section - Scheduled Maintenance Scheduled Maintenance Inspections Muffler High Pressure Filter Swing Drive Motor Air Filter Battery Charge Indicator Main Power Disconnect Switch.-3 Limit Switches (B) Detecting limit switch malfunction is essential to safe aerial platform operation. Ensure limit switches are properly secured with no signs of visible damage and movement is not obstructed. Visually inspect all limit switch located inside the turret and under the power track. Inspect for the following: broken or missing actuator arm missing fasteners loose wiring.-4 Engine Compartment Ensure all compartment latches are secure and in proper working order. Main Power Disconnect Switch (B) Turn main power disconnect switch to off position. Ensure there are no loose or missing parts and there is no visible damage. Ensure all cables are secure and switch is in proper working condition. Batteries (B) Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. WARNING Explosion hazard. Keep flames and sparks away. Do not smoke near batteries. WARNING Battery acid is extremely corrosive - Wear proper eye and facial protection as well as appropriate protective clothing. If contact occurs, immediately flush with cold water and seek medical attention.. Check battery cases for damage. 2. B - Frequent Inspection Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush. 3. Ensure all battery connections are tight. December 07 Page 3

14 Scheduled Maintenance Inspections Section - Scheduled Maintenance Muffler High Pressure Filter Swing Drive Motor Air Filter Battery Charge Indicator Main Power Disconnect Switch 4. If applicable, check battery fluid level. B - Frequent Inspection If plates are not covered by at least 3 mm (/2 ) of solution, add distilled or demineralized water. 5. B - Frequent Inspection Replace battery if damaged or incapable of holding a lasting charge. Charge Indicator - CE (B) Ensure there are no loose or missing parts and there is no visible damage. WARNING Use original or manufacturer-approved parts and components for the aerial platform. Swing Drive Motor (B,C) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts are properly tightened. Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. C - Annual Inspection For brake/motor oil replacement procedure, refer to Swing Drive Brake and Gearbox Oil Replacement. Turret Rotation Gear (B,C) Ensure there are no loose or missing parts and there is no visible damage. C - Annual Inspection For lubrication procedure, refer to Deutz Diesel Engine. High Pressure Filter (B,C) Ensure housing is secure and shows no visible damage or leakage. C - Annual Inspection For filter element replacement procedure, refer to 5.3- High Pressure Filter Replacement. Hydraulic Pumps (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts are properly tightened. Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. Page 4 December 07

15 Section - Scheduled Maintenance Scheduled Maintenance Inspections Muffler High Pressure Filter Swing Drive Motor Air Filter Battery Charge Indicator Main Power Disconnect Switch Muffler and Exhaust (B) Ensure muffler and exhaust system are properly secured, with no evidence of damage. Engine Pivot Tray (B) Ensure there are no loose or missing parts and no visible damage to the engine pivot tray. Ensure that each tray-securing bolt is in place. Engine Oil Level (B) Maintaining the engine components is essential to good performance and service life of the aerial platform. WARNING Beware of hot engine components. Check oil level on dipstick Oil level should be in the safe zone. Add oil as needed. Refer to Figure Table 2.2 Specifications and Features for recommended oil type. B - Frequent Inspection For recommended oil change, refer to engine manual Engine Air Filter (B,C) Ensure there are no loose or missing parts and there is no visible damage. B - Frequent Inspection For engine air filter maintenance procedure, refer to engine manual. C - Annual Inspection For engine air filter replacement procedure, refer to engine manual. Engine Fuel Leaks (B,C) Ensure that there no fuel leaks. DANGER Engine fuels are combustible. Inspect the aerial platform in an open, wellventilated area away from heaters, sparks and flames. Always have an approved fire extinguisher within easy reach. Ensure fuel tank, shutoff valve, hoses and fittings show no visible damage and no evidence of fuel leakage. Engine Fuel Filter (B,C) Ensure there are no loose or missing parts and there is no visible damage. C - Annual Inspection For engine fuel filter replacement procedure, refer to engine manual. December 07 Page 5

16 Scheduled Maintenance Inspections Section - Scheduled Maintenance Brake Manifold Main Manifold Hydraulic In-Tank Filter Base Control Console Hydraulic Tank Fuel Tank Emergency Power Unit.-5 Control Compartment Ensure all compartment latches are secure and in proper working order. Base Control Console (B) Ensure all switches are returned to their neutral positions. Ensure there are no loose or missing parts and there is no visible damage. Hydraulic Tank (B) Ensure hydraulic filler cap is secure. Ensure tank shows no visible damage and no evidence of hydraulic leakage. Hydraulic Oil (*,B) Be sure that the boom is in the stowed position, and then visually inspect the sight gauge located on the side of the hydraulic oil tank. The hydraulic oil level should be between the minimum and maximum marks on the sight glass. Add oil as needed. Refer to Table 2.9 Specifications and Features for recommended oil type. * - Bi-Annual Inspection For hydraulic oil replacement procedure, refer to 5.7- Hydraulic Oil Replacement. Hydraulic In-Tank Filter (B,C) C - Annual Inspection For hydraulic in-tank filter replacement procedure, refer to Turret Rotation Gear Backlash Adjustment. Brake and Main Manifolds (B,C) Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. Ensure there are no loose wire connections or missing fasteners. Emergency Power Unit (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure there are no loose wire connections or missing fasteners. Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. Page 6 December 07

17 Section - Scheduled Maintenance Scheduled Maintenance Inspections Brake Manifold Main Manifold Hydraulic In-Tank Filter Base Control Console Hydraulic Tank Fuel Tank Emergency Power Unit Fuel Tank (B,C) IMPORTANT Before using your aerial platform ensure there is enough fuel for expected use. Ensure fuel filler cap is secure. Ensure tank shows no visible damage and no evidence of fuel leakage. Fuel Leaks (B) Ensure that there no fuel leaks. DANGER Engine fuels are combustible. Inspect the aerial platform in an open, wellventilated area away from heaters, sparks and flames. Always have an approved fire extinguisher within easy reach. - - Ensure fuel tank, shutoff valve (if equipped), hoses and fittings show no visible damage and no evidence of fuel leakage. December 07 Page 7

18 Scheduled Maintenance Inspections Section - Scheduled Maintenance Overhead View Tie Rod Limit Switch Turret Rotation Gear Oscillating Cylinder Assembly Drive Axle Wheel/Tire Assembly Rotary Manifold Steer Cylinder Assembly.-6 Base Base Weldment (B) Ensure there are no visible cracks in welds or structure and there are no signs of deformation. Rotary Manifold (B) Ensure lock is secure and in place. Ensure all fittings and hoses are properly tightened and there is no evidence of damage or hydraulic leakage. Turret Transportation Lock (B) Ensure turret transportation lock is unlocked, there are no loose or missing parts and there is no visible damage. Drive Axle (B,C) Ensure drive axle is properly secured, there are no loose or missing parts, all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. Oscillating Cylinder Assembly (B,C) Ensure oscillating cylinder assembly is properly secured, there are no loose or missing parts, all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. Visually inspect the heads of the oscillating cylinder mounting bolts to ensure the torque seal is visible and undamaged. If the torque seal has been damaged or is missing, remove and replace the affected bolts. Refer to Oscillating Cylinder Bolt Replacement. NOTE Oscillating axle is locked when aerial platform is in work mode. Refer to Diagram 2.3 Axle Oscillation Diagram. Steer Cylinder Assembly (B) Ensure steer cylinder assembly is properly secured, there are no loose or missing parts, all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage. Steer Linkage (B) Ensure there are no loose or missing parts, tie rod end studs are locked and there is no visible damage. Page 8 December 07

19 Section - Scheduled Maintenance Scheduled Maintenance Inspections Overhead View Tie Rod Limit Switch Turret Rotation Gear Oscillating Cylinder Assembly Drive Axle Wheel/Tire Assembly Rotary Manifold Steer Cylinder Assembly Wheel/Tire Assembly (B,C) Tire and/or wheel failure could result in an aerial platform tip over. Component damage may also result if problems are not discovered and repaired in a timely fashion. WARNING An over-inflated tire can explode and may cause death or serious injury. Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. Check each wheel for damage and cracked welds. Check each lug nut for proper torque to ensure none are loose. B - Frequent Inspection For proper torque information, please refer to Table 2.3 Axles Torque Specifications. To maximize stability, it is essential to maintain proper pressure in all air-filled tires. Check each tire with an air pressure gauge and add air as needed. WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability. Therefore, replace tires ONLY with exact Skyjack-approved types. Failure to operate with matched, approved tires in good condition may result in death or serious injury. Refer to Table 2.8 Tire Specifications for wheel/ tire specifications. December 07 Page 9

20 Scheduled Maintenance Inspections Section - Scheduled Maintenance Platform Railing Platform Control Console Lanyard Attachment Anchorage Manual Box Footswitch Platform Assembly.-7 Platform Assembly (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all fasteners are securely in place. Ensure all railings are properly positioned and secured. Ensure gate/drop-bar(s) are in good working order. Ensure footswitch is in good working order and has not been modified, disabled or blocked. Ensure lanyard attachment anchorages are secure and there is no visible damage..-8 Platform Control Console (B) Ensure all switches/controllers are returned to neutral and are properly secured. Ensure there are no loose or missing parts and there is no visible damage. Page December 07

21 Section - Scheduled Maintenance Scheduled Maintenance Inspections Wear Pads Main and Fly Booms Jib Power Track Load Cell Rotary Actuator Riser Cylinders.-9 Rotatory Actuator (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts and pins are properly tightened. Ensure all hoses are properly tightened and there is no evidence of hydraulic leakage..-0 Load Cell - CE (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts are properly tightened. Ensure all cables are secure and are in proper working condition. Ensure debris is not lodged between the platform and boom adaptor..- Jib (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts and pins are properly tightened. Ensure all hoses are properly tightened and there is no evidence of hydraulic leakage..-2 Boom (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts and pins are properly tightened. Ensure there are no visible cracks in welds or structure and there are no signs of deformation. Ensure all hoses are properly tightened and there is no evidence of hydraulic leakage. Riser (B) Ensure there are no loose or missing parts and there is no visible damage. Ensure all bolts and pins are properly tightened. Ensure there are no visible cracks in welds or structure and there are no signs of deformation. Cylinders (B) Ensure all cylinders are properly secured and there are no loose or missing parts and there is no evidence of damage. Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage December 07 Page 2

22 Scheduled Maintenance Inspections Section - Scheduled Maintenance Wear Pads Main and Fly Booms Jib Power Track Load Cell Rotary Actuator Riser Cylinders Wear Pads (B) Ensure all bolts are tight, there is no visible damage to the wear pads and that no parts are missing. Cable Carrier (B) Ensure there are no loose or missing parts and there is no visible damage. Control Cables and Hoses (B) Ensure all hoses are properly tightened and there is no evidence of hydraulic leakage. Page 22 December 07

23 Section - Scheduled Maintenance Funtion Tests.2 Function Tests Function tests are designed to discover any malfunctions before aerial platform is put into service. The operator must understand and follow step-by-step instructions to test all aerial platform functions. IMPORTANT Never use a malfunctioning aerial platform. If malfunctions are discovered, aerial platform must be tagged and placed out of service. Repairs to aerial platform may only be made by a qualified service technician. After repairs are completed, operator must perform a pre-operation inspection and a series of function tests again before putting aerial platform into service. Prior to performing function tests, be sure to read and understand Section Start Operation of the operating manual. For function test that are to be performed, please refer to the operating manual that corresponds to the correct serial number. Found there will be detailed instructions for which tests to preform, as well as how to properly and successfully perform them. NOTE All-function motion alarm should sound while operating any boom and drive function. December 07 Page 23

24 Notes Page 24 December 07

25 Section 2 MAINTENANCE TABLES AND DIAGRAMS Table of Contents Tables Table 2. Standard Hose Numbering System...26 Table 2.2 Aerial Platform Torque Specifications...28 Table 2.3 Axles Torque Specifications...29 Table 2.4 Torque Specifications for Fasteners (Imperial)...30 Table 2.5 Torque Specifications for Fasteners (Metric)...3 Table 2.6 Torque Specifications for Hydraulic Couplings & Hoses...32 Table 2.7 Axles Maintenance Intervals...33 Table 2.8 Tire Specifications...34 Table 2.9 Maximum Platform Capacities...34 Table 2.0 Floor Loading Pressure...35 Table 2. Hydraulic Specifications...36 Table 2.2 Specifications and Features Diagrams Diagram 2. Dimension and Reach Diagram - SJ 46AJ...39 Diagram 2.2 Dimension and Reach Diagram - SJ 5AJ...40 Diagram 2.3 Axle Oscillation Diagram...4 December 07 Page 25

26 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2. Standard Hose Numbering System H FITTING ARRANGEMENT (See Schedule Below) HOSE SIZE (See Chart Below) LENGTH OF HOSE IN WHOLE INCHES LENGTH IN FRACTIONS (/4 INCREMENTS) I.E. =/4 2=/2 3=3/4 Using the number above as an example (H 008 2). This hose requires a 37 JIC, female swivel fitting on one end. A medium length 90 JIC, female swivel fitting for the other end. The Hose must meet or exceed S.A.E. 00R3 hose specification, and be a total of 8-/2 long. NOTE: Hose ends and hose must be from same manufacturer per S.A.E. J273 Nov. 9, Sections 3.0 and 4.2. Hose ends and hose must be of the same size i.e. #4 size fittings must be used with #4 size hose. Hose Size Chart SIZE ID 3/6 /4 3/8 /2 5/8 3/4 -/4 -/2 2 2-/2 3 3-/2 4 HOSE PREFIX HOSE END FITTING HOSE END FITTING S.A.E. HOSE SPECIFICATION H0 FEMALE, 37 JIC, SWIVEL FEMALE, 37 JIC, SWIVEL 00R7 H FEMALE, 37 JIC, SWIVEL FEMALE, 37 JIC, SWIVEL 00R3 H03 FEMALE, 37 JIC, SWIVEL 45, FEMALE, 37 JIC, SWIVEL 00R7 H FEMALE, 37 JIC, SWIVEL 45, FEMALE, 37 JIC, SWIVEL 00R3 H05 FEMALE, 37 JIC, SWIVEL LONG 90, FEMALE, 37 JIC, SWIVEL 00R7 H06 FEMALE, 37 JIC, SWIVEL SHORT 90, FEMALE, 37 JIC, SWIVEL 00R7 H07 LONG 90, FEMALE, 37 JIC, SWIVEL LONG 90, FEMALE, 37 JIC, SWIVEL 00R7 H08 FEMALE, 37 JIC, SWIVEL FEMALE, 37 JIC, SWIVEL 00R4 H FEMALE, 37 JIC, SWIVEL 45, FEMALE, 37 JIC, SWIVEL 00R4 H0 FEMALE, 37 JIC, SWIVEL MALE PIPE THREAD FITTING 00R7 H FEMALE, 37 JIC, SWIVEL MEDIUM 90, FEMALE, 37 JIC, SWIVEL 00R3 H2 SHORT 90, FEMALE, 37 JIC, SWIVEL SHORT 90, FEMALE, 37 JIC, SWIVEL 00R7 H3 FEMALE, 37 JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI H4 REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI H5 REUSABLE FEMALE, 37 JIC, SWIVEL REUSABLE FEMALE, 37 JIC, SWIVEL 300 PSI Fitting Arrangement Schedule (Continued on the following page) Page 26 December 07

27 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2. Standard Hose Numbering System (Continued) Fitting Arrangement Schedule (Continued from the previous page) HOSE PREFIX HOSE END FITTING HOSE END FITTING H6 NO FITTING NO FITTING 00R4 H7 NO FITTING NO FITTING 300 PSI H8 REUSABLE, FEMALE, 37º JIC, SWIVEL NO FITTING 300 PSI H9 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R3 H FEMALE, SHORT 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 00R4 H2 FEMALE, SHORT 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 00R2AT H22 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R2AT H23 FEMALE, LONG 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 00R2AT H24 FEMALE, SHORT 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 00R3 H25 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R4 H26 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H27 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H28 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H29 SHORT 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H30 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H3 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H32 SHORT 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H33 MEDIUM 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H34 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H35 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H36 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H37 SHORT 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R4 H38 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R4 H39 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R4 H40 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R6 H43 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R6 H5 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H52 SHORT 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H53 MEDIUM 45º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H54 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H55 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 H56 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 00R7 S.A.E. HOSE SPECIFICATION December 07 Page 27

28 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.2 Aerial Platform Torque Specifications Location Description Torque (ft-lb) Torque (Nm) Base Trunnion Mount BOLT, Hex head (3/4"-0 x 5", Grade 8) Rear Axle Mount NUT, Torque lock (3/4"-0, Grade C) Axle Lock BOLT, Hex head (/2"-3 x 2.25", Grade 8) Swing Drive Motor SCREW, Socket head cap (3/4"-0 x 2.25") Rotation Gear BOLT, Hex head (5/8"- x 4.5", Grade 8) Hydraulic Drive Motor BOLT, Hex head (M4 x 2 x 30mm, ZP, Grade 8.8) Wheel Nut NUT, Wheel Turret Rotation Gear BOLT, Hex head (5/8"- x 2.75", Grade 8) BOLT, Hex head (5/8"- x 3", Grade 8) Engine Deutz Engine Mount BOLT, Hex head (/2"-3 x 3.75", Grade 5) Coupling Assembly (Deutz) BOLT (M0) COUPLING CLAMP BOLT 45 6 GM Engine Mount NUT, Hex head (/2"-3, Grade 5) Drive Pump BOLT, Hex head (/2"-3 x.5", Grade 5) System Pump BOLT, Socket (3/8"-6 x, Grade 5) 23 3 Cylinders Lift ROD NUT GLAND ROD NUT (46A / 5AJ) Extension ROD NUT (46AJ) 50 3 GLAND Master ROD NUT GLAND Slave ROD NUT GLAND Axle Lock BOLT, Hex head (/2"-3 x 2.25", Grade 8) Jib BOLT, Hex head ( x 2.75", Grade 5 \ ZP) 5 Riser ROD NUT GLAND Platform Rotary Mount BOLT, Hex head, patch (3/8"-6 x 7/8", Grade 8 \ ZP) BOLT, Hex head ("-8 x 0.5", zinc, Grade 8) Rotary Actuator BOLT, Hex head (3/4"-0 x 3", Grade 8) Load Cell Mounting (CE) BOLT, Hex head patch (M6 x.5 x 4.5, Grade 8.8 \ ZP) BOLT, Hex head (/2"-3 x 2.5", Grade 8) AC Page 28 December 07

29 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Course Pitch Size of Bolt Normali Loctite 242 (Nm) Table 2.3 Axles Torque Specifications Type of Bolt Loctite 270 (Nm) Normali Loctite 242 (Nm) Loctite 270 (Nm) Normali Loctite 242 (Nm) Loctite 270 (Nm) M6 x M8 x M0 x M2 x M4 x M6 x M8 x M x M22 x M24 x M27 x M30 x Fine Pitch M8 x M0 x M2 x M2 x M4 x M6 x M8 x M x M22 x M24 x M27 x M30 x Note: Nm = ft-lb Screw-locking, Sealing and Lubricating Materials 6057AA Loctite 242 Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator. Loctite 270 Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80 C approx. December 07 Page 29

30 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.4 Torque Specifications for Fasteners (Imperial) IMPERIAL BOLT TORQUE CHART IMPERIAL BOLT TORQUE CHART Size Torque Type SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8 Size Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed 4-40 (in lb) (5) (4) (8) (6) (2) (9) ft lb /6-2 Nm Nm (in lb) (6) (5) (9) (7) (3) (0) ft lb /6-8 Nm Nm /4- /4-28 5/6-8 5/6-24 (in lb) (0) (8) (6) (2) (23) (7) ft lb /8- Nm Nm (in lb) (2) (9) (8) (3) (25) (9) ft lb /8-8 Nm Nm (in lb) (9) (4) (30) (22) (4) (3) ft lb /4-0 Nm Nm (in lb) () (5) (3) (23) (43) (32) ft lb /4-6 Nm Nm (in lb) (27) (2) (43) (32) (60) (45) ft lb /8-9 Nm Nm (in lb) (3) (23) (49) (36) (68) (5) ft lb /8-4 Nm Nm (in lb) / ft lb (66) (50) 8 (75) 2 9 ft lb Nm Nm (in lb) / ft lb (76) (56) 0 (86) 4 0 ft lb Nm Nm ft lb ft lb Nm Nm ft lb ft lb /8-7 Nm Nm /8-6 3/8-24 7/6-4 7/6- /2-3 /2- ft lb ft lb /8-2 Nm Nm ft lb ft lb /4-7 Nm Nm ft lb ft lb /4 2 Nm Nm ft lb ft lb /8 6 Nm Nm ft lb ft lb /8 2 Nm Nm ft lb ft lb /2 6 Nm Nm Inch Pound Force = in lb Foot Pound Force = ft lb Newton Meter = Nm ft lb /2 2 NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. Nm Page 30 December 07

31 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.5 Torque Specifications for Fasteners (Metric) METRIC BOLT TORQUE CHART Size Torque Units Dry Lubed Dry Lubed M5 x 0.80 M6 x.00 M7 x.00 M8 x.25 M0 x.50 M2 x.75 M4 x 2.00 M6 x 2.00 M8 x 2.50 M x 2.50 M22 x 2.50 M24 x 3.00 M27 x 3.00 M30 x 3.50 M33 x 3.50 M36 x 4.00 (in lb) (in lb) (in lb) (in lb) ft lb ft lb ft lb ft lb ft lb ft lb ft lb ft lb ft lb ft lb ft lb ft lb (54) (92) (56) (225) (4) (69) (6) (69) (78) (33) (222) (333) (59) (99) (67) (242) Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Inch Pound Force = in lb Foot Pound Force = ft lb Newton Meter = Nm NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. December 07 Page 3

32 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.6 Torque Specifications for Hydraulic Couplings & Hoses SAE Size HYDRAULIC COUPLING TORQUE CHART O Ring Port Connectors Steel Ports Non ferrous Ports ft lb Nm ft lb Nm HOSE END TORQUE CHART for JIC Size Steel Brass Dash Frac. ft lb Nm ft lb Nm Min. Max. Min. Max. Min. Max. Min. Max. 4 /4" /8" /2" /8" /4" " /4" / " HOSE END TORQUE CHART for Flat Face O Ring Seal (Steel) Size Torque Specification ft lb Nm Dash Frac. Min. Max. Min. Max. 4 /4" /8" /2" /8" /4" " /4" / " Page 32 December 07

33 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.7 Axles Maintenance Intervals Operation Frequency Lubricants Check Levels Oil Change Differential monthly Planetary reduction every 0 hours Differential every 800 hours * Planetary reduction every 000 hours * SAE85W90 (API GL4 - MIL L-205) With additives for oil-bath brakes Self-locking differential gear every 700 * & Operation Member Conditions Frequency Lubricants Greasing Articulations Normal work Awkward work Unit Operation Frequency Negative Brake Adjustment every 000 hours * Service Brake Adjustment every 500 hours Wheel Nuts Tightening every 0 hours * Initially after 00 working hours & When it starts sounding noisy Check levels Oil change Screw/bolt tighten Lubricant Adjustments and Checks Gear Box Lubricant Intervals monthly weekly monthly once at 50 hours after every 000 hours MOLIKOTE Service Brake Circuit Only for mineral oil use, e.g., ATF Dexron II. Make sure that master cylinder seals are suitable for mineral oil. every 0 hours SAE 90 oil API GL3 Size of Screw M4 M6 M8 M2 M0 x.25 M2 M4 M4 x.5 M6 A8 Torque Wrench Settings (Nm) 8G/8.8 0K/0.9 2K/ AA Note: Nm = ft-lb December 07 Page 33

34 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2.8 Tire Specifications SJ 46AJ (ANSI/CSA) SJ 46AJ & SJ 5AJ (CE & AS) Tire Size 35/55 D 35/55 D Type Air/Foam-Filled Foam Filled Tire Ply Rating 2 2 Wheel Nuts Torque 290 ft-lb (393.2 Nm) 290 ft-lb (393.2 Nm) -ALL Standards IMPORTANT For proper function of each axle differential, all four wheels must have same tire size installed at all times. Failure to comply with this requirement will reduce the life of the differentials and reduce overall mobility of aerial platform. Table 2.9 Maximum Platform Capacities SJ 46AJ (ANSI/CSA) SJ 46AJ & SJ 5AJ (CE & AS) Total Capacity* 500 lb. (227 kg) 35/55 D 2 Persons Foam Filled Maximum Wind 28 mph (2.5 m/s) 2 Maximum Side Force 90 lbg (400N) 290 ft-lb (393.2 Nm) 2-ALL Standards * WARNING DRIVING ON A SLOPE When driving on a slope greater than 30%, the platform capacity is limited to 36 kg (300 lb.). The platform must be between the non-steer wheels and must be on the downside of the hill. When slope increases to above 45%, the forward drive is disabled but reverse drive remains active. Page 34 December 07

35 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.0 Floor Loading Pressure MODEL SJ 46A (ANSI Standard configuration) SJ 46AJ (ANSI Standard configuration) SJ 46AJ (CE & AS Standard configuration) SJ 5AJ (CE & AS Standard configuration) Total Aerial Platform Weight Wheel Total Aerial Platform Load OUP lb. kg lb. kg psi kpa psf kpa 4,960 6,786 7,775 3, ,230 6,908 7,775 3, ,830 7,80 7,775 3, ,630 7,543 8,470 3, LCP ANSI Standard Configuration = 4WD + Oscillating Axle + 35/55 D Air Tires CE & AS Standard Configuration = 4WD + Oscillating Axle + 35/55 D Foam Tires Gross Aerial Platform Weight = Weight + platform capacity 3-ALL Standards LCP Locally Concentrated Pressure is a measure of how hard the aerial platform tire tread presses on the area in direct contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more than the indicated values above. OUP Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface projected directly underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above. Foam tires option will add approximately 600 lb. (272 kg) to total aerial platform weight and 50 lb. (68 kg) to max. wheel load. OUP will increase by 4% and LCP will increase by approx. %. NOTE: The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or architect for that particular structure. Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP): Foot Print Area = Tread Contact Area Base Area = Length x Width LCP = Maximum Wheel Load Foot Print Area OUP = Aerial Platform Weight + Capacity Base Area Width Tread Contact Area Length WARNING Intermixing tires of different types or using tires of types other than those originally supplied with this equipment can adversely affect stability. Therefore, replace tires only with the exact original Skyjack-approved type. Failure to operate with matched approved tires in good condition may result in death or serious injury. December 07 Page 35

36 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Table 2. Hydraulic Specifications DESCRIPTION Displacement - 00 rpm SJ 46AJ SJ 46AJ / 5AJ SJ 46AJ / 5AJ ANSI/CSA CE AS 2.8 CIR rpm 46 CC 46 CC Pump Specifications Drive Pump System Pump Drive Pump Pressure 5000 psi 345 bar 345 bar Charge Pump Displacement 0.85 CIR 3.9 CC 3.9 CC Charge Pump Pressure 33 psi 22 bar 22 bar Displacement - Static 0.67 CIR / rpm CC CC System Pump Pressure 3000 psi 7 bar 7 bar Charge Pump Filter 50 psi 9 μm/35 9 μm/35 Filter Specifications High Pressure Filter 87 psi 0 μm/25 0 μm/25 Return Filter 22 psi 0 μm/40 0 μm/40 Motor Specifications Drive Motor Swing Motor Displacement - Low.55 CIR 2 CC 2 CC Displacement - High 2.32 CIR 38 CC 38 CC Motor Displacement 4 CIR CC CC Maximum Swing Pressure 400 psi 97 bar 97 bar Bore 2 in. 5. cm 5. cm Extension Cylinder Rod Diameter.25 in. 3.2 cm 3.2 cm Stroke 67 in..7 m 2.5 m Maximum Boom Pressure 3000 psi 7 bar 7 bar Bore 4 in. 0.2 cm 0.2 cm Cylinder Specifications Lift Cylinder (Main) Rod Diameter.75 in. 4.5 cm 4.5 cm Stroke in cm 64.6 cm Maximum Lift Pressure 3000 psi 7 bar 7 bar Bore 2.5 in. 6.4 cm 6.4 cm Lift Cylinder (Riser) Rod Diameter.75 in. 4.5 cm 4.5 cm Stroke 36.2 in. 92 cm 92 cm Maximum Lift Pressure 3000 psi 7 bar 7 bar Maximum Lower Pressure 2750 psi 90 bar 90 bar Steer Cylinder Steering Cylinder Stroke N/A N/A N/A Maximum Steering Pressure 3000 psi 7 bar 7 bar For other component specifications, refer to hydraulic schematic. 6-ALL Standards Page 36 December 07

37 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Table 2.2 Specifications and Features Height & Reach MODEL Working Height Platform Elevated Height Drive Height Horizontal Reach Horizontal Reach at Maximum Height Tailswing Up and Over Clearance at Platform Up and Over Clearance at Main Boom Platform Rotation Platform Height - Stowed Platform Height - Overall Railing Height - Platform Height - Stowed Length - Stowed Width Wheelbase Ground Clearance - Chassis Ground Clearance - Rear Axle Axle Oscillation Turning Radius - Inside Turning Radius - Outside Turning Angle Turret Rotation Length - Stowed Travel - Down Travel - Up Lift Lift Capacity to Maximum Gradeability Capacity Platform Dimenional Data Jib Performance & Speeds Platform Size Gradeability - Maximum Drive Speed - Stowed/Low Torque Drive Speed - Stowed/High Torque Drive Speed - Elevated Turret Rotation Platform Rotation Main Boom Elevation - Up Main Boom Elevation - Down Riser Boom Elevation - Up SJ 46AJ ANSI/CSA SJ 46AJ CE & AS SJ 5AJ CE & AS 52' 3-/4" (5.93 m) 6.0 m 7.55 m 46' 3-/4" (4.0 m) 4.0 m 5.55 m Driveable at all heights Driveable at all heights Driveable at all heights 24' 8-3/4" (7.54 m) 7.54 m 9.03 m 8' " (2.47 m) 2.47 m 2.86 m ' 8-3/4" (7.53 m) 7.53 m 7.53 m 24' 5-/4" (7.45 m) 7.45 m 7.45 m 30 x 60" (0.76 x.52 m) 30 x 72" (0.76 x.83 m) 0.76 m x.52 m 0.76 m x.83 m 0.76 m x.52 m 0.76 m x.83 m " (0.25 m) 0.25 m 0.25 m 52' /2" (.33 m).33 m.33 m 43' /2" (.0 m).0 m.0 m 6' 9" ( 2.06 m) 2.06 m 2.06 m ' 0" (6.35 m) 6.35 m 7.0 m 7' 6" (2.29 m) 2.29 m 2.29 m 6' 8" (2.03 m) 2.03 m 2.03 m 5-/4" (0.39 m) 0.39 m 0.39 m 0-3/4" (0.27 m) 0.27 m 0.27 m ' -/4" (.50 m).50 m.50 m 4' 3" (4.34 m) 4.34 m 4.34 m continuous 360 continuous 360 continuous 55-3/4" (.42 m).42 m.42 m lbs (227 kg) 500 lbs (227 kg) 227 kg 45% 45% 45% 4.8 mph (7.7 km/h) 7.7 km/h 7.7 km/h.8 mph (2.9 km/h) 2.9 km/h 2.9 km/h 0.5 mph (0.8 km/h) 0.8 km/h 0.8 km/h seconds 90-0 seconds 90-0 seconds 5-25 seconds 5-25 seconds 5-25 seconds seconds seconds seconds (CE) seconds (AS) seconds (CE) seconds (AS) seconds (CE) seconds (AS) seconds (CE) seconds (AS) seconds seconds seconds Riser Boom Elevation - Down seconds seconds seconds Fly Boom Extend 8-4 seconds 8-4 seconds 2-8 seconds Fly Boom Retract 6-2 seconds 6-2 seconds seconds Jib Elevation - Up seconds seconds seconds Jib Elevation - Down 8-28 seconds 8-28 seconds 8-28 seconds Main Boom + Riser Boom Elevation - Down N/A >39 seconds >39 seconds Size 2 x 6.5" (0.3 x 0.42 m) 0.3 m x 0.42 m 0.3 m x 0.42 m Wheel Assembly Weight - Air 5 lbs. (52 kg) N/A N/A Wheel Assembly Weight - Foam 35 lbs (43 kg) 43 kg 43 kg System Voltage 2 VDC 2 VDC 2 VDC Electrical Type Lead / Acid Lead / Acid Lead / Acid Weight with Air Tires - No Options 3,300 lbs. (6050 kg) N/A N/A Weight with Foam Tires - No Options 4,0 lbs. (6400 kg) 6500 kg (CE) 6400 kg (AS) 7300 kg Wheel Load 6900 lbs (330 kg) Air 7308 lbs. (335 kg) Foam 335 kg 3640 kg Locally Concentrated Pressure - LCP 5 psi (793 kpa) Air 24 psi (856 kpa) Foam 856 kpa 940 kpa Overall Uniform Pressure - OUP 0 psf (9.6 kpa) Air 46 psf (0. kpa) Foam 0. kpa.0 kpa NOTE: All dimensional values are nominal and do not account for tire deflection. 43AA Tire Weight & Pressure December 07 Page 37

38 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Engine - Deutz D2.9L Engine - Deutz D Engine - GM Engine - Kubota Hydraulic Oil Gear Oil Table 2.2 Specifications and Features (Continued) SJ46AJ & SJ5AJ Deutz D2.9L 900 Low / 700 / 2600 High 29.8 kw / 40 Hp Diesel 7 gal (63 L) Standard Lube Oil 0 F to 5 F (- 8 C to 45 C) SAE 5W-40 API CF/CG/CH-4 Cold Lube Oil - F to 90 F (- 29 C to 32 C) SAE 0W-30 API CF/CG/CH-4 Arctic Lube Oil - 40 F to 5 F (- 40 C to 45 C) SAE 0W-40 API CF/CG/CH-4 See Engine Manual 2.38 gal (9 L) Standard & Arctic Coolant - 40 F to 5 F (- 40 C to 45 C) Delo 50/50 Extended Life Coolant Coolant Capacity 3.0 gal (.4 L) Engine Type RPM Settings Gross Intermittent HP 00 rpm (intermittent) Fuel Type Fuel Tank Capacity Deutz DL03i 300 Low / 650 / 00 High 35.8 kw / 48 Hp 28.9 kw / 38.8 Hp Diesel 7 gal (63 L) Standard Lube Oil 0 F to 5 F (- 8 C to 45 C) SAE 5W-40 API CF/CG/CH-4 Cold Lube Oil - F to 90 F (- 29 C to 32 C) SAE 0W-30 API CF/CG/CH-4 Arctic Lube Oil - 40 F to 5 F (- 40 C to 45 C) SAE 0W-40 API CF/CG/CH-4 Approved Alternates Lube Oil Sump Capacity Engine Type RPM Settings Gross Intermittent HP Fuel Type - Dual Fuel Tank Capacity MODEL Engine Type RPM Settings 00 rpm (intermittent) Fuel Type Fuel Tank Capacity Approved Alternates Lube Oil Sump Capacity Engine Type RPM Settings Gross Intermittent HP 00 rpm (intermittent) Fuel Type - Dual Fuel Tank Capacity See Engine Manual.45 gal (5.5 L) 3.0L GM Dual Fuel 900 Low / 650 / 00 High 52.2 kw / 70 Hp 40.8 kw / 54.8 Hp Gasoline/Propane 7 gal (63 L) Standard Lube Oil Approved Alternates Lube Oil Capacity - 40 F to 5 F (- 40 C to 45 C) SAE 5W-30 API SL See Engine Manual.9 gal (4.5 L) Standard Coolant - F to 5 F (- 29 C to 45 C) Delo 50/50 Extended Life Coolant Arctic Coolant Option Coolant Capacity - 40 F to 5 F (- 40 C to 45 C) Recochem 60/40 Extended Life Coolant 3.0 gal (.4 L) Kubota 2.5L Dual Fuel WG Low / 700 / 2675 High 45.5 kw / 6 Hp Gasoline/Propane 45 gal (70.3 L) Standard Lube Oil - 40 F to 5 F (- 40 C to 45 C) SAE 5W-30 API SL Approved Alternates Lube Oil Capacity See Engine Manual 2.5 gal (9 L) Standard Coolant - F to 5 F (- 29 C to +45 C) Recochem 50/50 Extended Life Coolant Arctic Coolant Coolant Capacity - 40 F to 5 F (- 40 C to 45 C) Recochem 60/40 Extended Life Coolant 3.7 gal (2 L) Oil Cooler Option 00 F to 5 F (+38 C to 45 C) Oil cooler option recommended Standard Oil -5 F to 00 F (-26 C to 38 C) Shell Tellus T46 Petro-Canada Hydrex MV46 Arctic Oil Hydraulic Tank Capacity - 40 F to 00 F (- 40 C to 38 C) Esso/Mobil Univis HVI 26 Petro-Canada Hydrex Extreme 24 gal (9 L) Standard Gear Oil - F to 5 F (- 29 C to 45 C) LS 80W-90 GL5 Arctic Gear Oil - 40 F to 5 F (- 40 C to 45 C) Duratran XL Synthetic Oil Gear Oil Capacity 0 gal (38 L) 5AE Page 38 December 07

39 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Diagram 2. Dimension and Reach Diagram - SJ 46AJ Feet (Meters) 55 (6.76) 50 (5.24) 45 (3.72) 40 (2.9) 35 (0.67) 30 (9.4) 25 (7.62) (6.0) 5 (4.57) 0 (3.05) 5 (.52) 0-5 (-.52) -0 (-3.05) -0-5 (-3.05) (-.52) (.52) (3.05) (4.57) (6.0) (7.62) (9.4) Figure 2-3. Reach Diagram - 46AJ -5 (-2.70 cm) 30 (76 cm) (2.24 m) 72 (83 cm) 8-6 (2.58 m) 25-2 (7.68 m) 3.5 (9 cm) (4.6 cm) 46-5 (4.5 m) 2-4 (6.5 m) 25 (7.63 m) 24-6 (7.48 m) 6-0 (2.07 m) (34 cm) 44 ( cm) (2.03 m) 6 (40.6 cm) 4 (36 cm).5 (29.2 cm) Figure 2-4. Dimension - 46AJ December 07 Page 39

40 Service and Maintenance Section 2 - Maintenance Tables and Diagrams Diagram 2.2 Dimension and Reach Diagram - SJ 5AJ Feet (Meters) 60 (8.28) 55 (6.76) 50 (5.24) 45 (3.72) 40 (2.9) 35 (0.67) 30 (9.4) 25 (7.62) (6.0) 5 (4.57) 0 (3.05) 5 (.52) 0-5 (-.52) -0 (-3.05) (-3.05) (-.52) (.52) (3.05) (4.57) (6.0) (7.62) (9.4) (0.67) Figure 2-5. Reach Diagram - 5AJ 0 (0 cm) (76 cm) (2.24 m) 72 (83 cm) 9-9 (2.96 m) 30 - (9.6 m) 3.5 (9 cm) (4.6 cm) 5 - (5.58 m) 23-9 (7.25 m) 25 (7.63 m) 24-6 (7.48 m) 53 (34 cm) 44 ( cm) 6-0 (2.07 m) 70 6 (40.6 cm) 6-8 (2.03 m) 4 (36 cm) 6.5 (29.2 cm) Figure 2-6. Dimension - 5AJ Page 40 December 07

41 Section 2 - Maintenance Tables and Diagrams Service and Maintenance Diagram 2.3 Axle Oscillation Diagram WARNING Do not raise the platform in work mode if it is not on a firm level surface. Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max. Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max. Axle oscillation locked (work mode) - drive speed 0.8 km/h (0.5 mph) max. Figure 2-7. Axle Oscillation December 07 Page 4

42 Notes Page 42 December 07

43 Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table of Contents Charts 3. Hydraulic Symbol Chart Electrical Symbol Chart Wire Number and Color Code...47 Parts Lists 3.4 Hydraulic Component Parts List Electrical Component Parts List Brake Manifold and Port Identifications...54 Diagrams and Schematics 3.7 Rotary Manifold and Port Identifications Drive and System Pump and Port Identifications Drive and System Pump and Port Identifications (with Welder Option) Drive Motors and Port Identifications Jib Valves and Port Identifications Pressure Reducing Valve Port Identifications Main Manifold and Port Identifications Generator Control Valve and Manifold Identification Main Electrical Harness and Fuel Level Switch Harness ECU Engine Wiring Diagram (Deutz D Diesel Engine) Glow Plug Harnesses (Deutz D2.9L Diesel Engine) Glow Plug Harnesses (Deutz D Diesel Engine) Engine Interface Harness (GM Dual Fuel Engine) Platform Harnesses Platform Control Cable Harnesses Limit Switch Connections at Base Control Console Load Sensing Cable Connection (CE & AS) All Motion Alarm Connections (CE & AS) Flashing Amber Light Option SGE Wiring Diagram Oil Cooler and 3.5 kw Generator Base Control Console Wiring Generator (3.5 kw) Platform Control Box Wiring Oil Cooler and 2 kw Generator Base Control Console Wiring Generator (2 kw) Platform Control Box Wiring kW Generator Connection Assembly Telematics Wiring Diagram Load Circuit Wiring Hydraulic Schematic Diagram (serial number and above) Hydraulic Schematic Diagram (serial number and below) Platform Control Console Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine) Platform Control Console Diagram (46AJ ANSI/CSA - Deutz Diesel Engine) Platform Control Console Diagram (46AJ & 5AJ CE - Deutz Diesel Engine) Platform Control Console Diagram (46AJ & 5AJ AS - Deutz Diesel Engine) Base Control Console Diagram (46AJ ANSI/CSA - GM Engine) December 07 Page 43

44 Table of Contents 3.4 Base Control Console Diagram (46AJ ANSI/CSA - Kubota WG2503 Engine) Base Control Console Diagram (46AJ ANSI/CSA - Deutz D Diesel Engine) Base Control Console Diagram (46AJ ANSI/CSA - Deutz D Diesel Engine with Positive Air Shut-Off Base Control Console Diagram (46AJ & 5AJ CE - Deutz D Diesel Engine) Base Control Console Diagram (46AJ & 5AJ AS - Deutz D Diesel Engine) Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine) Electrical Schematic Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine) Electrical Schematic Diagram (46AJ ANSI/CSA - Kubota WG2503 Dual Fuel Engine) Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D Diesel Engine) Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine) Electrical Schematic Diagram (46AJ & 5AJ CE - Deutz D Diesel Engine) Electrical Schematic Diagram (46AJ & 5AJ AS - Deutz D Diesel Engine) Interface & Engine Electrical Schematic - GM Dual Fuel Engine Interface & Engine Electrical Schematic - Kubota WG2503 Dual Fuel Engine Interface & Engine Electrical Schematic - Deutz D2.9L Engine Engine Harness - Deutz D2.9L...06 Page 44 December 07

45 Section 3 - System Component Identification and Schematics Service and Maintenance 3. Hydraulic Symbol Chart LINE CROSSING VARIABLE DISPLACEMENT PUMP SHUTTLE VALVE VELOCITY FUSE LINE JOINED HAND PUMP ACCUMULATOR, GAS CHARGED SINGLE ACTING CYLINDER HYDRAULIC TANK RELIEF VALVE CUSHION CYLINDER DOUBLE ACTING CYLINDER HYDRAULIC FILTER WITH BYPASS PRESSURE REDUCING VALVE PRESSURE SWITCH DOUBLE ACTING DOUBLE RODDED CYLINDER ELECTRIC MOTOR FIXED ORIFICE MOTION CONTROL VALVE SPRING APPLIED HYDRAULIC RELEASED BRAKE ENGINE ADJUSTABLE FLOW CONTROL FLOW DIVIDER COMBINER BRAKE CYLINDER FIXED DISPLACEMENT PUMP CHECK VALVE COUNTER BALANCE VALVE ROTARY ACTUATOR VARIABLE THREE POSITION DISPLACEMENT FOUR WAY HYDRAULIC PROPORTIONAL MOTOR OIL COOLER VALVE COIL BI DIRECTIONAL HYDRAULIC MOTOR SERIES PARALLEL HYDRAULIC MOTOR TWO POSITION TWO WAY NORMALLY CLOSED VALVE TWO POSITION THREE WAY VALVE THREE POSITION FOUR WAY CLOSED CENTER OPEN PORT TWO POSITION TWO WAY NORMALLY OPEN VALVE TWO POSITION THREE WAY VALVE THREE POSITION FOUR WAY CLOSED CENTER CLOSED PORT THREE POSITION FOUR WAY PROPORTIONAL PRESSURE TRANSDUCER MAIN LINES Solid PILOT LINES Dashed SERVO December 07 Page 45

46 Service and Maintenance Section 3 - System Component Identification and Schematics 3.2 Electrical Symbol Chart CIRCUITS CROSSING NO CONNECTION HOURMETER KEY SWITCH LIMIT SWITCH CIRCUITS CONNECTED LIGHT FOOT SWITCH LIMIT SWITCH CLOSED BATTERY HYDRAULIC VALVE COIL TOGGLE SWITCH LIMIT SWITCH GROUND PROPORTIONAL HYDRAULIC VALVE COIL PUSH BUTTON LIMIT SWITCH FUSE ELECTRIC MOTOR ROTARY SWITCH SILICON CONTROLLED RECTIFIER CIRCUIT BREAKER HORN LIMIT SWITCH PROXIMITY SWITCH VOLT METER EMERGENCY STOP BUTTON CAM OPERATED LIMIT SWITCH PNP TRANSISTOR CAPACITOR RESISTOR TILT SWITCH NPN TRANSISTOR POTENTIOMETER LEVEL SENSOR SINGLE POLE SINGLE THROWN RELAY VACUUM SWITCH SINGLE POLE DOUBLE THROW RELAY DOUBLE POLE SINGLE THROW RELAY DOUBLE POLE DOUBLE THROW RELAY TEMPERATURE SWITCH TRIPLE POLE DOUBLE THROW RELAY DIODE RHEOSTAT Page 46 December 07

47 Section 3 - System Component Identification and Schematics Service and Maintenance 3.3 Wire Number and Color Code WIRE NO. WIRE COLOR WIRE NO. WIRE COLOR WIRE NO. WIRE COLOR WIRE NO. WIRE COLOR WIRE NO. WIRE COLOR 00 WHT ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD 000 WHT 2 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD B BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY 0 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY WHT 25 BRN/BLK 48 YEL/GREY 7 RED/ORG 97 ORG/GREY 03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD 05 PUR 28 GRN 5 BLK/GRN 74 GRN/ GREY 99 BLK/GREY GREY/ORG 52 GRN/BLU 75 GREY/PUR 03 BLK/PUR 07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU GRN/ORG 08 PUR/WHT 3 RED/WHT 54 PUR/RED 77 BRN/GREY 05 GRN/BRN YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 06 GRN/PINK 0 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 07 BLK/BLU GREY/ WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 08 YEL/BRN 2 RED/YEL/ BLK 35 ORG/WHT 58 WHT/PUR 8 GREY/BLK GRN/YEL 3 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 0A BLU 4 BLK 37 WHT/RED/ BLK 5 BLU 38 ORG/RED 6 GREY/BRN WHT/BLU 83 BLU/GREY 0B BRN WHT/BLK/ PUR GREY/GRN 6 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 2 BLU/ORG 7 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 3 BLU/BRN 8 GRN/BLU 4 BLU/PUR 64 WHT/BRN 88 BLK/ORG 4 YEL/RED 9 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 5 WHT/PUR 22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 9 RED SHLD 8 PUR/PINK This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red. December 07 Page 47

48 Service and Maintenance Section 3 - System Component Identification and Schematics 3.4 Hydraulic Component Parts List Index No. Skyjack Part No. Qty. Description 2H-2A VALVE (Dump) 2H-34A VALVE, Control (Jib) 2H-36A VALVE, Control (Platform Rotate) 3H VALVE, Control (Load Circuit) 3H VALVE, Control (Brake Release) 3H VALVE, Control (Boom Retract) 3H VALVE, Control (Boom Extend) 3H VALVE, Control (2 Speed Motor) 3H VALVE, Control (Axle Lockout) 3H VALVE, Generator Bypass (3.5kW Generator) 3H-85- N/A VALVE, Generator (2kW Generator Option) 3H-85-2 N/A VALVE, Generator (2kW Generator Option) 3H VALVE, Control (Differential Lock) 4H-3 66 VALVE, Control (Main Boom Lift Down) 4H-4 66 VALVE, Control (Main Boom Lift Up) 4H-5 N/A VALVE, Control (Drive Pump Control) 4H-6 N/A VALVE, Control (Drive Pump Control) 4H-23A 5886 VALVE, Control (Steering Left) 4H-24A 5886 VALVE, Control (Steering Right) 4H VALVE, Control (Riser Down) 4H-3 66 VALVE, Control (Riser Up) 4H VALVE, Control (Turret Rotate Left) 4H VALVE, Control (Turret Rotate Right) 4H VALVE, Control (Jib Down) 4H VALVE, Control (Jib Up) 4H VALVE, Control (Platform Rotate Left) 4H VALVE, Control (Platform Rotate Right) C 4874 CYLINDER (Jib) C CYLINDER (Fly Boom) (46AJ) C3 487 CYLINDER (Main Boom Lift) C CYLINDER (Platform Level, Master) C CYLINDER (Platform Level, Slave) C CYLINDER (Riser Lift) C CYLINDER (Riser Lift) C8 N/A CYLINDER (Steer) C9 65 RAM (Axle Lockout) C0 65 RAM (Axle Lockout) C 4873 CYLINDER (Fly Boom) (5AJ) C2 N/A CYLINDER (Brake) C3 N/A CYLINDER (Differential Lock) CB 608 VALVE, Counterbalance (Axle Lockout) CB2 608 VALVE, Counterbalance (Axle Lockout) CB VALVE, Counterbalance (Swing Drive) CB VALVE, Counterbalance (Swing Drive) CB VALVE, Counterbalance (Riser Down) CB VALVE, Counterbalance (Riser Down) CB VALVE, Counterbalance (Platform Level, Slave) CB VALVE, Counterbalance (Platform Level, Slave) Parts list continued on following page. Page 48 December 07

49 Section 3 - System Component Identification and Schematics Service and Maintenance 3.4 Hydraulic Component Parts List (continued) Index No. Skyjack Part No. Qty. Description Parts list continued from previous page. CB VALVE, Counterbalance (Boom Lift) CB VALVE, Counterbalance (Fly Boom Extend) CB 4453 VALVE, Counterbalance (Fly Boom Retract) CB VALVE, Counterbalance (Jib) CB VALVE, Counterbalance (Jib) CB VALVE, Counterbalance (Rotary Actuator) CB VALVE, Counterbalance (Rotary Actuator) CV N/A VALVE, Check (EPU) CV VALVE, Check (Loop Flush) CV VALVE, Check (Main Control) CV VALVE, Check (Double, Piloted, Platform Level) CV VALVE, Check (Riser) CV VALVE, Check (Riser) CV VALVE, Check (LS) CV VALVE, Check (LS) CV VALVE, Check (LS) CV VALVE, Check (LS) CV VALVE, Check (LS) CV VALVE, Check (LS) CV3 N/A VALVE, Check (Generator 3.5kW) CV4 N/A VALVE, Check (Generator 2kW) CV5 N/A VALVE, Check (Generator 2kW) CV VALVE, Check (2 SPD) DSV VALVE, System Load Sense (Differential Sensing Valves) DSV VALVE, Differential Sensing (Boom Rotate) DSV VALVE, Differential Sensing (Riser) DSV VALVE, Differential Sensing (Main Lift) DSV VALVE, Differential Sensing (Jib/Platform Rotate) EPU 623 PUMP (Emergency Power Unit) F 6932 FILTER (High Pressure) F FILTER (Return) M 6964 MOTOR (Drive) M2 N/A MOTOR (Swing) M3 N/A MOTOR, Generator (3.5kW Generator Option) M4 N/A MOTOR, Generator (2kW Generator Option) MB MANIFOLD (Main Control) MB MANIFOLD (Brake) MB MANIFOLD (Jib) MB MANIFOLD (Generator 3.5kW) MB5 684 MANIFOLD (Generator 2kW) MB MANIFOLD (Pressure Reducing) MB MANIFOLD (Load Circuit) OC COOLER, Oil (Oil Cooler Option) OR ORIFICE, Main Control (Platform Rotate) OR ORIFICE, Main Control (Jib) OR ORIFICE, Main Control (Boom Extend) Parts list continued on following page. December 07 Page 49

50 Service and Maintenance Section 3 - System Component Identification and Schematics 3.4 Hydraulic Component Parts List (continued) Index No. Skyjack Part No. Qty. Description Parts list continued from previous page. OR ORIFICE, Main Control (Platform Level) OR ORIFICE, Brake Manifold (Loop Flush) OR ORIFICE, Riser Down (0.067 ) OR VALVE, Needle (Load Circuit) P 6686 PUMP (Drive) PA 6686 PUMP (Charge) P PUMP (System) P PUMP (System With Generator) PFC CONTROL, Priority Flow (Steer) PFC CONTROL, Priority Flow (Generator 3.5kW) PFC3 N/A CONTROL, Priority Flow (Generator 2kW) PR 6605 VALVE, Pressure Reducing PR VALVE, Pressure Reducing QD 224 DISCONNECT, Quick RA 4470 ROTARY ACTUATOR RA2 679 ROTARY ACTUATOR RV N/A VALVE, Relief (Drive Pump) RV2 N/A VALVE, Relief (Drive Pump) RV3 N/A VALVE, Relief (Charge Pump) RV4 666 VALVE, Relief (Brake Release) RV5 N/A VALVE, Relief (EPU) RV6 663 VALVE, Relief (Main Control) RV VALVE, Relief (Boom Rotate) RV8 664 VALVE, Relief (Riser Down) RV9 598 VALVE, Relief (Platform Level) RV VALVE, Relief (3.5 kw Generator Option) RV N/A VALVE, Relief (2 kw Generator Option) RV2 694 VALVE, Relief (3.5 kw Generator Option) RV VALVE, Relief (Load Circuit) SV 444 SHUTTLE VALVE, Brake Manifold (LS) SV SHUTTLE VALVE, Brake Manifold (M / M2) SV3 N/A SHUTTLE VALVE, Swing Drive SV SHUTTLE VALVE, Main Manifold (Swing) SV SHUTTLE VALVE, Main Manifold (Riser) SV SHUTTLE VALVE, Main Manifold (Boom Lift) SV SHUTTLE VALVE, Main Manifold (Platform Level) SV SHUTTLE VALVE, Main Manifold (Platform Level) V 4436 VALVE, Control (Brake Release Override) V VALVE, Control (Loop Flush) V HAND PUMP (Brake Release) V4 N/A VALVE, Control (Bypass Towing) Page 50 December 07

51 Section 3 - System Component Identification and Schematics Service and Maintenance 3.5 Electrical Component Parts List SUPPLY (B+) (Common) CONTROL (B+) GROUND (B-) NORMALLY CLOSED CONTACT NORMALLY OPEN CONTACT Index No. Skyjack Part No. Qty. Description 0ACR 273 RELAY, 2 Volt 40 Amp (Base control console - E-pump) 07CR 273 RELAY, 2 Volt 40 Amp (Base control console - E-pump/Enable) 08CR 273 RELAY, 2 Volt 40 Amp (Platform control console - Footswitch/Starter interlock) CR 273 RELAY, 2 Volt 40 Amp (Engine power on) 2CR 273 RELAY, 2 Volt 40 Amp (Base control console - Dump valve) 27CR 273 RELAY, 2 Volt 40 Amp (Platform control console - Tilt alarm) 45CR 273 RELAY, 2 Volt 40 Amp (Base control console - 2-SPD motor) 45CR2 273 RELAY, 2 Volt 40 Amp (Base control console - 2-SPD motor controller) 49CR 273 RELAY, 2 Volt 40 Amp (Base control console - Horn) 57ACR 273 RELAY, 2 Volt 40 Amp (Base control console - Engine Start) 59CR 273 RELAY, 2 Volt 40 Amp (Base control console - Overload sensor) (CE & AS) 60CR 273 RELAY, 2 Volt 40 Amp (Base control console - System power) 78CR 273 RELAY, 2 Volt 40 Amp (Base control console - High idle) 79CR 273 RELAY, 2 Volt 40 Amp (Base control console - Low idle) 82CR 273 RELAY, 2 Volt 40 Amp (Platform control console - Load sensing alarm) 65CR 273 RELAY, 2 Volt 40 Amp (Platform control console - Differential lock) 2H-2A 5989 COIL, 2 Volt (Dump valve) 2H-34A 5982 COIL, 2 Volt (Jib enble valve) 2H-36A 5982 COIL, 2 Volt (Platform rotate enble valve) 3H COIL, 2 Volt (Brake valve) 3H COIL, 2 Volt (Motor 2-speed valve) 3H COIL, 2 Volt (Axle lock valve) Parts list continued on following page. December 07 Page 5

52 Service and Maintenance Section 3 - System Component Identification and Schematics 3.5 Electrical Component Parts List (continued) Index No. Skyjack Part No. Qty. Description Parts list continued from previous page. 3H COIL, 2 Volt (Differential lock valve) 4H COIL, 2 Volt (Boom down valve) 4H COIL, 2 Volt (Boom up valve) 4H-23A 5989 COIL, 2 Volt (Right steer valve) 4H-24A 5989 COIL, 2 Volt (Left steer valve) 4H COIL, 2 Volt (Riser down valve) 4H COIL, 2 Volt (Riser up valve) 4H COIL, 2 Volt (Left turret rotate valve) 4H COIL, 2 Volt (Right turret rotate valve) 4H COIL, 2 Volt (Jib down valve) 4H COIL, 2 Volt (Jib up valve) 4H COIL, 2 Volt (Platform left rotate valve) 4H COIL, 2 Volt (Platform right rotate valve) 4H COIL, 2 Volt (Boom retract valve) 4H COIL, 2 Volt (Boom extend valve) 4H COIL, 2 Volt (Platform level down valve) 4H COIL, 2 Volt (Platform level up valve) A JOYSTICK (Fly boom/turret) A JOYSTICK (Drive/Steer) A JOYSTICK (Riser boom) AT ANGLE TRANSDUCER B BATTERY, 2V (Wet) BP BEEPER, 4-28 VDC Slow pulsing (Platform control console) BP BEEPER, VDC (Base control console) (ANSI/CSA & AS) BP ALARM, Overload (CE & AS) CB 7325 CIRCUIT BREAKER (5 Amp) CB CIRCUIT BREAKER (5 Amp) CB CIRCUIT BREAKER (5 Amp) CB CIRCUIT BREAKER ( Amp) CB CIRCUIT BREAKER ( Amp) CI INDICATOR, Charge DXX 92 AR DIODE FU FUSE, 50 Amp FS SWITCH, Low fuel H HORN, 2 Volt LS 207 SWITCH, Limit (Direction sensing) LS2 356 SWITCH, Limit (Riser down) LS SWITCH, Limit (Boom down) LS SWITCH, Limit (Fly in) M PUMP, Emergency PL 4897 LIGHT, Pilot (Engine fault) PL LIGHT, Pilot (Glow plug) PL LED BLOCK, Red (2 volts) (Base control console) Parts list continued on following page. Page 52 December 07

53 Section 3 - System Component Identification and Schematics Service and Maintenance AD 3.5 Electrical Component Parts List (continued) Index No. Skyjack Part No. Qty. Description Parts list continued from previous page. PL LED BLOCK, Red (2 volts) (Platform control console) PL MODULE, Upper indicating PL LIGHT, Pilot (Platform control console) QD 224 QUICK DISCONNECT (CE & AS) R 99 RESISTOR, 5 ohm 25 W R RESISTOR, 250 ohm W R3 63 RESISTOR, ohm /2 W R RESISTOR, 2.2k ohm /2 W R RESISTOR, 5 ohm 2 W (Deutz D and Kubota) RESISTOR, 2.k ohm /2 W (Deutz D2.9L) R RESISTOR, 3.9k ohm /2 W R RESISTOR, 680 ohm W (Deutz D2.9L) 5643 RESISTOR, 250 ohm W (Deutz D and Kubota) S 9725 SWITCH, Main power disconnect S KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA, AS Deutz D) KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA Deutz D2.9L) KEYSWITCH, Base/Off/Platform (Base control) (CE) S N.C. CONTACT, Emergency stop (Base control console) S N.C. CONTACT, Emergency stop (Platform control console) S SWITCH, Ignition/emergency pump toggle (Base control console) S SWITCH, Ignition/emergency toggle (Platform control console) S8 853 SWITCH, Diagnose toggle (Base control console) (Deutz engine) S SWITCH, Ignition (Platform control console) S SWITCH, Throttle toggle (Platform control console) S 3872 ASSEMBLY, Footswitch S SWITCH, Boom up/down toggle (Base control console) S3 853 SWITCH, Turret rotate toggle (Base control console) S4 853 SWITCH, Telescope in/out toggle (Base control console) S5 853 SWITCH, Platform leveling toggle (Base control console) S6 853 SWITCH, Platform rotate toggle (Base control console) S7 853 SWITCH, Jib up/down toggle (Base control console) S SWITCH, Telescope in/out toggle (Platform control console) S SWITCH, Platform leveling toggle (Platform control console) (ANSI/CSA) S SWITCH, Platform rotate toggle (Platform control console) S SWITCH, Jib up/down toggle (Platform control console) S N.O. CONTACT, Horn (Platform control console) S SWITCH, Riser boom up/down toggle (Base control console) S SWITCH, Fuel select (Platform control console) (GM engine) S SWITCH, Differential (Platform control console) S SWITCH, Drive torque toggle (Platform control console) TT HOUR METER X PORT, Diagnose (Deutz engine) X CONNECTOR, Engine (Deutz engine) December 07 Page 53

54 Service and Maintenance Section 3 - System Component Identification and Schematics 3.6 Brake Manifold and Port Identifications AL To Rotary Manifold 3H-65 Axle Lock Valve 3H-45 2 Speed Valve 3H-26 Brake Valve 3H-65 Differential Lock Valve V Brake Release Override Valve BRG To Rotary Manifold D To Rotary Manifold T To Hydraulic Tank PR Pressure Reducing Valve RV4 Relief Valve SV2 Shuttle Valve SV Shuttle Valve V2 Loop Flush Valve M To Drive Pump 2-SPD To Rotary Manifold LS To Main Manifold TO To Hydraulic Tank M2 To Drive Pump V3 Hand Pump Release Page 54 December 07

55 Section 3 - System Component Identification and Schematics Service and Maintenance 3.7 Rotary Manifold and Port Identifications Port 7 To Drive Pump Port 8 To Drive Pump Port 9 To Hydraulic Tank Port To Main Manifold Port 5 To Main Manifold Port 3 To Axlelock Cylinder Port 2 To Axlelock Cylinder Port 6 To Drive Motor Port 7 To Drive Motor Port 9 To Drive Motor Port 0 To Drive Motor Port 2 To Brake Manifold Port 6 To Brake Manifold Port 4 To Rear Brake Cylinder Port 4 To Brake Manifold Port 0 To Brake Manifold Port 3 To Drive Pump Port To Steer Cylinder Port 5 To Steer Cylinder Port 8 To Drive Motor M4938AA_S3 December 07 Page 55

56 Service and Maintenance Section 3 - System Component Identification and Schematics 3.8 Drive and System Pump and Port Identifications M2 To Brake Manifold D2 To Hydraulic Tank A To Hydraulic Tank C To Rotary Manifold A To Rotary Manifold B To Rotary Manifold B To High Pressure Filter S To Hydraulic Tank M. To Brake Manifold M6760AA Page 56 December 07

57 Section 3 - System Component Identification and Schematics Service and Maintenance 3.9 Drive and System Pump and Port Identifications (with Welder Option) For machines with Welder Option M To Brake Manifold - To Hydraulic Tank (Pump Case Drain) 8 To Rotary Manifold - To Hydraulic Tank (System Suction) P2 To Generator Manifold 3 To Rotary 7 Manifold To Rotary Manifold B To High Pressure Filter - To Hydraulic Tank (Drive Suction) M2 To Brake Manifold M656AB December 07 Page 57

58 Service and Maintenance Section 3 - System Component Identification and Schematics 3.0 Drive Motors and Port Identifications L To Rotary Manifold B To Rotary Manifold X To Rotary Manifold A To Rotary Manifold M46243AA_S3 Page 58 December 07

59 Section 3 - System Component Identification and Schematics Service and Maintenance 3. Jib Valves and Port Identifications 4H-34 Jib Down Valve 4H-35 Jib Up Valve 4H-37 Platform Right Rotate Valve 4H-36 Platform Left Rotate Valve B To Jib Cylinder A To Bulkhead #2 2B To Jib Cylinder 2A To Bulkhead #2 4 To Bulkhead # 4H-37 Platform Right Rotate Valve 3B To Bulkhead # To Bulkhead #2 4H-36 Platform Left Rotate Valve 3 To Bulkhead #2 4 To Bulkhead # 2 To Bulkhead # M38AA_S3 December 07 Page 59

60 Service and Maintenance Section 3 - System Component Identification and Schematics 3.2 Pressure Reducing Valve Port Identifications AD 3 To Hydraulic Tank To Rotary Manifold Port 6 2 To Brake Manifold 2SPD Port M68993AA- Page 60 December 07

61 3.3 Main Manifold and Port Identifications A B C D E F G H TEST 3 TEST TEST 2 TEST 5 V TEST 4 W P2 To Lift Cylinder JBT To Jib Valve JBP To Jib Valve EXT To Boom Extension Cylinder RET To Boom Extension Cylinder PL To Master Cylinder P To Lift Cylinder PL2 To Master Cylinder S2 To Riser Cylinder S To Riser Cylinder SW To Swing Drive Motor SW2 To Swing Drive Motor ST2 To Rotary Manifold ST To Rotary Manifold T3 To Brake Manifold P To Hi Pressure Filter AUX To Emergency Power Unit X Y Z M625AA-SMS3-A SKYJACK, Page 6

62 3.3 Main Manifold and Electrical Identifications (continued) A B C D E F G H 2H-36A Platform Rotate Valve 3H-39 Boom Extend Valve 2H-34A Jib Boom Valve 3H-38 Boom Retract Valve 4H-40 Platform Leveling Valve 4H-4 Platform Leveling Valve 4H-30 Riser Down Valve 4H-32 Turret Rotate Left Valve 4H-33 Turret Rotate Right Valve V W 4H-3 Riser Up Valve X 4H-3 Boom Down Valve 4H-24A Left Steer Valve 4H-4 Boom Up Valve 4H-23A Right Steer Valve Y 2H-2A Dump Valve Z M625AA-SMS3-B SKYJACK, Page 62

63 3.3 Main Manifold and Hydraulic Identifications (continued) A B C D E F G H DSV5 Differential Sensing Valve OR OR3 OR2 CV4 Check Valve OR4 DSV4 Differential Sensing Valve V SV5 Shuttle Valve SV4 Shuttle Valve CV9 Check Valve W RV8 Relief Valve RV6 Relief Valve PFC Priority Flow Control Valve CV8 Check Valve CV7 Check Valve CV0 Check Valve X CV Check Valve SV7 Shuttle Valve SV8 Shuttle Valve CV2 Check Valve Y DSV3 Differential Sensing Valve CV3 Check Valve RV9 Relief Valve SV6 Shuttle Valve OR6 CV5 Shuttle Valve DSV Differential Sensing Valve RV7 Relief Valve DSV2 Differential Sensing Valve CV6 Shuttle Valve Z M625AB-S3 SKYJACK, Page 63

64 3.4 Generator Control Valve and Manifold Identification A B C D E F G H 3500W Generator 2kW Generator (Welder option) V 2H-85 Generator Valve IN To High Pressure Filter MAIN To Main Manifold T To Oil Cooler P To Hydraulic Tank 3H-85 Generator Valve W CV5 Check Valve LS To Shuttle Valve 3H-85 Generator Valve X TM To Generator P2 To Drive/System Pump Y RV Relief Valve OUT To Generator 8 GPM Flow Regulator M To Generator GPM Flow Regulator Z M38405AA_M62947AC SKYJACK, Page 64

65 3.5 Main Electrical Harness and Fuel Level Switch Harness A B C D E F G H FUEL LEVEL SWITCH HARNESS DIFFERENTIAL LOCK VALVE PIN - 65 PINK/BLACK PIN 2 - WHITE (SPLICE #) SOCKET - BLACK SOCKET 2 - WHITE AXLE LOCK VALVE PIN - 65 YELLOW/PINK PIN 2 - WHITE (SPLICE #) V PIN ORANGE PIN BLACK PIN 3-2A - WHITE/RED PIN 4-23A - BLACK/WHITE PIN 5-24A - BLUE/BLACK PIN BLUE/YELLOW PIN RED/GREEN PIN RED/WHITE PIN GREEN/BLACK PIN GREEN/WHITE PIN - 34A - ORANGE/BLACK PIN 2-36A - RED/PURPLE PIN ORANGE/RED PIN BLACK/RED PIN BLUE/RED PIN BLUE/PURPLE PIN 7-45A - YELLOW/ORANGE PIN 8-49A - GREEN/RED PIN YELLOW/PINK PIN YELLOW/BROWN PIN PINK/BLACK PIN WHITE (SPLICE #) PIN WHITE (SPLICE #2) PIN WHITE (SPLICE #3) HORN 49A - GREEN/RED - WHITE (SPLICE #) 49A DUMP VALVE PIN - 2A WHITE/RED PIN 2 - WHITE (SPLICE #2) SPLICE # SPLICE #2 RISER UP PIN - 3 RED/WHITE PIN 2 - WHITE (SPLICE # 2) RISER DOWN PIN - 30 RED/GREEN PIN 2 - WHITE (SPLICE # 2) BOOM UP PIN - 4 BLACK PIN 2 - WHITE (SPLICE # 3) BRAKE VALVE PIN - 26 BLUE/YELLOW PIN 2 - WHITE (SPLICE # ) MOTOR TORQUE PIN - 45A YELLOW/ORANGE PIN 2 - WHITE (SPLICE # ) BOOM DOWN PIN - 3 ORANGE PIN 2 - WHITE (SPLICE # 3) JIB ENABLE PIN - 34A ORANGE/BLACK PIN 2 - WHITE (SPLICE # 3) SPLICE #3 08 EMERGENCY PUMP 08 - YELLOW/BROWN PLATFORM ROTATE ENABLE PIN - 36A RED/PURPLE PIN 2 - WHITE (SPLICE # 3) W X MAIN ELECTRICAL HARNESS Y PIN 24 THIS CORNER STEER RIGHT PIN - 23A BLACK/WHITE PIN 2 - WHITE (SPLICE # 2) STEER LEFT PIN - 24A BLUE/BLACK PIN 2 - WHITE (SPLICE # 2) TURRET ROTATE LEFT PIN - 32 GREEN/BLACK PIN 2 - WHITE (SPLICE # 2) TURRET ROTATE RIGHT PIN - 33 GREEN/WHITE PIN 2 - WHITE (SPLICE # 2) PLATFORM LEVEL UP PIN - 4 BLUE/PURPLE PIN 2 - WHITE (SPLICE # 2) PLATFORM LEVEL DOWN PIN - 40 BLUE/RED PIN 2 - WHITE (SPLICE # 3) TELESCOPE IN PIN - 39 BLACK/RED PIN 2 - WHITE (SPLICE # 3) TELESCOPE OUT PIN - 38 ORANGE/RED PIN 2 - WHITE (SPLICE # 3) Z M4902AA_S3 SKYJACK, Page 65

66 3.6 ECU Engine Wiring Diagram (Deutz D Diesel Engine) A B C D E F G H V 00A 00A - L=25.00" PIN - - WHITE PIN GREEN/PINK PIN WHITE/GREY PIN BROWN/BLUE PIN GREEN/GREY PIN 6 - PLUGGED PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 - PLUGGED PIN GREEN/BROWN PIN - - GREEN/ORANGE PIN 2 - PLUGGED PIN 3 - PLUGGED PIN 4-54A - PURPLE/RED PIN WHITE/BLACK/PURPLE PIN 6 - PLUGGED PIN BLACK/PURPLE PIN BLACK/GREY PIN 9 - PLUGGED PIN - PLUGGED PIN RED/GREY PIN 22 - PLUGGED PIN 23 - JUMPER TO PIN 24 PIN 24 - JUMPER TO PIN 23 PIN 25 - PLUGGED PIN BROWN/GREY PIN 4-57C - BROWN/GREEN [2 GA.] PIN WHITE/ORANGE PIN - 00A - WHITE - L=7.00" - L=3.00" 54A 54A - L=9.00" C C - L=32.00" L=0.00" L=0.00" L=0.00" L=6.00" 90 - L=29.00" 96 - L=6.00" 99 - L=3.00" 03 - L=9.50" - L=6.00" 05 - L=6.00" 06 - L=6.00" W X Y Z M38708AA SKYJACK, Page 66

67 3.7 Glow Plug Harnesses (Deutz D2.9L Diesel Engine) A B C D E F G H CONNECTOR J5 PIN - C PIN 2 - A PIN 3 - AA PIN 4 - PLUGGED V 8 AWG B W B A C RELAY CONNECTION DETAIL TERM 30 - B (8GA) TERM 85 - A (8GA) TERM 86 - (8GA) TERM 87 - C (8GA) X CONNECTOR P SOCKET - C (0GA) SOCKET 2 - C (0GA) Y J5 4 P BK A-8 BK C-8 RD -8 BK A-8 BK TO 86 TO 85 C-0 RD Z (+) B-8 RD 2 C-0 RD C-8 RD B-8 RD TO 87 TO 30 M658AB SKYJACK, Page 67

68 3.8 Glow Plug Harnesses (Deutz D Diesel Engine) A B C D E F G H TO AIR BOX V LEFT CYLINDER CENTER CYLINDER RIGHT CYLINDER RELAY SOCKET DETAIL W SOCKET #87 WHITE - 54A BLACK - 54A BASE CONTROL BOX TERMINAL STRIP X Y 6 AWG 03 TO ENGINE STARTER Z M48653AA SKYJACK, Page 68

69 3.9 Engine Interface Harness (GM Dual Fuel Engine) A B C D E F G H BACK VIEW ENGINE CONNECTOR 2 ENGINE CONNECTOR 2 PIN C - 00A WHITE PIN E - WHITE PIN J - 78 RED/BLUE PIN K - 79 BROWN/PURPLE PINS (A,B,D,F,G,H,L,M,N,P,R&S) - N/U FUEL PUMP (+) 3056 BLACK FUEL PUMP (-) 30 WHITE PIN - WHITE PIN 2 - WHITE/ORANGE PIN 3-54A PURPLE/RED PIN 4-57A BROWN/GREEN PIN 5 - PLUGGED PIN 6-76 BROWN/BLUE PIN 7-77 BROWN/GREY PIN 8-78 RED/BLUE PIN 9-79 BROWN/PURPLE PIN 0-00A WHITE PIN - PLUGGED PIN 2 - PLUGGED BACK VIEW V W BACK VIEW ENGINE CONNECTOR DEUTSCH X ENGINE CONNECTOR PIN A - 54A PURPLE/RED PIN B - 77 BROWN/GREY PIN C - 30 WHITE PIN D BLACK PIN F - 57A BROWN/GREEN PIN G - 76 BROWN/BLUE PIN H - WHITE/ORANGE PINS (E,J,K,L,M,N,P,R&S) - N/U Y Z M4948AB_S3 SKYJACK, Page 69

70 3. Platform Harnesses A B C D E F G H V BLACK (A) A 08A WHITE (08A) WHITE/RED/BLACK (37) RED/PURPLE (36) ORANGE/WHITE (35) ORANGE/BLACK (34) WHITE () WHITE () W JIB / PLATFORM ROTATE VALVE HARNESS X CAVITY WIRE COLOUR DESCRIPTION 34 ORANGE/BLK JIB DOWN 2 WHITE (SPLICE 2) GROUND PLATFORM CONTROL BOX WIRING CAVITY WIRE COLOUR DESCRIPTION 35 ORANGE/WHITE JIB UP 2 WHITE (SPLICE 2) GROUND Y CAVITY WIRE COLOUR DESCRIPTION 36 RED/PURPLE ROTATE CW 2 WHITE (SPLICE ) GROUND FOOT SWITCH CAVITY WIRE COLOUR DESCRIPTION 37 WHITE/RED/BLK ROTATE CCW 2 WHITE (SPLICE ) GROUND Z M67525AA SKYJACK, Page 70

71 3.2 Platform Control Cable Harnesses A B C D E F G H BASE & PLATFORM CONNECTIONS POSITION - PURPLE/ BLACK POSITION 2 - RED POSITION 3 - RED POSITION 4 - BLUE/ WHITE POSITION 5 - RED/ YELLOW/ BLACK POSITION 6 - ORANGE POSITION 7 - BLACK POSITION 8 - ORANGE/ BLUE POSITION 9 - BLACK/ WHITE POSITION 0 - BLUE/ BLACK POSITION - BLUE/ YELLOW POSITION 2 - RED/GREEN POSITION 3 - RED/WHITE POSITION 4 - GREEN/ BLACK POSITION 5 - GREEN/ WHITE POSITION 6 - ORANGE/ BLACK POSITION 7 - ORANGE/ WHITE POSITION 8 - RED/PURPLE POSITION 9 - WHITE/RED/BLACK POSITION - YELLOW/ORANGE POSITION 2 - YELLOW/PINK POSITION 22 - PINK/WHITE POSITION 23 - PINK/PURPLE POSITION 24 - PINK/BLACK MALE CONTROL CABLE A MALE V W X BASE & PLATFORM CONNECTIONS POSITION - WHITE POSITION 2 - WHITE POSITION 3 - WHITE/ ORANGE POSITION 4 - BLUE POSITION 5 - WHITE/ BLACK POSITION 6 - BLUE/ GREEN POSITION 7 - GREEN POSITION 8 - ORANGE/ RED POSITION 9 - BLACK/ RED POSITION 0 - BLUE/ RED POSITION - BLUE/ PURPLE POSITION 2 - GREEN/RED POSITION 3 - YELLOW/PURPLE POSITION 4 - BROWN/ GREEN POSITION 5 - YELLOW/BLUE POSITION 6 - WHITE/BLUE POSITION 7 - GREEN/GREY POSITION 8 - BROWN/BLUE POSITION 9 - RED/BLUE POSITION - BROWN/PURPLE POSITION 2 - GREY/BLUE POSITION 22 - BLACK/YELLOW POSITION 23 - BLUE/WHITE/YELLOW POSITION 24 - BLUE/WHITE/BLACK FEMALE CONTROL CABLE B FEMALE Y Z M49292AA SKYJACK, Page 7

72 3.22 Limit Switch Connections at Base Control Console A B C D E F G H V W 29A 59 BLACK 29 29A 9 29 WHITE BLACK WHITE BLACK WHITE BLACK 7 BLK/WHT X LS4 LS3 LS2 LS FLY BOOM EXTENSION LIMIT SWITCH MAIN BOOM DOWN LIMIT SWITCH RISER DOWN LIMIT SWITCH DIRECTIONAL SENSING LIMIT SWITCH Y Z M53854AD M53855AD M53856AD M9348AB-SM SKYJACK, Page 72

73 3.23 Load Sensing Cable Connection (CE & AS) A B C D E F G H 3 V 2 D P-FEMALE 24P-MALE 'A' PLUG 'B' PLUG W GREEN/YELLOW 5 X Y PLATFORM CONTOL BOX WIRING 4P-MALE 4P-FEMALE 3P-FEMALE 4" PIGTAIL TYP. Z M525AA SKYJACK, Page 73

74 3.24 All Motion Alarm Connections (CE & AS) A B C D E F G H V PASS WIRES THROUGH TOP-MOST STRAIN RELIEF (LOOSEN GLAND FIRST) ALARM W -ORANGE/BLUE -WHITE X -WIRE INSTALLATION- Y Z SKYJACK, Page 74

75 3.25 Flashing Amber Light Option A B C D E F G H V W X BLACK - WHITE- CONTROL COMPARTMENT BASE CONTROL BOX LAYOUT Y TO LAMP CONNECTOR Z SKYJACK, Page 75

76 3.26 SGE Wiring Diagram A B C D E F G H 07A 62A-AJ -TBOOM 07A E-pump DD D Reset E Amber 07C E delatch 4ECR 07B Sensor Bar 07C 07C 07C 07B 07D 62A 62B-AJ A B-TBOOM 7CCR - Kill Drive E 7CCR2 - Kill Dump Beacon Siren 60 60A NEW DIODE D-2 D-2 D- LOW FUEL (IF PRESENT) MIL NEW DIODE D V W 7DCR - Kill Engine 07C PLATFORM CONTROLS MODIFICATION - All Models 07C Delay on Timer D07D 07D BASE CONTROLS MODIFICATION - Models with Deutz D2.9 or TD2.9 Engines X START/E-pump BASE TOGGLE SW. 2A 2A (WAS ) AT ANGLE TRANSDUCER & TILT SWITCH 2A (WAS ) 6 (PINK/WH) TO 24 POLE PLUG "A" POSITION #22 START/E-pump BASE TOGGLE SW. 2A 2A (WAS ) 6 (PINK/WH) TO 24 POLE PLUG "B" POSITION #2 Y 59 59CR 62A BASE CONTROLS MODIFICATION - AJ Models NEW DIODE D62B BASE CONTROLS MODIFICATION - T Models Z M6633AC SKYJACK, Page 76

77 3.27 Oil Cooler and 3.5 kw Generator Base Control Console Wiring A B C D E F G H Base Control Console - Oil Cooler Wiring Base Control Console kw Generator Wiring V INSERT BLACK WIRE 85 INTO PLUG B - POSITION B 86A (EXISTING) -DETAIL A- TOP VIEW RELAY SOCKET A 03 03B 0CR 57ACR 86CR 49CR 79CR INSERT WHITE WIRE INTO TERMINAL BLOCK PLUG B W 86 03B 86A 3 INSERT WIRES 03B, 86 & 86A INTO EXISTING RELAY BLOCK, PER DETAIL A X INSERT WIRE INTO TERMINAL BLOCK TO EMERG. PUMP POWER STUD 03 Y TO TEMPERATURE SWITCH CONNECTOR TO COOLER FAN CONNECTOR 00 INSTALL UNDER COOLER MOUNTING BOLT TO GENERATOR SOLENOID VALVE Z M5248AB_48596AB SKYJACK, Page 77

78 3.28 Generator (3.5 kw) Platform Control Box Wiring A B C D E F G H V 38 A 35 A A 34 A S-ROT S9-LEV S8-TELE S2-JIB S22- GEN Remove 78 W 85 08C A KEYWAY POSITION SEALING WASHER S6-EPUMP S48- TORQ 79 S0- THROT X Y A A A Z REMOVE JUMPER 2 M52583AA SKYJACK, Page 78

79 AD 3.29 Oil Cooler and 2 kw Generator Base Control Console Wiring A B C D E F G H Oil Cooler Wiring 2kW Generator Wiring A V A 03 03B 0CR 86CR 49CR SEE TOP VIEW RELAY SOCKET 57ACR TO TERMINAL BLOCK 87 CONNECT 2B TO PIN 2, CONNECTOR B W 57ACR 86 03B 86A 79CR TO TERMINAL BLOCK A SECTION A-A SEE TOP VIEW RELAY SOCKET TO TERMINAL BLOCK 87 TO TERMINAL BLOCK TO TERMINAL BLOCK 85 X TO EMERG. PUMP POWER STUD 03 TO GENERATOR SOLENOID VALVES TO TERMINAL BLOCK 85 TO TERMINAL BLOCK 86 03B 86A (existing) TOP VIEW RELAY SOCKET TO TEMPERATURE SWITCH CONNECTOR TO COOLER FAN CONNECTOR 00 INSTALL UNDER COOLER MOUNTING BOLT (existing) TOP VIEW RELAY SOCKET TO CIRCUIT BREAKER BOX Y Z M5248AC_M63088AC SKYJACK, Page 79

80 3.30 Generator (2 kw) Platform Control Box Wiring A B C D E F G H A JOYSTICK A3 SPEED CONTROL A2 JOYSTICK V S22 GEN A S PLATFORM ROTATE S9 LEVEL S8 TELE S2 JIB W S9 IGNITION S23 HORN PL2 ABCDEFGH S4 E-STOP S6 E-PUMP S48 TORQUE S0 THROTTLE X 08CR 57A CR 57A 85A A 85 57A 85 57A CBL 'D' Y A CBL 'C' Z M6958AC SKYJACK, Page 80

81 3.3 2kW Generator Connection Assembly A B C D E F G H GENERATOR WIRING DIAGRAM (REF) LOCATED ON PLATFORM V Z G Y X GREEN 8 GA WHITE 8 GA WHITE 8 GA RED 8 GA BLACK 8 GA 8 GA JUMPER W WHITE 8 GA RED 8 GA BLACK 8 GA GREEN 8 GA BLACK 8 GA RED 8 GA X WELDER CABLE 0V CABLE (REF) Y VIEW UNDER GENERATOR COVER WHITE 8 GA GREEN 8 GA WHITE 8 GA RED 8 GA BLACK 8 GA WHITE 8 GA GREEN 8 GA Z M66832AA SKYJACK, Page 8

82 3.32 Telematics Wiring Diagram A B C D E F G H V (TELEMATICS) CR B W B KEY 03B: BLACK N/U: WHITE 03B DETAIL A 8 PIN CONNECTOR X B KEY KEY B USE SEALING PLUG FOR ALL UNUSED CONNECTOR, CAVITIES, FOR THE FOLLOWING PINS # 5,6,7, B B KEY 03B TO MASTER DISCCONET (BATTERY SIDE) Y B KEY KEY B Z DETAIL A SCALE 4: M706AA_M789AB SKYJACK, Page 82

83 AC 3.33 Load Circuit Wiring A B C D E F G H V CONNECT TO LOAD CIRCUIT SOLENOID W DETAIL "A" USE EXISTING STRAIN RELIEF CONNECT TO 57A ON ENABLE / INGITION TOGGLE SWITCH 0 D2 57A 57A A S5- IGN. 60 0A 0A 3 4 CONNECT TO 2B TERMINAL BLOCK 7 2 2B 29 29A D57A B (BLACK) A 99B A 65 (WHITE) X SEPERATE TERMINAL BLOCK 2 AND 29 ADD 2B TERMINAL BLOCK Y ADD D2 DIODE FROM TERMINAL BLOCK 2 TO 2B (NOTE ORIENTATION) D2 Z 2 2B DETAIL "A" M94959AB SKYJACK, Page 83

84 AD A B C D E 3.34 Hydraulic Schematic Diagram (serial number and above) F G H I J K L M N O C7 RISER CYLINDER C6 RISER CYLINDER RV9 RELIEF VALVE 2500 PSI SAE 08 T3 CV 2VDC MOTOR SAE M EPU EMERGENCY POWER UNIT CB4 000 PSI BR2 RA2 BOOM ROTATE SWING DRIVE SV3 M2 SAE CB3 000 PSI SAE CV6 OR6 CB PSI.5: SAE 06 SAE 06 SAE 06 SAE 06 CV5 SAE SAE 06 CB PSI.5: SAE C4 MASTER CYLINDER SAE C3 MAIN BOOM LIFT CYLINDER CB PSI 3: SAE SAE CB 000 PSI 3: C2/C FLY BOOM EXTENSION CYLINDER SAE 06 SAE 06 CB PSI 4.5: CB PSI 4.5: C5 PLATFORM LEVELING SLAVE CYLINDER SAE SAE CB PSI 4.5: CB PSI.5: BULKHEAD # TOP OF FLYBOOM - AT TIP SAE 4H-35 UP C JIB LIFT CYLINDER SAE CB PSI.5: CB PSI 3: 2B B 2A A 4H-35 DOWN SAE RA PLATFORM ROTARY ACTUATOR SAE CB PSI 3: R S ST ST2 SW SW2 S S2 PL PL2 P P2 EXT RET JBP JBT 3B 4H-37 RIGHT 4H-36 LEFT SV8 3A 4A M V2 LOOP FLUSH VALVE MB2 BRAKE MANIFOLD SV2 M2 4H-23A RIGHT 4H-24A LEFT 4H-33 RIGHT SV4 4H-32 LEFT RV PSI 4H-3 UP SV5 4H-30 DOWN CV4 SV7 RV PSI 4H-4 UP SV6 4H-3 DOWN 3H-38 BOOM RET 3H-39 BOOM EXT OR 0.035" OR " 2H-34A JIB 2H-36A PLATFORM POWER TRACK CARRIER ASSEMBLY MB3 JIB LIFT & PLATFORM ROTATE MANIFOLD T OR5 n 0.073" CV2 PR PRESS. REDUCING VALVE 500 PSI QD CE ONLY AUX TEST P TEST4 PFC CV3 RV7 750 PSI CV7 DSV2 CV8 DSV3 4H-4 UP CV9 OR4 4H-40 DOWN CV0 DSV4 OR3 CV CV2 DSV5 DSV SAE SAE SAE SAE U D 3H-65 DIFF LOCK VALVE 3H-65 AXLE LOCKOUT VALVE SV AL LS T T2 2H-2A DUMP RV6 300 PSI T3 TEST3 TEST5 TEST2 MB MAIN MANIFOLD 2SPD 3H-45A 2 SPEED VALVE V3 BRAKE HAND PUMP 3H-26 BRAKE VALVE V BRAKE RELEASE OVERRIDE BRG BR WITHOUT GENERATOR SAE 2 SAE 08 WITH GENERATOR SAE 08 SAE SAE PORT # STEER RIGHT PORT #5 STEER LEFT SAE SAE C8 FRONT AXLE STEERING CYLINDER C3 REAR AXLE DIFF. LOCK V T SAE 06 SAE SAE PORT #0 DIFF.LOCK PORT #2 AXLE LOCK SAE SAE C2 REAR AXLE SAHR BRAKE CYLINDER SAE PORT #6 2-SPD SAE SAE CB 5000 PSI 0: T4 SAE PORT #4 BRAKE SAE SAE 06 SAE SAE 2 PORT #3 AXLE PRESS. PORT #7 DRIVE REVERSE SAE SAE 2 C9/C0 AXLE LOCK-OUT CYLINDERS W SAE 2 PORT #8 DRIVE FORWARD SAE 2 SAE 06 P 3H-2 OR7 A SAE 0 F PRESSURE FILTER WITH GENERATOR T6 SAE 08 PORT #9 MOTOR DRAIN SAE 08 M DRIVE MOTOR (7.5 CC/.07 CIR) (40.6 CC/2.48 CIR) S SAE A B D2 CB PSI 0: DIESEL OR DUAL FUEL ENGINE P DRIVE PUMP (40.6 CC/ 2.48 CIR) (.4 00 RPM) D D2 PUMP DISPL CONTROL 4H-5 = REVERSE 4H-6 = FORWARD a RV3 33 PSI b SAE Mb Ma TP C2 C TP RV PSI RV 5000 PSI S V4 BYPASS VALVE PA CHARGE PUMP (3.8 CC/ 0.84 CIR) B A SAE 0 WITH LOAD CIRCUIT P2 SYSTEM PUMP ( CC/0.66CIR) (5.7 00RPM) w/o 2kW GENERATOR RV PSI MB7 LOAD CIRCUIT MANIFOLD LOAD CIRCUIT OPTION WITHOUT LOAD CIRCUIT SAE 0 P3 DUAL SYSTEM PUMP ( CC/0.66CIR) (4 CC/0.84CIR) (3 00RPM) T SAE 0 SAE 0 WITH GENERATOR G 3H-85-2 GENERATOR SELECT WITH GENERATOR SAE 08 MAIN SAE 08 P2 RV PSI 3.5KW GENERATOR OPTION PFC3 3H-85 GENERATOR SELECT P3 RV2 400 PSI PFC2 MB5 GENERATOR CONTROL MANIFOLD P4 P5 P CV3 M3 GEN T4 WITH GENERATOR WITH GENERATOR WITHOUT GENERATOR OC OIL COOLER SAE 2 T6 T5 T4 T3 T T2 VIEW OF TANK PORT PHYSICAL LOCATION X Y TP P M SAE 0 SAE 2 SAE 2 T5 SAE SAE 6 T2 SAE 6 T P2 G2 RV 3250 PSI RV5 400 PSI RV PSI G4 CV4 M4 GEN SAE 08 WITH GENERATOR F2 RETURN FILTER 3H-85- GENERATOR SELECT CV5 T TM T4 Z MB4 GENERATOR CONTROL MANIFOLD 2KW GENERATOR OPTION M9634AC SKYJACK, Page 84

85 AD A B C D E 3.35 Hydraulic Schematic Diagram (serial number and below) F G H I J K L M N O C7 RISER CYLINDER C6 RISER CYLINDER SAE RA2 BOOM ROTATE SWING DRIVE M2 Bore 2.5 Bore 2.5 Rod.75 Rod.75 Stroke 36.2 Stroke 36.2 C4 MASTER CYLINDER C3 MAIN BOOM LIFT CYLINDER C2/C FLY BOOM EXTENSION CYLINDER C5 PLATFORM LEVELING SLAVE CYLINDER C JIB LIFT CYLINDER RA PLATFORM ROTARY ACTUATOR R RV9 RELIEF VALVE 2500 PSI SAE 08 CV 2VDC MOTOR M EPU EMERGENCY POWER UNIT CB4 000 PSI BR2 SV3 SAE CB3 000 PSI SAE CV6 OR6 CB PSI.5: SAE 06 SAE 06 SAE 06 SAE 06 CV5 SAE SAE 06 CB PSI.5: SAE Bore 3.75 Rod.5 Stroke 2.06 SAE Bore 4.0 Bore 2.5 Rod 3 Rod.5 Stroke 60 Stroke 75 CB PSI 3: SAE SAE CB 000 PSI 3: SAE 06 SAE 06 CB PSI 4.5: CB PSI 4.5: SAE Bore 3.25 Rod.5 Stroke.63 SAE CB PSI 4.5: CB PSI.5: BULKHEAD # TOP OF FLYBOOM - AT TIP SAE 4H-35 UP Bore 2.5 Rod.6 Stroke 29.5 DISPL: 239CC SAE CB PSI.5: CB PSI 3: 2B B 2A A 4H-35 DOWN SAE SAE CB PSI 3: S T3 ST ST2 SW SW2 S S2 PL PL2 P P2 EXT RET JBP JBT SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SAE 4 SV8 3B 3A 4A 4H-37 RIGHT 4H-36 LEFT M MB2 BRAKE MANIFOLD SAE 6 SAE 6 V2 LOOP FLUSH SV2 OR5 CV AA BRAKE VALVE ASSY M AD MAIN MANIFOLD 4H-23A RIGHT 4H-24A LEFT 4H-33 RIGHT SV4 4H-32 LEFT RV PSI 4H-3 UP PROVISION FOR ORIFICE PLUG /6-27 NPTF SV5 4H-30 DOWN CV4 SV7 RV PSI 4H-4 UP PROVISION FOR ORIFICE PLUG /6-27 NPTF SV6 4H-3 DOWN 3H-38 BOOM RET 3H-39 BOOM EXT OR 0.035" OR " 2H-34A JIB 2H-36A PLATFORM POWER TRACK CARRIER ASSEMBLY MB3 JIB LIFT & PLATFORM ROTATE MANIFOLD T PR PRESSURE REDUCING VALVE 500 PSI 3H-65 DIFF. LOCK SAE 4 D QD CE ONLY AUX TEST P TEST4 SAE 8 SAE 4 SAE 8 SAE 4 CV3 PFC RV7 750 PSI CV7 DSV2 CV8 DSV3 4H-4 UP CV9 OR4 4H-40 DOWN CV0 DSV4 OR3 CV CV2 DSV5 DSV SAE SAE SAE SAE U GLS LS SAE 4 SAE 4 SV 3H-65 AXLE LOCK 3H-45A 2-SPEED SAE 4 SAE 4 AL 2-SPD CV6 T T2 SAE 2 SAE 2 T3 SAE 8 2H-2A DUMP RV6 300 PSI SAE 4 SAE 4 TEST3 TEST5 SAE 4 TEST2 MB MAIN MANIFOLD SAE 2 BR BRG 3H-26 BRAKE V BRAKE OVERRIDE RV4 RELIEF VALVE 550 PSI SAE 6 SAE 4 SAE 6 T V3 BRAKE HAND PUMP SAE 4 T0 T4 MB6 PR2 PRESSURE REDUCING VALVE 300 PSI SAE WITHOUT GENERATOR SAE 08 WITH GENERATOR SAE 08 SAE SAE SAE SAE PORT # STEER RIGHT PORT #5 STEER LEFT PORT #0 DIFF.LOCK PORT #2 AXLE LOCK SAE SAE SAE SAE Bore? Rod? Stroke 4.7 C8 FRONT AXLE STEERING CYLINDER Bore? Rod? Stroke? Bore 2.75 Rod.25 Stroke 2 C3 REAR AXLE DIFF. LOCK C2 REAR AXLE SAHR BRAKE CYLINDER V SAE PORT #6 2-SPD SAE SAE CB 5000 PSI 0: SAE PORT #4 BRAKE SAE SAE 06 Bore 3.5 Stroke 4.25 SAE SAE 2 PORT #3 AXLE PRESS. PORT #7 DRIVE REVERSE SAE SAE 2 C9/C0 AXLE LOCK-OUT CYLINDERS W SAE 2 PORT #8 DRIVE FORWARD SAE 2 SAE 06 Bore 3.5 Stroke 4.25 RV PSI P 3H-2 OR7 T SAE 0 F PRESSURE FILTER WITH GENERATOR T6 SAE 08 PORT #9 MOTOR DRAIN SAE 08 M DRIVE MOTOR (7.5 CC/.07 CIR) (40.6 CC/2.48 CIR) S SAE A B D2 CB PSI 0: DIESEL OR DUAL FUEL ENGINE P DRIVE PUMP (40.6 CC/ 2.48 CIR) (.4 00 RPM) D D2 PUMP DISPL CONTROL 4H-5 = REVERSE 4H-6 = FORWARD a RV3 33 PSI b Mb SAE 8 SAE 8 SAE 6 Ma TP C2 TP C TP SAE 6 SAE 8 SAE 8 SAE 6 RV PSI RV 5000 PSI S V4 BYPASS VALVE PA CHARGE PUMP (3.8 CC/ 0.84 CIR) SAE 6 B A SAE 6 SAE 0 WITH LOAD CIRCUIT P2 SYSTEM PUMP ( CC/0.66CIR) (5.7 00RPM) w/o 2kW GENERATOR RV PSI MB7 LOAD CIRCUIT MANIFOLD LOAD CIRCUIT OPTION WITHOUT LOAD CIRCUIT SAE 0 P3 DUAL SYSTEM PUMP ( CC/0.66CIR) (4 CC/0.84CIR) (3 00RPM) SAE 0 SAE 0 WITH GENERATOR G P SAE 6 SAE 0 3H-85-2 GENERATOR SELECT WITH GENERATOR SAE 08 MAIN SAE 0 SAE 08 P2 RV PSI 3.5KW GENERATOR OPTION 3H-85 GENERATOR SELECT P3 RV2 400 PSI PFC2 MB5 GENERATOR CONTROL MANIFOLD 62788AC GENERATOR VALVE ASSY P4 P5 P CV3 M3 GEN T4 WITH GENERATOR WITH GENERATOR WITHOUT GENERATOR SAE 2 OC OIL COOLER SAE 2 T6 T5 T4 T3 T T2 VIEW OF TANK PORT PHYSICAL LOCATION X Y SAE 2 T5 SAE 6 T2 SAE 6 T 2KW GENERATOR OPTION P2 G2 SAE 0 SAE 6 3H-85- GENERATOR SELECT RV 3000 PSI MB4 GENERATOR CONTROL MANIFOLD PFC3 CV5 SAE 0 SAE 6 SAE 0 SAE 0 M GM CV4 TM T SAE 0 M4 GEN SAE 08 T4 WITH GENERATOR F2 RETURN FILTER Z M67959AD SKYJACK, Page 85

86 AD A B C D E 3.36 Platform Control Console Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine) F G H I J K L M N O A3 JOYSTICK A2 JOYSTICK R A JOYSTICK (YELLOW) POWER RED (RED/YELLOW) POWER RED (WHITE) GROUND BLK (WHITE) GROUND BLK BLACK D-SIGNAL YEL R (RED/GREEN) R-SIGNAL YL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL RED (+) POWER (RED/YELLOW) BLK (-) GROUND (WHITE) WHT (X) BLU (Y) X-SIGNAL Y-SIGNAL RED BLUE S-ROT S9-LEVEL JUMPER(08) S8-TELE JUMPER(A) S2-JIB S28-DIFF. S PL5 37 A A 4 A A A 08 A A 08 A A 65 26A A B C D E F G H PL6 AMB T D A D -2 S26- FUEL 60 A S9-IGN 57 A 49 S23-HORN A 76 S4-E STOP 07A A 2 0 S6-EPUMP 0 A 0 S48- TORQ S0- THROT U D V CR 65 A 65 26B D08- D26A A 08 08A A 26A D-SIG A 4 28A A A 32 07A A 65 24A P-FEMALE (A) 24P-MALE (B) W CR 27A DB B 45 X 08CR 08FCR 08 08F 57 57A D59 59 D-SIG X-SIG Y-SIG R-SIG A A 7 24A 08A B 24 08F A A Y BP + 60 _ 27A Z M68603AC SKYJACK, Page 86

87 AD A B C D E 3.37 Platform Control Console Diagram (46AJ ANSI/CSA - Deutz Diesel Engine) F G H I J K L M N O A3 JOYSTICK A2 JOYSTICK R A JOYSTICK (YELLOW) POWER RED (RED/YELLOW) POWER RED (WHITE) GROUND BLK (WHITE) GROUND BLK BLACK D-SIGNAL YEL R (RED/GREEN) R-SIGNAL YL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL RED (+) BLK (-) WHT (X) BLU (Y) POWER GROUND X-SIGNAL Y-SIGNAL (RED/YELLOW) (WHITE) RED BLUE S- BASKET ROTATE S9-LEVEL JUMPER(08) S8-TELE JUMPER(A) S2-JIB S28-DIFF. S PL5 A B C D E F G H 37 A A 4 A A A 08 A A 08 A A 65 26A 65 D27 D76 D PL6 AMB T D08 57 S23-HORN S4-E STOP I (8) A S6-EPUMP S48- TORQ 45 S0- THROT U S9-IGN V 65CR 82CR (OPT.) A 26B D26A D-SIG 49 28A 4 28A A 55 24P-FEMALE (A) 24P-MALE (B) PLUG B PLUG A W 08A 26A 45 23A 26 27CR 45 X 08CR 08FCR 57 57A D-SIG X-SIG Y-SIG R-SIG A A 7 24A 08A B 24 08F A A Y 08 27A A A 49 A 07A 0 A D D08- A 08 08A A 32 07A A A DB B 08 08F 08 D59 59 BP + _ 60 27A Z M68576AC SKYJACK, Page 87

88 AD A B C D E 3.38 Platform Control Console Diagram (46AJ & 5AJ CE - Deutz Diesel Engine) F G H I J K L M N O A3 JOYSTICK A2 JOYSTICK R A JOYSTICK 62A (YELLOW) POWER RED (RED/YELLOW) POWER RED (WHITE) GROUND BLK (WHITE) GROUND BLK BLACK D-SIGNAL YEL R (RED/GREEN) R-SIGNAL YL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL RED (+) POWER (RED/YELLOW) BLK (-) WHT (X) BLU (Y) GROUND X-SIGNAL Y-SIGNAL (WHITE) RED BLUE S-BASKET ROTATE S9-LEVEL S8-TELE S2-JIB S28-DIFF. S PL5 A B C D E F G H 37 A 26C 26C 36 A 4 26A 40 C 26A C 38 26C 39 A 26C A 35 26C 34 A 26C A A C D26C A D27 D76 D PL6 AMB T 27A B A 57 A S23-HORN A S4-E STOP 07A A S6-EPUMP 0 62A A 0 S48- TORQ 45 S0- THROT U S9-IGN D V 26C 26CR 26 D-SIG 62A 49 28A 4 28A A P-FEMALE (A) 24P-MALE (B) PLUG B PLUG A W 08A A 26 82CR 65CR 27CR 08CR A 27 B 27A 57A D-SIG X-SIG Y-SIG R-SIG A C C C 28A 7 24A 08A B 24 08F A A X Y 57 BP3 + _ 08FCR 08 08B 08 D08 08B 62ACR 62A C C A 08 08A C C B C C DC D8 08F A 32 07A A D59 59 DB 8 BP Z + _ 60 27A M790AB SKYJACK, Page 88

89 AD A B C D E 3.39 Platform Control Console Diagram (46AJ & 5AJ AS - Deutz Diesel Engine) F G H I J K L M N O A3 JOYSTICK A2 JOYSTICK R A JOYSTICK 62A (YELLOW) POWER RED (RED/YELLOW) POWER RED (WHITE) GROUND BLK (WHITE) GROUND BLK BLACK D-SIGNAL YEL R (RED/GREEN) R-SIGNAL YL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL RED (+) POWER (RED/YELLOW) BLK (-) WHT (X) BLU (Y) GROUND X-SIGNAL Y-SIGNAL (WHITE) RED BLUE S-BASKET ROTATE S9-LEVEL JUMPER(26A) S8-TELE JUMPER(A) S2-JIB S28-DIFF. S PL5 A B C D E F G H 37 A 26C 26C 36 A 4 26C 40 A 26C A 38 26C 39 A 26C A 35 26C 34 A 26C A A A D27 D76 D74 62A - + PL6 AMB T 57 S23-HORN S4-E STOP S6-EPUMP S48- TORQ 45 S0- THROT U S9-IGN C (2) V 57A 27A B B B B 07A B 0 B 0 08 D D ACR C C 62A C 26ACR 65 82CR 65CR 27CR 62A 49 28A 4 28A FCR 08CR A 26A 08F A B 08 27A 26B A D08- D26A A 08 08A D DB D8 D-SIG X-SIG Y-SIG R-SIG A 6 33 D-SIG 34 08A 26A C C B C C C 28A 7 24A 08A B 24 08F A A A 32 07A A 65 24A P-FEMALE (A) 24P-MALE (B) 45 PLUG B PLUG A 8 + _ BP3 W X Y + _ BP 60 27A Z M67937AD SKYJACK, Page 89

90 00 A B C D E 3.40 Base Control Console Diagram (46AJ ANSI/CSA - GM Engine) F G H I J K L M N O R CB4 03A 05-4ga 03A-4ga 00-2ga CB3-4ga CB CB 03-2ga 0ACR 07CR CR 2CR 45CR 45CR2 49CR 08 54A 2A 45A 49A 0A 0 00B A 28A 0 03A BP2 RED BLACK BACK VIEW DEUTSCH PIN - WHITE PIN 2 - WHITE/ORANGE PIN 3-54A PURPLE/RED PIN 4-57A BROWN/GREEN PIN 5 - PLUGGED PIN 6-76 BROWN/BLUE PIN 7 - PLUGGED PIN 8-78 RED/BLUE PIN 9-79 BROWN/PURPLE PIN 0-00A WHITE PIN - PLUGGED PIN 2 - PLUGGED S S3 E STOP 05 0 S2-KSW TT D00B 60CR BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD 07 07A A 00A T 07 24P-MALE 'B' BATTERY (B-) 00 - WHITE 2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING PL FAULT 54A MAIN HARNESS PLUG P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A 49 28A A (BLK) 60 5(RED) 59 57A A 23A A-4ga 33 07A-4ga PLUG B PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN - 5 RED PIN 2 - WHITE PIN 3 - GREEN PIN 4-6 BLACK U V S7 -JIB 34 0A D34 D35 34A S5- LEVEL 40 0A 4 S6-ROT 36A 36 D36 37 D A 37 S4-TELE 38 0A A 0A A A 54A P-FEMALE 'A' RESERVED FOR OPTIONS W S25-RISER 3 30 S2-BOOM 0A 0C 0A 0C 4 3 S3-TUR 32 0C 33 57A 0 0A 2 0 S5- IGN. 60 D0A D0A R7=680 RESERVED FOR LIMIT SWITCH WIRING X RESERVED FOR MISC. WIRING (DIRECTION SWITCH, FUEL LEVEL) Y 0A R=5 0C AT ANGLE TRANS. YEL GREEN WHITE BLACK 4 3 DEUTSCH BACK VIEW 2 TILT SWITCH PIN - YELLOW PIN 2 - GREEN PIN 3 - WHITE PIN 4 - BLACK TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3 - WHITE PIN 4-28 BLACK/YELLOW Z M63579AB SKYJACK, Page 90

91 A B C D E 3.4 Base Control Console Diagram (46AJ ANSI/CSA - Kubota WG2503 Engine) F G H I J K L M N O CB4 03A 05-4ga 03A-4ga 00-2ga CB3-4ga CB ga CB 0ACR 07CR CR 2CR 45CR 45CR2 49CR 08 54A 2A 45A 49A 0A 0 00B A 28A 0 03A BP2 RED BLACK BACK VIEW DEUTSCH PIN - PLUGGED PIN 2-54A PURPLE/RED PIN 3-57A BROWN/GREEN PIN 4 - WHITE/ORANGE PIN 5-76 BROWN/BLUE PIN 6 - PLUGGED PIN 7-78 RED/BLUE PIN 8-79 BROWN/PURPLE PIN 9 - PLUGGED PIN 0-00A WHITE PIN - PLUGGED PIN 2 - PLUGGED R S S3 E STOP 05 0 TT D00B 00A 60CR 60 BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD A A 00A 00 BATTERY (B-) 00 - WHITE 2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING T D78 24P-MALE 'B' PL FAULT 54A MAIN HARNESS PLUG P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A 49 28A A (BLK) 60 5(RED) 59 57A A 23A A-4ga 33 07A-4ga PLUG B PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN - 5 RED PIN 2 - WHITE PIN 3 - GREEN PIN 4-6 BLACK U V S7 -JIB 34 0A D34 D35 34A S5- LEVEL 40 0A 4 S6-ROT 36A 36 D36 37 D A 37 S4-TELE 38 0A A D0A - 0A A A 54A P-FEMALE 'A' RESERVED FOR OPTIONS W S25-RISER A 0C 0A 0C S2-BOOM S3-TUR C 33 57A 0 0A 2 0 S5- IGN. 60 D0A D0A R7=680 RESERVED FOR LIMIT SWITCH WIRING X RESERVED FOR MISC. WIRING (DIRECTION SWITCH, FUEL LEVEL) 0A R=5 0C AT ANGLE TRANS. YEL GREEN WHITE BLACK 4 3 DEUTSCH 2 BACK VIEW Y TILT SWITCH PIN - YELLOW PIN 2 - GREEN PIN 3 - WHITE PIN 4 - BLACK TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3 - WHITE PIN 4-28 BLACK/YELLOW Z M73AA SKYJACK, Page 9

92 00 AC A B C D E 3.42 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D Diesel Engine) F G H I J K L M N O 03A 03A-4ga 00-2ga CB3-4ga CB2 05-4ga 05 CB 03-2ga S8 DIAGNOSE 76 0ACR 07CR CR 2CR 45CR 45CR2 49CR 08 0A 54A 2A 45A 28B 49A 0A 0 00B A 0 03A BP2 RED BLACK R 03 R2= S S3 E STOP 05 0 S2-KSW TT 57ACR 60CR 78CR 79CR 57B B A 00A DEUTZ EDC HARNESS 03 BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD 54A A T D7A D P-MALE 'B' BATTERY (B-) 00 - WHITE 2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING PL2 GLOW 54A PL FAULT A 76 MAIN HARNESS PLUG P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A 49 28A A (RED) 59 57A A 23A A-4ga 33 07A-4ga PLUG B PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN U V S7 -JIB 34 0A D34 D35 34A S5- LEVEL 40 0A 4 S6-ROT 36A 36 D36 37 D A 37 S4-TELE 38 0A A D0A - R5=5 0A A A 54A P-FEMALE 'A' RESERVED FOR OPTIONS W S25-RISER S2-BOOM A 0E 0A 0C 3 4 S3-TUR 32 0C 33 57A 0 0A 2 0 S5- IGN. 60 D0A D0A R7=680 RESERVED FOR LIMIT SWITCH WIRING X KEY B X22 A 05 54A 06 B K L RESERVED FOR MISC. WIRING (GLOWPLUG, FUEL LEVEL) Y 0A R=5 0C AT ANGLE TRANS. YEL WHITE BLACK GREEN 4 3 DEUTSCH BACK VIEW 2 TILT SWITCH PIN - YELLOW PIN 2 - GREEN PIN 3 - WHITE PIN 4 - BLACK TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3 - Z M63572AE SKYJACK, Page 92

93 00 AC A B C D E 3.43 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D Diesel Engine with Positive Air Shut-Off Option) F G H I J K L M N O R 03A 03A-4ga CB3 00-2ga -4ga CB2 05-4ga 05 CB 03-2ga S8 DIAGNOSE ACR 07CR CR 2CR 45CR 45CR2 49CR 08 0A 54 2A 45A 28B 49A 0A 0 00B A 0 03A R2=250 BP2 RED BLACK S DO NOT ATTACH 03 S3 E STOP 05 0 S2-KSW SPLICE (.5") Y Z TT 57ACR 60CR 78CR 79CR 57B B A 00A A A DEUTZ EDC HARNESS 03 BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD 54A A BATTERY (B-) 00 - WHITE 2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING T 07 D7A D2 24P-MALE 'B' F (22) POSI AIR (RED) 403A 4 PL2 GLOW 54A PL FAULT A 76 MAIN HARNESS PLUG P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A 49 28A A (RED) A A 23A A-4ga 33 07A-4ga PLUG B PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN U V TO SOLENOID PIN A-BLACK (408) PIN B-RED (403A) PIN C-WHITE (40) POSITIVE AIR SHUT OFF MODULE 0 PIN CONNECTOR PLUG PIN -WHITE (40) PIN 6 -BLUE (403) PIN 2 -EMPTY PIN 7 -WHITE () PIN 3 -RED (403A) PIN 8 -BLACK(408) PIN 4 -GREEN (4) PIN 9 -EMPTY PIN 5 -EMPTY PIN 0 -YELLOW (40) A S7 -JIB 34 0A S25-RISER D34 D35 34A S5- LEVEL 0A S2-BOOM A 0E 0A 0C A S6-ROT R=5 36 D C 0A 37 S3-TUR 32 36A 37 D37 0C 33 S4-TELE 38 0A 39 57A 0 0A 2 0 S5- IGN A D0A D0A - 0A A A 54A D0A AT ANGLE TRANS. YEL WHITE BLACK GREEN R5=5 R7=680 KEY B 4 3 X22 A 05 DEUTSCH BACK VIEW 54A 06 B K L 2 24P-FEMALE 'A' F (9) H (2) RESERVED FOR OPTIONS RESERVED FOR LIMIT SWITCH WIRING RESERVED FOR MISC. WIRING (GLOWPLUG, FUEL LEVEL) W X Y TILT SWITCH PIN - YELLOW PIN 2 - GREEN PIN 3 - WHITE PIN 4 - BLACK TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3 - Z M95377AB SKYJACK, Page 93

94 00 A B C D E 3.44 Base Control Console Diagram (46AJ & 5AJ CE - Deutz D Diesel Engine) F G H I J K L M N O 03A 03A-4ga 00-2ga CB3 CB2 05-4ga -4ga CB 03-2ga S8 DIAGNOSE 76 0ACR 08 0A 07CR CR 2CR 45CR 45CR2 49CR 0A 54A 0 00B A 2A 62A 45A 45 28B 45 28A 28 49A R 03 R2= S3 E STOP S2-KSW TT 57ACR 62BCR 59CR 60CR 78CR 79CR 57B A 00A 62B 0B DEUTZ EDC HARNESS 03 BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD S 07A B F 05 54A 0A 62A T 07 D2 D59 24P-MALE 'B' BATTERY (B-) 00 - WHITE 2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING 07A D07A 2A PL2 GLOW 54A PL FAULT A 76 REFER TO DETAIL C P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A D0A - D A 28A A A A 6 23A A-4ga 33 07A-4ga PLUG B P-FEMALE 'A' PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN - 5 RED PIN 2 - WHITE PIN 3 - GREEN PIN 4-6 BLACK U V S7 -JIB D34 34A S5- LEVEL S6-ROT S4-TELE 0A 0A 0A D D A 0A D R5=5 R6=680 RESERVED FOR OPTIONS W S25-RISER S2-BOOM A 0C 0A 0C 3 4 S3-TUR 32 0C 33 57A 0 0A 2A 0 S5- IGN. D0A F D0A D0A -2 R7=680 62A D62 X A A 06 B K L RESERVED FOR LIMIT SWITCH WIRING RESERVED FOR MISC. WIRING (GLOWPLUG, FUEL LEVEL) DETAIL C CONNECTOR (FEMALE) PIN - 05 PURPLE PIN2-77 BROWN PIN3-0B PURPLE/BLACK PIN4 - n/a PIN5 - F YELLOW PIN6 - WHITE X Y 0A R=5 0C AT ANGLE TRANS. YEL WHITE BLACK GREEN DEUTSCH BACK VIEW 2 TILT SWITCH PIN - YELLOW PIN 2 - GREEN PIN 3 - WHITE PIN 4 - BLACK TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3 - WHITE PIN 4-28 BLACK/YELLOW Z M70773AC SKYJACK, Page 94

95 A B C D E 3.45 Base Control Console Diagram (46AJ & 5AJ AS - Deutz D Diesel Engine) F G H I J K L M N O SPARE SPARE 03A 03A-4ga 00-2ga CB3-4ga CB2 05-4ga 05 CB 03-2ga S8 DIAGNOSE 76 0ACR 07CR CR 2CR 45CR 45CR2 49CR 08 0A 54A 2A 45A 28B 49A 0A 0 00B A 0 03A 62A BP2 RED BLACK R 03 R2= S3 E STOP 05 0 S2-KSW TT 57ACR 59CR 60CR 78CR 79CR 57B A 00A DEUTZ EDC HARNESS 03 BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD S 54A 62A A D2 24P-MALE 'B' 00 BATTERY (B-) 00 - WHITE 2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING T 07A D07A 2A PL2 GLOW 54A PL FAULT A 76 MAIN HARNESS PLUG P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A A 28A A A A 23A A-4ga 33 07A-4ga PLUG B PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN - 5 RED PIN 2 - WHITE PIN 3 - GREEN PIN 4-6 BLACK U V D0A - 24P-FEMALE 'A' 36A 34 0A 35 S7 -JIB D34 D35 34A S5- LEVEL 40 0A 4 S6-ROT 36 D36 37 D A 37 S4-TELE 38 0A A R5=5 0A A A 54A A R6=680 RESERVED FOR OPTIONS W S25-RISER S2-BOOM A 0C 0A 0C 3 4 S3-TUR 32 0C 33 57A 0 0A 2A 0 S5- IGN. 60 D0A D0A D0A -2 R7=680 RESERVED FOR LIMIT SWITCH WIRING RESERVED FOR MISC. WIRING (GLOWPLUG, FUEL LEVEL) X 0A R=5 0C 62A D62 62 AT ANGLE TRANS. BLACK WHITE GREEN YEL X22 A 05 54A 06 B K L Y TILT SWITCH PIN - YELLOW PIN 2 - GREEN PIN 3 - WHITE PIN 4 - BLACK 4 3 DEUTSCH BACK VIEW 2 TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3 - WHITE PIN 4-28 BLACK/YELLOW Z M6362AC SKYJACK, Page 95

96 A B C D E 3.46 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine) F G H I J K L M N O R S3 E STOP 05 0 CB4 S2-KSW A ga CB3-4ga CB2 05-4ga CB 03-2ga S8 DIAGNOSE TT 03A 03 03A B D - 76A B 0ACR 2CR 45CR 45CR2 49CR 08 2A 45A 28B 49A 56B 0A A 28A CR 78CR 79CR 99A 99B A R7=250 KEY B D2 D7A 56A 56B 57A 03 03A B A A RED BLACK BP2 CONNECTOR J PIN - 03 PIN 2-03A PIN 3-56B PIN 4-56A PIN 5 - PLUGGED PIN 6 - PLUGGED PIN 7-3 PIN 8-57A PIN 9 - PLUGGED PIN 0-74 PIN - 05 PIN 2 - CONNECTOR J2 SOCKET - 76B SOCKET 2 - PLUGGED SOCKET 3-76A SOCKET 4-99 SOCKET 5-90 SOCKET 6 - JUMPER WITH SOCKET 7 SOCKET 7 - JUMPER WITH SOCKET 6 SOCKET 8 - SOCKET 9-54 SOCKET 0-8 SOCKET - 77 SOCKET 2 - A BATTERY (B+) 03 - BLACK 2 GAUGE Ø5/6" CONNECT TO E-PUMP POWER STUD 03 S T 07 F (6) 07 3 NOEM 4 NCLB BATTERY (B-) 00 - WHITE2 GAUGE Ø5/6" CONNECT TO E-PUMP HOUSING 24P-MALE 'B' U MAIN HARNESS PLUG P-FEMALE A 4 23A 45A 24A 49A GA 33-4GA 34A -4GA 36A 57A 49 28A A (BLK) 60 5(RED) 59 57A A 23A A-4ga 33 07A-4ga PLUG B PLUG A DEUTSCH BACK VIEW DRIVE PUMP VALVE PIN - V W 36A S7 -JIB 0A 34 0A S25-RISER 30 0B D34 D35 34A S5- LEVEL 0A 40 0A 4 4 S2-BOOM 3 0B S6-ROT D A 0B D S3-TUR 33 S4-TELE 38 0A 39 57A A S5- IGN D0A D A D0A - 0A 0A D0A A R6=3.9k R5=2.k R4=2.2k R3= RESERVED FOR OPTIONS RESERVED FOR LIMIT SWITCH WIRING R5=2.k R6=3.9k R4=2.2k R3= X 0A R=6 0B AT ANGLE TRANS. TILT SWITCH CONNECTION PIN - YELLOW PIN 2-28 GREEN PIN 3-05 B A X22 CONN. A - Y Z M64995AE SKYJACK, Page 96

97 A B C D E 3.47 Electrical Schematic Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine) F G H I J K L M N O R S3 EMERGENCY STOP S4 EMERGENCY STOP 05 CB 5 AMP BATTERY 0 0 EMERGENCY PUMP 08 0ACR 0 0 S6 E-PUMP SWITCH 0 2 A STARTER A 7 ALTERNATOR S23 HORN SWITCH 22 49CR A H HORN 07 49A OVERLOAD A CR PROPANE WHITE/ORANGE POSITION 3-B B 5 6 M AD S9 IGNITION 00 07A 05 PL CB2 5 AMP S2 07A RED 07A KEY SWITCH BASE/OFF/PLATFORM POSITION 2-A 07A RED 07A RT POSITION 3-A CTR 2 RED/YELLOW/BLACK 2 2 LEFT 0 POSITION 5-A 57 START S DISCONNECT SWITCH A RUN 03B ENGINE OFF A CB3 5 AMP 03 BLUE/WHITE POSITION 4-A PL4 08CR 03 0A PURPLE/BLACK POSITION -A 0 CB4 08 OPTIONAL OIL COOLER M 86CR 03B 86A A 86 TSW S5 CR IGNITION/E-PUMP SWITCH 0 0 E-PUMP 2 54A 03A D0A 0A ENABLE 0 00B 0 START 07CR D00B 57A BROWN/GREEN POSITION 4-B HOURMETER 00A 00A 54A TT TT HOURMETER 57 57A GEN. OPTION 08CR 57ACR 07 D0 D TO ENGINE BLOCK TO ENGINE STARTER 60 WHITE/BLUE 60 POSITION 6-B 60CR GREEN/RED POSITION 2-B ENGINE RUNNING 00A HORN 57A START COMMAND WHITE POSITION -B CR PL5 03B 00A B TELEMATICS OPTION WHITE POSITION 2-B 08 27A FOOTSWITCH TILT FS LOW FUEL SWITCH 76 BROWN/BLUE 76 POSITION 8-B 55 YELLOW/PURPLE 55 POSITION 3-B 76 ENGINE FAULT FUEL LEVEL INDICATOR 55 LOW FUEL BP TILT ALARM B 27A 60 PL ENGINE FAULT (MIL) A ENGINE FAULT D- 54A 27 ENGINE ON (VSW) S26 FUEL SELECT SWITCH (LOW = GASOLINE) FUEL SELECT (HI = PROPANE) Refer to 3.5 Interface & Engine Electrical Schematic - GM Dual Fuel Engine KEY B TELEMATICS OPTION D7A D2 R7=680 ohm 54A HIGH IDLE N=2675 RPM LOW IDLE N=600 RPM 79 GM EFI DUAL FUEL ENGINE S0 00 RPM 78 RED/BLUE 78 POSITION 9-B 650 RPM 79 BROWN/PURPLE 79 POSITION -B SWITCH THROTTLE D LS2 RISER DN LS LS3 BOOM DN LS LS4 FLY IN LS D59 BOOM TURRET LIMIT SWITCHES 29A N/C 29 N/C N/C YELLOW/BLUE 59 POSITION 5-B 56 45CR S48 DRIVE TORQUE SWITCH YELLOW/ORANGE POSITION -A 3H LOW TORQUE 45A 45A MOTOR 2-SPEED VALVE (COIL ON = HIGH SPEED) 58 SUPPR S FOOT D85A- SWITCH 08A 6 SUPPR. 62 2H-2A A DUMP VALVE 63 2A D0A JMPR2 DUMP VALVE RELAY 2CR 64 JMPR3 ORANGE/BLUE POSITION 8-A WITH OPTIONAL GENERATOR REMOVE JMPR2 65 S22 SUPPR. 66 ELECTRICAL GENERATOR OPTIONAL GENERATOR VALVE 2H-85 A 85A GRAY/BLUE POSITION 2-B 68 OPTIONAL STROBE LIGHT 69 S28 DIFF LOCK SWITCH 65 26B D08- LB2 70 LOCK OFF 65 LOCK ON 65 PINK/BLACK 65 POSITION 24-A A 65 D26A ALL MOTION ALARM 7 BP2 3H CR DIFFERENTIAL LOCK (COIL ON = LOCKED) 26A 72 SUPPR. 73 PL OCM-VALVE DRIVER 08A FORWARD DRIVE VALVE REVERSE DRIVE VALVE H-6 3H H-26 BRAKE VALVE WHITE/BLACK 6 POSITION 5-B 5 BLUE 5 POSITION 4-B 26 BLUE/YELLOW 26 POSITION -A LS 87 SENSING DIRECTION BOOM/TUR Vbat Xaxis X Y Yaxis H-24A LEFT STEER VALVE 24A 24A 24 RIGHT STEER VALVE 4H-23A 23A 23A S3 TURRET ROTATE LT 03 RT 4H-32 TURRET ROTATE LEFT VALVE TURRET ROTATE RIGHT VALVE H BOOM UP VALVE BOOM DOWN VALVE 4H H A 33 2 IN 3 S4 TELESCOPE OUT 38 3H-38 4 TELESCOPE IN VALVE H-39 TELESCOPE OUT VALVE SUPPR A 7 0A 8 9 4H-4 4 PLATFORM LEVEL UP VALVE PLATFORM LEVEL DOWN VALVE 40 4H A 2H-36A 36A D PLATFORM ROT. ENABLE VALVE RED/PURPLE POSITION 8-A LT RT PLATFORM ROT. LEFT VALVE S6 PLATFORM ROTATE LT 0A 4H S PLATFORM ROTATE RT 4H-37 PLATFORM ROT. RIGHT VALVE A 36A D WHITE/RED/BLACK POSITION 9-A H-34A 34A 34A D JIB ENABLE VALVE ORANGE/WHITE POSITION 7-A UP 08 UP 34 0A 4H DN S2 JIB UP/DOWN JIB UP VALVE 33 DN 4H A 34A D ORANGE/BLACK POSITION 6-A 34 46AJ ONLY S T U V W X A RISER Y A BOOM/TURRET JOYSTICK A3 RISER JOYSTICK A2 DRIVE/STEER JOYSTICK 3H AXLE LOCK VALVE 78 (COIL ON = FLOATING AXLE) SUPPR. 27 R4=30 ohm R3=30 ohm N.C. HELD OPEN WITH ENGINE OVER STEERING AXLE 7 BLUE/GREEN 7 POSITION 6-B 25 Gnd SUPPR. POSITION 0-A BLUE/BLACK 24A 24A 4 Gnd 30 R Output SUPPR. BLACK/WHITE POSITION 9-A 23A 23A 2 3 UP 0A S25 RISER 30 DN 0B 0B 0A R=6 ohm GREEN/BLACK POSITION 4-A GREEN/WHITE POSITION 5-A 4 BLACK 3 POSITION 7-A ORANGE POSITION 6-A 0A ORANGE/RED POSITION 8-B BLACK/RED POSITION 9-B S5 PLATFORM LEVELING UP 4 DN 40 Vbat DRIVE Vbat Gnd 4H RED/WHITE 3 POSITION 3-A RED/GREEN 30 POSITION 2-A RISER UP VALVE 4H RISER DOWN VALVE S2 BOOM LIFT S8 IN 08 TELESCOPE RET/EXT OUT JIB DOWN VALVE YELLOW/PINK POSITION 2-A 26A 9 45CR2 45 AT ANGLE TRANSDUCER & TILT SWITCH 28A BLUE/WHITE/YELLOW POSITION 23-B 28A 28 28A BLACK/YELLOW 28A POSITION 22-B 4 28A 28A SUPPR. RESISTORS MAY NOT BE PRESENT DA GREEN POSITION 7-B D Output Left 23 Right UP 0A DN 0B SUPPR. SUPPR. 4 UP 4 4 BLUE/PURPLE 4 08 POSITION -B BLUE/RED 40 DN POSITION 0-B A S9 40 PLATFORM LEVELING SUPPR. SUPPR. SUPPR. SUPPR. S7 JIB UP/DOWN SUPPR. 2H-85- OPTIONAL 2KW GENERATOR VALVE 85 3Ø F 40 2H OPTIONAL 2KW GENERATOR VALVE 4 42 GREEN CB5 50 AMP WHITE WHITE ORANGE RED RED RED BLACK BLACK BLACK GREEN GREEN GREEN D85 WHITE 0A 43 0C CB4 5 AMP 0B 44 HYDRAULIC 2KW GENERATOR MALE AND FEMALE PLUGS ARE CONNECTED NOTE: WITH WELDER GENERATOR OPTION F 45 WELDER OPTION V PLATFORM POWER 0A 0A WHITE 0A 0B 0B BLACK 0B M GND GREEN GND OPTIONAL 3.5KW GENERATOR HYDRAULIC 3.5KW GENERATOR OPTION 0A 0C CB6 5 AMP 0B F NOTE: WITH HYDRAULIC GENERATOR OPTION MALE AND FEMALE PLUGS ARE CONNECTED Z M69635AC SKYJACK, Page 97

98 A B C D E 3.48 Electrical Schematic Diagram (46AJ ANSI/CSA - Kubota WG2503 Dual Fuel Engine) F G H I J K L M N O R S3 EMERGENCY STOP S2 KEY SWITCH BASE/OFF/PLATFORM S4 EMERGENCY STOP 05 CB 5 AMP BATTERY 0 0 EMERGENCY PUMP 08 0ACR 0 0 S6 E-PUMP SWITCH C STARTER A 7 08CR ALTERNATOR S23 HORN SWITCH 22 49CR C H HORN 07 49A OVERLOAD A CR PROPANE WHITE/ORANGE POSITION 3-B KUBOTA EFI DUAL FUEL ENGINE 47 B 5 6 M AD S9 IGNITION 57 START S DISCONNECT SWITCH 00 07A 05 PL CB2 5 AMP 07A RED 07A POSITION 2-A 07A RED 07A RT POSITION 3-A CTR LEFT 0 C RUN ENGINE OFF 03A CB3 5 AMP 03 RED/YELLOW/BLACK POSITION 5-A BLUE/WHITE POSITION 4-A 2 0 PL4 08CR 03 0A PURPLE/BLACK POSITION -A 0 08 OPTIONAL OIL COOLER M CB4 86CR 03B 86A TSW 86 A S5 CR IGNITION/E-PUMP SWITCH 0 0 E-PUMP 2 54A 03A D0A 0A ENABLE 0 00B 0 START 07CR D00B 57A BROWN/GREEN POSITION 4-B HOURMETER 00A 00A 54A 57 57A GEN. OPTION TT TT HOURMETER 57ACR 07 D0 D TO ENGINE BLOCK TO ENGINE STARTER 60 WHITE/BLUE 60 POSITION 6-B 60CR GREEN/RED POSITION 2-B ENGINE RUNNING 00A HORN 57A START COMMAND WHITE POSITION -B CR PL5 03B 00A TELEMATICS OPTION WHITE POSITION 2-B 08 27A FOOTSWITCH TILT 76 BROWN/BLUE 76 POSITION 8-B 55 YELLOW/PURPLE 55 POSITION 3-B 76 ENGINE FAULT FUEL LEVEL INDICATOR 55 LOW FUEL BP TILT ALARM B 27A PL 76 54A ENGINE FAULT D- 27 (LOW = GASOLINE) FUEL SELECT (HI = PROPANE) Refer to Oscillating Cylinder Bolt Replacement B TELEMATICS OPTION B KEY D7A FS LOW FUEL SWITCH D2 R7=680 ohm 54A ENGINE FAULT (MIL) 76 54A ENGINE ON (VSW) S26 FUEL SELECT SWITCH ON = HIGH IDLE, N=00 RPM 79 ON = LOW IDLE, N=700 RPM D0A- D78 S0 00 RPM 78 RED/BLUE 78 POSITION 9-B 700 RPM 79 BROWN/PURPLE 79 POSITION -B THROTTLE SWITCH D LS2 RISER DN LS LS3 BOOM DN LS LS4 FLY IN LS D59 BOOM TURRET LIMIT SWITCHES 29A N/C 29 N/C N/C YELLOW/BLUE 59 POSITION 5-B 56 45CR S48 DRIVE TORQUE SWITCH YELLOW/ORANGE POSITION -A 3H LOW TORQUE 45A 45A MOTOR 2-SPEED VALVE (COIL ON = HIGH SPEED) 58 SUPPR S FOOT D85A- SWITCH 08A 6 SUPPR. 62 2H-2A A DUMP VALVE 63 2A D0A JMPR2 DUMP VALVE RELAY 2CR 64 JMPR3 ORANGE/BLUE POSITION 8-A WITH OPTIONAL GENERATOR REMOVE JMPR2 65 S22 SUPPR. 66 ELECTRICAL GENERATOR OPTIONAL GENERATOR VALVE 2H-85 A 85A GRAY/BLUE POSITION 2-B 68 OPTIONAL STROBE LIGHT 69 S28 DIFF LOCK SWITCH 65 26B D08- LB2 70 LOCK OFF 65 LOCK ON 65 PINK/BLACK 65 POSITION 24-A A 65 D26A ALL MOTION ALARM 7 BP2 3H CR DIFFERENTIAL LOCK (COIL ON = LOCKED) 26A 72 SUPPR. 73 PL SCM-VALVE DRIVER 3H AXLE LOCK VALVE 78 (COIL ON = FLOATING AXLE) SUPPR YELLOW/PINK POSITION 2-A 26A A CR2 6 08F AT ANGLE TRANSDUCER & TILT SWITCH FORWARD DRIVE VALVE REVERSE DRIVE VALVE H-6 3H H-26 BRAKE VALVE WHITE/BLACK 6 POSITION 5-B 5 BLUE 5 POSITION 4-B 26 BLUE/YELLOW 26 POSITION -A LS 87 SENSING DIRECTION A BOOM/TUR Vbat Xaxis X Y Yaxis H-24A LEFT STEER VALVE 24A 24A 24 RISER 4H-23A RIGHT STEER VALVE 23A 23A S3 TURRET ROTATE LT 03 RT 4H-32 TURRET ROTATE LEFT VALVE TURRET ROTATE RIGHT VALVE H BOOM UP VALVE BOOM DOWN VALVE 4H H A 33 2 IN 3 S4 TELESCOPE OUT H-38 TELESCOPE IN VALVE H-39 TELESCOPE OUT VALVE 6 SUPPR A 7 0A 8 9 4H-4 4 PLATFORM LEVEL UP VALVE PLATFORM LEVEL DOWN VALVE 40 4H A 2H-36A 36A D PLATFORM ROT. ENABLE VALVE RED/PURPLE POSITION 8-A LT RT PLATFORM ROT. LEFT VALVE S6 PLATFORM ROTATE LT 0A 4H S PLATFORM ROTATE RT 4H-37 PLATFORM ROT. RIGHT VALVE A 36A D WHITE/RED/BLACK POSITION 9-A H-34A 34A 34A D ORANGE/WHITE JIB ENABLE VALVE UP 08 UP 34 0A POSITION 7-A 4H DN S2 JIB UP/DOWN JIB UP VALVE 33 DN 4H A 34A D ORANGE/BLACK POSITION 6-A S T U V W X Y A BOOM/TURRET JOYSTICK A3 28A RISER JOYSTICK A2 DRIVE/STEER JOYSTICK BLUE/WHITE/YELLOW POSITION 23-B 28A 28 28A BLACK/YELLOW 28A POSITION 22-B 4 28A 28A SUPPR. N.C. HELD OPEN WITH ENGINE OVER STEERING AXLE DA 7 BLUE/GREEN 7 POSITION 6-B 25 Gnd GREEN POSITION 7-B POSITION 0-A BLUE/BLACK 24A 24A 4 SUPPR. Gnd Vbat 30 R Output SUPPR. BLACK/WHITE POSITION 9-A 23A 23A 2 3 UP 0A S25 RISER DRIVE Vbat Gnd 30 DN 0B 27 D Output 4H RED/WHITE 3 POSITION 3-A RED/GREEN 30 POSITION 2-A RISER UP VALVE Left 4H RISER DOWN VALVE Right 0B 0A R=6 ohm GREEN/BLACK POSITION 4-A GREEN/WHITE POSITION 5-A UP 0A S2 BOOM LIFT DN 0B 4 BLACK 3 POSITION 7-A ORANGE POSITION 6-A 0A SUPPR. ORANGE/RED POSITION 8-B IN 08 S8 TELESCOPE RET/EXT BLACK/RED POSITION 9-B OUT S5 PLATFORM LEVELING UP 4 SUPPR. DN UP 4 4 BLUE/PURPLE 4 08 POSITION -B BLUE/RED 40 DN POSITION 0-B A S9 PLATFORM LEVELING SUPPR. SUPPR. SUPPR. SUPPR. S7 JIB UP/DOWN SUPPR. JIB DOWN VALVE 2H-85- CB5 50 AMP OPTIONAL 2KW GENERATOR VALVE 85 ORANGE WHITE 3Ø RED WHITE RED RED F 40 2H OPTIONAL 2KW GENERATOR VALVE 4 42 GREEN BLACK BLACK BLACK GREEN GREEN GREEN D85 WHITE 0A 43 0C CB4 5 AMP 0B 44 HYDRAULIC 2KW GENERATOR MALE AND FEMALE PLUGS ARE CONNECTED NOTE: WITH WELDER GENERATOR OPTION F 45 WELDER OPTION V PLATFORM POWER 0A 0A WHITE 0A 0B 0B BLACK 0B M GND GREEN GND OPTIONAL 3.5KW GENERATOR HYDRAULIC 3.5KW GENERATOR OPTION 0A 08 08F 0C CB6 5 AMP 0B F NOTE: WITH HYDRAULIC GENERATOR OPTION MALE AND FEMALE PLUGS ARE CONNECTED 08FCR Z M79AC SKYJACK, Page 98

99 A B C D E 3.49 Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D Diesel Engine) F G H I J K L M N O R S9 IGNITION S3 S2 KEY SWITCH BASE/OFF/PLATFORM S4 EMERGENCY STOP 57 START EMERGENCY STOP RUN 03 CB 5 AMP ENGINE OFF BATTERY 0 0 EMERGENCY PUMP 08 0ACR 0 0 S6 E-PUMP SWITCH A STARTER M A 57A B 08CR ALTERNATOR 8 A 9 2 S23 HORN SWITCH COLD START RELAY GLOW PLUGS (3) A 23 H HORN A TT TT HOURMETER 29 OVERLOAD A CR B M A CB3 5 AMP 03 S5 IGNITION /E-PUMP SWITCH 0 E-PUMP 03A 0 START 57A 77 FS LOW FUEL SWITCH BP TILT ALARM 4 54A S0 THROTTLE SWITCH JMPR LS2 BOOM DN LS LS3 FLY IN LS BOOM TURRET LIMIT SWITCHES 29A N/C YELLOW/BLUE 59 POSITION 5-B 56 45CR YELLOW/ORANGE POSITION -A 3H B L K A S DISCONNECT SWITCH 00 07A 05 PL CB2 5 AMP 07A RED 07A POSITION 2-A 07A RED 07A RT POSITION 3-A CTR LEFT 0 A RED/YELLOW/BLACK POSITION 5-A BLUE/WHITE POSITION 4-A 2 0 PL4 08CR 03B 03 0A PURPLE/BLACK POSITION -A 0 08 OPTIONAL OIL COOLER M CB4 86CR 03B 86A TSW 86 A CR 57BCR 2 54 D0A 03 0A ENABLE 57B X23-ENGINE CONNECTOR 00B 0 PS ENGINE OIL PR. 57ACR 07CR 00B 00B 00A 57A BROWN/GREEN POSITION 4-B 4 57B 54A GEN. OPTION 03 57ACR D0 0 FU 60 50A 60CR 49CR A 49 54ACR D WHITE/BLUE 60 POSITION 6-B B 54A GREEN/RED POSITION 2-B HORN TO ECU D5., PIN 3 WHITE POSITION -B PL5 HOURMETER ENGINE CONTROLLER ECU 77 R5=5 ohm 54A CONNECTOR D5.2 (LOCATED ON ECU R.H.S.) WHITE POSITION 2-B 08 27A FOOTSWITCH D27 TILT 00A 6 ANTI-RESTART 76 BROWN/BLUE 76 POSITION 8-B 55 YELLOW/PURPLE 55 POSITION 3-B 74 GREEN/GRAY 74 POSITION 7-B 76 D76 ENGINE FAULT 55 LOW FUEL 74 D74 DIAGNOSTIC CONNECTOR GLOW PLUG X22 DIAG PORT 27A 54A 76 R7=680 ohm 54A 54A PL 76 54A 27 ENGINE FAULT PL2 AIR S.O. PL40 403A GLOW PLUG DIAGNOSE SWITCH S A 03 D0A- 403ACR RPM 78 RED/BLUE 78 POSITION 9-B 650 RPM 79 BROWN/PURPLE 79 POSITION -B D08 LOW IDLE RELAY N=650 RPM HIGH IDLE RELAY N=00 RPM 79CR 650RPM 78 78CR 00RPM 77CR B B B D2 KEY TELEMATICS OPTION D7A LS2 RISER DN LS D59 TELEMATICS OPTION N/C 29 N/C S48 DRIVE TORQUE SWITCH MOTOR 2-SPEED VALVE (COIL ON = HIGH SPEED) LOW TORQUE 45A 45A SUPPR S FOOT D85A- SWITCH 08A 6 SUPPR. 62 2H-2A A DUMP VALVE 63 2A D0A JMPR2 DUMP VALVE RELAY 2CR 2 JMPR3 64 ORANGE/BLUE POSITION 8-A WITH OPTIONAL GENERATOR REMOVE JMPR2 65 S22 66 ELECTRICAL GENERATOR 2H-85 A 85A OPTIONAL STROBE LIGHT 69 LB2 70 S28 DIFF LOCK SWITCH 65 26B D08- ALL MOTION ALARM 7 BP2 LOCK OFF 65 LOCK ON 65 PINK/BLACK 65 POSITION 24-A A 65 D26A 72 3H CR DIFFERENTIAL LOCK (COIL ON = LOCKED) 26A 73 SUPPR. 74 PL SCM-VALVE DRIVER 08A F FORWARD DRIVE VALVE REVERSE DRIVE VALVE H-6 3H H-26 BRAKE VALVE WHITE/BLACK 6 POSITION 5-B 5 BLUE 5 POSITION 4-B 26 BLUE/YELLOW 26 POSITION -A LS 87 SENSING DIRECTION B BOOM/TUR Vbat Xaxis Yaxis X Y H-24A LEFT STEER VALVE 24A 24A 24 RISER 4H-23A RIGHT STEER VALVE 23A 23A S3 TURRET ROTATE LT 03 RT 4H-32 TURRET ROTATE LEFT VALVE TURRET ROTATE RIGHT VALVE H BOOM UP VALVE BOOM DOWN VALVE 4H H A 33 2 IN 3 S4 TELESCOPE OUT H-38 TELESCOPE IN VALVE H-39 TELESCOPE OUT VALVE 6 SUPPR A 7 0A 8 9 4H-4 4 PLATFORM LEVEL UP VALVE PLATFORM LEVEL DOWN VALVE 40 4H A 2H-36A D36 PLATFORM ROT. ENABLE VALVE A RED/PURPLE POSITION 8-A LT 08 PLATFORM ROT. LEFT VALVE LT 0A 4H RT S PLATFORM ROTATE PLATFORM ROT. RIGHT VALVE S6 PLATFORM ROTATE RT 4H-37 A 36A D WHITE/RED/BLACK POSITION 9-A JIB ENABLE VALVE H-34A 34A 34A D ORANGE/WHITE UP JIB UP VALVE UP 0A POSITION 7-A 4H DN S2 JIB UP/DOWN 33 DN 4H A 34A D ORANGE/BLACK POSITION 6-A 34 46AJ ONLY V PLATFORM POWER 0A WHITE 0A 0A 49 0B 0B BLACK 0B OPTIONAL 3.5KW GENERATOR HYDRAULIC 3.5KW GENERATOR OPTION 0A 0C CB6 5 AMP 0B NOTE: WITH HYDRAULIC GENERATOR OPTION MALE AND FEMALE PLUGS ARE CONNECTED S T U V W X Y A BOOM/TURRET JOYSTICK A3 RISER JOYSTICK A2 DRIVE/STEER JOYSTICK - AD 03 CB40 A 403 S40 POSITIVE AIR SHUT OFF SWITCH REV CONTROLLER SHUT OFF 403A SOLENOID + SUPPR. 08 OPTIONAL 3.5 KW GENERATOR VALVE GRAY/BLUE POSITION 2-B 3H AXLE LOCK VALVE 78 (COIL ON = FLOATING AXLE) SUPPR YELLOW/PINK POSITION 2-A 26A CR2 45 AT ANGLE TRANSDUCER & TILT SWITCH 28A 28A BLUE/WHITE/YELLOW POSITION 23-B 28 28A BLACK/YELLOW 28A POSITION 22-B 4 28A 28A R4=30 ohm R3=30 ohm SUPPR. N.C. HELD OPEN WITH ENGINE OVER STEERING AXLE RESISTORS MAY NOT BE PRESENT DB 7 BLUE/GREEN 7 POSITION 6-B 25 Gnd GREEN POSITION 7-B POSITION 0-A BLUE/BLACK 24A 24A 4 SUPPR. Gnd Vbat 30 R Output SUPPR. BLACK/WHITE POSITION 9-A 23A 23A 2 3 UP 0A S25 RISER DRIVE Vbat Gnd 30 DN C 27 D Output 4H RED/WHITE POSITION 3-A RISER UP VALVE Left 4H RED/GREEN 30 POSITION 2-A RISER DOWN VALVE Right C 0A R=6 ohm GREEN/BLACK POSITION 4-A GREEN/WHITE POSITION 5-A UP 0A S2 BOOM LIFT DN C 4 BLACK 3 POSITION 7-A ORANGE POSITION 6-A 0A SUPPR. ORANGE/RED POSITION 8-B IN 08 S8 TELESCOPE RET/EXT BLACK/RED POSITION 9-B OUT S5 PLATFORM LEVELING UP 4 SUPPR. DN 40 4 UP 4 4 BLUE/PURPLE 4 08 POSITION -B BLUE/RED 40 DN POSITION 0-B A S9 40 PLATFORM LEVELING SUPPR. SUPPR. SUPPR. SUPPR. SUPPR. JIB DOWN VALVE S7 JIB UP/DOWN OPTIONAL 2KW GENERATOR VALVE 2H-85- CB5 50 AMP 85 ORANGE WHITE 3Ø RED WHITE RED RED 40 4 F 2H OPTIONAL 2KW GENERATOR VALVE GREEN BLACK BLACK BLACK GREEN GREEN GREEN 42 D85 WHITE 0A HYDRAULIC 2KW GENERATOR 0C CB4 5 AMP MALE AND FEMALE PLUGS ARE CONNECTED NOTE: WITH WELDER GENERATOR OPTION 0B F WELDER OPTION 403A U n SPEED SENSOR POSITIVE AIR SHUT OFF OPTION POSITIVE AIR SHUT OFF VALVE OPTION 403A M GND GREEN GND F 08F 08FCR Z M69634AF SKYJACK, Page 99

100 A B C D E 3.50 Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine) F G H I J K L M N O R IGNITION S3 OPTIONAL STROBE LIGHT DIFFERENTIAL LOCK (COIL ON = LOCKED) S2 KEY SWITCH BASE/OFF/PLATFORM S4 EMERGENCY STOP 57 START TURRET ROTATE LEFT VALVE TURRET ROTATE RIGHT VALVE BOOM UP VALVE EMERGENCY STOP RUN DUMP VALVE DUMP VALVE RELAY ALL MOTION ALARM BRAKE VALVE 05 CB 5 AMP ENGINE OFF LEFT 0ACR S6 E-PUMP SWITCH 0 LEFT STEER VALVE A 57A 57A RIGHT STEER VALVE 57 BOOM DOWN VALVE PLATFORM LEVEL UP VALVE PLATFORM LEVEL DOWN VALVE 08CR S23 HORN SWITCH PLATFORM ROT. ENABLE VALVE PLATFORM ROT. LEFT VALVE PLATFORM ROT. RIGHT VALVE JIB ENABLE VALVE 49CR JIB UP VALVE OPTIONAL 3.5KW GENERATOR A H HORN 07 49A OVERLOAD BOOM TURRET LIMIT SWITCHES 27A FORWARD DRIVE VALVE REVERSE DRIVE VALVE 27CR S0 BATTERY THROTTLE SWITCH EMERGENCY PUMP STARTER B M S5 IGNITION/E-PUMP SWITCH 0 E-PUMP 0 START 57A BP TILT ALARM LS2 BOOM DN LS LS3 FLY IN LS 29A N/C YELLOW/BLUE 59 POSITION 5-B 56 45CR YELLOW/ORANGE POSITION -A 3H LOW TORQUE 45A 45A S FOOT SWITCH 08A 6 TELESCOPE IN VALVE 62 TELESCOPE OUT VALVE S DISCONNECT SWITCH 00 B+ RT 07A A 05 PL CB2 5 AMP 0 07A RED 07A POSITION 2-A 07A RED 07A POSITION 3-A 2 RED/YELLOW/BLACK 2 POSITION 5-A 0 BLUE/WHITE 0 POSITION 4-A 0 00 PL4 08CR CB3 5A 03 0A PURPLE/BLACK POSITION -A D0A CB4 M 86CR 03B 86A A 77CR TSW A ENABLE BROWN/GREEN POSITION 4-B TO ENGINE GROUND TO ENGINE STARTER POST D0 D B WHITE/BLUE 60 POSITION 6-B TO ECU TO ECU 60CR SEE ENGINE DETAIL ON SHEET 2 GREEN/RED POSITION 2-B WHITE POSITION 2-B DIAGNOSE WHITE POSITION -B SWITCH S8 PL A 56B FOOTSWITCH 56 FS LOW FUEL SWITCH 08 27A D27 TILT 56ACR 56A 76 BROWN/BLUE 76 POSITION 8-B 55 YELLOW/PURPLE 55 POSITION 3-B 74 GREEN/GRAY 74 POSITION 7-B 76 D76 54 ENGINE FAULT LOW FUEL 55 LOW FUEL 74 D74 GLOW PLUG 3 57A X22 DIAGNOSTIC 27A PREHEAT PL RPM 78 RED/BLUE 78 POSITION 9-B 750 RPM 79 BROWN/PURPLE 79 POSITION -B D08 LS2 RISER DN LS D59 N/C 29 N/C S48 DRIVE TORQUE SWITCH SUPPR. D85A- SUPPR. 2H-2A A 63 2A D0A JMPR2 2CR JMPR3 ORANGE/BLUE POSITION 8-A WITH OPTIONAL GENERATOR REMOVE JMPR2 66 S22 67 SUPPR. AH ELECTRICAL GENERATOR 68 2H-85 A 85A 85A GRAY/BLUE POSITION 2-B 70 7 LB2 S28 DIFF LOCK SWITCH 65 26B D08-72 BP2 LOCK OFF 65 LOCK ON 65 PINK/BLACK 65 POSITION 24-A A 65 D26A 73 3H CR 26A SUPPR PL SCM-VALVE DRIVER H YELLOW/PINK POSITION 2-A 26A 9 SUPPR CR A F 82 AT ANGLE TRANSDUCER & TILT SWITCH 26 28A 83 28A BLUE/WHITE/YELLOW POSITION 23-B H-6 3H H WHITE/BLACK 6 POSITION 5-B 5 BLUE 5 POSITION 4-B 26 BLUE/YELLOW 26 POSITION -A LS SENSING DIRECTION A BOOM/TUR Vbat Xaxis Yaxis X Y H-24A 24A 24A 24 RISER 4H-23A 23A 23A S3 TURRET ROTATE LT RT 4H H H H A 33 4 S4 TELESCOPE IN 5 OUT H-38 3H A 9 0A 2 4H H A 2H-36A 36A D RED/PURPLE POSITION 8-A LT LT 0A 4H RT S PLATFORM ROTATE 28 S6 PLATFORM ROTATE RT 4H-37 A 36A D WHITE/RED/BLACK POSITION 9-A H-34A 34A 34A D ORANGE/WHITE UP UP 34 0A POSITION 7-A 4H-35 DN S2 JIB UP/DOWN 34 DN 35 4H-34 A 36 34A D ORANGE/BLACK POSITION 6-A 34 46AJ ONLY CB5 50 AMP 2H-85- WHITE WHITE ORANGE A 0A WHITE 0A 0B 0B BLACK 0B HYDRAULIC 3.5KW GENERATOR OPTION 0A 0C CB6 5 AMP 0B NOTE: WITH HYDRAULIC GENERATOR OPTION MALE AND FEMALE PLUGS ARE CONNECTED S T U V W X Y A BOOM/TURRET JOYSTICK A3 RISER JOYSTICK A2 DRIVE/STEER JOYSTICK OPTIONAL OIL COOLER FUEL PUMP RELAY DIAGNOSTIC CONNECTOR LOW IDLE RELAY N=750 RPM HIGH IDLE RELAY N=00 RPM HOURMETER MOTOR 2-SPEED VALVE (COIL ON = HIGH SPEED) OPTIONAL 3.5 KW GENERATOR VALVE AXLE LOCK VALVE (COIL ON = FLOATING AXLE) RISER UP VALVE RISER DOWN VALVE JIB DOWN VALVE OPTIONAL 2KW GENERATOR VALVE OPTIONAL 2KW GENERATOR VALVE 0V PLATFORM POWER - - B AD 03B 03B PREHEAT/GLOW PLUG INDICATOR GEN. OPTION WATER IN FUEL INDICATOR TELEMATICS OPTION OPTIONAL LOAD CIRCUIT VALVE 57ACR Refer to 3.53 Interface & Engine Electrical Schematic - Deutz D2.9L Engine 55 PL4 + + R3= ohm 05 PORT A G H 76ACR 76B 76B 76A MIL PL3 + 76A JMPR D0A- 79CR 750 RPM R6= 3.9k ohm R4= 2.2k ohm 99B 90 W.I.F. PL8 78CR 00 RPM A H.M. TT + D 08 R5= 2.k ohm 90 99A CR 03B 77 D - B KEY B BLACK/YELLOW 28A POSITION 22-B 4 28A 28A SUPPR. N.C. HELD OPEN WITH ENGINE OVER STEERING AXLE DA 7 BLUE/GREEN 7 POSITION 6-B 25 Gnd GREEN POSITION 7-B POSITION 0-A BLUE/BLACK 24A 24A 4 SUPPR. Gnd Vbat 30 R Output SUPPR. BLACK/WHITE POSITION 9-A 23A 23A 2 3 UP 0A S25 RISER DRIVE Vbat Gnd 30 TELEMATICS OPTION DN C 27 D D7A D2 Output 4H RED/WHITE POSITION 3-A Left 4H RED/GREEN 30 POSITION 2-A H-2B Right C 0A R=6 ohm GREEN/BLACK POSITION 4-A GREEN/WHITE POSITION 5-A UP 0A S2 BOOM LIFT DN C 4 BLACK 3 POSITION 7-A ORANGE POSITION 6-A 0A SUPPR. ORANGE/RED POSITION 8-B IN 08 S8 TELESCOPE RET/EXT BLACK/RED POSITION 9-B OUT SUPPR. S5 PLATFORM LEVELING 2B D2 D85- UP 4 SUPPR. D57A SUPPR. R7=250 ohm DN B 40 UP 4 4 BLUE/PURPLE 4 08 POSITION -B BLUE/RED 40 DN POSITION 0-B A S9 PLATFORM LEVELING SUPPR. SUPPR. SUPPR. SUPPR. SUPPR. S7 JIB UP/DOWN 3Ø 4 2H RED RED RED F BLACK BLACK BLACK GREEN 43 D85 44 GREEN GREEN GREEN 0A WHITE 45 HYDRAULIC 2KW GENERATOR 0C CB4 5 AMP 28A MALE AND FEMALE PLUGS ARE CONNECTED NOTE: WITH WELDER GENERATOR OPTION 0B F WELDER OPTION M GND GREEN GND 08F 08FCR F Z M69636AH SKYJACK, Page 00

101 A B C D E 3.5 Electrical Schematic Diagram (46AJ & 5AJ CE - Deutz D Diesel Engine) F G H I J K L M N O R S9 IGNITION S3 57 START EMERGENCY STOP S2 KEY SWITCH BASE/OFF/PLATFORM S4 EMERGENCY STOP RUN CB 5 AMP BATTERY ENGINE OFF 0 0 EMERGENCY PUMP 08 0ACR 0 B 0 0 S6 E-PUMP SWITCH M A CB3 5 AMP 03 S5 IGNITION/E-PUMP SWITCH 62A 0 E-PUMP 03A A STARTER M 0 4 START A 57A 57A B 08CR ALTERNATOR 8 A S23 HORN SWITCH COLD START RELAY GLOW PLUGS (3) A 23 H HORN A OVERLOAD 3 FS LOW FUEL SWITCH B BP TILT ALARM 36 27A A CR S0 THROTTLE SWITCH 45CR 45 YELLOW/ORANGE POSITION -A 3H LOW TORQUE 45A 45A SUPPR. WITH OPTIONAL GENERATOR REMOVE JMPR2 S28 DIFF LOCK SWITCH 65 LOCK OFF 65 LOCK ON 65 PINK/BLACK 65 POSITION 24-A A 65 3H CR DIFFERENTIAL LOCK (COIL ON = LOCKED) 26C SUPPR. PL S3 TURRET ROTATE LT RT A 33 A PLATFORM ROT. ENABLE VALVE 36A 2H-36A 36A D RED/PURPLE POSITION 8-A LT 26C 37 PLATFORM ROT. LEFT VALVE LT 0A 4H-36 RT S PLATFORM ROTATE PLATFORM ROT. RIGHT VALVE S6 PLATFORM ROTATE RT 4H-37 A 36A D WHITE/RED/BLACK POSITION 9-A 37 2H-34A 34A 34A D ORANGE/WHITE UP 26C 34 JIB ENABLE VALVE UP 0A POSITION 7-A 4H-35 DN S2 JIB UP/DOWN DN JIB UP VALVE 4H-34 A 34A D ORANGE/BLACK POSITION 6-A 34 0A WHITE 0A 0B BLACK 0B S T U V W X Y L AD CI CHARGE INDICATOR V S DISCONNECT SWITCH 00 07A A 05 CB2 5 AMP PL A RED 07A POSITION 2-A 07A RED 07A 07A RT POSITION 3-A CTR LEFT CR 03 RED/YELLOW/BLACK POSITION 5-A BLUE/WHITE POSITION 4-A PL4 D07A 0A PURPLE/BLACK POSITION -A 0 08 M CB4 86CR 03B 86A TSW 86 A D2 OPTIONAL OIL COOLER CR 57BCR 2A 54A D0A 03 0A ENABLE 57B X23-ENGINE CONNECTOR 00B 0 PS ENGINE OIL PR. 57ACR 07CR 00B 00B 00A 57A BROWN/GREEN POSITION 4-B 4 GEN. OPTION 57B 54A 03 57ACR FU 60 50A 60CR 49CR A 49 54ACR D0 D JMPR BOOM TURRET LIMIT SWITCHES YELLOW/BLUE 59 POSITION 5-B S FOOT SWITCH 08A H-2A A DUMP VALVE 63 2A DUMP VALVE RELAY 64 2CR 2 65 S22 66 ELECTRICAL GENERATOR 2H-85 OPTIONAL GENERATOR VALVE WHITE/BLUE 60 POSITION 6-B B 54A GREEN/RED POSITION 2-B HORN TO ECU D5., PIN 3 A 85A OPTIONAL STROBE LIGHT 69 LB2 70 OPTIONAL ALL MOTION ALARM WHITE POSITION -B PL5 08 HOURMETER ENGINE CONTROLLER ECU 77 R5=5 ohm 54A CONNECTOR D5.2 (LOCATED ON ECU R.H.S.) WHITE POSITION 2-B FOOTSWITCH 27A D27 TILT 00A 6 B ANTI-RESTART 76 BROWN/BLUE 76 POSITION 8-B 55 YELLOW/PURPLE 55 POSITION 3-B 74 GREEN/GRAY 74 POSITION 7-B 76 D76 ENGINE FAULT 55 LOW FUEL 74 D74 DIAGNOSTIC CONNECTOR GLOW PLUG X22 DIAG PORT K 27A 60 54A A 76 R7=680 ohm 54A 54A PL 76 54A 27 ENGINE FAULT 82 PL2 GLOW PLUG CR DIAGNOSE BP3 OVERLOAD ALARM D8 8 SWITCH S8 PLATFORM LOAD SENSOR JMPR4 LOW IDLE RELAY N=650 RPM 79CR 650RPM PINK/WHITE 6 POSITION 22-A HIGH IDLE RELAY N=00 RPM 78CR 00RPM 62 PINK/PURPLE 62 POSITION 23-A D0A- 00 RPM 78 RED/BLUE 78 POSITION 9-B 650 RPM 79 BROWN/PURPLE 79 POSITION -B D08 62 LOAD SENSOR RESISTOR R6=680 ohm LS2 RISER DN LS LS2 BOOM DN LS LS3 FLY IN LS JMPR3 7 BP FORWARD DRIVE VALVE H-6 3H-5 REVERSE DRIVE VALVE H-26 BRAKE VALVE WHITE/BLACK 6 POSITION 5-B 5 BLUE 5 POSITION 4-B 26 BLUE/YELLOW 26 POSITION -A LS 87 SENSING DIRECTION 90 4H-24A LEFT STEER VALVE 24A 24A H-23A RIGHT STEER VALVE 23A 23A TURRET ROTATE LEFT VALVE 03 4H TURRET ROTATE RIGHT VALVE 4H BOOM UP VALVE 4H BOOM DOWN VALVE 4H IN 3 S4 TELESCOPE OUT 38 3H-38 4 TELESCOPE IN VALVE H-39 TELESCOPE OUT VALVE SUPPR A 8 9 4H-4 4 PLATFORM LEVEL UP VALVE 40 4H-40 PLATFORM LEVEL DN VALVE 2 22 OPTIONAL GENERATOR HYDRAULIC GENERATOR OPTION 0A 0A 0C CB6 5 AMP 0B 0B NOTE: WITH HYDRAULIC GENERATOR OPTION MALE AND FEMALE PLUGS ARE CONNECTED 26C SUPPR N/C N/C 29 29A N/C 59 S48 DRIVE TORQUE SWITCH MOTOR 2-SPEED VALVE (COIL ON = HIGH SPEED) D85A CR 59 62A SUPPR. D0A-2 62A D0A JMPR2 62A D62 62A SCM-VALVE DRIVER 08A F 26 C C 34 6 C X BOOM/TUR Vbat Xaxis B Y Yaxis RISER A BOOM/TURRET JOYSTICK A3 RISER JOYSTICK A2 DRIVE/STEER JOYSTICK ORANGE/BLUE POSITION 8-A SUPPR. D62-2 D59 GRAY/BLUE POSITION 2-B 0B 0A 62BCR H AXLE LOCK VALVE SUPPR. 78 (COIL ON = FLOATING AXLE) N.C. HELD OPEN WITH ENGINE OVER STEERING AXLE 7 BLUE/GREEN 7 POSITION 6-B 25 Gnd POSITION 0-A BLUE/BLACK 24A 24A 4 SUPPR. Gnd Vbat 30 R Output SUPPR. BLACK/WHITE POSITION 9-A 23A 23A 2 3 UP 0A S25 RISER 30 DN C 4H RED/WHITE 3 POSITION 3-A RED/GREEN 30 POSITION 2-A RISER UP VALVE 4H RISER DOWN VALVE C 0A DRIVE Vbat Gnd 62A D Output R=6 ohm GREEN/BLACK POSITION 4-A GREEN/WHITE POSITION 5-A 62B YELLOW/PINK POSITION 2-A CR2 08F 45 AT ANGLE TRANSDUCER & TILT SWITCH 28A BLUE/WHITE/YELLOW POSITION 23-B 28A 28 28A BLACK/YELLOW 28A POSITION 22-B 4 28A 28A SUPPR. DB GREEN POSITION 7-B A BLUE/WHITE/BLACK POSITION 24-B 62A Left Right UP 0A S2 BOOM LIFT DN C 4 BLACK 3 POSITION 7-A ORANGE POSITION 6-A 0A SUPPR. S8 TELESCOPE RET/EXT ORANGE/RED POSITION 8-B IN 26C BLACK/RED POSITION 9-B OUT 26C S5 PLATFORM LEVELING UP 4 SUPPR. DN BLUE/PURPLE POSITION -B 4 4 UP 26A SUPPR. BLUE/RED POSITION 0-B S9 PLATFORM LEVELING DN C 26A SUPPR. SUPPR. 26C SUPPR. SUPPR. S7 JIB UP/DOWN 26C JIB DOWN VALVE V PLATFORM POWER 42 M F 43 GND GREEN GND 44 26ACR FCR 62A 05 TT HOURMETER C COUNTER TT C H- C- RC- 77 0B F DC driving=open stopped=closed 62ACR 9 26A Z M70600AB SKYJACK, Page 0

102 A B C D E 3.52 Electrical Schematic Diagram (46AJ & 5AJ AS - Deutz D Diesel Engine) F G H I J K L M N O R S9 IGNITION S3 57 START EMERGENCY STOP S2 KEY SWITCH BASE/OFF/PLATFORM S4 EMERGENCY STOP RUN CB 5 AMP BATTERY ENGINE OFF 0 0 EMERGENCY PUMP 08 0ACR 0 0 S6 E-PUMP SWITCH 0 2 B 0 3 A M STARTER M 4 03A CB3 5 AMP 03 S5 IGNITION/E-PUMP SWITCH 0 E-PUMP 03A 0 START A 57A 57A B 08CR ALTERNATOR 8 A S23 HORN SWITCH COLD START RELAY GLOW PLUGS (3) A 23 H HORN A TT TT HOURMETER OVERLOAD 3 FS LOW FUEL SWITCH B BP TILT ALARM 36 27A A CR S0 THROTTLE SWITCH 45CR 45 YELLOW/ORANGE POSITION -A 3H LOW TORQUE 45A 45A SUPPR. WITH OPTIONAL GENERATOR REMOVE JMPR2 S28 DIFF LOCK SWITCH 65 26B D08- LOCK OFF 65 LOCK ON 65 PINK/BLACK 65 POSITION 24-A A 65 D26A 3H CR DIFFERENTIAL LOCK (COIL ON = LOCKED) 26A SUPPR. PL S3 TURRET ROTATE LT RT A 33 A PLATFORM ROT. ENABLE VALVE 36A 2H-36A 36A D RED/PURPLE POSITION 8-A LT 26C 37 PLATFORM ROT. LEFT VALVE LT 0A 4H-36 RT S PLATFORM ROTATE PLATFORM ROT. RIGHT VALVE S6 PLATFORM ROTATE RT 4H-37 A 36A D WHITE/RED/BLACK POSITION 9-A 37 2H-34A 34A 34A D ORANGE/WHITE UP 26C 34 JIB ENABLE VALVE UP 0A POSITION 7-A 4H-35 DN S2 JIB UP/DOWN DN JIB UP VALVE 4H-34 A 34A D ORANGE/BLACK POSITION 6-A 34 0A WHITE 0A 0B BLACK 0B S T U V W X Y L AD CI CHARGE INDICATOR V S DISCONNECT SWITCH 00 07A A 05 CB2 5 AMP PL A RED 07A POSITION 2-A 07A RED 07A 07A RT POSITION 3-A CTR LEFT CR JMPR A BOOM/TURRET JOYSTICK 5 A3 RISER JOYSTICK 03 RED/YELLOW/BLACK POSITION 5-A BLUE/WHITE POSITION 4-A PL4 D07A 0A PURPLE/BLACK POSITION -A 0 08 M CB4 86CR 03B 86A TSW 86 A D2 OPTIONAL OIL COOLER CR 57BCR 2A 54A D0A 03 0A ENABLE 57B X23-ENGINE CONNECTOR 00B 0 PS ENGINE OIL PR. 57ACR 07CR 00B 00B 00A 57A BROWN/GREEN POSITION 4-B 4 GEN. OPTION 57B 54A 03 57ACR FU 60 50A 60CR 49CR A 49 54ACR D0 D WHITE/BLUE 60 POSITION 6-B B 54A GREEN/RED POSITION 2-B HORN TO ECU D5., PIN 3 WHITE POSITION -B PL5 08 HOURMETER ENGINE CONTROLLER ECU 77 R5=5 ohm 54A CONNECTOR D5.2 (LOCATED ON ECU R.H.S.) WHITE POSITION 2-B FOOTSWITCH 27A D27 TILT 00A 6 B ANTI-RESTART 76 BROWN/BLUE 76 POSITION 8-B 55 YELLOW/PURPLE 55 POSITION 3-B 74 GREEN/GRAY 74 POSITION 7-B 76 D76 ENGINE FAULT 55 LOW FUEL 74 D74 DIAGNOSTIC CONNECTOR GLOW PLUG X22 DIAG PORT K 27A 60 54A A 76 R7=680 ohm 54A 54A PL 76 54A 27 ENGINE FAULT 82 PL2 GLOW PLUG CR DIAGNOSE BP3 OVERLOAD ALARM D8 8 SWITCH S8 PLATFORM LOAD SENSOR JMPR4 LOW IDLE RELAY N=650 RPM 79CR 650RPM PINK/WHITE 6 POSITION 22-A HIGH IDLE RELAY N=00 RPM 78CR 00RPM 62 PINK/PURPLE 62 POSITION 23-A D0A RPM 78 RED/BLUE 78 POSITION 9-B 650 RPM 79 BROWN/PURPLE 79 POSITION -B D08 62 LOAD SENSOR RESISTOR 53 R6=680 ohm 54 LS2 RISER DN LS LS2 BOOM DN LS LS3 FLY IN LS D59 N/C N/C 29 BOOM TURRET LIMIT SWITCHES YELLOW/BLUE 59 POSITION 5-B S FOOT SWITCH 08A H-2A A DUMP VALVE 63 2A DUMP VALVE RELAY 64 2CR 2 JMPR3 65 S22 66 ELECTRICAL GENERATOR 2H-85 OPTIONAL GENERATOR VALVE A 85A OPTIONAL STROBE LIGHT 69 LB2 70 OPTIONAL ALL MOTION ALARM 7 BP FORWARD DRIVE VALVE H-6 3H-5 REVERSE DRIVE VALVE H-26 BRAKE VALVE WHITE/BLACK 6 POSITION 5-B 5 BLUE 5 POSITION 4-B 26 BLUE/YELLOW 26 POSITION -A LS 87 SENSING DIRECTION 90 4H-24A LEFT STEER VALVE 24A 24A H-23A RIGHT STEER VALVE 23A 23A TURRET ROTATE LEFT VALVE 03 4H TURRET ROTATE RIGHT VALVE 4H BOOM UP VALVE 4H BOOM DOWN VALVE 4H IN 3 S4 TELESCOPE OUT 38 3H-38 4 TELESCOPE IN VALVE H-39 TELESCOPE OUT VALVE SUPPR A 8 9 4H-4 4 PLATFORM LEVEL UP VALVE 40 4H-40 PLATFORM LEVEL DN VALVE 2 22 OPTIONAL GENERATOR HYDRAULIC GENERATOR OPTION 0A 0A 0C CB6 5 AMP 0B 0B NOTE: WITH HYDRAULIC GENERATOR OPTION MALE AND FEMALE PLUGS ARE CONNECTED 08 29A N/C 59 S48 DRIVE TORQUE SWITCH MOTOR 2-SPEED VALVE (COIL ON = HIGH SPEED) D85A CR 62A SUPPR. D0A-2 62A SCM-VALVE DRIVER 08A F C X BOOM/TUR Vbat Xaxis B Y Yaxis RISER D0A A2 DRIVE/STEER JOYSTICK JMPR2 62A ORANGE/BLUE POSITION 8-A GRAY/BLUE POSITION 2-B 3H AXLE LOCK VALVE 78 (COIL ON = FLOATING AXLE) SUPPR. 27 N.C. HELD OPEN WITH ENGINE OVER STEERING AXLE 7 BLUE/GREEN 7 POSITION 6-B 25 Gnd POSITION 0-A BLUE/BLACK 24A 24A 4 SUPPR. Gnd Vbat 30 R Output SUPPR. BLACK/WHITE POSITION 9-A 23A 23A 2 3 UP 0A S25 RISER DRIVE Vbat Gnd 62A 30 DN C 27 D Output 4H RED/WHITE 3 POSITION 3-A RED/GREEN 30 POSITION 2-A RISER UP VALVE Left 4H RISER DOWN VALVE Right C 0A R=6 ohm GREEN/BLACK POSITION 4-A GREEN/WHITE POSITION 5-A UP 0A S2 BOOM LIFT DN C 4 BLACK 3 POSITION 7-A ORANGE POSITION 6-A 0A S8 TELESCOPE RET/EXT ORANGE/RED POSITION 8-B IN BLACK/RED POSITION 9-B OUT 26A YELLOW/PINK POSITION 2-A 26C S5 PLATFORM LEVELING 26C D62 62A SUPPR. 26A CR2 08F 45 08FCR AT ANGLE TRANSDUCER & TILT SWITCH 28A BLUE/WHITE/YELLOW POSITION 23-B 28A C 28 28A BLACK/YELLOW 28A POSITION 22-B 4 28A 28A SUPPR. DB GREEN POSITION 7-B A BLUE/WHITE/BLACK POSITION 24-B 62A SUPPR. 26C UP 4 SUPPR. DN BLUE/PURPLE POSITION -B 4 4 UP 26C SUPPR. BLUE/RED POSITION 0-B S9 PLATFORM LEVELING DN A 26C SUPPR. SUPPR. 26C SUPPR. SUPPR. S7 JIB UP/DOWN 26C JIB DOWN VALVE V PLATFORM POWER 42 M F 43 GND GREEN GND 44 26ACR 08 C 62A C 62ACR Z M69638AB SKYJACK, Page

103 3.53 Interface & Engine Electrical Schematic - GM Dual Fuel Engine A B C D E F G H I J K L M N O ECU 650 RPM 00 RPM CAMSHAFT PRE-CAT POST-CAT SENSOR THROTTLE ACTUATOR GASOLINE PROPANE SWITCH SWITCH SWITCH RELAY SOLENOID LIGHT SOLENOID EL. MOTOR R ECU 8 (TAN/DK GREEN) AUX ANA PD 25 (RED/WHITE) SPEED + 26 (RED/BLACK) SPEED - 44 (TAN/BLACK) AUX DIG 3 43 (TAN/RED) AUX DIG 2 46 (DK BLUE/YELLOW) AUX ANA PU 47 (YELLOW/DK BLUE) AUX ANA PU 2 87 (TAN) AUX PWM 2 58 (GRAY) TACH 78 (WHITE/BROWN) PWM 5 RECIRC GOV 2 52 (GRAY/ORANGE) GOV 5 (GRAY/DK BLUE) PWM 5 77 (BROWN/WHITE) 69 (BLACK) GND TEMP 8 (BLACK) GND TEMP 22 (WHITE/PURPLE) CRANK - 2 (PURPLE/WHITE) CRANK + CAM+ 23 (GRAY/BROWN) CAM- 24 (PURPLE/ORANGE) 6 (BROWN/LT BLUE) INJ LS 63 (BROWN/YELLOW) INJ 3 LS 64 (BROWN/WHITE) INJ 4 LS 62 (BROWN/LT GREEN) INJ 2 LS 3 (YELLOW) SPK COIL A 72 (BLACK/WHITE) EGOH (DK GREEN/ORANGE) EGO 2 (DK GREEN/WHITE) EGO 2 73 (BLACK/YELLOW) EGOH 2 7 (WHITE/LT BLUE) RELAY 79 (RED/TAN) VBAT 60 (RED/TAN) VBAT 40 (TAN/WHITE) ECT 4 (WHITE/RED) EGT S T (TWIST WIRES 0 TURNS (360 DEG)/FOOT FULL LENGTH) 39 (YELLOW/GRAY) IAT 7 (LT GREEN) MAP 83 (TAN/ORANGE) DBW - GROUND TO BATTERY (PINK/DK GREEN) (RED) (RED/LT BLUE) 82 (PINK/WHITE) DBW + (WHITE) (RED) (PINK/YELLOW) 6 (LT BLUE/DK BLUE) TPS 2 (WHITE) 5 (PURPLE/LT BLUE) TPS 55 (DK GREEN) PC TX 56 (ORANGE) PC RX 48 (LT GREEN/WHITE) (FRT) AUX ANA PU 3 (RED/TAN) (RED) TO MAIN DISCONNECT U 54 (WHITE/LT GREEN) (FRP) AUX AND PUD 3 (WHITE/ORANGE) CAN TERM + 4 (BLUE/PINK) CAN + 5 (BLUE/WHITE) CAN - (BLACK/LT GREEN) 5V RTN V W 54A X FP GI- GI-4 GI-2 GI-3 IGC A B IGM D B A C OXS C D B A OXS2 A B C D TPS B A TPS2 B MS 2 S M G IG 9 (LT GREEN/RED) 5V EXT 49 (LT GREEN/PURPLE) 5V EXT 2 50 (LT GREEN/BLACK) 5V RTN 9 (DK BLUE/ORANGE) FPP 0 (PURPLE/YELLOW) FPP2/IVS 88 (DK BLUE) AUX PWM AUX PWM 3 86 (BLACK/RED) AUX PWM 3 RECIR 85 (PINK/YELLOW) 53 (LT BLUE) OIL PRES FPUMP 84 (TAN/BLACK) EGOH 4 75 (WHITE/BLACK) AUX DIG 42 (TAN/BROWN) MIL 80 (GREEN/YELLOW) (STARTER) AUX PWM4 89 (PINK/BLACK) VSW 45 (PINK/TAN) A RA GPS A B C D OPS 2P GM EFI DUAL FUEL ENGINE CPS A B CPS2 A B C (YELLOW) F0 FUSE 5A IGNITION CR F8 FUSE A ECM F9 PRV FUSE 0A EPR F FUSE 5A FUEL PUMP 56CR 57ACR F7 32BCR F2 FUSE 5A VSW STARTER FUSE 5A 69 F3 FUSE 60A ALTERNATOR R (TAN/DK GREEN) P (RED/BLACK) N (RED/WHITE) CONNECTOR 2 M (TAN/BLACK) L (TAN/RED) H (DK BLUE/YELLOW) G (YELLOW/DK BLUE) F (TAN) D (GRAY) B (WHITE/BROWN) 78 J (GRAY/ORANGE) 79 K (GRAY/DK BLUE) C (BROWN/WHITE) 00A E (BLACK) S (PINK/DK GREEN) A (UNUSED) (BLACK/LT GREEN) 2 (LT GREEN/RED) 3 (DK GREEN) DIAGNOSTIC 4 (ORANGE) 8 (BLUE/WHITE) 7 (BLUE/PINK) P (BLUE/WHITE) N (BLUE/PINK) L (BLACK/LT GREEN) CONNECTOR M (LT GREEN/RED) S (LT GREEN/PURPLE) R (LT GREEN/BLACK) K (DK BLUE/ORANGE) J (PURPLE/YELLOW) E (DK BLUE) C (BLACK/RED) D (PINK/YELLOW) H (TAN/BROWN) G (GREEN/YELLOW) 76 F (LT BLUE/PINK) 57A A (PINK) (PURPLE) B Y 00A 57A 76 54A Z M69635AC-2 SKYJACK, Page 03

104 AB A B C D E 3.54 Interface & Engine Electrical Schematic - Kubota WG2503 Dual Fuel Engine F G H I J K L M N O ECU ECU 2 (ORANGE/YELLOW) AUX ANA PD 2 29 (RED/WHITE) SPEED (RED/BLACK) SPEED (TAN/DK GREEN) AUX DIG (TAN/RED) AUX DIG (DK BLUE/YELLOW) AUX ANA PU (YELLOW/DK BLUE) AUX ANA PU (TAN) AUX PWM 9 43 (GRAY) TACH 0 83 (WHITE/BROWN) AUX PWM5 RECIRC 42 (GRAY/RED) (GOV 2) AUX DIG RPM 34 (GRAY/DK BLUE) GOV RPM 84 (BROWN/WHITE) AUX PWM5 3 ENGINE RUNNING 4 69 (BLACK) GROUND 5 8 (BLACK) GROUND CRANKSHAFT POSITION SENSOR 6 26 (WHITE/PURPLE) CRANK (PURPLE/WHITE) CRANK + CAMSHAFT POSITION SENSOR 8 28 (PURPLE/ORANGE) 9 CAM+ 27 (GRAY/BROWN) CAM- 52 (BLACK) KNK- KNOCK SENSOR 2 KNK+ 5 (BLACK/YELLOW) GAS INJECTOR CYLINDER # (BROWN/LT BLUE) INJ LS GAS INJECTOR CYLINDER #3 23 INJ 2 LS 65 (BROWN/LT GREEN) GAS INJECTOR CYLINDER #4 24 INJ 3 LS 66 (BROWN/YELLOW) GAS INJECTOR CYLINDER #2 25 INJ 4 LS 67 (BROWN/WHITE) SPARK COIL CYLINDER # (YELLOW) SPK COIL A 26 SPARK COIL CYLINDER #4 27 SPK COIL B 2 (YELLOW/BLACK) 3 (YELLOW/RED) SPK COIL 2A 28 SPARK COIL CYLINDER # (BLACK) SPARK GND 5 (YELLOW/WHITE) SPK COIL 2B 30 SPARK COIL CYLINDER #2 OXYGEN SENSOR PRE-CAT 3 2 (DK GREEN/ORANGE) EGO (BLACK/WHITE) EGOH OXYGEN SENSOR POST-CAT (DK GREEN/WHITE) EGO 2 POWER RELAY 34 6 (BLACK/YELLOW) EGOH 2 35 R S T B B D M 73 (WHITE/LT BLUE) RELAY GROUND TO BATTERY 79 (RED/TAN) VBAT ENGINE COOLANT TEMPERATURE SENSOR 37 (TAN/WHITE) ECT GASOLINE PRESSURE SENSOR (FRT) AUX ANA PU 38 (LT GREEN/WHITE) (FRP) AUX ANA PD2 3 (WHITE/LT GREEN) THROTTLE ACTUATOR 82 (TAN/ORANGE) DBW - 80 (PINK/WHITE) DBW + 48 (LT BLUE/DK BLUE) TPS 2 47 (PURPLE/LT BLUE) TPS M.A.P. SENSOR 36 (YELLOW/GRAY) IAT 23 (LT GREEN) MAP PROPANE DIRECT ELECTRONIC PRESSURE REGULATOR 4 (DK BLUE/PINK) CAN + 5 (BLUE/WHITE) CAN - (BLACK/LT GREEN) 5V RTN 9 (LT GREEN/RED) 5V EXT 3 (LT GREEN/PURPLE) 5V EXT 2 32 (LT GREEN/BLACK) 5V RTN 2 53 (DK BLUE/ORANGE) FPP 54 (PURPLE/YELLOW) FPP2 IVS MAIN ENGINE SWITCH 87 (DK BLUE) AUX PWM 2 90 (BLACK/RED) AUX PWM 3 58 FUEL PUMP ENGINE START SWITCH AUX PWM 3 REC 89 (PINK/YELLOW) OIL PRESSURE SWITCH 35 (LT BLUE) OIL PRES (FPUMP) AUX PWM6 78 (TAN/BLACK) LOCK OFF 77 (WHITE/BLACK) (FUEL SEL) AUX DIG 49 (DK GREEN/PURPLE) MIL 74 (GREEN/YELLOW) 72 (PINK/BLACK) (STARTER) AUX PWM4 65 STARTER RELAY VSW 44 (PINK/TAN) 4 FUEL PUMP RELAY PROPANE LOCKOFF SOLENOID GAS/PROPANE SELECTOR SWITCH CHECK ENGINE LIGHT ENGINE STARTER SOLENOID ENGINE STARTER EL. MOTOR ALTERNATOR KUBOTA EFI DUAL FUEL ENGINE (TWIST WIRES 0 TURNS (360 DEG)/FOOT FULL LENGTH) CPS 2 CPS2 2 KS 2 GI GI2 GI3 GI4 SC SC4 SC3 SC2 OXS A C (RED) (PINK/DK GREEN) OXS2 A A F0 C FUSE 5A IGNITION CR F8 TPS D FUSE 0A ECM TA 2 C 3 (PINK/DK GREEN) MS C F9 DEPR B D 3 5 FUSE 5A DEPR A D (WHITE) OPS (RED) (PINK/YELLOW) F 5 6 FUSE 5A FUEL PUMP 2P-56 56CR 57ACR 2 (WHITE) F7 32BCR F2 FUSE 5A VSW STARTER FUSE 5A (RED/TAN) (RED) 3 2 F3 G FUSE 60A ALTERNATOR TO MAIN DISCONNECT U V W R (ORANGE/YELLOW) P (RED/BLACK) N (RED/WHITE) M (TAN/DK GREEN) CONNECTOR VIC2 L (TAN/RED) H (DK BLUE/YELLOW) G (YELLOW/DK BLUE) F (TAN) D (GRAY) B (WHITE/BROWN) 78 J (GRAY/RED) 79 K (GRAY/DK BLUE) C (BROWN/WHITE) 00A E (BLACK) 3000 S (PINK/DK GREEN) A (UNUSED) A (BLACK/LT GREEN) (BLACK) GPS (GREEN/WHITE) B (LT GREEN/WHITE) 2 (WHITE) D (WHITE/LT GREEN) 3 4 C (LT GREEN/RED) (GREEN/RED) 8 (BLUE/WHITE) 7 (DK BLUE/PINK) DIAGNOSTIC DIAGNOSTIC DISPLAY 54A CAN L P (BLUE/WHITE) CAN H N (DK BLUE/PINK) 3 L (BLACK/LT GREEN) M (LT GREEN/RED) S (LT GREEN/PURPLE) R (LT GREEN/BLACK) CONNECTOR VIC K (DK BLUE/ORANGE) J (PURPLE/YELLOW) E (DK BLUE) C (BLACK/RED) 30 FP 3056 D (PINK/YELLOW) H (DK GREEN/PURPLE) G (GREEN/YELLOW) 76 F (LT BLUE/PINK) 57A A (PINK) 54A (PURPLE) B X Y Z 00A 57A 76 54A M79AB-2 SKYJACK, Page

105 A B C D E 3.55 Interface & Engine Electrical Schematic - Deutz D2.9L Engine F G H I J K L M N O D PIN TO ECU D PIN TO ECU R A-6 WH A32-6 BK A03-6 WH A46-6 BK A-6 WH A05-6 BK A6-6 WH A33-6 BK A8-6 WH A48-6 BK A37-8 WH A52-8 BK A53-8 RD A38-8 RD A39-8 WH A54-8 BK A07-8 BK A9-6 BK A-6 WH A23-8 BK A24-8 BK A25-8 BK A26-8 BK A27-8 BK A28-8 BK A29-8 BK A35-8 BK A40-8 BK A43-8 BK A44-8 BK A45-8 BK K0-4 RD K0-2 RD K0-4 RD K0-4 RD 00-4 WH SPLK WH 00-2 WH 00-4 WH 4-8 RD SPL BK SPL00 03A-8 WH K22-8 BK 56A-8 WH 84-8 WH K28-8 BK S T U V W X Y L L 3-8 BK L2 L COOLANT LEVEL SENSOR GP A CR FP SPL3 FU2 00A 57A-6 BK B 03 K44-8 BK C 74-8 WH C 05-8 WH C -8 WH C 3 AB K6-8 BK 0-8 BK 76A-8 WH 03-8 BK 96-8 WH 76-8 BK K73-8 BK 99-8 WH -8 BK 90-8 BK K82-8 BK K85-8 BK 2-8 WH SPL2-6 BK 54-8 BK 8-8 WH 77-8 WH 3-8 BK 2-8 WH 4-8 RD GP2 GP3 GP4 A45-8 BK A35-8 BK A23-8 BK A-6 WH TO BATTERY TO BATTERY B+ POST B- POST 00-2 WH 00-8 WH B+-2 RD FU 30A 00-6 WH 56B-6 BK -8 WH 0-8 BK 03-8 BK 03A-8 WH 56B-6 BK 56A-8 WH 84-8 WH (T-ONLY) 3-8 BK 57A-6 BK 74-8 WH 05-8 WH -8 BK 76A-8 WH 96-8 WH (T-ONLY) 76-8 BK 99-8 WH 90-8 BK K22-8 BK (46AJ ONLY) 2-8 WH (46AJ ONLY) -6 BK 54-8 BK 8-8 WH 77-8 WH A-8 BK A9-6 BK K82-8 BK K85-8 BK K44-8 BK A29-8 BK A44-8 BK A43-8 BK A24-8 BK A27-8 BK A40-8 BK A26-8 BK A25-8 BK A07-8 BK K6-8 BK A28-8 BK K73-8 BK K28-8 BK A54-8 BK A39-8 WH A38-8 RD A53-8 RD A52-8 BK A37-8 WH A48-6 BK A8-6 WH A33-6 BK A6-6 WH A05-6 BK A-6 WH A46-6 BK A03-6 WH A32-6 BK A-6 WH X7.-62 PIN AT ENGINE U U U U U U U M P p&t P P n n n FUEL RAIL PRESS. SENSOR ENGINE SPEED SENSOR CRANKSHAFT ENGINE SPEED SENSOR CAMSHAFT FUEL INJ. CYL.4 FUEL INJ. CYL. ACTUATOR MPROP FUEL INJ. CYL.2 FUEL INJ. CYL.3 EXHAUST GAS RECIRCULATION VALVE (EGR) OIL PRESSURE SENSOR BOOST PRESSURE & TEMPERATURE SENSOR FUEL LOW PRESSURE SENSOR COOLING TEMPERATURE SENSOR STARTER START RELAY STARTER SOLENOID TO BATTERY B- POST TO S BATTERY DISCONNECT SW. M B+ G D+ A (+) (-) FUEL PUMP WATER IN FUEL SWITCH CONNECTOR P TO CONTROL PANEL. SEE MACHINE ELEC. SCHEMATIC. CONNECTOR P2 TO CONTROL PANEL. SEE MACHINE ELEC. SCHEMATIC. Z M69636AE-2 SKYJACK, Page 05

106 A B C D E 3.56 Engine Harness - Deutz D2.9L F G H I J K L M N O D PIN TO ECU D PIN TO ECU A45-8 BK A44-8 BK A43-8 BK A35-8 BK A29-8 BK A28-8 BK A27-8 BK A26-8 BK A25-8 BK A24-8 BK A23-8 BK A9-6 BK A07-8 BK A54-8 BK A39-8 WH A38-8 RD A53-8 RD A52-8 BK A37-8 WH A48-6 BK A8-6 WH A33-6 BK A6-6 WH A05-6 BK A-6 WH A46-6 BK A03-6 WH A32-6 BK A-6 WH P6 30A A B K0-4 RD B+-2 RD K0-2 RD K0-4 RD K0-4 RD 00-4 WH 00-4 WH 00-4 WH 4-8 RD 03-8 BK 03A-8 WH K22-8 BK 56A-8 WH K28-8 BK 3-8 BK 57A-6 BK K44-8 BK 74-8 WH 05-8 WH -8 WH K6-8 BK 0-8 BK 76B-8 WH 03-8 BK 76A-8 BK K73-8 BK 99-8 WH -8 BK 90-8 BK K82-8 BK K85-8 BK 2-8 WH -6 BK 54-8 BK 8-8 WH 77-8 WH SPLK0 SPL WH SPL03 SPL3 SPL2 A40-8 BK A40-8 BK A-6 WH A-6 WH 56B-6 BK 00-6 WH 00-8 WH 00-2 WH 03-8 BK 03A-8 WH 56B-6 BK 56A-8 WH 3-8 BK 57A-6 BK 74-8 WH 05-8 WH -8 BK -8 WH 0-8 BK 76B-8 WH 76A-8 BK 99-8 WH 90-8 BK K22-8 BK 2-8 WH -6 BK 54-8 BK 8-8 WH 77-8 WH A-8 BK A23-8 BK A35-8 BK A45-8 BK 3-8 BK 2-8 WH 4-8 RD A-8 BK K82-8 BK K44-8 BK K85-8 BK A44-8 BK A43-8 BK A29-8 BK A28-8 BK A27-8 BK A26-8 BK A25-8 BK A24-8 BK K6-8 BK A9-6 BK K73-8 BK A07-8 BK K28-8 BK A54-8 BK A39-8 WH A38-8 RD A53-8 RD A52-8 BK A37-8 WH A48-6 BK A8-6 WH A33-6 BK A6-6 WH A05-6 BK A-6 WH A46-6 BK A03-6 WH A32-6 BK A-6 WH P D TO COOLANT SENSOR TO ALTERNATOR X PIN TO ENGINE R S T U V W X Y Z (+) (-) B- B P P3 P2 P5 TO FUEL PUMP TO BATTERY TO CTRL PNL TO WATER SENSOR TO CTRL PNL TO PRE-HEAT M650AB- SKYJACK, Page 06

107 Section 4 TROUBLESHOOTING INFORMATION Table of Contents Introduction Electrical System 4.- All Controls Inoperative No Power To Platform No Power to Base Engine Will Not Crank from Base Engine Will Not Crank from Platform Engine Will Not Crank from Platform or Base (Deutz Diesel D2.9L Engine Cranks but Will Not Start (Deutz Diesel D2.9L) Engine Will Not Crank from Platform or Base (Deutz Diesel D) Engine Cranks but Will Not Start (Deutz Diesel D) Engine Will Not Crank from Platform or Base Control (GM Dual Fuel) Engine Cranks but Will Not Start (GM Dual Fuel) Glow Plug Circuit Inoperative (Deutz Diesel D Engine) All Controls Inoperative from Base Console No Main Boom Down, Riser Down or Turret Rotate from Base Control Console No Boom Up from Base Control Console No Boom Down from Base Control Console No Riser Up from Base Control Console No Riser Down from Base Control Console No Turret Rotate Left from Base Control Console No Turret Rotate Right from Base Control Console No Telescope Retract from Base Control Console No Telescope Extend from Base Control Console No Platform Rotate Left from Base Control Console No Platform Rotate Right from Base Control Console No Jib Up from Base Control Console No Jib Down from Base Control Console No Manual Platform Level Up from Base Control Console No Manual Platform Level Down from Base Control Console All Controls Inoperative from Platform Control Console No Boom Up from Platform Control Console No Boom Down from Platform Control Console No Riser Up from Platform Control Console No Riser Down from Platform Control Console No Turret Left from Platform Control Console No Turret Right from Platform Control Console No Toggle Switch Functions from Platform Control Console No Telescope In from Platform Control Console No Telescope Out from Platform Control Console No Platform Rotate Left from Platform Control Console No Platform Rotate Right from Platform Control Console No Jib Up from Platform Control Console No Jib Down from Platform Control Console No Manual Platform Level Up from Platform Control Console No Manual Platform Level Down from Platform Control Console Throttle Inoperative, Mid and High (Deutz D2.9L only) December 07 Page 07

108 Service and Maintenance Section 4 - Troubleshooting Information Table of Contents (Continued) Mid Throttle Inoperative High Throttle Inoperative Brake will not Release Differential Lock will not Engage Differential Lock Engages Momentarily but will not stay Engaged No Drive and Steer No Forward Drive No Reverse Drive No High Speed Drive No Elevated Drive No Left Steer No Right Steer Direction Sensing Inoperative Hydraulic System 4.2- All Controls Inoperative All Boom Functions Inoperative No Main Boom Up No Main Boom Down No Riser Boom Up No Riser Boom Down Riser Boom Down Jerky No Turret Rotate Left No Turret Rotate Right No Boom Extend No Boom Retract No Jib Up No Jib Down No Platform Rotation Right No Platform Rotation Left Platform will not Level Down Manually Platform will not Level Up Manually Brake will not Release Brake will not Engage Differential Lock will not Engage No Drive Forward or Reverse No Forward Drive No Reverse Drive No High Speed Drive No Right Steer No Left Steer Axle Will Not Oscillate Axle Will Not Lock Load Sensing System - CE 4.3- Green Power LED is not Flashing Load Cell red Alarm LED is ON (with platform empty) Red Error LED is ON Load Cell red Alarm LED is OFF (with platform overloaded) Platform Indicator Light does not turn ON Audible Alarm does not turn ON Boom and Drive Functions are Enabled (with boom extended)...50 Page 08 December 07

109 Section 4 - Troubleshooting Information Service and Maintenance Introduction The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem. The content of this section is separated into probable cause and remedy. The information preceded by a number represents the probable cause. The following line, noted by a dash represents the remedy to the probable cause directly above it. See example below for clarification.. Probable Cause Remedy December 07 Page

110 Service and Maintenance Section 4 - Troubleshooting Information 4. Electrical System NOTE All tests should be performed with boom over non-steering axle. 4.- All Controls Inoperative. Battery disconnected or discharged. Connect battery or recharge. 2. Loose or broken B+ cable from battery to battery disconnect switch S. 3. Open or defective battery disconnect switch S. Close switch. Replace if defective. 4. Loose or broken wire #03 from battery disconnect switch S to circuit breaker CB. 5. Circuit breaker CB tripped or defective. Reset breaker, check for defective wiring. Replace if defective. 6. Loose or broken wire #05 from circuit breaker CB to base emergency stop switch S3. 7. Open or defective base emergency stop switch S3. Close switch. Replace if defective. 8. Loose or broken wire #07 from base emergency stop switch S3 to base key S2. 9. Open or defective key select switch S2. Close switch. Replace if defective. 0. Loose or broken wire #60 from base terminal block to relay 60CR.. Loose or broken wire #07 from base emergency stop switch S3 to relay 60CR. 2. Loose or broken wire # from relay 60CR to base terminal block. 3. Defective relay 60CR. Check relay. Replace if defective. 4. Loose or broken wire #9 from relay 60CR to base terminal block. 5. Loose or broken wire # from base terminal block to circuit breaker CB2. 6. Circuit breaker CB2 tripped or defective. Reset breaker, check for defective wiring. Replace if defective. 7. Loose or broken wire #00 from circuit breaker CB2 to battery negative No Power To Platform. Open or defective key select switch S2. Close switch. Replace if defective. 2. Loose or broken wire #07A from key select switch S2 to plug A pins # 2 & 3 in base control console. 3. Loose or broken wire #07A from plug A pins # 2 & 3 in platform control console to platform emergency stop switch S4. 4. Open or defective platform emergency stop switch S4. Check switch. Replace if defective. 5. Loose or broken wire # from platform emergency stop switch S4 to Ignition/E-pump switch S6 Page 0 December 07

111 Section 4 - Troubleshooting Information Service and Maintenance 4.-3 No Power to Base. Open or defective base key switch S2. Select base position on key switch. Check continuity through base key switch. Replace if defective. 2. Loose or broken wire #2 from base key switch S2 to Ignition/E-pump switch S5. 3. Loose or broken wire #2 from base key switch S2 to base connector plug A pin #5. 4. Loose or broken wire #2 in boom cable A or its connectors. Check for continuity between pins #5 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 5. Loose or broken wire #2 from plug A pin #5 to emergency stop switch S4 in platform control console. 6. Open or defective emergency stop switch S4. Check switch is in on position. Check continuity through switch. Replace if defective. 7. Loose or broken wire #0 from emergency stop switch S4 to plug A pin #4. 8. Loose or broken wire #0 in boom cable A or its connectors. Check for continuity between pins #4 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #0 from plug A pin #4 to base terminal block. 0. Open or defective diode D0. Check diode. Replace if defective.. Loose or broken wire #0 from base terminal block to Ignition/E-pump (enable) switch S5. 2. Open or defective Ignition/E-pump (enable) switch S5. Check switch. Replace if defective 4.-4 Engine Will Not Crank from Base. Loose or broken wire #57A from base start switch S5 to relay 57ACR (Deutz D and GM 3.0l engines). 2. Defective base start switch S5. Check start switch. Replace if defective Engine Will Not Crank from Platform NOTE Engine will not crank from platform with footswitch depressed.. Loose or broken wire #4 from emergency stop switch S4 to start switch S6. 2. Defective start switch S6. Check continuity through switch. Replace if defective. 3. Loose or broken wire #57 from start switch S6 to relay 08CR. 4. Defective relay 08CR. Check continuity through contacts of relay. Replace if defective. 5. Loose or broken wire #57A from relay 08CR to plug B pin #4. December 07 Page

112 Service and Maintenance Section 4 - Troubleshooting Information 6. Loose or broken wire #57A in boom cable B or its connectors. Check for continuity between pin #4 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 7. Loose or broken wire #57A from plug B pin #4 to relay 57ACR in base control console (Deutz D, GM 3.0L) or to base start switch S5 (Deutz TD2.9L) Engine Will Not Crank from Platform or Base (Deutz Diesel D2.9L. Loose or broken wire #57A from base start switch S5 to 2 pin connector (J) pin Loose or broken wire #57A from 2 pin connector (P) pin 8 to 94 pin ECU connector, pin Loose or broken B+ wire from battery B+ to ECU fuse connector P6 pin A. 4. ECU 30A fuse open or defective. Check for defective wiring. Replace if defective. Replace fuse. 5. Loose or broken wire #K0 from ECU fuse connector P6 pin B to 94 pin ECU connector 3 places pins, 3, and Loose or broken ground wire #00 from battery B- to 94 pin ECU connector 3 places pins 2, 4, and Engine Cranks but Will Not Start (Deutz Diesel D2.9L). Loose or broken wire #54 from 94 pin ECU connector, pin90 to 2 pin connector (P2), pin Loose or broken wire #54 from 2 pin connector (J2) pin 9 to relay 56ACR. 3. Loose or broken wire #03 to circuit breaker CB3. 4. Circuit breaker CB3 tripped or defective. Reset breaker, check for defective wiring. Replace if defective 5. Loose or broken wire #56 from CB3 to relay 56ACR. 6. Loose or broken wire #56A from relay 56ACR to 2 pin connector (J) pin Loose or broken wire #56A from 2 pin connector (P) pin 4 to 94 pin ECU connector, pin Loose or broken wire #56B from relay 56ACR to 2 pin connector (J) pin Defective relay 56ACR. Check continuity through contacts of relay. Replace if defective. 0. Loose or broken wire #56B from 2 pin connector (P) pin 3 to fuel pump.. Loose or broken ground wire #00 from fuel pump to battery B-. 2. Engine pre-heat circuit inoperative. Refer to Engine manufacturer s manual to diagnose. NOTE For other engine related problems, consult engine manufacturer s manual. Page 2 December 07

113 Section 4 - Troubleshooting Information Service and Maintenance 4.-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D). Loose or broken wire #57A at relay 57ACR (2 places). Check for connections at relay. Check for voltage on relay (2 places). 2. Loose or broken wire #57A from relay 57ACR to relay 57BCR. 3. Loose or broken wire #00A from X23 engine connector pin # to relay 57ACR. 4. Loose or broken wire #00A from X23 engine connector pin # to engine oil pressure switch. 5. Defective relay 57ACR. Check relay. Replace if defective. 6. Loose or broken wire # from base terminal block to relay CR. 7. Loose or broken wire #03A from circuit breaker CB3 to relay CR. 8. Tripped or defective circuit breaker CB3. Reset circuit breaker. Check continuity through circuit breaker. Replace if defective. 9. Loose or broken wire #3 from circuit breaker CB3 to turret harness plug pin #2. 0. Loose or broken wire # from relay CR to base terminal block.. Defective relay CR. Check relay. Replace if defective. 2. Loose or broken wire #54A from relay CR to base terminal block. 3. Loose or broken wire #54A from base terminal block to relay 57BCR. 4. Defective contacts in relay 57BCR. Check continuity between wires #54A and #57C when cranking. If no continuity, replace relay. 5. Loose or broken wire #57C from relay 57BCR to X23 engine connector pin #4. 6. Loose or broken wire #57C from X23 engine plug to start solenoid 57CCR. 7. Loose or broken starter cable #03 from disconnect switch S to start solenoid 57CCR. 8. Defective start solenoid 57CCR. Check solenoid. Replace if defective. 9. Defective starter motor. Check starter motor. Replace if defective Engine Cranks but Will Not Start (Deutz Diesel D). Loose or broken wire #57B from relay 57ACR to relay 57BCR (2 places). 57BCR maintains power for start circuit before engine starts and after oil pressure switch opens to relay 57BCR. Check wire #57B for continuity. Replace if defective. 2. Loose or broken wire #57A from relay 57ACR to relay 57BCR. 3. Loose or broken wire # from base terminal block to relay 57BCR. 4. Defective relay 57BCR. Check relay. Replace if defective. 5. Glow plug circuit not operating. See Glow Plug Circuit Inoperative in this section. December 07 Page 3

114 Service and Maintenance Section 4 - Troubleshooting Information 6. No fuel in fuel tank or fuel line obstructions. Check fuel level and flow through lines. Fill or repair if necessary. NOTE For other engine related problems, consult engine manufacturer s manual Engine Will Not Crank from Platform or Base Control (GM Dual Fuel). Loose or broken wire #54A from base terminal block TB to engine harness plug. 2. Loose or broken wire #54A from engine harness plug to GM engine connector. 3. Loose or broken pink wire from GM engine connector to fuse F Defective fuse F7. Check fuse. Replace if defective 5. Loose or broken pink/tan wire from fuse F7 to ECU connector pin #45. - Check continuity. Replace if defective 6. Loose or broken red wire from battery positive to ECU fuse F8. 7. Defective fuse F8. Check fuse. Replace if defective. 8. Loose or broken red/tan wire from fuse F8 to ECU connector pin #60 and pin # Loose or broken black wire from engine ground to ECU connector pin #69 and #8. 0. Loose or broken light blue/pink wire from GM engine connector to relay 57ACR.. Loose or broken pink/black wire from ECU connector pin #89 to relay 57ACR. 2. Defective relay 57ACR. Check relay. Replace if defective. 3. Loose or broken red wire from battery positive to starter fuse F2. 4. Defective fuse F2. Check fuse. Replace if defective. 5. Loose or broken red/tan wire from fuse F2 to relay 57ACR. 6. Loose or broken white wire from relay 57ACR to start solenoid 32BCR. 7. Defective starter solenoid 32BCR. Check solenoid. Replace if defective. 8. Loose or broken battery cable from starter solenoid 32BCR to starter motor Defective starter motor. Check motor. Repair or replace if defective. Page 4 December 07

115 Section 4 - Troubleshooting Information Service and Maintenance 4.- Engine Cranks but Will Not Start (GM Dual Fuel) NOTE For additional engine troubleshooting refer to diagnostic trouble codes for use with the check engine light.. Loose or broken red wire from battery positive to relay CR. 2. Loose or broken red/tan wire from ECU fuse F8 to relay CR. 3. Loose or broken white/ light blue wire from ECU connector pin #7 to relay CR. 4. Defective relay CR. Check relay. Replace if defective. 5. Loose or broken pink/dark green wire from relay CR to ignition fuse F0. 6. Defective fuse F0. Check fuse. Replace if defective. 7. Loose or broken pink/dark green wire from fuse F0 to ignition coil IGC pin #A. 8. Loose or broken yellow wire from ignition coil IGC pin #B to ignition module IGM. 9. Defective ignition coil IGC. Check coil for spark. Replace if defective. 0. Loose or broken pink/dark green wire from fuse F0 to ignition module IGM pin #A.. Loose or broken black wire from ignition module IGM pin #C to engine ground. 2. Loose or broken yellow wire from ignition module IGM pin #B to ECU connector pin #3. 3. Defective ignition module IGM. Check module for operation. Replace if defective. 4. Loose or broken pink/dark green wire from fuse F0 to gas injectors GI-, GI-2, GI-3 and GI Loose or broken pink/white wire from ECU connector pin #82 to throttle actuator RA. 6. Loose or broken tan/orange wire from ECU connector pin #83 to throttle actuator RA. 7. Loose or broken light green/red wire from ECU connector pin #9 to throttle actuator RA. 8. Loose or broken black/light green wire from ECU connector pin # to throttle actuator RA. 9. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA.. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA. Fuel Related Problems (Gasoline Only) 2. Loose or broken pink/tan wire from fuse F7 to fuel pump relay 56CR. 22. Loose or broken red wire from battery positive to fuel pump relay 56CR. December 07 Page 5

116 Service and Maintenance Section 4 - Troubleshooting Information 23. Loose or broken tan/black wire from ECU connector pin #84 to fuel pump relay 56CR. 24. Defective fuel pump relay 56CR. Check relay. Replace if defective. 25. Loose or broken pink/yellow wire from fuel pump relay 56CR to fuse F. 26. Defective fuse F. Check fuse. Replace if defective. 27. Loose or broken pink/yellow wire from fuse F to fuel pump FP. 28. Defective fuel pump FP. Check fuel pump by putting 2 volts and a ground to it. Replace if defective. 29. Loose or broken wire #30 from fuel pump FP to GM engine connector. 30. Loose or broken black/red wire from GM engine connector to ECU connector pin #86. (Propane Only) NOTE The fuel select switch is defaulted to gasoline. The engine will run on gasoline if propane is selected from the switch and either the switch is bad or a wire is loose or broken from the switch. This is providing there is nothing wrong on the gasoline side of the system. Disconnect fuel pump to test propane side. 3. Loose or broken wire #60 from platform terminal block to fuel select switch S Defective fuel select switch S26. Check switch. Replace if defective. 33. Loose or broken wire # from fuel select switch S26 to plug B pin #5 in platform control console. 34. Loose or broken wire # in boom cable B or its connectors. Check continuity between pins #5 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 35. Loose or broken wire # from plug B pin #5 to engine harness plug. 36. Loose or broken wire # from engine harness plug to GM engine connector. 37. Loose or broken tan/brown wire from GM engine connector to ECU connector pin # Loose or broken pink/tan wire from fuse F7 to propane lock off 2P Loose or broken white/black wire from ECU connector pin #75 to propane lock off 2P Defective propane lock off 2P-56. Check lock off. Replace if defective. 4. Loose or broken pink/dark green wire from fuse F0 to fuse F Defective fuse F9. Check fuse. Replace if defective. 43. Loose or broken red/light blue wire from fuse F9 to propane regulator PRV. 44. Loose or broken black wire from engine ground to propane regulator PRV. Page 6 December 07

117 Section 4 - Troubleshooting Information Service and Maintenance 4.-2 Glow Plug Circuit Inoperative (Deutz Diesel D Engine). Defective glow plug fuse FU 50 amp. Check fuse. Replace if defective. 2. Loose or broken wire #03 from start solenoid 57CCR to fuse holder FU. 3. Loose or broken wire #A from fuse holder FU to relay 54ACR. 4. Loose or broken wire #B from relay 54ACR to glow plugs. 5. Loose or broken wire #54A from base terminal strip to relay 54ACR. 6. Loose or broken wire # from base terminal block to relay 54ACR. 7. Defective relay 54ACR. Check relay. Replace if defective. 8. Defective glow plugs. Check glow plugs. Replace if defective. NOTE For other glow plug related problems, consult engine manufacturer s manual All Controls Inoperative from Base Console. Loose or broken wire #0 from base emergency stop switch S3 to base ignition/pump switch S5. 2. Defective ignition/pump switch S5. Check continuity through switch when activated. Replace if defective. 3. Loose or broken wire #0A from ignition/pump switch S5 to base terminal block. 4. Loose or broken wire #0A from base terminal block to diode D0A. 5. Open or defective diode D0A. Check diode. Replace if defective. 6. Loose or broken wire # from diode D0A to base terminal block. 7. Missing or broken terminal block jumper between wire # and #2. Check for jumper. Replace if missing or broken. NOTE Jumper is removed if equipped with generator option. 8. Loose or broken wire #2 from base terminal block to relay 2CR. 9. Loose or broken wire # from base terminal block to relay 2CR. 0. Loose or broken wire # from base terminal block to relay 2CR. (ANSI/CSA). Loose or broken wire # from base terminal block to relay 59CR. (CE) 2. Loose or broken wire #62A from relay 59CR to base terminal block. (CE) 3. Loose or broken wire #62A from base terminal block to relay 2CR. (CE) December 07 Page 7

118 Service and Maintenance Section 4 - Troubleshooting Information NOTE For further CE troubleshooting refer to Load Sensing System. 4. Defective relay 2CR. Check relay. Replace if defective. 5. Loose or broken wire #2A from relay 2CR to main harness plug pin #3. 6. Loose or broken wire #2A from main harness plug pin #3 to dump valve 2H-2A. 7. Loose or broken wire # from dump valve 2H-2A to main harness plug. 8. Defective dump valve coil 2H-2A. Check continuity and resistance through coil. Replace if defective No Main Boom Down, Riser Down or Turret Rotate from Base Control Console. Loose or broken wire #0A from base terminal block to resistor R. 2. Open resistor R. Check resistor for 6 ohms. If no resistance found, replace resistor. 3. Loose or broken wire #0B from resistor R to turret rotate switch S3, boom down switch S2 and riser down switch S No Boom Up from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to boom switch S2. 2. Defective boom switch S2. Check continuity through switch while activating up function between wires #0A and #4. Replace switch if no continuity. 3. Loose or broken wire #4 from boom switch S2 to base terminal block. 4. Loose or broken wire #4 from base terminal block to main harness plug pin #2. 5. Loose or broken wire #4 from main harness plug pin #2 to boom up valve 4H Loose or broken wire # from main harness plug to boom up valve 4H Defective boom up coil 4H-4. Check continuity and resistance through coil. Replace if defective No Boom Down from Base Control Console. Loose or broken wire #0B from resistor R to boom down switch S2. 2. Defective boom switch S2. Check continuity through switch while activating down function between wires #0B and #3. If no continuity found, replace switch. 3. Loose or broken wire #3 from boom down switch S2 to base terminal block. 4. Loose or broken wire #3 from base terminal block to main harness plug pin #. Page 8 December 07

119 Section 4 - Troubleshooting Information Service and Maintenance 5. Loose or broken wire #3 from main harness plug pin # to boom down valve 4H Loose or broken wire # from main harness plug to boom down valve 4H Defective boom down coil 4H-3. Check continuity and resistance through coil. Replace if defective No Riser Up from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to riser switch S Defective riser switch S25. Check continuity through switch while activating up function between wires #0A and #3. Replace switch if no continuity. 3. Loose or broken wire #3 from riser switch S25 to base terminal block. 4. Loose or broken wire #3 from base terminal block to main harness plug pin #8. 5. Loose or broken wire #3 from main harness plug pin #8 to riser up valve 4H Loose or broken wire # from main harness plug to riser up valve 4H Defective boom up coil 4H-3. Check continuity and resistance through coil. Replace if defective No Riser Down from Base Control Console. Loose or broken wire #0B from resistor R to riser down switch S Defective riser switch S25. Check continuity through switch while activating down function between wires #0B and #30. If no continuity found, replace switch. 3. Loose or broken wire #30 from riser down switch S25 to base terminal block. 4. Loose or broken wire #30 from base terminal block to main harness plug pin #7. 5. Loose or broken wire #30 from main harness plug pin #7 to riser down valve 4H Loose or broken wire # from main harness plug to riser down valve 4H Defective riser down coil 4H-30. Check continuity and resistance through coil. Replace if defective No Turret Rotate Left from Base Control Console. Loose or broken wire #0B from resistor R to turret rotate switch S3. 2. Defective turret rotate switch S3. Check continuity through switch while activating rotate left function between wires #0B and #32. If no continuity found, replace switch. 3. Loose or broken wire #32 from turret rotate switch S3 to base terminal block. 4. Loose or broken wire #32 from base terminal block to main harness plug pin #9. December 07 Page 9

120 Service and Maintenance Section 4 - Troubleshooting Information 5. Loose or broken wire #32 from main harness plug pin #9 to turret rotate left valve 4H Loose or broken wire # from main harness plug to turret rotate left valve 4H Defective turret rotate left valve coil 4H-32. Check continuity and resistance through coil. Replace if defective. 4.- No Turret Rotate Right from Base Control Console. Loose or broken wire #0B from resistor R to turret rotate switch S3. 2. Defective turret rotate switch S3. - Check continuity through switch while activating rotate right function between wires #0B and #33. If no continuity found, replace switch. 3. Loose or broken wire #33 from turret rotate switch S3 to base terminal block. 4. Loose or broken wire #33 from base terminal block to main harness plug pin #0. 5. Loose or broken wire #33 from main harness plug pin #0 to turret rotate right valve 4H Loose or broken wire # from main harness plug to turret rotate right valve 4H Defective turret rotate right valve coil 4H-33. Check continuity and resistance through coil. Replace if defective No Telescope Retract from Base Control Console. Loose or broken wire #0A from ignition/enable switch S5 to telescope switch S4. 2. Defective telescope switch S4. - Check continuity through switch while activating retract function between wires #0A and #38. If no continuity found, replace switch. 3. Loose or broken wire #38 from telescope switch S4 to base terminal block. 4. Loose or broken wire #38 from base terminal block to main harness plug pin #3. 5. Loose or broken wire #38 from main harness plug pin #3 to telescope retract valve 3H Loose or broken wire # from main harness plug to telescope retract valve 3H Defective telescope retract valve coil 3H-38. Check continuity and resistance through coil. Replace if defective No Telescope Extend from Base Control Console. Loose or broken wire #0A from ignition/enable switch S5 to telescope switch S4. 2. Defective telescope switch S4. Check continuity through switch while activating extend function between wires #0A and #39. If no continuity found, replace switch. 3. Loose or broken wire #39 from telescope switch S4 to base terminal block. Page December 07

121 Section 4 - Troubleshooting Information Service and Maintenance 4. Loose or broken wire #39 from base terminal block to main harness plug pin #4. 5. Loose or broken wire #39 from main harness plug pin #4 to telescope extend valve 3H Loose or broken wire # from main harness plug to telescope extend valve 3H Defective telescope extend valve coil 3H-39. Check continuity and resistance through coil. Replace if defective No Platform Rotate Left from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to platform rotate switch S6. 2. Defective platform rotate switch S6. Check continuity through switch while activating rotate left function between wires #0A and #36. If no continuity found, replace switch. 3. Open or defective diode D36. Check diode. Replace if defective. 4. Loose or broken wire #36A from diode D36 to main harness plug pin #2. 5. Loose or broken wire #36A from main harness plug pin #2 to platform rotate enable valve 2H-36A. 6. Loose or broken wire # from main harness plug to platform rotate enable valve 2H-36A. 7. Defective platform rotate enable valve 2H-36A. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #36 from platform rotate switch S6 to base connector plug A pin #8. 9. Loose or broken wire #36 in boom cable A or its connectors. Check for continuity between pins #8 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #36 plug A pin #8 to platform terminal block.. Loose or broken wire #36 from platform terminal block to platform rotate left valve 4H Loose or broken wire # from platform terminal block to platform rotate left valve 4H Defective platform rotate left valve coil 4H-36. Check continuity and resistance through coil. Replace if defective No Platform Rotate Right from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to platform rotate switch S6. 2. Defective platform rotate switch S6. Check continuity through switch while activating rotate right function between wires #0A and #37. If no continuity found, replace switch. 3. Open or defective diode D37. Check diode. Replace if defective. 4. Loose or broken wire #36A from diode D37 to main harness plug pin #2. 5. Loose or broken wire #36A from main harness plug pin #2 to platform rotate enable valve 2H-36A. December 07 Page 2

122 Service and Maintenance Section 4 - Troubleshooting Information 6. Loose or broken wire # from main harness plug to platform rotate enable valve 2H-36A. 7. Defective platform rotate enable valve 2H-36A. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #37 from platform rotate switch S6 to base connector plug A pin #9. 9. Loose or broken wire #37 in boom cable A or its connectors. Check for continuity between pins #9 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #37 plug A pin #9 to platform terminal block.. Loose or broken wire #37 from platform terminal block to platform rotate right valve 4H Loose or broken wire # from platform terminal block to platform rotate right valve 4H Defective platform rotate right valve coil 4H-37. Check continuity and resistance through coil. Replace if defective No Jib Up from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to jib switch S7. 2. Defective jib up switch S7. Check continuity through switch while activating jib up function between wires #0A and #35. If no continuity found, replace switch. 3. Open or defective diode D35. Check diode. Replace if defective. 4. Loose or broken wire #34A from diode D35 to main harness plug pin #. 5. Loose or broken wire #34A from main harness plug pin # to jib enable valve 2H-34A. 6. Loose or broken wire # from main harness plug to jib enable valve 2H-34A. 7. Defective jib enable valve 2H-34A. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #35 from jib up switch S7 to base connector plug A pin #7. 9. Loose or broken wire #35 in boom cable A or its connectors. Check for continuity between pins #7 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #35 from plug A pin #7 to platform terminal block.. Loose or broken wire #35 from platform terminal block to jib up valve 4H Loose or broken wire # from platform terminal block to jib up valve 4H Defective jib up valve coil 4H-35. Check continuity and resistance through coil. Replace if defective No Jib Down from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to jib switch S7. Page 22 December 07

123 Section 4 - Troubleshooting Information Service and Maintenance 2. Defective jib down switch S7. Check continuity through switch while activating jib down function between wires #0A and#34. If no continuity found, replace switch. 3. Open or defective diode D34. Check diode. Replace if defective. 4. Loose or broken wire #34A from diode D34 to main harness plug pin #. 5. Loose or broken wire #34A from main harness plug pin # to jib enable valve 2H-34A. 6. Loose or broken wire # from main harness plug to jib enable valve 2H-34A. 7. Defective jib enable valve 2H-34A. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #34 from jib down switch S7 to base connector plug A pin #6. 9. Loose or broken wire #34 in boom cable A or its connectors. Check for continuity between pins #6 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #34 from plug A pin #6 to platform terminal block.. Loose or broken wire #34 from platform terminal block to jib down valve 4H Loose or broken wire # from platform terminal block to jib down valve 4H Defective jib down valve coil 4H-34. Check continuity and resistance through coil. Replace if defective No Manual Platform Level Up from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to platform level switch S5. 2. Defective platform level switch S5. Check continuity through switch while activating level up function between wires #0A and#4. If no continuity found replace switch. 3. Loose or broken wire #4 from platform level switch S5 to base terminal block. 4. Loose or broken wire #4 from base terminal block to main harness pin plug pin#6. 5. Loose or broken wire #4 from main harness pin plug pin#6 platform level up valve 4H Loose or broken wire # from turret harness pin plug platform level up valve 4H Defective platform level up valve coil 4H-4. Check continuity and resistance through coil. Replace if defective No Manual Platform Level Down from Base Control Console. Loose or broken wire #0A from ignition/pump switch S5 to platform level switch S5. 2. Defective platform level switch S5. Check continuity through switch while activating level down function between wires #0A and#40. If no continuity found replace switch. 3. Loose or broken wire #40 from platform level switch S5 to base terminal block. 4. Loose or broken wire #40 from base terminal block to main harness pin plug pin#5. December 07 Page 23

124 Service and Maintenance Section 4 - Troubleshooting Information 5. Loose or broken wire #40 from main harness pin plug pin#6 platform level down valve 4H Loose or broken wire # from turret harness pin plug platform level down valve 4H Defective platform level down valve coil 4H-40. Check continuity and resistance through coil. Replace if defective All Controls Inoperative from Platform Control Console. Open or defective emergency stop switch S4. Pull emergency switch out. Check continuity through switch. Replace if defective. 2. Loose or broken wire #4A from emergency stop switch S4 to platform start switch S9. 3. Loose or broken wire #4 platform start switch S9 to platform terminal block. 4. Loose or broken pin jumper between # and #A on platform terminal block (without generator option only). 5. Loose or broken wire # from platform terminal block to generator switch S22 (generator option only). 6. Generator switch S22 in generator mode or is open or defective (generator option only). Select OFF mode on generator switch. Check continuity through switch from # to #A. Replace if defective. 7. Loose or broken wire #A from generator switch S22 to platform terminal block (generator option only). 8. Loose or broken wire #A from platform terminal block to footswitch S. 9. Open or defective footswitch S. Check continuity through switch while activating footswitch function between wires #A and #08A. If no continuity found replace switch. 0. Loose or broken wire #08A from footswitch S to valve driver pin #6.. Loose or broken wire # from platform terminal block to valve driver pin #, 2 & Loose or broken wire # from platform terminal block to valve driver pin #24, 25 & No output on pin #6 of the valve driver to wire #08. Check pin #6 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 4. Loose or broken wire # from platform terminal block to diode D. 5. Open or defective diode D. Check diode. Replace if defective. 6. Loose or broken wire #60 from diode D to platform terminal block. 7. Loose or broken wire #60 from platform terminal block to plug B pin #6 in platform control console. 8. Loose or broken wire #60 in boom cable B or its connectors. Check for continuity between pins #6 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #60 from plug B pin #6 to base terminal block. Page 24 December 07

125 Section 4 - Troubleshooting Information Service and Maintenance No Boom Up from Platform Control Console. Loose or broken wire # from platform terminal block to joystick controller A. 2. Loose or broken wire # from platform terminal block to joystick controller A. 3. No output on y-axis of joystick controller A. Refer to joystick test procedure in section Loose or broken wire Y from joystick controller A to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 6. No output on pin #22 of the valve driver to wire #4. Check pin #22 for minimum 3.5 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 7. Loose or broken wire #4 from valve driver pin #22 to plug A pin #7 in platform control console. 8. Loose or broken wire #4 in boom cable A or its connectors. Check for continuity between pins #7 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #4 from base connector plug A pin #7 to base terminal block. 0. Loose or broken wire #4 from base terminal block to main harness plug pin #2.. Loose or broken wire #4 from main harness plug pin #2 to boom up valve 4H Loose or broken wire # from main harness plug to boom up valve 4H Defective boom up valve coil 4H-4. Check continuity and resistance through coil. Replace if defective No Boom Down from Platform Control Console. Loose or broken wire # from platform terminal block to joystick controller A. 2. Loose or broken wire # from platform terminal block to joystick controller A. 3. No output on y-axis of joystick controller A. Refer to joystick test procedure in section Loose or broken wire Y from joystick controller A to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 6. No output on pin #8 of the valve driver to wire #3. Check pin #8 for minimum.5 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 7. Loose or broken wire #3 from valve driver pin #8 to plug A pin #6 in platform control console. 8. Loose or broken wire #3 in boom cable A or its connectors. Check for continuity between pins #6 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #3 from base connector plug A pin #6 to base terminal block. December 07 Page 25

126 Service and Maintenance Section 4 - Troubleshooting Information 0. Loose or broken wire #3 from base terminal block to main harness plug pin #.. Loose or broken wire #3 from main harness plug pin # to boom down valve 4H Loose or broken wire # from main harness plug to boom down valve 4H Defective boom down valve coil 4H-3. Check continuity and resistance through coil. Replace if defective No Riser Up from Platform Control Console. Loose or broken wire # from platform terminal block to joystick controller A3. 2. Loose or broken wire # from platform terminal block to joystick controller A3. 3. No output on R signal from joystick controller A3. Refer to joystick test procedure in section Loose or broken wire R from joystick controller A3 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 6. No output on pin #9 of the valve driver to wire #3. Check pin #9 for minimum 3 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 7. Loose or broken wire #3 from valve driver pin #9 to plug A pin #3 in platform control console Loose or broken wire #3 in boom cable A or its connectors. Check for continuity between pins #3 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #3 from base connector plug A pin #3 to base terminal block. 0. Loose or broken wire #3 from base terminal block to main harness plug pin #8.. Loose or broken wire #3 from main harness plug pin #8 to riser up valve 4H Loose or broken wire # from main harness plug to riser up valve 4H Defective riser up valve coil 4H-3. Check continuity and resistance through coil. Replace if defective No Riser Down from Platform Control Console. Loose or broken wire # from platform terminal block to joystick controller A3. 2. Loose or broken wire # from platform terminal block to joystick controller A3. 3. No output on R signal from joystick controller A3. Refer to joystick test procedure in section Loose or broken wire R from joystick controller A3 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. Page 26 December 07

127 Section 4 - Troubleshooting Information Service and Maintenance 6. No output on pin #2 of the valve driver to wire #30. Check pin #2 for minimum 3 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 7. Loose or broken wire #30 from valve driver pin #2 to plug A pin #2 in platform control console. 8. Loose or broken wire #30 in boom cable A or its connectors. Check for continuity between pins #2 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #30 from base connector plug A pin #2 to base terminal block. 0. Loose or broken wire #30 from base terminal block to main harness plug pin #7.. Loose or broken wire #30 from main harness plug pin #7 to riser down valve 4H Loose or broken wire # from main harness plug to riser down valve 4H Defective riser down valve coil 4H-30. Check continuity and resistance through coil. Replace if defective No Turret Left from Platform Control Console. Loose or broken wire # from platform terminal block to joystick controller A. 2. Loose or broken wire # from platform terminal block to joystick controller A. 3. No output on x-axis of joystick controller A. Refer to joystick test procedure in section Loose or broken wire X from joystick controller A to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 6. No output on pin # of the valve driver to wire #32. Check pin # for minimum 3.5 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 7. Loose or broken wire #32 from valve driver pin # to plug A pin #4 in platform control console. 8. Loose or broken wire #32 in boom cable A or its connectors. Check for continuity between pins #4 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #32 from base connector plug A pin #4 to base terminal block. 0. Loose or broken wire #32 from base terminal block to main harness plug pin #9.. Loose or broken wire #32 from main harness plug pin #9 to turret left valve 4H Loose or broken wire # from main harness plug to turret left valve 4H Defective turret left valve coil 4H-32. Check continuity and resistance through coil. Replace if defective. December 07 Page 27

128 Service and Maintenance Section 4 - Troubleshooting Information No Turret Right from Platform Control Console. Loose or broken wire # from platform terminal block to joystick controller A. 2. Loose or broken wire # from platform terminal block to joystick controller A. 3. No output on x-axis of joystick controller A. Refer to joystick test procedure in section Loose or broken wire X from joystick controller A to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 6. No output on pin #35 of the valve driver to wire #33. Check pin #35 for minimum 3.5 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 7. Loose or broken wire #33 from valve driver pin #35 to plug A pin #5 in platform control console. 8. Loose or broken wire #33 in boom cable A or its connectors. Check for continuity between pins #5 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #33 from base connector plug A pin #5 to base terminal block. 0. Loose or broken wire #33 from base terminal block to main harness plug pin #0.. Loose or broken wire #33 from main harness plug pin #0 to turret right valve 4H Loose or broken wire # from main harness plug to turret right valve 4H Defective turret right valve coil 4H-33. Check continuity and resistance through coil. Replace if defective No Toggle Switch Functions from Platform Control Console. Loose or broken wire #8 from platform terminal block to toggle switches. 2. Loose or broken wire #A from toggle switches to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference No Telescope In from Platform Control Console. Loose or broken wire #08 from platform terminal block to telescope switch S8. 2. Defective telescope switch S8. Check continuity through switch while activating in function between wires #08 and # Loose or broken wire #A from telescope switch S8 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #38 from telescope switch S8 to plug B pin #8 in platform control console. Page 28 December 07

129 Section 4 - Troubleshooting Information Service and Maintenance 6. Loose or broken wire #38 in boom cable B or its connectors. Check for continuity between pins #8 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 7. Loose or broken wire #38 from base connector plug B pin #8 to base terminal block. 8. Loose or broken wire #38 from base terminal block to main harness plug pin #3. 9. Loose or broken wire #38 from main harness plug pin #3 to telescope in valve 4H Loose or broken wire # from main harness plug to telescope in valve 4H-38.. Defective telescope in valve coil 4H-38. Check continuity and resistance through coil. Replace if defective No Telescope Out from Platform Control Console. Loose or broken wire #08 from platform terminal block to telescope switch S8. 2. Defective telescope switch S8. Check continuity through switch while activating out function between wires #08 and # Loose or broken wire #A from telescope switch S8 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #39 from telescope switch S8 to plug B pin #9 in platform control console. 6. Loose or broken wire #39 in boom cable B or its connectors. Check for continuity between pins #9 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 7. Loose or broken wire #39 from base connector plug B pin #9 to base terminal block. 8. Loose or broken wire #39 from base terminal block to main harness plug pin #4. 9. Loose or broken wire #39 from main harness plug pin #4 to telescope out valve 4H Loose or broken wire # from main harness plug to telescope out valve 4H-39.. Defective telescope out valve coil 4H-39. Check continuity and resistance through coil. Replace if defective No Platform Rotate Left from Platform Control Console. Loose or broken wire #08 from platform terminal block to platform rotate switch S. 2. Defective platform rotate switch S. Check continuity through switch while activating rotate left function between wires #08 and # Loose or broken wire #A from platform rotate switch S to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #36 from platform rotate switch S to platform terminal block. December 07 Page 29

130 Service and Maintenance Section 4 - Troubleshooting Information 6. Loose or broken wire #36 or # from platform terminal block to rotate left valve 4H Defective rotate left valve coil 4H-36. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #36 from platform terminal block to plug A pin#8 in platform control console. 9. Loose or broken wire #36 in boom cable A or its connectors. Check for continuity between pins #8 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #36 from base connector plug A pin #8 to base platform rotate switch S6.. Defective base platform rotate switch S6. Check continuity through switch while activating rotate left function between wires #0A and #36. If no continuity found, replace switch. 2. Open or defective diode D36. Check diode. Replace if defective. 3. Loose or broken wire #36A from diode D36 to main harness plug pin #2. 4. Loose or broken wire #36A from main harness plug pin #2 to platform rotate enable valve 2H-36A. 5. Loose or broken wire # from main harness plug to platform rotate enable valve 2H-36A. 6. Defective platform rotate enable valve 2H-36A. Check continuity and resistance through coil. Replace if defective No Platform Rotate Right from Platform Control Console. Loose or broken wire #08 from platform terminal block to platform rotate switch S. 2. Defective platform rotate switch S. Check continuity through switch while activating rotate right function between wires #08 and # Loose or broken wire #A from platform rotate switch S to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #37 from platform rotate switch S to platform terminal block. 6. Loose or broken wire #37 or # from platform terminal block to rotate right valve 4H Defective rotate right valve coil 4H-37. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #37 from platform terminal block to plug A pin#9 in platform control console. 9. Loose or broken wire #37 in boom cable A or its connectors. Check for continuity between pins #9 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #37 from base connector plug A pin #9 to base platform rotate switch S6.. Defective base platform rotate switch S6. Check continuity through switch while activating rotate right function between wires #0A and #37. If no continuity found, replace switch. Page 30 December 07

131 Section 4 - Troubleshooting Information Service and Maintenance 2. Open or defective diode D37. Check diode. Replace if defective. 3. Loose or broken wire #36A from diode D37 to main harness plug pin # Loose or broken wire #36A from main harness plug pin #2 to platform rotate enable valve 2H-36A. 5. Loose or broken wire # from main harness plug to platform rotate enable valve 2H-36A. 6. Defective platform rotate enable valve 2H-36A. Check continuity and resistance through coil. Replace if defective No Jib Up from Platform Control Console. Loose or broken wire #08 from platform terminal block to jib switch S2. 2. Defective jib up switch S2. Check continuity through switch while activating jib up function between wires #08 and # Loose or broken wire #A from jib switch S2 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #35 from jib switch S to platform terminal block. 6. Loose or broken wire #35 or # from platform terminal block to jib up valve 4H Defective jib up valve coil 4H-35. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #35 from platform terminal block to plug A pin#7 in platform control console. 9. Loose or broken wire #35 in boom cable A or its connectors. Check for continuity between pins #7 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #35 from base connector plug A pin #7 to base jib up switch S7.. Defective base jib up switch S7. Check continuity through switch while activating jib up function between wires #0A and #35. If no continuity found, replace switch. 2. Open or defective diode D35. Check diode. Replace if defective. 3. Loose or broken wire #34A from diode D35 to main harness plug pin #. 4. Loose or broken wire #34A from main harness plug pin # to jib enable valve 2H-34A. 5. Loose or broken wire # from main harness plug to jib enable valve 2H-34A. 6. Defective jib enable valve 2H-34A. Check continuity and resistance through coil. Replace if defective No Jib Down from Platform Control Console. Loose or broken wire #08 from platform terminal block to jib switch S2. 2. Defective jib down switch S2. Check continuity through switch while activating jib down function between wires #08 and #34. December 07 Page 3

132 Service and Maintenance Section 4 - Troubleshooting Information 3. Loose or broken wire #A from jib switch S2 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #34 from jib switch S to platform terminal block. 6. Loose or broken wire #34 or # from platform terminal block to jib down valve 4H Defective jib up valve coil 4H-34. Check continuity and resistance through coil. Replace if defective. 8. Loose or broken wire #34 from platform terminal block to plug A pin#6 in platform control console. 9. Loose or broken wire #34 in boom cable A or its connectors. Check for continuity between pins #6 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 0. Loose or broken wire #34 from base connector plug A pin #6 to base jib down switch S7.. Defective base jib down switch S7. Check continuity through switch while activating jib down function between wires #0A and #34. If no continuity found, replace switch. 2. Open or defective diode D34. Check diode. Replace if defective. 3. Loose or broken wire #34A from diode D34 to main harness plug pin #. 4. Loose or broken wire #34A from main harness plug pin # to jib enable valve 2H-34A. 5. Loose or broken wire # from main harness plug to jib enable valve 2H-34A. 6. Defective jib enable valve 2H-34A. Check continuity and resistance through coil. Replace if defective No Manual Platform Level Up from Platform Control Console. Loose or broken wire #08 from platform terminal block to platform leveling switch S9. 2. Defective platform leveling switch S9. Check continuity through switch while activating level up function between wires #08 and #4. 3. Loose or broken wire #A from platform leveling switch S9 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #4 from platform leveling switch S9 to plug B pin # in platform control console. 6. Loose or broken wire #4 in boom cable B or its connectors. Check for continuity between pins # on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 7. Loose or broken wire #4 from base connector plug B pin # to base terminal block. 8. Loose or broken wire #4 from base terminal block to main harness plug pin #6. Page 32 December 07

133 Section 4 - Troubleshooting Information Service and Maintenance 9. Loose or broken wire #4 from main harness plug pin #6 to level up valve 4H Loose or broken wire # from main harness plug to level up valve 4H-4.. Defective level up valve coil 4H-4. Check continuity and resistance through coil. Replace if defective No Manual Platform Level Down from Platform Control Console. Loose or broken wire #08 from platform terminal block to platform leveling switch S9. 2. Defective platform leveling switch S9. Check continuity through switch while activating level down function between wires #08 and # Loose or broken wire #A from platform leveling switch S9 to valve driver pin # No output on pin #5 of the valve driver to wire #. Check pin #5 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 5. Loose or broken wire #40 from platform leveling switch S9 to plug B pin #0 in platform control console. 6. Loose or broken wire #40 in boom cable B or its connectors. Check for continuity between pins #0 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 7. Loose or broken wire #40 from base connector plug B pin #0 to base terminal block. 8. Loose or broken wire #40 from base terminal block to main harness plug pin #5. 9. Loose or broken wire #40 from main harness plug pin #5 to level down valve 4H Loose or broken wire # from main harness plug to level down valve 4H-40.. Defective level down valve coil 4H-40. Check continuity and resistance through coil. Replace if defective Throttle Inoperative, Mid and High (Deutz D2.9L only). Loose or broken wire #90 from base terminal block to connector J2 pin #5. 2. Loose or broken wire #90 from connector P2 pin #5 94 pin ECU connector pin Loose or broken wire #99 from base terminal block to connector J2 pin 4 4. Loose or broken wire #99 from connector P2 pin 4 to 94 pin ECU connector pin Resistor R4 open or poor connection at base terminal block. Measure resistance (KΩ) between 99 and 99A. Check connections. Replace if defective. 6. Resistor R5 open or poor connection at base terminal block. Measure resistance (3.3KΩ) between 99A and 99B. Check connections. Replace if defective. 7. Resistor R6 open or poor connection at base terminal block. Measure resistance (3.9KΩ) between 99B and 90. Check connections. Replace if defective. December 07 Page 33

134 Service and Maintenance Section 4 - Troubleshooting Information Mid Throttle Inoperative. Loose or broken wire #08 from platform terminal block to throttle switch S0. 2. Defective throttle switch S0. Check continuity through switch while activating mid throttle function between wires #08 and #79. If no continuity found replace switch. 3. Loose or broken wire #79 from throttle switch S0 to plug B pin # in platform control console. 4. Loose or broken wire #79 in Cable B or its connectors. Check for continuity between pins # on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. (Deutz D2.9L Diesel Only) 5. Loose or broken wire #79 from base plug B pin # to relay 79CR. 6. Loose or broken wire # from base terminal block to relay 79CR. 7. Loose or broken wire #90 from relay 79CR to base terminal block. 8. Loose or broken wire #99B from relay 79CR to base terminal block. 9. Defective relay 79CR. Check relay. Replace if defective. (Deutz D Diesel Only) 5. Loose or broken wire #79 from base plug B pin # to relay 79CR. 6. Loose or broken wire # from base terminal block to relay 79CR. 7. Loose or broken wire #99 from relay 79CR to ECU connector pin #8. 8. Loose or broken wire #03 from relay 79CR to base terminal block. 9. Loose or broken wire #03 from base terminal block to ECU connector pin #7. 0. Defective relay 79CR. Check relay. Replace if defective. (GM Engine Only). Loose or broken wire #79 from base plug B pin # to engine harness plug. Check continuity. Replace if defective 2. Loose or broken wire #79 from engine harness plug to GM engine connector Loose or broken gray/dark blue wire from GM engine connector to ECU connector pin #5. 4. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA. 5. Defective throttle actuator RA. Check actuator. Replace if defective. Page 34 December 07

135 Section 4 - Troubleshooting Information Service and Maintenance High Throttle Inoperative. Loose or broken wire #08 from platform terminal block to throttle switch S0. 2. Defective throttle switch S0. Check continuity through switch while activating high throttle function between wires #08 and #78. If no continuity found replace switch. 3. Loose or broken wire #78 from throttle switch S0 to plug B pin #9 in platform control console. 4. Loose or broken wire #78 in Cable B or its connectors. Check for continuity between pins #9 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. (Deutz D2.9L Diesel Only) 5. Loose or broken wire #78 from base plug B pin #9 to relay 78CR. 6. Loose or broken wire # from base terminal block to relay 78CR. 7. Loose or broken wire #90 from relay 78CR to base terminal block. 8. Loose or broken wire #99A from relay 78CR to base terminal block. 9. Defective relay 78CR. Check relay. Replace if defective. (Deutz D Diesel Only) 5. Loose or broken wire #78 from base plug B pin #7 to relay 78CR. 6. Loose or broken wire # from base terminal block to relay 78CR. 7. Loose or broken wire #90 from relay 78CR to ECU connector pin #2. 8. Loose or broken wire #03 from relay 78CR to base terminal block. 9. Loose or broken wire #03 from base terminal block to ECU connector pin #7. 0. Defective relay 78CR. Check relay. Replace if defective Brake will not Release. No output on pin #0 from valve driver to wire #26 when operating a drive function. Check pin #0 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 2. Loose or broken wire #26 from valve drive pin #0 to plug A pin # in platform control console. 3. Loose or broken wire #26 in Cable A or its connectors. Check for continuity between pins # on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 4. Loose or broken wire #26 from base plug A pin # to main harness plug pin #6. 5. Loose or broken wire #26 or # from main harness plug to brake valve 3H Defective brake valve coil 3H-26. Check continuity and resistance through coil. Replace if defective. December 07 Page 35

136 Service and Maintenance Section 4 - Troubleshooting Information Differential Lock will not Engage NOTE Differential Lock cannot be engaged if a drive function has been selected.. No output on pin #9 from valve driver to wire #26A. Check pin #9 for 2 volts when drive in neutral position. If no voltage present make sure drive joystick output D is between 4.2 and 4.8 volts. 2. Loose or broken wire #26A from valve drive pin #9 to differential lock switch S Loose or broken wire #65 from differential lock switch S28 to plug A pin #24 in platform control console. 4. Loose or broken wire #65 in Cable A or its connectors. Check for continuity between pins #24 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 5. Loose or broken wire #65 from base plug A pin #24 to main harness plug pin #2. 6. Loose or broken wire #65 or # from main harness plug to differential lock valve 3H Defective differential lock valve coil 3H-65. Check continuity and resistance through coil. Replace if defective Differential Lock Engages Momentarily but will not stay Engaged NOTE Differential Lock will engage without light being illuminated. Check bulb.. Loose or broken wire #26A at diode D26A. 2. Open or defective diode D26A. Check diode. Replace if defective. 3. Loose or broken wire #26B from diode D26A to relay 65CR. 4. Loose or broken wire #65 from differential lock switch S28 to relay 65CR. (2 places) Check for 2 volts on wire #65 (2 places) while activating differential lock at relay 65CR. 5. Defective relay 65CR. Check relay. Replace if defective. 6. Loose or broken wire # from platform terminal block to differential lock switch S Loose or broken wire #A from differential lock switch S28 to relay 65CR. 8. Loose or broken wire #08 from platform terminal block to diode D Open or defective diode D08-. Check diode. Replace if defective. 0. Loose or broken wire #26B from diode D08- to relay 65CR. Page 36 December 07

137 Section 4 - Troubleshooting Information Service and Maintenance 4.-5 No Drive and Steer NOTE Aerial platform will not drive or steer if it is tilted and off limit switches.. Loose or broken wire #62A from base terminal block to base plug B pin #24. (CE only) 2. Loose or broken wire #62A in Cable B or its connectors. (CE only) Check for continuity between pins #24 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 3. Loose or broken wire #62A from plug B pin #24 in platform control console to drive joystick A2. (CE only) NOTE For further CE troubleshooting refer to Load Sensing System. 4. Loose or broken wire # from platform terminal block to drive joystick A2. 5. Loose or broken wire # from platform terminal block to drive joystick A No Forward Drive. No output on D when forward is selected on drive joystick A2. See drive joystick test procedure in section Loose or broken wire D-signal from drive joystick A2 to valve driver pin # No output from valve driver pin #34 to wire #6. Check pin #34 for minimum 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 4. Loose or broken wire #6 from valve driver pin #34 to plug B pin #5 in platform control console. 5. Loose or broken wire #6 in cable B or its connectors. Check for continuity between pins #5 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 6. Loose or broken wire #6 from base plug B pin #5 to forward drive valve 3H Loose or broken wire # from base terminal block to forward drive valve 3H Defective forward drive valve coil 3H-6. Check continuity and resistance through coil. Replace if defective No Reverse Drive. No output on D when reverse is selected on drive joystick A2. See drive joystick test procedure in section Loose or broken wire D-signal from drive joystick A2 to valve driver pin # No output from valve driver pin #23 to wire #5. Check pin #23 for minimum 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 4. Loose or broken wire #5 from valve driver pin #23 to plug B pin #4 in platform control console. December 07 Page 37

138 Service and Maintenance Section 4 - Troubleshooting Information 5. Loose or broken wire #5 in cable B or its connectors. Check for continuity between pins #4 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 6. Loose or broken wire #5 from base plug B pin #4 to reverse drive valve 3H Loose or broken wire # from base terminal block to reverse drive valve 3H Defective reverse drive valve coil 3H-5. Check continuity and resistance through coil. Replace if defective No High Speed Drive NOTE Aerial platform must be level and boom must be fully retracted and horizontal or below.. Loose or broken wire # from base terminal block to limit switch LS2. 2. Open or defective limit switch LS2. Ensure boom is horizontal or below and fully retracted. Adjust switch if required. Check continuity through switch. Replace if required. 3. Loose or broken wire #29 from limit switch LS2 to base terminal block. 4. Loose or broken wire #29 from base terminal block to limit switch LS3. 5. Open or defective limit switch LS3. Ensure boom is fully retracted and horizontal or below. Adjust switch if required. Check continuity through switch. Replace if defective. 6. Loose or broken wire #29A from limit switch LS3 to base terminal block Loose or broken wire #29A from base terminal block to limit switch LS4. 8. Open or defective limit switch LS4. Ensure boom is fully retracted and horizontal or below. Adjust switch if required. Check continuity through switch. Replace if defective. 9. Loose or broken wire #59 from limit switch LS4 to base terminal block. 0. Loose or broken wire #59 from base terminal block to plug B pin #5.. Loose or broken wire #59 in boom cable B or its connectors. Check for continuity between pins #5 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 2. Loose or broken wire #59 from plug B pin #5 to platform terminal block. 3. Loose or broken wire #59 from platform terminal block to valve driver pin #3. 4. Defective valve driver channel input for high drive enable. See section 5 for OCM pin voltage reference. 5. Loose or broken wire #59 from platform terminal block to torque switch S Open or defective torque switch S48. Check continuity through switch while activating low torque function between wires #59 and #45. If no continuity found replace switch. Page 38 December 07

139 Section 4 - Troubleshooting Information Service and Maintenance 7. Loose or broken wire #45 from torque switch S48 to plug A pin # in platform control console. 8. Loose or broken wire #45 in cable A or its connectors. Check for continuity between pins # on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 9. Loose or broken wire #45 from plug A pin # to relay 45CR.. Loose or broken wire # from base terminal block to relay 45CR. 2. Loose or broken wire # from relay 45CR to base terminal block. 22. Defective relay 45CR. Check relay. Replace if defective. 23. Loose or broken wire #45A from relay 45CR to main harness plug pin # Loose or broken wire #45A or # from main harness plug to 2 speed valve 3H-45A. 25. Defective 2 speed valve 3H-45A. Check continuity and resistance through coil. Replace if defective No Elevated Drive NOTE Aerial platform must be level to drive elevated.. Loose or broken wire # or # from base terminal block to level sensor TS. 2. Misadjusted, no output or defective level sensor TS. Adjust level sensor if required. Check for 2 volts on wire #28. If no voltage present with level sensor adjusted or if defective, replace level sensor. 3. Loose or broken wire #28 from level sensor TS to plug B pin #7. 4. Loose or broken wire #28 in cable B or its connectors. Check for continuity between pins #7 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 5. Loose or broken wire #28 from plug B pin #7 to platform terminal block. 6. Loose or broken wire #28 from platform terminal block to valve driver pin # No Left Steer. Loose or broken wire #24 from drive joystick A2 to valve driver pin #7. 2. No output from valve driver pin #4 to wire #24A. Check pin #4 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 3. Loose or broken wire #24A from valve driver pin #4 to plug A pin #0 in platform control console. 4. Loose or broken wire #24A in boom cable A or its connectors. Check for continuity between pins #0 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 5. Loose or broken wire #24A from base plug A pin #0 to main harness plug pin #5. December 07 Page 39

140 Service and Maintenance Section 4 - Troubleshooting Information 6. Loose or broken wire #24A or # from main harness plug to left steer valve 4H-24A. 7. Defective left steer valve coil 4H-24A. Check continuity and resistance through coil. Replace if defective No Right Steer. Loose or broken wire #23 from drive joystick A2 to valve driver pin #8. 2. No output from valve driver pin #2 to wire #23A. Check pin #2 for 2 volts. If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference. 3. Loose or broken wire #23A from valve driver pin #2 to plug A pin #9 in platform control console. 4. Loose or broken wire #23A in boom cable A or its connectors. Check for continuity between pins #9 on cable A. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 5. Loose or broken wire #23A from base plug A pin #9 to main harness plug pin #4. 6. Loose or broken wire #23A or # from main harness plug to right steer valve 4H-23A. 7. Defective right steer valve coil 4H-23A. Check continuity and resistance through coil. Replace if defective Direction Sensing Inoperative. Loose or broken wire # from base terminal block to limit switch LS. 2. Open or defective limit switch LS. Adjust limit switch if required. Check continuity through switch. Replace if defective. 3. Loose or broken wire #7 from limit switch LS to base terminal block. 4. Loose or broken wire #7 from base terminal block to base plug B pin #6. 5. Loose or broken wire #7 in boom cable B or its connectors. Check for continuity between pins #6 on cable B. Check for loose or corroded connections on cable connectors. Replace if wire is defective. 6. Loose or broken wire #7 from platform plug B pin #6 to valve driver pin #5 in platform control console. 7. Defective valve driver channel input for direction sense enable. See section 5 for test procedure on valve driver. Page 40 December 07

141 Section 4 - Troubleshooting Information Service and Maintenance 4.2 Hydraulic System 4.2- All Controls Inoperative. Broken or defective drive pump shaft or coupling. Check pump shaft and coupling. Replace if defective. 2. Hydraulic oil level low. Check oil level. Fill to proper level All Boom Functions Inoperative. Open or defective dump valve 2H-2A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective relief valve RV6. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 3. Stuck or defective Inlet Compensator/ differential sensing valve DSV. Check O-rings and clean valve. Check operation of valve. Repair or replace valve as required. 4. System pump P2 defective. Test pump with flow meter. Replace if defective. 5. Plugged or defective high pressure filter F. Check filter. Replace if plugged or defective No Main Boom Up. Stuck or defective lift up valve 4H-4. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV6. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective check valve CV0. Clean valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective differential sensing valve DSV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective counterbalance valve CB9. Clean valve. Check O-rings on valve. Repair or replace valve as required. 6. Defective lift cylinder C3. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Main Boom Down. Stuck or defective lift down valve 4H-3. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV6. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective check valve CV0. Clean valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective differential sensing valve DSV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective counterbalance valve CB9. Clean valve. Check O-rings on valve. Repair or replace valve as required. 6. Defective lift cylinder C3. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. December 07 Page 4

142 Service and Maintenance Section 4 - Troubleshooting Information No Riser Boom Up. Stuck or defective riser up valve 4H-3. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective check valve CV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective check valve CV8. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective differential pressure sensing valve DSV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB5 or CB6. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Defective riser cylinder C6 or C7. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Riser Boom Down. Stuck or defective riser down valve 4H-30. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Plugged or defective orifice OR6. Check orifice. Replace if plugged or defective. 4. Stuck or defective check valve CV6. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective relief valve RV8. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 6. Stuck or defective check valve CV8. Clean valve. Check operation of valve. Repair or replace valve as required. 7. Stuck or defective differential pressure sensing valve DSV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 8. Stuck or defective counterbalance valve CB5 or CB6. Clean valve. Check O-rings on valve. Repair or replace valve as required. 9. Defective riser cylinder C6 or C7. Check seals on cylinder. Replace as necessary. Replace cylinder if defective Riser Boom Down Jerky. Stuck open or defective check valve CV5. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or incorrectly set counterbalance valve CB5 or CB6. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. Page 42 December 07

143 Section 4 - Troubleshooting Information Service and Maintenance No Turret Rotate Left. Stuck or defective rotate left valve 4H-32. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective relief valve RV7. Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required. 4. Stuck or defective differential pressure sensing valve DSV2. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB4. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Stuck or defective check valve CV7. Clean valve. Check operation of valve. Repair or replace valve as required. 8. Turret rotate brake BR2 not releasing. Inspect brake for worn seals or broken components. Repair and replace as necessary. 9. Worn or defective swing drive motor RA2. Check motor. Repair or replace if defective No Turret Rotate Right. Stuck or defective rotate right valve 4H-33. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective relief valve RV7. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 4. Stuck or defective differential pressure sensing valve DSV2. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB3. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Stuck or defective check valve CV7. Clean valve. Check operation of valve. Repair or replace valve as required. 8. Turret rotate brake BR2 not releasing. Inspect brake for worn seals or broken components. Repair and replace as necessary. 9. Worn or defective swing drive motor RA2. Check motor. Repair or replace if defective. December 07 Page 43

144 Service and Maintenance Section 4 - Troubleshooting Information No Boom Extend. Stuck or defective boom extend valve 3H-39. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged, incorrectly adjusted or defective orifice OR3. Check orifice. Replace if plugged or defective. 3. Stuck in the shifted position or defective boom retract valve 3H-38. Clean valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective check valve CV. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective counterbalance valve CB0. Clean valve. Check O-rings on valve. Repair or replace valve as required. 6. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Boom Retract. Stuck or defective boom retract valve 3H-38. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged, incorrectly adjusted or defective orifice OR3. Check orifice. Replace if plugged or defective. 3. Stuck or defective check valve CV. Clean valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective counterbalance valve CB. Clean valve. Check O-rings on valve. Repair or replace valve as required. 5. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Jib Up. Stuck or defective jib enable valve 2H-34A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice. Replace if plugged or defective. 3. Stuck or defective differential pressure sensing valve DSV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective check valve CV2. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective jib up valve 4H-35. Clean valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB2. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Defective jib cylinder C. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Jib Down. Stuck or defective jib enable valve 2H-34A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice. Replace if plugged or defective. 3. Stuck or defective differential pressure sensing valve DSV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. Page 44 December 07

145 Section 4 - Troubleshooting Information Service and Maintenance 4. Stuck or defective check valve CV2. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective jib down valve 4H-34. Clean valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB3. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Defective jib cylinder C. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Platform Rotation Right. Stuck or defective platform rotate enable valve 2H-36A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR. Check orifice. Replace if plugged or defective. 3. Stuck or defective differential pressure sensing valve DSV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective check valve CV2. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective platform rotate right valve 4H-37. Clean valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB4. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Defective rotary actuator RA. Check actuator. Repair or replace as necessary No Platform Rotation Left. Stuck or defective platform rotate enable valve 2H-36A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR. Check orifice. Replace if plugged or defective. 3. Stuck or defective differential pressure sensing valve DSV5. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective check valve CV2. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective platform rotate left valve 4H-36. Clean valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective counterbalance valve CB5. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Defective rotary actuator RA. Check actuator. Repair or replace as necessary Platform will not Level Down Manually. Plugged, incorrectly adjusted or defective orifice OR4. Check orifice. Replace if plugged or defective. 2. Stuck or defective platform level down valve 4H-40. Clean valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective shuttle valve SV7. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. December 07 Page 45

146 Service and Maintenance Section 4 - Troubleshooting Information 4. Stuck or defective shuttle valve SV8. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective check valve CV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective relief valve RV9. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 7. Stuck or defective counterbalance valve CB8. Clean valve. Check O-rings on valve. Repair or replace valve as required. 8. Stuck or defective check valve CV9. Clean valve. Check operation of valve. Repair or replace valve as required. 9. Defective leveling cylinder C4 or slave cylinder C5. Check seals on cylinder. Replace as necessary. Replace cylinder if defective Platform will not Level Up Manually. Plugged, incorrectly adjusted or defective orifice OR4. Check orifice. Replace if plugged or defective. 2. Stuck or defective platform level up valve 4H-4. Clean valve. Check operation of valve. Repair or replace valve as required. 3. Stuck or defective shuttle valve SV7. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective shuttle valve SV8. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective check valve CV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 6. Stuck or defective relief valve RV9. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 7. Stuck or defective counterbalance valve CB7. Clean valve. Check O-rings on valve. Repair or replace valve as required. 8. Stuck or defective check valve CV9. Clean valve. Check Check operation of valve. Repair or replace valve as required. 9. Defective leveling cylinder C4 or slave cylinder C5. Check seals on cylinder. Replace as necessary. Replace cylinder if defective Brake will not Release. Stuck or defective shuttle valve SV2. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective or misadjusted pressure reducing valve PR. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 3. Stuck or defective brake valve 3H-26. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Stuck or defective shuttle valve SV. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 5. Defective or misadjusted relief valve RV4. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. Page 46 December 07

147 Section 4 - Troubleshooting Information Service and Maintenance 6. Stuck or defective brake release override valve V. Clean valve. Check O-rings on valve. Repair or replace valve as required. 7. Bypassing or defective brake hand pump V3. Clean valve. Check O-rings on valve. Repair or replace valve as required. 8. Bypassing or defective brake cylinder C2. Check seals on cylinder. Replace as necessary. Replace cylinder if defective Brake will not Engage. Brake cylinder defective. Check cylinders. Repair or replace as necessary. 2. Brake valve 3H-26 stuck in shifted position. Check valve. Replace if defective. 3. Brake inside axle out of adjustment. See section 5 for brake adjustment procedure Differential Lock will not Engage. Stuck or defective shuttle valve SV2. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective or misadjusted pressure reducing valve PR. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 3. Stuck or defective differential lock valve 3H-65. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 4. Bypassing or defective differential lock cylinder C3. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Drive Forward or Reverse. Brake not releasing. See brake will not release in this section. 2. Defective or misadjusted charge pump relief valve RV3. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 3. Plugged or defective charge pump filter F. -Check filter. Replace if plugged or defective. 4. Worn charge pump PA. Check pump. Replace if defective. 5. Defective pump displacement control 4H-5 and 4H-6. Check control. Replace if defective. 6. Open bypass valve V4. Close bypass valve. 7. Worn drive pump P. Check pump. Replace if defective. 8. Worn or defective drive motor M. Check motor. Replace if defective No Forward Drive. Defective pump displacement control 4H-6. Check control. Replace if defective. 2. Defective or misadjusted drive relief valve RV. See section 5 for drive pump set up procedures. 3. Drive pump servo stuck or not shifting. Check pump. Replace if defective. December 07 Page 47

148 Service and Maintenance Section 4 - Troubleshooting Information No Reverse Drive. Defective pump displacement control 4H-5. Check control. Replace if defective. 2. Defective or misadjusted drive relief valve RV2. See section 5 for drive pump set up procedures. 3. Drive pump servo stuck or not shifting. Check pump. Replace if defective No High Speed Drive. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective shift spool in drive motor M. Check motor. Repair or replace if necessary No Right Steer. Plugged, incorrectly adjusted or defective priority flow control PFC. Check operation. Set flow rate to psi. Replace if plugged or defective. 2. Stuck or defective right steer valve 4H-23A. Clean valve. Check operation of valve. Repair or replace valve as required. 3. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary. Replace cylinder if defective No Left Steer. Plugged, incorrectly adjusted or defective priority flow control PFC. Check operation. Set flow rate to psi. Replace if plugged or defective. 2. Stuck or defective left steer valve 4H-24A. Clean valve. Check operation of valve. Repair or replace valve as required. 3. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary. Replace cylinder if defective Axle Will Not Oscillate NOTE Axle will only oscillate when boom is fully retracted and is horizontal or below.. Stuck or defective axle lockout valve 3H-65. Clean valve. Replace if defective. 2. One or more counterbalance valves (CB or CB2) failed to shift or is defective. Clean valve. Check O-rings on valve. Repair or replace valve as required. Page 48 December 07

149 Section 4 - Troubleshooting Information Service and Maintenance Axle Will Not Lock NOTE Axle is in constant float if boom is fully retracted and is horizontal or below.. Axle lockout valve 3H-65 is stuck in shifted position or is defective. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Bypassing or defective axle lock cylinders C9 and C0. Check seals on cylinder. Replace as necessary. Replace cylinder if defective. 3. Counterbalance valves (CB or CB2) out of adjustment or are defective. Clean valve. Check O-rings on valve. Repair or replace valve as required. December 07 Page 49

150 Service and Maintenance Section 4 - Troubleshooting Information 4.3 Load Sensing System - CE 4.3- Green Power LED is not Flashing. Loose or broken wires #60 and # at platform terminal block. Check for connections. Check for voltage (2V). 2. Load cell has lost its calibration. Refer to calibration procedure for recalibration of load cell Load Cell red Alarm LED is ON (with platform empty). Load cell has lost its calibration. Refer to calibration procedure for recalibration of load cell Red Error LED is ON. Open safety contact circuit. Check for connections with wires #6 and #62A at platform terminal block and base terminal block. Check resistor R6 for 680 ohms Load Cell red Alarm LED is OFF (with platform overloaded). Open safety contact circuit. Check for connections with wires #6 and #62 at platform terminal block and base terminal block. Check resistor R6 for 680 ohms Platform Indicator Light does not turn ON. Defective lamp. Check lamp. Replace if defective. 2. Defective relay 82CR. Check relay. Replace if defective. 3. Load cell circuit not operating. Check for connections with wire #B at pilot light strip and relay 82CR, and wire #82 at platform terminal block and relay 82CR. 4. Defective load cell. Defective if 0V is measured between wire #82 and # from platform terminal block Audible Alarm does not turn ON. Defective alarm BP3. Check alarm. Replace if defective. 2. Open or defective diode D8. Check diode. Replace if defective. 3. Load cell circuit not operating. Check for connections with wires # and #8 at platform terminal block. 4. Defective load cell. Defective if 0V is measured between wire #8 and # from platform terminal block Boom and Drive Functions are Enabled (with boom extended). Fly IN limit switch LS3 is not operating properly. Check for voltage (0V) between wires #59 and # from platform terminal block. If 2V is measured, check for proper actuation of limit switch. Readjust limit switch if necessary. 2. Defective load cell. Safety contact remains closed. Check for voltage (0V) between wires #62 and # from base terminal block. Defective if 2V is measured. Page 50 December 07

151 Section 5 PROCEDURES Table of Contents General...53 Safety and Workmanship...53 Platform 5.- Human Machine Interface (HMI) User Interface Keys How to Select Functionality How to View OCM Operation How to Unlock and Modify OCM Settings OCM Pin Voltage Reference Platform Controller Voltage References...62 Boom 5.2- Check Wear Pads Shimming Wear Pads Cable Carrier Repair Master Cylinder Replacement...64 Turret 5.3- High Pressure Filter Replacement Check Swing Drive Motor Gearbox Oil Turret Rotation Gear Backlash Adjustment Swing Drive Motor Removal Swing Drive Motor Replacement Swing Drive Brake and Gearbox Oil Replacement Battery Replacement Bolt Torque Procedure Electronic Tilt Switch Setup Procedure Check Rotation Bearing for Axial Wear...73 Deutz Diesel Engine 5.4- Engine Oil and Filter Replacement Fuel Filter Replacement Air Filter Replacement Check Engine Belt Check Oil Cooler...75 GM Dual Fuel Engine 5.5- GM Map and IAT Sensor (3.0L GM Engine) LPG Temperature Sensor (3.0L GM Engine) Throttle Actuator (3.0L GM Engine) Engine Coolant Temperature Sensor (3.0L GM Engine) ECU Pin Reference Chart (3.0L GM Engine) Fuse Block Layout (3.0L GM Engine)...8 Kubota WG2503 Dual Fuel Engine 5.6- Engine Parameter Display (KAntrak 700) December 07 Page 5

152 Service and Maintenance Section 5 - Procedures Table of Contents Diagnostic Trouble Codes ECU Pin Reference Chart (Kubota WG2503) Fuse Box (Kubota WG2503) MAP Sensor (Kubota WG2503) IAT Sensor (Kubota WG2503) ECT (Kubota WG2503) TPS & Engine Speed (Kubota WG2503) Fuel Temperature Sensor (Kubota WG2503) Oil Pressure Sensor (Kubota WG2503)...92 Hydraulic Tank 5.7- Hydraulic Oil Replacement Hydraulic In-tank Filter Replacement...93 Manifold and Hydraulic Pumps 5.8- Hydraulic Brake Pressure Adjustment Hydraulic System Relief Valve Adjustment Riser Down Relief Valve Adjustment Turret Rotate Relief Valve Adjustment Platform Level Relief Valve Adjustment Test Charge Pump Pressure on Drive Pump Test Forward Drive Pressure on Drive Pump Test Reverse Drive Pressure on Drive Pump...98 Axles 5.9- Rear Axle Oil Replacement Front Axle Oil Replacement Check Torque Hub Oil Level Check Axle Gearbox Oil Level Axle Gearbox Oil Replacement Oscillating Cylinder Bolt Replacement Oscillating Cylinder Replacement Bleeding Oscillating Axle Cylinders Pin Brake Adjustments...2 Grease Points 5.0- Lubrication...4 Options 5.- Load Sensing System - CE...6 Page 52 December 07

153 Section 5 - Procedures Service and Maintenance General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter. Safety and Workmanship Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided. Platform 5.- Human Machine Interface (HMI) Maintaining proper calibration is essential for good performance of the aerial platform.. Ensure aerial platform is on a firm level surface, and is in stowed position and engine is off. 2. On base control, turn base/off/platform key switch to platform position. 3. Pull out emergency stop button. WARNING Ensure that you maintain three points of contact to mount/dismount platform. 4. Enter platform and close gate. WARNING DO NOT operate any control on platform control console without proper fall protection secured to designated location in platform. Failure to avoid this hazard could result in death or serious injury! WARNING Ensure that there are no personnel or obstructions in test area and that there is sufficient room for boom to swing. 5. At platform control, open the cover of the console to access the OCI- console. The OCI- has an integrated multi segment, two line display with membrane keys that allow it to be used as the main interface to system controls and adjustments. the Human Machine Interface (referred to as the HMI) will serve as your window into the application software to allow the operator to monitor/adjust the following information; - Active Function Being Used - Part Number and Serial Number - Restore the Factory Default Settings - Output Calibrations (Tresh, Max, Ramp.etc) - I-O Status - CANBus Status December 07 Page 53

154 Service and Maintenance Section 5 - Procedures 5.-2 User Interface Keys.0. MENU SELECT.0- <MENU> enters a new menu screen and/or.0-2 <SELECT> select the flashing item..- <MINUS> decreases an adjustable parameter such as ramp time..-2 <DOWN> selects the previous item in the current menu s list <PLUS> increases an adjustable parameter..2-2 <UP> selects the next item in the current menu s list..3 SAVE.3- <SAVE> saves the new data to EEPROM (permanent memory storage)..4 + Simultaneously press <UP> and <DOWN> will reset the HMI to menu screen 0. OCM Character Functions Charts OCM Keypad Function Attribute Keys Short Form THRESH Threshold Menu/Select (M/S) RAMPDN Ramp Down /- (-) RAMPUP Ramp Up /+ (+) LOWRNG Low Range Save/Exit (S/E) MAXOUT Maximum Output 60584AA OCM Function (Channel) Names DRIVE REV Fn0A Drive Reverse DRIVE FWD Fn0B Drive Forward CHAN 2A FnA Brakes CHAN 2B FnB Differential Lock Enable BOOM DOWN Fn03A Main Boom Down BOOM UP Fn03B Main Boom Up ROTATE L FnA Turret Rotate Left ROTATE R FnB Turret Rotate Right RISER DN Fn05A Riser Down RISER UP Fn05B Riser Up RISER UP Fn06A Virtual channel RISER UP Fn06B Virtual channel 29AB Page 54 December 07

155 Section 5 - Procedures Service and Maintenance OCM Operating Values Chart Input (Analog) Expected Value Description AI 0.5V to 8.5V Drive Controller AI 2 0.5V to 8.5V Turret Rotate Controller AI 3 0.5V to 8.5V Boom Elevation Controller AI 4 0.5V to 8.5V Riser Controller AI 7.0V to 5.0V Torque Mode (Angle Sensor) Input (Digital) Expected Value Description DI 0 or Drive Direction Reverse Limit Switch DI 2 0 or Footswitch Actuated DI 3 0 or Steer Left Rocker Switch DI 4 0 or Steer Right Rocker Switch DI 5 0 or Boom Function Toggle Switch Enabled DI 6 0 or 5 Degree Tilt Switch DI 0 or High Speed Drive Enable Limit Switch Output (PWM) Expected Value Description PWM 3% - 80% Drive Reverse PWM 2 3% - 80% Drive Forward PWM 3 0% or 00% Brake (Energized to Release) PWM 4 0% or 00% Differential Lock Enable PWM 5 27% - 45% Main Boom Down PWM 6 27% - 55% Main Boom Up PWM 7 30% - 50% Turret Rotate Left PWM 8 30% - 50% Turret Rotate Right PWM 9 50% - 55% Riser Down PWM 0 28% - 70% Riser Up Output (Digital) Expected Value Description DOUT 0 or Steer Left DOUT 2 0 or Load Sense Enable DOUT 3 0 or Footswitch Actuated Indicator DOUT 4 0 or Axle Lock (0=enabled) DOUT 7 0 or Tilt Alarm Indicator DOUT 8 0 or Steer Right 28AC December 07 Page 55

156 Service and Maintenance 5.-3 How to Select Functionality Section 5 - Procedures AC STARTING SCREEN MODE: NO CONFIG FUNCTIONS OFF + ENTER PASSWORD 0** 0 (FLASHING) MENU SELEC UNLOCK SETUP? PRESS SELECT (FLASHING) + SOFTWARE REVISION MODEL SERIAL NUMBER 5X + ENTER PASSWORD 5** 5 (FLASHING) MENU SELECT ENTER PASSWORD 50** 0 (FLASHING) X + ENTER PASSWORD 5** (FLASHING) SETUP UNLOCKED PRESS OR + (FLASHING) MENU SELECT ENTER PASSWORD 59 9 (FLASHING) 9X + ENTER PASSWORD 50 0 (FLASHING) MENU SELECT + SET DRIVE TIMER PRESS SELECT (FLASHING) + SET B BOUNDARY PRESS SELECT (FLASHING) + SET LRNG B&C PRESS SELECT (FLASHING) + MODE: CONFIG FUNCTIONS OFF SAVE EXIT TO SELECT MODEL + MENU SELECT SELECT MODEL # PRESS SELECT (FLASHING) RESTORE DEFAULTS (FLASHING) SELECT MULTIFNCT PRESS SELECT (FLASHING) MENU SELECT SELECT MULTIFNCT STD LTD (FLASHING) SAVE EXIT NOTE STD LTD Machines for the North American market (ANSI/CSA models) Machines for the European market (CE models) Recycle power to the OCM with E Stop to re enable password protection. If the OCM is inactive for more than 5 minutes, password must be re entered. USE THE CHART TO THE LEFT TO DETERMINE THE FUNCTIONALITY REQUIRED FOR YOUR MACHINE. PRESS SAVE/EXIT WHEN THE FUNCTIONALITY FOR YOUR MACHINE CONFIGURATION IS FLASHING. Page 56 December 07

157 Section 5 - Procedures Service and Maintenance 5.-4 How to View OCM Operation As a joystick or toggle switch is being activated, the OCM screen will display the active function and % output. Also, the following procedure will allow monitoring of all input and output channels: STARTING SCREEN CE Models MODE= XX/XX LTD FUNCTIONS OFF OR ANSI/CSA Models MODE= XX/XX STD FUNCTIONS OFF SAVE EXIT ADJUST (FLASHING) MENU SELECT IO TEST (FLASHING) MENU SELECT MENU SELECT MENU SELECT MENU SELECT Di to Di5 DISPLAYED Ai to Ai3 DISPLAYED Do to Do5 DISPLAYED Ai4 to Ai6 DISPLAYED SAVE EXIT Di6 to Di0 DISPLAYED Do6 to Do8 DISPLAYED Ai7 DISPLAYED Di to Di2 DISPLAYED SAVE EXIT PWM to PWM2 DISPLAYED PWM3 to PWM4 DISPLAYED PWM5 to PWM6 DISPLAYED PWM to PWM2 DISPLAYED PWM9 to PWM0 DISPLAYED PWM7 to PWM8 DISPLAYED MENU SELECT VDD POWER SUPPLY VALUE = VOLTAGE MENU SELECT 8V SENSOR SUPPLY VALUE = VOLTS See OCM Operating Values Chart on page 55 for operating valves for the previous observations. December 07 Page 57

158 Service and Maintenance Section 5 - Procedures 5.-5 How to Unlock and Modify OCM Settings CE Models MODE= XX/XX LTD FUNCTIONS OFF STARTING SCREEN ANSI/CSA Models OR MODE= XX/XX STD FUNCTIONS OFF MENU SELECT UNLOCK SETUP? PRESS SELECT (FLASHING) SOFTWARE REVISION MODEL SERIAL NUMBER ENTER PASSWORD 0** 0 (FLASHING) 7X ENTER PASSWORD 7** 7 (FLASHING) MENU SELECT ENTER PASSWORD 70* 0 (FLASHING) 5X MENU SELECT ENTER PASSWORD (FLASHING) 5X ENTER PASSWORD (FLASHING) MENU SELECT ENTER PASSWORD 75* 5 (FLASHING) SETUP UNLOCKED PRESS - OR + (FLASHING) SET DRIVE TIMER PRESS SELECT (FLASHING) SAVE EXIT MODE: XXXXX FUNCTIONS OFF DISPLAYED MENU SELECT ADJUST (FLASHING) MENU SELECT (DRIVE REV) THRESH Fn0A VALUE= % (FLASHING) ONCE THE VALUE HAS BEEN ADJUSTED WITHIN THE PARAMETER OF THE FUNCTION SELECTED, YOU MAY CONTINUE TO ANOTHER ADJUSTABLE PARAMETER OR SAVE/ EXIT ALL THE WAY OUT TO THE START SCREEN XXXX XX (THRESH) Fn0XX VALUE= % (FLASHING) MENU SELECT (DRIVE FWD) THRESH Fn0B VALUE= % (FLASHING) SAVE EXIT Decreases Value TOGGLE TOGGLE Recycle power to the OCM with the E-Stop to re-enable password protection. If the OCM is inactive for more than 5 minutes, password must be re-entered. Increases Value XXXX XX (XXXXXX) Fn0XX VALUE = % or SEC (FLASHING) MENU SELECT XXXX XX (THRESH/MAXOUT/ LOWRNG/RAMPUP/RAMPDN) Fn0XX VALUE= % (FLASHING) (DRIVE REV) THRESH Fn0A VALUE= % + (DRIVE FWD) THRESH Fn0B VALUE= % + (CHAN 2A) THRESH FnA VALUE= % + (CHAN 2B) THRESH FnB VALUE= % + (BOOM DOWN) THRESH Fn03A VALUE= % + (BOOM UP) THRESH Fn03B VALUE= % + + (ROTATE L) THRESH FnA VALUE= % + (ROTATE R) THRESH FnB VALUE= % + (RISER DOWN) THRESH Fn05A VALUE= % + + (RISER UP) THRESH Fn05B VALUE= % (LR REV) THRESH Fn06A VALUE= % (LR FWD) THRESH Fn06B VALUE= % (FLASHING) Page 58 December 07

159 Section 5 - Procedures Service and Maintenance 5.-6 OCM Pin Voltage Reference All voltages given are with OCM controller at maximum % adjustable settings. All voltages should be tested with key on, engine off and foot switch depressed. All tests should be performed with platform over drive axle, boom fully stowed and on flat level surface. Pin - 2 volt input from wire 4. Test between pin and wire. Pin 2-2 volt input from wire 4. Test between pin 2 and wire. Pin 3 - Pin 4 - Pin 5 - Pin 6 - Pin 7 - Pin 8 - Pin 9 - Not used. 2 Volt output on wire 24A to left steer valve 4H-24A Test between pin 4 and wire. 2 volt output on wire to dump valve relay 2CR. Test between pin 5 and wire while selecting a function. 2 volt output on wire 08 to toggle switch boom functions. (Foot switch activated) Test between pin 6 and wire. 2 volt output on wire 65 to axle lock valve 3H-65. Test between pin 7 and wire. Boom down selected. Proportional output on wire 3 to boom down valve 4H-3. 0 volts to 5.5 volts depending on position of joystick. Threshold=.0 volt. Test between pin 8 and wire while operating boom down. Riser up selected. Proportional output on wire 3 to riser up valve 4H-3. 0 volts to 7.5 volts depending on position of joystick. Threshold= 2.8 volts. Test between pin 9 and wire while operating boom down. Pin 0-2 volt output on wire 26 brake valve 3H-26. 2V=Footswitch activated. Test between pin 0 and wire. December 07 Page 59

160 Service and Maintenance Section 5 - Procedures Pin - 2 volt output on wire 27 to tilt alarm relay 27CR. Test between pin and wire Pin 2 - Riser down selected. Proportional output on wire 30 to riser down valve 4H volts to 4.3 volts depending on position of joystick. Threshold= 2.8 volts.. Test between pin 2 and wire. Pin 3-2 volt input from wire 4. Test between pin 3 and wire. Pin 4 - Variable input from wire 28A. volt to 5 volts depending on angle of machine. volt = Level Test between pin 4 and wire. Pin 5 - Turret position. 2 volt input from limit switch LS on wire 7. 0 volts= Platform over drive axle. 2 volts= Platform over steer axle. Test between 5 and wire. Pin 6 - Foot switch activated. 2 volt input from wire 08A. Test between pin 6 and wire. Pin 7 - Left steer selected. 2 volt input from wire 24. Test between pin 7 and wire. Pin 8 - Right steer selected. 2 volt input from wire 23. Test between pin 8 and wire. Pin 9-2 Volt output on wire 26A to differential lock switch. Test between pin 9 and wire. Pin - Turret rotate left selected. Proportional output on wire 32 to turret rotate left valve 4H volts to 6.0 volts depending on position of joystick. Threshold= 3.5 volts. Test between pin and wire while operating turret rotate left.. Pin 2-2 Volt output on wire 23A to right steer valve 4H-23A Test between pin 2 and wire. Pin 22 - Boom up selected. Proportional output on wire 4 to boom up valve 4H-4. 0 volts to 6.5 volts depending on joystick position. Threshold= 3.2 volts. Test between pin 22 and wire while operating boom up. Pin 23 - Reverse drive selected. Proportional output on wire 5 to reverse drive valve 3H-5. 0 volts to 5.5 volts depending on joystick position. Threshold=. volts. Test between pin 23 and wire while operating reverse drive. Pin 24 - Battery negative. Wire. Pin 25 - Battery negative. Wire. Page 60 December 07

161 Section 5 - Procedures Service and Maintenance Pin 26 - Battery negative. Wire. Pin 27 - Accelerator input. Wire D from drive joystick controller. Neutral position= 4.2 volts to 4.8 volts. Forward function= 4.9 volts to 8.5 volts. Reverse function= 4. volts to.5 volts. Test between pin 27 and wire. Pin 28 - Turret rotate input. Wire X from boom joystick controller. Neutral position= 4.2 volts to 4.8 volts. Rotate right function= 4.9 volts to 8.5 volts. Rotate left function= 4. volts to.5 volts. Test between pin 28 and wire. Pin 29 - Boom elevation input. Wire Y from boom joystick controller. Neutral position= 4.2 volts to 4.8 volts. Boom up function= 4.9 volts to 8.5 volts. Boom down function= 4. volts to.5 volts. Test between pin 29 and wire. Pin 30 - Riser input. Wire R from riser joystick controller. Neutral position= 4.2 volts to 4.8 volts. Boom up function= 4.9 volts to 8.5 volts. Boom down function= 4. volts to.5 volts. Test between pin 30 and wire. Pin 3-2 volt input from LS2 boom/riser elevation limit switch and LS3 telescope limit switch on wire volts= full speed. 0 volts= creep speed (one or more limit switches open). Test between pin 3 and wire. Pin 32-2 volt input from angle sensor on wire 28. 2V=<5% Test between pin 32 and wire. Pin 33 - Toggle switch boom function enable. 2 volt input from wire A. Test between pin 33 and wire. Pin 34 - Forward drive selected. Proportional output on wire 6 to forward drive valve 3H-6. 0 volts to 5.7 volts depending on joystick position. Threshold=.2 volts. Test between pin 34 and wire while operating forward drive. Pin 35 - Turret rotate right selected. Proportional output on wire 33 to turret rotate right valve 4H volts to 6.0 volts depending on position of joystick. Threshold= 3.5 volts. Test between pin 0 and wire while operating turret rotate right. December 07 Page 6

162 Service and Maintenance Section 5 - Procedures 5.-7 Platform Controller Voltage References Boom/Turret (A) Controller Boom Up Y 2 Volts RED (+) POWER RED/YEL Turret Rotate Left X Neutral Position Volts Turret Rotate Right BLK(-) GROUND WHT WHT(X) X-SIGNAL RED BLU(Y) Y-SIGNAL BLU Pin 28 Pin 29 OCM Boom Down Reference Analog Input AI 3 Reference Analog Input AI 2 Turret Rotation (X axis) Neutral Position = Volts Right = full stroke Left = full stroke Boom Elevation (Y axis) Neutral Position = Volts Up = full stroke Down = full stroke Page 62 December 07

163 Section 5 - Procedures Service and Maintenance 5.-7 Platform Controller Voltage References (Cont d) Drive (A2) Controller 2 Volts Drive Forward YEL POWER RED Pin 27 Pin 7 Pin 8 WHT GROUND BLK BLK D SIGNAL YEL 24 BLU/BLK LEFT WHT/RED 23 BLK/WHT RIGHT WHT/YEL Neutral Position Volts OCM Drive Reverse Reference Analog Input AI 2 Volts Left Steer Selected 2 Volts Right Steer Selected Neutral Position = Volts Forward = full stroke Reverse = full stroke Riser (A3) Controller Riser Up Pin 30 RED/YEL POWER RED WHT GROUND BLK R RED/GRN R SIGNAL YEL Neutral Position Volts OCM Reference Analog Input AI 4 RiserDown 2 Volts Neutral Position = Volts Forward = full stroke Reverse = full stroke December 07 Page 63

164 Service and Maintenance Boom 5.2- Check Wear Pads. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Start engine from base control console. 3. Raise main boom to a comfortable working height (chest high), and then extend fly boom approximately foot (30 cm). 4. Measure the thickness of each wear pad and replace wear pad if it is less than 7/6 inches ( mm) 5. If wear pad is within specified thickness, shim as necessary Shimming Wear Pads. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Raise main boom to a comfortable working height (chest high) and extend fly boom until wear pad are accessible. 3. Loosen wear pad fasteners. 4. Shim as necessary to obtain zero to /32 clearance and zero drag. Fly Boom Section 5 - Procedures Cable Carrier Repair The cable carrier can be repaired by simply using a screwdriver. Each crossbar can be snapped off from either side of the chain either by hand or by using the screwdriver as a lever. New crossbars may be installed by snapping links together. Female Side Crossbar Cable Carrier Assembly Master Cylinder Replacement Male Side. Ensure aerial platform is parked on a firm and level surface. WARNING Ensure that there is sufficient room for boom to swing and elevate. WARNING Shim Wear Pad Shim & Feeler Gauge /32 Feeler Gauge Be aware of overhead obstructions or other possible hazards around the machine when lifting. 2. By using the base controls, position the machine as below to allow for easy work access to the basket/jib boom and the master cylinder. 5. Extend and retract fly boom through the entire range of motion and observe for loose points. NOTE Always maintain squareness between the boom s outer and inner tubes. Machine Setup Position Page 64 December 07

165 Section 5 - Procedures Master Cylinder Master Cylinder Connecting Pin Service and Maintenance 6. Remove the hydraulic hoses and fittings on the master cylinder. Replace any worn or damaged component. 7. Disconnect the master cylinder from the main boom by removing the connecting pin, see below. Store all parts aside for reuse. Machine Setup Position 2 3. Turn main disconnect switch to off position. Lock the switch to prevent unauthorized use during this procedure. NOTE Ensure the all components are secured before lifting or removing 4. Using straps, secure the main boom on a suitable lifting equipment such as a crane. 5. Secure the master cylinder with straps. For example see below. Master Cylinder Connecting Pin Master Cylinder Removal 8. Install the new master by installing the cylinder pins as shonw above. Secure the keeper pin and the bolt with Loctile 242 (Blue) or equivalent. 7. Install the hydraulic hoses and fittings on the master cylinder. Master Cylinder Secured with Straps CAUTION Label all electrical cables and hydraulic hoses before removal CAUTION To prevent hydraulic system contaminations, cap all hydraulic hoses and fittings after removal. December 07 Page 65

166 Service and Maintenance Turret 5.3- High Pressure Filter Replacement. Turn engine off. 2. Place a suitable container under filter. Head Section 5 - Procedures Turret Rotation Gear Backlash Adjustment Adjusting the backlash clearance will allow proper mating between the turret rotation gear and the swing drive motor gear. WARNING Ensure that there are no personnel or obstructions in test area and there is sufficient room for boom to swing and elevate. Housing Bolt High Pressure Filter Filter 3. Using a 30 mm box wrench, loosen bolt and remove high pressure filter housing from filter head. 4. Remove high pressure filter from filter head and install a new high pressure filter. 5. Apply hydraulic oil to the o-ring on the high pressure filter housing. 6. Reinstall filter and re-tighten bolt Check Swing Drive Motor Gearbox Oil. Remove gearbox fill plug. 2. Check oil level (oil level should be slightly below the plug, see below). Add oil if needed. For oil specification, Refer to section 2. Swing Drive Motor Mount Fastener Adjustment Bolt & Nut Swing Drive Assembly NOTE The adjustment of the backlash must be performed on a flat level surface.. Ensure aerial platform is on a firm level surface. WARNING Operator must lock the turret to base to prevent the turret from spinning spontaneously. Fill to here Gearbox Fill Port Turret Lock Pin Base Turret Lock Pin Page 66 December 07

167 Section 5 - Procedures Service and Maintenance 2. Lock the turret to base with the turret lock pin. 3. Raise riser boom to access the swing drive motor. 4. Support the boom with an overhang crane. Do not lift the boom. 5. Turn main disconnect switch to off position. 6. Loosen mounting fasteners on the swing drive motor. 7. Pull the swing drive motor towards the center of turret as close as possible. (this will push the rotation gear into the rotation bearing) 8. Loosen lock nut on adjustment bolt. 9. Tighten adjustment bolt clockwise until it contacts the plate of gearbox. 0. Turn adjustment bolt /2 turn counterclockwise, then tighten lock nut on adjustment bolt.. Push the swing drive motor towards the counterweight until it contacts the adjustment bolt. 2. Tighten mounting fasteners on swing drive motor. 3. Unlock the turret lock pin. 4. Turn main disconnect switch to ON position. 5. Rotate turret through an entire rotation and check for a smooth rotation of the turret. 6. Adjust adjustment bolt until smooth rotation of the turret is achieved. 7. Unsecure riser boom and lower boom Swing Drive Motor Removal The swing drive motor is located near the center of the turret, underneath the riser/main boom. WARNING Operator must lock the turret to base to prevent the turret from spinning spontaneously. Turret Lock Pin Base Turret Lock Pin 2. Lock the turret to base with the turret lock pin. 3. Raise riser boom to access the swing drive motor. 4. Support the boom with an overhang crane. Do not lift the boom. 5. Turn main disconnect switch to off position. 6. Remove mid-turret cover. 7. Label the hydraulic hoses connected to swing drive and then remove hoses from motor. Plug hoses and fittings to prevent hydraulic contamination. 8. Loosen adjustment bolt and remove mounting fasteners fromm the swing drive motor. 9. use a lift device to remove swing drive motor out away from turret and place it aside. Lift Lugs WARNING Ensure that there are no personnel or obstructions in test area and there is sufficient room for boom to swing and elevate.. Ensure aerial platform is on a firm level surface. Swing Drive Lift Lugs December 07 Page 67

168 Service and Maintenance Swing Drive Motor Replacement. Refer to procedure Swing Drive Motor Removal. 2. Use a lift device to position new swing drive motor onto turret and loosely bolt swing drive motor to turret. 3. Refer to step 7 to 8 of procedure Turret Rotation Gear Backlash Adjustment to complete this procedure. Section 5 - Procedures Battery Replacement. Turn main disconnect switch to off position. Anchor Plate and Nuts Rods Swing Drive Brake and Gearbox Oil Replacement Periodic replacement of the motor/brake oil is essential to good motor performance. Battery Battery Pad. Refer to procedure Swing Drive Motor Removal. 2. Remove plug and drain old oil from the brake motor. Brake Drain/Fill Port Gearbox Ports Gearbox Fill Port Gearbox Drain Port Battery Assembly 2. Unlock and swing out engine tray from turret. 3. Remove positive and negative connector from battery. 4. Remove the battery. 5. Replace battery pad if needed. 6. Replace and secure the new battery. 7. Clean terminal posts and clamps of battery, and apply acid-free and acid-resistant grease. 8. Re-connect battery with the positive and negative connector cables. (Ensure the clamps make good contact) 9. Swing back and lock engine tray. 3. Refill brake motor with new oil and plug the port. For oil specification, Refer to Section Remove plug and drain old oil from gearbox. 5. Refill gearbox with new oil and plug the port. For oil specification, Refer to Section Use a lift device to position swing drive motor onto turret and loosely bolt swing drive to turret. 7. Refer to step 7 to 8 of procedure Refer to Turret Rotation Gear Backlash Adjustment to complete this procedure. Page 68 December 07

169 Section 5 - Procedures Bolt Torque Procedure Maintaining proper torque is essential to safe aerial platform operation. Improper bolt torque could result in an unsafe operating condition and component damage. Rotary Actuator Bolt Torque Sequence. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Turn main power disconnect switch to off position. 3. Set the torque wrench to 7 ft.ib and tighten mounting bolts in a cross pattern sequence Bolt Torque Sequence 4. Set torque wrench to 35 ft.ib and tighten mounting bolts with the same sequence. 5. Torque the center bolt to 480 ft.lb Service and Maintenance Turret Rotation Gear Bolt Torque Sequence. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Turn main power disconnect switch to off position. 3. Set the torque wrench to 85 ft.lb and tighten mounting bolts in a cross pattern sequence Bolt Torque Sequence 8 Outer Ring Gear 7 4. Set torque wrench to 70 ft.ib and tighten 4 mounting bolts with the same sequence Repeat step 3-4 6for bolt 2 torque sequence inner ring gear Bolt Torque Sequence Inner Ring Gear December 07 Page 69

170 Service and Maintenance Section 5 - Procedures Electronic Tilt Switch Setup Procedure The following information is supplied for replacement or reprogramming of the electronic tilt switch. Also included are test and verification instructions. Follow the appropriate procedures below. Tilt Switch Replacement 7. Install new switch to mount and connect switch plug to 4 pin connector. NOTE The tilt circuit is only powered when controls are powered up. 8. Turn main disconnect switch to ON position. Y AXIS X AXIS 9. Turn base/off/platform key switch to base position. 0. Pull out all emergency stop buttons.. Verify switch is powered. (Red or green LED will be continually blinking) Red LED Green LED Red LED Green LED. Ensure aerial platform is parked on a firm level surface. 2. Fully lower platform and retract fly boom. 2. Program the Tilt Switch a. Press and release the set up button 3 times. Observe LED flash codes as shown below. 3. Chock or block wheels to keep the aerial platform from rolling forward or backward. 4. Push in emergency stop buttons and turn main power disconnect switch to off position. 5. Disconnect tilt switch from 4 pin connector. NOTE Ensure part number of old and new tilt switch are the same. 6. Remove old tilt switch from mount. b. Only the red LED will blink for 4 seconds. c. Both LEDs will flash for second. Results: The switch is learning the new zero position. d. Both LEDs will turn on solid for second. Results: The new zero position has been learned. Red LED Green LED Red LED Green LED Red LED Green LED Page 70 December 07

171 Section 5 - Procedures e. The green LED will flash and then the red LED will turn on solid for 2 seconds. Results: The switch is verifying the new zero position. Service and Maintenance Reprogramming Existing Tilt Switch Light Indicators Set up button is located on this face next to harness Red LED Green LED Red LED Green LED Red LED Green LED f. The green LED will turn on solid. Results: The switch is ready for normal operation. Red LED Green LED 3. Turn main power disconnect switch to off position 4. Push in emergency stop buttons. 5. Remove chock or wheel blocks. 6. Proceed to Test and Verify Tilt Circuit.. Ensure aerial platform is parked on a firm level surface. 2. Fully lower platform and retract fly boom. 3. Chock or block wheels to keep the aerial platform from rolling forward or backward. NOTE The tilt circuit is only powered when controls are powered up. 4. Turn main disconnect switch to ON position. 5. Pull out all emergency stop buttons. 6. Turn base/off/platform key switch to base position. 7. Verify switch is powered. (Red or green LED will be continually blinking) Red LED Green LED Red LED Green LED 8. Reprogram the Tilt Switch a. Press and hold the set up button for 3 seconds. Results: Both LEDs will be OFF. Red LED Green LED December 07 Page 7

172 Service and Maintenance Section 5 - Procedures b. Both LEDs will flash. Red LED Green LED 9. Turn main power disconnect switch to off position. 0. Push in emergency stop buttons. IMPORTANT Step c must be completed within a 5 second period or the switch will automatically exit program mode and return to normal operation using previously stored data.. Remove chock or wheel blocks. 2. Proceed to Test and Verify Tilt Circuit. Test and Verify Tilt Circuit c. Press and release set up button 3 times. d. If 5 second period has expired prior completion, repeat Step a, b and c. Light Indicators Set up button is located on this face next to harness e. Observe program delay / stabilization time. (Only the red LED will blink for 4 seconds) Red LED Green LED Red LED Green LED f. Both LEDs will flash for second. Results: The switch is learning the new zero position. g. Both LEDs will turn on solid for second. Results: The new zero position has been learned. Red LED Green LED Red LED Green LED h. The green LED will flash and then the red LED will turn on solid for 2 seconds. Results: The switch is verifying the new zero position. Operations of Tilt Switch The following describes the LED s and what they indicate. Green LED Red LED Green & Red LED Illuminated whenever both tilt axes are within the specified degrees of the zero/ home learned position. Flashes when transitioning in or out of tilt angle limits, but built in time delay has not fully occurred. Illuminated whenever tilt on one or more axes is more than the specified degrees out from the zero/ home position. On together, no blinking when fault detected. Red LED Green LED i. The green LED will turn on solid. Results: The switch is ready for normal operation. Red LED Green LED Red LED Green LED Tilt Circuit Test. Refer to the Operating Manual s Test Tilt Sensor procedure within Functions Tests. Page 72 December 07

173 Section 5 - Procedures Service and Maintenance Check Rotation Bearing for Axial Wear. Position the boom so that it is centered over the front drive and steer axle and is horizontal with the ground. 2. Extend the boom to its full extension length. 3. Mount a dial indicator on the chassis. Place the dial indicator set directly under the boom, close to the bearing teeth. Make sure to allow clearance as the turret assembly rotates. 4. Position the indicator arm or shaft so that the pointer touches the bottom surface of the turret weldment. TURRET CHASSIS Check Axial Wear of the Rotation Bearing 5. Zero the dial indicator. 6. Rotate the turret 80 in the clockwise direction until the boom is centered over the rear axle. (Rotating the turret in the counterclockwise direction will cause the rotation gearbox pinion to impact the dial indicator). 7. If, when you are rotating the turret, the boom needs to be retracted or raised to avoid obstacles, be sure to again fully extend and level the boom when it is positioned over the rear axle. Do not be concerned with any dial indicator readings as the turret assembly rotates. 8. With the boom assembly rotation stopped and the boom centered over the rear axle, read the dial indicator and record the reading. This reading is the total amount of axial movement in the bearing assembly. If this reading is 0.00 (2.54 mm) or greater, the rotation bearing should be removed and replaced. December 07 Page 73

174 Service and Maintenance Deutz Diesel Engine Maintaining the engine components is essential to good performance and service life of the aerial platform Engine Oil and Filter Replacement Periodic replacement of the engine oil and filter is essential to good engine performance. NOTE Perform this operation after warming the engine to normal operating temperature. CAUTION Beware of hot engine components. Contact with hot engine components may cause severe burns. CAUTION When draining hot oil, there is a risk of scalding. Do not let used oil run into the soil, rather collect it in a container. Dispose of this in accordance with environmental regulations. Section 5 - Procedures 5. Remove oil filter and catch any escaping oil. 6. Clean the filter mounting surface on engine. 7. Add clean engine oil to new oil filter. 8. Apply a thin layer of engine oil to the new oil filter gasket. 9. Install filter and tighten it by hand. 0. Install oil drain plug with new seal ring and tighten firmly.. Refill engine with new oil as per specifications (Refer to engine manual). 2. Clean up any oil that may have spilled during this procedure. 3. Start engine from base control console and allow engine to run for 30 seconds then stop the engine. 4. Check for oil leakage. 5. Check engine oil level on dipstick and add oil if needed. NOTE Refer to your national/local regulations on how to dispose of used filter and oil.. Ensure aerial platform is on a firm level surface. 2. Allow engine to warm up. 3. Place suitable container under engine. 4. Remove oil drain plug and allow all engine oil to drain into container. Page 74 December 07

175 Section 5 - Procedures Fuel Filter Replacement. Place suitable container under engine filter. 2. Remove fuel filter and catch any escaping fuel. 3. Clean any dirt from filter carrier sealing surface. 4. Apply a thin layer of oil or diesel fuel to rubber gasket of new fuel filter. 5. Install fuel filter and tighten it by hand then tighten filter cartridge with final half-turn. 6. Use the fuel hand pump to pump fuel into filter. 7. Clean up any fuel that may have spilled during this procedure. 8. Check for fuel leakage. NOTE Refer to your national/local regulations on how to dispose of used filter and oil Air Filter Replacement Engine specifications require that this procedure be performed more often if dusty conditions exist. CAUTION Perform this procedure with the engine off.. Remove end cap from air filter canister. 2. Remove both filters from inside of canister. 3. Use a dry cloth to clean inside of canister and gasket. 4. Insert two new filters to inside of canister. 5. Reinstall end cap to canister. Service and Maintenance Check Engine Belt The aerial platform will not operate properly with a loose or defective belt. Continuous usage may cause component damage. WARNING Do not inspect while the engine is running. Remove the key to secure from operation. CAUTION Beware of hot engine components. Contact with hot engine components may cause severe burns.. Inspect the engine belt for: cracking glazing separation breaks 2. For correct tension of engine belt, refer to engine manual Check Oil Cooler. Remove cover from the side of engine. 2. Inspect oil cooler for leaks and physical damage. 3. Clean oil cooler of any kind of debris. 4. Reinstall cover. December 07 Page 75

176 Service and Maintenance Section 5 - Procedures GM Dual Fuel Engine Maintaining the engine components is essential to good performance and service life of the aerial platform GM Map and IAT Sensor (3.0L GM Engine) BLK/LT GRN SENSOR GROUND 2 YEL/GRY 5 VOLTS INTAKE AIR TEMPERATURE SIGNAL (IAT) 3 LT GRN/RED 5 VOLTS 4 LT GRN MANIFOLD ABSOLUTE PRESSURE SIGNAL (MAP) IAT Sensor Resistance TEMPERATURE F TOLERANCE ±0% OHMS ,0 77 2, , ,49-4 5, , , , AA Page 76 December 07

177 Section 5 - Procedures Service and Maintenance LPG Temperature Sensor (3.0L GM Engine) A WHITE/RED 5 VOLTS B BLK/LT GREEN SENSOR GROUND Temperature Sensor Resistance TEMPERATURE DEGREES F TOLERANCE ±0% OHMS AA December 07 Page 77

178 Service and Maintenance Section 5 - Procedures Throttle Actuator (3.0L GM Engine) DBW+ 4 PNK/WHT MOTOR DBW- TAN/ORG TPS SIGNAL 6 PPL/LT BLU SENSOR GROUND 2 BLK/LT GRN TPS SIGNAL 5 LT BLU/DK BLU 5 VOLTS 3 LT GRN/RED Page 78 December 07

179 Section 5 - Procedures Service and Maintenance Engine Coolant Temperature Sensor (3.0L GM Engine) A TAN/WHITE 5 VOLTS B BLK/LT GREEN SENSOR GROUND Temperature Sensor Resistance TEMPERATURE F TOLERANCE ±0% OHMS , , , , , , , , AA December 07 Page 79

180 Service and Maintenance Section 5 - Procedures ECU Pin Reference Chart (3.0L GM Engine) LOCK TAB Diagnostics Diagnostics Pin # Wire Color Description Pin # Wire Color Description DK GRN/ORN EGO Signal 46 DK BLU/YEL Not used 2 DK GRN/WHT EGO2 Signal 47 YEL/DK BLU Not used 3 EMPTY 48 LT GRN/WHT Output to gasoline temp sensor 4 EMPTY 49 LT GRN/PPL Not used 5 PPL/LT BLUE Throttle position signal 50 LT GRN/BLK Not used 6 LT BLU/DK BLU Throttle position 2 signal 5 GRY/DK BLU Mid throttle input 7 LT GRN MAP Signal 52 GRY/ORN High throttle input 8 TAN/DK GRN Not Used 53 LT BLU Input from oil pressure switch 9 DK BLU/ORN Not Used 54 WHT/LT GRN Signal from gasoline pressure sensor 0 PPL/YEL Not Used 55 DK GRN To diagnostic connector (PC) EMPTY 56 ORN To diagnostic connector (PC) 2 EMPTY 57 EMPTY 3 WHT/ORN Connected to pin #4 below 58 GRY Not used 4 BLU/PNK CAN + to propane regulator 59 EMPTY 5 BLU/WHT CAN from propane regulator 60 RED/TAN Battery positive 6 EMPTY 6 BRN/LT BLU To injector # 7 EMPTY 62 BRN/LT GRN To injector #3 8 EMPTY 63 BRN/YEL To injector #4 9 LT GRN/RED 5 volt + from ECU to sensors 64 BRN/WHT To injector #2 BLK/LT GREEN 5 volt to ECU from sensors 65 EMPTY 2 PPL/WHT +V from crank position sensor 66 EMPTY 22 WHT/PPL -V from crank position sensor 67 EMPTY 23 GRY/BRN +V from camshaft position sensor 68 EMPTY 24 PPL/ORN -V from camshaft position sensor 69 BLK Ground from engine block 25 RED/WHT Not used 70 EMPTY 26 RED/BLK Not used 7 WHT/LT BLU Negative supply to power relay CR 27 EMPTY 72 BLK/WHT EGO Heater ground 28 EMPTY 73 BLK/YEL EGO 2 Heater ground 29 EMPTY 74 EMPTY 30 EMPTY 75 WHT/BLK Negative supply to propane lock off 3 YEL Output to igition module 76 EMPTY 32 EMPTY 77 BRN/WHT Not used 33 EMPTY 78 WHT/BRN Not used 34 EMPTY 79 RED/TAN Battery positive 35 EMPTY 80 GRN/YEL To check engine light (MIL) 36 EMPTY 8 BLK Ground from engine block 37 EMPTY 82 PNK/WHT Positive to throttle actuator motor 38 EMPTY 83 TAN/ORN Negative from throttle actuator motor 39 YEL/GRY Output to IAT (part of MAP) 84 TAN/BLK Negative supply to fuel pump relay 56CR 40 TAN/WHT Output to TPS 85 PNK/YEL Fuel pump excite wire 4 WHT/RED Output to TPS2 86 BLK/RED Negative supply to fuel pump 42 TAN/BRN Propane selected 87 TAN Not used 43 TAN/RED Not used 88 DK BLU Not used 44 TAN/BLK Not used 89 PNK/BLK Negative supply to starter relay 57ACR 45 PNK/TAN 2 volt input 90 EMPTY 60594AB Page 80 December 07

181 Section 5 - Procedures Service and Maintenance Fuse Block Layout (3.0L GM Engine) CR POWER RELAY 56CR FUEL PUMP RELAY 57ACR STARTER RELAY EMPTY EMPTY F3 60A ALT F7 5 AMP VSW F 5 AMP FUEL PUMP F9 0 AMP EPR F8 AMP ECU F0 5 AMP IGNITION F2 5 AMP STARTER December 07 Page 8

182 Service and Maintenance Kubota WG2503 Dual Fuel Engine Maintaining the engine components is essential to good performance and service life of the aerial platform Engine Parameter Display (KAntrak 700) KAntrak 700 display allows users to easily monitor diagnostic trouble codes or critical engine faults such as oil pressure and water temperature as well as providing an alarm system to alert the user when the ECU (Engine Control Unit) detects an engine fault. Section 5 - Procedures 2. Dual Screen. This mode is used to monitor two parameters at a time. The screen also displays the associated parameter icon and units. 3. Multi Screen. This mode is used to monitor a list of four(4) parameters selected by the user. Every item is listed with its associated icon and units. 4. DTC Screen. This mode is used to display Data Trouble Codes. Diagnostic Trouble Codes (DTC) Diagnostic Trouble Codes (DTCs) are manufacturer s codes to indicate specific engine malfunction. These codes will appear on the KAntrak screen whenever an engine malfunction occurs. For DTCs, see Diagnostic Trouble Codes. Selecting DTC Screen The DTC Screen mode is used to display Data Trouble Codes. The header contains the total active/inactive faults, the associated SPN (Suspect Parameter Number) and FMI (Failure Mode Identifier), as well as the OCC (number of occurences). Menu Browsing The KAntrak 700 unit has only three (3) buttons for different features selection on its dynamic style menu system. These buttons, located at the bottom of the unit, are used to navigate on the menu. During normal operation, the buttons have no specific functions. When pressing any button once, a dynamic pop-up menu appears which contains some function icons aligned above the associated buttons. The user selects the required function from the displayed menu. When a fault occurs, the amber light on top of the KAntrak unit and the Check Engine Indicator Light on the Engine Control Console illuminate and will stay on until the fault is corrected. Display Modes KAntrak 700 unit has four display modes and can be accessed through the Setting Menu by selecting the tool.. Single Screen. This mode is used to monitor one parameter at a time. The screen also displays the associated parameter icon, the description, the units and a bar graph.. To access the DTC Screen, select the tool to access the Settings Menu. 2. On the Display Mode option, select Dtc. 3. To display the DTC detailed info, select the? function. A detailed screen of the selected DTC including the SPN description (Header), the FMI Description (Header), the fault status (Status), the SPN Number (SPN), the FMI Number (FMI), the total number of occurrences (OCC) and the related node source address (SRC) will then appear. 4. Note the SPN Number on the display and check it against the list found in Diagnostic Trouble Codes. Look for the Detected Item/ Hardware information and correct the error. Once the fault is fixed, the amber lights on KAntrak unit and on Engine Control Console will turn off. 5. To exit from DTC Screen, select tool to continue browsing for other parameters. The menu will be hidden after a few seconds. Page 82 December 07

183 Section 5 - Procedures Service and Maintenance Diagnostic Trouble Codes DTC (J939) (J939) SPN FMI Detected Item/Hardware Mechanical Misalignment between cam and crank Fuel Pressure Abormality (Low Side) Fuel Pressure Abormality (High Side) Sensor/Wiring Harness Open/Short To Ground Sensor Malfunction Sensor/Wiring Harness Short To Power Sensor Malfunction Sensor/Wiring Harness Open/Short To Ground Sensor Malfunction Sensor/Wiring Harness Short To Power Sensor Malfunction 05 5 Intake air temperature abnormality (High Side Stage ) Sensor/Wiring Harness Open/Short To Ground Sensor Malfunction Sensor/Wiring Harness Short To Power Sensor Malfunction Engine Coolant Temperature Abnormality (High Side Stage ) Sensor/Wiring Harness Short To Ground Sensor Malfunction Sensor/Wiring Harness Short To Power Sensor Malfunction 2 5 Throttle Position Sensor Malfunction Throttle Position Sensor Signal Voltage Low Throttle Position Sensor Signal Voltage High Intake Air Temperature Higher Than Expected Stage Open feed circuit to O2 heater Open heater ground circuit Open or shorted to ground O2 signal wire Open sensor ground (5Vrtn) Inoperative sensor Open feed circuit to O2 heater Open heater ground circuit Open or shorted to ground O2 signal wire Open sensor ground (5Vrtn) Inoperative sensor Exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure to the fuel injection system a inoperative sensor an injector that is stuck closed or dirty weak spark or lack of spark to a cylinder a MAP sensor that indicates pressure tjat is lower that the true pressure An inoperative O2 sensor High fuel supply pressure or temperature Operating in a frigid atmosphere Sensor out of calibration December 07 Page 83

184 Service and Maintenance Section 5 - Procedures Diagnostic Trouble Codes (continued) DTC (J939) SPN (J939) FMI Detected Item/Hardware Operating in a hot environment Sensor out of calibration Engine Coolant Temperature Exceeds Stage Engine over speed condition, stuck throttle, large vacuum leak into intake manifold after throttle blade Throttle Position Sensor Malfunction Throttle position sensor circuit in the harness short to ground Throttle position sensor malfunction Throttle position sensor circuit in the harness short to power Throttle position sensor malfunction Loss of 2.0 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness Injector coil shorted internally Injector driver circuit shorted to voltage between injector and ECM Loss of 2.0 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness Injector coil shorted internally Injector driver circuit shorted to voltage between injector and ECM Loss of 2.0 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness Injector coil shorted internally Injector driver circuit shorted to voltage between injector and ECM Loss of 2.0 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness Injector coil shorted internally Injector driver circuit shorted to voltage between injector and ECM Knock signal abnormality (High Side) Sensor Malfunction Sensor/wiring harness open/short to power Sensor malfunction Crank+ or Crank circuits in wrong connector terminal slot Loss of sensor feed Open sensor ground Open or shorted to ground sinal wire Page 84 December 07

185 Section 5 - Procedures Service and Maintenance Diagnostic Trouble Codes (continued) DTC (J939) SPN (J939) FMI Detected Item/Hardware Cam+ or Cam circuits in wrong connector terminal slot Loss of feed voltage to Cam sensor Loss of sensor feed Open sensor ground Open or shorted to ground signal wire Sensor malfunctioning Loss of feed voltage to Cam sensor Loss of signal or ground circuits Faulty sensor 359 n/a n/a n/a n/a n/a Low Oil Pressure Wiring harness open/short/damage Battery abnormality System voltage abnormality (High Side) Faulty ECU ROM Malfunction Faulty ECU Faulty ECU Open coil in relay Open in relay driver circuit in engine harness Relay pull in coil shorted internally Relay driver circuit shorted to ground in wire harness Shorted relay pull in coil Relay driver circuit shorted to voltage in wire harness Wiring harness short to ground ECM malfunction Wiring harness short to 2.0 V power ECM malfunction Wiring harness short to ground ECM malfunction Wiring harness short to 0.0 V power ECM malfunction Short to ground in relay pull in coil Short to ground in relay driver circuit in wire harness Shorted relay pull in coil Relay driver circuit shorted to voltage in wire harness Power Relay Error 55 6 Engine overspeed condition, faulty Crank sensor or input Engine overspeed condition, faulty Crank sensor or input exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure to the gaseous fuel control system a fuel supply or manifold leak a non responsive HEGO sensor December 07 Page 85

186 Service and Maintenance Section 5 - Procedures Diagnostic Trouble Codes (continued) DTC (J939) SPN (J939) FMI Detected Item/Hardware high fuel supply pressure to the gaseous fuel control or faulty pressure regulator a non responsive HEGO sensor exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure to the gaseous fuel control system a fuel supply or manifold leak a non responsive HEGO sensor high fuel supply pressure to the gaseous fuel control or faulty pressure regulator a non responsive HEGO sensor exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure an injector that is stuck closed high fuel supply pressure to the fuel injection system a non responsive HEGO sensor an injector that is stuck open exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure to the gaseous fuel control system a fuel supply or manifold leak a non responsive HEGO sensor high fuel supply pressure to the gaseous fuel control or faulty pressure regulator a non responsive HEGO sensor exhaust leaks upstream or near the HEGO sensor reduced fuel supply pressure to the gaseous fuel control system a fuel supply or manifold leak a non responsive HEGO sensor high fuel supply pressure to the gaseous fuel control or faulty pressure regulator a non responsive HEGO sensor n/a n/a n/a Faulty ECU Faulty ECU Faulty ECU Faulty ECU Faulty ECU TPS malfunction TPS malfunction Wiring harness open/short/damage FPP malfunction IVS malfunction Page 86 December 07

187 Section 5 - Procedures Service and Maintenance Diagnostic Trouble Codes (continued) DTC (J939) SPN (J939) FMI Detected Item/Hardware Wiring harness open/short/damage FPP malfunction IVS malfunction Wiring harness open/short/damage FPP malfunction Wiring harness open/short/damage FPP malfunction Wiring harness open/short/damage FPP malfunction Wiring harness open/short/damage FPP malfunction TPS malfunction Wiring harness open/short/damage FPP malfunction IVS malfunction Wiring harness open/short/damage FPP malfunction IVS malfunction a short to ground or open circuit in the harness an open internal to the primary coil a short to power in the harness a short internal to the primary coil a short to ground or open circuit in the harness an open internal to the primary coil a short to power in the harness a short internal to the primary coil a short to ground or open circuit in the harness an open internal to the primary coil a short to power in the harness a short internal to the primary coil a short to ground or open circuit in the harness an open internal to the primary coil a short to power in the harness a short internal to the primary coil December 07 Page 87

188 Service and Maintenance Section 5 - Procedures ECU Pin Reference Chart (Kubota WG2503) 90 B A Pin Wire Colour Description Pin Wire Colour Description YELLOW 8 SPK_COIL A 46 BLANK AUX ANA PUD 2 YELLOW/BLACK 8 SPK_COIL B 47 PURPLE/LT_BLUE 8 TPS 3 YELLOW/RED 8 SPK_COIL 2A 48 LT_BLUE/DK_BLUE 8 TPS 2 4 BLACK 6 SPK_GRND 49 DK_GREEN/PURPLE 8 AUX DIG 5 YELLOW/WHITE 8 SPK_COIL 2B 50 TAN/RED 8 AUX DIG 2 6 BLANK SPK_COIL 3A 5 BLACK/YELLOW 8 KNK + 7 BLANK SPK_COIL 3B 52 BLACK 8 KNK 8 BLANK EGO_3 53 DK_BLUE/ORANGE 8 FPP 9 54 PURPLE/YELLOW 8 FPP2 IVS 0 55 BLANK VRELAY 56 2 ORANGE/YELLOW 8 AUX ANA PD 57 BLANK KNK2 + 3 WHITE/LT_GREEN 8 AUX ANA PD2 58 BLANK KNK2 4 DK BLUE PINK 8 CAN + 59 BLANK VBAT PROT 5 BLUE/WHITE 8 CAN 60 RED/TAN 6 VBAT 6 6 BLACK/YELLOW 8 EGOH BLACK/WHITE 8 EGOH 8 BLANK AUX ANA PUD3 63 BLANK UEGOC 9 LT_GREEN/RED 8 5 V EXT 64 BROWN/LT_BLUE 8 INJ LS BLACK/LT_GREEN 8 5 V RTN 65 BROWN/LT_GREEN 8 INJ2 LS 2 DK_GREEN/ORANGE 8 EGO 66 BROWN/YELLOW 8 INJ3 LS 22 DK_GREEN/WHITE 8 EGO 2 67 BROWN/WHITE 8 INJ4 LS 23 LT_GREEN 8 MAP 68 BLANK INJ5 LS 24 BLANK AUX ANA PUD3 69 BLACK 6 GROUND 25 PURPLE/WHITE 8 CRANK + 70 BLANK INJ6 LS 26 WHITE/PURPLE 8 CRANK 7 BLANK AUX PWM8 27 GRAY/BROWN 8 CAM + 72 PINK/BLACK 8 STARTER 28 PURPLE/ORANGE 8 CAM 73 WHITE/LT_BLUE 8 RELAY 29 RED/WHITE 8 SPEED + 74 GREEN/YELLOW 8 MIL 30 RED/BLACK 8 SPEED 75 BLANK EGOH_3 3 LT_GREEN/PURPLE 8 5 V EXT 2 76 BLANK AUX PWM7 32 LT_GREEN/B;ACK 8 5 V RTN 2 77 WHITE/BLACK 8 LOCK OFF 33 BLANK PULSE_IN 78 TAN/BLACK 8 AUX PWM6 34 GRAY/DK_BLUE 8 GOV 79 RED/TAN 6 VBAT 35 LT_BLUE 8 OIL PRESSURE 80 PINK/WHITE 8 DBW + 36 YELLOW/GRAY 8 IAT 8 BLACK 6 GROUND 37 TAN/WHITE 8 ECT 82 TAN/ORANGE 8 DBW 38 LT_GREEN/WHITE 8 AUX ANA PU 83 WHITE/BROWN 6 AUX OWM5 REC 39 YELLOW/DK_BLUE 8 AUX ANA PU2 84 BROWN/WHITE 6 AUX PWM5 40 DK_BLUE/YELLOW 8 AUX ANA PU3 85 TAN 6 AUX PWM 4 TAN/DK_GREEN 8 AUX DIG 3 86 BLANK AUX PWM4 42 GRAY/RED 8 AUX DIG 4 87 DK_BLUE 8 AUX PWM2 43 GRAY 8 TACH 88 BLANK AUX PWM4 REC 44 PINK/TAN 8 VSW 89 PINK/YELLOW 6 AUX PWM3 REC 45 BLANK AUX ANA PUD 2 90 BLACK/RED 6 AUX PWM3 REC Page 88 December 07

189 Section 5 - Procedures Service and Maintenance Fuse Box (Kubota WG2503) Fuel Pump Relay Power Relay Starter Relay A A Fuse 5 A Fuse 5 A Fuse 5 A Fuse 0 A Fuse 5 A Fuse RED 8 ALTERNATOR 60A 0 RED 8 PINK/TAN 8 2 VSW 5A PINK 8 RED/TAN 6 3 ECM 0A 2 RED 6 3 RED 4 RED/TAN 6 WHITE/ LT_BLUE 8 LT_BLUE/ PINK POWER RELAY STARTER RELAY IGNITION 5A DEPR 5A PINK/ DK_GREEN 6 PINK/ DK_GREEN 6 PINK/ DK_GREEN 6 PINK/ DK_GREEN 8 PINK/ DK_GREEN 8 PINK/ DK_GREEN 8 RED/TAN 2 2 RED/TAN 2 PINK/BLACK 8 7 STARTER 5A 22 RED 2 23 WHITE 2 PINK/TAN RED 6 TAN/BLACK 8 9 FUEL_PUMP RELAY FUEL_PUMP 5A PINK/ YELLOW 6 PINK/ YELLOW 6 PINK/ YELLOW 6 December 07 Page 89

190 Service and Maintenance Section 5 - Procedures MAP Sensor (Kubota WG2503) TAMP Sensor ECM V B 9 5V ext V 5v D 23 MAP Signal C 5V rtn IAT Sensor (Kubota WG2503) ECM TAMP Sensor A 36 IAT V 5v Thermistor D 5V rtn Page 90 December 07

191 Section 5 - Procedures Service and Maintenance ECT (Kubota WG2503) ECM ECT Sensor A 37 ECT V 5v Thermistor B 5V rtn TPS & Engine Speed (Kubota WG2503) Electronic Throttle Body ECM + 80 DBW+ Motor - 82 DBW- H-Bridge TPS 9 5V ext 5v 47 TPS V TPS2 5V rtn 48 TPS2 V 9 5V ext 5v December 07 Page 9

192 Service and Maintenance Section 5 - Procedures Fuel Temperature Sensor (Kubota WG2503) FP/FT Sensor 9 3 5V ext FRP Signal V V ECM 5v 38 5V rtn FRP Signal V 5v Oil Pressure Sensor (Kubota WG2503) Oil Pressure Switch ECM + 5 V 35 Pressure Voltage Page 92 December 07

193 Section 5 - Procedures Hydraulic Tank Maintaining the hydraulic components and hydraulic oil at the proper level are essential to good performance and service life of the aerial platform Hydraulic Oil Replacement. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Allow hydraulic oil to warm up. 3. Turn main power disconnect switch to off position. 4. Place suitable container under the hydraulic tank. 5. Remove oil drain plug and allow all hydraulic oil to drain into container. 6. Install oil drain plug with new seal ring and tighten firmly. 7. Refill hydraulic tank with new oil as per specifications. (Refer to Section 2) 8. Check for leakage. 9. Clean up any oil that may have spilled during this procedure. 0. Check hydraulic oil level. (The hydraulic oil level should be at or slightly above the top mark on the sight gauge) Service and Maintenance Hydraulic In-tank Filter Replacement. Ensure aerial platform is on a firm level surface, is in stowed position and engine is off. Cap Housing In-tank Filter Assembly Filter Head 2. Twist off the cap from the filter head and remove old filter element and spring. 3. Insert the new filter element and spring into housing and recap the filter head. 4. Clean up any oil that may have spilled during this procedure. 5. Start engine from base control console. 6. Check for leakage. NOTE Refer to your national/local regulations on how to dispose of used filter and oil. NOTE Refer to your national/local regulations on how to dispose of used filter and oil. NOTE Samples of hydraulic oil should be drawn from the reservoir and tested annually. These samples should be taken when the oil is warmed through normal operation of the system. The sample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use. Oil change intervals will depend on the care used in keeping the oil clean, and the operating conditions. Dirt and/or moisture cotamination will dictate that the oil should be changed more often. Under normal use and operating conditions, the hydraulic oil should be changed every two years. For oil specification, Refer to Section 2. December 07 Page 93

194 Service and Maintenance Manifold and Hydraulic Pumps 5.8- Hydraulic Brake Pressure Adjustment Maintaining accurate hydraulic brake pressure is important when it comes to safe aerial platform operation.. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Locate BR port on the brake valve assembly. BR Port PR Pressure Reducing V Release Override RV4 Pressure Relief Valve Valve V3 Brake Hand Pump Brake Manifold 3. Connect a pressure gauge (000 psi) to BR port. 4. Remove the wiring from three valves: differential lock valve wire numbers 65 and, axle lockout valve wires 65 and, as well as two speed valve wires 45A and. Mark the valves to ensure you put the wiring back in the correct positions later. CAUTION Failure to remove the wiring may cause damage to components downstream. 5. Locate brake system pressure reducing valve PR. Loosen lock nut and turn adjustment stem gently clockwise 2 full turns. Section 5 - Procedures WARNING Ensure that there are no personnel or obstructions in test area and there is sufficient room for forward or reverse travel. 6. Start engine from platform control console and extend boom slightly to achieve low speed drive. 7. Drive aerial platform forward or reverse. Pressure gauge reading should be 550 psi. Stop the aerial platform. Follow the next steps for adjusting relief valve pressure if needed. If no adjustment is required continue to step Locate brake pressure relief valve RV4 and loosen the lock nut. 9. Turn the adjusting stem on pressure relief valve RV4 ¼ of a revolution at a time clockwise to increase pressure or counterclockwise to decrease pressure. Drive aerial platform forward or reverse, note pressure and stop the aerial platform. 0. Repeat step 8 until brake pressure is achieved (550 psi) then tighten lock nut on brake system pressure relief valve RV4.. Locate brake system pressure reducing valve PR and turn valve gently counterclockwise to initial position. 2. Drive aerial platform forward or reverse. Pressure gauge reading should be 500 psi. 3. Stop aerial platform and adjust pressure reducing valve PR /4 turn at a time by turning either clockwise to increase pressure or counterclockwise to decrease pressure. 4. Repeat step and 2 until brake pressure is achieved (500 psi) then tighten lock nut on brake system pressure reducing valve PR. 5. Reinstall the wiring in the same positions it was removed from in step Test the brake, differential lockout, and two speed functions. CAUTION Valve damage will occur if tightened too much. Page 94 December 07

195 Section 5 - Procedures Hydraulic System Relief Valve Adjustment. Locate Test Port on main manifold and remove the cap. 2. Connect a pressure gauge (5000 psi) to Test port. RV6 System Relief Valve Service and Maintenance Riser Down Relief Valve Adjustment. Locate Test 5 Port on main manifold. 2. Connect a pressure gauge (5000 psi) to Test 5 port. RV8 Riser Down Relief Valve TEST Port Main Manifold 3. Start engine from base control console and let it run for 2-5 minutes. 4. Steer fully to one direction and then check reading on gauge. Pressure should be 300 psi. Follow the next steps for adjusting pressure if needed. 5. Locate system relief valve RV6. 6. Loosen lock nut on system relief valve RV6. Turn the adjusting stem clockwise to increase pressure and counterclockwise to decrease pressure. 7. Tighten lock nut on system relief valve RV6 once 300 psi is observed on the gauge. (You must steer fully in one direction to activate pressure reading on gauge.) TEST 5 Port Main Manifold 3. Start engine from base control console and let it run for 2-5 minutes. 4. Raise main boom to ensure basket will not contact the ground. 5. Fully lower riser and check reading on gauge. Pressure should be 2750 psi. Follow the next steps for adjusting pressure if needed. 6. Locate riser down relief valve RV8. 7. Loosen lock nut on system relief valve RV8. Turn adjusting stem clockwise to increase pressure and counterclockwise to decrease pressure. 8. Tighten lock nut on system relief valve RV8 once 2750 psi is observed on the gauge. (You must fully lower riser to activate pressure reading on gauge.) December 07 Page 95

196 Service and Maintenance Turret Rotate Relief Valve Adjustment. Locate Test 5 Port on main manifold. 2. Connect a pressure gauge (5000 psi) to Test 5 port. Section 5 - Procedures Platform Level Relief Valve Adjustment. Locate Test 5 Port on main manifold. 2. Connect a pressure gauge (5000 psi) to Test 5 port. TEST 5 Port Main Manifold RV7 Turret Rotation Relief Valve 3. Start engine from base control console and let it run for 2-5 minutes. 4. Raise main boom to ensure basket will not contact the ground. 5. Engage the turret transport lock. 6. Attempt to rotate turret. Pressure should be 400 psi. Follow the next steps for adjusting pressure if needed. 7. Locate turret rotate relief valve RV7. 8. Loosen lock nut on turret rotate relief valve RV7. Turn adjusting stem clockwise to increase pressure and counterclockwise to decrease pressure. 9. Tighten lock nut on turret rotate relief valve RV7 once 400 psi is observed on the gauge. (You must activate turret rotate to obtain pressure reading on gauge.) 0. Disengage turret transport lock. RV9 Platf. Levelling Relief Valve TEST 5 Port Main Manifold 3. Start engine from base control console and let it run for 2-5 minutes. 4. Raise main boom to ensure basket will not contact the ground. 5. Fully raise or lower platform level and check reading on gauge. Pressure should be 2750 psi. Follow the next steps for adjusting pressure if needed. 6. Locate platform leveling relief valve RV9. 7. Loosen lock nut on platform level relief valve RV9. Turn adjusting stem clockwise to increase pressure and counterclockwise to decrease pressure. 8. Tighten lock nut on platform level relief valve RV9 once 2750 psi is observed on the gauge. (You must fully raise or lower platform level to activate pressure reading on gauge.) Page 96 December 07

197 Section 5 - Procedures Test Charge Pump Pressure on Drive Pump. Locate test port TP3 on drive pump. 2. Connect a pressure gauge (600 psi) to test port. RV0 Charge Pump Relief Valve Service and Maintenance Test Forward Drive Pressure on Drive Pump NOTE Make sure charge pump pressure test is completed first.. Locate test port TP on the drive pump. 2. Connect a pressure gauge (0000 psi) to test port TP. TP3 Charge Pressure Test Port Drive Pump - TP3 TP 3. Start engine from base control console. WARNING Do not activate any controls during procedure to protect gauge. 4. Check reading on gauge (standard pressure should be 33 ±0% psi.) 5. Replace charge pump relief valve RV3 if pressure is not achieved. 6. Repeat steps 2, 3, and 4 after charge pump relief valve is replaced. 7. if pressure still not in range, repair or replace the pump as necessary. Drive Pump - TP 3. Start engine from platform control console. 4. Unplug brake solenoid power cable (26) on brake valve. 5. Activate drive function slowly forward with engine at high speed. Wheels should not turn. NOTE Activating drive function too fast will stall the engine. 6. Check reading on gauges Standard pressure should be 5000 psi. Go to step 8 if pump pressure is achieved. 7. Replace pump if pressure is not achieved. 8. Turn engine off. 9. Remove pressure gauge from port, cap the port and re-plug brake solenoid power cable. December 07 Page 97

198 Service and Maintenance Section 5 - Procedures Test Reverse Drive Pressure on Drive Pump NOTE Make sure charge pump pressure test is completed first.. Locate test port TP2 on the drive pump. 2. Connect a pressure gauge (0000 psi) to test port TP2. Axles 5.9- Rear Axle Oil Replacement. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Turn main power disconnect switch to off position. 3. Place suitable container under the axle 4. Remove fill plug. 5. Remove all three drain plugs to allow oil to drain into container. FIll Port Check Port TP2 Drive Pump - TP2 3. Start engine from platform control console. 4. Unplug brake solenoid power cable (26) on brake valve. 5. Activate drive function slowly reverse with engine at high speed. Wheels should not turn. NOTE Activating drive function too fast will stall the engine. Drain Ports Rear Axle (shown) 6. Reinstall all drain plugs. 7. Remove check plug. NOTE Axle is filled when oil is leaking from the check port. 8. Refill axle with new oil as per specifications. (Refer to Section 2) 9. Reinstall both fill and check plugs. 6. Check reading on gauges Standard pressure should be 5000 psi. Go to step 8 if pump pressure is achieved. 7. Replace pump if pressure is not achieved. 8. Turn engine off. 9. Remove pressure gauge from port, cap the port and re-plug brake solenoid power cable Front Axle Oil Replacement. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Turn main power disconnect switch to off position. 3. Place suitable container under the axle. 4. Remove fill plug. Page 98 December 07

199 Section 5 - Procedures 5. Remove drain plug to allow oil to drain into container. Service and Maintenance Check Axle Gearbox Oil Level. Remove plug from gear box. 2. Check oil level. Oil level should be even with the bottom of plug hole. Add oil if needed. For oil specification, Refer to Section 2. Drain Port Front Axle Fill/Check Port 6. Reinstall drain plug. NOTE Axle is filled when oil is leaking from the check port. 7. Refill axle with new oil as per specifications. (Refer to Section 2) 8. Reinstall fill/check plug Check Torque Hub Oil Level. Drive the aerial platform to rotate the hub until the plug is located at 90 degrees. Gearbox Axle Gearbox Oil Replacement. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Turn main power disconnect switch to off position. 3. Place suitable container under the gearbox. 4. Remove fill plug. 5. Remove drain plug to allow oil to drain into container. 2. Remove the plug and check the oil level. The oil level should be even with the bottom of the plug hole. Add oil if needed. For oil specification, Refer to Section 2. Fill/Check Port Gearbox Drain Port Drive Torque Hub 6. Reinstall drain plug. NOTE Gearbox is filled when oil is leaking from the check port. 7. Refill gearbox with new oil as per specifications. (Refer to Section 2) 8. Reinstall fill/check plug. December 07 Page 99

200 Service and Maintenance Oscillating Cylinder Bolt Replacement If upon inspection it is determined that the oscillating cylinder bolts have missing or damaged torque seal, the affected bolts must be replaced. If replacing more than one bolt, do so one at a time to prevent the cylinder from shifting.. Remove the affected bolt. Section 5 - Procedures Oscillating Cylinder Replacement NOTE The oscillating axle cylinder weighs approximately 43 lbs [9.5 kg], so a second person to assist with the removal and replacement would be helpful.. Wedge a block of wood between the front axle and the chassis, to prevent the axle from oscillating during the procedure. 2. Clean the cylinder s corresponding internal threaded hole thoroughly. 3. Replace the removed bolt with a new x 2.25 grade 8 bolt, applying liquid blue Loctite 242 or 243 to the bottom half of the bolts. 4. Hand tighten the bolt. 5. Torque the new bolt to 80 ft-lbs. 6. Apply a line of torque seal to each new bolt extending from the bolt head over the washer and to the chassis wall. 2. Remove and set aside the base cover from the oscillating axle end of the chassis. Page 0 December 07

201 Section 5 - Procedures 3. With a rag in hand to catch any leaking oil, slowly loosen the bleeder screw to release any trapped air within the cylinder, then tighten it again. Slowly loosen the oscillating axle cylinder hoses to release the pressure, then disconnect them fully, being sure to plug the hose ends. Service and Maintenance 7. Adjust the oscillating cylinder position until there is continuous contact between the cylinder mounting surface and the mounting plate, and between the mounting plate and the cylinder shoulder, with no gaps. Torque the bolts to 80 ft-lbs [08 Nm]. 4. Remove, cap, and set aside the cylinder fittings, ensuring they stay clean. No gaps 5. Remove and throw away the bolts and washers securing the cylinder to the chassis. Lift the cylinder away. 6. Lift a new cylinder into place and install new bolts (0.5-3 x 2.25 grade 8) and 0.50 hardened washers, applying liquid blue Loctite 242 or 243 to the lower half of the bolts before installing them. Hand tighten the bolts. 8. Apply a line of torque seal to each bolt extending from the bolt head over the washer and to the chassis wall. 9. Reinstall the cylinder fittings, torquing the larger one to 24 ft-lbs [33 Nm] and the smaller one to 5 ft-lbs [ Nm]. December 07 Page

202 Service and Maintenance 0. Remove the plugs and reconnect the hoses to the cylinder fittings, torquing the larger hose end to 2 ft-lbs [28 Nm] and the smaller hose end to 2 ft-lbs [6 Nm] Pin Brake Adjustments Section 5 - Procedures. Reinstall the base cover and remove the block of wood. 2. Turn the aerial platform on and let it run for a few minutes to pressurize the cylinder, then turn it off again. 3. Check the oil level using the hydraulic tank sight gauge. Add more hydraulic oil if needed. 4. Bleed the cylinder (refer to the next procedure).. To manually release the brake give a light blow to the external ring of the check unit Bleeding Oscillating Axle Cylinders If the axle oscillation system is not operating properly, the stability of the aerial platform is compromised and it may tip over. Items you will need before starting: oil container hose (to reach from bleeders to bucket). Locate a bleeder on either side of the oscillating axle cylinder. 2. Connect a hose to the bleeder nipple. 3. Start the engine and slowly open the bleeder to allow the oil to flow in a continuous stream. 4. Close the bleeder. 5. Repeat the procedure with the other oscillating axle cylinder. 2. To adjust the idle elimination loosen jam nut and back out adjustment stem a few turns. 3. Apply a 2lb. force (Kg) in the direction of brake application and turn adjusting stem so that it touches the stop. Page 2 December 07

203 Section 5 - Procedures Service and Maintenance 4. Tighten the Jam nut. Repeat this procedure for the other side. 7. Release the pressure from the cylinder and check that the rod returns and stops in a position where it projects out from the cylinder head by 3/6 (5mm). 5. On the Cylinder side ensure that there is some clearance between the cylinder and the lever A with the lever against the stop. 8. If adjustment is needed loosen the jam nut, pressurize the cylinder and turn the adjustment stem. Repeat step 7 and tighten jam nut when correct adjustment is obtained. 6. Introduce pressure into the cylinder and ensure that the check unit engages. December 07 Page 3

204 Service and Maintenance Section 5 - Procedures Grease Points 5.0- Lubrication Maintaining proper lubrication is essential for good performance and service life of the aerial platform. If the bearing and gear of the aerial platform are improperly greased, it could result in component damage. WARNING Ensure that there are no personnel or obstructions in maintenance area and there is sufficient room for boom to swing. Grease Turret Rotation Bearing. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Raise the Riser and Main boom to access the grease line located near turret lock pin. 3. Pump grease into the turret rotation bearing and continue pumping until new lube appears continuously around the grease seal lip. (Refer to the Race column in the Table below) 4. Rotate the turret in increments of 4 to 5 inches (0 to 3 cm) at a time, and repeat step 3 until the entire bearing has been greased. Grease Turret Rotation Gear. Apply grease to each tooth of the drive gear, located under the turret. (Refer to the Gear column in the Table below) GREASE Model SJ40T & 45T SJ6T & 66T SJ46A/AJ & 5AJ Recommended Grease Type Race Gear Mobil Mobillux EP2 Mobil Mobiltac C Texaco Multifax EP2 Texaco Crater 2X or 3X Sun Prestige 742 EP Sun Gear Compound 407 Shell Alvania EP2 Shell Cardium EP Exxon Ronex WB Exxon Surrett Fluid 30 Turret Swing Drive Motor To Turret Rotation Bearing Turret Rotation Gear Page 4 December 07

205 Section 5 - Procedures Service and Maintenance Grease Drive Axle. Ensure aerial platform is on a firm level surface and is in stowed position. 2. Open axle cover plate and locate grease fitting. (see diagram below) 3. Pump grease into the grease fittings. (Refer to the Table below) Grease Drive Shaft. Locate the grease fittings on the drive shaft and pump grease. (Refer to the Table below) *GREASE Model Recommended Grease Type SJ40T & 45T SJ6T & 66T SJ46A/AJ & 5AJ Mobil Mobillux EP2 Texaco Multifax EP2 Sun Prestige 742 EP Shell Alvania EP2 Exxon Ronex WB Grease Fitting Grease Fitting Grease Fitting Grease Fitting Grease Fitting Drive Axle December 07 Page 5

206 Service and Maintenance Section 5 - Procedures Options 5.- Load Sensing System - CE The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The deck steel structure is isolated from the aerial platform. The load cell is permanently bolted between the deck and the rotary actuator mount. The load cell will only respond to the vertical component of the load in the platform. There are four external bolted connections that serve as a redundant back up system for the load cell connection. The system is first calibrated with an empty platform to set the tare weight to zero. The following steps of the process set the overload limit as regulated by applicable safety standards for Mobile Elevated Work Platforms. Aerial Platform (Rotary Actuator Mount) Error LED Alarm LED Interface Connector Zero/Tare LED Power LED External Bolts Load Cell Deck Permanent Bolts Bottom View of Deck Load Cell LED Display T Label Overload Light 4 Button Platform Control Console Indicator Module Teach in Handset (Service only) Error LED - Continously on when system error Alarm LED - Continously on when platform is overload or has base contact Interface Connector - Storage of limit valve ( Teach in handset connects here) Orange LED - Continously on when tare value is zero ± 5kg Green LED - Flashes slowly on when system powered and calibrated NOTE When power is turned on and after a four second time period elapses, the overload light and audible alarm will pulse two times. This indicates the system is active and there are no faults. Page 6 December 07