Professional Documents
Culture Documents
Engine Powered
TM
MAINTENANCE &
PARTS MANUAL
Skyjack Inc. Service Center 3451 Swenson Ave., St. Charles, IL. 60174 ..... FAX 630 262-0006
For Parts in North America and Asia please call .................................... 800 965-4626
Skyjack Inc. Parts Center 3451 Swenson Ave., St. Charles, IL. 60174 ................ FAX 888 782-4825
For Parts & Service in Europe please call ................................................. 44-1691-676-235
Skyjack Europe, Glovers Meadow, Maesbury Rd., Oswestry, Shropshire, U.K....FAX 44-1691- 676-239
129929AF Printed in Canada July 2013
Table of Contents
1
Sect on - Paragraph Page No.
S
Sect on 1 - About Your Aer al Platform
Aerial Platform Definition.................................................................................................................... 1
E
Purpose of Equipment ....................................................................................................................... 1
Use of Equipment .............................................................................................................................. 1
Manuals .............................................................................................................................................. 1
2
Operator ............................................................................................................................................. 1 C
Scope of this Manual ......................................................................................................................... 2
Operator Safety Reminders ............................................................................................................... 3
Electrocution Hazard ......................................................................................................................... 3
T
Safety Precautions ............................................................................................................................. 4
Sect on 2 - L st of Tables
3
Table of Contents ............................................................................................................................... 1 I
Sect on 3 - System Component Ident f cat on and Schemat cs - Operat on
Table of Contents ............................................................................................................................... 1
O
Sect on 4 - Troubleshoot ng Informat on - Operat on
Table of Contents ............................................................................................................................... 1 4
Sect on 5 - Ma ntenance and Serv ce - Operat on
N
Table of Contents ............................................................................................................................... 1
I
5
N
D
6
E
DANGER
DANGER nd cates an mm nently hazardous s tuat on wh ch, f not avo ded,
w ll result n death or ser ous njury.
WARNING
WARNING nd cates a potent ally hazardous s tuat on wh ch, f not avo ded,
could result n death or ser ous njury.
CAUTION
CAUTION nd cates a potent onally hazardous s tuat on wh ch, f not avo ded,
may result n m nor or moderate njury. It may also be used to
alert aga nst unsafe pract ces.
ImpORTANT
IMPORTANT nd cates a procedure essent al for safe operat on and wh ch,
f not followed, may result n a malfunct on or damage to the mach ne.
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications and
dimensions are subject to change without notice.
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.
Maintenance & Parts
The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator must read and completely understand both the 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.
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 2.1 of the Operating Manual. Operating instructions for these options (if equipped)
are located in Section 2 of the Operating Manual.
Include the model and serial number for each applicable aerial platform.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery
Directive 98/37/EC and EMC Directive 89/336/EEC and the corresponding EN standards.
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial plat-
form is mandatory. The following pages of this manual should be read and understood completely before operat-
ing 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.
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.
DANGER
Avoid Power Lines
Safety Precautions
Know and understand the safety precautions before going on to next section.
WARNING
Failure to heed the following safety • DO NOT increase the lateral
precautions could result in tip over, surface area of the platform.
falling, crushing, or other hazards leading Increasing the area exposed
to death or serious injury. to the wind will decrease aerial
platform stability.
• KNOW all national, state/provincial and local
rules which apply to your aerial platform and job-
site. • DO NOT drive or elevate the
aerial platform if it is not on a
• TURN the (emergency) main power disconnect firm level surface. Do not drive
switch off when leaving the aerial platform unat- elevated near depressions
tended. Remove the key to prevent unauthorized or holes of any type, loading
use of the aerial platform. docks, debris, drop-offs and
surfaces that may affect the
• WEAR all the protective clothing and personal stability of the aerial platform.
safety devices issued to you or called for by job
conditions.
• If operation in areas with
• DO NOT wear loose clothing, holes or drop-offs is abso-
dangling neckties, scarves, lutely necessary, elevated
rings, wristwatches or other driving shall not be allowed.
jewelry while operating this Position the aerial platform
aerial platform.
�
��
• DO NOT climb on scissor arm • STUNT driving and horseplay are prohibited.
assembly. It is prohibited.
• ENSURE ALL tires are in good condition and lug
nuts are properly tightened.
Table of Contents
Table 2-3b Maximum Platform Capacities (Evenly Distributed with #7 Tires Equipped) - ANSI/CSA ......................7
8,420 lb. 8,850 lb. 10,600 lb. 11,460 lb. 9,670 lb. 10,570 lb. 14,700 lb.
Weight*
3819 kg 4014 kg 4808 kg 5198 kg 4386 kg 4794 kg 6668 kg
71.5” 87” 92”
Width
1.82 m 2.21 m 2.34 m
150” 137.5” 176”
Length
3.81 m 3.5 m 4.47 m
64” x 117” 68” x 133” 74” x 168”
Platform Size
1.63 m x 2.97 m 1.73 m x 3.39 m 1.88 m x 4.27 m
33’ 41’ 49’ 56’ 37’ 47’ 56’
Working
10.1 m 12.5 m 14.9 m 17.1 m 11.3 m 14.3 m 17.1 m
27’ 35’ 43’ 50’ 31’ 41’ 50’
Platform Elevated
Height
Elevated Drive
0.56 km/h 0.97 km/h
Raise (Rated Load) 43 sec. 41 sec. 45 sec. 46 sec. 58 sec. 56 sec. 67 sec.
Lower (Rated Load) 46 sec. 44 sec. 58 sec. 52 sec. 44 sec. 53 sec. 72 sec.
Kubota (Diesel) 1400 (Low) / 2800 (High) 1400 (Low) / 2800 (High)
* Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 2WD machines on air tires with a manual
extension platform (Mid Size RT’s) and no extension platforms (Full Size RT’s).
7.9 m
Drive Full
25.9 ft.
Elevated Drive
0.34 mph 0.60 mph
Kubota (Diesel) 1400 (Low) / 2800 (High) 1400 (Low) / 2800 (High)
Normal Drive 4.8 km/h 5.6 km/h 5.6 km/h 3.2 km/h
0.58 km/h
Speed
Kubota (Diesel) 1400 (Low) / 2800 (High) 1400 (Low) / 2800 (High)
Recording Date
Recording Year # 1 2 3 4 5 6 7 8 9
Owner’s Name
Inspected By
60141AB
As described earlier in this section, 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.
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.
Table 2.3b Maximum Platform Capacities (Evenly Distributed w/ Optional #7 Tires) - ANSI/CSA
One Extension
5 2 Not Available
Platform 680 kg 227 kg
One Extension
6 2 Not Available
Platform 771 kg 227 kg
One Extension
5 2 Not Available
Platform 567 kg 227 kg
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.
3 3.4 – 5.4 12.5 – 19.4 11.5 – 17.75 5 – 12.0 Papers and thin branches move, flags wave
One Extension
7135 454 kg 4 159 kg 1 Not Available
Platform
No Extension
1134 kg 6 Not Available
Platform
One Extension
8831 908 kg 6 227 kg 2 Not Available
Platform
Two Extension
681 kg 6 227 kg 2 227 kg 2
Platforms
No Extension
771 kg 5 Not Available
Platform
One Extension
8841 681 kg 5 227 kg 2 Not Available
Platform
Two Extension
681 kg 5 227 kg 2 227 kg 2
Platforms
No Extension
908 kg 5 Not Available
Platform
One Extension
9250 681 kg 5 227 kg 2 Not Available
Platform
Two Extension
681 kg 5 227 kg 2 227 kg 2
Platforms
60376AD-AS
NOTE:
Occupants AND materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires except for model 9250A which is equipped with foam filled
tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
7127 min* 9360 4246 3744 1698 47.7 328.8 155.5 759.2
Outrigger Pads max* 12180 5525 4872 2210 62.1 427.9 202.3 987.9
7135 min* 9790 4441 3916 1776 49.9 343.9 162.6 794.1
Outrigger Pads max* 12110 5493 4844 2197 61.7 425.5 201.2 982.2
8243 min* 10600 4808 4240 1923 54.0 372.4 176.1 859.8
Outrigger Pads max* 12920 5860 5168 2344 65.8 453.9 214.6 1047.9
8850 min* 11460 5198 4584 2079 58.4 402.6 196.2 958.2
Outrigger Pads max* 12530 5684 5012 2273 63.8 440.2 214.6 1047.6
8831 min* 10540 4781 4216 1912 53.7 370.3 157.1 767.0
Outrigger Pads max* 14300 6486 5720 2594 72.9 502.4 213.1 1040.6
8841 min* 11440 5189 4576 2076 58.3 401.9 170.5 832.5
Outrigger Pads max* 14820 6722 5928 2689 75.5 520.7 220.9 1078.4
9250 min* 14700 6668 5880 2667 74.9 516.4 145.5 710.7
Outrigger Pads max* 18410 8351 7364 3340 93.8 646.8 182.3 890.0
60379AD-ANSI
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined
by the engineer or architect for that particular structure.
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.
7127 min* 4246 9360 1698 3744 328.8 47.7 759.2 155.5
Outrigger Pads max* 5525 12180 2210 4872 427.9 62.1 987.9 202.3
7135 min* 4441 9790 1776 3916 343.9 49.9 794.1 162.6
Outrigger Pads max* 5493 12110 2197 4844 425.5 61.7 982.2 201.2
8831 min* 4781 10540 1912 4216 370.3 53.7 767.0 157.1
Outrigger Pads max* 6486 14300 2594 5720 502.4 72.9 1040.6 213.1
8841 min* 5189 11440 2076 4576 401.9 58.3 832.5 170.5
Outrigger Pads max* 6722 14820 2689 5928 520.7 75.5 1078.4 220.9
9250 min* 6668 14700 2667 5880 516.4 74.9 710.7 145.5
Outrigger Pads max* 8851 18410 3540 7364 646.8 93.8 890.8 182.3
60379AD-CE
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally
determined by the engineer or architect for that particular structure.
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.
kg kg kPa kg/m2
min* 3592 1437 701.2 732.4
7127
max* 5525 2210 835.0 1126.4
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure
and is generally determined by the engineer or architect for that particular structure.
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.
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
7127
7135
8243
8850
8831
8841
9250
(kPa)
10-16.5 75*
#6A 10 S S S N/A S S S
CARLISLE US LOADER (517.1)*
10-16.5 OTR OUTRIGGER 75*
#6A Air 10 O O O N/A O O O
(Non-Marking) (517.1)*
31-15.5-15 45*
#7A 8 O O O N/A O O O
GOODYEAR TERRA XTRAC (310.3)*
10-16.5
#6F 10 N/A O O O S O O O
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
#6F Foam 10 N/A O O O O O O O
(Non-Marking)
31-15.5-15
#7F 8 N/A O O O O O O O
GOODYEAR TERRA XTRAC
60378AD-ANSI
*
Factory preset @ 20°C, Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal conditions.
Backspace A
SECTION A-A A
Backspace
Rim Size
7127
Contact Skyjack Service 7135 8831 8841 8243 8850 9250
Serial Number
Department
60380AC-ANSI
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
7127
7135
8243
8850
8831
8841
9250
(kPa)
10-16.5
#6A 10 517.1* S S S N/A S S S
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
#6A Air 10 517.1* O O O N/A O O O
(Non-Marking)
31-15.5-15
#7A 8 310.3* N/A N/A N/A N/A N/A N/A N/A
GOODYEAR TERRA XTRAC
10-16.5
#6F 10 N/A O O O S O O O
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
#6F Foam 10 N/A O O O O O O O
(Non-Marking)
31-15.5-15
#7F 8 N/A O O O O O O O
GOODYEAR TERRA XTRAC
60378AD-CE
* Factory preset @ 20°C. Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal conditions.
Backspace A
Inboard Outboard
SECTION A-A
A
Backspace
Rim Size
7127
Contact Skyjack Service 7135 8831 8841 9250
Serial Number
Department
121 mm 95 mm 95 mm 121 mm 121 mm 95 mm
#6 & #6F
4.75 in. 3.75 in. 3.75 in. 4.75 in. 4.75 in. 3.75 in.
60380AC-CE
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
Backspace A
SECTION A-A A
Backspace
Rim Size
7127
Contact Skyjack Service 7135 8831 8841 9250
Serial Number
Department
121mm 95 mm 95 mm 121mm 121mm 95 mm
#6A & #6F
4.75 in. 3.75 in. 3.75 in. 4.75 in. 4.75 in. 3.75 in.
60380AD-AS
AXLE OIL
*Qty. *Qty. Skyjack
Axle Type Oil Type Recommended Equivalent Oil
(Liters) (Gallons) Part No.
Cushman Front
2.4 0.634 Gear Oil, 80W-90 GL5 134612 -
Dana Front / Rear
Chevron Gear Lubricant Delo ESI 80W-90,
Caltex Gear Lubricant ESI 80W-90,
Cushman Rear 1 0.264 Gear Oil, ESI 80W-90 133461
Caltex RPM Borate EP 80W-90,
Texaco Star Gear Lubricant 80W-90
HYDRAULIC OIL
*Qty. *Qty. Skyjack
Model Oil Type
(Liters) (Gallons) Part No.
SJRT-68xx 86.88 22.95
SJRT-7127
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850
ATF Dexron III 119309
SJRT-8831
SJRT-8841
75.71 20
SJRT-8831E
SJRT-8841E
SJRT-9250 67.38 17.8
ENGINE OIL
*Qty. *Qty. Skyjack Recommended Equivalent Oil
Engine Type Oil Type, Viscosity
(Liters) (Gallons) Part No. (Viscosity - API Service Designation)
Kubota D902 3.9 1.03
Kubota D1105 5.1 1.35 10W30 - API Service Designation CG-4,
105287
Kubota DF972 3.4 0.9 Engine Oil, SAE 10W-30 CF-4, CF, CD, SH.
Nissan A15
3.5 0.98
GM 1.6 142454 10W30 - API Service Designation SF/CC.
ENGINE COOLANT
*Qty. *Qty. Skyjack
Component Type **Coolant Type
(Liters) (Gallons) Part No.
Kubota D902
Kubota D1105 3.1 0.82
AntI-freeze / Water 125985
Kubota DF972
Nissan A15
11.4 3.01
GM 1.6 Extended life antI-freeze / Water 142208
ENGINE FUEL
Tank Diesel Gasoline / Liquid Propane
Model *Qty. *Qty.
Kubota D902 Kubtoa D1105 Kubota DF972 GM 1.6 Nissan A15
(Liters) (Gallons)
SJRT-68xx 86.88 22.95 � N/A
SJRT-7127 � N/A
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850 N/A �
SJRT-8831 N/A �
49.21 13
SJRT-8841
SJRT-9250 64.35 17
General Maintenance
Before attempting any repair work, disconnect battery by turning emergency main power disconnect
switch to off position. Preventive maintenance is the easiest and least expensive type of maintenance.
3 months or 3 months or
Frequency Daily
150 hours
Yearly Frequency Daily
150 hours
Yearly
60603AA-ANSI-P
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.8 and Section 2.9 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection. Refer to Service & Maintenance manual.
* - Maintenance must be performed only by trained and competent personnel who are familiar with mechanical procedures.
WARNING
Use original or manufacturer-approved parts and components for aerial platform.
General Maintenance
Before attempting any repair work, disconnect battery by turning main power disconnect switch to off
position. Preventive maintenance is the easiest and least expensive type of maintenance.
3 months or 3 months or
Frequency Daily
150 hours
Yearly Frequency Daily
150 hours
Yearly
60603AA-CE-P
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.8 and Section 2.9 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection. Refer to Service & Maintenance manual.
* - Maintenance must be performed only by trained and competent personnel who are familiar with mechanical procedures.
WARNING
Use original or manufacturer-approved parts and components for aerial platform.
General Maintenance
Before attempting any repair work, disconnect battery by turning main power disconnect switch to off
position. Preventive maintenance is the easiest and least expensive type of maintenance.
3 months or 3 months or
Frequency Daily
150 hours
Yearly Frequency Daily
150 hours
Yearly
60603AA-AS-P
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.8 and Section 2.9 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection. Refer to Service & Maintenance manual.
* - Maintenance must be performed only by trained and competent personnel who are familiar with mechanical procedures.
WARNING
Use original or manufacturer-approved parts and components for aerial platform.
OPERATOR'S CHECKLIST
Serial Number:
Model:
Hourmeter Reading: Operator's Name (Printed):
Date:
Time: Operator's Signature:
Each item shall be inspected using the appropriate section of the Skyjack operating manual.
As each item is inspected, check the appropriate box.
P - PASS � DAILY
F - FAIL � FREQUENTLY
R - REPAIRED � ANNUALLY
NA - NOT APPLICABLE � BI-ANNUALLY
N/A P F R N/A P F R
Visual and Daily Maintenance Inspections Lifting Mechanism
Labels Scissor Guards
Electrical Sliders
Limit Switches Maintenance Support
Hydraulic Scissor Assembly
Hydraulic/Electrical Compartment Scissor Bumpers
Emergency Main Power Disconnect Switch Lift Cylinder(s)
Base Control Switches Base
Battery Base Weldment
Manifolds Wheel/Tire Assembly
Electrical Panel Drive Axle
Tilt Sensor Steer Cylinder Assembly
Hydraulic Tank (Model 9250) Tie Rod
Hydraulic Oil (Model 9250) Disc Brake (Models 71xx & 8xxx)
Emergency Lowering Access Rod (If Equipped) Pin Brakes (Model 9250)
Hydraulic/Fuel Compartment Drive Motor
Hydraulic Tank (Models 71xx & 8xxx) Ladder
Hydraulic Oil (Models 71xx & 8xxx) Outriggers
Fuel Tank Manuals
Fuel Leaks Function Tests
Engine Compartment Test Emergency Main Power Disconnect Switch
Engine Control Console Base Control Console
Radiator Test Platform Raise/Lower Switch
Muffler and Exhaust Test Emergency Lowering (Models 71xx & 8xxx)
Engine Tray Test Emergency Lowering (Model 9250)
Hydraulic Pump Platform Control Console
Engine Oil Level Test Emergency Stop
Engine Air Filter Test Enable Trigger Switch
Fuel Leaks Test Platform Raising/Lowering
Platform Assembly Test Steering
Lanyard Attachment Anchors Test Driving
AC Outlet on Platform Test Speed Limit
Platform Control Console Test Brakes
Powered Extension Control Console (If Equipped) Test Horn
Test Tilt Sensor
Note:
Make a copy of this page or visit the Skyjack web site: 60604AA-ANSI
www.skyjack.com for a printable copy.
OPERATOR'S CHECKLIST
Serial Number:
Model:
Hourmeter Reading: Operator's Name (Printed):
Date:
Time: Operator's Signature:
Each item shall be inspected using the appropriate section of the Skyjack operating manual.
As each item is inspected, check the appropriate box.
P - PASS � DAILY
F - FAIL � FREQUENTLY
R - REPAIRED � ANNUALLY
NA - NOT APPLICABLE � BI-ANNUALLY
N/A P F R N/A P F R
Visual and Daily Maintenance Inspections Lifting Mechanism
Labels Scissor Guards
Electrical Sliders
Limit Switches Maintenance Support
Hydraulic Scissor Assembly
Hydraulic/Electrical Compartment Scissor Bumpers
Main Power Disconnect Switch Lift Cylinder(s)
Base Control Switches Base
Battery Base Weldment
Manifolds Wheel/Tire Assembly
Electrical Panel Drive Axle
Load/Tilt Sensor Steer Cylinder Assembly
Hydraulic Tank (Model 9250) Tie Rod
Hydraulic Oil (Model 9250) Disc Brakes (Models 71xx & 88xx)
Emergency Lowering Access Rod (If Equipped) Pin Brake (Model 9250)
Hydraulic/Fuel Compartment Drive Motor
Hydraulic Tank (Models 71xx & 88xx) Ladder
Hydraulic Oil (Models 71xx & 88xx) Outriggers (If Equipped)
Fuel Tank Manuals
Fuel Leaks Function Tests
Engine Compartment Test Main Power Disconnect Switch
Engine Control Console Base Control Console
Radiator Test Emergency Stop
Muffler and Exhaust Test Platform Raise/Lower Switch
Engine Tray Test Emergency Lowering (Models 71xx & 88xx)
Hydraulic Pump Test Emergency Lowering (Model 9250)
Engine Oil Level Platform Control Console
Engine Air Filter Test Emergency Stop
Fuel Leaks Test Enable Trigger Switch
Platform Assembly Test Platform Raising/Lowering
Lanyard Attachment Anchors Test Lowering Warning
AC Outlet on Platform Test Steering
Platform Control Console Test Driving
Powered Extension Control Console (If Equipped) Test Speed Limit
Test Brakes
Note:
Test Horn
Make a copy of this page or visit the Skyjack web site:
Test Tilt Sensor
www.skyjack.com for a printable copy.
60604AA-CE
OPERATOR'S CHECKLIST
Serial Number:
Model:
Hourmeter Reading: Operator's Name (Printed):
Date:
Time: Operator's Signature:
Each item shall be inspected using the appropriate section of the Skyjack operating manual.
As each item is inspected, check the appropriate box.
P - PASS � DAILY
F - FAIL � FREQUENTLY
R - REPAIRED � ANNUALLY
NA - NOT APPLICABLE � BI-ANNUALLY
N/A P F R N/A P F R
Visual and Daily Maintenance Inspections Lifting Mechanism
Labels Scissor Guards
Electrical Sliders
Limit Switches Maintenance Support
Hydraulic Scissor Assembly
Hydraulic/Electrical Compartment Scissor Bumpers
Main Power Disconnect Switch Lift Cylinder(s)
Base Control Switches Base
Battery Base Weldment
Manifolds Wheel/Tire Assembly
Electrical Panel Drive Axle
Tilt Sensor Steer Cylinder Assembly
Hydraulic Tank (Model 9250) Tie Rod
Hydraulic Oil (Model 9250) Disc Brake (Models 71xx & 8xxx)
Emergency Lowering Access Rod (If Equipped) Pin Brakes (Model 9250)
Hydraulic/Fuel Compartment Drive Motor
Hydraulic Tank (Models 71xx & 8xxx) Ladder
Hydraulic Oil (Models 71xx & 8xxx) Outriggers (If Equipped)
Fuel Tank Manuals
Fuel Leaks Function Tests
Engine Compartment Test Main Power Disconnect Switch
Engine Control Console Base Control Console
Radiator Test Emergency Stop
Muffler and Exhaust Test Platform Raise/Lower Switch
Engine Tray Test Emergency Lowering (Models 71xx & 8xxx)
Hydraulic Pump Test Emergency Lowering (Model 9250)
Engine Oil Level Platform Control Console
Engine Air Filter Test Emergency Stop
Fuel Leaks Test Enable Trigger Switch
Platform Assembly Test Platform Raising/Lowering
Lanyard Attachment Anchors Test Steering
AC Outlet on Platform Test Driving
Platform Control Console Test Speed Limit
Powered Extension Control Console (If Equipped) Test Brakes
Test Horn
Note:
Test Tilt Sensor
Make a copy of this page or visit the Skyjack web site:
www.skyjack.com for a printable copy. 60604AA-AS
TABLE OF CONTENTS
Hydraulic System
Figure 3.2-1. Hydraulic Schematic Parts List ................................................................................................... 5
Figure 3.2-2. Hydraulic Schematic ................................................................................................................... 9
Figure 3.2-3. Hydraulic Manifold Component and Port Identification ............................................................ 10
3
Electrical System
Figure 3.3-7. Electrical Inverter Wiring Diagram.............................................................................................. 21
Figure 3.3-8. Hydraulic Generator Electric Panel Diagram
(Nissan & Kubota Engine with Hydraulic Generator Option) ANSI/CSA .................................. 22
Figure 3.3-9. Hydraulic Generator Electric Panel Diagram
(Nissan & Kubota Engine with Hydraulic Generator Option) CE .............................................. 24
Figure 3.3-10. Oil Cooler Electric Panel Diagram (Nissan Engine with No Hydraulic Generator Option) ....... 25
Figure 3.3-11. Engine Wiring Diagram (Nissan Engines) ................................................................................. 26
Figure 3.3-12. Engine Wiring Diagram (Kubota Diesel Engines) ..................................................................... 28
Figure 3.3-13. Main Manifold Wiring Diagram (ANSI/CSA) .............................................................................. 29
Figure 3.3-14. Main Manifold / Base Controls Wiring Diagram (CE) ................................................................ 30
Figure 3.3-15. Outrigger Connection Diagram ................................................................................................. 31
Figure 3.3-16. Horn/light/Beeper Wiring Diagram (ANSI/CSA) ........................................................................ 32
Figure 3.3-17. Powered Extension Related Assemblies and Electrical Connection Diagram ......................... 33
Figure 3.4-1. Electrical Panel Diagram - ANSI/SIA and CSA (No Options) .................................................... 35
Figure 3.4-2. Electrical Panel Diagram - ANSI/SIA and CSA (All Options) ..................................................... 37
Figure 3.4-3. Electrical Panel Diagram - CE (Shown with All Options)........................................................... 38
Electrical Schematics
Figure 3.5-1. ANSI/CSA (Nissan Dual Fuel Engine - No Options) ................................................................... 39
Figure 3.5-2. ANSI/CSA (Nissan Dual Fuel Engine - All Options) ................................................................... 42
Figure 3.5-3. CE (Kubota Diesel Engine - All Options) .................................................................................... 45
Figure 3.5-4. ANSI/CSA (Kubota Diesel Engine - All Options) ........................................................................ 47
Figure 3.5-5. ANSI/CSA (GM Dual Fuel Engine - No Options) ........................................................................ 50
Figure 3.5-6. ANSI/CSA (GM Dual Fuel Engine - All Options)......................................................................... 51
Figure 3.5-7. Interface & Engine Electrical Schematic - GM Dual Fuel Engine .............................................. 52
Figure 3.5-8. Engine Harnesses - GM Dual Fuel Engine ................................................................................ 53
COMMON COMMON
NORMALLY NORMALLY
OPEN OPEN
CONTACT CONTACT
NOTE: The power wire to the coil of the relay determines the relay number. (ie: #14 to the coil becomes 14CR)
ANGLE
WIRE CROSSING HOURMETER KEY SWITCH
TRANSDUCER
LIMIT SWITCH
ELECTRIC
FUSE ROTARY SWITCH N.C.
MOTOR
BATTERY SILICON
EMERGENCY CAM OPERATED
CHARGE CONTROLLED
STOP BUTTON LIMIT SWITCH
INDICATOR RECTIFIER
PROXIMITY
CAPACITOR RESISTOR TILT SWITCH
SWITCH
SINGLE POLE
PNP
POTENTIOMETER LEVEL SENSOR SINGLE THROWN
TRANSISTOR
RELAY
TEMPERATURE
SWITCH
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
VARIABLE
PRESSURE PILOT LINES Dashed DISPLACEMENT
MAIN LINES Solid
TRANSDUCER HYDRAULIC MOTOR
QUICK
SERVO DISCONNECT
4H-26A 128318 1 VALVE ASSEMBLY, Rear platform extend (opt) (includes 4H-27)
4H-27 128318 1 VALVE ASSEMBLY, Front platform retract (opt) (includes 4H-26A)
4H-27A 128318 1 VALVE ASSEMBLY, Rear platform retract (opt) (includes 4H-26)
4H-71 128318 1 VALVE ASSEMBLY, Left front outrigger retract (opt.) (includes 4H-75)
4H-72 128318 1 VALVE ASSEMBLY, Right front outrigger retract (opt.) (includes 4H-76)
4H-73 128318 1 VALVE ASSEMBLY, Right rear outrigger retract (opt.) (includes 4H-77)
4H-74 128318 1 VALVE ASSEMBLY, Left rear outrigger retract (opt.) (includes 4H-78)
4H-75 128318 1 VALVE ASSEMBLY, Left front outrigger extend (opt.) (includes 4H-71)
4H-76 128318 1 VALVE ASSEMBLY, Right front outrigger extend (opt.) (includes 4H-72)
4H-77 128318 1 VALVE ASSEMBLY, Right rear outrigger extend (opt.) (includes 4H-73)
4H-78 128318 1 VALVE ASSEMBLY, Left rear outrigger extend (opt.) (includes 4H-74)
HYDRAULIC
P2
GENERATOR
OPTION X
4H-16B
CV3 R2 FORWARD
CHECK LIFT DRIVE
GM1 RELIEF 4H-78 4H-75 4H-76 4H-77
VALVE VALVE
VALVE LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
EXTEND EXTEND EXTEND EXTEND
2H-86C MB12 2H-30A-1 VALVE VALVE VALVE VALVE
HYDRAULIC GENERATOR BRAKE
GENERATOR MANIFOLD 2H-30A-2
2H-14B FEED
VALVE BLOCK BRAKE
LIFT VALVE
CV2 FEED 4H-15B
VALVE
CHECK VALVE REVERSE
VALVE DRIVE
VALVE
2H-17A
LARGE
PUMP DUMP
VALVE 4H-74 4H-71 4H-72 4H-73
LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR
ENGINE 2H-17B OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
R1 OUTRIGGER RETRACT RETRACT RETRACT RETRACT Y
SYSTEM HOLDING VALVE VALVE VALVE VALVE
CV1 RELIEF VALVE
2H-18A CHECK VALVE
SMALL VALVE
PUMP DUMP
VALVE
LARGE SMALL
PUMP PUMP
P1 DUAL
INLET MB11 OUTRIGGER MANIFOLD BLOCK
PUMP QD1 SYSTEM PRESSURE
QUICK DISCONNECT
Z
F1
FILTER
RESERVOIR
M50151AG
TO BRAKE
TO QUICK BRAKE CYLINDER V
TO STEER
MANIFOLD BLOCK
CYLINDER TO CENTER
TO CENTER DRIVE (return) TO HYDRAULIC
DRIVE TANK
4H-23A
MB7 V6
LEFT STEER
4H-24A AUTO RESET BRAKE
2H-14B VALVE
RIGHT STEER MANIFOLD BLOCK RELEASE
LIFT
VALVE VALVE OVERRIDE
R1
VALVE
SYSTEM
RELIEF MB1 MAIN
TO LIFT VALVE 4H-16A MANIFOLD 2H-25 W
MANIFOLD FORWARD BLOCK QUICK BRAKE
BLOCK DRIVE VALVE VALVE
4H-15A
REVERSE
DRIVE VALVE
2H-30A-2
BRAKE FEED HP2
RETURN CV1 VALVE HAND PUMP
2H-30A-1
FROM CHECK
BRAKE
VALVE 2H-17A 4H-71A 4H-74A
OUTRIGGER DUMP
LARGE PUMP OUTRIGGER OUTRIGGER 2H-17B
MANIFOLD VALVE 4H-72A X
R2 LIFT DUMP VALVE LEFT FRONT LEFT REAR OUTRIGGER
OUTRIGGER
RELIEF RETRACT RETRACT HOLDING
2H-13A RIGHT FRONT
VALVE VALVE
MAIN RETRACT
LOWERING
VALVE
CV2
2H-18A CHECK
SMALL PUMP VALVE 4H-73A
4H-78A
DUMP VALVE TO OUTRIGGER
CV3 OUTRIGGER
OUTRIGGER RIGHT REAR
CHECK LEFT REAR
MANIFOLD RETRACT
VALVE EXTEND Y
TO HYDRAULIC TO 4H-75A
PUMP (small) HYDRAULIC OUTRIGGER
TANK LEFT FRONT
EXTEND
TO HYDRAULIC
PUMP (large)
TO EMERGENCY
LOWERING
MANIFOLD
4H-77A 4H-76A Z
OUTRIGGER OUTRIGGER
RIGHT REAR RIGHT FRONT OUTRIGGER
EXTEND EXTEND CYLINDER
JOYSTICK CONTROL
WITH ENABLE
NORM./HIGH
TORQUE
(16) WHITE BLACK GREEN WHITE (34) (77) GREEN BLACK WHITE
(15) BLUE GREEN BLACK (32) (76) RED GREEN
GROUND (00)
M50312AB
JOYSTICK CONTROL
WITH ENABLE
NORM./HIGH
TORQUE
(16) WHITE BLACK GREEN WHITE (34) (77) GREEN BLACK WHITE
(15) BLUE GREEN BLACK (32) (76) RED GREEN
(14) BLACK RED WHITE (31) (75) WHITE RED
(13) ORANGE BLUE BLACK (24) (74) BLACK RED RED BLACK GREEN (7C)
(10) BLUE WHITE BLACK WHITE (23) (73) ORANGE GREEN WHITE RED GREEN (10D)
(09) ORANGE RED BLACK WHITE RED (20) (72) WHITE BLACK RED BLACK RED GREEN (60)
(7A) RED ORANGE BLACK (19) (71) BLUE RED ORANGE BLACK WHITE (85)
(02) WHITE RED BLACK (18) (49) GREEN RED BLACK WHITE (78)
GROUND (00)
BLUE BLACK WHITE (GROUND) TO TERMINAL STRIP
M50313AB
M114942AK
M130711AC
S9A OL1
OUTRIGGER ENABLE SWITCH OUTRIGGER LIGHT
PIN 1 - 35D ORANGE/RED 70A RED/WHITE
PIN 2 - 35C WHITE/BLACK 02 WHITE
PIN 3 - 35D ORANGE/RED
BLUE/WHITE (N/U)
GREEN/WHITE (N/U)
OUTRIGGER CONTROL CABLE
M50249AA
INV1
34CR V
VIOLET WIRE
W
F4
EXISTING CABLE
ELECTRIC PANEL
TO AC OUTLET
POSTIVE NEGATIVE
B1
BATTERY Z
EXISTING CABLE
M50069AE
13
10A
86BCR
W
28CR 17CR
X
TO HYDRAULIC GENGERATOR SOLDNOID 110V 15A HYDRAULIC GENERATOR INTERNAL WIRING
86C - BLACK
02 - WHITE
W1 V1
V2 U2
RED BLK
86D - BLACK
00 - WHITE
TO OIL Z
COOLER FAN
M50287AB
14
34BCR
Figure 3.3-8a
10A
13
10A
86BCR
W
28CR 17CR
X
TO HYDRAULIC GENGERATOR SOLDNOID 110V 15A HYDRAULIC GENERATOR INTERNAL WIRING
86C - BLACK
02 - WHITE
W1 V1
V2 U2
RED BLK
86D - BLACK
00 - WHITE
TO OIL
COOLER FAN
Z
M129438AB
10A
13D
10A
86BCR
W
28ECR 17CR
NOTE:
IF THERE IS NO OUTRIGGER OPTION,
CONNECT THE END OF THIS WIRE
DIRECTLY TO PIN 14 OF 86ACR.
12 PIN OUTRIGGER
OPTION CONNECTOR
(IF EQUIPPED)
PIN 3 - 86A ORG/BLK/WHT
X
Y
LOAD BROWN
LOAD NEUTRAL BLUE
GROUND GREEN/YELLOW
COOLER FAN W1 V1
V2 U2
V2 U2
M50310AA
Z
86D - BLACK TO OIL
00 - WHITE COOLER FAN
M50294AB
M50238AE
32A
11
05
07
07
50
56
07
2002
2002
4002
10A
1003
00
OFF/ON/START SWITCH
GAS/PROPANE SWITCH
7002
7002
BACK VIEW
7002 - RED (10 AWG) PIN A - 1002 RED/BLACK (18 AWG)
7002 - RED (16 AWG) PIN B - 1001 BROWN/WHITE (18 AWG)
2005 - GREEN/WHITE (16 AWG)
7002
2005
ENGINE FAULT CODE GAS INJECTOR
RESET WIRE PIN A - 1002 RED/BLACK (16 AWG)
203 - ORANGE/BLACK (16 AWG) PIN B - 2001 BROWN (16 AWG)
THROTTLE ACTUATOR X
203
PIN A - 1008 GREY (16 AWG)
PIN B - 00 WHITE (16 AWG) OXYGEN SENSOR
203
PIN A - 200 BLACK/WHITE (18 AWG)
WHITE ECU CONNECTOR PIN B - 209 WHITE/BLACK (18 AWG)
PIN 1 - 50 ORANGE (16 AWG)
2005 GREEN/WHITE
PIN 2 - 34A GREEN/WHITE (16 AWG) PIN 8 - 2008 GREY (16 AWG) PIN 19 - 1006 LT. BLUE (16 AWG) AIR TEMP. SENSOR
PIN 3 - N/U 100 - FUSE HOLDER 102
STARTER SOLENOID PIN 9 - 34A GREEN/WHITE (16 AWG) PIN 20 - 00 WHITE (16 AWG) BACK VIEW
PIN 4 - 32A GREEN/BLACK (16 AWG) PIN 10 - N/U PIN 21 - 00 WHITE (16 AWG) PIN A - 106 BLUE (18 AWG)
32A - GREEN/BLACK (16 AWG) (2x)
100
PIN 11 - 3008 GREY (16 AWG) PIN 22 - 2002 RED (16 AWG)
WHITE
2002 RED
PIN 6 - N/U PIN 12 - 1003 ORANGE (16 AWG) PIN 23 - 2002 RED (16 AWG)
PIN 7 - 33 GREEN (16 AWG) CHASSIS GROUND
PIN 8 - 10A BLUE/WHITE (16 AWG) 00 WHITE (10 AWG)
32A
PIN 9 - 2A BLACK/RED (16 AWG) BLACK ECU CONNECTOR WATER TEMP. SENSOR
1002 RED/BLACK
100
SPLICE #12
PIN 1 - 105 GREEN (18 AWG)
1002
PIN 11 - 07 RED (16 AWG)
PIN 12 - 05 PURPLE/WHITE (16 AWG) PIN 2 - N/U PIN 13 - N/U BACK VIEW
PIN B - 1100 BLACK (18 AWG) Y
PIN 3 - N/U PIN 14 - N/U
PIN 4 - 1103 ORANGE (18 AWG) PIN 15 - N/U PROPANE VALVE
BLACK
PIN 5 - N/U PIN 16 - N/U 50 - ORANGE (16 AWG) (2x)
1100 BLACK
SPLICE #11
BACK VIEW PIN 6 - N/U PIN 17 - 205 GREEN (18 AWG) 00 - WHITE (16 AWG)
1100
2002 PIN 7 - 102 PINK (18 AWG) PIN 18 - N/U
7 6 IGNITION COIL PIN 8 - 203 ORANGE/BLACK (16 AWG) PIN 19 - N/U
DEUTSCH
8 5
50
00
9
10
4
3
2002 - RED (16 AWG) (2x) PIN 9 - 106 BLUE (18 AWG) PIN 20 - N/U
11 2 2006 2006 - LT. BLUE (16 AWG) PIN 10 - 209 WHITE/BLACK (18 AWG) PIN 21 - N/U
12 1 20 AMP PIN 11 - 1100 BLACK (18 AWG) PIN 22 - N/U
PIN 12 - 200 BLACK/WHITE (18 AWG) PIN 23 - N/U
SPLICE #6
RST4 2008 GREY RST5
00 2002 00
4002 100/7002
SPLICE #1 SPLICE #2 RST6 SPLICE #5 SPLICE #7 SPLICE #8 SPLICE #13 SPLICE #14
FUSE HOLDER TO 100 (14 AWG FUSE LINK) 102 PINK 3008 GREY 00 WHITE 2002 RED 00 WHITE
11
4002 RED TO 7002 RED (10 AWG)
00
FUEL PUMP Z
11 - BLUE (16 AWG)
00 - WHITE (16 AWG)
M132499AF
N/U - L
S30 ON/OFF SWITCH
05 - PURPLE/WHITE ALTERNATOR TRIGGER
5A - PURPLE/WHITE 37 - BLUE/WHITE
07 - RED
Y
2D-37 VALVE ON ENGINE
37 - BLUE/WHITE
57 - BLACK/WHITE
Z
ENGINE GROUND
00 - WHITE
M50010AE
INSERT ORIENTATION
BOTTOM VIEW
24A 02 23A 02
LEFT STEER VALVE RIGHT STEER VALVE
GREY HEIRSHMAN BLACK HEIRSHMAN
BLACK V
PIN 1 - 24A BLUE/BLACK GREY PIN 1 - 23A BLACK/WHITE
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
02
25
INSERT ORIENTATION
BOTTOM VIEW W
REVERSE VALVE FORWARD VALVE
GREY HEIRSHMAN BLACK HEIRSHMAN
02 16B
15B 02
PIN 1 - 15B BLUE PIN 1 - 16B WHITE/BLACK
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
GREY BLACK
LIFT VALVE
14B - BLACK LARGE PUMP DUMP VALVE
02 - WHITE 17A - BLUE/RED
02 - WHITE
X
14B
02
17A
02
SMALL PUMP DUMP VALVE LOWERING VALVE
18A - RED/BLACK 13A - ORANGE
02 - WHITE 02 - WHITE
BRAKE DUMP VALVE
18A
13A
30A - BROWN
02
02
BRAKE FEED VALVE 02 - WHITE
30A - BROWN
02 - WHITE
30A
02
30A
02
Y
02
TO ELECTRIC PANEL - 11 WIRES HOLDING VALVE HARNESS
13A
02
02 - WHITE 23A - BLACK/WHITE 13A - ORANGE
13A - ORANGE 02 - WHITE
24A - BLUE/BLACK
14B - BLACK 25 - ORANGE/GREEN
15B - BLUE 30A - BROWN
16B - WHITE/BLACK
17A - BLUE/RED
18A - RED/BLACK Z
02 02
M50307AA
13D
14E
BOTTOM VIEW BLACK HEIRSHMAN
07
2
10E
PIN 2 - 02 WHITE BASE CONTROLS - 7 WIRES
07 - RED
10D
REVERSE VALVE 7A - RED/WHITE
02 16B
15B 02
10E
GREY HEIRSHMAN 7C - RED/GREEN/BLACK
7C
PIN 1 - 15B BLUE W
7A
10D - WHITE/RED/GREEN
PIN 2 - 02 WHITE GREY BLACK 10E - BLUE/WHITE
13D - ORANGE/RED
14E - BLACK/RED
S10
PLATFORM/BASE
LIFT VALVE
SELECTOR KEY
14B - BLACK
SWITCH
02 - WHITE
14B
02
LARGE PUMP DUMP VALVE
17A
02
SMALL PUMP DUMP VALVE LOWERING VALVE 17A - BLUE/RED X
13A - ORANGE 02 - WHITE
18A - RED/BLACK
02 - WHITE 02 - WHITE
BRAKE DUMP VALVE
18A
13A
30A - BROWN
02
02
BRAKE FEED VALVE 02 - WHITE
30A - BROWN
02 - WHITE
30A
02
30A
02
TO ELECTRIC PANEL - 18 WIRES Y
02
7A - RED/WHITE 16B - WHITE/BLACK
7C - RED/GREEN/BLACK 17A - BLUE/RED
10D - WHITE/RED/GREEN 18A - RED/BLACK
10E - BLUE/WHITE
13A
02
23A - BLACK/WHITE
13A - ORANGE 24A - BLUE/BLACK
13D - ORANGE/RED HOLDING VALVE QUICK BRAKE VALVE
25 - ORANGE/GREEN
14B - BLACK 13A - ORANGE 25 - ORANGE/GREEN
30A - BROWN
02 - WHITE 02 - WHITE
Z
02
02 02
25
M50306AA
61CR
9CR3
LEFT FRONT 61
PIN 2 - 62 GREEN
62
D17B1
RIGHT FRONT PIN 3 - 62 RED 62
D17B2
PIN 4 - 63 GREEN 63
63
RIGHT REAR PIN 5 - 63 RED 64
9CR2
17B
64 1A
PIN 6 - 64 GREEN
CN22
17
OCM1 - OUTRIGGER CONTROL MODULE LEFT REAR
PIN 7 - 64 RED
01
10A 86A 36B W
10A 10A 02
PIN 8 - 01 GREEN 17B 09 02
10A
CN14
35C 02
65CR
PIN 9 - 10A BLACK (2) 10A 44 01
BACK VIEW BACK VIEW BACK VIEW - 78 78 01 44
TO CONTROL MODULE - P4 CONTROL MODULE - P2 PIN 10 - 10A BLACK (2) - 73 73 02 09
CN21
77 77
CN20
PIN 1 - 78 BLACK/WHITE (2x)
3 2 1
PIN 1 - 68A WHITE - 02 10A
3 2 1
PIN 1 - 65 GREEN/BLACK 3 2 1 PIN 11 - 10A BLACK (2) 74 74 36A
PIN 2 - 77 BLUE/BLACK (2x) 6 5 4
6 5 4
PIN 2 - 67A RED/WHITE 65 71 71
9 8 7 PIN 2 - 65A GREEN/WHITE 6 5 4 PIN 12 - 10A BLACK (2) 61 17
75 75
D36
PIN 3 - 76 RED/BLACK (2x) 9 8 7 PIN 3 - 66A BLUE/WHITE PIN 3 - 66A BLUE/WHITE 36 04
12 11 10
PIN 13 - (N/U) 72 72 OUTRIGGER ELECTRIC PANEL
J36
PIN 4 - 75 ORANGE/BLACK (2x) PIN 4 - 65A GREEN/WHITE PIN 4 - 67A RED/WHITE 76 76
PIN 5 - 74 BLACK (2x) PIN 5 - 70 GREEN/BLACK PIN 5 - 68A WHITE 1 2 3 PIN 14 - (N/U) 12 PIN CONNECTOR PLUG CN14
PIN 6 - 73 BLUE (2x) PIN 6 - 79 GREEN 4 5 6 PIN 15 - (N/U)
PIN 7 - 70A RED/WHITE
PIN 6 - N/U
FRONT LEFT REAR LEFT
PIN 1 - 04 RED/YELLOW
PIN 7 - 72 RED (2x) PIN 16 - 65 GREEN/BLACK
ENABLE
BACK VIEW
PIN 8 - 71 ORANGE (2x) PIN 8 - 65 GREEN/BLACK PIN 2 - 17 BLUE/RED
PIN 9 - 35C WHITE/BLACK (2x) PIN 9 - 28 GREEN/RED FRONT RIGHT REAR RIGHT
PIN 10 - 35 BROWN/RED
PIN 3 - N/U
TO OUTRIGGER PCB CN20
PIN 11 - 02 WHITE (2x) OUTR CTRL BOX PIN 1 - 35C WHITE/BLACK PIN 4 - 10A BLUE/WHITE
D74
D75
D76
D72
D78
D77
D73
D71
PIN 12 - 10A BLUE/WHITE PIN 2 - 78 BLACK/WHITE
PIN 3 - 73 BLUE
PIN 5 - 09 ORANGE/RED
PIN 4 - 77 BLUE/BLACK PIN 6 - 44 RED
PIN 5 - 74 BLACK
PIN 7 - 01 RED/BLUE
PIN 6 - 71 ORANGE
PIN 7 - 75 ORANGE/BLACK PIN 8 - 02 WHITE
X
PIN 8 - 72 RED
PIN 9 - 02 WHITE
PIN 9 - 76 RED/BLACK
TO " ELECTRIC PANEL " PIN 10 - 36A YELLOW
PIN 1 - 02 WHITE OUTR MANIFOLD PIN 1 - 78 BLACK/WHITE
PIN 2 - 02 WHITE
PIN 1 - 75 ORANGE/BLACK
PIN 2 - 02 WHITE
PIN 1 - 76 RED/BLACK
PIN 2 - 02 WHITE
PIN 1 - 77 BLUE/BLACK
PIN 2 - 02 WHITE
PIN 11 - N/U
PIN 2 - 35C WHITE/BLACK TEN PIN CONNECTOR PLUG CN21 PIN 12 - N/U
PIN 1 - 17B WHITE/BLACK
PIN 3 - 70 GREEN/BLACK PIN 2 - 02 WHITE 2 1 2 1 2 1 2 1
13 14 15
9
3
PIN 11 - 77 BLUE/BLACK 02
FROM ELECTRIC PANEL Y
2
02
10
1
7
4
PIN 12 - 78 BLACK/WHITE
PIN 13 - 79 GREEN 17B
PIN 14 - N/U
PIN 15 - N/U 02
35D ORANGE/RED 17B - WHITE/BLACK BLACK BLACK BLACK BLACK
70A RED/WHITE 02 - WHITE
02
74 02 71 02 72 02 73 02
70A 02 WHITE TO OUTRIGGER CONTROL BOX 1 2 1 2 1 2 1 2
PIN 3 - 78 BLACK/WHITE
3
4
PIN 4 - 77 BLUE/BLACK
5
6
Z
8
M50309AA
GREEN - 22 GREEN - 22
WHITE - 02 WHITE - 02
H1 - HORN
H1 - HORN 00 - WHITE
00 - WHITE 49A - GREEN
49A - GREEN Z
TO MAIN ELECTRICAL PANEL TO MAIN ELECTRICAL PANEL
M50311AA
NOTE: For CE machines equipped with load sensing system refer to the load sensing supplemental manual for additional components.
00
00 02 02 07 09 10A 13A 29 14B 17A 18A 33 20A 25 30 15A 16A 21 23A 24A 35 36A
V
TO POWER DECK DIRECTIONAL VALVE
103
SIDE WALL
103
FOUR PIN FOUR PIN
CONNECTOR PLUG CONNECTOR PLUG
PIN 1 - 02 WHITE PIN 1 - 27 BLACK
100 103 103 PIN 2 - 02 WHITE PIN 2 - 26 GREEN
PIN 3 - 26A GREEN PIN 3 - 02 WHITE
PIN 4 - 27A BLACK PIN 4 - 02 WHITE
03
EM RETRACT
120844AB
02 97A
PLATFORM
27
W
26 09 12A 12D 09 26A 27A
MANIFOLD
DCM1
10
P.M.T. UNIT MOTOR 27 26 02 02 02 02 26A 27A
BASE FEED
09
02
99CR
103B
103A
TO CONTACTOR X
00 - WHITE EIGHT PIN PCB PLUG
103B - BLACK PIN 1 - BLACK (27)
00 00 99 - GREEN PIN 2 - GREEN (26)
PIN 3 - WHITE (103C)
PIN 4 - N/U
PIN 5 - N/U
PIN 6 - WHITE (103C)
PIN 7 - GREEN (26A)
PIN 8 - BLACK (27A)
103
00
00
2 2
3 GREEN
00 100
LID
TO ENGINE
1
B1 - MAIN BATTERY
1
2
TO POWER DECK
3
CONTROL BOX
PIN 1 - BLACK (27)
PIN 2 - WHITE (103C)
PIN 3 - GREEN (26)
BACK VIEW
PIN 4 - (N/U)
BACK VIEW
MALE
FEMALE
3 2
2 3
4 1
1 4 Z
FEMALE
MALE
2 3
3 2
1 4
4 1
TO POWER DECK
PIN 1 BLACK (27 or 27A)
PIN 2 WHITE (103C) CONTROL BOX
PIN 3 GREEN (26 or 26A) PIN 1 - BLACK (27A) PIN 3 - GREEN (26A)
PIN 4 (N/U) PIN 2 - WHITE (103C) PIN 4 - (N/U)
M50314AA
Figure 3.4-1b
CUSHION CYLINDER
10A
30A - BLACK
2A
05
13
14
02 - WHITE
Serial Number
43578 & Below
05 31 49 34 32 2A 10 14 15 16 23 24 30A
FL-29 13
D10
Serial Breakdown Reference Chart
FLASHER
Refer to following page(s) to locate model,
10
12
L P R
7
8
9
11
R R R R R R R R R
41 32 2A 10B TO ENGINE
2A
02 31 02 49 42 34 02 10B 02 13 02 14 02 15 02 16 02 23 02 24 02 30
10A
PIN 7 - 33 GREEN
B
13
10A
18
1000 uF
20
00 02
14A 10A 15A 16A 18A 18A 17A 44 17 44
R R
02 28 02 40 02 18 02 17A 02 17 02 20 02 35
TILT SWITCH - TS1
03 05 PIN 1 - 10A BLACK
28 1 18 17A 17 20 35
C
D19
PIN 28 - WHITE RED GREEN (10D)
PIN 27 - BLACK RED GREEN (60)
NOTE: X AXIS OVER SIDES (2.5°)
D20A
B B B
00
PIN 18 - BLUE RED (71)
(Refer to Serial Breakdown Reference Chart)
00 02 02 07 09 10A 13A 29 14B 17A 18A 33 20A 25 30 15A 16A 21 23A 24A 35 36A
INSERT: 17-32
GROUND TERMINAL - BLUE BLACK WHITE
BATTERY NEGATIVE PIN 16 - GREEN WHITE (34)
R R R R B R B B B B B
D13A D28A D17A D18A D15A-1 D16A-1 D23A D24A PIN 15 - GREEN BLACK (32)
D30
00 WHITE - 14GA 02 PIN 14 - RED WHITE (31)
07
D
00
22 - RED LEGEND:
29 - BLACK
TO CONTROL BOX
49A
MAIN MANIFOLD HARNESS
TO ENGINE
49A - GREEN
ENGINE HARNESS
PLATFORM CONTROL BOX
M50293AD_1
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SECTION 3, Page 35
AD
FIGURE 3.4-1a. ELECTRICAL PANEL DIAGRAM - ANSI/SIA and CSA (Shown With No Options)(For Nissan no Option, also refer to Oil Cooler Figure 3.3-8)
Model
SJ-800
A
BACK VIEW
FEMALE
SECTION 3, Page 36
(32) GREEN BLACK 15 7 BLUE (15)
(31) RED WHITE 14 6 BLACK (14)
10A
(24) BLUE BLACK 13 5 ORANGE (13)
2A
05
13
14
12 4 BLUE WHITE (10)
Figure 3.4-1a
(23) BLACK WHITE
(20) BLACK WHITE RED 11 3 ORANGE RED (09)
(19) ORANGE BLACK 10 2 RED (7)
05 31 49 34 32 2A 10 14 15 16 23 24
(18) RED BLACK 9 1 WHITE (02)
13
D34 D10
Serial Number
GROUND
TO FLASHER
PIN X - 22 RED 05 05 43 41 05 02 10A 05 10A 36B 04 04 04 04 04 BACK VIEW
R
Serial Breakdown Reference Chart
R R R R R R R R
serial number and respective diagram
2A
02 31 02 49 42 34C 02 10B 02 13 02 14 02 15 02 16 02 23 02 24 02 30
10A
Refer to following page(s) to locate model,
10A 30A (85) ORANGE BLACK WHITE 26 18 BLUE RED (71) PIN 1 - 31A ORANGE
31A 34A 32A 37
25 17 DEUTSCH PIN 2 - 34A WHITE/BLACK
(78) RED BLACK WHITE GREEN (49))
PIN 3 - 02 WHITE
6
5
4
3
2
1
TO CONTROL BOX
10A PIN 7 - 33 GREEN
18
PIN 8 - 10A GREEN/BLACK
1000 uF
PIN 9 - 2A RED/BLACK
00 02 PIN 10 - 37 BLUE/BLACK
14A 10A 15A 16A 18A 18A 17A 44 17 44
R R
PIN 11 - 07 RED
02 28 02 40 02 18 02 17A 02 17 02 20 02 35 PIN 12 - 05 BLUE
BLACK (TIED BACK)
03 05
BLACK/WHITE (TIED BACK)
28 1 18 17A 17 20 35
C
CR TD CR CR CR CR CR
28A 15B 16B 21
PIN 3 - 02 WHITE
TO ENGINE
19
00 02 - WHITE
MAIN DISCONNECT POSITIVE
D30A D14B-2 D14B-1 D35 13A - ORANGE
D15A-2 D16A-2
D20A
03 BLUE - 14GA B B B
00
14B - BLACK
BATTERY NEGATIVE
(Refer to Serial Breakdown Reference Chart)
15B - BLUE
00 WHITE - 14GA
00 02 02 07 09 10A 13A 29 14B 17A 18A 33 20A 25 30 15A 16A 21 23A 24A 35 36A 16B - WHITE/BLACK
17A - BLUE/RED
03 R R R R B R B B B B B
TWO SPEED MOTOR D17A D18A D15A-1 D16A-1 D23A D24A 18A - RED/BLACK
D30
D13A D28A
D
49A
30A CUSHION CYLINDER
30A - BLACK
TO HORN/LIGHT/BEEPER
02 - WHITE
00 - WHITE 02
22 - RED LEGEND:
29 - BLACK
E
49A - GREEN
MAIN MANIFOLD HARNESS
ENGINE HARNESS
PLATFORM CONTROL BOX
M133943AE
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10A
2A
05
13
14
TO MAIN CONTROL BOX
INSERT 1-16
05 31 49 34 32 2A 10 14 15 16 23 24
GROUND TERMINAL - EMPTY
13 PIN 32 - EMPTY
D10
PIN 31 - EMPTY
PIN 30 - EMPTY
PIN 29 - RED BLACK GREEN (7C)
05 05 43 41 05 02 10A 05 10A 36B 04 04 04 04 04 PIN 28 - WHITE RED GREEN (10D)
R R R R R R R R
R R
41 32 2A 10B PIN 27 - BLACK RED GREEN (60)
2A
02 31 02 49 42 34 02 10B 02 13 02 14 02 15 02 16 02 23 02 24 02 30
10A
FL-29 PIN 26 - ORANGE BLACK WHITE (85)
PIN 25 - RED BLACK WHITE (78)
FLASHER 31 49 34 32 10B 10B 13 14 15 16 23 24 30 PIN 24 - GREEN BLACK WHITE (77)
1000 uF
PIN 13 - BLUE BLACK (24)
PIN 5 - 09 ORANGE/RED PIN 12 - BLACK WHITE (23)
00 02 PIN 11 - BLACK WHITE RED (20)
14A 10A 15A 16A 18A 18A 17A 44 17 44 PIN 6 - 44 RED
R R PIN 10 - ORANGE BLACK (19)
02 28 02 40 02 18 02 17A 02 17 02 20 02 35 PIN 7 - 01 RED/BLUE PIN 9 - RED BLACK (18)
PIN 8 - WHITE BLACK (16)
03 05 PIN 8 - 02 WHITE PIN 7 - BLUE (15)
28 1 18 17A 17 20 35 PIN 9 - 02 WHITE PIN 6 - BLACK (14)
CR TD CR CR CR CR CR PIN 5 - ORANGE (13)
PIN 10 - 36A BLACK
28A 15B 16B 21 PIN 4 - BLUE WHITE (10)
PIN 11 - N/U PIN 3 - ORANGE RED (09)
14B 01 10A 10A 20A 19A 10A
PIN 12 - N/U PIN 2 - RED (07)
D19
PIN 1 - WHITE (02)
1
04
2
17
3
4
09
6
19 44
7
01
8
02 BACK VIEW
10
12
7
8
9
11
02
TO ENGINE PIN 7 - 33 GREEN
02 36A PIN 1 - 31A ORANGE
MAIN DISCONNECT POSITIVE DEUTSCH PIN 8 - 10A GREEN/BLACK
9 10 11 12
D20A
B B B
6
5
4
3
2
1
00
BATTERY NEGATIVE PIN 10 - 37 BLUE/BLACK
PIN 1 - 10A BLACK PIN 4 - 32A ORANGE/BLACK
00 WHITE - 14GA 00 02 02 07 09 10A 13A 29 14B 17A 18A 33 20A 25 30 15A 16A 21 23A 24A 35 36A PIN 11 - 07 RED
PIN 2 - 28 GREEN PIN 5 - N/U - BLACK/WHITE PIN 12 - 05 BLUE
TWO SPEED MOTOR 03 B B B B B B
R R R R R PIN 6 - N/U - GREEN
D13A D28A D17A D18A D15A-1 D16A-1 D23A D24A PIN 3 - 02 WHITE
D30
20A - BLACK
02 07 PIN 4 - 35 RED
02 - WHITE 00 13A
02 09 14B 17A 18A 33 25 23A 24A
00
02
02 07 10A
29 10A - BLUE
35 - BROWN
22
7 8 9 10 11 12 4
4 5 6 7 8 9 3
49A
1 2 3 4 5 6 2 30A CUSHION CYLINDER
1 2 3 1
M50292AE
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SECTION 3, Page 37
AD
A
15 16
FRONT VIEW BACK VIEW 31 49 32 2A 05 10 13A 15 16 23 24
SECTION 3, Page 38
D10
2A
10A
43 41 40
14D
31A 49A 34A 02 32A 42 37 10A 10C 13B 14A 15A 16A 23A 24A 30A
PIN 1 - 04 RED/YELLOW
13D PIN 2 - 17 BLUE/RED
28E 28 18 20 PIN 3 - N/U
10A 30
D15A-2 D16A-2
PIN 4 - 10A BLUE/WHITE
PIN 5 - 09 ORANGE/RED
00 02
ZZ 117389AA 10A 13B 14A 1B 14B 1B 15A 16A 10A 21 17A 44 17 10C PIN 6 - 44 RED
R R
02 28E 02 28 02 28E 02 28 02 40 02 18 02 17A 02 17 02 20 02 35 PIN 7 - 01 RED/BLUE
03 05 PIN 8 - 02 WHITE
ZZ 117387AA
PIN 9 - 02 WHITE
1000 uF
PIN 10 - 36B BLACK
15B 16B 18A 35B
PIN 11 - N/U
13C 13C 14C 10A 14C 01 18A 10A 20A 19A 44
PIN 12 - N/U
D19
BACK VIEW BACK VIEW 04
FEMALE FEMALE
1 2
10A
5
(34) GREEN WHITE 16 8 WHITE BLACK (16) 32 24 GREEN BLACK WHITE (77) 09
6
TO S7 01
C
D14E-1
D14B-1
D14E-2
(18) RED BLACK 9 1 WHITE (02) 25 17 B B B B B
(78) RED BLACK WHITE GREEN (49)) 00 GRN/YEL - 14GA
00
35 - BLK/WHT
(GROUND) BLUE BLACK WHITE TO (00) 03 00 02 02 07 7A 7C 09 10A 10D 10E 13D 14D 14E 34B 14B 17A 33 18A 25 35 60
GROUND 2H-30A-1
30A
00 R R R R R R B B B R CUSHION CYLINDER
D13 D14 D34
D17A
DEUTSCH
8 5
7 6
PIN 5 - N/U PIN 11 - 07 RED PLATFORM CONTROL BOX
PIN 6 - N/U PIN 12 - 05 BLUE TO AUTO-LEVEL HARNESS
L.S.S. CONTROL MODULE
D
BACK VIEW 7 8 9 10 11 12 4
PIN 1 - 10A (BLACK)
4 5 6 7 8 9 3 PIN 2 - N/U
3 2 1 1 2 3 4 5 6 2
M10935AC
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BLACK
PIN 17 1
OXS1
200 200 00
PIN 12 A C 2 OXYGEN
PIN 10
209 209
B D
2002
4 F
Refer to following page(s) to locate model, PIN 9
106 106
TPS2
t°
5 AIR INTAKE
TEMP. SENSOR
WHITE
PIN 23 10
2002
PIN 22 11
00 00
PIN 21 12
00
PIN 20 13
IGC1
1006 1006 2002
PIN 19 14 IGNITION COIL
33
PIN 17 15
PI1
PIN 15
1002 1002 1001
16 PROPANE
IN�ECTOR
G
2A RST4
PIN 14 1 WATT 17
1K OHM
GI1
1003 2001
PIN 12 RST5 GAS
18
1 WATT IN�ECTOR
3008 10K OHM
PIN 11 19
34A
PIN 9 20
2008
PIN 8 21
RA1
1008 1008 00 00
PIN 5 THROTTLE
22
ACTUATOR
56
PIN 4 23
2001
PIN 3 24
1001
PIN 2 25
S4 BASE
CONTROL BOX
EMERGENCY 50
STOP PIN 1 26
SWITCH
08 07 RED 07 07 07 S30
27
07
05 05 05 START
MAIN ENGINE
H
ON 28
OFF SWITCH
29
32A
05 31A 31A 07 ENGINE START
30
SWITCH
05 43 34A 34A 34A 11
S33 00
FP 31 FUEL PUMP
GAS
33 33 56 GAS�PROPANE
32
SELECTOR SWITCH
PROP 2P-50
50 00 PROPANE VALVE
33
SOLENOID
B1
103 100 12V
00 43 12V BATTERY
03
44
S8 CB1
HORN 05 05 03
45
49CR 20A BREAKER
08 49 GREEN 49 49
46 HORN RELAY
H1
05 HORN
PL1 05 49A
47 HORN
POWER ON
CB3
LIGHT
00 BLUE�BLACK�WHITE 00 00 02
48 20 A BREAKER
D10 10BCR1
10 BLUE�WHITE 10 10B 10B
49 ENGINE ON RELAY
53
ALL FUNCTION
J
FLASHING LIGHT
D13A FL-29 FL-22
02
54
S3
TS1 28CR
KEY SWITCH
OFF�LIFT�DRIVE 10A TILT SWITCH 28 28
55 TILT SW. RELAY
�IN OFF POSITION�
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
56
D02-4 VALVE SOLENOID
08 10 2H-30A-1
BRAKE DUMP
57
NC D02-5 VALVE SOLENOID
HELD D30A 2H-30A-2
OPEN BRAKE FEED
58
D02-6 VALVE SOLENOID
10A 10A 28A
59
S13 D28A
GLOW PLUG SWITCH 10 31 RED�WHITE 31 31
60 GLOW PLUG RELAY
31CR
41 02
61
29
62 BEEPER
S15 BP-29
ENGINE START 32 GREEN�BLACK 32 32 41 02
63 START RELAY
S14 32CR
LOW�HIGH THROTTLE 34 GREEN�WHITE 34 34 42 02
64 THROTTLE RELAY
S9
LIFT
ENABLE
S5
UP�DOWN
13 ORANGE 13
34CR D14B-2
ALL MOTION 65 K
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
66 DOWN RELAY
NC S17 14CR
UP
14 BLACK 14 13CR
14
67 UP RELAY
CB4
FAN
10A UP 14 03 85A 85A 86D 00
F 68 OIL COOLER FAN
S16
15A BREAKER
10B 2A
69 OIL COOLER RELAY
10BCR3
70
17ACR
33 17A
71 SMALL PUMP RELAY
D18A D17A
10A 10A 17A 2H-17A
72 LARGE PUMP DUMP
D02-7 VALVE SOLENOID
D14B-1
10A 36A 36B 14A 14B 2H-14B
73 LIFT VALVE
S29 S41
OUTRIGGER LS4 D02-8 SOLENOID
HIGH�LOW HIGH�LOW 35CR
RANGE TOR�UE �UMPER 1 35
74 TILT OVERIDE
END OF STROKE RELAY
20CR
12A 20 BLACK�WHITE�RE
D 20 NORMALLY CLOSED
20B 20 75 SERIES�PARELLEL
RELAY
S7-7 �OYSTICK 10A 10A 44 20A D20A 3H-20A
76 SERIES�PARELLEL
�OYSTICK ENABLE S7-1
D02-9 VALVE SOLENOID
ENABLE RELAY 2ND
NO
DR 12 12A SPEED 19 ORANGE�BLACK 19 19 19A 17 17 77 2ND SPEED�LARGE
PUMP RELAY
L
D19 17CR
12 12B 02 02 WHITE 02
78
CAP1
12BCR
40 79
CAPACITOR
LS5 1TD 1000 MFD
04 04 40
80 TIME DELAY #1
TILT OVERRIDE�
04 15A 15B 4H-15B
HIGH DRIVE CUTOUT 81 REVERSE
LIMIT SWITCH VALVE SOLENOID
NORMALLY OPEN D02-10
HELD CLOSED D15A-1 D15A-2 D30
10A 01 01 1A 04 25 2H-25 82 �UICK BRAKE VALVE
OUTRIGGER 26� DRIVE D02-11
28CR
�UMPER 2 CUTOUT D16A-1 D16A-2
30 83
�UMPER BRAKE RELAY
D35 30CR
S7 04 16A 16B 4H-16B FORWARD
84
�OYSTICK VALVE SOLENOID
CONTROLLER D02-12
04 23A 4H-23A RIGHT STEERING
85
D02-13 VALVE SOLENOID
D23A
04 24A 4H-24A LEFT STEERING
86
D02-14 VALVE SOLENOID
D24A
21 18A 2H-18A
87 SMALL PUMP DUMP
D02-15 VALVE SOLENOID
10A 18A 88
S7-6
3RD
SPEED
S7-5
18B 18 RED�BLACK 18 18
18CR
89
3RD SPEED
RELAY M
FWD 16 WHITE�BLACK 16 16 90 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15 91 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK�WHITE 23 23 92 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE�BLACK 24 24
93 LEFT RELAY
24CR
M50289AD
BLACK
PIN 17 1
O�S1
200 200 00 O�YGEN
PIN 11
1100
A C 2 SENSOR
1103 B
205
1100
7 SWITCH
2002 2002
WHITE
PIN 23 10
2002
PIN 22 11
00 00
PIN 21 12
00
PIN 20 RST6 13
1 WATT
1K OHM IGC1
1006 2006 2002
PIN 19 14 IGNITION COIL
33
PIN 17 15
PI1
PIN 15
1002 1002 1001
16
PROPANE
INJECTOR G
2A RST4
PIN 14 1 WATT 17
1K OHM
GI1
1003 2001 GAS
PIN 12 RST5 18 INJECTOR
1 WATT
3008 10K OHM
PIN 11 19
34A
PIN 9 20
2008
PIN 8 21
RA1
1008 1008 00 00 THROTTLE
PIN 5
22 ACTUATOR
56
PIN 4 23
2001
PIN 3 24
1001
PIN 2 25
S4 BASE
CONTROL BO�
EMERGENCY 50
STOP PIN 1 26
SWITCH
08 07 RED 07 07 07 S30
27
07
05 05 05 START MAIN ENGINE
ON
OFF
28 SWITCH
H
29
32A
05 31A 31A 07 ENGINE START
30 SWITCH
100 B1
103 12V
00 43 12V BATTERY
03
44
S8 CB1
HORN 05 05 03
45
49CR 20A BREAKER
08 49 GREEN 49 49
46 HORN RELAY
H1
05 HORN
PL1 05 49A
47 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
48 20 A BREAKER
D10 10BCR1
10 BLUE/WHITE 10 10B 10B
49 ENGINE ON RELAY
53
VALVE SOLENOID
ALL FUNCTION
J
FLASHING LIGHT
D13A FL-29 FL-22
02
54
S3
TS1 28CR
KEY SWITCH
OFF/LIFT/DRIVE 10A TILT SWITCH 28 28
55 TILT SW. RELAY
(IN OFF POSITION)
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
56
D02-4 VALVE SOLENOID
08 10 2H-30A-1
BRAKE DUMP
57
NC D02-5 VALVE SOLENOID
HELD D30A 2H-30A-2
OPEN BRAKE FEED
58
D02-6 VALVE SOLENOID
10A 10A 28A
59
S13 D28A
GLOW PLUG/CHOKE 10 31 RED/WHITE 31 31
GLOW PLUG/
60
CHOKE RELAY
31CR
41 02
61
29
62 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
63 START RELAY
S14 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34 42 02
64 THROTTLE RELAY
S9
LIFT
ENABLE
S5
UP/DOWN
13 ORANGE 13
34CR D14B-2
ALL MOTION 65
K
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
66 DOWN RELAY
NC S17
UP 14CR
14 BLACK 14 13CR
14
67 UP RELAY
CB4
FAN
10A UP 14 03 85A 85A 86D 00
F 68 OIL COOLER FAN
S16
15A BREAKER
10B 2A
69 OIL COOLER RELAY
10BCR3
70
17ACR
33 17A
71 SMALL PUMP RELAY
D18A D17A
10A 10A 17A 2H-17A
72 LARGE PUMP DUMP
D02-7 VALVE SOLENOID
D14B-1
10A 36A 36B 14A 14B 2H-14B
73 LIFT VALVE
S29 S41
OUTRIGGER LS4 D02-8 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE JUMPER 1 35
74 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20B 20 75 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 10A 44 20A D20A 3H-20A
76 SERIES/PARELLEL
JOYSTICK ENABLE S7-1
D02-9 VALVE SOLENOID
2ND
NO
DR
ENABLE
12
RELAY
12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17 77 2ND SPEED/LARGE
PUMP RELAY
L
D19 17CR
12 12B 02 02 WHITE 02
78
CAP1
12BCR
40 79
CAPACITOR
LS5 1TD 1000 MFD
04 04 40
80 TIME DELAY #1
TILT OVERRIDE/
HIGH DRIVE CUTOUT 04 15A 15B 4H-15B
81 REVERSE
LIMIT SWITCH VALVE SOLENOID
NORMALLY OPEN D02-10
HELD CLOSED D15A-1 D15A-2 D30
10A 01 01 1A 04 25 2H-25 82 QUICK BRAKE VALVE
OUTRIGGER 26' DRIVE D02-11
28CR
JUMPER 2 CUTOUT D16A-1 D16A-2
30 83
JUMPER BRAKE RELAY
D35 30CR
S7 04 16A 16B 4H-16B FORWARD
84
JOYSTICK VALVE SOLENOID
CONTROLLER D02-12
04 23A 4H-23A RIGHT STEERING
85
D02-13 VALVE SOLENOID
D23A
04 24A 4H-24A LEFT STEERING
86
D02-14 VALVE SOLENOID
D24A
21 18A 2H-18A
87 SMALL PUMP DUMP
D02-15 VALVE SOLENOID
10A 18A 88
S7-6
3RD
SPEED
S7-5
18B 18 RED/BLACK 18 18 89
3RD SPEED
RELAY
M
18CR
FWD 16 WHITE/BLACK 16 16 90 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15 91 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23 92 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24
93 LEFT RELAY
24CR
M134135AH
F
P�T��BA�E �6
�E� ��IT C� E�E�GENC�
�4 BA�E �IN P�T� P��ITI�N� �T�P
C�NT��� B� � �� B� TA �IE�E� ENGINE
E�E�GENC� �2
�T�P �P����N ����� B� TA ��PP�IE� �I�E
��I TC� ��I TC�
08 7A �E� 7A 7A 7C 07 07 07
NEGATIV
NC�B �31 -
�30 �AIN
13� G��� P� �G
10E 10� ENGINE ��
14E ��IT C� 1
N�E�
05 05 07 31A
2
GPT1
10� 7C �E��B�AC��G�EEN 7C 5A �32A 32A 02 G��� P� �G
3 TI�E �
�32 ENGINE 31AC�
05 31A 31A �TA�T �� 31A 02
4 G��� P� �G
�T� -34A �E�A�
05 43 34A 34A 34A
5 �IG� T��� TT�E
���EN�I�
90
10� ��ITE��E��G�EEN 10� 33 �02-32
GP�1 G��� P� �G
6
IN�ICAT� �
EGP1
10E 103 91A
7 ENGINE
G��� P� �G �
05 32A 32A 37 2�37
8 �IE�E� VA�VE
���EN�I�
�57
10A 57
�P�1 �I� 9
�����ETE � P�E� ��� E �02-33
�10E ��IT C� 32A 32AC�
TT 10 ENGINE �TA�TE�
10A C�NT ACT� �
10BC�2
10B 2A 2A 2A 2B 2B TP�1
11 TE�PE�A T��E
��IT C�
ENGINE
10A 37 37 TE�PE�A T��E
��IT C� 12
�3
�E� ��I TC�
02 02
�����I�T���IVE
13
�IN ��� P��ITI�N�
00
�104 ENGINE �TA�TE�
� 14
E�� ��T� �
�10
08 10 10 B��E���ITE 10
G 15 A�TE�NAT��
NC �E�� �13
�PEN
G��� P� �G ��IT C� 10 31 �E����IT E 31 31
16 G��� P� �G �E�A�
31C�
41
17
G
18
�15
ENGINE �TA�T 10 32 G�EEN�B�AC� 32 32 41
19 �TA�T �E�A�
�14 �34 32C�
�� ���IG� T���T T�E 10 34 G�EEN���ITE 34 34B 42
20 T��� TT�E �E�A�
�C�1 �1
�14E-2 34BC� �AIN P��E �
P���T��NIT
�I�C�NNEC T 21
��T� � �2
���E 100 B1
00 103B 103B 103B 103A 103 12V
� 22 12V BATTE��
�5 100 A� P
103C ���E 103B 03
23
10 A� P 20A B�EA�E � INVE�TE� �PTI�N
�26 05 05 03
99
�34 24 P���T�C�NT ACT��
�02-27 CB1 �4
ENAB�E �11
99C� 4�-26 103 ���E INV1
��T 26 ���NT �EC �
103C 25
�27 �02-28 200 A� P ��T ���EN�I�
IN 4�-27 34A
27 ���NT �EC �
�34A 26
�26A IN ���EN�I�
ENAB�E �11A �02-29
9C�1 2�-13A-3
����ING VA�VE
33
�02-1 ���EN�I�
�02-26
2�-13A-2
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15A BREAKER
10B 2A
69 OIL COOLER RELAY
10BCR3
70
17ACR
33 17A
71 SMALL PUMP RELAY
D18A D17A
10A 10A 17A 2H-17A
72 LARGE PUMP DUMP
D02-7 VALVE SOLENOID
D14B-1
10A 36A 36B 14A 14B 2H-14B
73 LIFT VALVE
S29 S41
OUTRIGGER LS4 D02-8 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE JUMPER 1 35
74 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20B 20 75 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 10A 44 20A D20A 3H-20A
76 SERIES/PARELLEL
JOYSTICK ENABLE S7-1
D02-9 VALVE SOLENOID
2ND
NO
DR
ENABLE
12
RELAY
12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17 77 2ND SPEED/LARGE
PUMP RELAY
L
D19 17CR
12 12B 02 02 WHITE 02
78
CAP1
12BCR
40 79
CAPACITOR
LS5 1TD 1000 MFD
04 04 40
80 TIME DELAY #1
TILT OVERRIDE/
04 15A 15B 4H-15B
HIGH DRIVE CUTOUT 81 REVERSE
LIMIT SWITCH VALVE SOLENOID
NORMALLY OPEN D02-10
HELD CLOSED D15A-1 D15A-2 D30
10A 01 01 1A 04 25 2H-25 82 QUICK BRAKE VALVE
OUTRIGGER 26' DRIVE D02-11
28CR
JUMPER 2 CUTOUT D16A-1 D16A-2
30 83
JUMPER BRAKE RELAY
D35 30CR
S7 04 16A 16B 4H-16B FORWARD
84
JOYSTICK VALVE SOLENOID
CONTROLLER D02-12
04 23A 4H-23A RIGHT STEERING
85
D02-13 VALVE SOLENOID
D23A
04 24A 4H-24A LEFT STEERING
86
D02-14 VALVE SOLENOID
D24A
21 18A 2H-18A
87 SMALL PUMP DUMP
D02-15 VALVE SOLENOID
10A 18A 88
S7-6
3RD
SPEED
S7-5
18B 18 RED/BLACK 18 18 89
3RD SPEED
RELAY
M
18CR
FWD 16 WHITE/BLACK 16 16 90 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15 91 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23 92 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24
93 LEFT RELAY
24CR
M134135AH
BLACK
PIN 17 1
O�S1
1100
PIN 11 3
PIN 8
106
203
106
TPS2
��
5
AIR INTAKE
TEMP. SENSOR
F
SWITCH
205
PIN 1
1103
105
C
B
MS1
A
1100
TPS1
��
OPS1
8 M.A.P. SENSOR
COOLANT
9
2002 2002
WHITE
PIN 23 10
2002
PIN 22 11
00 00
PIN 21 12
33
PIN 17 15
PI1
1002 1002 1001 PROPANE
PIN 15 16 INJECTOR
2A RST4
PIN 14 1 WATT 17
1K OHM
GI1
1003 2001 GAS
PIN 12 RST5 18 INJECTOR
1 WATT
3008 10K OHM
PIN 11 19
34A
PIN 9 20
2008
PIN 8 21
RA1
1008 1008 00 00
PIN 5 THROTTLE
22 ACTUATOR
56
PIN 4 23
2001
PIN 3 24
1001
PIN 2 25
S4 BASE
CONTROL BO�
EMERGENCY 50
STOP PIN 1 26
G
SWITCH
08 07 RED 07 07 07 S30
27
07
05 05 05 START
ON MAIN ENGINE
28
OFF SWITCH
29
32A
05 31A 31A 07 ENGINE START
30
SWITCH
05 43 34A 34A 34A 11
S33 00
FP 31 FUEL PUMP
GAS
33 33 56 GAS/PROPANE
32
SELECTOR SWITCH
PROP 2P-50
50 00 PROPANE VALVE
33
SOLENOID
H
99CR 4H-26
OUT 46 FRONT DECK
103C 26 D02-28 F4 OUT SOLENOID
D27 FUSE
4H-27 100B INV1
27 FRONT DECK
IN 47
S34A 200 AMP IN SOLENOID
D02-29
ENABLE S11A D26A
4H-26A 34A
OUT 48 REAR DECK
103C 26A D02-30 OUT SOLENOID
D27A D34A
27A 4H-27A
IN REAR DECK
49
IN SOLENOID
D02-31
POWER DECK OPTION 00 00
50
9CR1
52
S8 D02-26
HORN
53
49CR
08 49 GREEN 49 49
54 HORN RELAY
H1
05 HORN
PL1 05 49A
55 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
56 20 A BREAKER
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
62
D02-4 VALVE SOLENOID
08 10 05 2H-30A-1
BRAKE DUMP
63
NC D02-5 VALVE SOLENOID
HELD 10A D30A 2H-30A-2
OPEN 10A 05 BRAKE FEED
64
D02-6 VALVE SOLENOID
D10
10 BLUE/WHITE 10 10B
I
10B
65 ENGINE ON RELAY
10BCR1
10A 10A 28A 29
66 ROTATING AMBER
RL-29 BEACON OPTION
S13 D28A
GLOW PLUG/CHOKE 10 31 RED/WHITE 31 31
67 GLOW PLUG/
CHOKE RELAY
31CR
41 02
68
29
69 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
70 START RELAY
S14 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34 34 42 02
71 THROTTLE RELAY
S9
S5 34CR D14B-2
LIFT 13 ORANGE 13
ENABLE UP/DOWN 72
ALL MOTION
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A 73
DOWN RELAY
NC S17 14CR
UP
14 BLACK 14 13CR
14
74 UP RELAY
FAN
10A UP 14 85A 86D 00
F 75 OIL COOLER FAN
S16
10B 2A
76 OIL COOLER RELAY
10BCR3
77
09 (BLACK) 09 09 09 85
78
CB4
03 85A 85A 86C 2H-86C
79 HYDR. GENERATOR
S12 15A BREAKER HYDRAULIC GENERATOR D02-7 SOLENOID
HYDRAULIC OPTION
GENERATOR 80
SWITCH
85 GREEN 85 85 86B 86B 2A
81 HYDR. GENERATOR
ON RELAY
09
86BCR
86 WHITE 86 86A
OFF 82 HYDR. GENERATOR
STOP RELAY
D86
86ACR D86C-2
83
D86C-1 D14B-3
J
84
17ACR
09 ORANGE/RED 09 33 17A
85 SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
86 LARGE PUMP DUMP
D02-8 VALVE SOLENOID
D14B-1
36A 36B 14A 14B 2H-14B
D18A 87 LIFT VALVE
S29 S41
LS4 D02-9 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE 35
88 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20B 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20
89 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 44 20A D20A 3H-20A
SERIES/PARELLEL
JOYSTICK ENABLE S7-1 90
D02-10 VALVE SOLENOID
ENABLE RELAY 2ND
DR 12 12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17
91 2ND SPEED/LARGE
NO
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
92
CAP1
12BCR
28CR 40
93 CAPACITOR
1TD 1000 MFD
04 04 40
94 TIME DELAY #1
10A 18A
S7-6 102
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
103
K
RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
104 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
105 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
106 RIGHT RIGHT
S7-3
23CR
LEFT 24 BLUE/BLACK 24 24 LEFT RELAY
107
24CR
FF EE CC HH KK GG BB PP II,JJ
OUTRIGGER OPTION 108
WITH AUTO LEVELLING
109
01 1A
110
S9B UP UP UP UP 17BCR
OUTRIGGER
OUTRIGGER 119 CONTROL MODULE
ENABLE DN DN DN DN D71 OCM1
71
71 = P4-8 120 LEFT FRONT UP
D72
72
72 = P4-7 121 RIGHT FRONT UP
D73
73
73 = P4-6 122 RIGHT REAR UP
75
74
D75
D74
74 = P4-5 123 LEFT REAR UP L
75 = P4-4 124 LEFT FRONT DOWN
D76
76
76 = P4-3 125 RIGHT FRONT DOWN
D77
77
77 = P4-2 126 RIGHT REAR DOWN
D78
78
78 = P4-1 127 LEFT REAR DOWN
35
TILT OVERRIDE/
35 = P2-10 128
HIGH DRIVE CUTOUT
28
28 = P2-9 129 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 130 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 131 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 132 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 133 RIGHT FRONT DOWN
RIGHT FRONT
LS65
GREEN/WHITE 10A 65A
65A = P2-4 134 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER BLUE/WHITE 10A
ENABLE 10A = P2-12 135 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 136 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 137
ALL UP 79 = P2-6 AUTO RETRACT
MODE 35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 138 AUTO LEVEL
02 WHITE 02
141
FRONT
LEFT 35D
S20
UP
DN
71
75
ORANGE
ORANGE/BLACK
71
75 75
71
D02-18
4H-71
4H-75
142
LEFT FRONT UP
OUTRIGGER SOLENOID
M134104AH
S30 MAIN
ENGINE SW
S31
GLOW PLUG
SWITCH NEGATIVE
05 05 07 31A
1
GPT1
5A D32A 32A 02
02 02
12
00
*104 ENGINE STARTER
M 13
EL. MOTOR
G 14 ALTERNATOR
DCM1
P.M.T. UNIT
MOTOR F2
S1
MAIN POWER
DISCONNECT
15
16
G
FUSE 100 B1 12V BATTERY
00 103B 103B 103B 103A 103 12V
M 00 17 P.M.T. UNIT
F5 100 AMP MOTOR
103C FUSE 103B 03
18
10 AMP CB1
05 05 03
99
19 P.M.T. CONTACTOR
S34 D02-33 20A BREAKER INVERTER OPTION
ENABLE S11 D26
99CR 4H-26
OUT 20 FRONT DECK
103C 26 D02-34 F4 OUT SOLENOID
D27 FUSE
4H-27 100B INV1
27 FRONT DECK
IN 21
S34A 200 AMP IN SOLENOID
D02-35
ENABLE S11A D26A
4H-26A 34A
OUT 22 REAR DECK
103C 26A D02-36 OUT SOLENOID
D27A D34A
27A 4H-27A
IN REAR DECK
23
IN SOLENOID
D02-37
POWER DECK OPTION 00 00
24
97 98 2H-98-4
AUXILIARY HOLDING
29
RST2 D02-4 VALVE SOLENOID
S8 D96
3 OHM B2
HORN 100 96 12V
30 AUXILIARY 12V BATTERY
49CR
08 49 GREEN 49 49
31 HORN RELAY
H1
05 HORN
PL1 05 49A
32 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
H
33 20 A BREAKER
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
41
D02-10 VALVE SOLENOID
08 10 05 2H-30A-1
BRAKE DUMP
42
NC D02-11 VALVE SOLENOID
HELD 10A D30A 2H-30A-2
OPEN 10A 05 BRAKE FEED
43
D02-12 VALVE SOLENOID
D10
10 BLUE/WHITE 10 10B 10B
44 ENGINE ON RELAY
10BCR1
10A 10A 28A 29 ROTATING AMBER
45
RL-29 BEACON OPTION
S13 D28A
GLOW PLUG SWITCH 10 31 RED/WHITE 31 31
46 GLOW PLUG RELAY
31CR
41 02
47
29
48 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
49 START RELAY
S14 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34 34 42 02
50 THROTTLE RELAY
S9
S5 34CR D14B-2
LIFT 13 ORANGE 13
LFT 09 09
ENABLE
9A
UP/DOWN
DN 10A DOWN
S17
13 13
ALL MOTION
ALARM
51
52 DOWN RELAY
I
NC 14CR
UP
14 BLACK 14 13CR
14
53 UP RELAY
FAN
10A UP 14 85A 86D 00
F 54 OIL COOLER FAN
S16
10B 2A
55 OIL COOLER RELAY
10BCR3
56
09 (BLACK) 09 09 09 85
57
CB4
03 85A 85A 86C 2H-86C
HYDR. GENERATOR
58
S12 15A BREAKER HYDRAULIC GENERATOR D02-13 SOLENOID
HYDRAULIC OPTION
GENERATOR 59
SWITCH
85 GREEN 85 85 86B 86B 2A HYDR. GENERATOR
ON 60
09 RELAY
86BCR
86 WHITE 86 86A
OFF HYDR. GENERATOR
61
STOP RELAY
D86
86ACR D86C-2
62
D86C-1 D14B-3
63
17ACR
09 ORANGE/RED 09 33 17A
64 SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
65 LARGE PUMP DUMP
D02-14 VALVE SOLENOID
D14B-1
36A 36B 14A 14B 2H-14B
D18A 66 LIFT VALVE
S29 S41
LS4 D02-15 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE 35
67 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20B 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20
68 SERIES/PARELLEL
RELAY
NO
DR
S7-7
JOYSTICK
ENABLE
12
JOYSTICK
ENABLE
RELAY
12A
S7-1
2ND
SPEED 19 ORANGE/BLACK 19 19
10A
19A
44
17 17
20A D20A 3H-20A
D02-16
69
70
SERIES/PARELLEL
VALVE SOLENOID
2ND SPEED/LARGE
J
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
71
CAP1
12BCR
28CR 40
72 CAPACITOR (NOTE: REMOVED ON
MACHINES WITH WET BRAKES)
1TD 1000 MFD
04 04 40
73 TIME DELAY #1
10A 18A
S7-6 81
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
82 RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
83 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
84 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
85 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24 LEFT RELAY
86
24CR
OUTRIGGER OPTION
WITH AUTO LEVELLING
FF EE CC HH KK GG BB PP II,JJ
87
K
88
01 1A
89
S9B UP UP UP UP 17BCR
OUTRIGGER
OUTRIGGER 98 CONTROL MODULE
ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 99 LEFT FRONT UP
D72
72
72 = P4-7 100 RIGHT FRONT UP
D73
73
73 = P4-6 101 RIGHT REAR UP
D74
74
74 = P4-5 102 LEFT REAR UP
D75
75
75 = P4-4 103 LEFT FRONT DOWN
D76
76
76 = P4-3 104 RIGHT FRONT DOWN
77
D78
D77
77 = P4-2 105 RIGHT REAR DOWN L
78
78 = P4-1 106 LEFT REAR DOWN
35 TILT OVERRIDE/
35 = P2-10 107
HIGH DRIVE CUTOUT
28
28 = P2-9 108 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 109 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 110 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 111 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 112 RIGHT FRONT DOWN
RIGHT FRONT
LS65
GREEN/WHITE 10A 65A
65A = P2-4 113 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER BLUE/WHITE 10A
ENABLE 10A = P2-12 114 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 115 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 79 = P2-6 116 AUTO RETRACT
MODE ALL UP
35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 117 AUTO LEVEL
02 WHITE 02
120
S20
71 ORANGE 71 71 4H-71
FRONT LEFT FRONT UP
UP 121
LEFT 35D OUTRIGGER SOLENOID
D02-24
75 ORANGE/BLACK 75 75 4H-75
LEFT FRONT DOWN
M
DN 122
OUTRIGGER SOLENOID
D02-25
S21
72 RED 72 72 4H-72
FRONT RIGHT FRONT UP
UP 123
RIGHT 35D OUTRIGGER SOLENOID
D02-26
76 RED/BLACK 76 76 4H-76
DN RIGHT FRONT DOWN
124
OUTRIGGER SOLENOID
D02-27
S22
73 BLUE 73 73 4H-73
REAR RIGHT REAR UP
UP 125
RIGHT 35D OUTRIGGER SOLENOID
D02-28
77 BLUE/BLACK 77 77 4H-77
DN RIGHT REAR DOWN
126
OUTRIGGER SOLENOID
D02-29
S23
74 BLACK 74 74 4H-74
REAR LEFT REAR UP
UP 127
LEFT 35D OUTRIGGER SOLENOID
D02-30
78 BLACK/WHITE 78 78 4H-78
DN LEFT REAR DOWN
128
OUTRIGGER SOLENOID
D02-31
M134583AE
F
S30 MAIN S31
07
GLOW PLUG
SWITCH
31A
NEGATIVE
-
supplemental manual.
SOLENOID
90
33 D02-32
GPL1 5 GLOW PLUG
INDICATOR
EGP1
103 91A ENGINE
6 GLOW PLUGS
02 02
12
00
*104
M ENGINE STARTER
13
EL. MOTOR
G 14 ALTERNATOR
DCM1
P.M.T. UNIT
MOTOR F2
S1
MAIN POWER
DISCONNECT
15
16
G
FUSE B1 12V BATTERY
00 103B 103B 103B 103A 103 100 12V
M 00 17 P.M.T. UNIT
F5 100 AMP MOTOR
103C FUSE 103B 03
18
10 AMP CB1
05 05 03
99
19 P.M.T. CONTACTOR
S34 D02-27 20A BREAKER INVERTER OPTION
ENABLE S11 D26
99CR 4H-26
OUT 20 FRONT DECK
103C 26 D02-28 F4 OUT SOLENOID
D27 FUSE
4H-27 100B INV1
27 FRONT DECK
IN 21
S34A 200 AMP IN SOLENOID
D02-29
ENABLE S11A D26A
4H-26A 34A
OUT 22 REAR DECK
103C 26A D02-30 OUT SOLENOID
D27A D34A
27A 4H-27A
IN REAR DECK
23
IN SOLENOID
D02-31
POWER DECK OPTION 00 00
24
9CR1
26
S8 D02-26
HORN
27
49CR
08 49 GREEN 49 49
28 HORN RELAY
H1
05 HORN
PL1 05 49A
29 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
30 20 A BREAKER
H
D02-2 SOLENOID
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
36
D02-4 VALVE SOLENOID
08 10 05 2H-30A-1
BRAKE DUMP
37
NC D02-5 VALVE SOLENOID
HELD 10A D30A 2H-30A-2
OPEN 10A 05 BRAKE FEED
38
D02-6 VALVE SOLENOID
D10
10 BLUE/WHITE 10 10B 10B
39 ENGINE ON RELAY
10BCR1
10A 10A 28A 29 ROTATING AMBER
40
RL-29 BEACON OPTION
S13 D28A
GLOW PLUG SWITCH 10 31 RED/WHITE 31 31
41 GLOW PLUG RELAY
31CR
41 02
42
29
43 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
44 START RELAY
S14 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34 34 42 02
45 THROTTLE RELAY
S9
S5 34CR D14B-2
LIFT 13 ORANGE 13
ENABLE UP/DOWN ALL MOTION 46
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
47 DOWN RELAY
NC S17
UP 14CR
14 BLACK 14 13CR
14
48 UP RELAY
FAN
10A UP 14 85A 86D 00
F 49 OIL COOLER FAN
S16
10B 2A
50 OIL COOLER RELAY
I
10BCR3
51
09 (BLACK) 09 09 09 85
52
CB4
03 85A 85A 86C 2H-86C
HYDR. GENERATOR
53
S12 15A BREAKER HYDRAULIC GENERATOR D02-7 SOLENOID
HYDRAULIC OPTION
GENERATOR 54
SWITCH
85 GREEN 85 85 86B 86B 2A HYDR. GENERATOR
ON 55
09 RELAY
86BCR
86 WHITE 86 86A
OFF HYDR. GENERATOR
56
STOP RELAY
D86
86ACR D86C-2
57
D86C-1 D14B-3
58
17ACR
09 ORANGE/RED 09 33 17A
59 SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
LARGE PUMP DUMP
60
D02-8 VALVE SOLENOID
D14B-1
36A 36B 14A 14B 2H-14B
D18A LIFT VALVE
S29 S41 61
LS4 D02-9 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE 35
62 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20B 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20
63 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 44 20A D20A 3H-20A
SERIES/PARELLEL
JOYSTICK ENABLE S7-1 64
D02-10 VALVE SOLENOID
ENABLE RELAY 2ND
DR 12 12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17
65 2ND SPEED/LARGE
NO
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
66
12BCR
28CR 40
CAP1
67 CAPACITOR
J
1TD 1000 MFD
04 04 40
68 TIME DELAY #1
10A 18A
S7-6 76
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
77 RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
78 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
79 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
80 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24 LEFT RELAY
81
24CR
FF EE CC HH KK GG BB PP II,JJ
OUTRIGGER OPTION 82
WITH AUTO LEVELLING
K
83
01 1A
84
S9B UP UP UP UP 17BCR
OUTRIGGER
OUTRIGGER 93 CONTROL MODULE
ENABLE DN DN DN DN D71 OCM1
71
71 = P4-8 94 LEFT FRONT UP
D72
72
72 = P4-7 95 RIGHT FRONT UP
D73
73
73 = P4-6 96 RIGHT REAR UP
D74
74
74 = P4-5 97 LEFT REAR UP
D75
75
75 = P4-4 98 LEFT FRONT DOWN
D76
76
76 = P4-3 99 RIGHT FRONT DOWN
D77
77
L
77 = P4-2 100 RIGHT REAR DOWN
D78
78
78 = P4-1 101 LEFT REAR DOWN
35 TILT OVERRIDE/
35 = P2-10 102
HIGH DRIVE CUTOUT
28
28 = P2-9 103 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 104 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 105 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 106 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 107 RIGHT FRONT DOWN
RIGHT FRONT
LS65
GREEN/WHITE 10A 65A
65A = P2-4 108 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER BLUE/WHITE 10A
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S24
79 GREEN 79
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02 WHITE 02
115
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71 ORANGE 71 71 4H-71
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M
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119
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121
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3
RELAY
HTS-34A
05 43 34A 34A 34A HIGH THROTTLE
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33 D02-32
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103 91A ENGINE
6 GLOW PLUGS
02 02
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12
13
ENGINE STARTER
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DCM1 15
P.M.T. UNIT S1
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MOTOR F2
FUSE 100 B1 12V BATTERY
00 103B 103B 103B 103A 103 12V
M 00 17 P.M.T. UNIT
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103C FUSE 103B 03
18
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05 05 03
99
19 P.M.T. CONTACTOR
S34 D02-27 20A BREAKER INVERTER OPTION
ENABLE S11 D26
99CR 4H-26
OUT 20 FRONT DECK
103C 26 D02-28 F4 OUT SOLENOID
D27 FUSE
4H-27 100B INV1
27 FRONT DECK
IN 21
S34A 200 AMP IN SOLENOID
D02-29
ENABLE S11A D26A
4H-26A 34A
OUT 22 REAR DECK
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D27A D34A
27A 4H-27A
IN REAR DECK
23
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D02-31
POWER DECK OPTION 00 00
24
9CR1
26
S8 D02-26
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27
49CR
08 49 GREEN 49 49
28 HORN RELAY
H1
05 HORN
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29 HORN
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00 BLUE/BLACK/WHITE 00 00 02
30 20 A BREAKER
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
36
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08 10 05 2H-30A-1
BRAKE DUMP
37
NC D02-5 VALVE SOLENOID
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OPEN 10A 05 BRAKE FEED
38
D02-6 VALVE SOLENOID
D10
10 BLUE/WHITE 10 10B 10B
39 ENGINE ON RELAY
10BCR1
10A 10A 28A 29 ROTATING AMBER
40
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S13 D28A
GLOW PLUG SWITCH 10 31 RED/WHITE 31 31
41 GLOW PLUG RELAY
31CR
41 02
42
29
43 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
44 START RELAY
S14 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34 34 42 02
45 THROTTLE RELAY
S9
S5 34CR D14B-2
LIFT 13 ORANGE 13
ENABLE UP/DOWN ALL MOTION 46
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
47 DOWN RELAY
I
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14 BLACK 14 13CR
14
48 UP RELAY
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S16
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50 OIL COOLER RELAY
10BCR3
51
09 (BLACK) 09 09 09 85
52
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03 85A 85A 86C 2H-86C
HYDR. GENERATOR
53
S12 15A BREAKER HYDRAULIC GENERATOR D02-7 SOLENOID
HYDRAULIC OPTION
GENERATOR 54
SWITCH
85 GREEN 85 85 86B 86B 2A HYDR. GENERATOR
ON 55
09 RELAY
86BCR
86 WHITE 86 86A
OFF HYDR. GENERATOR
56
STOP RELAY
D86
86ACR D86C-2
57
D86C-1 D14B-3
58
17ACR
09 ORANGE/RED 09 33 17A
59 SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
LARGE PUMP DUMP
60
D02-8 VALVE SOLENOID
D14B-1
36A 36B 14A 14B 2H-14B
D18A LIFT VALVE
S29 S41 61
LS4 D02-9 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE 35
62 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20B 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20
63 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 44 20A D20A 3H-20A
SERIES/PARELLEL
JOYSTICK ENABLE S7-1 64
D02-10 VALVE SOLENOID
ENABLE RELAY 2ND
J
DR 12 12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17
65 2ND SPEED/LARGE
NO
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
66
CAP1
12BCR
28CR 40
67 CAPACITOR
1TD 1000 MFD
04 04 40
68 TIME DELAY #1
10A 18A
S7-6 76
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
77 RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
78 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
79 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
80 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24 LEFT RELAY
81
24CR
FF EE CC HH KK GG BB PP II,JJ
OUTRIGGER OPTION 82
WITH AUTO LEVELLING
83
K
01 1A
84
S9B UP UP UP UP 17BCR
OUTRIGGER
OUTRIGGER 93 CONTROL MODULE
ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 94 LEFT FRONT UP
D72
72
72 = P4-7 95 RIGHT FRONT UP
D73
73
73 = P4-6 96 RIGHT REAR UP
D74
74
74 = P4-5 97 LEFT REAR UP
D75
75
75 = P4-4 98 LEFT FRONT DOWN
D76
76
76 = P4-3 99 RIGHT FRONT DOWN
D77
77
78
D78
77 = P4-2 100
101
RIGHT REAR DOWN
L
78 = P4-1 LEFT REAR DOWN
35 TILT OVERRIDE/
35 = P2-10 102
HIGH DRIVE CUTOUT
28
28 = P2-9 103 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 104 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 105 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 106 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 107 RIGHT FRONT DOWN
RIGHT FRONT
LS65
GREEN/WHITE 10A 65A
65A = P2-4 108 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER BLUE/WHITE 10A
ENABLE 10A = P2-12 109 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 110 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 79 = P2-6 111 AUTO RETRACT
MODE ALL UP
35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 112 AUTO LEVEL
02 WHITE 02
115
S20
71 ORANGE 71 71 4H-71
FRONT LEFT FRONT UP
UP 116
LEFT 35D OUTRIGGER SOLENOID
D02-18
75 ORANGE/BLACK 75 75 4H-75
DN LEFT FRONT DOWN
117
FRONT
RIGHT 35D
S21
UP
72 RED 72 72
D02-19
4H-72
D02-20
118
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
M
76 RED/BLACK 76 76 4H-76
DN RIGHT FRONT DOWN
119
OUTRIGGER SOLENOID
D02-21
S22
73 BLUE 73 73 4H-73
REAR RIGHT REAR UP
UP 120
RIGHT 35D OUTRIGGER SOLENOID
D02-22
77 BLUE/BLACK 77 77 4H-77
DN RIGHT REAR DOWN
121
OUTRIGGER SOLENOID
D02-23
S23
74 BLACK 74 74 4H-74
REAR LEFT REAR UP
UP 122
LEFT 35D OUTRIGGER SOLENOID
D02-24
78 BLACK/WHITE 78 78 4H-78
DN LEFT REAR DOWN
123
OUTRIGGER SOLENOID
D02-25
S31
05
31A
43 34A 34A
31A 31A
34A
START SW 31A 02
HTS-34A
3
GLOW PLUG
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HIGH THROTTLE
4
SOLENOID
90
33 D02-32
GPL1 5 GLOW PLUG
INDICATOR
EGP1
103 91A ENGINE
6 GLOW PLUGS
02 02
12
00
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M ENGINE STARTER
13
EL. MOTOR
G
G 14 ALTERNATOR
DCM1 15
P.M.T. UNIT S1
MAIN POWER
DISCONNECT 16
MOTOR F2
FUSE 100 B1 12V BATTERY
00 103B 103B 103B 103A 103 12V
M 00 17 P.M.T. UNIT
F5 100 AMP MOTOR
103C FUSE 103B 03
18
10 AMP CB1
05 05 03
99
19 P.M.T. CONTACTOR
S34 D02-27 20A BREAKER INVERTER OPTION
ENABLE S11 D26
99CR 4H-26
OUT 20 FRONT DECK
103C 26 D02-28 F4 OUT SOLENOID
D27 FUSE
4H-27 100B INV1
27 FRONT DECK
IN 21
S34A 200 AMP IN SOLENOID
D02-29
ENABLE S11A D26A
4H-26A 34A
OUT 22 REAR DECK
103C 26A D02-30 OUT SOLENOID
D27A D34A
27A 4H-27A
IN REAR DECK
23
IN SOLENOID
D02-31
POWER DECK OPTION 00 00
24
9CR1
26
S8 D02-26
HORN
27
49CR
08 49 GREEN 49 49
28 HORN RELAY
H1
05 HORN
PL1 05 49A
29 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
30 20 A BREAKER
2H-13A-1
D02-2
2H-13A
32
HOLDING VALVE
SOLENOID
MAIN LOWERING
H
33
D02-3 VALVE SOLENOID
FLASHER
10A 10A 13A 22 ALL FUNCTION
34
S3 FLASHING LIGHT
28CR D13A FL-29 FL-22
KEY SWITCH 28
OFF/LIFT/DRIVE 28
35 TILT SW. RELAY
(IN OFF POSITION)
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
36
D02-4 VALVE SOLENOID
08 10 05 2H-30A-1
BRAKE DUMP
37
NC D02-5 VALVE SOLENOID
HELD 10A D30A 2H-30A-2
OPEN 10A 05 BRAKE FEED
38
D02-6 VALVE SOLENOID
D10
10 BLUE/WHITE 10 10B 10B
39 ENGINE ON RELAY
10BCR1
10A 10A 28A 29 ROTATING AMBER
40
RL-29 BEACON OPTION
S13 D28A
GLOW PLUG SWITCH 10 31 RED/WHITE 31 31
41 GLOW PLUG RELAY
31CR
41 02
42
29
43 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
44 START RELAY
S14 D34 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34 34 42 02
45 THROTTLE RELAY
S9
S5 34CR D14B-2
LIFT 13 ORANGE 13
ENABLE UP/DOWN 46
ALL MOTION
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
47 DOWN RELAY
NC S17
UP 14CR
14 BLACK 14 13CR
14
48 UP RELAY
FAN
10A UP 14
I
85A 86D 00
F 49 OIL COOLER FAN
S16
10B 2A
50 OIL COOLER RELAY
10BCR3
51
09 (BLACK) 09 09 09 85
52
CB4
03 85A 85A 86C 2H-86C
HYDR. GENERATOR
53
S12 15A BREAKER HYDRAULIC GENERATOR D02-7 SOLENOID
HYDRAULIC OPTION
GENERATOR 54
SWITCH
85 GREEN 85 85 86B 86B 2A HYDR. GENERATOR
ON 55
09 RELAY
86BCR
86 WHITE 86 86A
OFF HYDR. GENERATOR
56
STOP RELAY
D86
86ACR D86C-2
57
D86C-1 D14B-3
58
17ACR
09 ORANGE/RED 09 33 17A
59 SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
LARGE PUMP DUMP
60
D02-8 VALVE SOLENOID
D14B-1
36A 36B 14A 14B 2H-14B
D18A LIFT VALVE
S29 S41 61
LS4 D02-9 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE 35
62 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20B 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20
63 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 44 20A D20A 3H-20A
SERIES/PARELLEL
JOYSTICK ENABLE S7-1 64
D02-10 VALVE SOLENOID
ENABLE RELAY 2ND
DR 12 12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17
65 2ND SPEED/LARGE
NO
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
66
12BCR
28CR
1TD
40
CAP1
1000 MFD
67 CAPACITOR
J
04 04 40
68 TIME DELAY #1
10A 18A
S7-6 76
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
77 RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
78 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
79 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
80 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24 LEFT RELAY
81
24CR
FF EE CC HH KK GG BB PP II,JJ
OUTRIGGER OPTION 82
WITH AUTO LEVELLING
83
01 1A
84 K
10A 10A 36A
85
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
65
86 OUTRIGGER LIFT
ENABLE RELAY
LS64 LS63 LS62 LS61 65CR
01 64 63 62 61 61
87 OUTRIGGER DRIVE
ENABLE RELAY
LEFT RIGHT RIGHT LEFT 61CR
REAR REAR FRONT FRONT 88
26' LIFT D36 D17B-1 D17B-2
CUTOUT JUMPER
OUTRIGGERS SHOWN IN 2H-17B
61 36 17B OUTRIGGER
RETRACTED POSITION 89 HOLDING SOLENOID
9CR3 MM NN D02-17
09 OUTRIGGER
90 PROOF RELAY
9CR2
09 OUTRIGGER
91 ENABLE RELAY
S20A S21A S22A S23A
44 35B 35C 35C 35E FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT 17B OUTRIGGER
92 LIFT DISABLE RELAY
S9B UP UP UP UP 17BCR
OUTRIGGER
OUTRIGGER 93 CONTROL MODULE
ENABLE DN DN DN DN D71 OCM1
71
71 = P4-8 94 LEFT FRONT UP
D72
72
72 = P4-7 95 RIGHT FRONT UP
D73
73
73 = P4-6 96 RIGHT REAR UP
D74
74
74 = P4-5 97 LEFT REAR UP
D75
75
75 = P4-4 98 LEFT FRONT DOWN
D76
76
76 = P4-3 99 RIGHT FRONT DOWN
D77
77
77 = P4-2 100 RIGHT REAR DOWN
D78
L
78
78 = P4-1 101 LEFT REAR DOWN
35 TILT OVERRIDE/
35 = P2-10 102
HIGH DRIVE CUTOUT
28
28 = P2-9 103 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 104 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 105 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 106 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 107 RIGHT FRONT DOWN
RIGHT FRONT
LS65
GREEN/WHITE 10A 65A
65A = P2-4 108 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER BLUE/WHITE 10A
ENABLE 10A = P2-12 109 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 110 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 79 = P2-6 111 AUTO RETRACT
MODE ALL UP
35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 112 AUTO LEVEL
02 WHITE 02
115
S20
71 ORANGE 71 71 4H-71
FRONT LEFT FRONT UP
UP 116
LEFT 35D OUTRIGGER SOLENOID
D02-18
75 ORANGE/BLACK 75 75 4H-75
DN LEFT FRONT DOWN
117
OUTRIGGER SOLENOID
D02-19
S21
72 RED 72 72 4H-72
FRONT RIGHT FRONT UP
M
UP 118
RIGHT 35D OUTRIGGER SOLENOID
D02-20
76 RED/BLACK 76 76 4H-76
DN RIGHT FRONT DOWN
119
OUTRIGGER SOLENOID
D02-21
S22
73 BLUE 73 73 4H-73
REAR RIGHT REAR UP
UP 120
RIGHT 35D OUTRIGGER SOLENOID
D02-22
77 BLUE/BLACK 77 77 4H-77
DN RIGHT REAR DOWN
121
OUTRIGGER SOLENOID
D02-23
S23
74 BLACK 74 74 4H-74
REAR LEFT REAR UP
UP 122
LEFT 35D OUTRIGGER SOLENOID
D02-24
78 BLACK/WHITE 78 78 4H-78
DN LEFT REAR DOWN
123
OUTRIGGER SOLENOID
D02-25
S4 BASE
CONTROL BOX
EMERGENCY
STOP NEGATIV
SWITCH -
08 07 RED 07 07
1
05
2
05 31A 31A
4
05 43 34A 34A
Refer to 5
Figure 3.5-7
33
6
8
G
05 32A 32A
9
10A
10
HOURMETER
10A 10A 2A
TT 11
10BCR2
10B 10B 2A 2A
12
10A 37 37
13
TO ENGINE TO ENGINE
02 STARTER BLOCK
14
15
S1
MAIN POWER
DISCONNECT 16
B1
103 100 12V
00 17 12V BATTERY
03
18
S8 CB1
HORN 05 05 03
19
08 49 GREEN 49 49
49CR 20A BREAKER
20 HORN RELAY
H
H1
05 HORN
PL1 05 49A
21 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
22 20 A BREAKER
D10 10BCR1
10 BLUE/WHITE 10 10B 10B
23 ENGINE ON RELAY
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
30
D02-4 VALVE SOLENOID
08 10 2H-30A-1
BRAKE DUMP
NC
HELD
OPEN
D30A
D02-5
2H-30A-2
31
VALVE SOLENOID
BRAKE FEED
I
32
D02-6 VALVE SOLENOID
10A 10A 28A
33
S13 D28A
GLOW PLUG/CHOKE 10 31 RED/WHITE 31 31
GLOW PLUG/
34
CHOKE RELAY
31CR
41 02
35
29
36 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
37 START RELAY
S14 D34 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34B 42 02
38 THROTTLE RELAY
S9
S5 34BCR D14B-2
LIFT 13 ORANGE 13
ENABLE UP/DOWN ALL MOTION 39
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
40 DOWN RELAY
NC S17
UP 14CR
14 BLACK 14 13CR
14
41 UP RELAY
CB4
FAN
10A UP 14 03 85A 85A 86D 00
F 42 OIL COOLER FAN
S16
15A BREAKER
10B
10BCR3
2A
43 OIL COOLER RELAY
J
44
17ACR
33 17A
45 SMALL PUMP RELAY
D18A D17A
10A 10A 17A 2H-17A
LARGE PUMP DUMP
46
D02-7 VALVE SOLENOID
D14B-1
10A 36A 36B 14A 14B 2H-14B
LIFT VALVE
S29 S41 47
OUTRIGGER LS4 D02-8 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE JUMPER 1 35
48 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20B 20
49 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 10A 44 20A D20A 3H-20A
SERIES/PARELLEL
JOYSTICK ENABLE S7-1 50
D02-9 VALVE SOLENOID
ENABLE RELAY 2ND
DR 12 12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17 2ND SPEED/LARGE
NO 51
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
52
CAP1
12BCR
40
53 CAPACITOR
LS5 1TD 1000 MFD
04 04 40
54 TIME DELAY #1
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
04 15A 15B
D02-10
4H-15B
55
REVERSE
VALVE SOLENOID
K
NORMALLY OPEN
HELD CLOSED D15A-1 D15A-2 D30
10A 01 01 1A 04 25 2H-25
56 QUICK BRAKE VALVE
OUTRIGGER 26' DRIVE D02-11
28CR
JUMPER 2 CUTOUT D16A-1 D16A-2
30
JUMPER 57 BRAKE RELAY
D35 30CR
S7 04 16A 16B 4H-16B FORWARD
JOYSTICK 58 VALVE SOLENOID
CONTROLLER D02-12
04 23A 4H-23A RIGHT STEERING
59 VALVE SOLENOID
D02-13
D23A
04 24A 4H-24A LEFT STEERING
60 VALVE SOLENOID
D02-14
D24A
21 18A 2H-18A
SMALL PUMP DUMP
61 VALVE SOLENOID
D02-15
10A 18A
S7-6 62
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
63 RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
64 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
65 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
66 RIGHT RIGHT
S7-3
LEFT 24 BLUE/BLACK 24 24
23CR
67 LEFT RELAY
L
24CR
05
2
05 31A 31A
4
05 43 34A 34A
33
Refer to 5
F
6
Figure 3.5-7
05 32A 32A
9
HOURMETER
2A 10A 10A
TT 10
11
10BCR2
10B 10B 2A 2A
12
10A 37 37
13
TO ENGINE TO ENGINE
02 STARTER BLOCK
14
15
DCM1 S1
MAIN POWER
P.M.T. UNIT
DISCONNECT 16
MOTOR
F2
FUSE 100 B1 12V BATTERY
00 103B 103B 103B 103A 103 12V
M 00 17 P.M.T. UNIT
F5 100 AMP MOTOR
103C FUSE 103B 03
18
10 AMP CB1
05 05 03
99
19 P.M.T. CONTACTOR
S34 D02-27 20A BREAKER INVERTER OPTION
ENABLE S11 D26
99CR 4H-26
OUT 20 FRONT DECK
103C 26 D02-28 F4 OUT SOLENOID
D27 FUSE
4H-27 100B INV1
27 FRONT DECK
IN 21
IN SOLENOID
G
S34A D02-29 200 AMP
ENABLE S11A D26A
4H-26A 34A
OUT 22 REAR DECK
103C 26A D02-30 OUT SOLENOID
D27A D34A
27A 4H-27A
IN REAR DECK
23
IN SOLENOID
D02-31
POWER DECK OPTION 00 00
24
9CR1
26
S8 D02-26
HORN
27
49CR
08 49 GREEN 49 49
28 HORN RELAY
H1
05 HORN
PL1 05 49A
29 HORN
POWER ON
CB3
LIGHT
00 BLUE/BLACK/WHITE 00 00 02
30 20 A BREAKER
04 30A 2H-30A
CRD1 CRD2 CRD3 FREE-WHEELING
36
D02-4 VALVE SOLENOID
08 10 05 2H-30A-1
BRAKE DUMP
37
NC D02-5 VALVE SOLENOID
H
HELD 10A D30A 2H-30A-2
OPEN 10A 05 BRAKE FEED
38
D02-6 VALVE SOLENOID
D10
10 BLUE/WHITE 10 10B 10B
39 ENGINE ON RELAY
10BCR1
10A 10A 28A 29 ROTATING AMBER
40
RL-29 BEACON OPTION
S13 D28A
GLOW PLUG/CHOKE 10 31 RED/WHITE 31 31
GLOW PLUG/
41
CHOKE RELAY
31CR
41 02
42
29
43 BEEPER
S15 BP-29
ENGINE START 32 GREEN/BLACK 32 32 41 02
44 START RELAY
S14 D34 32CR
LOW/HIGH THROTTLE 34 GREEN/WHITE 34 34B 34B 42 02
45 THROTTLE RELAY
S9
S5 34BCR D14B-2
LIFT 13 ORANGE 13
ENABLE UP/DOWN ALL MOTION 46
ALARM
DN 10A DOWN 13 13
LFT 09 09 9A
47 DOWN RELAY
NC S17 14CR
UP
14 BLACK 14 13CR
14
48 UP RELAY
FAN
10A UP 14 85A 86D 00
F 49 OIL COOLER FAN
S16
10B 2A
50 OIL COOLER RELAY
10BCR3
51
09 (BLACK) 09 09 09 85
52
CB4
03 85A 85A 86C 2H-86C
HYDR. GENERATOR
53
S12 15A BREAKER HYDRAULIC GENERATOR D02-7 SOLENOID
HYDRAULIC
GENERATOR
SWITCH
85 GREEN 85 85 86B
OPTION
54 I
86B 2A HYDR. GENERATOR
ON 55
09 RELAY
86BCR
86 WHITE 86 86A
OFF HYDR. GENERATOR
56
STOP RELAY
D86
86ACR D86C-2
57
D86C-1 D14B-3
58
17ACR
09 ORANGE/RED 09 33 17A
59 SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
LARGE PUMP DUMP
60
D02-8 VALVE SOLENOID
D14B-1
36A 36B 14A 14B 2H-14B
D18A LIFT VALVE
S29 S41 61
LS4 D02-9 SOLENOID
HIGH/LOW HIGH/LOW 35CR
RANGE TORQUE 35
62 TILT OVERIDE
END OF STROKE RELAY
20CR
12 20B 20 BLACK/WHITE/RED 20 NORMALLY CLOSED
20
63 SERIES/PARELLEL
RELAY
S7-7 JOYSTICK 10A 44 20A D20A 3H-20A
SERIES/PARELLEL
JOYSTICK ENABLE S7-1 64
D02-10 VALVE SOLENOID
ENABLE RELAY 2ND
DR 12 12A SPEED 19 ORANGE/BLACK 19 19 19A 17 17
65 2ND SPEED/LARGE
NO
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
66
CAP1
12BCR
28CR 40
67 CAPACITOR
1TD 1000 MFD
04 04 40
68 TIME DELAY #1
J
LS5 D15A-1 D15A-2 D30
1A 04 25 2H-25
70 QUICK BRAKE VALVE
26' DRIVE D02-12
TILT OVERRIDE/ CUTOUT D16A-1 D16A-2
HIGH DRIVE CUTOUT 10A 01 30
JUMPER 71 BRAKE RELAY
LIMIT SWITCH
NORMALLY OPEN 30CR
S7 HELD CLOSED 04 16A 16B 4H-16B
72 FORWARD
JOYSTICK VALVE SOLENOID
CONTROLLER D02-13
35 04 23A 4H-23A
73 RIGHT STEERING
D02-14 VALVE SOLENOID
D35 D23A
04 24A 4H-24A LEFT STEERING
74
D02-15 VALVE SOLENOID
D24A
21 18A 2H-18A
SMALL PUMP DUMP
75
D02-16 VALVE SOLENOID
10A 18A
S7-6 76
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
77 RELAY
S7-5 18CR
FWD 16 WHITE/BLACK 16 16
78 FORWARD RELAY
S7-4 16CR
REV 15 BLUE 15 15
79 REVERSE RELAY
S7-2 15CR
RIGHT 23 BLACK/WHITE 23 23
80 RIGHT RIGHT
S7-3 23CR
LEFT 24 BLUE/BLACK 24 24 LEFT RELAY
81
24CR
FF EE CC HH KK GG BB PP II,JJ
OUTRIGGER OPTION 82
WITH AUTO LEVELLING
83
01 1A
84
LS64
NORMALLY OPEN HELD CLOSED
65CR
86 OUTRIGGER LIFT
ENABLE RELAY
K
01 64 63 62 61 61
87 OUTRIGGER DRIVE
ENABLE RELAY
LEFT RIGHT RIGHT LEFT 61CR
REAR REAR FRONT FRONT 88
26' LIFT D36 D17B-1 D17B-2
CUTOUT JUMPER
OUTRIGGERS SHOWN IN 2H-17B
61 36 17B OUTRIGGER
RETRACTED POSITION 89 HOLDING SOLENOID
9CR3 MM NN D02-17
09 OUTRIGGER
90 PROOF RELAY
9CR2
09 OUTRIGGER
91 ENABLE RELAY
S20A S21A S22A S23A
44 35B 35C 35C 35E FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT 17B OUTRIGGER
92 LIFT DISABLE RELAY
S9B UP UP UP UP 17BCR
OUTRIGGER
OUTRIGGER 93 CONTROL MODULE
ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 94 LEFT FRONT UP
D72
72
72 = P4-7 95 RIGHT FRONT UP
D73
73
73 = P4-6 96 RIGHT REAR UP
D74
74
74 = P4-5 97 LEFT REAR UP
D75
75
75 = P4-4 98 LEFT FRONT DOWN
D76
76
76 = P4-3 99 RIGHT FRONT DOWN
D77
77
77 = P4-2 100 RIGHT REAR DOWN
D78
78
78 = P4-1 101 LEFT REAR DOWN
35
35 = P2-10 102
TILT OVERRIDE/
HIGH DRIVE CUTOUT L
28
28 = P2-9 103 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 104 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 105 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 106 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 107 RIGHT FRONT DOWN
RIGHT FRONT
LS65
GREEN/WHITE 10A 65A
65A = P2-4 108 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER BLUE/WHITE 10A
ENABLE 10A = P2-12 109 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 110 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 79 = P2-6 111 AUTO RETRACT
MODE ALL UP
35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 112 AUTO LEVEL
02 WHITE 02
115
S20
71 ORANGE 71 71 4H-71
FRONT LEFT FRONT UP
UP 116
LEFT 35D OUTRIGGER SOLENOID
D02-18
75 ORANGE/BLACK 75 75 4H-75
DN LEFT FRONT DOWN
117
OUTRIGGER SOLENOID
D02-19
FRONT
RIGHT 35D
S21
UP
72 RED 72 72 4H-72
D02-20
118
RIGHT FRONT UP
OUTRIGGER SOLENOID M
76 RED/BLACK 76 76 4H-76
DN RIGHT FRONT DOWN
119
OUTRIGGER SOLENOID
D02-21
S22
73 BLUE 73 73 4H-73
REAR RIGHT REAR UP
UP 120
RIGHT 35D OUTRIGGER SOLENOID
D02-22
77 BLUE/BLACK 77 77 4H-77
DN RIGHT REAR DOWN
121
OUTRIGGER SOLENOID
D02-23
S23
74 BLACK 74 74 4H-74
REAR LEFT REAR UP
UP 122
LEFT 35D OUTRIGGER SOLENOID
D02-24
78 BLACK/WHITE 78 78 4H-78
DN LEFT REAR DOWN
123
OUTRIGGER SOLENOID
D02-25
NEGATIV
ECU1 -
R (TAN/DK GREEN)
CONNECTOR 2
(TWIST WIRES 10 TURNS (360 DEG)/FOOT FULL LENGTH)
8 (TAN/DK GREEN) AUX ANA PD 1 1 ECU
F
P (RED/BLACK)
25 (RED/WHITE) SPEED + 2
N (RED/WHITE)
26 (RED/BLACK) SPEED - 3
M (TAN/BLACK)
44 (TAN/BLACK) AUX DIG 3 4
L (TAN/RED)
43 (TAN/RED) AUX DIG 2 5
H (DK BLUE/YELLOW)
46 (DK BLUE/YELLOW) AUX ANA PU 1 6
G (YELLOW/DK BLUE)
47 (YELLOW/DK BLUE) AUX ANA PU 2 7
F (TAN)
87 (TAN) AUX PWM 2 8
D (GRAY)
58 (GRAY) TACH 9
B (WHITE/BROWN)
78 (WHITE/BROWN) PWM 5 RECIRC 10
34A J (GRAY/ORANGE)
52 (GRAY/ORANGE) GOV 2 11 G
33 K (GRAY/DK BLUE)
51 (GRAY/DK BLUE) GOV 1 12
2A C (BROWN/WHITE)
77 (BROWN/WHITE) PWM 5 13
E (BLACK)
69 (BLACK) GND TEMP 14
S (PINK/DK GREEN)
81 (BLACK) GND TEMP 15
CPS1
A (UNUSED) CRANKSHAFT
1 22 (WHITE/PURPLE) CRANK - 16
POSITION SENSOR
2 21 (PURPLE/WHITE) CRANK + 17
3 18
GI1-1
61 (BROWN/LT BLUE) INJ 1 LS 19 GAS INJECTOR
CYLINDER #1
GI1-4
20 GAS INJECTOR
CYLINDER #4
GI1-2
21 GAS INJECTOR H
CYLINDER #2
GI1-3
62 (BROWN/LT GREEN) INJ 2 LS 22 GAS INJECTOR
CYLINDER #3
IGC1
A 33 (YELLOW/RED) SPK COIL 2A 23
D C 25
OXS1
C D 72 (BLACK/WHITE) EGOH 1 26 OXYGEN SENSOR
PRE-CAT
F8
2002CR I
79 (RED/TAN) VBAT 31
FUSE 20A
ECM
60 (RED/TAN) VBAT 32
TPS1
B A 40 (TAN/WHITE) ECT 33 ENGINE COOLANT
TEMPERATURE SENSOR
TPS2
B A 41 (WHITE/RED) EGT 34 LPG TEMPERATURE
SENSOR
MS1
1 2 39 (YELLOW/GRAY) IAT 35 M.A.P. SENSOR
RA1
2 1 83 (TAN/ORANGE) DBW - 37 THROTTLE
ACTUATOR
3 4 82 (PINK/WHITE) DBW + 38
1 (BLACK/LT GREEN)
DIAGNOSTIC
2 (LT GREEN/RED)
6 5 (PURPLE/LT BLUE) TPS 1 40
J
3 (DK GREEN)
55 (DK GREEN) PC TX 41
(RED/LT BLUE)
4 (ORANGE)
56 (ORANGE) PC RX 42
PRV1 F9 GPS1
8 (BLUE/WHITE) GASOLINE
1 7 A B 48 (LT GREEN/WHITE) (FRT) AUX ANA PU 3 43
FUSE 10A PRESSURE SENSOR
7 (BLUE/PINK) EPR
3 C D 54 (WHITE/LT GREEN) (FRP) AUX AND PUD 1 44 PROPANE
REGULATOR/VAPORIZER
(WHITE)
P (BLUE/WHITE)
CONNECTOR 1
14 (BLUE/PINK) CAN 1 + 46
N (BLUE/PINK)
15 (BLUE/WHITE) CAN 1 - 47
L (BLACK/LT GREEN)
20 (BLACK/LT GREEN) 5V RTN 48
M (LT GREEN/RED)
19 (LT GREEN/RED) 5V EXT 1 49
S (LT GREEN/PURPLE)
49 (LT GREEN/PURPLE) 5V EXT 2 50 K
R (LT GREEN/BLACK)
50 (LT GREEN/BLACK) 5V RTN 51
K (DK BLUE/ORANGE)
9 (DK BLUE/ORANGE) FPP1 52
START J (PURPLE/YELLOW)
ON 10 (PURPLE/YELLOW) FPP2/IVS 53
OFF
07 S30 E (DK BLUE)
88 (DK BLUE) AUX PWM 1 54 MAIN ENGINE
SWITCH
07
05 05 3002 C (BLACK/RED)
FP 86 (BLACK/RED) AUX PWM 3 55 FUEL PUMP
2A STARTER
M 65 ENGINE STARTER
EL. MOTOR
(RED/TAN)
37 37 B (PURPLE)
66
(RED)
67
F13 S IG
G 68 ALTERNATOR
FUSE 60A
ALTERNATOR
TO MAIN TO BATTERY
M
DISCONNECT GROUND
F13
G
F7
F11
F8
56CR
F12
H
TPS1
32ACR
F10
F9
OXS1
2002CR
PRV1
I
MS1
OXS2
CPS1
J
OPS1
2P-56
IGC1
RA1
GI1-1
TPS2
K
GI1-2
GPS1
GI1-3
L
GI1-4
Section 4
Troubleshooting Information
Table Of Contents
Introduction ........................................................................................................................................................ 3
Electrical System
4.1-1. All Controls Inoperative......................................................................................................................... 4
4.1-2. No Power to Platform ............................................................................................................................ 4
4.1-3. All Functions Inoperative from Platform ............................................................................................... 4
4.1-4. Engine Will Not Crank from Platform.................................................................................................... 5
4.1-5. Engine Will Not Crank from Base Controls (GM Dual Fuel) ................................................................ 5
4.1-6. Engine Will Not Crank from Platform or Base Control (Additional for GM Dual Fuel))........................ 5
4.1-7. Engine Will Not Crank from Engine Controls ....................................................................................... 6
4.1-8. Engine Cranks But Will Not Start (Kubota Diesel)................................................................................ 6
4.1-9. Engine Cranks But Will Not Start (GM Dual Fuel) ................................................................................ 7
4.1-10. Engine Cranks But Will Not Start (Check Engine Light Does Not Come Out) (Nissan Dual Fuel) ... 8
4.1-11. Glow Plugs Inoperative from Engine Controls (Diesel Models).......................................................... 9
4.1-12. Glow Plugs Inoperative from Platform (Diesel Models) ...................................................................... 9
4.1-13. Mid Throttle Inoperative (On Demand).............................................................................................. 10
4.1-14. Mid Throttle Inoperative (On Demand) (GM Engine) .........................................................................10
4.1-15. High Throttle Inoperative ................................................................................................................... 10
4.1-16. High Throttle Inoperative (Additional for GM Dual Fuel) ....................................................................11
4.1-17. Drive and Steer Inoperative (Machines without Outriggers Option) ................................................. 11
4.1-18. Drive and Steer Inoperative (Machines with Outriggers Option) ...................................................... 11
4.1-19. Brake Will Not Release ...................................................................................................................... 12
4.1-20. Steer Right Inoperative ...................................................................................................................... 13
4.1-21. Steer Left Inoperative ......................................................................................................................... 13
4.1-22. Drive Reverse Inoperative .................................................................................................................. 14
4.1-23. Drive Forward Inoperative.................................................................................................................. 14
4.1-24. First Drive Speed and Steering Inoperative ...................................................................................... 15
4
4.1-25. Second Drive Speed Inoperative....................................................................................................... 15
4.1-26. Third Drive Speed Inoperative ........................................................................................................... 16
4.1-27. HIGH/LOW Range Speed Inoperative ............................................................................................... 16
4.1-28. Up Circuit Inoperative from Platform or Base (Machines without Outriggers) ................................. 17
4.1-29. Up Circuit Inoperative from Base ...................................................................................................... 18
4.1-30. Up Circuit Inoperative from Base (Base Control Box Option) .......................................................... 18
4.1-31. Platform Will Not Lift from Platform or Base Controls with Outriggers Retracted
(Lift Operates Correctly with Outriggers Extended) .......................................................................... 18
4.1-32. Platform Will Not Lift from Platform or Base Controls with Outriggers Extended ............................. 19
4.1-33. Down Circuit Inoperative from Platform or Base ............................................................................... 20
4.1-34. Down Circuit Inoperative from Base .................................................................................................. 20
4.1-34. Down Circuit Inoperative from Base (Base Control Box Option) ...................................................... 21
4.1-35. Powered Extension Deck Inoperative................................................................................................ 21
4.1-36. Powered Extension Deck Will Not Extend ......................................................................................... 21
4.1-37. Powered Extension Deck Will Not Retract ........................................................................................ 22
4.1-38. Hydraulic Generator Inoperative ....................................................................................................... 22
4.1-40. Generator Will Not Shut Off from Generator Switch.......................................................................... 23
Table of Contents
Hydraulic System
4.2-1. All Functions Inoperative.................................................................................................................... 31
4.2-2. Steering Inoperative ........................................................................................................................... 31
4.2-3. Steering and First Drive Speed Inoperative....................................................................................... 31
4.2-4. Lift and Second Drive Speed Inoperative .......................................................................................... 31
4.2-5. Drive Inoperative ................................................................................................................................ 31
4.2-6. Reverse Drive Inoperative .................................................................................................................. 32
4.2-7. Forward Drive Inoperative .................................................................................................................. 32
4.2-8. Brake Will Not Release ...................................................................................................................... 32
4.2-9. Up Circuit Inoperative ........................................................................................................................ 32
4.2-10. Down Circuit Inoperative.................................................................................................................... 32
4.2-11. All Outriggers Inoperative .................................................................................................................. 33
4.2-12. Left Front Outrigger Inoperative......................................................................................................... 33
4.2-13. Right Front Outrigger Inoperative ...................................................................................................... 33
4.2-14. Right Rear Outrigger Inoperative ....................................................................................................... 33
4.2-15. Left Rear Outrigger Inoperative ......................................................................................................... 33
4.2-16. Outriggers Drift In ............................................................................................................................... 33
4.2-17. Powered Platform Inoperative ........................................................................................................... 34
4.2-18. Hydraulic Generator Inoperative........................................................................................................ 34
Introduction
The following pages contain a table of troubleshooting information for locating and correcting most service
trouble which can develop. Careful inspection 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 and a greater indentation repre-
sents the “remedy” to the “probable cause” directly above it. See example below for clarification.
1. Probable Cause
-Remedy
4. - . Engine Will Not Crank from Base Controls (GM Dual Fuel)
1. Loose or broken wire #10A from base terminal block (TB1) to engine harness plug.
-Check continuity. Replace if defective.
2. Loose or broken wire #10A from engine harness plug to base start switch (S30).
-Check continuity. Replace if defective.
3. Defective base start switch (S30).
-Check switch. Replace if defective.
4. Loose or broken wire #32A from base start switch (S30) to GM engine connector 1.
-Check continuity. Replace if defective.
4. -6. Engine Will Not Crank from Platform or Base Control (Additional for GM Dual Fuel)
1. Loose or broken wire #10A from base terminal block (TB1) to engine harness plug.
-Check continuity. Replace if defective.
2. Loose or broken wire #10A from engine harness plug to GM engine connector 1.
-Check continuity. Replace if defective.
3. Loose or broken PINK wire from GM engine connector 1 to fuse (F7).
-Check continuity. Replace if defective.
4. Defective fuse (F7).
-Check fuse. Replace if defective
5. Loose or broken PINK/TAN wire from fuse (F7) to ECU connector pin #45.
-Check continuity. Replace if defective
6. Loose or broken RED wire from battery positive to ECU fuse (F8).
-Check continuity. Replace if defective.
7. Defective fuse (F8).
-Check fuse. Replace if defective.
8. Loose or broken RED/TAN wire from fuse (F8) to ECU connector pin #60 and pin #79.
-Check continuity. Replace if defective.
1. Open diode (D32A) from engine start switch (S32) to glow plug switch (S31).
-Check diode. Replace if defective.
2. Loose or broken wire #37 from base terminal block to diesel valve solenoid (2D37).
-Check continuity. Replace if defective.
3. Loose or broken wire #57 from starter contactor (32ACR) to diesel valve solenoid (2D37).
-Check continuity. Replace if defective.
4. Defective fuel valve solenoid (2D37).
-Check solenoid. Replace if defective.
5. Defective glow plugs.
-Check glow plugs. Repair if necessary.
6. Defective glow plug timer (GPT1).
-Check timer. Replace if defective.
7. Defective glow plug relay (31ACR).
-Check relay. Replace if defective.
NOTE
For additional engine troubleshooting refer to diagnostic trouble codes for use
with the check engine light.
(GASOLINE ONLY)
16. Loose or broken PINK/TAN wire from fuse (F7) to fuel pump relay (56CR).
-Check continuity. Replace if defective.
17. Loose or broken RED wire from battery positive to fuel pump relay (56CR).
-Check continuity. Replace if defective.
18. Loose or broken TAN/BLACK wire from ECU connector pin #42 to fuel pump relay (56CR).
-Check continuity. Replace if defective.
19. Defective fuel pump relay (56CR).
-Check relay. Replace if defective.
20. Loose or broken PINK/YELLOW wire from fuel pump relay (56CR) to fuse (F11).
-Check continuity. Replace if defective.
21. Defective fuse (F11).
-Check fuse. Replace if defective.
22. Loose or broken PINK/YELLOW wire from fuse (F11) to fuel pump (FP).
-Check continuity. Replace if defective.
23. Loose or broken PINK/YELLOW wire from fuse (F11) to ECU connector pin #85.
-Check continuity. Replace if defective
24. Defective fuel pump (FP).
-Check fuel pump by putting 12 volts and a ground to it. Replace if defective.
25. Loose or broken wire #3002 from fuel pump (FP) to GM engine connector 1.
-Check continuity. Replace if defective.
26. Loose or broken BLACK/RED wire from GM engine connector to ECU connector pin #86.
-Check continuity. Replace if defective.
(PROPANE ONLY)
NOTE
The fuel select switch is defaulted to gasoline. The engine will run
on gasoline if propane is selected from the switch and either the switch is bad
or a wire is loose or broken from the switch. This is providing there is nothing wrong
on the gasoline side of the system. Disconnect fuel pump to test propane side.
27. Loose or broken wire #10A from engine harness plug to fuel select switch (S33).
-Check continuity. Replace if defective.
28. Defective fuel select switch (S33).
-Check switch. Replace if defective.
29. Loose or broken wire #50 from fuel select switch (S33) to GM engine connector 1.
-Check continuity. Replace if defective.
30. Loose or broken TAN/BROWN wire from GM engine connector 1 to ECU connector pin #42.
-Check continuity. Replace if defective.
31. Loose or broken PINK/TAN wire from fuse (F7) to propane lock off (2P-56).
-Check continuity. Replace if defective.
32. Loose or broken WHITE/BLACK wire from ECU connector pin #75 to propane lock off (2P-56).
-Check continuity. Replace if defective.
33. Defective propane lock off (2P-56).
-Check lock off. Replace if defective.
34. Loose or broken PINK/DR GREEN wire from fuse (F10) to fuse (F9).
-Check continuity. Replace if defective.
35. Defective fuse (F9).
-Check fuse. Replace if defective.
36. Loose or broken RED/LT BLUE wire from fuse (F9) to propane regulator (PRV1).
-Check continuity. Replace if defective.
37. Loose or broken BLACK wire from engine ground to propane regulator (PRV1).
-Check continuity. Replace if defective.
4. - 0. Engine Cranks But Will Not Start (Check Engine Light Does Not Come On) (Nissan Dual Fuel)
1. Loose or broken wire #10A from base terminal block (TB1) to engine harness plug.
-Check continuity. Replace if defective.
2. Loose or broken wire #10A from engine harness plug to main power relay (10ACR).
-Check continuity. Replace if defective.
3. Loose or broken wire #00 from chassis ground to main power relay (10ACR).
-Check continuity. Replace if defective.
4. Defective main power relay (10ACR).
-Check relay. Replace if defective.
5. Loose or broken wire #103 from engine start solenoid (32ACR) to fuse (F6).
NOTE
For further information on Nissan Dual Fuel Troubleshooting,
refer to Section 4, EMS Troubleshooting.
1. Loose or broken wire #31A from glow plug switch (S31) to glow plug relay (31ACR).
-Check continuity. Replace if defective.
2. Loose or broken wire #02 from glow plug relay (31ACR) to base terminal block (TB1).
-Check continuity. Replace if defective.
3. Loose or broken wire #103 from starter solenoid to relay (31ACR).
-Check continuity. Replace if defective.
4. Loose or broken wire #91A from relay (31ACR) to engine glow plugs (EGP1).
-Check continuity. Replace if defective.
5. Defective glow plug relay (31ACR).
-Check relay. Replace if defective.
6. Defective glow plugs.
-Check glow plugs. Replace if defective.
1. Loose or broken wire #10 from key selector switch (S3) to glow plug switch (S13).
-Check continuity. Replace if defective.
2. Defective glow plug switch (S13).
-Check switch. Replace if defective.
3. Loose or broken wire #31 from glow plug switch (S13) to glow plug relay (31CR).
-Check continuity. Replace if defective.
4. Loose or broken wire #02 from relay (31CR) to base terminal block (TB1).
-Check continuity. Replace if defective.
5. Loose or broken wire #05 from base terminal block (TB1) to relay (31CR).
-Check continuity. Replace if defective.
6. Loose or broken wire #31A from relay (31CR) to base terminal block (TB1).
-Check continuity. Replace if defective.
7. Loose or broken wire #31A from base terminal block (TB1) to glow plug relay (31ACR).
-Check continuity. Replace if defective.
8. Defective relay (31CR).
-Check relay. Replace if defective.
9. Loose or broken wire #02 from relay (31ACR) to base terminal block (TB1).
-Check continuity. Replace if defective.
10. Loose or broken wire #103 from starter solenoid to relay (31ACR).
-Check continuity. Replace if defective.
11. Loose or broken wire #91A from relay (31ACR) to engine glow plugs (EGP1).
-Check continuity. Replace if defective.
12. Defective glow plug relay (31ACR).
-Check relay. Replace if defective.
13. Defective glow plugs.
-Check glow plugs. Replace if defective.
1. Loose or broken wire #10 from key select switch (S3) to LOW/HIGH throttle switch (S14).
-Check continuity. Replace if defective.
2. Defective LOW/HIGH throttle switch (S14).
-Check switch. Replace if defective.
3. Loose or broken wire #34 from LOW/HIGH throttle switch (S14) to relay (34CR).
-Check continuity. Replace if defective.
4. Defective relay (34CR).
-Check relay. Replace if defective.
5. Loose or broken wire #42 from relay (34CR) to relay (10BCR2).
-Check continuity. Replace if defective.
6. Defective relay (10BCR2).
-Check relay. Replace if defective.
7. Loose or broken wire #02 from relay (10BCR2) to base terminal block (TB-1).
-Check continuity. Replace if defective.
8. Loose or broken wire #05 from relay (10BCR1) to relay (32CR).
-Check continuity. Replace if defective.
9. Defective relay (32CR).
-Check relay. Replace if defective.
10. Loose or broken wire #43 from relay (32CR) to relay (34CR).
1. Loose or broken wire #34A from engine harness plug to GM engine connector 2.
-Check continuity. Replace if defective.
2. Loose or broken GRAY/ORANGE wire from GM engine connector 2 to ECU connector pin #52.
-Check continuity. Replace if defective.
3. Loose or broken LT BLUE/DR BLUE wire from ECU connector pin #6 to throttle actuator (RA1).
-Check continuity. Replace if defective.
4. Defective throttle actuator (RA1).
-Check actuator. Replace if defective.
NOTE
For more troubleshooting information, refer to Manufacture Engine Manual.
1. Loose or broken wire #30 from Diodes (D15A-2) and (D16A-2) to relay (30CR).
-Check continuity. Replace if defective.
2. Defective relay (30CR).
-Check relay. Replace if defective.
3. Loose or broken wire #02 from relay (30CR) to base terminal block (TB-1).
-Check continuity. Replace if defective.
4. Loose or broken wire #4 from relay (28CR) to relay (30CR).
-Check continuity. Replace if defective.
5. Loose or broken wire #30A from relay (30CR) to brake dump valve (2H-30A-1) or brake feed valve (2H-30A-
2).
-Check continuity. Replace if defective.
6. Defective valve coil (2H-30A-1) brake dump or (2H-30A-2) brake feed.
-Check continuity through coil. Replace if defective.
7. Loose or broken wire #02 from (2H-30A-1) brake dump or (2H-30A-2) brake feed coil to base terminal block
(TB-1).
-Check continuity. Replace if defective.
13. Loose or broken wire #02 from reverse valve coil (4H-15B) to base terminal block (TB-1).
-Check continuity. Replace if defective.
14. Open diode (D15A-1 or D15A-2).
-Check diode. Replace if defective.
1. Loose or broken wire #21 from base terminal block (TB-1) to relay (17ACR).
-Check continuity. Replace if defective.
2. Defective relay (17ACR).
-Check relay. Replace if defective.
3 Loose or broken wire #18A from relay (17ACR) to base terminal block (TB-1).
-Check continuity. Replace if defective.
4. Loose or broken wire #18A from base terminal block (TB-1) to small pump dump valve coil (2H-18A).
-Check continuity. Replace if defective.
5. Defective small pump dump valve coil (2H-18A).
-Check continuity through coil. Replace if defective.
6. Loose or broken wire #02 from small pump dump valve coil (2H-18A) to base terminal block (TB-1).
-Check continuity. Replace if defective.
1. Loose or broken wire #12 from key select switch (S3) to LOW/HIGH range switch (S29).
-Check continuity. Replace if defective.
2. Defective LOW/HIGH range switch (S29).
-Check switch. Replace if defective.
3. Loose or broken wire #20B from LOW/HIGH range switch (S29) to LOW/HIGH torque switch (S41).
-Check continuity. Replace if defective.
4. Defective LOW/HIGH torque switch (S41).
-Check switch. Replace if defective.
5. Loose or broken wire #20 from LOW/HIGH torque switch (S41) to platform terminal block switch (TB-5).
-Check continuity. Replace if defective.
6. Loose or broken wire #20 from platform terminal block (TB-5) to relay (20CR).
-Check continuity. Replace if defective.
7. Defective relay (20CR).
-Check relay. Replace if defective.
8. Loose or broken wire #02 from relay (20CR) to base terminal block (TB-1).
-Check continuity. Replace if defective.
9. Loose or broken wire #10A from relay (17CR) to relay (35CR).
-Check continuity. Replace if defective.
10. Defective relay (35CR).
-Check relay. Replace if defective.
11. Loose or broken wire #44 from relay (35CR) to relay (20CR).
-Check continuity. Replace if defective.
1. Loose or broken wire #10A from base terminal block to base up switch (S16)
-Check continuity. Replace if defective.
2. Loose or broken wire #14 from base up switch (S16) to base terminal block.
-Check continuity. Replace if defective.
3. Defective base up switch (S16).
-Check switch. Replace if defective.
1. Loose or broken wire #10E from base terminal block to UP/OFF/DOWN switch (S2)
-Check continuity. Replace if defective.
2. Loose or broken wire #14E from UP/OFF/DOWN switch (S2) to base terminal block.
-Check continuity. Replace if defective.
3. Defective UP/OFF/DOWN switch (S2).
-Check switch. Replace if defective.
4. Open diode (D14E-1 or D10E).
-Check diode. Replace if defective.
4. - . Platform Will Not Lift from Platform or Base Controls with Outriggers Retracted (Lift Operates
Correctly with Outriggers Extended)
1. Loose or broken wire #10A from relay (13CR) to base down switch (S17).
-Check continuity. Replace if defective.
1. Loose or broken wire #10E from base key switch (S10) to UP/OFF/DOWN switch (S2).
-Check continuity. Replace if defective.
2. Loose or broken wire #13D from UP/OFF/DOWN switch (S2) to base terminal block.
-Check continuity. Replace if defective.
3. Defective base UP/OFF/DOWN switch (S2).
-Check switch. Replace if defective.
1. Loose or broken battery cable from main power disconnect switch (S1) to 100 Amp. fuse (F2).
-Check continuity. Replace if defective.
5. Loose or broken wire #00 from platform retract valve coil (4H27) or (4H27A) to battery cable #00.
-Check continuity. Replace if defective.
WARNING
Scissors lift must be below high speed limit switch for outriggers to function.
NOTE
For the outriggers to function the upper control box must be in the lift position
and the scissor stack stowed or fully retracted.
1. Loose or broken wire #35C from pin #1 on connector (CN20) on outrigger board through outrigger cables
and plugs to the outrigger enable switch (S9A) in the control box.
-Check for continuity. Replace if defective.
2. Loose or broken wire #35D from outrigger enable switch (S9A) to pin #5 on the outrigger control box plug.
-Check for continuity. Replace if defective.
3. Defective outrigger enable switch (S9A).
-Check switch. Replace if defective.
1. Loose or broken wire #10A from pin #1 of the tilt switch connector to pin P2-12 on the outrigger control module
(OCM1).
-Check for continuity. Replace if defective.
2. Loose or broken wire #10A from pin #1 of the tilt switch connector to main terminal block (TB1).
-Check for continuity. Replace if defective.
3. Loose or broken wire #02 from pin #3 of the tilt switch connector to pin P2-11 on the outrigger control module
(OCM1).
-Check for continuity. Replace if defective.
4. Loose or broken wire #02 from pin #3 of the tilt switch connector to main terminal block (TB1).
-Check for continuity. Replace if defective.
5. Defective outrigger control module (OMC1).
-Replace.
1. Loose or broken wire #71-#75 (depending on function not working) at outrigger control module plug (P4)
pins 1-8.
-Check connections of outrigger functions not working (refer to Section 5 for pin reference chart). Replace
if defective.
2. No output from outrigger control module (OCM1) at plug (P4) pins 1-8.
-Turn off power to reset the outrigger control module. Turn power back on and retest. If problem persists,
replace outrigger control module.
1. Loose or broken wire #35D from outrigger enable switch (S9A) to auto mode outrigger switch (S24).
-Check continuity. Replace if defective.
2. Defective auto mode outrigger switch (S24).
-Check switch. Replace if defective.
3. Loose or broken wire #10A at PIN#P2-12 on outrigger control module (OCM1).
-Check for power at P2-12. If no voltage present, check continuity of wire. Replace if defective.
4. Loose or broken wire #35 at PIN#P2-10 on outrigger control module (OCM1).
-Check for power at P2-10. If no voltage present, check continuity of wire. Replace if defective.
5. Loose or broken wire #02 at PIN#P2-11 on outrigger control module (OCM1).
-Check for ground at P2-11. If no ground present, check continuity of wire. Replace if defective.
6. Loose or broken wire #70 from auto mode outrigger switch (S24) to PIN#P2-5 on outriger control module
(OCM1).
-Check continuity. Replace if defective.
7. For additional information, refer to sections 4 & 5 “Outrigger Control Module - Troubleshooting.”
1. Loose or broken wire #35D from outrigger enable switch (S9A) to auto mode outrigger switch (S24).
-Check continuity. Replace if defective.
2. Defective auto mode outrigger switch (S24).
-Check switch. Replace if defective.
3. Loose or broken wire #10A at PIN#P2-12 on outrigger control module (OCM1).
-Check for power at P2-12. If no voltage present, check continuity of wire. Replace if defective.
4. Loose or broken wire #35 at PIN#P2-12 on outrigger control module (OCM1).
-Check for power at P2-10. If no voltage present, check continuity of wire. Replace if defective.
5. Loose or broken wire #02 at PIN#P2-11 on outrigger control module (OCM1).
-Check for ground at P2-11. If no ground present, check continuity of wire. Replace if defective.
60417AA
The check engine light is located near the base start switch at the front of the machine. Below you will find the
operation of the light.
Note: It is normal for a 12 flash code at power up, but not started.
Note: Always be sure that 2. Loose or broken wire #1100 from 2. Check for continuity. Replace if
proper air filter maintenance pin #11 of the black ECU defective.
23 has been performed and that connector to the air intake
the air filter and air intake are temperature sensor TPS2.
free of debris. 3. Loose or broken wire #106 from 3. Check for continuity. Replace if
pin #9 of the black ECU connector defective.
to the air intake temperature sensor
TPS2.
1. Air intake temperature sensor short 1. Check resistance of sensor. Refer
Note: Always be sure that circuit. to Section 5 of this manual.
proper air filter maintenance
24 has been performed and that 2. Wire #106 shorted to ground. 2. Check the condition of the wire
the air filter and air intake are from pin #9 of the black ECU
free of debris. connector to the air temperature
sensor.
1. Map sensor indicates high voltage a. Check all wire connections at
on wire #105 at the map sensor map sensor.
(voltage above 4.98 volts). b. Check voltage signals for map
33 sensor. Refer to Section 5 of this
manual.
c. If voltages and connections are
OK, replace map sensor.
1. Map sensor detects short to a. Check all wire connections at
ground. map sensor.
b. Check voltage signals for map
34 sensor. Refer to Section 5 of this
manual.
c. If voltages and connections are
OK, replace map sensor.
1. Oxygen sensor detects lean 1. Check for correct fuel pressure at
condition. the throttle body (gas–14psi,
propane-15psi). Incorrect
pressure may require replacing of
the following components:
a. Fuel filter
b. Fuel pump
44 c. Fuel pressure regulator
d. Fuel lines
e. Oxygen sensor. Refer to
Section 5 of this manual.
2. Clean injector. If cleaning does
not clear fault, replace injector.
3. Oxygen sensor out of range.
Refer to Section 5 of this manual.
1. Oxygen sensor detects rich 1. Check for correct fuel pressure at
condition. the throttle body (gas–14psi,
propane-15psi).
45 2. Check injector o-rings to ensure
proper position.
3. Clean injector. If cleaning does
not clear fault, replace injector.
60418AA
1. Stuck or defective drive reverse valve (4H-15B) or drive forward valve (4H-16B).
-Clean valve. Replace if defective.
2. Defective motion control valve (MC1).
-Clean valve. Replace if defective.
3. One or more check balls missing or defective in series/parallel valve manifold (3H-20A).
-Replace missing check balls(3/16”) steel. Refer to Section 5, for proper inspection.
4. Stuck main series/parallel valve spool (V3) in drive motor.
-Clean valve. Replace if defective.
5. Defective drive motor (M1).
-Check motor. Replace if defective.
6. Stuck free wheeling valve (2H-30A).
-Clean valve. Replace if defective.
1. Defective check valve left front (CV4), right front (CV5), right rear (CV6) or left rear (CV7).
-Clean valve. Replace if defective.
2. Outrigger cylinder bypassing left front (C9), right front (C10), right rear (C11), or left rear (C12).
-Repack cylinder. Replace if defective.
Section 5
Maintenance and Service
Table of Contents
List of Tables
Table 5-1 General Specifications ......................................................................................................................... 5
Table 5-2 Torque Specifications ........................................................................................................................... 6
Table 5-3 Rough Terrain Scissor Fluids ............................................................................................................... 7
Table 5-4 Auto-Leveling Outrigger Settings and Error Codes ........................................................................... 18
Table 5-5 Auto-Leveling Outrigger Error Code Breakdown .............................................................................. 19
Table of Contents
List of Figures
Figure 5.1-1 Brake Adjustment ........................................................................................................................ 9
Figure 5.1-2 Plug Removal and Replacement................................................................................................. 9
Figure 5.1-3 Multiple Disc Brake Assembly ................................................................................................... 11
Figure 5.1-4 Disc Parking Brake .................................................................................................................... 12
Figure 5.1-5 Parking Brake Release Hand Pump and Brake Valve Plunger................................................. 12
Figure 5.1-6 Drive Motor ................................................................................................................................ 14
Figure 5.1-7 Wheel Fastener Tightening Sequence ...................................................................................... 15
Figure 5.1-8 Auto-Leveling Outrigger PC Board Layout ............................................................................... 16
Figure 5.1-9 Outrigger Mechanical Limit Switch Wiring ................................................................................ 17
Figure 5.1-10 Hand Held Calibration/Diagnostic Tool Key Functions ............................................................. 20
Figure 5.1-11 Auto-Leveling Outrigger Control Module Pin Reference Chart ................................................ 24
Figure 5.1-12. ECU Pin Reference Chart .......................................................................................................... 25
Figure 5.1-13a Fuel Injector and Throttle Actuator Testing (Voltage Tests) ...................................................... 26
Figure 5.1-13b Fuel Injector and Throttle Actuator Testing (Ohm Tests) .......................................................... 27
Figure 5.1-14 MAP Sensor Testing .................................................................................................................. 29
Figure 5.1-15 Oxygen Sensor Testing ............................................................................................................. 30
Figure 5.1-16 ECU Pin Reference Chart (GM)................................................................................................. 31
Figure 5.1-17 Throttle Actuator (GM) ............................................................................................................... 32
Figure 5.1-18 GM Map and IAT Sensor (GM) .................................................................................................. 33
Figure 5.1-19 Engine Coolant Temperature Sensor (GM) .............................................................................. 34
Figure 5.1-20 LPG Temperature Sensor (GM) ................................................................................................ 35
Figure 5.1-21 Fuse Block Layout (GM) ........................................................................................................... 36
The operator should be assured that the work platform • The actual operating environment of the aerial
has been properly maintained before using it. Included in platform may affect the maintenance schedule.
this section is information on lubrication and inspection
points that require maintenance. WARNiNG
Use original or manufacturer-approved
Even if the operator is not responsible for the maintenance
parts and components for the aerial
of this work platform, the operator should perform the
platform.
daily inspections found in Table 2.7 - Maintenance and
Inspection Schedule.
Owner’s Inspections
It is the responsibility of the owner to arrange daily,
iMPORTANT NOTE
quarterly (or 150 hours) and annual inspections of the
Replace all worn or damaged parts or labels
aerial platform. Refer to Table 2.8 for recommended
discovered during this inspection. Any
maintenance and inspection areas and intervals. A
problems or malfunctions that may affect the
record of annual inspection is kept on a label located
safe operation of this work platform must be
on the scissor assembly. Refer to Table 2.2 - Owner’s
repaired immediately.
Annual Inspection Record in section 2 is to be used for
recording the date of inspection, owner’s name and
the person responsible for the inspection of this work
WARNiNG platform.
Maintenance must be performed by
trained and competent personnel who are General Maintenance Hints
familiar with mechanical procedures. • Before attempting any repair work, disconnect
battery ground negative (-) lead.
Death or serious injury could result from
the use of an aerial platform that is not • Properly position maintenance bar if the scissors
properly maintained or kept in good assembly is raised.
working condition.
• Preventive maintenance is the easiest and least
expensive type of maintenance.
WARNiNG
Do not reach through the scissor assembly
when the platform is raised without the
maintenance support properly positioned.
Failure to avoid this hazard could result
in death or serious injury.
6. DO NOT use synthetic or fire resistant oils in this 1. Change filters regularly.
work platform. Use ATF Dexron III (ESSO) or
equivalent hydraulic oil. For conditions causing 2. Maintain a sufficient quantity of clean hydraulic
oil temperatures below -31°F (-35°C) and above oil of the proper type and viscosity in the
122°F (50°C) consult Skyjack, Inc. hydraulic reservoir.
2WD
Outside 15 ft. (4.6m) 18.7 ft. (5.7m) 25.9 ft. (7.9m)
12.25ft 12.2 ft
Inside 10 ft. (3m) 10.8 ft. (3.3m) 18.6 ft. (5.7m)
(3.7m) (3.7m)
4WD
20.1 ft 20.4 ft
Outside 17 ft. (5.2m) 19.7 ft. (6m) 29.3 ft. (9m)
(6.1m) (6.2m)
Tires Please refer to Table 2-5a or Table 2-5b for tire specification and usage.
Ground Clearance 8in (0.20m) 8.13in (0.21m) 7in (0.178m) 8in (0.20m)
High Speed Drive
10 ft. (3.05m)
Cut-Out Height
Nissan
Dual Fuel N/A 900 (Idle) / 1400 (Low) / 2800 (High)
GM
RPM 1400 (Low) /
Kubota Diesel N/A 1400 (Low) / 2800 (High)
2800 (High)
Kubota 2050 (Low) /
N/A
Dual Fuel 3500 (High)
Nissan
43 hp (as used) water cooled
Dual Fuel
GM 65 hp water cooled
Power
Kubota Diesel 25.5 hp water cooled
Kubota
31 hp N/A
Dual Fuel
Nissan
Dual Fuel Non-Blended Unleaded Gasoline / HD5 Grade Liquid Propane
Engine *
GM
Fuel
Kubota Diesel No. 2 Diesel N/A No. 2 Diesel
Kubota
Non-Blended Unleaded Gasoline / HD5 Grade Liquid Propane
Dual Fuel
Nissan
Dual Fuel N/A 230°F (110°C)
Engine GM
Temp.
Cutout Kubota Diesel N/A 230°F (110°C)
230°F (110°C)
Kubota Dual
N/A
Fuel
17.5 gal.
Fuel Tank Capacity 20 gal. (75.71 L) 13.5 gal. (51.1 L)
(66.2 L)
Battery (Main) 12 Volt, 60 Ampere Hour (Type 27F700)
12 Volt (Type
Battery (Emergency
N/A 12N14-3A)
Lowering System)
(If Equipped)
*For additional engine specifications and service information, consult the engine manufacturer’s documentation. 60400AD
Cartridge
Size
Torque
8 38 58 10 12 16
Lbf.ft
20 25 35 50
(max)
Lbf.in
240 300 420 600
(max)
Coils
Size
Torque
All coils
Lbf.ft
4 to 5
(max)
Lbf.in
48 to 60
(max)
SAE Plugs
Size
Torque
2 4 5 6 8 10 12 16
Lbf.ft
3 10 15 25 30 35
(max)
Lbf.in
36 120 180 300 360 420
(max)
Directional valve
2.33 (28-32 in-lb) 3.16 - 3.61
mounting bolts
AXLE OIL
*Qty. *Qty. Skyjack
Axle Type Oil Type Recommended Equivalent Oil
(Liters) (Gallons) Part No.
Cushman Front
2.4 0.634 Gear Oil, 80W-90 GL5 134612 -
Dana Front / Rear
Chevron Gear Lubricant Delo ESI 80W-90,
Caltex Gear Lubricant ESI 80W-90,
Cushman Rear 1 0.264 Gear Oil, ESI 80W-90 133461
Caltex RPM Borate EP 80W-90,
Texaco Star Gear Lubricant 80W-90
HYDRAULIC OIL
*Qty. *Qty. Skyjack
Model Oil Type
(Liters) (Gallons) Part No.
SJRT-68xx 86.88 22.95
SJRT-7127
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850
ATF Dexron III 119309
SJRT-8831
SJRT-8841
75.71 20
SJRT-8831E
SJRT-8841E
SJRT-9250 67.38 17.8
ENGINE OIL
*Qty. *Qty. Skyjack Recommended Equivalent Oil
Engine Type Oil Type, Viscosity
(Liters) (Gallons) Part No. (Viscosity - API Service Designation)
Kubota D902 3.9 1.03
Kubota D1105 5.1 1.35 10W30 - API Service Designation CG-4,
105287
Kubota DF972 3.4 0.9 Engine Oil, SAE 10W-30 CF-4, CF, CD, SH.
Nissan A15
3.5 0.98
GM 1.6 142454 10W30 - API Service Designation SF/CC.
ENGINE COOLANT
*Qty. *Qty. Skyjack
Component Type **Coolant Type
(Liters) (Gallons) Part No.
Kubota D902
Kubota D1105 3.1 0.82
AntI-freeze / Water 125985
Kubota DF972
Nissan A15
11.4 3.01
GM 1.6 Extended life antI-freeze / Water 142208
ENGINE FUEL
Tank Diesel Gasoline / Liquid Propane
Model *Qty. *Qty.
Kubota D902 Kubtoa D1105 Kubota DF972 GM 1.6 Nissan A15
(Liters) (Gallons)
SJRT-68xx 86.88 22.95 � N/A
SJRT-7127 � N/A
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850 N/A �
SJRT-8831 N/A �
49.21 13
SJRT-8841
SJRT-9250 64.35 17
4. Depress and turn the red knurled knob on the brake BRAKE ADJUSTER
valve counter-clockwise to a fully closed position
or depress black knob (current manifold).
Figure 5-1-2. Plug Removal and Replacement
5. Grasp the red plunger and rapidly depress until
plunger can no longer be depressed and the brake
is fully released. 11. Using a 1/4” Allen wrench, turn brake adjuster
counter-clockwise until it bottoms out. Turn
6. Inspect caliper and brake pads for binding. Pads Allen wrench clockwise 1/2 turn clockwise to set
should move freely on the pins. adjustment.
7. Remove pin from brake cylinder clevis and brake 12. Replace plastic plug back into the end of the
actuating lever. Rotate actuating lever counter- caliper shaft.
clockwise to the end of its stroke.
13. Depress red knurled knob on brake valve and turn
HOLD ACTUATOR ARM
clockwise to a fully open position.
TO FULL COUNTER-CLOCKWISE
14. Remove Wheel blocks. Turn emergency power
disconnect switch on. Operate drive several times
1/2”
to seat pads to brake disc.
BRAKE ADJUSTER
6. Before removing springs, record the pattern and Holding Torque Testing Procedure
color for reassembly purposes. Remove dowel 1. Make sure the machine is parked on level
pins, springs and spring retainer from cover. ground.
7. Press oil seal from cover. 2. Locate the brake feed valve (2H30A-2) on the main
manifold. Disconnect the electrical connectors
Spring Chart From this valve. This will prevent the hydraulic
Model Yellow Red Blue system from releasing the brake.
Springs (14) Springs (14) Springs (14)
21-100-114 16 0 0 3. With the engine running, machine in drive mode,
engine on high idle, high torque selected and low
speed range selected, hold the enable switch on
Assembly the joystick and push the joystick forward as if you
(Refer to Figures 5.1-3) were to drive forward. This provides torque from
1. Use an alkaline wash to clean parts before the drive motor to the unreleased brake.
assembly.
4. If the brake slips and the machine starts to move
2. Press new oil seal into cover until it is flush with in this condition, either the brake plates are worn
bearing shoulder. Note direction of seal. or the springs have broken. Both the springs and
3. Install shaft, dowel pins, spring retainer and the brake plates must be replaced to return the
new spring in cover. Be sure to install springs brake to its original holding torque.
according to pattern and color recorded during
disassembly.
Oil Seal
Cover
Dowel Pins
Spring Retainer
Springs
Return Plate
Rotor Discs
Shaft Stator Discs
Back-Up Rings
O-Rings
Piston
Back-Up Rings
O-Rings
Case Seal
Pressure Plate
Cap Screws
M11512AA
WARNiNG
Do not manually disengage parking
brakes if work platform is on a slope.
4
5
TOP OF BLOCK
Index Skyjack
Qty. Description
No. Part No.
Part Usage:
The 3 smaller holes have O-rings and no Check Balls
The 2 bigger holes get Check Balls
In the Motor piece there are 2 holes that get 1 check ball each (4 Check Balls total)
It is necessary to check the torque on all wheel nuts and When a Wheel/Tire Assembly has been removed or
wheel bolts at pre-delivery, after 8 hours of operation and replaced, it will be necessary to follow the procedure
at weekly intervals using the following procedure: below to ensure proper installation:
1. Confirm that each wheel fastener is torqued to 1. Inspect wheel fastener threads for damage of
140 ft. lbs. (± 5 ft. lbs.) using a suitable torque defects. Replace if defective.
wrench of known accuracy. If any fastener
falls outside of the specified tolerance, ALL 2. Clean the mounting surfaces of the hub and
fasteners MUST be torqued using the tightening wheel rim of debris, rust, excess paint, etc.
sequence shown in Figure 5.1-6.
3. Mount wheel on the hub, centering mounting
holes on the wheel studs or bolt holes. Use
1 appropriate lifting device as required.
3 8
4. Install the wheel nuts or wheel bolts and hand
5 tighten to center the rim.
6
5. Tighten the nuts or bolts to approximately 50 ft.
7 4 lbs. torque using the tightening sequence in Figure
5.1-6. above.
2
6. Tighten to 100 ft. lbs. using the same
Figure 5.1-7. Wheel Fastener Tightening Sequence sequence.
2. Again, confirm that each wheel fastener is 7. Tighten to 140 ft. lbs. using the same
torqued to the specified tolerance. Re-torque sequence.
as necessary until ALL fasteners are properly
torqued. 8. Repeat the tightening sequence to confirm that
none have changed from 140 ft. lbs. If any
are found below 140 ft. lbs., repeat complete
sequence until there is no change in torque
values. If possible, drive the machine prior to
checking torques.
M50318AA
O.R. UP SWITCH (NO) - BLUE & BROWN O.R. UP SWITCH (NO) - BLUE & BROWN
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT FRONT OUTRIGGER SECTION VIEW RIGHT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE) (SHOWN IN THE RETRACTED STATE)
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT REAR OUTRIGGER SECTION VIEW RIGHT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE) (SHOWN IN THE RETRACTED STATE)
M11449AC
1. Half second flashes followed by half second pauses indicate the first digit.
2. A 2.5 second pause.
3. Half second flashes followed by half second pauses indicate the second digit
4. A 5 second pause.
Since the outrigger control module only reports one error, only one code can be read from the LED per instance.
If the error is cleared and another error is present, it will then be presented.
These are internal faults. If the fault persists after the power has been reset, the outrigger control module
may need to be replaced.
WARNiNG
Only trained and authorized personnel shall be permitted
to service an aerial platform.
WARNiNG
Read all instructions closely before attempting each phase
of this procedure.
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
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 the machine 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.
12. The display will show “Calibrate Level: Yes: Enter, No: ESC”.
Select the “Yes” from the menu by press the ENTER button.
13. The display will show “Calibrate Level: Tilt 0.0’ , 0.0’”.
Select the “ESCAPE” from the menu once.
15. The Calibration procedure is complete, unplug and remove the EZ-Cal.
LED
WIRE #
PIN
PLUG AND CO- WIRE FUNCTION
#
LOUR
P1 The Calibration Connection
P2 1 68A White Input indicating that the LEFT REAR outrigger is in contact with the ground
P2 2 67A Red/White Input indicating that the RIGHT REAR outrigger is in contact with the ground
P2 3 66A Blue/White Input indicating that the RIGHT FRONT outrigger is in contact with the ground
P2 4 65A Green/White Input indicating that the LEFT FRONT outrigger is in contact with the ground
P2 5 70 Green/Black Input for AUTO-LEVEL function to extend the outriggers to level the machine
P2 6 79 Green Input for AUTO-RETRACT function to retract the outriggers until the switch is released
P2 7 70A Red/White Outrigger Light on Outrigger Control Box
P2 8 65 Green/Black STABLE output to indicate that all outriggers are in contact with the ground
P2 9 28 Green TILT output to indicate that the machine is level (ANSI/CSA only)
P2 10 35 Green Tilt override / High Drive Cutout
P2 11 02 White Negative Input
P2 12 10A Black Main Power Input
P4 1 78 Black/White Output used to extend the LEFT REAR outrigger
P4 2 77 Blue/Black Output used to extend the RIGHT REAR outrigger
P4 3 76 Red/Black Output used to extend the RIGHT FRONT outrigger
P4 4 75 Orange/Black Output used to extend the LEFT FRONT outrigger
P4 5 74 Black Output used to retract the LEFT REAR outrigger
P4 6 73 Blue Output used to retract the RIGHT REAR outrigger
P4 7 72 Red Output used to retract the RIGHT FRONT outrigger
P4 8 71 Orange Output used to retract the LEFT FRONT outrigger
P4 9 35C White/Black Power input for outriggers
60401AB
Diagnostics
White Connector Black Connector
Pin # Wire# Wire Color Description Pin # Wire# Wire Color Description
50 Orange V to LP lock off 05 Green Coolant Sensor
00 Brown/White LP Injector (Ground) N/U Empty
00 Brown Gas Injector (Ground) N/U Empty
Orange/
5 V to Gas/Propane switch 0 Orange 5V to (MAP)
Green
5 00 Gray Signal to Throttle/Actuator 5 N/U Empty
N/U Empty N/U Empty
N/U Empty 0 Pink Oil pressure switch
V thru 0K resistor to pin Orange/
00 Gray 0 Fault lamp reset
Black
A Green/White V+high speed input 0 Blue Air Temp sensor (5volts)
Oxygen sensor sense
0 N/U Empty 0 0 White/Black
input( V+)
00 Gray 5V from resistor pin 00 Black Ground to all sensors
Signal ground for oxygen
00 Orange Ground to diagnostic light 00 Black/White
sensor
N/U Empty N/U Empty
A Black/Red Ground for relay 0BCR N/U Empty
5 00 Red/Black V for both Injectors 5 N/U Empty
N/U Empty N/U Empty
Green V+Mid speed input 05 Green MAP Sensor signal
N/U Empty N/U Empty
00 Blue Distributor input (Tach signal) N/U Empty
0 00 White Ground 0 N/U Empty
00 White Ground N/U Empty
00 Red Power N/U Empty
00 Red Power N/U Empty
60419AA
P/N ...........................................................
Figure 5.1-13a Fuel Injector and Throttle Actuator Testing (Voltage Tests) (Nissan)
NOTE: Control box must be powered up and either lift or drive selected. All tests are to be
completed with the actuator and injector connectors disconencted.
12 Volts
GASOLINE INJECTOR
PIN A - 1002 Red/Black - Positive signal from ECU
PIN B - 2001 Brown - Pulsed negative signal from ECU
-2001 Brown
RED BLACK
+1002 Red/Black
To negative post
on battery
PROPANE INJECTOR
PIN A - 1002 Red/Black - Positive signal from ECU
PIN B - 1001 Brown/White - Pulsed negative signal from ECU
-1001 Brown/White
Fluctuating voltage
+1002 Red/Black
BLACK
RED
-00 White
+1008 Grey 2.3 - 6.2 volts
(fluctuating)
- Test for 12 volts on the suspect injector as shown above on the gasoline injector connector. Red lead
to wires 1002 and the black lead to the negative post on the battery. Base engine switch to the ON
position.
- Test for a fluctuating voltage on the suspect injector as shown above on the propane injector connector.
Black lead to wires 1001 (propane) or 2001 (gasoline) and the red lead to the positive post on the
battery. Turn the base engine switch to the START position while observing the multimeter.
- Test for voltage at the throttle actuator connector with a multimeter as shown above. Voltage should
fluctuate between 2.3 and 6.2 volts with the base engine switch ON.
Figure 5.1-13b Fuel Injector and Throttle Actuator Testing (Ohm Tests) (Nissan)
NOTE
All tests are to be completed with the actuator and injector connectors disconencted.
Gasoline Injector
1.2 - 1.6 Ohms
Air Intake
Temp. Switch
Gasoline Inlet
14 PSI
Propane Inlet
15 PSI
White ECU
Propane Injector Plug
1.2 - 1.6 Ohms
Black ECU
Plug
Throttle Actuator
3.0 - 4.5 Ohms M.A.P.
Sensor
- Gasoline and propane injectors should read 1.2 - 1.6 ohms between the 2 pins.
- Throttle actuator should read 3.0 - 4.5 ohms between the 2 pins.
5.9 Air Intake Temperature Sensor and Coolant Temperature Sensor Testing (Nissan)
MAP SENSOR
CAUTiON
This is a Heated Oxygen Sensor
61 75 76 90
31 45 46 60 LOCK TAB
1 15 16 30
Diagnostics
Pin # Wire Color Description Pin # Wire Color Description
1 DK GRN/ORN EGO1 Signal 46 DK BLU/YEL Not used
2 DK GRN/WHT EGO2 Signal 47 YEL/DK BLU Not used
3 EMPTY 48 LT GRN/WHT Output to gasoline temp sensor
4 EMPTY 49 LT GRN/PPL Not used
5 PPL/LT BLUE Throttle position 1 signal 50 LT GRN/BLK Not used
6 LT BLU/DK BLU Throttle position 2 signal 51 GRY/DK BLU Mid throttle input
7 LT GRN MAP Signal 52 GRY/ORN High throttle input
8 TAN/DK GRN Not Used 53 LT BLU Input from oil pressure switch
9 DK BLU/ORN Not Used 54 WHT/LT GRN Signal from gasoline pressure sensor
10 PPL/YEL Not Used 55 DK GRN To diagnostic connector (PC)
11 EMPTY 56 ORN To diagnostic connector (PC)
12 EMPTY 57 EMPTY
13 WHT/ORN Connected to pin #14 below 58 GRY Not used
14 BLU/PNK CAN + to propane regulator 59 EMPTY
15 BLU/WHT CAN – from propane regulator 60 RED/TAN Battery positive
16 EMPTY 61 BRN/LT BLU To injector #1 and #4
17 EMPTY 62 BRN/LT GRN To injector #2 and #3
18 EMPTY 63 EMPTY
19 LT GRN/RED 5 volt + from ECU to sensors 64 EMPTY
20 BLK/LT GREEN 5 volt – to ECU from sensors 65 EMPTY
21 PPL/WHT +V from crank position sensor 66 EMPTY
22 WHT/PPL -V from crank position sensor 67 EMPTY
23 EMPTY 68 EMPTY
24 EMPTY 69 BLK Ground from engine block
25 RED/WHT Not used 70 EMPTY
26 RED/BLK Not used 71 WHT/LT BLU Negative supply to power relay 2002CR
27 EMPTY 72 BLK/WHT EGO 1 Heater ground
28 EMPTY 73 BLK/YEL EGO 2 Heater ground
29 EMPTY 74 EMPTY
30 EMPTY 75 WHT/BLK Negative supply to propane lock off
31 YEL Output to spark coil 1 76 EMPTY
32 EMPTY 77 BRN/WHT Negative supply to relay 10BCR2
33 YEL/RED Output to spark coil 2 78 WHT/BRN Not used
34 EMPTY 79 RED/TAN Battery positive
35 EMPTY 80 GRN/YEL To check engine light (MIL)
36 EMPTY 81 BLK Ground from engine block
37 EMPTY 82 PNK/WHT Positive to throttle actuator motor
38 EMPTY 83 TAN/ORN Negative from throttle actuator motor
39 YEL/GRY Output to IAT (part of MAP) 84 TAN/BLK Negative supply to fuel pump relay 56CR
40 TAN/WHT Output to ECT 85 PNK/YEL Fuel pump excite wire
41 WHT/RED Output to EGT 86 BLK/RED Negative supply to fuel pump
42 TAN/BRN Propane selected 87 TAN Not used
43 TAN/RED Not used 88 DK BLU Not used
44 TAN/BLK Not used 89 PNK/BLK Negative supply to starter relay 32ACR
45 PNK/TAN 12 volt input 90 EMPTY
60594AA
DBW+ PNK/WHT
4
MOTOR
DBW- TAN/ORG
1
5 VOLTS
3 LT GRN/RED
BLK/LT GRN
1 SENSOR GROUND
YEL/GRY 5 VOLTS
2 INTAKE AIR TEMPERATURE SIGNAL (IAT)
LT GRN/RED
3 5 VOLTS
LT GRN
4
MANIFOLD ABSOLUTE PRESSURE SIGNAL
(MAP)
A TAN/WHITE
5 VOLTS
BLK/LT GREEN
B
SENSOR GROUND
A WHITE/RED
5 VOLTS
BLK/LT GREEN
B
SENSOR GROUND
EMPTY F7 F8
5 AMP 20 AMP
VSW ECU
F11 F10
EMPTY 15 AMP 15 AMP
FUEL PUMP IGNITION
F9 F12
10 AMP 15 AMP
F13 60A ALT EPR STARTER
Resistance of Ignitor
Negative
A B C D E F G H
Positive
A 10 to 40 kΩ 10 to 40 kΩ 11 to 47 kΩ infinity infinity infinity infinity
0.33 to 1.3 1.8 to 7.3
B 10 to 40 kΩ infinity infinity infinity infinity
kΩ kΩ
0.33 to 1.3 1.5 to 6.0
C 10 to 40 kΩ infinity infinity infinity infinity
kΩ kΩ
1.8 to 7.3 1.5 to 6.0
D 11 to 47 kΩ infinity infinity infinity infinity
kΩ kΩ
E infinity infinity infinity infinity infinity infinity infinity
2 megohm 2 megohm 2 megohm 2 megohm
F infinity infinity infinity
(minimum) (minimum) (minimum) (minimum)
2 megohm 2 megohm 2 megohm 2 megohm
G infinity infinity infinity
(minimum) (minimum) (minimum) (minimum)
2 megohm 2 megohm 2 megohm 2 megohm
H infinity infinity infinity
(minimum) (minimum) (minimum) (minimum)
60434AA
CUSTOMER___________________________________________________________________
DEALER______________________________________________________________________
Table of Contents
Platform and Related Parts
Figure 6.1-1. Main Platform And Railings ...................................................................................................................6
Figure 6.1-2. 4 Ft. Roll-out Extension Platform Assembly ........................................................................................10
Figure 6.1-3. 4 Ft. Powered Extension Platform Assembly ......................................................................................12
Figure 6.1-4. Powered Extension Platform Control Box Assembly ..........................................................................16
Figure 6.1-5. Powered Extension Platform Cylinder Assembly................................................................................17
Figure 6.1-6. Powered Extension Platform Electrical Panel .....................................................................................18
Figure 6.1-7. Hydraulic Hose Connections - Single Powered Extension Platform ..................................................21
Figure 6.1-8. Hydraulic Hose Connections - Dual Powered Extension Platforms (Model 8831) ...........................22
Figure 6.1-9. Hydraulic Hose Connections - Dual Powered Extension Platforms (Model 8841) ............................23
Figure 6.1-10. Platform AC Outlet .............................................................................................................................24
Figure 6.1-11. Safety D-ring Assembly .....................................................................................................................25
Drivetrain components
Figure 6.5-1. Front Idle Axle Assembly (For 2-wheel Drive Machines) ....................................................................84
Figure 6.5-2 Front Axle Hardware Assembly - All Wheel Drive Option (Cushman Axles) .....................................86
Figure 6.5-3. Front Axle Assembly - All Wheel Drive Option (Cushman Axles) ......................................................88
Figure 6.5-4. Front Axle Assembly (Axle End) - All Wheel Drive Option (Cushman Axles) ....................................90
Figure 6.5-5. Front Axle (Differential Assembly) - All Wheel Drive Option (Cushman Axles) ...............................92
Figure 6.5-6. Front & Rear Axle (Wheel Hub Assembly) - All Wheel Drive Option (Cushman Axles) ....................94
Figure 6.5-7. Front Axle (Axle Shaft Assembly) - All Wheel Drive Option (Cushman Axles) .................................95
Figure 6.5-8. Steer Cylinder Assembly (4WD / Cushman Front Axle - 4WD) (Cushman Axles) ............................96
Figure 6.5-9. Front Axle Assembly (For 4-wheel Drive Machines) (Dana Axles) ....................................................98
Figure 6.5-10. Front Drive Axle Assembly (4-wheel Drive Machines) (Dana Axles) ..............................................100
Figure 6.5-11. Steer Cylinder Assembly (Dana Axles) ...........................................................................................104
Figure 6.5-12. Drive Shaft Assembly ......................................................................................................................105
Figure 6.5-13. Drive Motor Assembly .....................................................................................................................107
Figure 6.5-14. Center Drive Assembly ....................................................................................................................108
Figure 6.5-15. Rear Axle Assembly - (Cushman Axles) .........................................................................................110
Figure 6.5-16. Rear Axle (Differential Assembly) - (Cushman Axles) ....................................................................112
Figure 6.5-17. Rear Axle (Brake Assembly) - (Cushman Axles).............................................................................114
Figure 6.5-18. Rear Drive Axle Assembly (Dana Axles) .........................................................................................116
Figure 6.5-19. Disc Brake Assembly (Dana Axles) ................................................................................................118
Figure 6.5-20. Disc Brake Cylinder Assembly (Dana Axles) ..................................................................................120
Optional Equipment
Figure 6.7-1. Hydraulic Outrigger Option - Hydraulic Hose Connections .............................................................168
Figure 6.7-2. Hydraulic Outrigger Option - Leg Assembly .....................................................................................170
Figure 6.7-3. Hydraulic Outrigger Option - Cylinder Assembly .............................................................................172
Figure 6.7-4. Hydraulic Outrigger Option - Manifold Assembly .............................................................................173
Figure 6.7-5. Hydraulic Outrigger Option - Electrical Panel Assembly ..................................................................174
Figure 6.7-6. Hydraulic Outrigger Option (Auto level) - Electrical Panel Connections .........................................175
Figure 6.7-7. Outrigger/Hydraulic Generator Control Box Assembly ....................................................................176
Figure 6.7-8. Hydraulic Generator Option - Hydraulic Hose Connections ............................................................178
Figure 6.7-9. Hydraulic Generator and Oil Cooler Options ....................................................................................181
Figure 6.7-10. 1500W Inverter Option ....................................................................................................................182
Figure 6.7-11. Air Hose To Platform Option ............................................................................................................185
Figure 6.7-12. Scissor Guard Option ......................................................................................................................186
Figure 6.7-13. Work Light Option ...........................................................................................................................190
Labels
Figure 6.8-1. Label Kit .............................................................................................................................................191
Figure 6.8-2. Labels And Nameplates - Misc .........................................................................................................192
Figure 6.8-3. Labels And Nameplates - Main Control Box .....................................................................................194
Figure 6-8-4. Labels And Nameplates ...................................................................................................................196
Figure 6.8-5. Labels - Outrigger..............................................................................................................................198
Tables
Table 1.1. SJRT Scissor Fluids ...............................................................................................................................200
37
36
34
4
20
21
35 16
14
17
18
15
22 13
23
25 11
7
8 10
12 6
24
28
26 27
29
9
30 5
3
2
4
32 33
31
30
M1003AD
37
36
34
4
20
21
35 16
14
17
18
15
22 13
23
25 11
7
8 10
12 6
24
28
26 27
29
9
30 5
3
2
4
32 33
31
30
M1003AD
L 24 5 10
3
21
19 20
22
14
17
11
18
12
14
23
2 1
16 17 15 14 13
M10033AA
2 L 9
7
3 8 13
11
30
10
14
29 13
12
1 17
18
15
25
27 19
21
20
23
31
24
26
27
28
22
M10034AA
2 L 9
7
3 8 13
11
30
10
14
29 13
12
1 17
18
15
25
27 19
21
20
23
31
24
26
27
28
22
M10034AA
5 6
1
7
3
4
M115592AH
Index Skyjack
Qty. Description
No. Part No.
8
2
7
6
11
12
5
4
10
3
M120275AB
Index Skyjack
Qty. Description
No. Part No.
TO ELECTRICAL PANEL
12
2
11
3 10
TO ENGINE
MAIN BATTERY
4 5 6 9
TO POWER DECK DIRECTIONAL VALVE
EM RETRACT
120844AB
02 97A
PLATFORM
27
26 09 12A 12D 09 26A 27A
MANIFOLD
10
27 26 02 02 02 02 26A 27A
BASE FEED
8
TO POWER DECK MOTOR CONTACTOR
7
M11425AA
3
4
4
ML3F-1009AA
Index Skyjack
Qty. Description
No. Part No.
1 3 5 8
FRONT REAR
4 6 9
2 7
ML3F-1011AB
Index Skyjack
Qty. Description
No. Part No.
7 4
6 9
FRONT REAR
1 3 5 8
ML3F-1012AB
Index Skyjack
Qty. Description
No. Part No.
L
5
1
8
3 2
6
3 2 7
L
4
6 4
M11090AF M11090AG
Index Skyjack
Qty. Description
No. Part No.
M10983AA
Index Skyjack
Qty. Description
No. Part No.
18
17
11 1
14
15 16
13 9
12
20 21
20 19
21
5 1
1
8
4 10
2
1
4
12
13
11
7
8
9
10
2
1
4
12
13
11
7
8
9
10
4 2
5
6
7
5
9 3
8 15
1
13
14
11 12
10
16
16
17 35
17
18
19
32 33
20
31 30 34
29
28
23 24
27 25 26 22 21
M11318AA M132537AC_2 M132537AC_1
8
6
7 9
10
5
11
13
12
3 14
16 17
15
18
1
24 2 23 22 17 20 21 19 M10049AA
8
6
7 9
10
5
11
13
12
3 14
16 17
15
18
1
24 2 23 22 17 20 21 19 M10049AA
9 2
10
8 7 6
11
13
12
14
3
5
17 18 15
19
3
20 21
22
2
27
1 28 2 26 25 20 23 24 16
M10050AA
9 2
10
8 7 6
11
13
12
14
3
5
17 18 15
19
3
20 21
22
2
27
1 28 2 26 25 20 23 24 16
M10050AA
11
10
9 1
2
12
4
13
1 5
11
2
3 6
14
7
8
2 1
4
5
6 3
7
8
1
2
3
4 6
11
8
10 9
12
2 1
1
2
7 13 14 15
13
12
1
11
2
10
16
5
9 6
7 14 15 17
13
14
15
2 7
11
8
9
10 12 11
6
5
4 13
3
ML2F-1002AA
6
5
2 2
3
15
10 9
11 8
12 13
14 11
ML2F-1003AA
7 3
4
10
24
13
6 17
29
5
18
12
11
26
8 11
2 25 3
10
11
26 19
11
* Note: Non-marking tires are lighter in color.
M10072AB
24
13
6 17
29
5
18
12
11
26
8 11
2 25 3
10
11
26 19
11
* Note: Non-marking tires are lighter in color.
M10072AB
24
13
6 17
29
5
18
12
11
26
8 11
2 25 3
10
11
26 19
11
* Note: Non-marking tires are lighter in color.
M10072AB
26 26
25 25
1
For models equipped with Cushman Axles For models equipped with Dana Axles
MANIFOLD
MANIFOLD
TO MAIN
TO MAIN
BRAKE
5
21 22 2 3 23 20
TO MOTION
SMALL PUMP
LARGE PUMP
CTRL.
4
RETURN
11
3 8
7
STEERING
6 15
SAE-10
SAE-10
10
16
11 14 24
3
18
9
12 13
19 17
M11564AB
7 1
M11345AA
1 109779 1 WELDMENT, Fuel/hydraulic oil tank cabinet (Without scissor guard option)
116616 1 WELDMENT, Fuel/hydraulic oil tank cabinet (With scissor guard option)
2 108464 1 DOOR, Hydraulic oil tank access
103628 AR • SEAL, Door (102” total)
101541 1 • HANDLE W/LOCK, Recessed
111944 AR • • KEY, Door (#CH501)
3 108463 1 DOOR, Fuel tank access
103628 AR • SEAL, Door (88” total)
101541 1 • HANDLE W/LOCK, Recessed
111944 AR • • KEY, Door (#CH501)
4 116052 AR CABLE, Door stop (18”)
124296 1 CABLE, Door stop (13.25”)
5 (Ref.) - TANK ASSEMBLY, Fuel
(For components, refer to Figure 6.4-5)
101632 2 • BOLT, Hex head (3/8-16 x 3/4” lg.)
103472 2 • WASHER, Flat (3/8”)
103999 2 • WASHER, Lock (3/8”)
103978 2 • NUT, Hex (3/8-16)
6 (Ref.) - TANK ASSEMBLY, Hydraulic oil
(For components, refer to Figure 6.4-4)
101632 2 • BOLT, Hex head (3/8-16 x 3/4” lg.)
103472 2 • WASHER, Flat (3/8”)
103999 2 • WASHER, Lock (3/8”)
103978 2 • NUT, Hex (3/8-16)
7 117398 1 CONDUIT, Convoluted (24” lg.) (Edge protection)
7
9 11
10
8
6 4 5
1
2
M11060AA
Nissan Engine
6
Kubota Engine 3
6 6
GM Engine 3
7
6 2
7
5
1
M11061AA_1
27
1 18
7 L
25
26
13
L 4
15 14
6
12
17
5
24
23 21 29 2
28
22 3
16 10
11
19
27
1 18
7 L
25
20 26
13
L 4
15 14
6
12
17
5
24
23 21 29 2
28
22 3
16 10
11
19
26 6 5 1
4
3
SAE-8
SAE-6
SAE-8 SAE-8
7
15 14
HY DR A HY
D
FO
R
XX X X
AF
RCE
XX
O RCE
XX
XX
IN
X
X C. IN
C.
SAE-8
HY
D
R
XX X X
AF
O RC E
XX
IN
C.
X
XX
HY
XX
D RA F
O
. R
CE
I NC
SAE-8
HY
D
ORCE
8
AF
R
XXXX
R
AF
D
IN
HY
OR CE
C.
17 18 16
XX
XX
XX XX IN
C.
SAE-8
SAE-6 SAE-12
SAE-8
LARGE PUMP
SMALL PUMP
STEER RIGHT
STEER LEFT
TANK
MAIN
BRAKE
SAE-8
TANK
10
20
CENTER DRIVE
CENTER DRIVE
BRAKE CYLINDER
CENTER DRIVE
CENTER DRIVE
27
21
25 12 28
22 11
23 12
8
V1 10
V2
24 21 13
M11339AB
8
3
7
4
MLP-1018AA
Index Skyjack
Qty. Description
No. Part No.
2
1
4
8
3
7
M11116AC
Index Skyjack
Qty. Description
No. Part No.
16
15
18
13
10
5 2 23
15
11
15
19 1
20
20
10
21 7
20 23 3 17
9
4
20
12 22
10 6 11
8
10 14
15
15
16
M50150AC
31 30
32
33
14
18
17
16 L
13
1
28
L
15
29
5
23 7
11
9
19 20
10 6 23 21 8 23 M10981AB
27
24
25
3 4 22 12
26
M10982AA
31 30
32
33
14
18
17
16 L
13
1
28
L
15
29
5
23 7
11
9
19 20
10 6 23 21 8 23 M10981AB
27
24
25
3 4 22 12
26
M10982AA
L
7
4
8
3
1 L 5
ML1F-1013AB
26
24
27 29
25
23
29 1
22
28
21
5 4
18
20
19
16
7
15 17
8 14
6
12
11 13
10
9
ML1F-1004AB
11 10 9 8 7
14
12
14
5
14
14
13 4
M128847AD
1 2 3
M371C
6 12 13 14 15 5 4
7
8
8
9
9
10 10
11 11
M371-3
26
25
24
23
22
21
20
19
18
17
16
1
15
2
14
3 13
4 12
5 11
K4 10
6 9
7 8
M371-2
1 2 K1 3 15
4 14
5
K2
K3
10
11 12 13
M371-001
6
1
7
2
5
M371-002
Index Skyjack
Qty. Description
No. Part No.
1 2 3 4
M371-002SH
Index Skyjack
Qty. Description
No. Part No.
10
11
12
13
14
15
7
16
17
6
M11453AA
11 12 13 14
16 15
10
2
9
21
18
GEAR OIL
19
3
6 17 20 1
5 4
M116098AF
37
35
36
35
34
33
32
28
38 29
39 30
40 31
47 46 41
21
42
1 11
22
23
20
45 43 24
44
19 25
26
27
18 17
15
16 14
13
12
5 11
6
10
9
4 8
7
MTIF-1028AD_1
37
35
36
35
34
33
32
28
38 29
39 30
40 31
47 46 41
21
42
1 11
22
23
20
45 43 24
44
19 25
26
27
18 17
15
16 14
13
12
5 11
6
10
9
4 8
7
MTIF-1028AD_1
2 3
4
5
1
13 13
6 15
12
14 15
13
12
13
11
10
8 7 ML1F-1005AA
Index Skyjack
Qty. Description
No. Part No.
B 4
12 5 9
3
2
10
11
4
1
M11515AA
M10788AB
Index Skyjack
Qty. Description
No. Part No.
3 5
8
6
8 7
2
M10377AA
Index Skyjack
Qty. Description
No. Part No.
8 10
11
7
12
6
13
5 4
4 14
15
3
2 1
17 16 18 16
19
20
M10500AB
15
5 4
10
11
12
14 13
M11295AB
1
16
15
K1
14
13
3
4 12
5 K2 6 7 K3 8 9 10 11
M370
11
10
9
8
7
2
1
M11512AA
8
17 9
18 16 10
14 11
15 12
14 13
19
20 6
27
21
22
23
24
28
25 7
26 6
5
1 2
MTID-1029AA
10
12
11
4
5
6
3
13
2
1
2
ML1F-1002AA
7
8
9
10
11 12
2
3
ML1F-1003AA
Index Skyjack
Qty. Description
No. Part No.
2 9 10 3 4
37
38 21 20 18 19 20 21 38
1
35 23 19 20 22
24
18 38 22
36 16
26 13 33
9 12 13
27 11
10
23
9 5
6
17 7
28
27
15
8
9
10
11
34
27
29
31
30 32
14
M11338AH_1
2 9 10 3 4
37
38 21 20 18 19 20 21 38
1
35 23 19 20 22
24
18 38 22
36 16
26 13 33
9 12 13
27 11
10
23
9 5
6
17 7
28
27
15
8
9
10
11
34
27
29
31
30 32
14
M11338AH_1
8 5
12
7 4
6
3
L 2 1
9 10 9 10
1 L 11
M11235AB
25
6
26
23 24
20 3 16
1 19
36
30 13
15
5 8 10
9
14
2
12
32
11
21
4
35 34
38 7
37
22
39 40
31
29
17
18
28
32 27
36
33
M11347AB
25
6
26
23 24
20 3 16
1 19
36
30 13
15
5 8 10
9
14
2
12
32
11
21
4
35 34
38 7
37
22
39 40
31
29
17
18
28
32 27
36
33
M11347AB
25
6
26
23 24
20 3 16
1 19
36
30 13
15
5 8 10
9
14
2
12
32
11
21
4
35 34
38 7
37
22
39 40
31
29
17
18
28
32 27
36
33
M11347AB
M11467AA_1
*Note: Part No. 134770 is used only for machines in the table below.
9 18
10
29
4 5 6 8
25 24 23 22 21 3
7 11 12 28 14 19
17 1 2
15 13 14
21 26 14
20
27 16
M11349AA
3 4
10 5
6
7
9 M11242AA
Index Skyjack
Qty. Description
No. Part No.
A (Ref.) - ASSEMBLY, EFI system components
4
5
2 3
5
7
8
M11243AB
Index Skyjack
Qty. Description
No. Part No.
9 7 17 19 18
8 6
10
11
17
19 12
6 16
4
15
5 13 14
3
M11241AD
Index Skyjack
Qty. Description
No. Part No.
1 2 3 8 9
32
5 6 7
10
13 12 11
19
18
16
15 17
Starter 14
25 23
21
29 11 20
22
23
30 31
24
27
26
28
M11378AB M139452AD_1
1 2 3 8 9
32
5 6 7
10
13 12 11
19
18
16
15 17
Starter 14
25 23
21
29 11 20
22
23
30 31
24
27
26
28
M11378AB M139452AD_1
1 2 3 8 9
32
5 6 7
10
13 12 11
19
18
16
15 17
Starter 14
25 23
21
29 11 20
22
23
30 31
24
27
26
28
M11378AB M139452AD_1
28 - - RADIATOR ASSEMBLY
(Machines with Serial #’s 37686 (8831), 43546 (8841) and Above)
139380 1 • ASSEMBLY, Radiator
139467 1 • PIPE, Lower water
139381 1 • PIPE, Upper water
132898 2 • CUSHION, Radiator
132899 2 • CUSHION, Radiator
132901 1 • SUPPORT, Radiator
132902 1 • SUPPORT, Radiator
132903 2 • STAY, Radiator
132904 1 • STAY, Radiator
29 102984 73” FUEL LINE, (5/16)
(Machines with Serial #’s 37686 (8831), 43546 (8841) and Above)
30 147142 1 RESERVOIR, Coolant
(Order Part # 132519 for Machines with S/N 37686 to 34001164 (8831),
43546 to 40000377 (8841))
31 - - HARDWARE, Coolant reservoir (Machines with 34001165 (8831),
40000378 (8841) and Above)
103887 2 BOLT, Hex head (5/16-18 x 0.75, Grade 5)
103996 2 WASHER, Flat (5/16)
100397 2 NUT, Hex head (5/16-18 Grade 5)
103404 2 WASHER, Lock (5/16)
- - HARDWARE, Coolant reservoir (Machines with Serial #’s 37686 to
34001164 (8831), 43546 to 40000377 (8841))
103995 2 • WASHER, Flat (1/4)
104000 2 • WASHER, Lock (0.25)
103892 2 • BOLT, Hex head (1/4-20 x 0.625 Grade 5)
103980 2 • NUT, (1/4-20)
32 (Ref.) - EXHAUST MANIFOLD ASSEMBLY
(For components, refer to Figure 6.6-13)
5 9
6
4
3
10
2
M11064AB
1 1
10
2 1
4
6
7
3
4 3
4
6 4
5 7 5
8
8
M11381AB M133945AD
Index Skyjack
Qty. Description
No. Part No.
2 3 4 5
M10341AA
Index Skyjack
Qty. Description
No. Part No.
4 1 2 3
6 7 5
M11420AA
Index Skyjack
Qty. Description
No. Part No.
2 36 37 38
34 35
1 26
16 23
32
3 17
18 21 24
4
11
22
5 12
23
6 13
25
14 27
7
15 19
23
17
20
29
30 32 7
23
31
8 9
10 9
6 7
28
33
M141849AC
2 36 37 38
34 35
1 26
16 23
32
3 17
18 21 24
4
11
22
5 12
23
6 13
25
14 27
7
15 19
23
17
20
29
30 32 7
23
31
8 9
10 9
6 7
28
33
M141849AC
39 38 37 36
2 29 28
3 1
4
27
7 6
24
25
22 23
9 8 26
30
16 17 18 19
10
15
31
35
33
34
11
33
32
12
13 14
20 21 40 41
M142207AA_1
39 38 37 36
2 29 28
3 1
4
27
7 6
24
25
22 23
9 8 26
30
16 17 18 19
10
15
31
35
33
34
11
33
32
12
13 14
20 21 40 41
M142207AA_1
1
7
3
2
12 5 6
11
10
M 142207AA_3 M143487AA
15 16 17 18
1003
10A
32A
10A
10A
10A
10A
50
05
07
1 12
DEUTSCH
2 11
3 10
4 9
5 8
6 7
1
2
3
4
1
6 7 8 9 10 12 13 14
1 2
8
9
M142399AB
12 20
7 8 18 21 19 27
28
22 23 24 25 26 10
17 19
29
31 30
13 14 15 16
32 19 20 32 33 19 34 35 36
12
11
37
5 9 10
32 19 32
38 7 8 18
5 6 7 8
3 4 39 39
40
41
1 2
M142206AB
6
2 3
4 4 3 2
12
13
To Main
Manifold
7
Lower
Ports
5 Upper
Ports
14
11
9
8
2 3 10 3 2
6
13
12 10
11
14 15
16 25
17
18
19
23
24 1
20 21 25
15
22 26
12
17
13
4 3
27 L
8
28
5 7
29
6
30
2
31
M132697AD
3
4 8
13
5
1 12
9 14
7
6
4 11 17
10
15
16
M10373AB
Index Skyjack
Qty. Description
No. Part No.
3 9 5
7
8
4
ML1F-1017AB
Index Skyjack
Qty. Description
No. Part No.
1 2 3
4 5
1
2
8
5 9
M11403AC
Index Skyjack
Qty. Description
No. Part No.
1 2
4 6
M11404AB
Index Skyjack
Qty. Description
No. Part No.
18
6
5
4
1 3
16 2
17
16 7
8
9
15
10
13 11
14 12
M11280AA
1 4
2 3 5 6 7 8
10 11
27 26 12
25
24
23 22 21 17 18 19 20
16 15 14 13
M11426AB
3 2 3
4 5 6 7
M11428AB
Index Skyjack
Qty. Description
No. Part No.
1 2 3
6 5 4 3
7
8
2
5
4
9
17
14 13 12 VIOLET WIRE
34CR
11 10 4
15 4 3
18 19
16 TERMINAL BLOCK - #33
ELECTRIC PANEL
20
22 23
POSITIVE NEGATIVE
21
11411AA
ML3F-1017AA
Index Skyjack
Qty. Description
No. Part No.
8
13
6
12
10
3
1
11
7
14
ML2F-1004AB
8
13
6
12
10
3
1
11
7
14
ML2F-1004AB
3 6
5
4
M137979AB
Index Skyjack
Qty. Description
No. Part No.
Label Kits
The following label kits are for models SJ 8831 and 8841. Each contains labels that are common to both
machines.
It excludes:
• serial numbers
• nameplates
• registrations
• stripes
• tapes
• platform capacities
• model designations
• all special options
There are two kits for these machines, one for ANSI/CSA and one for CE. Supply model number, country and
language when ordering complete machine labels. Items with * are part of the label kit.
Label Kit
MODELS ANSI/CSA CE
Part # 129984 Part # 129985
TM
2 28
3 4
6
1
8 29
24
12
11
7
10
BASE CONTROL
BOX LIFT CYLINDER MANUAL BOX OUTLET BOX EXTENSION PLATFORM
22
21
19
16
17 9
14 15 18
HYDRAULIC/ELECTRIC CABINET
13 20
23
(GASOLINE/DUAL) (DIESEL)
M11005AA_1B
13
12
11
10
9
1
2
3 8
4
5
6
7
14
M11015AC
1 2 3 4 5 6 7 8 9
25
18
26 24 22 30
14
17
21
8
15 35
19 20
10 11 13 12 16 23
33 34
25
27
28
27
32 31
29
M11008AD
M11523AA
HYDRAULIC OIL
*Qty. *Qty. Skyjack
Model Oil Type
(Liters) (Gallons) Part No.
SJRT-68XX 86.88 22.95
SJRT-7127
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850
ATF Dexron III 119309
SJRT-8831
SJRT-8841
75.71 20
SJRT-8831E
SJRT-8841E
SJRT-9250 67.38 17.8
ENGINE COOLANT
*Qty. *Qty. Skyjack
Component Type **Coolant Type
(Liters) (Gallons) Part No.
Kubota D902
Kubota D1105 3.1 0.82
Anti-freeze / Water 125985
Kubota DF972
Nissan A15
11.4 3.01
GM 1.6 Extended life anti-freeze / Water 142208
ENGINE FUEL
Tank Diesel Gasoline / Liquid Propane
Model *Qty. *Qty.
Kubota D902 Kubtoa D1105 Kubota DF972 GM 1.6 Nissan A15
(Liters) (Gallons)
SJRT-68xx 86.88 22.95 � N/A
SJRT-7127 � N/A
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850 N/A �
SJRT-8831 N/A �
49.21 13
SJRT-8841
SJRT-9250 64.35 17
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