Académique Documents
Professionnel Documents
Culture Documents
Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174
USA
Phone: 630-262-0005
Toll Free: 1-800-275-9522
Fax: 630-262-0006
Email: service@skyjack.com
Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK
Phone: +44-1691-676-235
Fax: +44-1691-676-238
Email: info@skyjackeurope.co.uk
SKYJACK, Page 3
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.
SKYJACK, Page 4
Section 1
SCHEDULED MAINTENANCE
Table of Contents
Operators Responsibility for Maintenance
Tables
Scheduled Maintenance
1.1
1.2
SKYJACK, Page 5
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Rough Terrains mid and full size aerial platforms are 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 companys website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located
on the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial
platform with the labels found within this manual. If any labels are damaged or missing, replace them immediately.
Service Policy and Warranty
SKYJACK warrants each new SJRT Series aerial 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 the SKYJACK Service Department for warranty statement extensions or exclusions.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under Standard and Optional Features in Table 4.1. of the Operating manual. Operating instructions for these options (if
equipped) are located in Section 3 of the Operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at
North America:
( : 800 275-9522
7 : 630 262-0006
Include the model and serial number for each applicable aerial platform.
SKYJACK, Page 6
CSA (Canada)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
c.
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.
You, as a careful operator, are the best insurance against an accidenvt. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK.
SKYJACK, Page 7
Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This
aerial platform does not provide protection from contact with or proximity to an electrically charged conductor.
Per ANSI A92.6-2006 8.10(7)
The operator shall perform only that work for which he or she is qualified, in compliance with all applicable safety
related work practices intended to prevent electric shock covered by the Code of Federal Regulations (CFR)
1910.333. The operators level of competence shall be established only by persons qualified to do so. Operators
shall maintain the appropriate minimum approach distance (MAD) from energized power lines and parts covered
by CFR 1910.333 (c).
Unqualified persons must maintain a minimum approach distance of 10 feet from any energized power line up to
50 kV. Energized power lines over 50 kV require a greater minimum approach distance to be maintained. Refer to
CFR 1910.333.
As per CSA B354.2-01
The operator shall maintain the minimum safe approach distance (MSAD) from energized conductors at all times
in accordance with the authority having jurisdiction.
As per AS 2550.1-2002
Elevating Work Platforms must remain 6.4 m from electrical distribution lines up to 133 kV and 8 m from transmission lines greater than 133 kV. State regulations may take precedence over these approach distances.
DO NOT USE THE AERIAL PLATFORM AS A GROUND FOR WELDING.
DO NOT OPERATE THE AERIAL PLATFORM DURING LIGHTNING OR STORMS.
DO NOT OPERATE THE AERIAL PLATFORM NEAR POWER LINES. MAINTAIN A MININUM SAFE APPROACH DISTANCE (MSAD) FROM ENERGIZED POWER LINES.
REFER TO SECTION 1: ELECTROCUTION HAZARD.
DANGER
Avoid Power Lines
0 to 300V
Avoid Contact
10
15
20
25
35
45
SKYJACK, Page 8
Safety Precautions
Know and understand the safety precautions before going on to next section.
WARNING
Failure to heed the following safety
precautions could result in tip over,
falling, crushing, or other hazards leading
to death or serious injury.
KNOW all national, state or territorial/provincial
and local rules which apply to your aerial platform
and jobsite.
TURN main power disconnect switch off
when leaving the aerial platform unattended.
Remove the key to prevent unauthorized use of
the aerial platform.
WEAR all the protective clothing and personal
safety devices issued to you or called for by job
conditions.
DO NOT wear loose clothing,
dangling neckties, scarves,
rings, wristwatches or other
jewelry while operating this lift.
AVOID entanglement
ropes, cords or hoses.
with
SKYJACK, Page 9
Know and understand the safety precautions before going on to next section.
DO NOT operate on surfaces not capable of
holding the weight of the aerial platform including
the rated load, e.g. covers, drains, and trenches.
DO NOT operate an aerial
platform that has ladders,
scaffolding or other devices
mounted on it to increase
its size or work height. It is
prohibited.
SKYJACK, Page 10
Know and understand the safety precautions before going on to next section.
DO NOT use the aerial platform
without guardrails, locking pins
and the entry gate(s) in place.
DO NOT
unevenly.
distribute
load
SKYJACK, Page 11
Know and understand the safety precautions before going on to next section.
Fall Protection
WARNING
Entering and exiting the aerial platform
should only be done using the three
points of contact.
Use only equipped access openings.
Enter and exit only when the aerial
platform is in the fully retracted
position.
If additional fall protection is required, by an employer or the authority having jurisdiction, Skyjack
recommends the use of a fall restraint system
to keep an occupant within the confines of the
platform, and thus not expose the occupant to
any fall hazard requiring a fall arrest.
All personal fall protection equipment must comply with applicable governmental regulations and
must be inspected and used in accordance with
the manufacturers recommendations.
All personal fall protection equipment must be attached only to approved anchorage points within
the platform of the aerial platform.
WARNING
An operator should not use any aerial
platform that:
does not appear to be working properly.
has been damaged or appears to have worn
or missing parts.
has alterations or modifications not approved
by the manufacturer.
has safety devices which have been altered
or disabled.
has been tagged or blocked out for non-use
or repair.
Failure to avoid these hazards could
result in death or serious injury.
Jobsite Inspection
SKYJACK, Page 12
Replacement Parts
SKYJACK, Page 13
2.
3.
4.
5.
6.
SKYJACK, Page 14
7.
8.
9.
Service Bulletins
Maintenance Instructions
Inspection Schedule
Daily
Frequently
Annually
Bi-annually
A
A+B
A+B+C
A+B+C+D
Legend
P = Pass
F = Fail
R = Repaired
SKYJACK, Page 15
*
**
1000AA
This decal is located on the scissor assembly. 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 13 months.
Pictorial
Description
Inspection Date
*
Inspector Signature
**
SKYJACK, Page 16
Name (Printed):
Date:
Time:
Signature:
Each item shall be inspected using the the appropriate section of the Skyjack service manual.
As each item is inspected, write the apropriate grade in the box.
Inspection Schedule
INSPECTION FREQUENCY
Daily
A
DAILY
Frequently*
A+B
P - PASS
FREQUENTLY
Annually
A+B+C
F - FAIL
ANNUALLY
Bi-annually
A+B+C+D
R - REPAIRED
BI-ANNUALLY
Schedule
Schedule
A
A, B
A, B
A, B
A, B
Battery
A, B
A, B, C
Base Weldment
A, B
Wheel/Tire Assembly
A, B
Axles
A, B
A, B
Tie Rod
A, B
Ladder
A, B
A, B
Manual
A, B
A, B
A, B
A, B
A, B
Hydraulic Oil
A, B
A, B
A, B
A, B
A, B, C
Test Steering
A, B
A, B, C
Test Horn
A, B
Fuel Tank
A, B
Test Driving
A, B
Fuel Leaks
A, B
Test Brake
A, B
A, B
A, B
A, B
Engine Compartment
Radiator
A, B
A, B, C
A, B
Engine Tray
A, B
Hydraulic Pump
A, B
A, B
A, B
A, B
A, B
Fuel Leaks
A, B
A, B
A, B
A, B
A, B
A, B
Platform Assembly
Lanyard Attachment Anchors
AC Outlet on Platform
A, B
A, B
Function Tests
Electrical Panel
Base
Limit Switches
Manifolds
A, B
110AD
Lift Mechanism
Scissor Guards (If equipped)
A, B
Sliders
A, B
Maintenance Support
A, B
Scissor Assembly
A, B
Scissor Bumpers
A, B
Lift Cylinder(s)
A, B
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual.
* Perform scheduled inspection every three months or 150 hours.
Refer to Skyjack's webiste @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.
SKYJACK, Page 17
Platform Control
Console
Platform
Assembly
Scissor
Assembly
Outrigger
Ladder
Electrical/Hydraulic
Compartment
Base
Limit Switch
Main Manifold
Base Control
Switches
Electrical Panel
Emergency Lowering
Access Rod
Emergency Main
Power Disconnect
Switch
Brake Manifold
Battery
Load/Tilt
Sensor
--
Cushion Cylinder
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.
1. Check battery case for damage.
2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or
wire brush.
3. Ensure all battery connections are tight.
4. If applicable, check battery fluid level. If plates
are not covered by at least 1/2 in. (13 mm) of
solution, add distilled or demineralized water.
5. Replace battery if damaged or incapable of
holding a lasting charge.
WARNING
Use original or manufacturer-approved
parts and components for the aerial
platform.
SKYJACK, Page 19
Main Manifold
Base Control
Switches
Electrical Panel
Emergency Lowering
Access Rod
Emergency Main
Power Disconnect
Switch
Brake Manifold
Battery
Load/Tilt
Sensor
Cushion Cylinder
Manifolds
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
Electrical Panel
-- Ensure panel is properly secured and
there is no visible damage.
Tilt Sensor
-- Ensure tilt sensor is properly secured and
there is no visible damage.
SKYJACK, Page 20
PROPANE
Propane Tank
Hydraulic Tank
Hydraulic Oil
-- Ensure platform is fully lowered, and then
visually inspect the sight gauge located
on the side of the hydraulic oil tank.
C - Annual Inspection
-- Refer to Section 1 - Hydraulic System
& Component Maintenance and Repair
Fuel Tank
Fuel Tank
IMPORTANT
Before using your aerial platform ensure
there is enough fuel for expected use.
Fuel Leaks
-- Ensure there are no fuel leaks.
DANGER
Engine fuels are combustible. Inspect
the aerial platform in an open, well-ventilated area away from heaters, sparks
and flames. Always have an approved
fire extinguisher within easy reach.
SKYJACK, Page 21
Engine
Radiator
Engine Control
Console
Hydraulic Pump
Engine Tray
SKYJACK, Page 22
Engine
Radiator
Engine Control
Console
Hydraulic Pump
Engine Tray
Fuel Leaks
B - Frequent Inspection
-- For recommand oil change, refer to
engine manual
SKYJACK, Page 23
Platform
Railing
Platform Control
Console
Platform
Assembly
AC Outlet on Platform
-- Ensure outlet has no visible damage and
free from dirt or obstructions.
SKYJACK, Page 24
Scissor Assembly
Slider
Scissor Bumper
Maintenance
Support
Limit Switch
Lift Cylinder
1.1-8 Lifting Mechanism
Sliders
-- Ensure sliders are secure and there is no
visible damage.
Scissor Bumpers
-- Ensure bumpers are secure and shows
no sign of visible damage.
Scissor Pin Inspection
-- Complete a structural inspection of
the scissor pin connections, looking
for indicators of pin and/or scissor arm
damage. These indicators include, but
are not limited to:
-- Rotated pin
SKYJACK, Page 25
Scissor Assembly
Slider
Scissor Bumper
Maintenance
Support
Limit Switch
Lift Cylinder
Examples of pivot pin connections with no
damage:
-- No rust
Scissor Assembly
Slider
Scissor Bumper
Maintenance
Support
Limit Switch
Lift Cylinder
Examples of damaged pin connections:
Broken retainer
bolt
Lift Cylinder(s)
-- Ensure each lift cylinder is properly
secured, there are no loose or missing
parts and there is no evidence of damage.
Rust is evident
around pin
SKYJACK, Page 27
Ladder
Steer Cylinder
Assembly
Outrigger
Manual Storage
Box
Wheel/Tire
Assembly
Tie Rod
Axle
1.1-9 Base
Base Weldment
-- Ensure there are no visible cracks in
welds or structure and there are no signs
of deformation.
Wheel/Tire Assembly
The aerial platform is either equipped with
air tires or foam-filled tires. Tire and/or wheel
failure could result in an aerial platform
tipover. Component damage may also result
if problems are not discovered and repaired
in a timely fashion.
WARNING
Air filled tires are not permitted on some
models. Refer to Table 2.3.
WARNING
An over-inflated tire can explode and
may cause death or serious injury.
--
--
--
SKYJACK, Page 28
Base
Weldment
--
Ladder
Steer Cylinder
Assembly
Outrigger
Manual Storage
Box
Wheel/Tire
Assembly
Tie Rod
Axle
Ladder
-- Ensure there are no loose or missing
parts and there is no visible damage.
Outriggers (If Equipped)
-- Ensure there are no loose or missing
parts and there is no visible damage.
Base
Weldment
1.1-10 Manuals
Ensure a copy of operating manual, manual
of responsibilities and ANSI/CSA certificate
are enclosed in manual storage box.
SKYJACK, Page 29
Function Tests
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
4.
WARNING
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 3 - Start Operation of the operating
manual.
6.
7.
8.
2.
3.
SKYJACK, Page 30
emergency
9.
low throttle
Drive/Steer Enable
Trigger Switch
Function Tests
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
CAUTION
Do not start the engine in the high throttle
position.
10. To start the engine:
If (ANSI/CSA) dual fuel engine is cold,
depress and hold
start pushbutton
1. Push in
emergency stop button.
Result: Engine should shut down and
aerial platform functions should not
operate.
Test Lift Enable
1. Pull out
enable pushbutton.
Result: Platform should not rise.
SKYJACK, Page 31
Function Tests
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
Test Platform Raising/Lowering
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Press and hold lift
enable
pushbutton, then select and hold
raise/off/lower switch to raise
position and raise the platform to an
approximate height of 1 ft. (30.5 cm).
Release switch to stop.
Result: Platform should rise.
2. Press and hold lift
enable
pushbutton, then select and hold
raise/off/lower switch to
lower
position and lower the platform fully.
Release switch to stop.
Result: Platform should lower.
Test Enable Trigger Switch
controller to
left and
right.
Result: Steer wheels should turn left and
right.
Test Horn
1. Push
horn pushbutton.
Result: Horn should sound.
SKYJACK, Page 32
Drive/Steer Enable
Trigger Switch
Function Tests
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
Test Brake
Test Driving
1. Ensure path of intended motion is clear.
2. Activate and hold
switch.
WARNING
Brake will engage instantly when
controller handle is released, causing
aerial platform to stop immediately.
enable trigger
enable trigger
forward. Test
SKYJACK, Page 33
Function Tests
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
Test Speed Limit
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Ensure path of intended motion is clear.
2. Select off/lift/drive key switch to
position.
lift
SKYJACK, Page 34
the
selecting
enable switch.
Result: Platform should not extend.
Test Extension Platform(s)
(If Equipped)
1. Extend each extension platform to about
1 ft. (30.5 cm).
Result: Each extension platform should
extend.
2. Retract each extension platform fully.
Result: Each extension platform should
fully retract.
Function Tests
Emergency Lowering
Valve
Platform Lower/Neutral/
Raise Switch
TM
Enable Switch
Emergency Stop
Button
hold
enable
to raise
SKYJACK, Page 35
Function Tests
Emergency Lowering
Valve
Platform Lower/Neutral/
Raise Switch
TM
Enable Switch
Emergency Stop
Button
SKYJACK, Page 36
Function Tests
Left-Rear
Left-Front
Platform Control
Console
Right-Rear
Right-Front
3.
WARNING
Be aware of overhead obstructions or
other possible hazards around the aerial
platform when lifting or driving.
8.
(approximately 4).
Result: Outrigger will not extend.
(approximately 4).
Result: Outrigger will not extend.
(approximately 4).
Result: Outrigger will not extend.
SKYJACK, Page 37
Function Tests
Left-Rear
Left-Front
Platform Control
Console
Right-Rear
Right-Front
SKYJACK, Page 38
Function Tests
Left-Rear
Left-Front
Platform Control
Console
Right-Rear
Right-Front
18. Extend all four outriggers until all tires are off the
ground and the aerial platform is levelled.
SKYJACK, Page 39
Notes
SKYJACK, Page 40
Section 2
MAINTENANCE TABLES AND DIAGRAMS
Table of Contents
Tables
SKYJACK, Page 41
MODEL
Weight*
7127
7135
8831
8841
9250
8,420 lb.
8,850 lb.
9,670 lb.
10,570 lb.
14,700 lb.
3819 kg
4014 kg
4386 kg
4794 kg
6668 kg
Width
Height
Working
Platform Elevated
Platform Lowered
71.5
87
92
1.82 m
2.21 m
2.34 m
150
137.5
176
3.81 m
3.5 m
4.47 m
64 x 117
68 x 133
74 x 168
Length
Platform Size
1.63 m x 2.97 m
37
47
56
10.1 m
12.5 m
11.3 m
14.3 m
17.1 m
27
35
31
41
50
8.2 m
10.7 m
9.4 m
12.5 m
15.2 m
60.5
67.5
59
69
79
1.54 m
1.71 m
1.5 m
1.75 m
2.01 m
7.9 m
Normal Drive
Speed
26
Full
Tires
Engine
(RPM)
1.88 m x 4.27 m
41
Drive
Elevated Drive
1.73 m x 3.39 m
33
3.5 mph
3.0 mph
2.0 mph
5.6 km/h
4.8 km/h
3.2 km/h
0.35 mph
0.6 mph
0.56 km/h
0.97 km/h
43 sec.
41 sec.
58 sec.
56 sec.
67 sec.
46 sec.
44 sec.
44 sec.
53 sec.
72 sec.
N/A
Kubota (Diesel)
GM (Dual Fuel)
N/A
Gradeability
30%
60348AI-ANSI-R
Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 4WD machines
on air tires with a manual extension platform (Mid Size RTs) and no extension platforms (Full Size RTs).
SKYJACK, Page 42
7135 7127
MODEL
One Extension
Platform
1500 lb.
One Extension
Platform
1000 lb.
8841
8831
No Extension
Platform
9250
Capacity
681 kg
454 kg
2500 lb.
1134 kg
One Extension
Platform
2000 lb.
Two Extension
Platforms
1700 lb.
No Extension
Platform
1700 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
No Extension
Platform
2000 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
908 kg
771 kg
771 kg
681 kg
681 kg
907 kg
681 kg
681 kg
First Extension
Number of
Occupants
5
4
Capacity
500 lb.
227 kg
350 lb.
159 kg
Number of
Occupants
12.5 m/s
2x4
Not Available
12.5 m/s
2x4
Not Available
12.5 m/s
2.5 x 4.5
12.5 m/s
2.5 x 4.5
12.5 m/s
2.5 x 4.5
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
500 lb.
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
5
5
Number of
Occupants
Tilt
Cutout
Setting
(Degrees)
Not Available
5
5
Capacity
Maximum
Wind
Speed
6
6
Second Extension
Not Available
500 lb.
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
Not Available
500 lb.
227 kg
2
60376AG-ANSI-R
NOTE:
Occupants and materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
SKYJACK, Page 43
9250
8841
8831
7135 7127
MODEL
One Extension
Platform
One Extension
Platform
Capacity
1500 lb.
681 kg
900 lb.
408 kg
No Extension
Platform
2000 lb.
One Extension
Platform
1700 lb.
Two Extension
Platforms
1400 lb.
No Extension
Platform
1250 lb.
One Extension
Platform
1250 lb.
Two Extension
Platforms
1250 lb.
No Extension
Platform
1500 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
908 kg
771 kg
635 kg
567 kg
567 kg
567 kg
681 kg
681 kg
681 kg
First Extension
Number of
Occupants
5
3
Capacity
500 lb.
227 kg
300 lb.
136 kg
Number of
Occupants
12.5 m/s
2x4
Not Available
12.5 m/s
2x4
Not Available
12.5 m/s
2.5 x 4.5
12.5 m/s
2.5 x 4.5
12.5 m/s
2.5 x 4.5
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
500 lb.
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
5
5
Number of
Occupants
Tilt
Cutout
Setting
(Degrees)
Not Available
5
5
Capacity
Maximum
Wind
Speed
6
6
Second Extension
Not Available
500 lb.
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
Not Available
500 lb.
227 kg
60377AF-ANSI-R
NOTE:
Occupants and materials are not to exceed rated load.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
SKYJACK, Page 44
#6F
#6F
#7F
Air
(517.1)*
75*
10
(517.1)*
45*
Foam
(310.3)*
FULL SIZE
9250
75*
10
MID SIZE
8841
#7A
Pressure (Factory)
(kPa)
8831
#6A
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
31-15.5-15
GOODYEAR TERRA XTRAC
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
31-15.5-15
GOODYEAR TERRA XTRAC
Ply
Rating
7135
#6A
Fill
Type
7127
Tire Size
Usage
10
N/A
10
N/A
N/A
O
60378AG-ANSI-R
Factory preset @ 20C, Check pressures regularly as tires can lose pressure over time and over different ambient
temperatures even under normal conditions.
Backspace
Inboard
Outboard
SECTION A-A
Rim Size
Serial Number
#6 & #6F
#7 & #7F
Backspace
7127
Contact Skyjack Service
Department
7135
8831
8841
9250
3-3/4
3-3/4
4-3/4
4-3/4
3-3/4
95 mm
95 mm
121mm
121mm
95 mm
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.
Full-Size Rough Terrain Series
Models 8831 & 8841
163732
SKYJACK, Page 45
LCP =
OUP =
Length
Width
Width
Length
Width
Diameter
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.
SKYJACK, Page 46
MODEL
7127
7127
Outrigger Pads
7135
7135
Outrigger Pads
8831
8831
Outrigger Pads
8841
8841
Outrigger Pads
9250
9250
Outrigger Pads
WHEEL
LCP **
OUP **
lb.
kg
lb.
kg
psi
kPa
psf
kg/m2
min*
7920
3592
3168
1437
101.7
701.2
150.0
732.4
max*
12180
5525
4872
2210
121.1
835.0
230.7
1126.4
min*
9360
4246
3744
1698
47.7
328.8
155.5
759.2
max*
12180
5525
4872
2210
62.1
427.9
202.3
987.9
min*
8850
4014
3540
1606
106.8
736.4
167.6
818.4
max*
11980
5434
4792
2174
120.4
830.1
226.9
1107.9
min*
9790
4441
3916
1776
49.9
343.9
162.6
794.1
max*
12110
5493
4844
2197
61.7
425.5
201.2
982.2
min*
9670
4386
3868
1754
110.9
764.6
148.8
726.4
max*
13350
6055
5340
2422
125.0
861.8
205.4
1002.9
min*
10540
4781
4216
1912
53.7
370.3
157.1
767.0
max*
14300
6486
5720
2594
72.9
502.4
213.1
1040.6
min*
10570
4794
4228
1918
114.9
792.2
162.6
794.0
max*
13830
6273
5532
2509
126.4
871.5
212.8
1038.9
min*
11440
5189
4576
2076
58.3
401.9
170.5
832.5
max*
14820
6722
5928
2689
75.5
520.7
220.9
1078.4
min*
14700
6668
5880
2667
128.9
888.7
179.5
876.4
max*
17470
7924
6988
3170
135.6
934.9
213.3
1041.5
min*
14700
6668
5880
2667
74.9
516.4
145.5
710.7
max*
18410
8351
7364
3340
93.8
646.8
182.3
890.0
60379AF-ANSI-R
*
**
SKYJACK, Page 47
AXLE OIL
Axle Type
Dana
Front / Rear
Capacity
(Liters)
Capacity
(US Gallons)
Oil Type
Skyjack
Part No.
2.4
0.634
134612
Capacity
(Liters)
Capacity
(US Gallons)
Oil Type
Skyjack
Part No.
Center Drive
0.8
0.21
134612
HYDRAULIC OIL
Model
SJ 7127
SJ 7135
Capacity
(Liters)
Capacity
(US Gallons)
80.5
21.26
75.7
20.00
67.4
17.80
Oil Type
SJ 8831
SJ 8841
SJ 8831E
SJ 8841E
SJ 9241
SJ 9250
SKYJACK, Page 48
Capacity
(Liters)
Capacity
(US Gallons)
Kubota D1305
3.1
0.818
Kubota DF972
3.4
0.898
GM 1.6
3.7
0.977
ENGINE COOLANT
Engine Type
Capacity
(Liters)
Capacity
(US Gallons)
Kubota D1305
5.1
1.346
Kubota DF972
3.5
0.924
GM 1.6
6.0
1.584
Skyjack
Part Number
*Coolant Type
125985
Anti-freeze / Water
142208
ENGINE FUEL
Tank
Model
SJ 7127
SJ 7135
SJ 8831
SJ 8841
SJ 9241
SJ 9250
Capacity
Capacity
(Liters) (US Gallons)
80.5
21.2
49.2
13
64.4
17
Diesel
Unleaded
Gasoline
125987
125986
SKYJACK, Page 49
CARTRIDGE
Size
Torque
8
38
58
10
12
16
20
25
35
50
Lb-ft (max)
240
300
420
600
Lb-in (max)
27.12
33.9
47.46
67.8
Nm (max)
COILS
Size
Torque
All coils
4 to 5
Lb-ftt (max)
48 to 60
Lb-in (max)
5.42 to 6.78
Nm (max)
SAE PLUGS
Size
Torque
8
10
12
16
2
4
5
6
3
10
15
25
30
35
Lb-ft (max)
36
120
180
300
360
420
Lb-in (max)
4.07
13.56
20.34
33.9
40.68
47.46
Nm (max)
BOLTS
Type of Bolt
Torque (ft-lb)
Torque (Nm)
2.33 (28-32 in-lb)
3.16 - 3.61
Directional valve mounting bolts
140
189.8
Wheel mounting bolts
Center drive sprocket mounting bolts
110 - 115 (242 Loctite)
149 -156
Hydraulic drive motor mounting bolts
120 (242 Loctite)
162
Positive battery post cable/fuse nut
7.5 (90 in-lb)
10.2
Newton-meter = Nm
Foot-Pound Force = ft-lb
Inch-Pound Force = in-lb
60022AG_RT
SKYJACK, Page 50
IMPERIALBOLTTORQUECHART
Size
4-40
4-48
6-32
6-40
8-32
8-36
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
TorqueType
SAE2
SAE8
SAE5
Dry
Lubed
Dry
Lubed
Dry
Lubed
(inlb)
(5)
(4)
(8)
(6)
(12)
(9)
Nm
0.6
0.5
0.9
0.7
1.4
1.0
Size
9/16-12
SAE2
SAE5
SAE8
Torque
Type
Dry
Lubed
Dry
Lubed
Dry
Lubed
ftlb
70
55
110
80
150
110
Nm
95
75
149
108
203
149
(inlb)
(6)
(5)
(9)
(7)
(13)
(10)
ftlb
80
60
120
90
170
130
Nm
0.7
0.6
1.0
0.8
1.5
1.1
Nm
108
81
163
122
230
176
(inlb)
(10)
(8)
(16)
(12)
(23)
(17)
ftlb
100
75
150
110
220
170
9/16-18
5/8-11
Nm
1.1
0.9
1.8
1.4
2.6
1.9
Nm
136
102
203
149
298
230
(inlb)
(12)
(9)
(18)
(13)
(25)
(19)
ftlb
110
85
180
130
240
180
Nm
1.4
1.0
2.0
1.5
2.8
2.1
Nm
149
115
244
176
325
244
(inlb)
(19)
(14)
(30)
(22)
(41)
(31)
ftlb
175
130
260
200
380
280
Nm
2.1
1.6
3.4
2.5
4.6
3.5
Nm
237
176
353
271
515
380
(inlb)
(20)
(15)
(31)
(23)
(43)
(32)
ftlb
200
150
300
220
420
320
Nm
2.3
1.7
3.5
2.6
4.9
3.6
Nm
271
203
407
298
569
434
(inlb)
(27)
(21)
(43)
(32)
(60)
(45)
ftlb
170
125
430
320
600
460
Nm
3.1
2.4
4.9
3.6
6.8
5.1
Nm
230
169
583
434
813
624
(inlb)
(31)
(23)
(49)
(36)
(68)
(51)
ftlb
180
140
470
360
660
500
678
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
Nm
3.5
2.6
5.5
4.1
7.7
5.8
Nm
244
190
637
488
895
(inlb)/ftlb
(66)
(50)
(75)
12
ftlb
250
190
640
480
900
680
Nm
7.5
5.6
11
8.5
16
12
Nm
339
258
868
651
1220
922
(inlb)/ftlb
(76)
(56)
10
(86)
14
10
ftlb
270
210
710
530
1000
740
Nm
8.6
6.3
14
9.7
19
14
Nm
366
285
963
719
1356
1003
ftlb
11
17
13
25
18
ftlb
280
210
730
540
1020
760
Nm
15
11
23
18
34
24
Nm
380
285
990
732
1383
1030
ftlb
12
19
14
25
20
ftlb
350
270
800
600
1280
960
Nm
16
12
26
19
34
27
Nm
475
366
1085
813
1735
1302
ftlb
20
15
30
23
45
35
ftlb
400
300
880
660
1440
1080
1464
1-8
1-12
1-14
1 1/8-7
1 1/8-12
Nm
27
20
41
31
61
47
Nm
542
407
1193
895
1952
ftlb
23
17
35
25
50
35
ftlb
500
380
1120
840
1820
1360
Nm
31
23
47
34
68
47
Nm
678
515
1519
1139
2468
1844
ftlb
32
24
50
35
70
55
ftlb
550
420
1240
920
2000
1500
Nm
43
33
68
47
95
75
Nm
746
569
1681
1247
2712
2034
ftlb
36
27
55
40
80
60
ftlb
670
490
1460
1100
2380
1780
Nm
49
37
75
54
108
81
Nm
908
664
1979
1491
3227
2413
ftlb
50
35
75
55
110
80
Nm
68
47
102
75
149
108
ftlb
55
40
90
65
120
90
Nm
75
54
122
88
163
122
InchPoundForce=inlbFootPoundForce=ftlbNewtonMeter=Nm
NOTE:Lubedincludeslubricantssuchaslubrizing,oil,greaseoruncuredLoctite.
1 1/4-7
11/412
13/86
13/812
11/26
11/212
ftlb
750
560
1680
1260
2720
2040
Nm
1017
759
2278
1708
3688
2766
ftlb
870
650
1940
1460
3160
2360
3200
Nm
1180
881
2630
1979
4284
ftlb
980
730
2200
1640
3560
2660
Nm
1329
990
2983
2224
4827
3606
SKYJACK, Page 51
Size
METRICBOLTTORQUECHART
8.8
Torque
Units
Dry
Lubed
10.9
Dry
Lubed
(inlb)
(54)
(41)
(78)
(59)
M5x0.80
Nm
6.1
4.6
8.8
6.7
(inlb)
(92)
(69)
(133)
(99)
M6x1.00
Nm
10.4
7.8
15
11.2
(inlb)
(156)
(116)
(222)
(167)
M7x1.00
Nm
17.6
13.1
25.1
18.9
(inlb)
(225)
(169)
(333)
(242)
M8x1.25
Nm
25.4
19.1
37.6
27.3
ftlb
37
28
53
40
M10x1.50
Nm
50
38
72
54
ftlb
65
49
93
69
M12x1.75
Nm
88
66
126
94
ftlb
104
78
148
111
M14x2.00
Nm
141
106
201
150
ftlb
161
121
230
172
M16x2.00
Nm
218
164
312
233
ftlb
222
167
318
238
M18x2.50
Nm
301
226
431
323
ftlb
314
235
449
337
M20x2.50
Nm
426
319
609
457
ftlb
428
321
613
460
M22x2.50
Nm
580
435
831
624
ftlb
543
407
776
582
M24x3.00
Nm
736
552
1052
789
ftlb
796
597
1139
854
M27x3.00
Nm
1079
809
1544
1158
ftlb
1079
809
1543
1158
M30x3.50
Nm
1463
1097
2092
1570
ftlb
1468
1101
2101
1576
M33x3.50
Nm
1990
1493
2849
2137
ftlb
1886
1415
2699
2024
M36x4.00
Nm
2557
1918
3659
2744
InchPoundForce=inlbFootPoundForce=ftlbNewtonMeter=Nm
NOTE:Lubedincludeslubricantssuchaslubrizing,oil,greaseoruncuredLoctite.
SKYJACK, Page 52
HYDRAULICCOUPLINGTORQUECHART
ORingPortConnectors
SteelPorts
SAESize
NonferrousPorts
ftlb
Nm
ftlb
Nm
1416
2022
910
1213
2426
3335
1516
2021
5060
6878
3036
4147
10
7280
98110
4348
6066
12
125135
170183
7581
102110
16
200220
270300
120132
162180
20
210280
285380
126168
171228
24
270360
370490
162216
222294
32
HOSEENDTORQUECHART
forFlatFaceORingSeal(Steel)
HOSEENDTORQUECHART
forJIC
Size
Steel
Dash Frac.
ftlb
Size
Brass
Nm
ftlb
Nm
TorqueSpecification
Dash Frac.
ftlb
Nm
1/4"
10
11
13
15
6.75
1/4"
10
12
14
16
3/8"
17
19
23
26
12
15
17
20
3/8"
18
20
24
27
1/2"
34
38
47
52
20
24
27.66
33
1/2"
32
40
43
54
10
5/8"
50
56
69
76
34
40
46.33
55
10
5/8"
46
56
60
75
12
3/4"
70
78
96
106
53
60
72.33
82
12
3/4"
65
80
90
110
16
1"
94
104
127
141
74
82
100.5
111
14
1"
65
80
90
110
20
11/4" 124
138
169
188
75
83
101.5
113
16 11/4"
92
105
125
240
24
11/2
156
173
212
235
79
87
107
118
20
11/2
125
140
170
190
32
2"
219
243
296
329
158
175
214
237
24
2"
150
180
200
245
SKYJACK, Page 53
Notes
SKYJACK, Page 54
Section 3
SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Table of Contents
Charts
Parts List
SKYJACK, Page 55
VARIABLE
DISPLACEMENT
PUMP
SHUTTLE VALV
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
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
DOUBLE ACTING
DOUBLE
RODDED
BI DIRECTIONAL
HYDRAULIC
MOTOR
THREE POSITION
FOUR WAY
PROPORTIONAL
OIL COOLER
SERIES
PARALLEL
HYDRAULIC
MOTOR
TWO POSITION
TWO WAY
NORMALLY
CLOSED
TWO POSITION
TWO WAY
NORMALLY
OPEN
TWO POSITION
THREE WAY
THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT
PRESSURE
TRANSDUCER
SERVO
SKYJACK, Page 56
VALVE COIL
THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT
TWO POSITION
THREE WAY
THREE POSITION
FOUR WAY
PROPORTIONAL
VARIABLE
DISPLACEMENT
HYDRAULIC MOTOR
QUICK
DISCONNECT
WIRE CROSSING
HOURMETER
KEY SWITCH
WIRES JOINED
LIGHT
FOOT SWITCH
PRESSURE
TRANSDUCER
BATTERY
HYDRAULIC
VALVE COIL
TOGGLE SWITCH
LIMIT SWITCH
N.O.
GROUND
PROPORTIONAL
HYDRAULIC
VALVE COIL
PUSH BUTTON
LIMIT SWITCH
N.O. HELD
CLOSED
FUSE
ELECTRIC
MOTOR
ROTARY SWITCH
LIMIT SWITCH
N.C.
CIRCUIT
BREAKER
HORN
LIMIT SWITCH
LIMIT SWITCH
N.C. HELD OPEN
BATTERY
CHARGE
INDICATOR
EMERGENCY
STOP BUTTON
CAM OPERATED
LIMIT SWITCH
SILICON
CONTROLLED
RECTIFIER
CAPACITOR
RESISTOR
TILT SWITCH
PROXIMITY
SWITCH
POTENTIOMETER
LEVEL SENSOR
SINGLE POLE
SINGLE THROWN
RELAY
PNP
TRANSISTOR
SINGLE POLE
DOUBLE THROW
RELAY
DOUBLE POLE
SINGLE THROW
RELAY
DOUBLE POLE
DOUBLE THROW
RELAY
NPN
TRANSISTOR
TRIPLE POLE
DOUBLE THROW
RELAY
DIODE
TRANSISTOR
PRESSURE/
VACUUM
SWITCH
TEMPERATURE
SWITCH
SKYJACK, Page 57
Skyjack
Part No.
Qty.
2H-13A
2B-13A-1
2B-13A-2
2H-14B
2H-17A
2H-17B
2H-18A
2H-25
2H-30A
2H-30A-1
2H-30A-2
2H-86C
3H-20A
4H-15B
4H-16B
4H-23A
4H-24A
4H-26
4H-27
4H-26A
4H-27A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
BC1
C1
C2
C5
C7
C8
C9
C10
C11
C12
C13
C14
CBV1
CBV1
CBV2
CV1
CV2
CV3
CV4
CV5
CV6
CV7
103655
107269
107269
103655
114365
103655
103656
102626
112218
103656
103655
104412
103623
139256
-
153336
-
153336
-
153336
-
153336
153336
153336
153336
-
-
-
-
163175
120349
120349
120412
120405
107752
132694
132694
132694
132694
120275
120275
132249
158530
158530
104624
104624
104624
104415
104415
104415
104415
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SKYJACK, Page 58
Description
Index
No.
CV11
CV12
CV13
CV14
CV15
DCM1
F1
GM1
HP2
M1
MB1
MB2
MB3
MB4
MB7
MB9
MB10
MB11
MB12
MB13
MB14
MB15
MB16
MC1
O2
O3
O4
O5
O7
OC1
P1
P3
QD1
R1
R2
R3
R4
R8
V1
V2
V6
Skyjack
Part No.
Qty.
158531
1
158531
1
132248
1
132248
1
104567
1
300248
109568
1
104254
1
113875
AR
110652
1
109311
1
162838
1
103137
1
106688
1
106688
1
125430
1
113494
1
163026
1
111970
1
103137
1
111290
1
111291
1
103615
1
158529
1
132244
1
125011
2
141518
1
116725
1
125012
1
125244
1
114284
1
110460
1
113173
1
122419
1
104534
1
104534
1
106557
1
106557
1
113286
1
107271
2
113556
1
113752
1
Description
SKYJACK, Page 59
COMMON
COIL
CONTROL
(B+)
12 VOLT
RELAY
(SPDT)
SINGLE
POLE
DOUBLE
THROW
COIL
CONTROL
(B-)
NORMALLY
CLOSED
CONTACT
NORMALLY
OPEN
CONTACT
COMMON
COIL
CONTROL
(B+)
COIL
CONTROL
(B-)
12 VOLT
RELAY
(DPDT)
DOUBLE
POLE
DOUBLE
THROW
NORMALLY
CLOSED
CONTACT
NORMALLY
CLOSED
CONTACT
NORMALLY
OPEN
CONTACT
SKYJACK, Page 60
Index
No.
Skyjack
Part No.
Qty.
1TD
2D37
9CR1
9CR2
9CR3
10ACR1
10ACR2
10BCR1
12BCR
13CR
14CR
15CR
16CR
17CR
17ACR
17DCR
18CR
20CR
23CR
24CR
28CR
30CR
31ACR
31CR
32CR
32ACR
34BCR
35CR
49CR
56CR
61CR
65CR
86ACR
86BCR
99CR
2002CR
2H-13A
2H-13A-1
2H-13A-2
2H-14B
2H-17A
2H-17B
2H-18A
2H-25
2H-30A
2H-30A-1
2H-30A-2
2H-86C
103207
147131
111787
127131
127131
103207
127035
103316
127035
103316
103316
103316
103316
103316
103316
127131
103316
103316
103316
103316
103207
103316
127035
103316
103207
147125
103316
103207
103316
143805
127131
127131
103316
103207
300242
143805
103613
104410
104410
103613
106272
103613
103613
103613
103613
103613
103613
106272
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
SKYJACK, Page 61
Skyjack
Part No.
3H-20A 103613
4H-15B 128321
4H-16B 128321
4H-23A 153337
4H-24A 153337
4H-26
153337
4H-27
153337
4H-26A 153337
4H-27A 153337
4H-71
153337
4H-72
153337
4H-73
153337
4H-74
153337
4H-75
153337
4H-76
153337
4H-77
153337
4H-78
153337
B1
103295
BP-29
103056
BP1
133441
CAP1
103319
CAP2
117679
CB1
117326
CB3
117326
CB4
117325
CRD1
115283
CRD2
115278
115279
CRD3
115284
DA1
127688
DA2
129434
DA3
127684
DA6
127685
DA7
127926
DA8
129303
DA9
132807
DA10
129213
DA12
104313
DXX 102921
DCM1
300248
EGP1 KUBOTA
F
115384
F2
111282
F4
119469
F5
120658
FL-22
126677
FL-29 103743
G
136101
137138
GPL1
132884
GPT1
132883
SKYJACK, Page 62
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
1
1
1
1
1
1
1
1
1
1
1
1
Description
Index
No.
Skyjack
Part No.
Qty.
H1
HTS-34A
INV1
LED1
LED2
LED3
LS4
LS5
LS61
LS62
LS63
LS64
LS65
LS66
LS67
LS68
M
OCM1
OL1
OPS1
RA1
RL-22
RL-29
S1
S2
S3
S4
S5
S6
S7
S7-1
S7-2
S7-3
S7-4
S7-5
S7-6
S7-7
S8
S9
S9A
S9B
S10
S11
S11A
S12
S13
S14
S15
146652
106370
123629
147229
147229
147229
115658
119296
115658
115658
115658
115658
115658
115658
115658
115658
159216
147125
132804
133133
102838
102838
--
107098
107098
119726
147054
147054
147053
147053
147054
147053
132537
122869
122877
122877
122869
122869
122869
122872
147054
147054
102853
127132
147054
102853
102853
102853
147054
147054
147054
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
1
1
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
HORN, 12 Volt
SOLENOID, High throttle (Diesel fuel engine)
INVERTER, 1500 Watt
POWER INDICATOR LIGHT (Platform control console)
POWER INDICATOR LIGHT (Base control console)
POWER INDICATOR LIGHT (Platform control console)
LIMIT SWITCH (End-of-stroke)
LIMIT SWITCH (High drive cut-out/tilt-override)
LIMIT SWITCH (Left front outrigger extend)
LIMIT SWITCH (Right front outrigger extend)
LIMIT SWITCH (Right rear outrigger extend)
LIMIT SWITCH (Left rear outrigger extend)
LIMIT SWITCH (Left front outrigger retract)
LIMIT SWITCH (Right front outrigger retract)
LIMIT SWITCH (Right rear outrigger retract)
LIMIT SWITCH (Left rear outrigger retract)
MOTOR, Engine starter (Dual fuel engine)
MOTOR, Engine starter (Diesel fuel engine)
MODULE, Auto-level control (Outrigger)
LIGHT, Indicator (Outrigger)
SWITCH, Oil pressure (Diesel fuel engine)
SWITCH, Oil pressure (Dual fuel engine)
ACTUATOR, Throttle body (Dual fuel engine)
LIGHT, Rotating amber beacon (Option)
BEACON, Rotating Amber (Option)
SWITCH, Main power disconnect
N.O. CONTACT (Base - up/off/down switch)
N.O. CONTACT (Platform - off/lift/drive select key switch)
N.C. CONTACT (Platform - off/lift/drive select key switch)
N.C. CONTACT (Platform - emergency stop switch)
N.O. CONTACT (Platform - up/down switch)
N.C. CONTACT (Base - emergency stop switch)
DRIVE/STEER CONTROLLER ASSEMBLY
SWITCH (2nd speed)
SWITCH (Right steer)
SWITCH (Left steer)
SWITCH (Reverse drive)
SWITCH (Forward drive)
SWITCH (3rd speed)
SWITCH (Enable pushbutton)
N.O. CONTACT (Platform - Horn pushbutton)
N.O. CONTACT (Platform - Lift enable switch)
SWITCH, Toggle (Outrigger enable)
SWITCH, Toggle (Outrigger enable)
N.O. CONTACT (Base - enable switch)
SWITCH, Toggle (Front powered platform extend/retract)
SWITCH, Toggle (Rear powered platform extend/retract)
SWITCH, Toggle (Hydraulic generator option)
N.O. CONTACT (Platform - choke/glow plug switch)
N.O. CONTACT (Platform - low/high throttle switch)
N.O. CONTACT (Platform - engine start switch)
SKYJACK, Page 63
S20
S21
S22
S23
S20A
S21A
S22A
S23A
S24
S29
S30
S31
S33
S34
S34A
S41
TPS1
TS1
TT
Skyjack
Part No.
Qty.
102853
102853
102853
102853
127132
127132
127132
127132
102853
147054
124446
102853
115574
102853
102853
114373
113400
113400
146661
103336
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SKYJACK, Page 64
Description
PIN # - FUNCTION
PIN 1 - LEFT
PIN 2 - JOYSTICK VS+
PIN 3 - RIGHT
PIN 4 - FORWARD
PIN 5 - STEERING VS+
PIN 6 - REVERSE
PIN 7 - 2nd SPEED
PIN 8 - ENABLE VS+
PIN 9 - 3rd SPEED
JOYSTICK HARNESS
24 WHITE/RED
12 WHITE/BLACK
23 WHITE
16 YELLOW
12A WHITE/GREEN
15 GREY
19 BROWN
12A WHITE/BLUE
18B RED/BLACK
KEY SWITCH
POWER ON LIGHT
12A
X1
X2
NC 1
10
NO
JOYSTICK CONTROL
WITH ENABLE
34
10
08
13
4
12
NORM./HIGH
TORQUE
14
UP/DOWN
EMERGENCY STOP
09
18B
20B
HIGH/LOW RANGE
08
00
10
18
20
NO 3
9A
NO 3
X1
X2
00
10
NO 3
NC 1
7A
5
6
08
02
00
NC 1
09
THROTTLE
10
2
3
NO 3
12
LIFT
ENABLE
31
32
9A
START
HYDR.
GEN
16
7
6
15
14
5
4
13
12
3
2
11
10
19
20
23 24
31
32
34
49
18GA
18GA
18GA
18GA
18GA
18GA
18
18GA
16
18GA
15
18GA
14
18GA
13
HORN
BACK VIEW
MALE
MALE
10
49
NOT USED OR
GLOW PLUG
OR CHOKE
BACK VIEW
(16) WHITE BLACK
(15) BLUE
(14) BLACK
(13) ORANGE
(10) BLUE WHITE
(09) ORANGE RED
(7A) RED
(02) WHITE
09
7A
18GA
18GA
02
18GA
NO
18GA
18GA
NO
00
NO
18GA
NO
18GA
3
4
24
32
23
22
31
30
21
20
29
28
19
18
27
26
17
25
GROUND (00)
BLUE BLACK WHITE (GROUND) TO TERMINAL STRIP
M147234AE
SKYJACK, Page 65
16
24
32
17
25
INSERTS 1-16
INSERTS: 17-32
TO CONTROL BOX
BACK VIEW
FEMALE
17
25
16
24
32
17
25
16
15
14
7
6
13
12
11
10
24
32
16
BACK VIEW
FEMALE
TO CONTROL BOX
32
24
31
23
30
22
29
21
28
20
27
19
26
18
25
17
SKYJACK, Page 66
86
09
85
79
1
70
35D
2
1
35D
35C
35C
35D
35D
35D
70A
02
TO OUTRIGGER LIGHT
70A RED/WHITE
02 WHITE
TO ELECT
86 WHITE
09 BLACK
85 GREEN
7
10
11 12
13 14 15
M129301AB
SKYJACK, Page 67
TO ELECTR
PIN 1 - 02 W
PIN 2 - 35C
PIN 3 - 70 G
PIN 4 - 70A
PIN 5 - 71 O
PIN 6 - 72 R
PIN 7 - 73 B
PIN 8 - 74 B
Notes
SKYJACK, Page 68
P3
4H-26
EXTEND
VALVE
4H-27A
RETRACT
VALVE
4H-26A
EXTEND
VALVE
R8
RELIEF
VALVE
MB2 EMERGENCY
LOWERING VALVE MANIFOLD
BLOCK
MB12
GENERATOR
MANIFOLD
BLOCK
2H-86C
HYDRAULIC
GENERATOR
VALVE
CV2
CHECK
VALVE
4H-23A RIGHT
STEER VALVE
2H-14B
LIFT
VALVE
CV15
CHECK
VALVE
2H-30A-2
BRAKE
FEED
VALVE
2H-18A
SMALL
PUMP DUMP
VALVE
SMALL
PUMP
P1 DUAL
INLET
PUMP
CV1
CHECK
VALVE
C8
CUSHION
CYLINDER
C9 LEFT FRONT
OUTRIGGER
CYLINDER
CV4
CHECK
VALVE
CV7
CHECK
VALVE
4H-24A LEFT
STEER VALVE
4H-16B
FORWARD
DRIVE
VALVE
4H-78
LEFT REAR
OUTRIGGER
EXTEND
VALVE
4H-15B
REVERSE
DRIVE
VALVE
2H-17A
LARGE
PUMP DUMP
VALVE
ENGINE
LARGE
PUMP
R2
LIFT
RELIEF
VALVE
2H-30A
FREE
WHEEL
VALVE
M1
TWO STAGE
HYDRAULIC
MOTOR
CBV2
MB15 FREE
WHEEL
MANIFOLD
BLOCK
OUTRIGGER OPTION
C7 STEER
CYLINDER
CV3
CHECK
VALVE
GM1
CV14
2H-13A MAIN
LOWERING
VALVE
P2
3H-20A
SERIES/PARALLEL
VALVE
MB9 CONTROLLED
V2
CONTROLLED LOWERING
MANIFOLD BLOCK
LOWERING
VALVE
V1 EMERGENCY
LOWERING
VALVE
MB16
CASE DRAIN
HYDRAULIC
GENERATOR
OPTION
CV11
V6
AUTO
RESET
VALVE
2H-25
BRAKE
DUMP
VALVE
O7 LIFT LINE
ORIFICE 0.120
BASE/DRIVE ASSEMBLY
CBV1
O3
CALIPER ORIFICE
.031"
R3
RELIEF
VALVE
O5
CONTROLLED
LOWERING
ORIFICE 0.110
O4 EMERGENCY
LOWERING
ORIFICE
0.067
BC1
BRAKE
CALIPER
MB10
QUICK BRAKE
MANIFOLD BLOCK
HP2
HAND
PUMP
O2
LIFT
ORIFICE
0.159
PT1
PRESSURE
OVERLOAD
TRANSDUCER
R4
RELIEF
VALVE
PRESSURE
OVERLOAD
TRANSDUCER
OPTION
O2
LIFT
ORIFICE
0.159
MB14 REAR
POWERED EXTENSION
MANIFOLD BLOCK
RESERVOIR
2H-13A-2
HOLDING
VALVE
C14 REAR
EXTENSION
CYLINDER
C13 FRONT
EXTENSION
CYLINDER
C1
LIFT
CYLINDER
R1
SYSTEM
RELIEF
VALVE
2H-17B
OUTRIGGER
HOLDING
VALVE
4H-76
RIGHT FRONT
OUTRIGGER
EXTEND
VALVE
4H-75
LEFT FRONT
OUTRIGGER
EXTEND
VALVE
4H-77
RIGHT REAR
OUTRIGGER
EXTEND
VALVE
4H-74
LEFT REAR
OUTRIGGER
RETRACT
VALVE
4H-71
LEFT FRONT
OUTRIGGER
RETRACT
VALVE
4H-72
RIGHT FRONT
OUTRIGGER
RETRACT
VALVE
4H-73
RIGHT REAR
OUTRIGGER
RETRACT
VALVE
OC1 OIL
COOLER
OPTION
Z
F1
FILTER
RESERVOIR
M163625AB
SKYJACK, Page 69
CV15
CHECK
VALVE
TO BRAKE
MANIFOLD BLOCK
TO LIFT
MANIFOLD
BLOCK
TO CENTER
DRIVE
TO STEER
CYLINDER
V
4H-23A
LEFT STEER
VALVE (shown)
2H-14B
LIFT
VALVE
4H-24A
RIGHT STEER
VALVE
R1
SYSTEM
RELIEF
VALVE
MB1 MAIN
MANIFOLD
BLOCK
RETURN FROM
OUTRIGGER
MANIFOLD
4H-16A
FORWARD
DRIVE VALVE
TO OUTRIGGER
MANIFOLD
TO CENTER
DRIVE (return)
4H-15A
REVERSE
DRIVE VALVE
TO HYDRAULIC
PUMP (small)
2H-13A
MAIN
LOWERING
VALVE
TO HYDRAULIC
TANK
Y
CV1
CHECK
VALVE
TO EMERGENCY
LOWERING
MANIFOLD
R2 LIFT
RELIEF
VALVE
TO HYDRAULIC
PUMP (large)
2H-17A
LARGE PUMP
DUMP VALVE
CV3
CHECK
VALVE
2H-30A-2
BRAKE FEED
VALVE
CV2
CHECK
VALVE
2H-18A
SMALL PUMP
DUMP VALVE
M163219AA_1
SKYJACK, Page 70
4H-71A
OUTRIGGER
RIGHT FRONT
EXTEND
4H-74A
OUTRIGGER
RIGHT REAR
EXTEND
4H-72A
OUTRIGGER
LEFT FRONT
EXTEND
MB7
AUTO-RESET
BRAKE MANIFOLD
BLOCK
4H-73A
OUTRIGGER
LEFT REAR
EXTEND
TO MAIN
MANIFOLD
V6
AUTO-RESET
VALVE
TO BRAKE
CYLINDER
4H-78A
OUTRIGGER
RIGHT REAR
RETRACT
2H-25
BRAKE
VALVE
4H-75A
OUTRIGGER
RIGHT FRONT
RETRACT
HP2
HAND
PUMP
TO HYDRAULIC
OIL TANK
TO EMERGENCY
LOWERING
MANIFOLD
2H-17B
OUTRIGGER
HOLDING
VALVE
TO OUTRIGGER
CYLINDERS
4H-77A
OUTRIGGER
LEFT REAR
RETRACT
4H-76A
OUTRIGGER
LEFT FRONT
RETRACT
OUTRIGGER MANIFOLD
M163254AA_1, M133122AE
SKYJACK, Page 71
10E-BLUE/WHITE(1.75")
10E-BLUE/WHITE(4")
INSERT ORIENTATION
BOTTOM VIEW
NC 3
NC 3
10A
14
2
X2
02
13
7A
X1
BLACK
GREY
NC 3
NC 1
07
10A
7A
02
14
UP/DOWN SWITCH
N.O. CONTACT
PIN 4 - 14 BLACK/RED
PIN 3 - 10E BLUE/WHITE
INSERT ORIENTATION
BOTTOM VIEW
REVERSE VALVE
GREY HEIRSHMAN
PIN 1 - 15B BLUE
PIN 2 - 02 WHITE
13
NC 1
X2
X1
07
10A
FORWARD VALVE
BLACK HEIRSHMAN
PIN 1 - 16B WHITE/BLACK
PIN 2 - 02 WHITE
BLACK
GREY
LIFT VALVE
14B - BLACK
02 - WHITE
LED-2 LIGHT
PIN 1 - 07 RED
PIN 2 - 7A RED/WHITE
PIN X2 - 02 WHITE
PIN X1 - 10A BLUE/WHITE
25
LOWERING VALVE
13A - ORANGE
02 - WHITE
18A
02
02
02
17A
02 16B
NC 3
15B 02
NC 3
13A
NC 3
UP/DOWN SWITCH
N.O. CONTACT
PIN 4 - 13 ORANGE/RED
PIN 3 - 10E BLUE/WHITE
02
10E
14B
10E
10A
10E
10E
ENABLE SWITCH
N.O. CONTACT
PIN 4 - 10A BLUE/WHITE
PIN 3 - 10E BLUE/WHITE(2)
23A 02
24A 02
BASE CONTROLS
CONTACT ORIENTATION
BACK VIEW
10E
10E
30A
23A - BLACK/WHITE
24A - BLUE/BLACK
25 - ORANGE/GREEN
30A - BROWN
02
13A
02
Y
02
02
02
M163427AA
SKYJACK, Page 72
RL - 29
ROTATING BEACON
29 - RED
FL-22-2
BP - 29
BEEPER
29 - RED
00 - BLACK
Y
GREEN - 22
WHITE - 02
GREEN - 22
WHITE - 02
H1 - HORN
00 - WHITE
49A - GREEN
H1 - HORN
00 - WHITE
49A - GREEN
TO MAIN ELECTRICAL PANEL
M147681AA_S3
SKYJACK, Page 73
00
TO ELECTRIC PANEL
00
02
02
07
09
10A
13A
29
14B
17A 18A
33
20A
25
30
15A
16A
21
23A
24A
35
36A
103
103
103
103
FOUR PIN
CONNECTOR PLUG
PIN 1 - 27 BLACK
PIN 2 - 26 GREEN
PIN 3 - 02 WHITE
PIN 4 - 02 WHITE
03
100
FOUR PIN
CONNECTOR PLUG
PIN 1 - 02 WHITE
PIN 2 - 02 WHITE
PIN 3 - 26A GREEN
PIN 4 - 27A BLACK
EM RETRACT
UNDERNEATH
PLATFORM
103
02
120844AB
F2 FUSE
103A
97A
CTRL BOX
27
26
09
12A
12D
09
26A
27A
02
26A
27A
MANIFOLD
10
DCM1
P.M.T. UNIT MOTOR
27
26
02
02
02
02
PMP PWR
02
12D
12A
99CR
12V POWER UNIT
SOLENOID
103B
103A
09
BASE FEED
99
00
00
TO CONTACTOR
00 - WHITE
103B - BLACK
99 - GREEN
00
103
BOX
00
WHITE
GREEN
00
B1 - MAIN BATTERY
LID
1
BACK VIEW
MALE
3
FEMALE
2
FEMALE
MALE
TO POWER DECK
CONTROL BOX
PIN 1 - BLACK (27)
PIN 2 - WHITE (103C)
PIN 3 - GREEN (26)
PIN 4 - (N/U)
BACK VIEW
SKYJACK, Page 74
100
TO ENGINE
00
BLACK
103B
103B
TO POWER DECK
CONTROL BOX
PIN 1 - BLACK (27A)
PIN 2 - WHITE (103C)
M50314AA
86B
CR
86C
D86C-3
18A
M141779AA
SKYJACK, Page 75
GM1 GENERATOR
MOTOR
FC1
ADJUSTABLE
FLOW CONTROL
W
4H-86C
HYDRAULIC
GENERATOR
VALVE
PRESSURE TO MANIFOLD
PRESSURE TO MANIFOLD
ENGINE
LARGE
PUMP
SMALL
PUMP
P1
DUAL INLET
PUMP
OC1
OIL
COOLER
F1
FILTER
RESERVOIR
HYDRAULIC SCHEMATIC
M141608AA1
SKYJACK, Page 76
ANSI/CSA & AS
V05
43
05
R
02
49
05
41
R
42
34
49
CR
34B
CR
49A
34A
41
32
02
10A
05
04
36B
R
2A
32
CR
02
10A
10B
02 10B
10A
CR1
43
41
32A
42
02
04
R
13
14
02
02
04
04
R
15
16
02
04
23
02
24
02
02
43
41
02 31
02 49
42 34B
41
31
CR
49
CR
34B
CR
31A
49A
34A
30
10B
CR1
13
CR
14
CR
15
CR
16
CR
23
CR
24
CR
30
CR
10A
13A
14A
15A
16A
23A
24A
30A
40
37
05
32
CR
02
01 - 04
W
10A
14A
10A
15A
16A
02
28
02
40
18A
18A
44
17A
28
CR
1
TD
28A
14B
01
15B
02
18
18
CR
17
44
02
35
02 28E
02 17A
02
17A
CR
20
02
17
17
CR
20
CR
10A
20A
28E
CR2
35
CR
10A
19A
10A
1 2
04
17
10A - 36A
3
4
5
6
7
8
9 10 11 12
10A
09
44
01
02
02
36A
10A - 36B
00
00
02
09
13C
21
16B
10A
02
09
36A
P4
P2
10
P1
11 12
M134134AE_M134630AC
SKYJACK, Page 77
02
Notes
SKYJACK, Page 78
BLACK (N/U)
BLACK/WHITE (N/U)
87
103
103
87a
86
85
30
91A
31A
103
02
0"
1
2
3
4
5
6
PIN 1 - N/U
PIN 2 - N/U
PIN 3 - 02 WHITE
PIN 4 - 91A RED
PIN 5 - 32A GREEN/BLACK
PIN 6 - 90 RED
91A
02
90 - RED
91A - RED
37
103
91A
31A
07
57 - BLACK/WHITE
02 - WHITE
31A - RED/WHITE
5A - PURPLE/WHITE
07
STARTER MOTOR
31A
103 - RED
PRESSURE SWITCH
2A - BLACK/RED
2B - WHITE
07
57
91A
07
MAIN STARTER
2A
90
2B
90
57
02
32A
12
11
10
9
8
7
BACK VIEW
32A
4
1
90
6
3
5
2
02
91A
ELECTRIC PANEL
BACK VIEW
DEUTSCH
5.00
MAIN STARTER
00"
5.5
6.
6.00 000"
0"
ALTERNATOR MAIN
STARTER SOLENOID
07
32A - GREEN/BLACK
N/U - L
IG
05
32A
07
32A
05
07
05
05
ALTERNATOR TRIGGER
N/U - L
37 BLUE/WHITE
05 - PURPLE/WHITE
07 - RED
32A - GREEN/BLACK
TEMPERATURE SWITCH
2B - WHITE
2B
37
37
57
57
00
00 - WHITE
THROTTLE SOLENOID
34A - GREEN/WHITE
02 - WHITE
34A
02
Y
00
ENGINE GROUND
GLOW PLUG
00 - WHITE
91A - RED
91A
M147615AA_1
SKYJACK, Page 79
OFF/ON/START SWITCH
PIN 1 - 07 RED (2x)
PIN 2 - 05 PURPLE/WHITE
PIN 3 - N/U
PIN 4 - 32A GREEN/BLACK
PIN 5 - 07 RED
PIN 6 - N/U
2B
GAS/PROPANE SWITCH
PIN 1 - 50 ORANGE
PIN 2 - 56 ORANGE/GREEN
PIN 3 - 11 BLUE
07 - RED
07
07
07
32A
05
32A
11
56
50
11
50
31A
02
CHOKE SWITCH
07 - RED
31A - RED/WHITE
07
3
2
1
56
3
05
07
07
31A
2
1
31A
31A
31A
87
86
87a
30
00
50
50
11
11
00
GAS SOLENOID
11 - BLUE
BAC
FUEL PUMP
POS - BLACK
NEG - WHITE/BLACK
K VI
ENGINE GROUND
00 - WHITE
EW
PROPANE SOLENOID
50 - ORANGE
DEUTSCH
1
2
3
4
5
6
12
11
10
9
8
7
ELECTRIC PANEL
PIN 1 - 31A RED/WHITE
PIN 2 - 34A GREEN/WHITE
PIN 3 - 02 WHITE
PIN 4 - 32A GREEN/BLACK
PIN 5 - N/U
PIN 6 - N/U
PIN 7 - 33 GREEN
PIN 8 - N/U
PIN 9 - 2A BLACK/RED
PIN 10 - 37 BLUE/WHITE
PIN 11 - 07 RED
PIN 12 - 05 PURPLE/WHITE
STARTER SOLENOID
32A - GREEN/BLACK
32A
321
2B
2A
34A
56
34C
07
33
02
02
37
PRESSURE SWITCH
2A - BLACK/RED
2B - WHITE
00
ENGINE GROUND
00 - WHITE
00
11
37
57
D57
34C
50
00
37
50
BACK VIEW
57
37
00
ALTERNATOR TRIGGER
PIN 1 - N/U
PIN 2 - 37 BLUE/WHITE
PIN 3 - N/U
STARTER MOTOR
57 - BLACK/WHITE
00
02
85
PROPANE SOLENOID
50 - ORANGE
00 - WHITE
FUEL PUMP
11 - BLUE
00 - WHITE
X
00
02
37
100
ALTERNATOR MAIN
100
MAIN STARTER
M148338AB_1
SKYJACK, Page 80
31
05
49
34
32
13
14
13
2A
10A
TO FLASHER
PIN X - 22 RED
PIN L - 29 BLU/YEL
22
05
02 31
02 49
42 34B
31
CR
49
CR
34B
CR
31A
29
43
49A
ZZ
ZZ
00
02
03
05
05
41
41
02
32
02
34A
10A
2A
32
CR
34A
31A
15
16
23
24
14
D10
D34
05
10A
10
2A
05
2A
05
41
32A
42
36B
04
R
10A
10A
CR1
43
10A
04
04
04
04
02 10B
02 13
02 14
02 15
02 16
02 23
02 24
02 30
10B
CR1
13
CR
14
CR
15
CR
16
CR
23
CR
24
CR
30
CR
40
37
32A
10A
13A
14A
15A
16A
23A
24A
30A
30A
37
117389AA
20
T
18
117387AA
D44
10A
14A
15A
28
02
02
14B
15B
18A
17A
44
02 18
02 17A
02 17
02 20
18
CR
17A
CR
17
CR
20
CR
10A
20A
16B
17
44
10A
02
35
02 25A
10A
25
3300 uF
28A
NO OUTRIGGER
JUMPER 2
01-04
40
1000 uF
28
CR
18A
16A
35
CR
21
01
10A
19A
B
D19
15B
16B
25
19
02
00
TO HORN/LIGHT/BEEPER
00 - WHITE
22 - RED
29 - BLACK
49A - GREEN
02
03
02
02
07
7A
02
00
00
07
02
10A
R
7A
02
00
09
7A
07
09
13A
B
29
D13A
13A
D14B-1
14B 17A
D14B-2
D15A-2 B D16A-2 B
18A
33
20A 25A
B D17A B D18A
14B 17A
18A
30
D30
D28A
00
D30A
NO OUTRIGGER
JUMPER 1
10A-36A
33
15A
16A
D15A-1
D16A-1
21
23A 24A
TILT SWITCH
PIN 1 - 10A BLACK
PIN 2 - 28 GREEN
PIN 3 - 02 WHITE
PIN 4 - 35 RED
36A
D23A B D24A B
23A
24A
10A
20A
END OF STROKE
36A - BLACK
36B - BLK/WHT
00
00
HIGH SPEED
10A - BLUE
35 - BROWN
29
22
49A
30A
TO S7
JOYSTICK
CONTROLLER
02
CUSHION CYLINDER
30A - BLACK
02 - WHITE
BACK VIEW
BACK VIEW
FEMALE
16
32
15
14
7
6
BLUE (15)
BLACK (14)
31
30
13
12
5
4
ORANGE (13)
BLUE WHITE (10)
11
10
3
2
WHITE (02)
(GROUND) BLUE BLACK WHITE TO (00)
GROUND
21
20
29
28
27
26
19
18
25
17
ENGINE HARNESS
PIN 1 - 31A ORANGE
PIN 2 - 34A WHITE/BLACK
PIN 3 - 02 WHITE
PIN 4 - 32A ORANGE/BLACK
PIN 5 - N/U
PIN 6 - N/U
PIN 7A - 33 GREEN
BLACK (N/U)
BLACK/WHITE (N/U)
BACK VIEW
12
11
10
9
8
7
DEUTSCH
FEMALE
1
2
3
4
5
6
BLACK (N/U)
BLACK/WHITE (N/U)
ENGINE HARNESS
LEGEND:
MAIN MANIFOLD HARNESS
ENGINE HARNESS
PLATFORM CONTROL BOX
M163424AC
SKYJACK, Page 81
S34A
ENABLE
12B
12BCR
02
12A
23
24
S7-2
RIGHT
S7-3
LEFT
35D
S23
S22
S21
S20
DN
UP
DN
UP
DN
UP
DN
UP
78
74
77
BLACK/WHITE
BLACK
BLUE/BLACK
BLUE
RED/BLACK
76
73
RED
ORANGE/BLACK
75
72
ORANGE
71
WHITE
RED/WHITE
70A
02
GREEN/BLACK
GREEN
70
79
WHITE/BLACK
35C
78
74
77
73
76
72
75
71
02
70A
70
79
35C
35
44
09
9CR2
35B
09
35C
9CR3
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
NORMALLY OPEN
HELD CLOSED
LS5
D19
35C
10A
02
03
CB4
17
19A
01
18CR
10A
10A
S2
85A
HH
D18A
D86
14
13
33
02
02
KK
LEFT
REAR
GG
1A
RIGHT
REAR
LS63
63
RIGHT
FRONT
LS62
75
71
76
DN
DN
71
UP
UP
04
04
04
04
86A
85
72
15A
14A
16CR
16A
D86C-2
J36
73
78
DN
DN
77
UP
UP
S23A
REAR LEFT
MM
73
BB
17
10A
78
74
74
NN
36
D78
65CR
10A
25A
D74
LS68
LS66
66A
68A
LS67
LS65
65A
LEFT FRONT
10A
29
D71
CUT
J17D
D02-3
00
02
02
4H-15B
D02-12
D02-25
D02-24
4H-78
D02-23
4H-74
D02-22
4H-77
D02-21
4H-73
D02-20
4H-76
D02-19
4H-72
D02-18
4H-75
4H-71
02 = P2-11
70A = P2-7
70 = P2-5
79 = P2-6
35C = P4-9
10A = P2-12
65A = P2-4
66A = P2-3
67A = P2-2
68A = P2-1
65 = P2-8
28 = P2-9
35 = P2-10
78 = P4-1
77 = P4-2
76 = P4-3
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
D02-17
2H-17B
II,JJ
CAP2
3300 MFD
D02-16
2H-25
D02-15
2H-18A
D02-14
4H-24A
D02-13
4H-23A
16B 4H-16B
D02-11
15B
CAP1
40
1000 MFD
D02-10
3H-20A
00
00
00
00
CB3
02
D02-8
2H-14B
D02-9
00
2H-17A
D02-7
2H-86C
00
BP-29
D02-6
2H-30A-2
D02-4
2H-30A
FL-22
29
1TD
17B
D02-2
2H-13A
22
D17B-2
PP
67A
RIGHT REAR
10A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10A
LEFT REAR
10A
D72
25
25ACR
D73
FAN
D14B-3
40
17ACR
17A
D17B-1
D14B-2
D02-1
2H-13A-1
RL-29
D30A
FL-29
INV1
B1
2H-13A-2
H1
HORN
34A
FLASHER
ALL MOTION
ALARM
D76
D75
36A
J17E
30A
D13A
100B
OIL COOLER
OPTION
30CR
30
D30
04
20A
18A
D36
65
17E
21
D77
17DCR
17D
10A
D24A
D23A
D16A-2
D16A-1
20CR
20
14B
2A
86C
85
D14B-1
86BCR
10ACR2
2A
86D
D28A
13CR
D15A-2
17A
86B
85A
09
10A
85A
13
28A
D15A-1
17CR
D86C-1
26' LIFT
CUTOUT JUMPER
61
1A
15CR
16
10A
HYDRAULIC GENERATOR
OPTION
23A
14CR
77
15
24A
61CR
61
01
14
86B
23CR
24CR
23
86ACR
S22A
REAR RIGHT
24
72
04
76
61
04
LEFT
FRONT
S21A
FRONT RIGHT
62
LS61
26' DRIVE
CUTOUT
JUMPER
S20A
FRONT LEFT
75
OUTRIGGERS SHOWN IN
RETRACTED POSITION
35E
64
36B
END OF STROKE
NORMALLY CLOSED
LS4
36A
D17A
D44
LS64
18A
S9B
OUTRIGGER
ENABLE
35C
10A
CC
18
10A
10A
01
28CR
44
10A
UP
15A BREAKER
35CR
S10
10E DOWN
10A
35
10A
10A
10A
42
41
34BCR
32CR
34B
ENABLE
32
10BCR1
04
12V
57
D57
2P-50-2
50
2P-50-1
50
00
00
TEMPERATURE
SWITCH
PROPANE VALVE
SOLENOID
11
12
ALTERNATOR
12V BATTERY
P.M.T. UNIT
MOTOR
15
16
17
HOLDING VALVE
SOLENOID
MAIN LOWERING
VALVE SOLENOID
ALL FUNCTION
FLASHING LIGHT
TILT SW. RELAY
FREE-WHEELING
VALVE SOLENOID
32
33
34
35
36
ENGINE ON RELAY
ROTATING AMBER
BEACON OPTION
GLOW PLUG/
CHOKE RELAY
39
40
41
START RELAY
THROTTLE RELAY
44
45
49
50
HYDR. GENERATOR
STOP RELAY
56
60
61
62
63
64
65
74
REVERSE RELAY
RIGHT RIGHT
81
82
OUTRIGGER DRIVE
ENABLE RELAY
89
OUTRIGGER
ENABLE RELAY
OUTRIGGER
LIFT DISABLE RELAY
OUTRIGGER
CONTROL MODULE
LEFT FRONT UP
RIGHT FRONT UP
RIGHT REAR UP
LEFT REAR UP
LEFT FRONT DOWN
RIGHT FRONT DOWN
RIGHT REAR DOWN
LEFT REAR DOWN
TILT OVERRIDE/
HIGH DRIVE CUTOUT
TILT
LIFT ENABLE
LEFT REAR DOWN
RIGHT REAR DOWN
RIGHT FRONT DOWN
LEFT FRONT DOWN
POWER
OUTRIGGER ENABLE
AUTO RETRACT
AUTO LEVEL
OUTRIGGER LIGHT
GROUND
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
LEFT FRONT UP
OUTRIGGER SOLENOID
LEFT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
RIGHT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT REAR UP
OUTRIGGER SOLENOID
RIGHT REAR DOWN
OUTRIGGER SOLENOID
LEFT REAR UP
OUTRIGGER SOLENOID
LEFT REAR DOWN
OUTRIGGER SOLENOID
118
119
120
121
122
123
124
125
117
OUTRIGGER
PROOF RELAY
92
91
90
OUTRIGGER LIFT
ENABLE RELAY
OUTRIGGER
HOLDING SOLENOID
88
87
86
85
84
LEFT RELAY
FORWARD RELAY
80
83
3RD SPEED
RELAY
79
78
CAPACITOR
LEFT STEERING
VALVE SOLENOID
73
77
RIGHT STEERING
VALVE SOLENOID
72
BRAKE DUMP
VALVE SOLENOID
FORWARD
VALVE SOLENOID
71
76
70
BRAKE RELAY
69
75
TIME DELAY #1
REVERSE
VALVE SOLENOID
68
CAPACITOR
67
66
59
58
57
HYDR. GENERATOR
RELAY
55
54
53
52
HYDR. GENERATOR
SOLENOID
UP RELAY
48
51
DOWN RELAY
47
46
BEEPER
43
42
BRAKE FEED
VALVE SOLENOID
38
37
20 A BREAKER
HOLDING VALVE
SOLENOID
31
HORN
29
30
HORN RELAY
BASE CONTACTOR
REAR DECK
IN SOLENOID
REAR DECK
OUT SOLENOID
28
27
26
25
24
23
22
FRONT DECK
IN SOLENOID
FRONT DECK
OUT SOLENOID
20
21
P.M.T. CONTACTOR
19
18
FUEL RELAY
ENGINE STARTER
EL. MOTOR
14
13
PROPANE VALVE
SOLENOID
ENGINE STARTER
CONTACTOR
10
FUEL PUMP
GAS VALVE
SOLENOID
HIGH THROTTLE
SOLENOID
CHOKE
SOLENOID
IGNITION COILS
2
3
IGNITION
CONTROL MODULE
REAR
LEFT
35D
FRONT
RIGHT 35D
REAR
RIGHT
LEVEL
ALL UP
OL1
OUTRIGGER
LIGHT
02
35D
S24
35C
28
EE
35
19
31CR
41
10B
05
28CR
13A
IG
G
37
PROP
GAS
FP
2G-11
11
11
02
00
00
NEGATIV
-
FRONT
LEFT
35D
AUTO
MODE
35D
35C
FF
09
34B
31
10A
10A
28
10A
D34A
200 AMP
AB
35C
65
24
23
15
D34
D10
10A
49A
56
S33 FUEL
SELECT SW
D02-37
HTS-34C
D02-36
CS-31A
IGC3
IGC2
IGC1
INVERTER OPTION
F4
FUSE
37CR
02
32ACR
33CR
02
34C
31A
AB
BLUE/WHITE
GREEN/WHITE
BLUE/BLACK
BLACK/WHITE
BLUE
16
18
02
19
20
09
14
13
34
32
31
10
05
10A
05
49CR
20A BREAKER
03
03
100
37
TPS1
07
32A
33
34A
S31
ICM1
35C
35C
15
WHITE/BLACK
RED/BLACK
WHITE
02
18
ORANGE/BLACK
86
85
09
CRD3
28
05
49
CB1
103
S1
MAIN POWER
DISCONNECT
OPS1
2B
ENGINE
START SW
ENGINE
CHOKE SW
37
S9A
OUTRIGGER
ENABLE
ORANGE/RED
WHITE
GREEN
(BLACK)
BLACK/WHITE/RED
86
85
09
BLACK
ORANGE
19
20
16
S41
HIGH/LOW
TORQUE
09
14
S7-4
REV
18B
20B
OFF
ON
UP
DN
13
GREEN/WHITE
GREEN/BLACK
RED/WHITE
BLUE/WHITE
CRD2
00
49
9CR1
D02-26
09
05
100 AMP
F2
FUSE
02
02
103A
37
37
OIL
PRESSURE
SWITCH
32A
START
ON
OFF
CPS1
CRANKSHAFT
POSITION
SENSOR
S7-5
FWD
S7-6
3RD
SPEED
S7
JOYSTICK
CONTROLLER
S7-1
2ND
SPEED
12
S29
HIGH/LOW
RANGE
09
S12
HYDRAULIC
GENERATOR
SWITCH
9A
S5
UP/DOWN
CRD1
BLUE/BLACK/WHITE
GREEN
00
LED-2
POWER
ON LIGHT
2A
32A
33
34A
2A
10A
32A
33
34A
31A
07
05
07
S30
MAIN
ENGINE SW.
OUTRIGGER OPTION
WITH AUTO LEVELLING
09
S9
LIFT
ENABLE
34
S14
LOW/HIGH THROTTLE
31
32
10
S15
ENGINE START
S13
GLOW PLUG/CHOKE
10
00
49
00
37
10A
10A
10ACR1
10A
2A
10A
32A
D02-34A
34A
HIGH
ALTITUDE OPT.
31A
05
07
12
12
JOYSTICK
ENABLE
RELAY
S8
HORN
LED-1
POWER ON LIGHT
10
D02-31
D02-30
4H-27A
D02-29
4H-26A
D02-28
4H-27
4H-26
D02-27
HOURMETER
2A
10A
TT
43
31A
05
07
NO
DR
S7-7
JOYSTICK
ENABLE
10
D27A
LED-3
POWER ON LIGHT
D26A
D27
99CR
05
05
05
05
07
NC
LFT 09
10
27A
26A
27
26
99
103B
7A
08
S3
KEY SWITCH
OFF/LIFT/DRIVE
(IN OFF POSITION)
IN
OUT
IN
OUT
D26
103B
7A
NC
HELD
OPEN
S11A
S11
103C
103C
S34
ENABLE
103B
103B
RED
BASE
10 AMP
F5
103C FUSE
00
7A
CONTROL BOX
S6
EMERGENCY
STOP
SWITCH
DCM1
P.M.T. UNIT
MOTOR
08
S4
EMERGENCY
STOP
SWITCH
7A
AC
3.20 Electrical Schematic - Dual Fuel - All Options (ANSI/CSA)
M163634AB
SKYJACK, Page 82
S34A
ENABLE
DR
12B
12BCR
S7-3
LEFT
S7-2
RIGHT
18B
REAR
LEFT
35D
35D
FRONT
RIGHT 35D
REAR
RIGHT
ALL UP
LEVEL
S23
S22
S21
S20
DN
RED/WHITE
70A
BLACK
BLACK/WHITE
78
BLUE/BLACK
77
74
BLUE
RED/BLACK
76
73
RED
ORANGE/BLACK
75
72
ORANGE
71
WHITE
GREEN/BLACK
70
02
GREEN
79
78
74
77
73
76
72
75
71
02
70A
70
79
09
35
44
9CR2
35B
09
35C
9CR3
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
NORMALLY OPEN
HELD CLOSED
LS5
D19
35C
10A
17
44
01
18CR
10A
10A
85A
HH
D18A
D86
14
13
33
KK
LEFT
REAR
GG
1A
RIGHT
REAR
LS63
63
RIGHT
FRONT
LS62
75
71
76
DN
DN
71
UP
UP
04
04
04
04
86A
85
72
16CR
16A
J36
77
73
78
DN
DN
73
UP
UP
S23A
REAR LEFT
MM
61
1A
15A
14A
D86C-2
BB
17
10A
78
74
74
NN
D78
65CR
D75
36A
30A
10A
25A
D74
LS68
LS66
66A
68A
LS67
LS65
65A
LEFT FRONT
10A
29
D71
CUT
J17D
D02-3
00
4H-15B
D02-12
101
102
103
104
105
106
76 = P4-3
77 = P4-2
78 = P4-1
35 = P2-10
28 = P2-9
65 = P2-8
112
113
114
115
116
35C = P4-9
79 = P2-6
70 = P2-5
70A = P2-7
02 = P2-11
D02-25
D02-24
4H-78
D02-23
4H-74
D02-22
4H-77
D02-21
4H-73
D02-20
4H-76
D02-19
4H-72
D02-18
4H-75
125
124
123
122
121
120
119
118
117
111
10A = P2-12
4H-71
110
109
108
65A = P2-4
66A = P2-3
67A = P2-2
68A = P2-1
100
75 = P4-4
107
99
98
97
96
95
94
93
92
91
90
89
88
87
86
85
84
83
82
81
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
D02-17
2H-17B
II,JJ
CAP2
3300 MFD
D02-16
2H-25
2H-18A
D02-15
D02-14
4H-24A
D02-13
4H-23A
16B 4H-16B
D02-11
15B
CAP1
40
1000 MFD
D02-10
3H-20A
D02-9
D02-8
2H-14B
2H-17A
D02-7
CB3
02
00
00
2H-86C
00
BP-29
D02-6
2H-30A-2
D02-4
2H-30A
FL-22
29
1TD
17B
D02-2
2H-13A
22
D17B-2
PP
67A
RIGHT REAR
10A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10A
LEFT REAR
10A
D72
25
25ACR
D73
FAN
D14B-3
40
17ACR
17A
D17B-1
D14B-2
D02-1
2H-13A-1
RL-29
D30A
FL-29
INV1
B1
2H-13A-2
H1
HORN
34A
FLASHER
ALL MOTION
ALARM
D13A
100B
D76
30CR
30
J17E
18A
D36
65
17E
21
D77
17DCR
17D
10A
D23A
D16A-2
D30
04
20A
D14B-1
20CR
20
14B
2A
86C
85A
86B
85
09
D16A-1
D24A
36
2A
10A
86BCR
86D
10ACR2
13CR
D28A
04
85A
13
28A
D15A-2
17A
28CR
D15A-1
17CR
D86C-1
26' LIFT
CUTOUT JUMPER
16
10A
28
HYDRAULIC GENERATOR
OPTION
23A
15CR
77
15
24A
61CR
61
01
14
14CR
86B
23CR
24CR
23
86ACR
S22A
REAR RIGHT
24
72
04
76
61
04
LEFT
FRONT
S21A
FRONT RIGHT
62
LS61
26' DRIVE
CUTOUT
JUMPER
S20A
FRONT LEFT
75
OUTRIGGERS SHOWN IN
RETRACTED POSITION
35E
64
36B
END OF STROKE
NORMALLY CLOSED
LS4
36A
D17A
D44
LS64
18A
01
28CR
35CR
S9B
OUTRIGGER
ENABLE
35C
10A
CC
18
10A
10A
10A
19A
CB4
S2
15A BREAKER
03
UP
10E DOWN
02
02
28
13A
D34A
200 AMP
F4
FUSE
INVERTER OPTION
12V
*104
11
10
LEFT REAR UP
OUTRIGGER SOLENOID
RIGHT REAR UP
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
LEFT FRONT UP
OUTRIGGER SOLENOID
GROUND
OUTRIGGER LIGHT
AUTO LEVEL
AUTO RETRACT
OUTRIGGER ENABLE
POWER
LIFT ENABLE
TILT
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LEFT REAR UP
RIGHT REAR UP
RIGHT FRONT UP
LEFT FRONT UP
OUTRIGGER
CONTROL MODULE
OUTRIGGER
LIFT DISABLE RELAY
OUTRIGGER
ENABLE RELAY
OUTRIGGER
PROOF RELAY
OUTRIGGER DRIVE
ENABLE RELAY
OUTRIGGER LIFT
ENABLE RELAY
OUTRIGGER
HOLDING SOLENOID
LEFT RELAY
RIGHT RIGHT
REVERSE RELAY
FORWARD RELAY
3RD SPEED
RELAY
CAPACITOR
BRAKE DUMP
VALVE SOLENOID
LEFT STEERING
VALVE SOLENOID
RIGHT STEERING
VALVE SOLENOID
FORWARD
VALVE SOLENOID
BRAKE RELAY
REVERSE
VALVE SOLENOID
TIME DELAY #1
CAPACITOR
2ND SPEED/LARGE
PUMP RELAY
SERIES/PARELLEL
VALVE SOLENOID
SERIES/PARELLEL
RELAY
TILT OVERIDE
RELAY
LIFT VALVE
SOLENOID
HYDR. GENERATOR
STOP RELAY
HYDR. GENERATOR
RELAY
HYDR. GENERATOR
SOLENOID
UP RELAY
DOWN RELAY
THROTTLE RELAY
START RELAY
BEEPER
ROTATING AMBER
BEACON OPTION
ENGINE ON RELAY
BRAKE FEED
VALVE SOLENOID
FREE-WHEELING
VALVE SOLENOID
ALL FUNCTION
FLASHING LIGHT
MAIN LOWERING
VALVE SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
20 A BREAKER
HORN
HORN RELAY
BASE CONTACTOR
REAR DECK
IN SOLENOID
REAR DECK
OUT SOLENOID
FRONT DECK
IN SOLENOID
FRONT DECK
OUT SOLENOID
P.M.T. CONTACTOR
12V BATTERY
P.M.T. UNIT
MOTOR
ALTERNATOR
ENGINE STARTER
EL. MOTOR
TEMPERATURE
SWITCH
ENGINE STARTER
CONTACTOR
DIESEL VALVE
SOLENOID
ENGINE
GLOW PLUGS
GLOW PLUG
INDICATOR
HIGH THROTTLE
SOLENOID
GLOW PLUG
RELAY
GLOW PLUG
TIMER
UP
DN
UP
DN
UP
DN
UP
OL1
OUTRIGGER
LIGHT
02
35D
S24
35C
WHITE/BLACK
35C
28
EE
35
19
10A
35
10A
S10
34BCR
42
41
02
10A
TPS1
D02-33
57
ENGINE
TEMPERATURE
SWITCH
2B
32ACR
D57
2D37
EGP1
D02-32
HTS-34A
02
FRONT
LEFT
35D
AUTO
MODE
35C
BLUE/WHITE
35C
35C
FF
09
10A
10A
02
32CR
34B
ENABLE
32
31CR
41
10BCR1
05
TS1
TILT SWITCH
49A
03
100
32A
37
GPL1
91A
90
GPT1
AB
35C
24
BLUE/BLACK
24
GREEN/WHITE
23
BLACK/WHITE
23
35C
15
BLUE
15
65
16
WHITE/BLACK
18
02
16
WHITE
02
19
RED/BLACK
ORANGE/BLACK
19
20
09
18
BLACK/WHITE/RED
20
86
85
09
14
34B
31
10A
10B
10A
03
103
S1
MAIN POWER
DISCONNECT
103
31ACR
31A
02
32A
NEGATIVE
-
35D
WHITE
86
ORANGE/RED
GREEN
85
(BLACK)
BLACK
13
D10
10A
NO OUTRIGGER
OPTION
49CR
05
CB1
100 AMP
F2
FUSE
20A BREAKER
103A
2B
31A
S9A
OUTRIGGER
ENABLE
S41
HIGH/LOW
TORQUE
09
14
ORANGE
D34
05
10A
10A
9CR1
D02-26
09
05
49
POWER
ON LIGHT
LED-2
OPS1 OIL
PRESSURE
SWITCH
32A
07
S31
GLOW PLUG
SWITCH
S7-4
REV
S7-5
FWD
20B
OFF
ON
UP
DN
13
34
32
31
10
28
05
02
02
37
2A
32A
34A
S30 MAIN
ENGINE SW
OFF/ON/START
AB
S7-6
3RD
SPEED
S7
JOYSTICK
CONTROLLER
S7-1
2ND
SPEED
12
S29
HIGH/LOW
RANGE
09
S12
HYDRAULIC
GENERATOR
SWITCH
9A
S5
UP/DOWN
CRD3
00
49
00
10A
37
37
02
2A
10ACR1
2A
10A
10A
32A
33
34A
31A
05
07
OUTRIGGER OPTION
WITH AUTO LEVELLING
09
S9
LIFT
ENABLE
34
S14
LOW/HIGH THROTTLE
GREEN/WHITE
GREEN/BLACK
32
BLUE/WHITE
CRD2
S15
ENGINE START
09
CRD1
BLUE/BLACK/WHITE
GREEN
RED/WHITE
10
10
00
49
31
S13
GLOW PLUG SWITCH
12A
02
JOYSTICK
ENABLE
RELAY
00
LED-3
POWER ON LIGHT
10
S8
HORN
00
10A
10A
32A
34A
31A
05
07
12
12
00
D02-31
D02-30
4H-27A
D02-29
4H-26A
D02-28
4H-27
05
HOURMETER
2A
10A
TT
43
31A
07
NO
S7-7
JOYSTICK
ENABLE
D27A
LED-1
POWER ON LIGHT
10
D26A
D27
4H-26
D02-27
103B
05
05
05
7A
NC
NC
HELD
OPEN
10
27A
26A
27
26
99CR
103B
7A
LFT 09
S3
KEY SWITCH
OFF/LIFT/DRIVE
(IN OFF POSITION)
IN
OUT
IN
OUT
D26
99
103B
RED
08
S11A
S11
103C
103C
S34
ENABLE
103B
MOTOR
7A
BASE
10 AMP
F5
103C FUSE
00
7A
CONTROL BOX
S6
EMERGENCY
STOP
SWITCH
DCM1
P.M.T. UNIT
08
S4
EMERGENCY
STOP
SWITCH
M163635AB
SKYJACK, Page 83
R
BACK VIEW
FEMALE
2
PIN 1 - BLACK ( )
PIN 2 - WHITE ( )
PIN 3 - GREEN ( )
PIN 4 - RED ( )
LEFT FRONT
12
11 10
CONTROL MODULE - P2
PIN 1 - 68A WHITE
PIN 2 - 67A RED/WHITE
PIN 3 - 66A BLUE/WHITE
PIN 4 - 65A GREEN/WHITE
PIN 5 - 70 GREEN/BLACK
PIN 6 - 79 GREEN
PIN 2 - 28 GREEN/RED
PIN 3 - 02 WHITE
PIN 4 - 35 BROWN/RED
D75
PIN 1 - 78 BLACK/WHITE
PIN 2 - 02 WHITE
REAR LEFT
FRONT RIGHT
REAR RIGHT
D71
D72
D78
D77
PIN 1 - 75 ORANGE/BLACK
PIN 2 - 02 WHITE
78
02
D76
FRONT LEFT
GREY
GREY
17
04
D73
PIN 1 - 77 BLUE/BLACK
PIN 2 - 02 WHITE
76
02
36B
02
02
01
44
09
10A
PIN 1 - 76 RED/BLACK
PIN 2 - 02 WHITE
75
02
D74
GREY
77
02
GREY
02
02
17B
02
74
02
17B - WHITE/BLACK
02 - WHITE
70A RED/WHITE
02 WHITE
02
13 14 15
9
8
11 12
10
2
1
OUTR MANIFOLD
J17E
D36
BACK VIEW
PIN 1 - 02 WHITE
PIN 2 - 35C WHITE/BLACK
PIN 3 - 70 GREEN/BLACK
PIN 4 - 70A RED/WHITE
PIN 5 - 71 ORANGE
PIN 6 - 72 RED
PIN 7 - 73 BLUE
PIN 8 - 74 BLACK
PIN 9 - 75 ORANGE/BLACK
PIN 10 - 76 RED/BLACK
PIN 11 - 77 BLUE/BLACK
PIN 12 - 78 BLACK/WHITE
PIN 13 - 79 GREEN
PIN 14 - 35C WHITE/BLACK
PIN 15 - 35C WHITE/BLACK
J17D
ENABLE
TO LIMIT SWITCHES
PIN 1 - 65 GREEN/BLACK
PIN 2 - 65A GREEN/WHITE
PIN 3 - 66A BLUE/WHITE
PIN 4 - 67A RED/WHITE
PIN 5 - 68A WHITE
PIN 6 - N/U
BACK VIEW
CN21
BACK VIEW
17B
02
78
73
77
74
71
75
72
76
CN20
BACK VIEW
TO CONTROL MODULE
PIN 1 - 65 GREEN/BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE
PIN 5 - 68A WHITE
PIN 6 - N/U
35C
78
73
77
74
71
75
72
76
65CR
TO CONTROL MODULE - P4
PIN 1 - 78 BLACK/WHITE (2x)
PIN 2 - 77 BLUE/BLACK (2x)
PIN 3 - 76 RED/BLACK (2x)
PIN 4 - 75 ORANGE/BLACK (2x)
PIN 5 - 74 BLACK (2x)
PIN 6 - 73 BLUE (2x)
PIN 7 - 72 RED (2x)
PIN 8 - 71 ORANGE (2x)
PIN 9 - 35C WHITE/BLACK (2x)
LEFT REAR
CN14
04
17
86A
10A
09
44
01
02
02
36A
61
36
9CR2
RIGHT REAR
D17B-1
D17B-2
17BCR
RIGHT FRONT
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
11 12
10
9CR3
61CR
7
4
70A
35D
PIN 1 - 74 BLACK
PIN 2 - 73 BLUE
1 2
35D PURPLE/WHITE
3
4
5
6
7
8
9 10
79
70
79 GREEN
35C
70 GREEN/BLACK
BLACK
PIN 1 - 74 BLACK
PIN 2 - 02 WHITE
BLACK
PIN 1 - 71 ORANGE
PIN 2 - 02 WHITE
BLACK
PIN 1 - 72 RED
PIN 2 - 02 WHITE
02
73
02
72
02
71
2
BLACK
PIN 1 - 73 BLUE
PIN 2 - 02 WHITE
PIN 3 - 78 BLACK/WHITE
PIN 4 - 77 BLUE/BLACK
PIN 5 - 35D PURPLE/WHITE
PIN 6 - N/U
PIN 7 - 71 ORANGE
PIN 8 - 72 RED
PIN 9 - 75 ORANGE/BLACK
35C
PIN 10 - 76 RED/BLACK
35C BLUE/WHITE
35C GREEN/WHITE
M134630AC
SKYJACK, Page 84
05
43
05
02
2A
10A
05
41
31
02
31
CR
49
49
CR
31A
49A
32
41
42 34B
34B
CR
02
02
10A
36B
04
2A
32
CR
34A
05
10A
10A
02 10B
10A
CR1
43
41
32A
42
10B
CR1
02
04
R
13
02
13
CR
14
02
14
CR
04
15
02 16
15
CR
04
04
R
02
16
CR
24
02
23
23
CR
02
24
CR
30
30
CR
40
10A
37
14A
13A
15A
16A
23A
24A
30A
00
02
14A
10A
15A
16A
18A
18A
17A
44
02
03
03
05
28
02
28
CR
85A
1
TD
28A
14B
40
01
15B
02 18
02 17A
18
CR
17A
CR
16B
17
44
02
35
02
17
02
20
17
CR
20
CR
10A
20A
35
CR
21
10A
19A
10A
00
00
10A
85
30
86D
85A
2A
10A
86
10ACR2
87a
87
86D - BLACK
00 - WHITE
86D
TO OIL
COOLER FAN
00
M134188AC_1
SKYJACK, Page 85
34B
CR
32
CR
43
34A
02
85
32
09
42 34B
41
05
86
41
2A
10A
43
D86C-2
32A
09
86
D86
00
03
03
02
85A
09
2A
86B
05
86B
CR
86B
14A
10A
02
28
86A
02
86A
CR
85A
28
CR
85
86C
02
17
17
CR
28A
85
14B
01
10A
9 10 11 12
LOAD
LOAD NEUTRAL
GROUND
30
85
86D
85A
2A
10A
86
87a
14B
02
87
00
12 PIN OUTRIGGER
OPTION CONNECTOR
(IF EQUIPPED)
PIN 3 - 86A ORG/BLK/WHT
10ACR2
10A
09
02
NOTE:
IF THERE IS NO OUTRIGGER OPTION,
CONNECT THE END OF THIS WIRE
DIRECTLY TO PIN 14 OF 86ACR.
D14B-3
00
1A
17
86A
10A
09
44
01
02
02
36A
61
36
85
D86C-1
17A
X
GROUND
LOAD NEUTRAL
LOAD
W1
V2
86D - BLACK
00 - WHITE
V1
Y
U2
RED
86D
TO OIL
COOLER FAN
BLK
00
M129438AD_1
SKYJACK, Page 86
Section 4
TROUBLESHOOTING INFORMATION
Table of Contents
Introduction.................................................................................................................................................................89
Electrical System
4.1-1
4.1-2
4.1-3
4.1-4
4.1-5
4.1-6
4.1-7
4.1-8
4.1-9
4.1-10
4.1-11
4.1-12
4.1-13
4.1-14
4.1-15
4.1-16
4.1-17
4.1-18
4.1-19
4.1-20
4.1-21
4.1-22
4.1-23
4.1-24
4.1-25
4.1-26
4.1-27
4.1-28
4.1-29
4.1-30
4.1-31
4.1-32
4.1-33
4.1-34
4.1-35
4.1-36
4.1-37
4.1-38
4.1-39
4.1-40
SKYJACK, Page 87
Hydraulic System
4.2-1
4.2-2
4.2-3
4.2-4
4.2-5
4.2-6
4.2-7
4.2-8
4.2-9
4.2-10
4.2-11
4.2-12
4.2-13
4.2-14
4.2-15
4.2-16
4.2-17
4.2-18
SKYJACK, Page 88
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.
1. Probable Cause
-- Remedy
SKYJACK, Page 89
Electrical System
4.1-1 All Controls Inoperative
1. Battery disconnected or discharged.
-- Reconnect battery. Recharge if discharged.
2. Loose or dirty battery cables.
-- Clean and tighten battery cables.
3. Open or defective main power disconnect switch S1.
-- Close switch. Replace if defective.
4. Loose or broken wire #03 from main power disconnect switch S1 to circuit breaker CB1.
-- Check continuity. Replace if defective.
5. Tripped or defective circuit breaker CB1.
-- Reset breaker. Check for defective wiring. Replace breaker if defective.
6. Loose or broken wire #05 from breaker CB1 to base terminal block TB-1.
-- Check continuity. Replace if defective.
7. Loose or broken wire #05 from base terminal block TB-1 to base engine switch S30.
-- Check continuity. Replace if defective.
8. Loose or broken wire #00 from battery B1 to base terminal block TB-1.
-- Check continuity. Replace if defective.
9. Loose or broken wire #00 from base terminal block TB-1 to circuit breaker CB3.
-- Check continuity. Replace if defective.
10. Tripped or defective circuit breaker CB3.
-- Reset breaker. Check for defective wiring. Replace breaker if defective.
11. Loose or broken wire #02 from circuit breaker CB3 to base terminal block TB-1.
-- Check continuity. Replace if defective.
4.1-2 No Power to Platform (ANSI/CSA)
1. Open or defective base engine switch S30.
-- Check switch. Replace if defective.
2. Loose or broken wire #07 from base engine switch S30 to base terminal block TB-1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #07 from base terminal block TB-1 to emergency stop switch S6.
-- Check continuity. Replace if defective.
4. Open or defective emergency stop switch S6.
-- Check switch. Replace if defective.
5. Loose or broken wire #7A from emergency stop switch S6 to base terminal block TB-1.
-- Check continuity. Replace if defective.
6. Loose or broken wire #7A from base terminal block TB-1 to emergency stop switch S4.
-- Check continuity. Replace if defective.
7. Open or defective emergency stop switch S4.
-- Check switch. Replace if defective.
4.1-3 All Functions Inoperative from Platform
1. Loose or broken wire #08 from emergency stop switch S4 to off/lift/drive key switch S3.
-- Check continuity. Replace if defective.
2. Open or defective off/lift/drive key switch S3.
-- Check switch. Replace if defective.
3. Loose or broken wire #10 from off/lift/drive key switch S3 to platform terminal block.
-- Check continuity. Replace if defective.
4. Loose or broken wire #10 from platform terminal block to diode D10 located at the base terminal block
TB-1.
-- Check continuity. Replace if defective.
SKYJACK, Page 90
SKYJACK, Page 91
SKYJACK, Page 92
SKYJACK, Page 93
SKYJACK, Page 94
SKYJACK, Page 95
SKYJACK, Page 96
SKYJACK, Page 97
SKYJACK, Page 98
SKYJACK, Page 99
--
Probable Cause
1.
1.
1.
2.
1.
2.
3.
1.
1.
2.
Excessive vibration.
Defective outrigger control module.
Outriggers are being manually
controlled.
Error occured while self diagnosing the
hardware fail safe.
1.
2.
1.
Check for power on wire #70 or #79 at pin P2-5 or P2-6 of the
outrigger control module. Replace defective component.
Check for power on wire #70 or #79 while manually operating an
outrigger.
Check battery and charging system to ensure minimum 9 volts.
Check for input voltage on wire #35c at pin P4-9 of outrigger
control module (OCM1).
Outrigger control module cannot read tilt sensor.
Replace.
Indicates function activated. No repair necessary.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
1.
2/2
2.
3.
2/1
1.
1.
5/5
5/2
7/1
6/6
7/8
5/1
7/7
7/5
7/2
8/1
8/2
8/3
8/4
8/5
7/6
Remedy
2.
1.
2.
1.
2.
1.
1.
1.
1.
1.
2.
1.
1.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Check for minimum 9 volts between wire #02 at pin P2-11 and wire
#10A at pin P2-12 at outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
60416AA
Hydraulic System
4.2-1 All Functions Inoperative
1. Hydraulic oil level low.
-- Refill tank to proper level.
2. Defective pump P1.
-- Check pump. Repair or replace if defective.
3. Broken engine to pump coupler.
-- Check coupler. Replace if defective.
4. Open relief valve R1.
-- Check valve. Replace if defective.
4.2-2 Steering Inoperative
1. Stuck or defective brake feed valve 2H-30A-2.
-- Check valve. Repair or replace if defective.
2. Stuck or defective steer right valve 4H-23A or steer left valve 4H-24A.
-- Check valves. Replace if defective.
3. Steer cylinder C7 damaged or bypassing internally.
-- Check cylinder. Repair or replace if defective.
4.2-3 Steer and First Drive Speed Inoperative
1. Small pump dump valve 2H-18A stuck open.
-- Check valve. Repair or replace if defective.
2. Worn or defective small pump section of pump P1.
-- Check pump. Repair or replace if defective.
3. Check valve CV1 or CV2 stuck.
-- Check valves. Clean or replace if defective.
4.2-4 Lift and Second Drive Speed Inoperative
1. Large pump dump valve 2H-17A stuck open.
-- Check valve. Repair or replace if defective.
2. Worn or defective large pump section of pump P1.
-- Check pump. Repair or replace if defective.
3. Check valve CV1 or CV2 stuck.
-- Check valves. Clean or replace if defective.
4.2-5 Drive Inoperative
1. Stuck or defective drive reverse valve 4H-15B or drive forward valve 4H-16B.
-- Check valves. Repair or replace if defective.
2. Defective motion control valve MC1.
-- Check valve. Repair or replace if defective.
3. Missing or defective check balls in series/parallel valve manifold 3H-20A.
-- Repair or replace balls. Refer to Section 5 for proper location.
4. Stuck or defective main series/parallel valve spool V3 in drive motor.
-- Check valve. Repair or replace if defective.
Notes
Section 5
PROCEDURES
Table of Contents
General .....................................................................................................................................................................118
Safety and Workmanship..........................................................................................................................................118
Hydraulic System......................................................................................................................................................118
Base
5.1-1
5.1-2
5.1-3
5.1-4
5.1-5
5.1-6
5.1-7
5.1-8
5.1-9
5.1-10
5.1-11
5.1-12
Engines
5.2-1
5.2-2
5.2-3
5.2-4
5.2-5
5.2-6
5.2-7
5.2-8
5.2-9
5.2-10
5.2-11
Outriggers
5.3-1
5.3-2
5.3-3
5.3-4
5.3-5
5.3-6
5.3-7
5.3-8
5.3-9
Scissors
5.4-1
5.4-2
Platform
5.5-1
Section 5 - Procedures
Base
5.1-1 Brake Caliper Adjustment
1. Prime the brake manifold and brake caliper by
starting the engine and driving the aerial platform
backward and forward approximately 10 ft / 3 m.
2.
3.
4.
5.
Hydraulic System
All service and repairs to the hydraulic system or
hydraulic components must be done in a clean work
environment. Refer to Section 1 - Hydraulic System &
Component Maintenance and Repair
2. Pump handle
1 - 3 times
Section 5 - Procedures
NOTE
If the brake manifold requires more than 3
pumps, or the brake does not release, the
brake caliper may need to be bled. See
5.1-2 Bleeding the Brake Caliper.
6.
8.
Turn screw
clockwise
Tighten
nut
Disc brake
OVERHEAD
VIEW
Calipers
9.
OVERHEAD
VIEW
7.
Loosen
hex nut
Back off
adjusting screw
1/2 turn
Replace cap
Adjustment
bolt
Section 5 - Procedures
5.1-2 Bleeding the Brake Caliper
1. Chock or block the wheels.
2.
3.
4.
5.
11. Pull out the black brake valve knob to reset the
brake.
Section 5 - Procedures
6.
9.
7.
8.
1.
2.
Air bubbles
in line
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. Refer
to Table 1.2 of this manual.
Section 5 - Procedures
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 of this
manual)
8. Check for leakage.
9. Clean up any oil that may have spilled
during this procedure.
10. Check hydraulic oil level. (The hydraulic oil
level should be at or slightly above the top
mark on the sight gauge)
NOTE
Refer to your national/local regulations
on how to dispose of used filter and oil.v
Section 5 - Procedures
5.1-4
5.1-5
1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
5
3
8
7
4
6
2
Section 5 - Procedures
11
10
9
8
6
3
2
1
NOTE
Keep work area clean and visibly free from
contamination at all times.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Section 5 - Procedures
Section 5 - Procedures
controls are powered up.
8.
9.
lift position
drive position.
X AXIS
Red LED
Red LED
Green LED
Green LED
1.
2.
3.
4.
Push in
emergency stop buttons and turn
main disconnect switch to off position.
5.
b.
c.
d.
Red LED
Green LED
Red LED
Green LED
Red LED
Green LED
NOTE
Ensure part number of old and new tilt
switch are the same.
6.
7.
Section 5 - Procedures
e.
Red LED
Red LED
Green LED
Green LED
off position
Red LED
Green LED
Section 5 - Procedures
8.
b.
R
Gre ed LE
en
D
LE
D
1.
Red LED
Green LED
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.
c.
2.
d.
3.
e.
NOTE
The tilt circuit is only powered when
controls are powered up.
4.
5.
f.
lift position
drive position.
g.
6.
Pull out
7.
Red LED
Green LED
Green LED
Red LED
Green LED
Red LED
Green LED
Red LED
Green LED
Red LED
Red LED
Green LED
Green LED
Section 5 - Procedures
i.
9.
10. Push in
Red LED
Light Indicators
Green LED
off position.
R
Gre ed LE
en
D
LE
D
Green LED
Red LED
1.
2.
3.
4.
5.
Section 5 - Procedures
6.
7.
8.
Section 5 - Procedures
5.1-9
3.
4.
Box
Wrench
Torque Wrench
with Crows Foot
5.
6.
3.
4.
5.
3.
4.
5.
Section 5 - Procedures
1.
2.
3.
FFWR
Frac. (in.)
37 Tube
Nut
Swivel Nut
-4
1/4"
1.5
-5
5/16"
-6
3/8"
1.5
1.5
Dash
-8
1/2"
1.5
1.25
-10
5/8"
1.5
-12
3/4"
1.25
-16
1"
-20
1 1/4"
-24
1 1/2
-32
2"
7.
Section 5 - Procedures
6.
7.
1.
2.
3.
1.
2.
or
System pressure
relief valve
Pressure gauge
attached to
quick disconnect
fitting
4.
5.
3. psi should
match serial
plate
8.
9.
Section 5 - Procedures
5.
6.
2.
3.
8.
Disconnect lift
hose
Plug
Cap
1.
4.
2.
or
3. psi should
match serial
plate
Lift pressure
relief valve
Pressure gauge
attached to
quick disconnect
fitting
9.
Section 5 - Procedures
Engines
5.2-1
Resistance
Factory
Specification
A-B
Factory
Specification
A-B
A-C
Resistance of Ignitor
1. Disconnect connector from ignitor.
2. Measure the resistance with an ohmmeter.
3. If resistance is not within the factory specifications,
replace it.
B
D
F
H
IMPORTANT
To replace the ignitor with a service part, make sure the ignitor has the same part cord No /ID mark as
the old one. (See the information label #1.)
Ignitor Check Chart
Negative
Positive
10 to 40 k
10 to 40 k
11 to 47 k
infinity
infinity
infinity
infinity
0.33 to 1.3
k
1.8 to 7.3 k
infinity
infinity
infinity
infinity
1.5 to 6.0 k
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
10 to 40 k
10 to 40 k
0.33 to 1.3
k
11 to 47 k
1.8 to 7.3 k
1.5 to 6.0 k
infinity
infinity
infinity
infinity
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
F
G
H
infinity
infinity
infinity
infinity
infinity
infinity
infinity
60434AA
Section 5 - Procedures
High Throttle Check and Setting
4.
5.
6.
7.
Preparation
1.
2.
3.
1. Turn threaded
link
2. Tighten nut
Section 5 - Procedures
Section 5 - Procedures
High Throttle Check and Setting
4.
5.
6.
Preparation
1.
2.
Solenoid
nut
Solenoid rod
7.
3.
Section 5 - Procedures
9.
Low idle
jam nut
Section 5 - Procedures
Fan
Alternator
pulley
Fan
pulley
2.
9.
4.
5.
6.
Pulley cover
Section 5 - Procedures
5.2-5
Kubota recommends replacing the air cleaner element once a year. More frequent changes may be
needed in dusty environments.
NOTE
The air cleaner uses a dry element.
Never apply oil to it.
1.
2.
3.
4.
Section 5 - Procedures
2.
3.
4.
5.
6.
5.2-7
2.
3.
Fuel Lever
Open
Closed
Fuel Lever
Open
4.
5.
Closed
Filter Element
Filter Cup
Retaining Ring
Section 5 - Procedures
5.2-8
2.
3.
4.
5.
Below 0C (32F)
NOTE
When using oil of a different maker or
viscosity than the previous oil, be sure to
drain all of the old oil before refilling with
new oil. Do not intermix different types.
6.
2.
3.
Filler Caps
NOTE
Do not over tighten the filter as it may
cause deformation of the rubber gasket.
4.
5.
6.
Dipstick
Drain Plug
Section 5 - Procedures
2.
1.
2.
A - Leaks
3.
4.
3.
NOTE
Do not intermix different brands of
coolant. If the existing coolant cannot
be identified, drain the remaining coolant
and refill with new coolant. Refer to
5.2-11 for instructions on draining the
coolant.
4.
5.
6.
7.
8.
9.
B - Evaporation
5.
Radiator Cap
FULL
LOW
Drain Plugs
Section 5 - Procedures
Outriggers
Auto-Leveling Outrigger PC Board Layout
D73
D78
17BCR
D72
61CR
J17E
ENABLE
D75
65CR
J17D
D76
9CR2
D74
REAR RIGHT
FRONT RIGHT
9CR3
35C
78
73
77
74
71
75
72
76
CN20
D77
REAR LEFT
FRONT LEFT
D17B-1
17B
02
78
73
77
74
71
75
72
76
CN21
D71
D17B-2
CN14
04
17
86A
10A
09
44
01
02
02
36A
61
36
5.3-1
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
M50318AA
Section 5 - Procedures
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
2
1
LEFT FRONT
RIGHT FRONT
RIGHT REAR
LEFT REAR
TO CONTROL MODULE
PIN 1 - 65 GREEN / BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE
PIN 5 - 68A WHITE
PIN 6 - (N/U)
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
M11449AC
Section 5 - Procedures
5.3-3
ON
VEHICLE TILTED
1/1
1/2
2/2
2/1
5/5
5/2
7/1
6/6
TESTING HWFS
7/8
5/1
STARTUP!
7/7
7/5
7/1
7/2
8/1
8/2
8/3
8/4
8/5
7/6
60402AB
Section 5 - Procedures
5/5
Check inputs on P2 pins 5 & 6 - the auto-level or auto-retract input is active at power-on
or when it is not allowed to carry out the function.
OUTRIGGERS CANNOT BE MOVED!
1/2
Check input on P2 pin 10 auto-level or auto-retract has been requested but the platform
is elevated.
NOT FULLY LEVEL
2/1
The outrigger legs are all down (touching the ground) but the platform is not fully level.
OUTRIGGERS NOT HOME
2/2
The outrigger legs are not all down (touching the ground) and also are not all home (fully
retracted).
B+ SUPPLY TOO LOW
CHECK OUTRIGGER SUPPLY (P4-9)
5/1
5/2
1/1
6/6
This is not a true fault the outriggers are being manually operated (one or more outrigger
legs on P4 pins 1-8 is high, when the outrigger control module is not active.
CANNOT LEVEL (BAD TILT SENSOR)
FAULT: BAD TILT SENSOR
FAULT: BAD HWFS
FAULT: BAD SLAVE MICRO
FAULT: HWFS STALLED!
FAULT: P2-5 FAULTY
FAULT: P2-6 FAULTY
FAULT: P2-8 STUCK ON
FAULT: P2-8 ALWAYS ON
FAULT: P2-8 ALWAYS OFF
7/1
7/1
7/2
7/5
7/6
8/1
8/2
8/3
8/4
8/5
These are internal faults. If the fault persists after the power has been reset, the outrigger control
module may need to be replaced.
60412AB
Section 5 - Procedures
5.3-5
WARNING
Read all instructions closely before attempting each phase of this procedure.
SYMBOL
KEY FUNCTIONS
ESC/ENTER BUTTONS
To move back and forth between menu and sub-menu
LEFT/RIGHT BUTTONS
Select menus and setting to be adjusted
UP/DOWN BUTTONS
Adjust setting values
Outrigger Settings
Model
O.R. Settings
7127
7135
8831
8841
9250
Section 5 - Procedures
When EZcal hand-held device is connected to the OCM1 control module, a two line displays shows various menus
and settings. At any time the top line of the display describes the currently selected menu and the bottom line shows
the currently selected item in that menu.
Six buttons on EZcal allow easy navigation through the menus:
and change the selected item (the bottom line display)
ENTER enters the selected new menu when available (top line display changes)
and adjusts the selected item when available
ESC exits the current menu back to the previous menu
TOP LEVEL MENU OPTIONS
HELP
Select this menu to see a description of current OCM1 status
DIAGNOSTICS Select this menu to see switch input status & logged data
ACCESS LEVEL Select this menu & enter correct code to enable adjustments and calibrations
ADJUSTMENTS Select this menu to see and adjust OCM1 settings
NOTE: this menu provides for adjustments which might be needed for different work
activities
SETUPS
Select this menu to carry out initial set-up of the OCM1
NOTE: this menu provides for set-ups which are needed to configure the OCM1 for a
particular vehicle
HELP MENU OPTIONS
(help message)
A message displays current OCM1 status, indicating if everything is OK or if there is an
error code (see LED Error Codes - Table 5.3)
DIAGNOSTIC MENU OPTIONS
SYSTEM
Select this menu to see general OCM1 system information
SWITCHES
Select this menu to see switch input status
OUTPUTS
Select this menu to see OCM1 output status
LOG
Select this menu to see logged information
DIAGNOSTIC / SYSTEM MENU OPTIONS
OUTRIGGERS
Displays various status during the auto-level function
TILT
Displays vehicle tilt in X and Y orientations measured by integral sensor
TILTED
Displays whether vehicle is tilted (YES or NO)
BATTERY
Displays battery supply voltage (on P2-12)
DIAGNOSTIC / SWITCHES MENU OPTIONS
LR/P2-1
High when the left rear outrigger is in contact with the ground
RR/P2-2
High when the right rear outrigger is in contact with the ground
RF/P2-3
High when the right front outrigger is in contact with the ground
LF/P2-4
High when the left front outrigger is in contact with the ground
EXTEND/P2-5
High to activate the auto-level function
RETRACT/P2-6 High to activate the auto-retract function
ELEV/P2-10
High when the scissor stack is stowed (elevated input indicates that the vehicle is
stowed).
Section 5 - Procedures
Section 5 - Procedures
IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
Always follow the instructions of the Calibration instrument.
1.
2.
Elevate the scissors high enough to lay a level accross the base tubes. Ensure there is no debris on the base
and the level sits flat. Do not elevate aerial platform higher than the high speed/tilt override limit switch.
3.
Manually operate the outriggers and level the machine in 4 places: left side, right side, front and rear. All 4
outriggers must be firmly placed and all 4 tires are off the ground.
4.
5.
6.
7.
8.
9.
Section 5 - Procedures
5.3-7
LED
GP106 Control Module
PLUG
P1
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P4
P4
P4
P4
P4
P4
P4
P4
P4
PIN
#
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
WIRE #
AND COLOUR
68A White
67A Red/White
66A Blue/White
65A Green/White
70 Green/Black
79 Green
70A Red/White
65 Green/Black
28 Green
35 Green
02 White
10A Black
78 Black/White
77 Blue/Black
76 Red/Black
75 Orange/Black
74 Black
73 Blue
72 Red
71 Orange
35C White/Black
WIRE FUNCTION
The Calibration Connection
Input indicating that the LEFT REAR outrigger is in contact with the ground
Input indicating that the RIGHT REAR outrigger is in contact with the ground
Input indicating that the RIGHT FRONT outrigger is in contact with the ground
Input indicating that the LEFT FRONT outrigger is in contact with the ground
Input for AUTO-LEVEL function to extend the outriggers to level the machine
Input for AUTO-RETRACT function to retract the outriggers until the switch is released
Outrigger Light on Outrigger Control Box
STABLE output to indicate that all outriggers are in contact with the ground
TILT output to indicate that the machine is level (ANSI/CSA only)
Tilt override / High Drive Cutout
Negative Input
Main Power Input
Output used to extend the LEFT REAR outrigger
Output used to extend the RIGHT REAR outrigger
Output used to extend the RIGHT FRONT outrigger
Output used to extend the LEFT FRONT outrigger
Output used to retract the LEFT REAR outrigger
Output used to retract the RIGHT REAR outrigger
Output used to retract the RIGHT FRONT outrigger
Output used to retract the LEFT FRONT outrigger
Power input for outriggers
60401AB
Machine Preparation
1. Ensure the aerial platform is parked on a firm level
surface.
2.
3.
4.
3.
4.
Section 5 - Procedures
Limit Switch Replacement
1. Mount the new limit switch (115658) loosely
on the bracket, using the hardware removed
previously.
2.
3.
4.
5.
6.
Section 5 - Procedures
5.3-9
Machine Preparation
1. Ensure the aerial platform is parked on a firm level
surface.
2.
3.
4.
3.
4.
2.
5.
6.
3.
7.
4.
Cut the tie wraps and tape around the split loom
as needed to expose the limit switch cable.
5.
Section 5 - Procedures
Section 5 - Procedures
Scissors
5.4-1
Machine Preparation
1. Ensure the aerial platform is parked on a firm level
surface.
2.
Locking Plate
Mounting Plate
Limit Switch
#8 Lock Washer
#8-32 x 3/4 Screw
3.
4.
5.
3.
4.
4.
Section 5 - Procedures
6.
FRONT
7.
FRONT
5.
3.
Section 5 - Procedures
5.4-2
Machine Preparation
1. Ensure the aerial platform is parked on a firm level
surface.
2.
3.
4.
5.
6.
3.
3.
4.
Section 5 - Procedures
Section 5 - Procedures
Platform
5.5-1
1.
2.
3.
4.
5.
Notes
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