194313AC

SERVICE MANUAL
ARTICULATING BOOMS
MODELS SJ46AJ SJ51AJ
194313AC October 2015

This manual is based on Serial Number(s):
SJ46AJ & SJ51AJ: 95 001 105 & Above
Please refer to the website (www.skyjack.com) for older Serial Numbers.
Skyjack Service Center Parts & Service (Europe)

3451 Swenson Ave. St. Charles, Unit 1 Maes Y Clawdd
Illinois, 60174 USA Maesbury Road Industrial Estate
Phone: 630-262-0005 Oswestry, Shropshire SY10 8NN UK
Toll Free: 1-800-275-9522 Phone: +44-1691-676-235
Fax: 630-262-0006 Fax: +44-1691-676-238
Email: service@skyjack.com E-mail: info@skyjackeurope.co.uk
Parts (North America) Skyjack Brasil

Toll Free: 1-800-965-4626 Alameda Júpiter, 710
Toll Free Fax: 1-888-782-4825 Loteamento American Park Empresarial
E-mail: parts@skyjack.com Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
Skyjack Australia Pty Ltd.
4 Coates Place
Wetherill Park
New South Wales 2164
Australia
Tel: +61 (0) 28786 3200
Fax: +61(0) 28786 3222
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance

Table of Contents
Section 2 - Maintenance Tables

Table of Contents
Section 3 - System Component Identification and Schematics

Table of Contents
Section 4 - Troubleshooting
Table of Contents
Section 5 - Procedures
Table of Contents
Articulating Boom Series December 2007

Model SJ46AJ & SJ51AJ Page 3
194313
The Safety Alert Symbol identifies important
safety messages on aerial platforms, safety This Safety Alert Symbol means attention!
signs in manuals or elsewhere. When you
see this symbol, be alert to the possibility of Become alert! Your safety is involved.
personal injury or death. Follow the instructions
in the safety message.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
IMPORTANT
IMPORTANT indicates a procedure essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.
Articulating Boom Series

Page 4 December 2007 Model SJ46AJ & SJ51AJ
194313
1
Section 1
SCHEDULED MAINTENANCE
Table of Contents
Operator’s Responsibility for Maintenance

Aerial Platform Definition...............................................................................................................................................6
Purpose of Equipment .................................................................................................................................................6
Use of Equipment.........................................................................................................................................................6
Manuals.........................................................................................................................................................................6
Service Policy and Warranty.........................................................................................................................................6
Operator Safety Reminders, Warnings, and Precautions............................................................................................6
Maintenance and Inspection Schedule........................................................................................................................7
Owner’s Annual Inspection Record..............................................................................................................................7
Replacement Parts........................................................................................................................................................7
Maintenance and Service Safety Tips..........................................................................................................................7
Hydraulic System & Component Maintenance and Repair.........................................................................................8
Maintenance Hints........................................................................................................................................................8
Service and Maintenance

About this Section.........................................................................................................................................................9
Service Bulletins............................................................................................................................................................9
Maintenance and Inspection........................................................................................................................................9
Maintenance Instructions..............................................................................................................................................9
Tables
Table 1.1 Owner’s Annual Inspection Record...........................................................................................................10
Table 1.2 Pre-Delivery/Maintenance Inspection Checklist........................................................................................11
Scheduled Maintenance Inspections and Function Tests

1.1 Scheduled Maintenance Inspections...............................................................................................................12
1.2 Function Tests..................................................................................................................................................23

194313
Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform Definition

A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Articulating Boom Series (Models SJ 46A, 46AJ, & 51AJ) aerial platform is designed to transport and
raise personnel, tools and materials to overhead work areas
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.
Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Service & Maintenance

The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Service Policy and Warranty

SKYJACK warrants each new SJT series work platform to be free of defective parts and workmanship for the first
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact SKYJACK Service Department for warranty statement extensions or exclusions.
Operator Safety Reminders, Warnings, and Precautions

Operator safety is SKYJACK’s priority. The operator should comply with all applicable safety-related reminders,
warnings and precautions found in the Operating Manual. They should be read and understood completely before
operating the aerial platform.

194313
Section 1 - Scheduled Maintenance Operator’s Responsibility for Maintenance
Maintenance and Inspection Schedule Maintenance and Service Safety Tips

The actual operating environment of the work platform Maintenance and repair should only be performed by
governs the use of the maintenance schedule. The personnel who are trained and qualified to service this
inspection points covered in Table 1.2. Maintenance aerial platform.
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at All maintenance and service procedures should be
what intervals the maintenance and inspections are to performed in a well lighted and well ventilated area.
be performed.
Anyone operating or servicing this aerial platform
Owner’s Annual Inspection Record must read and completely understand all operating
It is the responsibility of the owner to arrange quarterly instructions and safety hazards in this manual and
and annual inspections of the aerial platform. Table 1.1. operating manual.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name, All tools, supports and lifting equipment to be used
and the person responsible for the inspection of the must be of proper rated load and in good working order
work platform. before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
Replacement Parts components while servicing.
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and All service personnel must be familiar with employer
dimensions different from original parts will affect and governmental regulations that apply to servicing
stability of the aerial platform and must not be used this type of equipment.
without manufacturer’s consent.
Keep sparks and flames away from all flammable or
All replacement tires must be of the same size and load combustible materials.
rating as originally supplied tires; to maintain safety and
stability of aerial platform. Properly dispose of all waste material such as lubricants,
rags, and old parts according to the relative law
Consult SKYJACK’s Service Department for optional provisions obtaining in the country.
tires specifications and installation.
Before attempting any repair work, turn Battery
Disconnect Switch to “ ” off position.
WARNING
Any unit that is damaged or not operating Preventive maintenance is the easiest and least
properly must be immediately tagged and expensive type of maintenance.
removed from service until proper repairs
are completed.

194313
Operator’s Responsibility for Maintenance Section 1 - Scheduled Maintenance
Hydraulic System & Component 7. All hydraulic components must be disassembled

Maintenance and Repair in spotlessly clean surroundings. During
The following points should be kept in mind when disassembly, pay particular attention to the
working on the hydraulic system or any component: identification of parts to assure proper reassembly.
Clean all metal parts in a clean mineral oil solvent.
Be sure to thoroughly clean all internal passages.
WARNING
After the parts have been dried thoroughly, lay
Escaping fluid from a hydraulic pressure them on a clean, lint-free surface for inspection.
leak can damage your eyes, penetrate the
skin and cause serious injury. Use proper 8. Replace all O-rings and seals when overhauling
personal preotection at all times. any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
1. Any structure has limits of strength and durability. amounts of petroleum jelly to hold O-rings in place
To prevent failure of structural parts of hydraulic during assembly.
components, relief valves which limit pressure to
safe operating values are included in the hydraulic 9. Be sure to replace any lost hydraulic oil when
circuits. completing the installation of the repaired
component, and bleed any air from the system
2. Tolerance of working parts in the hydraulic system when required.
is very close. Even small amounts of dirt or foreign
materials in the system can cause wear or damage 10. All hydraulic connections must be kept tight. A
to components, as well as general faulty operation loose connection in a pressure line will permit
of the hydraulic system. Every precaution must the oil to leak out or air to be drawn into the
be taken to assure absolute cleanliness of the system. Air in the system can cause damage
hydraulic oil. to the components and noisy or erratic system
operation.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are metal Maintenance Hints
particles or foreign materials in the system, drain Three simple maintenance procedures have the
and flush the entire system and replace the filter greatest effect on the hydraulic system performance,
cartridges. A complete change of oil must be efficiency and life. Yet, the very simplicity of them may
performed under these circumstances. be the reason they are so often overlooked. They are
simply these:
4. Whenever the hydraulic system is drained, check
the magnets in the hydraulic reservoir for metal 1. Change filters annually. The filters will need
particles. If metal particles are present, flush the to be changed more often depending on the
entire system and add a new change of oil. The operating conditions. Dirty, dusty, high moisture
presence of metal particles also may indicate the environments may cause the hydraulic system to
possibility of imminent component failure. A very be contaminated more quickly.
small amount of fine particles is normal.
2. Maintain a sufficient quantity of clean hydraulic oil
5. All containers and funnels used in handling of the proper type and viscosity in the hydraulic
hydraulic oil must be absolutely clean. Use a reservoir.
funnel when necessary for filling the hydraulic oil
reservoir, and fill the reservoir only through the 3. Keep all connections tight.
filter opening. The use of cloth to strain the oil
should be avoided to prevent lint from getting into
the system.
6. When removing any hydraulic component, be sure

to cap and tag all hydraulic lines involved. Also,
plug the ports of the removed components.

194313
Section 1 - Scheduled Maintenance Service and Maintenance
About this Section Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four schedules to be done for
schedule that is to be performed. maintaining on an aerial platform. Inspection schedule
frequency is shown below:
References are made to the procedures in Section 5
that outline detailed step-by-step instructions for checks Inspection Schedule
and replacements. PDI / Frequent B
Annual B+C
Additional *
Service Bulletins
Before performing any scheduled maintenance
B - Perform PDI prior to each delivery, or Frequent
inspection procedure, refer to service bulletins found in
Inspection every 3 months or 150 hours.
our web site: www.skyjackinc.com for updates related
C - Perform Scheduled Maintenance Inspections
to service and maintenance of this aerial platform.
every year.
* - Perform at time sensitive maintenance intervals.
Maintenance and Inspection
Death or injury can result if the aerial platform is not kept • Make copies of the maintenance and inspection
in good working order. Inspection and maintenance checklist to be used for each inspection.
should be performed by competent personnel who • Check the schedule on the checklist for the type of
are trained and qualified on mantenance of this aerial inspection to be performed.
platform. • Place a check in the appropriate box after each
inspection procedure is completed.
WARNING • Use the maintenance and inspection checklist and
step-by-step procedures in Section 1 to perform
Failure to perform each procedure as pre-
these inspections.
sented and scheduled may cause death,
• If any inspection receives a fail, tag and remove the
serious injury or substantial damage.
aerial platform from service.
• If any aerial platform component(s) has been
NOTE
repaired, an inspection must be performed again
Preventive maintenance is the easiest and
before removing the tag. Place a check in the repair
least expensive type of maintenance.
column.
• Unless otherwise specified, perform each
Legend
maintenance procedure with the aerial platform in
P = Pass
the following configuration:
F = Fail
R = Repaired
- Aerial platform parked on a flat and level
N/A = Not applicable
surface
- Disconnect the battery by turning the main
power disconnect switch to “ ”off position.
• Repair any damaged or malfunction components

before operating aerial platform.
• Keep records on all inspections.

194313
Service and Maintenance Section 1 - Scheduled Maintenance
Table 1.1 Owner’s Annual Inspection Record
Model Number: _________________ Serial Number:__________________
* 20__ 20__ 20__ 20__ 20__ 20__ 20__ 20__ 20__
**
1001AB
This decal is located on the control compartment cowling. It must be completed after an annual inspection has been
completed. Do not use the aerial platform if an inspection has not been recorded in the last 6 months.
Pictorial Description
Inspection Date
Inspector Signature
**

194313
Section 1 - Scheduled Maintenance Service and Maintenance
Pre-Delivery/Maintenance Inspection Checklist

Articulating Booms & Telescopic Booms
Serial Number: Product Owner:
Model:
Hourmeter Reading: Product User:
Date/Time:
Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to the
applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection Intervals,
etc.).
Inspection Type Schedule
 PDI B B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 150 hrs. For further details refer to Service P - Pass
 Frequent B & Operating Manuals. F - Fail
 Annual B+C C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals. R - Repaired
 Additional * * - Perform time sensitive maintenance intervals. Refer to the Service Manual. N/A - Not Applicable
Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided.
Items for Inspection P F R N/A Items for Inspection P F R N/A

Refer to skyjack.com for the latest service bulletins. B, C Fuel Tank Leaks. Tight fittings and hoses & no damage or
B
Ensure Annual Inspection has been completed within the leaks.
B
last 13 months. Base Weldment. No cracks or deformation. B
Manuals & Required Documents. In storage box, in Turret Transportation Lock. Unlocked & no damage or
B B
good condition & legible. missing parts.
Labels. In place, secure & legible. B Drive Axle. Secure & no missing parts. Tight fittings and
B, C
Limit Switches. Secured & no obstructions or damage. B hoses & no leaks.
Main Power Disconnect Switch. Cables secure & in Oscillating Cylinder Assembly. Secure & no missing
B B, C
working order. parts. Tight fittings and hoses & no leaks.
Battery. No damage, tight connections, adequate fluid Steer Cylinder Assembly. Secure & no missing parts.
B B
levels. Clean terminals and cable ends. Tight fittings and hoses & no leaks.
Swing Drive Motor. Tight fittings, hoses & bolts. No Pins & Bushings. No damage/wear, or loose or missing
B, C B
damage, missing parts or leaks. parts.
Turret Rotation Gear. No damage or missing parts. B, C Steer Linkage. No damage/wear or missing parts. B
Rotary Manifold. Tight fittings & hoses, & no leaks. B Wheel/Tire Assembly. Check all tires for damage, wear
B, C
High Pressure Filter. Secure & no damage or leaks. B, C & proper alignment. Lug nuts torqued as recommended.
Hydraulic Pumps. Tight fittings, hoses & bolts. No Platform Assembly. No damage or missing parts. B
B
damage, missing parts or leaks. Raillings and Gate. Secure & no damage or missing parts. B
Muffler and Exhaust. Secure & no damage. B Lanyard Attachment Anchorage. Attachment rings
B
Engine Pivot Tray. Secure & no damage or missing parts. B secure & no damage.
Engine Oil. Level in the "safe" zone. Ensure oil change Platform Control Console. Switches in neutral position &
B B
interval has not been exceeded. secure. No damage or missing parts.
Engine Air Filter. No damage or missing parts. B, C Rotary Actuator. No damage or missing parts. Tight
B
Engine Fuel Leaks. No damage or leaks from tank, fittings, hoses and bolts & no leaks.
B, C
shutoff valve & hoses and fittings. Jib. No damage or missing parts. Tight hoses and bolts &
B
Engine Fuel Filter. No damage, missing parts or leaks. B, C no leaks.
Base Control Console. Switches in neutral position & no Boom. No damage or missing parts. No deformation or
B B
damage or missing parts. cracks in welds. Tight hoses and bolts & no leaks.
Hydraulic Tank. Filler cap secure & no damage or leaks. B Control Cables and Hoses. No damage or missing parts.
Hydraulic Oil. Level between min. & max. marks. *, B No spring gaps. Ensure Inspection Interval has not been *, B
Hydraulic Filter. Secure & no damage, missing parts or exceeded.
B, C
leaks. Riser. Secure & no damage/deformation or missing parts. B
Brake & Main Manifolds. Tight fittings and hoses & no Cylinders. Secure & no damage or leaks. B
B, C
leaks. Tight wire connections. Wear Pads. No damage or missing parts. Bolts tightened. B
Emergency Power Unit. Tight fittings and hoses & no Cable Carrier. No damage or missing parts. B
leaks. Tight wire connections & no damage or missing B Special Options and Approved Attachments. Secure &
parts. no damage or missing parts.
Fuel Tank. Filler cap is secure & no damage or leaks. B, C Function Tests (Refer to your corresponding Serial #'s Operating  PASS
Manual for information on running these tests.)  FAIL
Comments:
The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner. Furthermore, the
undersigned confirms that all discrepancies have been corrected prior to using this machine.
Owner: ________________________________________________ / _____________________________________________ / ___________________________________________________

Print Name Signature Date (DD/MM/YY)
User: _________________________________________________ / _____________________________________________ / ___________________________________________________

Print Name Signature Date (DD/MM/YY)
Note: Visit skyjack.com for a printable copy of this form. 167834AA

194313
Scheduled Maintenance Inspections Section 1 - Scheduled Maintenance
Manual Box
Platform
Assembly
1.1 Scheduled Maintenance Inspections Hydraulic

Begin the visual and daily maintenance inspections Maintaining hydraulic components is essential to good
by checking each item in sequence for the conditions performance and service life of the aerial platform.
listed in this section.
Perform a visual inspection around the following areas:
WARNING • hydraulic tank filter, fittings, hoses, emergency
power unit and turret/base surface
To avoid injury, do not operate an aerial • engine compartment fittings, hoses, main
platform until all malfunctions have been pump, filter and turret/base surface
corrected. • all hydraulic cylinders
• all hydraulic manifolds
WARNING • the underside of the turret
• the underside of the base
To avoid possible injury, ensure aerial
• ground area under the aerial platform
platform power is off during your visual
and daily maintenance inspections.
1.1-1 Manuals & Required Documents(B)
Ensure a copy of the operating manual and other
Electrical
important documents are enclosed in the manual
Maintaining electrical components is essential to good
storage box.
performance and service life of aerial platform.
-- Check to be sure manual storage box is
Perform a visual inspection around the following areas:
present and in good condition.
• boom to platform cable harness
• engine compartment electrical panel -- Ensure manuals are legible and in good
• engine wiring harness condition.
• rotary manifold wiring
-- Always return manuals to the manual storage
box after use.
1.1-2 Labels (B)

Refer to the labels section in the operating manual and
ensure that all labels are in place and are legible.

194313
Section 1 - Scheduled Maintenance Scheduled Maintenance Inspections
Muffler
High Pressure
Filter
Air Filter
Swing Drive
Motor Battery
Charge
Indicator
Main Power
Disconnect
Switch
1.1-3 Limit Switches (B)

Detecting limit switch malfunction is essential to safe • Batteries (B)
aerial platform operation. Ensure limit switches are Proper battery condition is essential to good
properly secured with no signs of visible damage and engine performance and operational safety.
movement is not obstructed. Improper fluid levels or damaged cables and
connections can result in engine component
Visually inspect all limit switch located inside the turret damage and hazardous conditions.
and under the power track. Inspect for the following: WARNING
• broken or missing actuator arm Explosion hazard. Keep flames and
• missing fasteners sparks away. Do not smoke near
• loose wiring batteries.
1.1-4 Engine Compartment WARNING

Ensure all compartment latches are secure and in Battery acid is extremely corrosive -
proper working order. Wear proper eye and facial protection as
well as appropriate protective clothing.
• Main Power Disconnect Switch (B) If contact occurs, immediately flush with
-- Turn main power disconnect switch to cold water and seek medical attention.
“ ” off position.
1. Check battery cases for damage.
-- Ensure there are no loose or
missing parts and there is no
2. B - Frequent Inspection
visible damage.
Clean battery terminals and cable ends
-- Ensure all cables are secure thoroughly with a terminal cleaning tool or
and switch is in proper working condition. wire brush.
3. Ensure all battery connections are tight.

194313
Muffler
High Pressure
Filter
Air Filter
Swing Drive
Motor Battery
Charge
Indicator
Main Power
Disconnect
Switch
4. If applicable, check battery fluid level. -- For brake/motor oil replacement

procedure, refer to 5.3-6 Swing Drive
B - Frequent Inspection Brake and Gearbox Oil Replacement.
If plates are not covered by at least 13 mm
(1/2”) of solution, add distilled or demineralized • Turret Rotation Gear (B,C)
water. -- Ensure there are no loose or missing
parts and there is no visible damage.
5. B - Frequent Inspection C - Annual Inspection
Replace battery if damaged or incapable of -- For lubrication procedure, refer to
holding a lasting charge. Deutz Diesel Engine.
• Charge Indicator - CE (B)

-- Ensure there are no loose or missing • High Pressure Filter (B,C)
parts and there is no visible damage. -- Ensure housing is secure and shows no
visible damage or leakage.
WARNING
C - Annual Inspection
Use original or manufacturer-approved -- For filter element replacement procedure,
parts and components for the aerial refer to 5.3-1 High Pressure Filter
platform. Replacement.
• Swing Drive Motor (B,C)

-- Ensure there are no loose or missing • Hydraulic Pumps (B)
parts and there is no visible damage. -- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure all bolts are properly tightened.
-- Ensure all bolts are properly tightened.
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of -- Ensure all fittings and hoses are properly
hydraulic leakage. tightened and there is no evidence of
hydraulic leakage.

194313
Muffler
High Pressure
Filter
Air Filter
Swing Drive
Motor Battery
Charge
Indicator
Main Power
Disconnect
Switch
• Muffler and Exhaust (B) • Engine Air Filter (B,C)

-- Ensure muffler and exhaust system are -- Ensure there are no loose or missing
properly secured, with no evidence of parts and there is no visible damage.
damage.
B - Frequent Inspection
-- For engine air filter maintenance
• Engine Pivot Tray (B) procedure, refer to engine manual.
-- Ensure there are no loose or missing
parts and no visible damage to the engine
-- For engine air filter replacement
pivot tray. Ensure that each tray-securing
procedure, refer to engine manual.
bolt is in place.
• Engine Fuel Leaks (B,C)
-- Ensure that there no fuel leaks.
• Engine Oil Level (B)
-- Maintaining the engine components DANGER
is essential to good performance and
service life of the aerial platform. Engine fuels are combustible. Inspect
the aerial platform in an open, well-
WARNING ventilated area away from heaters,
sparks and flames. Always have an
Beware of hot engine components.
approved fire extinguisher within easy
reach.
Check oil level on dipstick
-- Oil level should be in the “safe” zone.
-- Ensure fuel tank, shutoff valve, hoses and
Add oil as needed. Refer to Figure Table
fittings show no visible damage and no
2.12 Specifications and Features for
evidence of fuel leakage.
recommended oil type.
B - Frequent Inspection • Engine Fuel Filter (B,C)
-- For recommended oil change, refer to -- Ensure there are no loose or missing
engine manual parts and there is no visible damage.
-- For engine fuel filter replacement
procedure, refer to engine manual.

194313
Brake Manifold Main Manifold
Hydraulic In-Tank
Filter
Base Control
Console
Hydraulic Tank
Fuel Tank
Emergency Power
Unit
1.1-5 Control Compartment • Hydraulic In-Tank Filter (B,C)

-- Ensure all compartment latches are
secure and in proper working order. C - Annual Inspection
-- For hydraulic in-tank filter replacement
• Base Control Console (B) procedure, refer to 5.3-3 Turret Rotation
-- Ensure all switches are returned to their Gear Backlash Adjustment.
neutral positions.
-- Ensure there are no loose or missing • Brake and Main Manifolds (B,C)
parts and there is no visible damage. -- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
• Hydraulic Tank (B)
-- Ensure hydraulic filler cap is secure. -- E n s u r e t h e r e a r e n o l o o s e w i r e
connections or missing fasteners.
-- Ensure tank shows no visible damage
and no evidence of hydraulic leakage.
• Emergency Power Unit (B)
• Hydraulic Oil (*,B) -- Ensure there are no loose or missing
-- Be sure that the boom is in the stowed parts and there is no visible damage.
position, and then visually inspect the
-- E n s u r e t h e r e a r e n o l o o s e w i r e
sight gauge located on the side of the
connections or missing fasteners.
hydraulic oil tank.
-- Ensure all fittings and hoses are properly
-- The hydraulic oil level should be between
the minimum and maximum marks on the
hydraulic leakage.
sight glass. Add oil as needed. Refer to
Table 2.9 Specifications and Features for
recommended oil type.
* - Bi-Annual Inspection
-- For hydraulic oil replacement procedure,
refer to 5.7-1 Hydraulic Oil
Replacement.

194313
Brake Manifold Main Manifold
Hydraulic In-Tank
Filter
Base Control
Console
Hydraulic Tank
Fuel Tank
Emergency Power
Unit
• Fuel Tank (B,C) • Fuel Leaks (B)

-- Ensure that there no fuel leaks.
IMPORTANT
Before using your aerial platform DANGER
ensure there is enough fuel for Engine fuels are combustible. Inspect
expected use. the aerial platform in an open, well-
ventilated area away from heaters,
-- Ensure fuel filler cap is secure. sparks and flames. Always have an
-- Ensure tank shows no visible damage approved fire extinguisher within easy
and no evidence of fuel leakage. reach.
-- Ensure fuel tank, shutoff valve (if

equipped), hoses and fittings show no
visible damage and no evidence of fuel
leakage.

194313
Overhead View
Tie Rod
Oscillating
Limit Switch Turret Rotation Cylinder
Gear Assembly
Drive Axle
Wheel/Tire
Assembly
Rotary
Manifold
Steer Cylinder
Assembly
1.1-6 Base • Oscillating Cylinder Assembly (B,C)

• Base Weldment (B) -- Ensure oscillating cylinder assembly is
-- Ensure there are no visible cracks in properly secured, there are no loose
welds or structure and there are no signs or missing parts, all fittings and hoses
of deformation. are properly tightened and there is no
evidence of hydraulic leakage.
• Rotary Manifold (B) -- Visually inspect the heads of the oscillating

-- Ensure lock is secure and in place. cylinder mounting bolts to ensure the
torque seal is visible and undamaged. If
-- Ensure all fittings and hoses are properly the torque seal has been damaged or is
tightened and there is no evidence of missing, remove and replace the affected
damage or hydraulic leakage. bolts. Refer to 5.9-6 Oscillating Cylinder
Bolt Replacement.
• Turret Transportation Lock (B)
-- Ensure turret transportation lock is NOTE
unlocked, there are no loose or missing Oscillating axle is locked when aerial
parts and there is no visible damage. platform is in work mode. Refer to
Diagram 2.3 Axle Oscillation Diagram.
• Drive Axle (B,C)
-- Ensure drive axle is properly secured,
• Steer Cylinder Assembly (B)
there are no loose or missing parts, all
-- Ensure steer cylinder assembly is
fittings and hoses are properly tightened
properly secured, there are no loose
and there is no evidence of hydraulic
or missing parts, all fittings and hoses
leakage.
are properly tightened and there is no
evidence of hydraulic leakage.
• Steer Linkage (B)

parts, tie rod end studs are locked and
there is no visible damage.

194313
Overhead View
Tie Rod
Oscillating
Limit Switch Turret Rotation Cylinder
Gear Assembly
Drive Axle
Wheel/Tire
Assembly
Rotary
Manifold
Steer Cylinder
Assembly
• Wheel/Tire Assembly (B,C)

Tire and/or wheel failure could result in WARNING
an aerial platform tip over. Component
damage may also result if problems are not Intermixing tires of different types or using
discovered and repaired in a timely fashion. tires of types other than those originally
supplied with this equipment can adversely
affect stability. Therefore, replace tires
WARNING ONLY with exact Skyjack-approved types.
An over-inflated tire can explode and Failure to operate with matched, approved
may cause death or serious injury. tires in good condition may result in death
or serious injury.
-- Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear. Refer to Table 2.8 Tire Specifications for wheel/
tire specifications.
-- Check each wheel for damage and cracked
welds.
-- Check each lug nut for proper torque to
ensure none are loose.
B - Frequent Inspection
-- For proper torque information, please
refer to Table 2.3 Axles Torque
Specifications.
To maximize stability, it is essential to maintain
proper pressure in all air-filled tires.
-- Check each tire with an air pressure gauge
and add air as needed.

194313
Platform Platform Control

Railing Console
Lanyard
Attachment
Anchorage
Manual Box
Footswitch
Platform
Assembly
1.1-7 Platform Assembly (B) 1.1-8 Platform Control Console (B)

-- Ensure there are no loose or missing parts -- Ensure all switches/controllers are returned
and there is no visible damage. to neutral and are properly secured.
-- Ensure all fasteners are securely in place. -- Ensure there are no loose or missing parts
and there is no visible damage.
-- Ensure all railings are properly positioned
and secured.
-- Ensure gate/drop-bar(s) are in good working
order.
-- Ensure footswitch is in good working order
and has not been modified, disabled or
blocked.
-- Ensure lanyard attachment anchorages are
secure and there is no visible damage.

194313
Wear Pads
Main and Fly Booms
Jib
Power Track
Riser
Rotary Actuator
Load Cell Cylinders
1.1-9 Rotatory Actuator (B) 1.1-12 Boom (B)

-- Ensure there are no loose or missing parts -- Ensure there are no loose or missing parts
and there is no visible damage. and there is no visible damage.
-- Ensure all bolts and pins are properly -- Ensure all bolts and pins are properly
tightened. tightened.
-- Ensure all hoses are properly tightened and -- Ensure there are no visible cracks in welds
there is no evidence of hydraulic leakage. or structure and there are no signs of
deformation.
1.1-10 Load Cell - CE (B) -- Ensure all hoses are properly tightened and
-- Ensure there are no loose or missing parts there is no evidence of hydraulic leakage.
-- Ensure all bolts are properly tightened. • Riser (B)
-- Ensure all cables are secure and are in proper parts and there is no visible damage.
working condition.
-- Ensure all bolts and pins are properly
-- Ensure debris is not lodged between the tightened.
platform and boom adaptor.
-- Ensure there are no visible cracks in
welds or structure and there are no signs
1.1-11 Jib (B) of deformation.
-- Ensure there are no loose or missing parts
• Cylinders (B)
-- Ensure all bolts and pins are properly -- Ensure all cylinders are properly secured
tightened. and there are no loose or missing parts
-- Ensure all hoses are properly tightened and and there is no evidence of damage.
there is no evidence of hydraulic leakage. -- Ensure all fittings and hoses are properly
hydraulic leakage

194313
Wear Pads
Main and Fly Booms
Jib
Power Track
Riser
Rotary Actuator
Load Cell Cylinders
• Wear Pads (B) • Cable Carrier (B)

-- Ensure all bolts are tight, there is no -- Ensure there are no loose or missing
visible damage to the wear pads and parts and there is no visible damage.
that no parts are missing.
• Control Cables and Hoses (B)

-- Ensure all hoses are properly tightened
and there is no evidence of hydraulic
leakage.

194313
Section 1 - Scheduled Maintenance Funtion Tests
1.2 Function Tests

Function tests are designed to discover any malfunctions
before aerial platform is put into service. The operator
must understand and follow step-by-step instructions
to test all aerial platform functions.
IMPORTANT
Never use a malfunctioning aerial
platform. If malfunctions are discovered,
aerial platform must be tagged and
placed out of service. Repairs to aerial
platform may only be made by a qualified
service technician.
After repairs are completed, operator must perform a

pre-operation inspection and a series of function tests
again before putting aerial platform into service.
Prior to performing function tests, be sure to read

and understand “Section 3.8 - Start Operation” of the
operating manual.
For function test that are to be performed, please

refer to the operating manual that corresponds to the
correct serial number. Found there will be detailed
instructions for which tests to preform, as well as
how to properly and successfully perform them.
NOTE
All-function motion alarm should sound
while operating any boom and drive
function.

194313
Notes

194313
Section 2
MAINTENANCE TABLES AND DIAGRAMS
Table of Contents
Tables
Table 2.1 Standard Hose Numbering System...........................................................................................................26
Table 2.2 Aerial Platform Torque Specifications........................................................................................................28
Table 2.3 Axles Torque Specifications.......................................................................................................................29
Table 2.4 Torque Specifications for Fasteners (Imperial)..........................................................................................30
2
Table 2.5 Torque Specifications for Fasteners (Metric).............................................................................................31
Table 2.6 Torque Specifications for Hydraulic Couplings & Hoses...........................................................................32
Table 2.7 Axles Maintenance Intervals.......................................................................................................................33
Table 2.8 Tire Specifications......................................................................................................................................34
Table 2.9 Maximum Platform Capacities....................................................................................................................34
Table 2.10 Floor Loading Pressure............................................................................................................................35
Table 2.11 Hydraulic Specifications...........................................................................................................................36
Table 2.12 Specifications and Features.....................................................................................................................37
Diagrams
Diagram 2.1 Dimension and Reach Diagram - SJ 46AJ...........................................................................................39
Diagram 2.2 Dimension and Reach Diagram - SJ 51AJ...........................................................................................40
Diagram 2.3 Axle Oscillation Diagram.......................................................................................................................41

194313
Service and Maintenance Section 2 - Maintenance Tables and Diagrams
Table 2.1 Standard Hose Numbering System
H1104 0081 2
FITTING LENGTH IN
ARRANGEMENT LENGTH OF HOSE IN FRACTIONS (1/4”
(See Schedule WHOLE INCHES INCREMENTS) I.E.
HOSE SIZE
Below) 1=1/4”
(See Chart
2=1/2”
Below)
3=3/4”
Using the number above as an example (H1104 0081 2). This hose requires a 37° JIC, female swivel fitting
on one end. A medium length 90° JIC, female swivel fitting for the other end. The Hose must meet or exceed
S.A.E. 100R13 hose specification, and be a total of 81-1/2” long. NOTE: Hose ends and hose must be from
same manufacturer per S.A.E. J1273 Nov. ‘91, Sections 3.10 and 4.2. Hose ends and hose must be of the
same size i.e. #4 size fittings must be used with #4 size hose.
Hose Size Chart

SIZE 03 04 06 08 10 12 16 20 24 32 40 48 56 64
ID 3/16” 1/4” 3/8” 1/2” 5/8” 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 3-1/2” 4”
S.A.E. HOSE
HOSE PREFIX HOSE END FITTING HOSE END FITTING
SPECIFICATION
H01 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H03 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R17
H05 FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R17
H06 FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17
H07 LONG 90°, FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R17
H10 FEMALE, 37° JIC, SWIVEL MALE PIPE THREAD FITTING 100R17
H11 FEMALE, 37° JIC, SWIVEL MEDIUM 90°, FEMALE, 37° JIC, SWIVEL 100R13
H12 SHORT 90°, FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17
H13 FEMALE, 37° JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI
H14 REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI
H15 REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI
Fitting Arrangement Schedule (Continued on the following page)

194313
Section 2 - Maintenance Tables and Diagrams Service and Maintenance
Table 2.1 Standard Hose Numbering System (Continued)

Fitting Arrangement Schedule (Continued from the previous page)
S.A.E. HOSE
HOSE PREFIX HOSE END FITTING HOSE END FITTING
SPECIFICATION
H16 NO FITTING NO FITTING 100R4
H17 NO FITTING NO FITTING 300 PSI
H18 REUSABLE, FEMALE, 37º JIC, SWIVEL NO FITTING 300 PSI
H19 LONG 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R13
H20 FEMALE, SHORT 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R4
H21 FEMALE, SHORT 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R2AT
H22 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R2AT
H23 FEMALE, LONG 37º JIC, SWIVEL LONG 90º, FEMALE, 37º JIC, SWIVEL 100R2AT
H24 FEMALE, SHORT 37º JIC, SWIVEL SHORT 90º, FEMALE, 37º JIC, SWIVEL 100R13
H25 FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R4
H26 SHORT 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17
H30 MEDIUM 90º, FEMALE, 37º JIC, SWIVEL FEMALE, 37º JIC, SWIVEL 100R17

194313
Table 2.2 Aerial Platform Torque Specifications
Location Description Torque (ft-lb) Torque (Nm)

Base
Trunnion Mount BOLT, Hex head (3/4"-10 x 5", Grade 8) 210 285
Rear Axle Mount NUT, Torque lock (3/4"-10, Grade C) 210 285
Axle Lock BOLT, Hex head (1/2"-13 x 2.25", Grade 8) 80 108
Swing Drive Motor SCREW, Socket head cap (3/4"-10 x 2.25") 280 380
Rotation Gear BOLT, Hex head (5/8"-11 x 4.5", Grade 8) 170 230
Hydraulic Drive Motor BOLT, Hex head (M14 x 2 x 30mm, ZP, Grade 8.8) 80 108
Wheel Nut NUT, Wheel 247-302 335-410
Turret
BOLT, Hex head (5/8"-11 x 2.75", Grade 8)
Rotation Gear 170 230
BOLT, Hex head (5/8"-11 x 3", Grade 8)
Engine
Deutz Engine Mount BOLT, Hex head (1/2"-13 x 3.75", Grade 5) 55 75
BOLT (M10) 40 55
Coupling Assembly (Deutz)
COUPLING CLAMP BOLT 45 61
GM Engine Mount NUT, Hex head (1/2"-13, Grade 5) 50 68
Drive Pump BOLT, Hex head (1/2"-13 x 1.5", Grade 5) 55 75
System Pump BOLT, Socket (3/8"-16 x 1, Grade 5) 23 31
Cylinders
ROD NUT 425 576
Lift
GLAND 400 542
ROD NUT (46A / 51AJ) 300 407
Extension ROD NUT (46AJ) 150 203
GLAND 450-500 610-678
ROD NUT 350 475
Master
GLAND 350 475
ROD NUT 350 475
Slave
GLAND 350 475
Axle Lock BOLT, Hex head (1/2"-13 x 2.25", Grade 8) 80 108
Jib BOLT, Hex head (0.312-18 x 2.75", Grade 5 \ ZP) 15 20
ROD NUT 350 475
Riser
GLAND 350 475
Platform
BOLT, Hex head, patch (3/8"-16 x 7/8", Grade 8 \ ZP) 35 48
Rotary Mount
BOLT, Hex head (1"-8 x 10.5", zinc, Grade 8) 480 569
Rotary Actuator BOLT, Hex head (3/4"-10 x 3", Grade 8) 210 285
BOLT, Hex head patch (M16 x 1.5 x 4.5, Grade 8.8 \ ZP) 130 177
Load Cell Mounting (CE)
BOLT, Hex head (1/2"-13 x 2.5", Grade 8) 80 108
124AC

194313
Table 2.3 Axles Torque Specifications
Type of Bolt
8.8 10.9 12.9
Size of Bolt Normali Normali Normali
Loctite 270 Loctite 270 Loctite 270
Loctite 242 Loctite 242 Loctite 242
(Nm) (Nm) (Nm)
(Nm) (Nm) (Nm)
M6 x 1 9.5-10.5 10.5-11.5 14.3-15.7 15.2-16.8 16.2-17.8 18.1-20.0
M8 x 1.25 23.8-26.2 25.6-28.4 34.2-37.8 36.7-40.5 39.0-43.0 43.7-48.3
M10 x 1.5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1.75 82-91 90-100 116-128 126-139 139-153 152-168
Course Pitch
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263

M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2.5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2.5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2.5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3.5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8 x 1 25.7-28.3 27.5-30.5 36.2-39.8 40.0-44.0 42.8-47.2 47.5-52.5

M10 x 1.25 49.4-54.6 55.2-61.0 71.5-78.5 78.0-86.0 86.0-94.0 93.0-103.0
M12 x 1.25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1.5 86-95 94-104 120-132 133-147 143-158 159-175
M14 x 1.5 143-158 157-173 200-222 219-242 238-263 261-289
Fine Pitch
M16 x 1.5 214-236 233-257 302-334 333-368 361-399 394-436

M18 x 1.5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1.5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1.5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
60571AA
Note: 1 Nm = 0.7376 ft-lb
Screw-locking, Sealing and Lubricating Materials
Loctite 242
• Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength lock-
ing. Before using it, completely remove any lubricant by using the specific activator.
Loctite 270
• Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength lock-
ing. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may
be necessary to heat them at 80˚C approx.

194313
Table 2.4 Torque Specifications for Fasteners (Imperial)
IMPERIAL BOLT TORQUE CHART IMPERIAL BOLT TORQUE CHART

SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8
Size Torque Type Size
Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in‐lb) (5) (4) (8) (6) (12) (9) ft‐lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in‐lb) (6) (5) (9) (7) (13) (10) ft‐lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in‐lb) (10) (8) (16) (12) (23) (17) ft‐lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in‐lb) (12) (9) (18) (13) (25) (19) ft‐lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in‐lb) (19) (14) (30) (22) (41) (31) ft‐lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in‐lb) (20) (15) (31) (23) (43) (32) ft‐lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
(in‐lb) (27) (21) (43) (32) (60) (45) ft‐lb 170 125 430 320 600 460
10-24 7/8-9
Nm 3.1 2.4 4.9 3.6 6.8 5.1 Nm 230 169 583 434 813 624
(in‐lb) (31) (23) (49) (36) (68) (51) ft‐lb 180 140 470 360 660 500
10-32 7/8-14
Nm 3.5 2.6 5.5 4.1 7.7 5.8 Nm 244 190 637 488 895 678
(in‐lb) / ft‐lb (66) (50) 8 (75) 12 9 ft‐lb 250 190 640 480 900 680
1/4-20 1-8
Nm 7.5 5.6 11 8.5 16 12 Nm 339 258 868 651 1220 922
(in‐lb) / ft‐lb (76) (56) 10 (86) 14 10 ft‐lb 270 210 710 530 1000 740
1/4-28 1-12
Nm 8.6 6.3 14 9.7 19 14 Nm 366 285 963 719 1356 1003
ft‐lb 11 8 17 13 25 18 ft‐lb 280 210 730 540 1020 760
5/16-18 1-14
Nm 15 11 23 18 34 24 Nm 380 285 990 732 1383 1030
ft‐lb 12 9 19 14 25 20 ft‐lb 350 270 800 600 1280 960
5/16-24 1 1/8-7
Nm 16 12 26 19 34 27 Nm 475 366 1085 813 1735 1302
ft‐lb 20 15 30 23 45 35 ft‐lb 400 300 880 660 1440 1080
3/8-16 1 1/8-12
Nm 27 20 41 31 61 47 Nm 542 407 1193 895 1952 1464
ft‐lb 23 17 35 25 50 35 ft‐lb 500 380 1120 840 1820 1360
3/8-24 1 1/4-7
Nm 31 23 47 34 68 47 Nm 678 515 1519 1139 2468 1844
ft‐lb 32 24 50 35 70 55 ft‐lb 550 420 1240 920 2000 1500
7/16-14 1 1/4‐12
Nm 43 33 68 47 95 75 Nm 746 569 1681 1247 2712 2034
ft‐lb 36 27 55 40 80 60 ft‐lb 670 490 1460 1100 2380 1780
7/16-20 1 3/8‐6
Nm 49 37 75 54 108 81 Nm 908 664 1979 1491 3227 2413
ft‐lb 50 35 75 55 110 80 ft‐lb 750 560 1680 1260 2720 2040
1/2-13 1 3/8‐12
Nm 68 47 102 75 149 108 Nm 1017 759 2278 1708 3688 2766
ft‐lb 55 40 90 65 120 90 ft‐lb 870 650 1940 1460 3160 2360
1/2-20 1 1/2‐6
Nm 75 54 122 88 163 122 Nm 1180 881 2630 1979 4284 3200
Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm ft‐lb 980 730 2200 1640 3560 2660
1 1/2‐12
NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. Nm 1329 990 2983 2224 4827 3606

194313
Table 2.5 Torque Specifications for Fasteners (Metric)
METRIC BOLT TORQUE CHART

Torque 8.8 10.9
Size
Units Dry Lubed Dry Lubed
(in‐lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in‐lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in‐lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in‐lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft‐lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft‐lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft‐lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft‐lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft‐lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft‐lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft‐lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft‐lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft‐lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft‐lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft‐lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft‐lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm
NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite.

194313
Table 2.6 Torque Specifications for Hydraulic Couplings & Hoses
HYDRAULIC COUPLING TORQUE CHART

O‐Ring Port Connectors
Steel Ports Non‐ferrous Ports
SAE Size
ft‐lb Nm ft‐lb Nm
4 14‐16 20‐22 9‐10 12‐13
6 24‐26 33‐35 15‐16 20‐21
8 50‐60 68‐78 30‐36 41‐47
10 72‐80 98‐110 43‐48 60‐66
12 125‐135 170‐183 75‐81 102‐110
16 200‐220 270‐300 120‐132 162‐180
20 210‐280 285‐380 126‐168 171‐228
24 270‐360 370‐490 162‐216 222‐294
32 ‐ ‐ ‐ ‐
HOSE END TORQUE CHART HOSE END TORQUE CHART

for JIC for Flat‐Face O‐Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft‐lb Nm ft‐lb Nm ft‐lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
‐4 1/4" 10 11 13 15 5 6 6.75 9 ‐4 1/4" 10 12 14 16
‐6 3/8" 17 19 23 26 12 15 17 20 ‐6 3/8" 18 20 24 27
‐8 1/2" 34 38 47 52 20 24 27.66 33 ‐8 1/2" 32 40 43 54
‐10 5/8" 50 56 69 76 34 40 46.33 55 ‐10 5/8" 46 56 60 75
‐12 3/4" 70 78 96 106 53 60 72.33 82 ‐12 3/4" 65 80 90 110
‐16 1" 94 104 127 141 74 82 100.5 111 ‐14 1" 65 80 90 110
‐20 1 1/4" 124 138 169 188 75 83 101.5 113 ‐16 1 1/4" 92 105 125 240
‐24 1 1/2 156 173 212 235 79 87 107 118 ‐20 1 1/2 125 140 170 190
‐32 2" 219 243 296 329 158 175 214 237 ‐24 2" 150 180 200 245

194313
Table 2.7 Axles Maintenance Intervals
Operation Frequency Lubricants
Differential monthly
Check Levels
Planetary reduction every 200 hours
SAE85W90 (API GL4 - MIL L-2105)
Differential every 800 hours *
With additives for oil-bath brakes
Oil Change Planetary reduction every 1000 hours *
Self-locking
every 700 * &
differential gear
Operation Member Conditions Frequency Lubricants

Normal work monthly
Greasing Articulations MOLIKOTE
Awkward work weekly
Adjustments and Checks
Unit Operation Frequency Service Brake Circuit

Negative Brake Adjustment every 1000 hours *
Only for mineral oil use, e.g., ATF Dexron II.
Service Brake Adjustment every 500 hours Make sure that master cylinder seals are
suitable for mineral oil.
Wheel Nuts Tightening every 200 hours
* Initially after 100 working hours
& When it starts sounding noisy
Gear Box Lubricant Intervals
Check levels monthly
Oil change once at 50 hours after every 1000 hours
Screw/bolt tighten every 200 hours
Lubricant SAE 90 oil API GL3
Torque Wrench Settings (Nm)

Size of Screw 8G/8.8 10K/10.9 12K/12.9
M4 2.9 4.1 -
M6 10 14 -
M8 25 35 -
M12 49 69 -
M10 x 1.25 - 73 -
M12 86 120 -
M14 135 190 -
M14 x 1.5 - - 250
M16 210 295 -
A18 325 - -
60572AA
Note: 1 Nm = 0.7376 ft-lb

194313
Table 2.8 Tire Specifications
SJ 46AJ (ANSI/CSA) SJ 46AJ & SJ 51AJ (CE & AS)

Tire Size 315/55 D20 315/55 D20
Type Air/Foam-Filled Foam Filled
Tire Ply Rating 12 12
Wheel Nuts Torque 290 ft-lb (393.2 Nm) 290 ft-lb (393.2 Nm)
1091-ALL Standards
IMPORTANT
For proper function of each axle differential, all four wheels must have same tire size installed at
all times. Failure to comply with this requirement will reduce the life of the differentials and reduce
overall mobility of aerial platform.
Table 2.9 Maximum Platform Capacities
SJ 46AJ (ANSI/CSA) SJ 46AJ & SJ 51AJ (CE & AS)

500 lb. (227 kg) 315/55 D20
Total Capacity*
2 Persons Foam Filled
Maximum Wind 28 mph (12.5 m/s) 12
Maximum Side Force 90 lbg (400N) 290 ft-lb (393.2 Nm)
1092-ALL Standards
WARNING
*
DRIVING ON A SLOPE
• When driving on a slope greater than 30%, the platform capacity is limited to
136 kg (300 lb.).
• The platform must be between the non-steer wheels and must be on the downside
of the hill.
• When slope increases to above 45%, the forward drive is disabled but reverse drive
remains active.

194313
Table 2.10 Floor Loading Pressure
Total Aerial Platform Total Aerial Platform Load

MODEL Weight Wheel LCP OUP
lb. kg lb. kg psi kPa psf kPa
SJ 46A (ANSI Standard configuration) 14,960 6,786 7,775 3,527 108 745.0 219 10.5
SJ 46AJ (ANSI Standard configuration) 15,230 6,908 7,775 3,527 108 745.0 219 10.5
SJ 46AJ (CE & AS Standard configuration) 15,830 7,180 7,775 3,527 120 827.0 227 10.9
SJ 51AJ (CE & AS Standard configuration) 16,630 7,543 8,470 3,842 133 917.0 239 11.4
1093-ALL Standards
 ANSI Standard Configuration = 4WD + Oscillating Axle + 315/55 D20 Air Tires
 CE & AS Standard Configuration = 4WD + Oscillating Axle + 315/55 D20 Foam Tires
 Gross Aerial Platform Weight = Weight + platform capacity
 LCP – Locally Concentrated Pressure – is a measure of how hard the aerial platform tire tread presses on the area in direct contact with the
floor. The floor covering (tile, carpet, etc.) must be able to withstand more than the indicated values above.
 OUP – Overall Uniform Pressure – is a measure of the average load the aerial platform imparts on the whole surface projected directly
underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.
 Foam tires option will add approximately 600 lb. (272 kg) to total aerial platform weight and 150 lb. (68 kg) to max. wheel load. OUP will
increase by 4% and LCP will increase by approx. 11%.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or
architect for that particular structure.
Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):
Foot Print Area = Tread Contact Area Base Area = Length x Width
Maximum Wheel Load Aerial Platform Weight + Capacity

LCP = OUP =
Foot Print Area Base Area
Width
Tread Contact Area Length
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.

194313
Table 2.11 Hydraulic Specifications
SJ 46AJ SJ 46AJ / 51AJ SJ 46AJ / 51AJ

DESCRIPTION
ANSI/CSA CE AS
2.8 CIR
Displacement - 2000 rpm 46 CC 46 CC
24.3 gpm @ 2000 rpm
Drive Pump Pressure 5000 psi 345 bar 345 bar

Drive Pump
Specifications
Charge Pump Displacement 0.85 CIR 13.9 CC 13.9 CC

Pump
Charge Pump Pressure 313 psi 22 bar 22 bar
0.67 CIR /
Displacement - Static 11 CC 11 CC
System 5.8 gpm @ 2000 rpm
Pump
System Pump Pressure 3000 psi 207 bar 207 bar
Charge Pump Filter 50 psi 9 μm/35 9 μm/35
Filter
High Pressure Filter 87 psi 10 μm/25 10 μm/25
Specifications
Return Filter 22 psi 10 μm/40 10 μm/40
Displacement - Low 1.55 CIR 21 CC 21 CC

Drive
Specifications
Motor
Displacement - High 2.32 CIR 38 CC 38 CC
Motor
Motor Displacement 4 CIR 65.56 CC 65.56 CC

Swing
Motor
Maximum Swing Pressure 1400 psi 97 bar 97 bar
Bore 2 in. 5.1 cm 5.1 cm
Rod Diameter 1.25 in. 3.2 cm 3.2 cm

Extension
Cylinder
Stroke 67 in. 1.7 m 2.5 m
Maximum Boom Pressure 3000 psi 207 bar 207 bar
Bore 4 in. 10.2 cm 10.2 cm
Lift Rod Diameter 1.75 in. 4.5 cm 4.5 cm

Cylinder
(Main) Stroke 25.44 in. 64.6 cm 64.6 cm
Specifications
Cylinder
Maximum Lift Pressure 3000 psi 207 bar 207 bar
Bore 2.5 in. 6.4 cm 6.4 cm
Rod Diameter 1.75 in. 4.5 cm 4.5 cm

Lift
Cylinder Stroke 36.21 in. 92 cm 92 cm
(Riser)
Maximum Lift Pressure 3000 psi 207 bar 207 bar
Maximum Lower Pressure 2750 psi 190 bar 190 bar
Steering Cylinder Stroke N/A N/A N/A

Steer
Cylinder
Maximum Steering Pressure 3000 psi 207 bar 207 bar
For other component specifications, refer to hydraulic schematic.

1096-ALL Standards

194313
Table 2.12 Specifications and Features
MODEL SJ 46AJ ANSI/CSA SJ 46AJ CE & AS SJ 51AJ CE & AS

Working Height 52' 3-1/4" (15.93 m) 16.10 m 17.55 m
Platform Elevated Height 46' 3-1/4" (14.10 m) 14.10 m 15.55 m
Height & Reach

Drive Height Driveable at all heights Driveable at all heights Driveable at all heights
Horizontal Reach 24' 8-3/4" (7.54 m) 7.54 m 9.03 m
Horizontal Reach at Maximum Height 8' 1" (2.47 m) 2.47 m 2.86 m
Tailswing 0 0 0
Up and Over Clearance at Platform 24' 8-3/4" (7.53 m) 7.53 m 7.53 m
Up and Over Clearance at Main Boom 24' 5-1/4" (7.45 m) 7.45 m 7.45 m
30 x 60" (0.76 x 1.52 m) 0.76 m x 1.52 m 0.76 m x 1.52 m
Platform Size
30 x 72" (0.76 x 1.83 m) 0.76 m x 1.83 m 0.76 m x 1.83 m
Platform Rotation 178° 178° 178°
Platform
Platform Height - Stowed 10" (0.25 m) 0.25 m 0.25 m

Platform Height - Overall 52' 1/2" (1.33 m) 1.33 m 1.33 m
Railing Height - Platform 43' 1/2" (1.10 m) 1.10 m 1.10 m
Height - Stowed 6' 9" ( 2.06 m) 2.06 m 2.06 m
Length - Stowed 20' 10" (6.35 m) 6.35 m 7.10 m
Width 7' 6" (2.29 m) 2.29 m 2.29 m
Wheelbase 6' 8" (2.03 m) 2.03 m 2.03 m
Dimenional Data
Ground Clearance - Chassis 15-1/4" (0.39 m) 0.39 m 0.39 m

Ground Clearance - Rear Axle 10-3/4" (0.27 m) 0.27 m 0.27 m
Axle Oscillation 3.25° 3.25° 3.25°
Turning Radius - Inside 4' 11-1/4" (1.50 m) 1.50 m 1.50 m
Turning Radius - Outside 14' 3" (4.34 m) 4.34 m 4.34 m
Turning Angle 45° 45° 45°
Turret Rotation 360° continuous 360° continuous 360° continuous
Length - Stowed 55-3/4" (1.42 m) 1.42 m 1.42 m
Jib
Travel - Down 70° 70° 70°

Travel - Up 75° 75° 75°
Lift
Lift Capacity to Maximum Gradeability 500 lbs (227 kg) 500 lbs (227 kg) 227 kg
Capacity
Gradeability - Maximum 45% 45% 45%
Drive Speed - Stowed/Low Torque 4.8 mph (7.7 km/h) 7.7 km/h 7.7 km/h
Drive Speed - Stowed/High Torque 1.8 mph (2.9 km/h) 2.9 km/h 2.9 km/h
Drive Speed - Elevated 0.5 mph (0.8 km/h) 0.8 km/h 0.8 km/h
Turret Rotation 68-88 seconds 90-110 seconds 90-110 seconds
Performance & Speeds
Platform Rotation 15-25 seconds 15-25 seconds 15-25 seconds

26-32 seconds (CE) 26-32 seconds (CE)
Main Boom Elevation - Up 23-29 seconds
23-29 seconds (AS) 23-29 seconds (AS)
26-32 seconds (CE) 26-32 seconds (CE)
Main Boom Elevation - Down 23-29 seconds
23-29 seconds (AS) 23-29 seconds (AS)
Riser Boom Elevation - Up 23-29 seconds 23-29 seconds 23-29 seconds
Riser Boom Elevation - Down 28-34 seconds 28-34 seconds 28-34 seconds
Fly Boom Extend 8-14 seconds 8-14 seconds 12-18 seconds
Fly Boom Retract 16-21 seconds 16-21 seconds 23-29 seconds
Jib Elevation - Up 34-44 seconds 34-44 seconds 34-44 seconds
Jib Elevation - Down 18-28 seconds 18-28 seconds 18-28 seconds
Main Boom + Riser Boom Elevation - Down N/A >39 seconds >39 seconds
Size 12 x 16.5" (0.31 x 0.42 m) 0.31 m x 0.42 m 0.31 m x 0.42 m
Tire
Wheel Assembly Weight - Air 115 lbs. (52 kg) N/A N/A
Wheel Assembly Weight - Foam 315 lbs (143 kg) 143 kg 143 kg
System Voltage 12 VDC 12 VDC 12 VDC
Electrical
Type Lead / Acid Lead / Acid Lead / Acid
Weight with Air Tires - No Options 13,300 lbs. (6050 kg) N/A N/A
6500 kg (CE)
Weight & Pressure
Weight with Foam Tires - No Options 14,110 lbs. (6400 kg) 7300 kg
6400 kg (AS)
6900 lbs (3130 kg) Air
Wheel Load 3315 kg 3640 kg
7308 lbs. (3315 kg) Foam
115 psi (793 kPa) Air
Locally Concentrated Pressure - LCP 856 kPa 940 kPa
124 psi (856 kPa) Foam
200 psf (9.6 kPa) Air
Overall Uniform Pressure - OUP 10.1 kPa 11.0 kPa
146 psf (10.1 kPa) Foam
1143AA
NOTE: All dimensional values are nominal and do not account for tire deflection.

194313
Table 2.12 Specifications and Features (Continued)
MODEL SJ46AJ & SJ51AJ

Engine Type Deutz D2.9L
RPM Settings 900 Low / 1700 / 2600 High
Horsepower @ 2000 rpm (intermittent) 29.8 kW / 40 Hp
Engine - Deutz D2.9L
Fuel Type Diesel

Fuel Tank Capacity 17 gal (63 L)
Standard Lube Oil 0°F to 115°F (- 18°C to 45°C) SAE 15W-40 API CF/CG/CH-4
Cold Lube Oil - 20°F to 90°F (- 29°C to 32°C) SAE 0W-30 API CF/CG/CH-4
Arctic Lube Oil - 40°F to 115°F (- 40°C to 45°C) SAE 0W-40 API CF/CG/CH-4
Approved Alternates See Engine Manual
Lube Oil Sump Capacity 2.38 gal (9 L)
Standard & Arctic Coolant - 40°F to 115°F (- 40°C to 45°C) Delo 50/50 Extended Life Coolant
Coolant Capacity 3.0 gal (11.4 L)
Engine Type Deutz D2011L03i
Engine - Deutz D2011
Gross Intermittent HP 35.8 kW / 48 Hp

Horsepower @ 2000 rpm (intermittent) 28.9 kW / 38.8 Hp
Fuel Type Diesel
Standard Lube Oil 0°F to 115°F (- 18°C to 45°C) SAE 15W-40 API CF/CG/CH-4
Cold Lube Oil - 20°F to 90°F (- 29°C to 32°C) SAE 0W-30 API CF/CG/CH-4
Arctic Lube Oil - 40°F to 115°F (- 40°C to 45°C) SAE 0W-40 API CF/CG/CH-4
Lube Oil Sump Capacity 1.45 gal (5.5 L)
Engine Type 3.0L GM Dual Fuel
Horsepower @ 2000 rpm (intermittent) 40.8 kW / 54.8 Hp
Engine - GM
Fuel Type - Dual Gasoline/Propane

Standard Lube Oil - 40°F to 115°F (- 40°C to 45°C) SAE 5W-30 API SL
Lube Oil Capacity 1.19 gal (4.5 L)
Standard Coolant - 20°F to 115°F (- 29°C to 45°C) Delo 50/50 Extended Life Coolant
Arctic Coolant Option - 40°F to 115°F (- 40°C to 45°C) Recochem 60/40 Extended Life Coolant
Coolant Capacity 3.0 gal (11.4 L)
Engine Type Kubota 2.5L Dual Fuel WG2503
Engine - Kubota
Fuel Type - Dual Gasoline/Propane

Fuel Tank Capacity 45 gal (170.3 L)
Standard Lube Oil - 40°F to 115°F (- 40°C to 45°C) SAE 5W-30 API SL
Lube Oil Capacity 2.5 gal (9 L)
Standard Coolant - 20°F to 115°F (- 29°C to +45°C) Recochem 50/50 Extended Life Coolant
Arctic Coolant - 40°F to 115°F (- 40°C to 45°C) Recochem 60/40 Extended Life Coolant
Coolant Capacity 3.17 gal (12 L)
Oil Cooler Option 100°F to 115°F (+38°C to 45°C) Oil cooler option recommended
Standard Oil -15°F to 100°F (-26°C to 38°C) Shell Tellus T46
Esso/Mobil UNIVIS HVI 26,
Hydraulic Oil
Arctic Oil - 40°F to 100°F (- 40°C to 38°C)

Petro-Canada HYDREX EXTREME
Mobilfluid 424, Esso UNIVIS N46,
-15°F to 100°F (-26°C to 38°C)
Chevron Rycon MV
Approved Alternates
Mobil DTE 13M, Esso UNIVIS N22,
- 40°F to 80°F (- 40°C to 27°C)
Petro-Canada HYDREX MV Arctic 15
Hydraulic Tank Capacity 24 gal (91 L)
Standard Gear Oil - 20°F to 115°F (- 29°C to 45°C) LS 80W-90 GL5
Gear
Oil
Arctic Gear Oil - 40°F to 115°F (- 40°C to 45°C) Duratran XL Synthetic Oil
Gear Oil Capacity 10 gal (38 L)
1095AD

194313
Diagram 2.1 Dimension and Reach Diagram - SJ 46AJ
Feet
(Meters)
55
(16.76)
50
(15.24)
45
(13.72)
40
(12.19)
35
(10.67)
30
(9.14)
25
(7.62)
20
(6.10)
15
(4.57)
10
(3.05)
5
(1.52)
-5
(-1.52)
-10
(-3.05)
-10 -5 0 5 10 15 20 25 30
(-3.05) (-1.52) (1.52) (3.05) (4.57) (6.10) (7.62) (9.14)
Figure 2-3. Reach Diagram - 46AJ
-5”
(-12.70 cm)
30”
75° (76 cm)
45°
7’ - 4”
(2.24 m)
72”
8’ - 6” (183 cm)
(2.58 m)
25’ - 2”
(7.68 m)
3.5”
(9 cm)
55.75”
(141.6 cm)
46’ - 5”
(14.15 m)
21’ - 4”
(6.5 m)
25’
(7.63 m)
24’ - 6” 53”
(7.48 m) (134 cm)
6’ - 10” 44”
(2.07 m) (111 cm)
70°
6°
6’ - 8”
11.5”
(2.03 m) 16” 14” (29.21 cm)
(40.6 cm) (36 cm)
Figure 2-4. Dimension - 46AJ

194313
Diagram 2.2 Dimension and Reach Diagram - SJ 51AJ
Feet
(Meters)
60
(18.28)
55
(16.76)
50
(15.24)
45
(13.72)
40
(12.19)
35
(10.67)
30
(9.14)
25
(7.62)
20
(6.10)
15
(4.57)
10
(3.05)
5
(1.52)
-5
(-1.52)
-10
(-3.05)
-10 -5 0 5 10 15 20 25 30 35
(-3.05) (-1.52) (1.52) (3.05) (4.57) (6.10) (7.62) (9.14) (10.67)
Figure 2-5. Reach Diagram - 51AJ
0”
(0 cm)
75° 30”
(76 cm)
45°
7’ - 4”
(2.24 m)
72”
9’ - 9” (183 cm)
(2.96 m)
30’ - 1”
(9.16 m)
3.5”
(9 cm)
55.75”
(141.6 cm)
51’ - 1”
(15.58 m)
23’ - 9”
(7.25 m)
25’
(7.63 m)
24’ - 6” 53”
(7.48 m)
(134 cm)
6’ - 10” 44”
(2.07 m) (111 cm)
70°
16’ 14”
(40.6 cm) (36 cm) 6°
6’ - 8”
(2.03 m) 11.5”
(29.21 cm)
Figure 2-6. Dimension - 51AJ

194313
Diagram 2.3 Axle Oscillation Diagram
WARNING
Do not raise the platform in work mode if it is not on a firm level surface.
Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max.
Axle oscillation locked (work mode) - drive speed 0.8 km/h (0.5 mph) max.
Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max.
Axle oscillation locked (work mode) - drive speed 0.8 km/h (0.5 mph) max.
Figure 2-7. Axle Oscillation

194313
Notes

194313
Section 3
SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS
Table of Contents
Charts
3.1 Hydraulic Symbol Chart.......................................................................................................................................45
3.2 Electrical Symbol Chart.......................................................................................................................................46
3.3 Wire Number and Color Code.............................................................................................................................47
Parts Lists
3.4 Hydraulic Component Parts List..........................................................................................................................48
3.5 Electrical Component Parts List..........................................................................................................................51
3.6 Brake Manifold and Port Identifications...............................................................................................................54
Diagrams and Schematics

3.7 Rotary Manifold and Port Identifications..............................................................................................................55
3.8 Drive and System Pump and Port Identifications................................................................................................56
3.9 Drive and System Pump and Port Identifications (with Welder Option).............................................................57
3.10 Drive Motors and Port Identifications................................................................................................................58
3
3.11 Jib Valves and Port Identifications.....................................................................................................................59
3.12 Pressure Reducing Valve Port Identifications....................................................................................................60
3.13 Main Manifold and Port Identifications..............................................................................................................61
3.14 Generator Control Valve and Manifold Identification.........................................................................................64
3.15 Main Electrical Harness and Fuel Level Switch Harness.................................................................................65
3.16 ECU Engine Wiring Diagram (Deutz D2011 Diesel Engine).............................................................................66
3.17 Glow Plug Harnesses (Deutz D2.9L Diesel Engine).........................................................................................67
3.18 Glow Plug Harnesses (Deutz D2011 Diesel Engine)........................................................................................68
3.19 Engine Interface Harness (GM Dual Fuel Engine)............................................................................................69
3.20 Platform Harnesses............................................................................................................................................70
3.21 Platform Control Cable Harnesses....................................................................................................................71
3.22 Limit Switch Connections at Base Control Console..........................................................................................72
3.23 Load Sensing Cable Connection (CE & AS).....................................................................................................73
3.24 All Motion Alarm Connections (CE & AS)..........................................................................................................74
3.25 Flashing Amber Light Option.............................................................................................................................75
3.26 SGE Wiring Diagram..........................................................................................................................................76
3.27 Oil Cooler and 3.5 kW Generator Base Control Console Wiring......................................................................77
3.28 Generator (3.5 kW) Platform Control Box Wiring..............................................................................................78
3.29 Oil Cooler and 12 kW Generator Base Control Console Wiring.......................................................................79
3.30 Generator (12 kW) Platform Control Box Wiring...............................................................................................80
3.31 12kW Generator Connection Assembly............................................................................................................81
3.32 Telematics Wiring Diagram................................................................................................................................82
3.33 Load Circuit Wiring............................................................................................................................................83
3.33 Hydraulic Schematic Diagram...........................................................................................................................85
3.34 Platform Control Console Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine)................................................86
3.35 Platform Control Console Diagram (46AJ ANSI/CSA - Deutz Diesel Engine)..................................................87
3.36 Platform Control Console Diagram (46AJ & 51AJ CE - Deutz Diesel Engine).................................................88
3.37 Platform Control Console Diagram (46AJ & 51AJ AS - Deutz Diesel Engine).................................................89
3.38 Base Control Console Diagram (46AJ ANSI/CSA - GM Engine)......................................................................90
3.39 Base Control Console Diagram (46AJ ANSI/CSA - Kubota WG2503 Engine).................................................91

194313
Table of Contents
3.40 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2011 Diesel Engine)............................................92
3.41 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2011 Diesel Engine with Positive Air Shut-Off)...93
3.42 Base Control Console Diagram (46AJ & 51AJ CE - Deutz D2011 Diesel Engine)...........................................94
3.43 Base Control Console Diagram (46AJ & 51AJ AS - Deutz D2011 Diesel Engine)...........................................95
3.44 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine).............................................96
3.45 Electrical Schematic Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine) ......................................................97
3.46 Electrical Schematic Diagram (46AJ ANSI/CSA - Kubota WG2503 Dual Fuel Engine) .................................98
3.47 Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D2011 Diesel Engine)...............................................99
3.48 Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine)..............................................100
3.49 Electrical Schematic Diagram (46AJ & 51AJ CE - Deutz D2011 Diesel Engine)............................................101
3.50 Electrical Schematic Diagram (46AJ & 51AJ AS - Deutz D2011 Diesel Engine)............................................102
3.51 Interface & Engine Electrical Schematic - GM Dual Fuel Engine ..................................................................103
3.52 Interface & Engine Electrical Schematic - Kubota WG2503 Dual Fuel Engine .............................................104
3.53 Interface & Engine Electrical Schematic - Deutz D2.9L Engine......................................................................105
3.54 Engine Harness - Deutz D2.9L.......................................................................................................................106

194313
Section 3 - System Component Identification and Schematics Service and Maintenance
3.1 Hydraulic Symbol Chart
VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE
PUMP
ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER
HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER
DOUBLE ACTING
HYDRAULIC PRESSURE
PRESSURE DOUBLE
FILTER WITH REDUCING
SWITCH RODDED
BYPASS VALVE
CYLINDER
ELECTRIC MOTION SPRING APPLIED

MOTOR FIXED ORIFICE CONTROL VALVE HYDRAULIC
RELEASED
BRAKE
ADJUSTABLE FLOW DIVIDER BRAKE

ENGINE FLOW CONTROL COMBINER CYLINDER
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
THREE POSITION
VARIABLE BI DIRECTIONAL
FOUR WAY
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
PROPORTIONAL
HYDRAULIC MOTOR MOTOR
SERIES TWO POSITION THREE POSITION

PARALLEL TWO WAY FOUR WAY
HYDRAULIC TWO POSITION CLOSED CENTER
NORMALLY
MOTOR THREE WAY VALVE OPEN PORT
CLOSED VALVE
TWO POSITION THREE POSITION THREE POSITION

TWO WAY TWO POSITION FOUR WAY FOUR WAY
NORMALLY THREE WAY VALVE CLOSED CENTER PROPORTIONAL
OPEN VALVE CLOSED PORT
PRESSURE PILOT LINES Dashed

MAIN LINES Solid
TRANSDUCER
SERVO

194313
Service and Maintenance Section 3 - System Component Identification and Schematics
3.2 Electrical Symbol Chart
CIRCUITS CROSSING LIMIT SWITCH

NO CONNECTION HOURMETER KEY SWITCH
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH
VALVE COIL
PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PROXIMITY
HORN LIMIT SWITCH
BREAKER SWITCH
EMERGENCY CAM OPERATED PNP

VOLT METER STOP BUTTON LIMIT SWITCH TRANSISTOR
CAPACITOR RESISTOR NPN

TILT SWITCH
TRANSISTOR
SINGLE POLE
POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

DOUBLE THROW SINGLE THROW DOUBLE THROW SWITCH
RELAY RELAY RELAY
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT
RELAY

194313
3.3 Wire Number and Color Code
WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE

WIRE COLOR
NO. COLOR NO. NO. COLOR NO. COLOR NO. COLOR
00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD
000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD
B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY
01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY
02 WHT 25 BRN/BLK 48 YEL/GREY 71 RED/ORG 97 ORG/GREY
03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD
04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD
GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR
07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG
08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN
09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK
10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

GREY/
11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 108 YEL/BRN
RED/YEL/
12 35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL
BLK
13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU
WHT/RED/
14 BLK 37 60 WHT/BLU 83 BLU/GREY 110B BRN
BLK
WHT/BLK/
15 BLU 38 ORG/RED 61 GREY/BRN 84 111 GREY/GRN
PUR
16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG
17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN
18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED
19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR
22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.

194313
3.4 Hydraulic Component Parts List

Index Skyjack
Qty. Description
No. Part No.
2H-21A 166039 1 VALVE (Dump)

2H-34A 166038 1 VALVE, Control (Jib)
2H-36A 166038 1 VALVE, Control (Platform Rotate)
3H-21 195036 1 VALVE, Control (Load Circuit)
3H-26 159827 1 VALVE, Control (Brake Release)
3H-38 166037 1 VALVE, Control (Boom Retract)
3H-39 166037 1 VALVE, Control (Boom Extend)
3H-45 159827 1 VALVE, Control (2 Speed Motor)
3H-65 159827 1 VALVE, Control (Axle Lockout)
3H-85 168448 1 VALVE, Generator Bypass (3.5kW Generator)
3H-85-1 N/A 1 VALVE, Generator (12kW Generator Option)
3H-85-2 N/A 1 VALVE, Generator (12kW Generator Option)
3H-165 159827 1 VALVE, Control (Differential Lock)
4H-13 166041 1 VALVE, Control (Main Boom Lift Down)
4H-14 166041 1 VALVE, Control (Main Boom Lift Up)
4H-15 N/A 1 VALVE, Control (Drive Pump Control)
4H-16 N/A 1 VALVE, Control (Drive Pump Control)
4H-23A 158186 1 VALVE, Control (Steering Left)
4H-24A 158186 1 VALVE, Control (Steering Right)
4H-30 166041 1 VALVE, Control (Riser Down)
4H-31 166041 1 VALVE, Control (Riser Up)
4H-32 166041 1 VALVE, Control (Turret Rotate Left)
4H-33 166041 1 VALVE, Control (Turret Rotate Right)
4H-34 166036 1 VALVE, Control (Jib Down)
4H-35 166036 1 VALVE, Control (Jib Up)
4H-36 166036 1 VALVE, Control (Platform Rotate Left)
4H-37 166036 1 VALVE, Control (Platform Rotate Right)
C1 148714 1 CYLINDER (Jib)
C2 148712 1 CYLINDER (Fly Boom) (46AJ)
C3 148711 1 CYLINDER (Main Boom Lift)
C4 148715 1 CYLINDER (Platform Level, Master)
C5 148716 1 CYLINDER (Platform Level, Slave)
C6 148710 1 CYLINDER (Riser Lift)
C7 148710 1 CYLINDER (Riser Lift)
C8 N/A 1 CYLINDER (Steer)
C9 161095 1 RAM (Axle Lockout)
C10 161095 1 RAM (Axle Lockout)
C11 148713 1 CYLINDER (Fly Boom) (51AJ)
C12 N/A 1 CYLINDER (Brake)
C13 N/A 1 CYLINDER (Differential Lock)
CB1 160028 1 VALVE, Counterbalance (Axle Lockout)
CB2 160028 1 VALVE, Counterbalance (Axle Lockout)
CB3 141453 1 VALVE, Counterbalance (Swing Drive)
CB4 141453 1 VALVE, Counterbalance (Swing Drive)
CB5 149488 1 VALVE, Counterbalance (Riser Down)
CB6 149488 1 VALVE, Counterbalance (Riser Down)
CB7 149228 1 VALVE, Counterbalance (Platform Level, Slave)
CB8 149228 1 VALVE, Counterbalance (Platform Level, Slave)
Parts list continued on following page.

194313
3.4 Hydraulic Component Parts List (continued)

Index Skyjack
Qty. Description
No. Part No.
Parts list continued from previous page.
CB9 152326 1 VALVE, Counterbalance (Boom Lift)

CB10 149228 1 VALVE, Counterbalance (Fly Boom Extend)
CB11 141453 1 VALVE, Counterbalance (Fly Boom Retract)
CB12 149372 1 VALVE, Counterbalance (Jib)
CB13 149372 1 VALVE, Counterbalance (Jib)
CB14 141399 1 VALVE, Counterbalance (Rotary Actuator)
CB15 141399 1 VALVE, Counterbalance (Rotary Actuator)
CV1 N/A 1 VALVE, Check (EPU)
CV2 166065 1 VALVE, Check (Loop Flush)
CV3 166064 1 VALVE, Check (Main Control)
CV4 159187 1 VALVE, Check (Double, Piloted, Platform Level)
CV5 163183 1 VALVE, Check (Riser)
CV6 163182 1 VALVE, Check (Riser)
CV7 166067 1 VALVE, Check (LS)
CV13 N/A 1 VALVE, Check (Generator 3.5kW)
CV14 N/A 1 VALVE, Check (Generator 12kW)
CV15 N/A 1 VALVE, Check (Generator 12kW)
CV16 168243 1 VALVE, Check (2 SPD)
DSV1 166059 1 VALVE, System Load Sense (Differential Sensing Valves)
DSV2 166062 1 VALVE, Differential Sensing (Boom Rotate)
DSV3 166063 1 VALVE, Differential Sensing (Riser)
DSV4 166063 1 VALVE, Differential Sensing (Main Lift)
DSV5 166062 1 VALVE, Differential Sensing (Jib/Platform Rotate)
EPU 160923 1 PUMP (Emergency Power Unit)
F1 161932 1 FILTER (High Pressure)
F2 161934 1 FILTER (Return)
M1 161964 1 MOTOR (Drive)
M2 N/A 1 MOTOR (Swing)
M3 N/A 1 MOTOR, Generator (3.5kW Generator Option)
M4 N/A 1 MOTOR, Generator (12kW Generator Option)
MB1 162495 1 MANIFOLD (Main Control)
MB2 162496 1 MANIFOLD (Brake)
MB3 162497 1 MANIFOLD (Jib)
MB4 162788 1 MANIFOLD (Generator 3.5kW)
MB5 168402 1 MANIFOLD (Generator 12kW)
MB6 168158 1 MANIFOLD (Pressure Reducing)
MB7 194753 1 MANIFOLD (Load Circuit)
OC1 160800 1 COOLER, Oil (Oil Cooler Option)
OR1 167353 1 ORIFICE, Main Control (Platform Rotate)
OR2 167352 1 ORIFICE, Main Control (Jib)
OR3 166056 1 ORIFICE, Main Control (Boom Extend)

194313
3.4 Hydraulic Component Parts List (continued)

Index Skyjack
Qty. Description
No. Part No.
OR4 166057 1 ORIFICE, Main Control (Platform Level)

OR5 166073 1 ORIFICE, Brake Manifold (Loop Flush)
OR6 163710 1 ORIFICE, Riser Down (0.067”)
OR7 195033 1 VALVE, Needle (Load Circuit)
P1 161686 1 PUMP (Drive)
P1A 161686 1 PUMP (Charge)
P2 161963 1 PUMP (System)
P3 162330 1 PUMP (System With Generator)
PFC1 166055 1 CONTROL, Priority Flow (Steer)
PFC2 168452 1 CONTROL, Priority Flow (Generator 3.5kW)
PFC3 N/A 1 CONTROL, Priority Flow (Generator 12kW)
PR1 166051 1 VALVE, Pressure Reducing
PR2 168242 1 VALVE, Pressure Reducing
QD1 122420 1 DISCONNECT, Quick
RA1 144710 1 ROTARY ACTUATOR
RA2 167209 1 ROTARY ACTUATOR
RV1 N/A 1 VALVE, Relief (Drive Pump)
RV2 N/A 1 VALVE, Relief (Drive Pump)
RV3 N/A 1 VALVE, Relief (Charge Pump)
RV4 166046 1 VALVE, Relief (Brake Release)
RV5 N/A 1 VALVE, Relief (EPU)
RV6 166043 1 VALVE, Relief (Main Control)
RV7 168975 1 VALVE, Relief (Boom Rotate)
RV8 166044 1 VALVE, Relief (Riser Down)
RV9 159809 1 VALVE, Relief (Platform Level)
RV10 168449 1 VALVE, Relief (3.5 kW Generator Option)
RV11 N/A 1 VALVE, Relief (12 kW Generator Option)
RV12 169409 1 VALVE, Relief (3.5 kW Generator Option)
RV13 195035 1 VALVE, Relief (Load Circuit)
SV1 141414 1 SHUTTLE VALVE, Brake Manifold (LS)
SV2 166054 1 SHUTTLE VALVE, Brake Manifold (M1 / M2)
SV3 N/A 1 SHUTTLE VALVE, Swing Drive
SV4 166054 1 SHUTTLE VALVE, Main Manifold (Swing)
SV5 166054 1 SHUTTLE VALVE, Main Manifold (Riser)
SV6 166054 1 SHUTTLE VALVE, Main Manifold (Boom Lift)
SV7 166054 1 SHUTTLE VALVE, Main Manifold (Platform Level)
SV8 166054 1 SHUTTLE VALVE, Main Manifold (Platform Level)
V1 141436 1 VALVE, Control (Brake Release Override)
V2 166053 1 VALVE, Control (Loop Flush)
V3 159831 1 HAND PUMP (Brake Release)
V4 N/A 1 VALVE, Control (Bypass Towing)

194313
3.5 Electrical Component Parts List
SUPPLY (B+) (Common)
CONTROL (B+) GROUND (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
01ACR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - E-pump)

07CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - E-pump/Enable)
08CR 127131 1 RELAY, 12 Volt 40 Amp (Platform control console - Footswitch/Starter interlock)
09CR 127131 1 RELAY, 12 Volt 40 Amp (Engine power on)
21CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - Dump valve)
27CR 127131 1 RELAY, 12 Volt 40 Amp (Platform control console - Tilt alarm)
45CR1 127131 1 RELAY, 12 Volt 40 Amp (Base control console - 2-SPD motor)
45CR2 127131 1 RELAY, 12 Volt 40 Amp (Base control console - 2-SPD motor controller)
49CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - Horn)
57ACR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - Engine Start)
59CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - Overload sensor) (CE & AS)
60CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - System power)
78CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - High idle)
79CR 127131 1 RELAY, 12 Volt 40 Amp (Base control console - Low idle)
82CR 127131 1 RELAY, 12 Volt 40 Amp (Platform control console - Load sensing alarm)
165CR 127131 1 RELAY, 12 Volt 40 Amp (Platform control console - Differential lock)
2H-21A 159819 1 COIL, 12 Volt (Dump valve)
2H-34A 159821 1 COIL, 12 Volt (Jib enble valve)
2H-36A 159821 1 COIL, 12 Volt (Platform rotate enble valve)
3H-26 159827 1 COIL, 12 Volt (Brake valve)
3H-45 159827 1 COIL, 12 Volt (Motor 2-speed valve)
3H-65 159827 1 COIL, 12 Volt (Axle lock valve)


194313
3.5 Electrical Component Parts List (continued)

Index Skyjack
Qty. Description
No. Part No.

3H-165 159827 1 COIL, 12 Volt (Differential lock valve)

4H-13 159819 1 COIL, 12 Volt (Boom down valve)
4H-14 159819 1 COIL, 12 Volt (Boom up valve)
4H-23A 159819 1 COIL, 12 Volt (Right steer valve)
4H-24A 159819 1 COIL, 12 Volt (Left steer valve)
4H-30 159819 1 COIL, 12 Volt (Riser down valve)
4H-31 159819 1 COIL, 12 Volt (Riser up valve)
4H-32 159819 1 COIL, 12 Volt (Left turret rotate valve)
4H-33 159819 1 COIL, 12 Volt (Right turret rotate valve)
4H-34 159821 1 COIL, 12 Volt (Jib down valve)
4H-35 159821 1 COIL, 12 Volt (Jib up valve)
4H-36 159821 1 COIL, 12 Volt (Platform left rotate valve)
4H-37 159821 1 COIL, 12 Volt (Platform right rotate valve)
4H-38 159821 1 COIL, 12 Volt (Boom retract valve)
4H-39 159821 1 COIL, 12 Volt (Boom extend valve)
4H-40 159821 1 COIL, 12 Volt (Platform level down valve)
4H-41 159821 1 COIL, 12 Volt (Platform level up valve)
A1 138224 1 JOYSTICK (Fly boom/Turret)
A2 138225 1 JOYSTICK (Drive/Steer)
A3 148707 1 JOYSTICK (Riser boom)
AT1 149426 1 ANGLE TRANSDUCER
B1 144676 1 BATTERY, 12V (Wet)
BP1 103057 1 BEEPER, 4-28 VDC Slow pulsing (Platform control console)
BP2 103056 1 BEEPER, 7.5-16 VDC (Base control console) (ANSI/CSA & AS)
BP3 144387 1 ALARM, Overload (CE & AS)
CB1 117325 1 CIRCUIT BREAKER (15 Amp)
CI 152323 1 INDICATOR, Charge
DXX 102921 AR DIODE
FU1 138848 1 FUSE, 50 Amp
FS1 138230 1 SWITCH, Low fuel
H1 146652 1 HORN, 12 Volt
LS1 122007 1 SWITCH, Limit (Direction sensing)
LS2 111356 1 SWITCH, Limit (Riser down)
LS3 161582 1 SWITCH, Limit (Boom down)
LS4 160018 1 SWITCH, Limit (Fly in)
M1 706921 1 PUMP, Emergency
PL1 148971 1 LIGHT, Pilot (Engine fault)
PL2 148972 1 LIGHT, Pilot (Glow plug)
PL3 147229 1 LED BLOCK, Red (12 volts) (Base control console)


194313
AD 3.5 Electrical Component Parts List (continued)

Index Skyjack
Qty. Description
No. Part No.

PL4 147229 1 LED BLOCK, Red (12 volts) (Platform control console)
PL5 138229 1 MODULE, Upper indicating
PL6 148971 1 LIGHT, Pilot (Platform control console)
QD1 122420 1 QUICK DISCONNECT (CE & AS)
R1 110999 1 RESISTOR, 5 ohm 25 W
R2 151643 1 RESISTOR, 250 ohm 1 W
R3 163021 1 RESISTOR, 120 ohm 1/2 W
R4 164859 1 RESISTOR, 2.2k ohm 1/2 W
R5 143952 1 RESISTOR, 51 ohm 2 W (Deutz D2011 and Kubota)
164858 1 RESISTOR, 2.1k ohm 1/2 W (Deutz D2.9L)
R6 164857 1 RESISTOR, 3.9k ohm 1/2 W
R7 144492 1 RESISTOR, 680 ohm 1 W (Deutz D2.9L)
151643 1 RESISTOR, 250 ohm 1 W (Deutz D2011 and Kubota)
S1 119725 1 SWITCH, Main power disconnect
S2 138277 1 KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA, AS Deutz D2011)
164949 1 KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA Deutz D2.9L)
144366 1 KEYSWITCH, Base/Off/Platform (Base control) (CE)
S3 147053 1 N.C. CONTACT, Emergency stop (Base control console)
S4 147053 2 N.C. CONTACT, Emergency stop (Platform control console)
S5 138278 1 SWITCH, Ignition/emergency pump toggle (Base control console)
S6 138278 1 SWITCH, Ignition/emergency toggle (Platform control console)
S8 102853 1 SWITCH, Diagnose toggle (Base control console) (Deutz engine)
S9 124446 1 SWITCH, Ignition (Platform control console)
S10 115574 1 SWITCH, Throttle toggle (Platform control console)
S11 138721 1 ASSEMBLY, Footswitch
S12 138278 1 SWITCH, Boom up/down toggle (Base control console)
S13 102853 1 SWITCH, Turret rotate toggle (Base control console)
S14 102853 1 SWITCH, Telescope in/out toggle (Base control console)
S15 102853 1 SWITCH, Platform leveling toggle (Base control console)
S16 102853 1 SWITCH, Platform rotate toggle (Base control console)
S17 102853 1 SWITCH, Jib up/down toggle (Base control console)
S18 138278 1 SWITCH, Telescope in/out toggle (Platform control console)
S19 138278 1 SWITCH, Platform leveling toggle (Platform control console) (ANSI/CSA)
S20 138278 1 SWITCH, Platform rotate toggle (Platform control console)
S21 138278 1 SWITCH, Jib up/down toggle (Platform control console)
S23 147054 1 N.O. CONTACT, Horn (Platform control console)
S25 138278 1 SWITCH, Riser boom up/down toggle (Base control console)
S26 115574 1 SWITCH, Fuel select (Platform control console) (GM engine)
S28 148998 1 SWITCH, Differential (Platform control console)
S48 115747 1 SWITCH, Drive torque toggle (Platform control console)
TT1 103336 1 HOUR METER
X22 138576 1 PORT, Diagnose (Deutz engine)
X23 138574 1 CONNECTOR, Engine (Deutz engine)

194313
3.6 Brake Manifold and Port Identifications
3H-65
Axle Lock Valve
3H-26
Brake Valve
3H-45
2 Speed Valve
3H-165
Differential Lock
Valve
AL
To Rotary Manifold
BRG
D
To Rotary
To Rotary
Manifold
Manifold
T
V1
To Hydraulic
Brake Release
Tank
Override Valve
PR1
Pressure Reducing
Valve
M1 M2
RV4 To Drive Pump To Drive Pump
Relief Valve V2
Loop Flush Valve 2-SPD
To Rotary Manifold
SV2
Shuttle Valve
SV1 LS
Shuttle Valve To Main Manifold
TO
To Hydraulic Tank
V3
Hand Pump Release

194313
3.7 Rotary Manifold and Port Identifications
Port 7
To Drive Pump
Port 8
To Drive Pump
Port 9
To Hydraulic Tank
Port 1
To Main Manifold
Port 5
To Main Manifold
Port 3
To Axlelock Cylinder
Port 2
To Axlelock Cylinder
Port 6
To Drive Motor
Port 7
To Drive Motor
Port 10
Port 9 To Drive Motor
To Drive Motor
Port 4
Port 2 To Brake Manifold
To Brake Manifold
Port 10
To Brake Manifold
Port 3
Port 6 To Drive Pump
To Brake Manifold
Port 1
To Steer Cylinder
Port 5
To Steer Cylinder
Port 4
To Rear Brake Cylinder
Port 8
To Drive Motor
M149138AA_S3

194313
3.8 Drive and System Pump and Port Identifications
M2
To Brake Manifold
D2
To Hydraulic Tank
A
To Hydraulic Tank
C1
To Rotary Manifold
A
To Rotary Manifold
B
To Rotary Manifold
B
To High Pressure Filter
M1.
S To Brake Manifold
To Hydraulic Tank
M161760AA

194313
3.9 Drive and System Pump and Port Identifications (with Welder Option)
For machines with Welder Option
M1
To Brake Manifold
-
To Hydraulic Tank
(Pump Case Drain)
8
To Rotary Manifold
-
To Hydraulic Tank
(System Suction)
3
To Rotary
7 Manifold
P2 To Rotary Manifold
To Generator Manifold
B M2
To High Pressure Filter To Brake Manifold
-
To Hydraulic Tank
(Drive Suction)
M165046AB

194313
3.10 Drive Motors and Port Identifications
L1
To Rotary Manifold
B
To Rotary Manifold
A
X1 To Rotary Manifold
To Rotary Manifold
M146243AA_S3

194313
3.11 Jib Valves and Port Identifications
4H-34
Jib Down Valve 4H-37
Platform Right Rotate Valve
4H-35 4H-36
Jib Up Valve Platform Left Rotate Valve
1B
To Jib Cylinder
1A
To Bulkhead #2
2B
To Jib Cylinder
2A 4
To Bulkhead #2 To Bulkhead #1
3B
To Bulkhead #1
4H-37
Platform Right Rotate Valve
1
To Bulkhead #2
4H-36 3
Platform Left Rotate Valve To Bulkhead #2
4
To Bulkhead #1
2
To Bulkhead #1
M138120AA_S3

194313
3.12 Pressure Reducing Valve Port Identifications AD
1
To Rotary Manifold Port 6
3
To Hydraulic Tank
2
To Brake Manifold
2SPD Port
M168993AA-1

194313
3.13 Main Manifold and Port Identifications
A B C D E F G H
TEST 1
TEST 3
TEST 5 V
TEST 2
TEST 4
P2
To Lift Cylinder
JBT
To Jib Valve
JBP X
To Jib Valve
EXT
To Boom Extension Cylinder
P
RET To Hi Pressure Filter
To Boom Extension Cylinder
PL1
To Master Cylinder AUX Y
P1 To Emergency Power Unit
To Lift Cylinder
PL2
To Master Cylinder T3
ST2 To Brake Manifold
S2
To Rotary Manifold
To Riser Cylinder
S1 ST1
To Riser Cylinder To Rotary Manifold Z
SW1 SW2
To Swing Drive Motor To Swing Drive Motor
M161251AA-SMS3-11A
Articulating Boom Series SKYJACK, Page 61

Model SJ46AJ & SJ51AJ
194313
3.13 Main Manifold and Electrical Identifications (continued)
A B C D E F G H
4H-40
Platform Leveling Valve
3H-38 V
2H-34A Boom Retract Valve
Jib Boom Valve 4H-41
Platform Leveling Valve
3H-39 4H-32
Boom Extend Valve 4H-30 Turret Rotate Left Valve
Riser Down Valve
2H-36A 4H-33
Platform Rotate Valve Turret Rotate Right Valve
W
4H-31
Riser Up Valve
4H-24A
4H-13 Left Steer Valve
Boom Down Valve
Y
4H-14 4H-23A
Boom Up Valve Right Steer Valve
2H-21A
Z
Dump Valve
M161251AA-SMS3-11B
SKYJACK, Page 62 Articulating Boom Series

194313
3.13 Main Manifold and Hydraulic Identifications (continued)
A B C D E F G H
CV4 OR4
DSV5 OR3 Check Valve
Differential Sensing Valve OR2 DSV4 V
Differential Sensing Valve
OR1
SV5 SV4
Shuttle Valve Shuttle Valve
CV9 W
Check Valve
RV6
Relief Valve
CV8
PFC1 Check Valve
Priority Flow CV7
Control Valve Check Valve
RV8
Relief Valve CV10 X
Check Valve
CV11
Check Valve
CV12
SV7 Check Valve
Shuttle Valve SV8 Y
Shuttle Valve
OR6
DSV3 RV9 SV6
Differential Sensing Valve Relief Valve Shuttle Valve
CV3 CV5
Check Valve Shuttle Valve
DSV1 Z
Differential Sensing Valve CV6
RV7 DSV2 Shuttle Valve
Relief Valve Differential Sensing Valve
M161251AB-S3

194313
3.14 Generator Control Valve and Manifold Identification
A B C D E F G H
3500W Generator 12kW Generator (Welder option) V
2H-85
Generator Valve IN
To High Pressure Filter
P1
T1 To Hydraulic Tank W
MAIN To Oil Cooler
To Main Manifold 3H-85
Generator Valve
CV15
Check Valve
X
LS 3H-85
To Shuttle Valve Generator Valve
TM P2
To Generator To Drive/System Pump Y
RV11
Relief Valve
OUT 8 GPM
To Generator M1 11GPM
Flow Regulator To Generator Flow Regulator Z
M138405AA_M162947AC

194313
3.15 Main Electrical Harness and Fuel Level Switch Harness
A B C D E F G H
DIFFERENTIAL LOCK VALVE

PIN 1 - 165 PINK/BLACK
FUEL LEVEL SWITCH HARNESS PIN 2 - 02 WHITE (SPLICE #1)
1
AXLE LOCK VALVE V
1
PIN 1 - 65 YELLOW/PINK
SOCKET 1 - BLACK
PIN 2 - 02 WHITE (SPLICE #1)
SOCKET 2 - WHITE
1
PIN 1 - 13 - ORANGE
PIN 2 - 12 - BLACK 108
PIN 3 - 21A - WHITE/RED
PIN 4 - 23A - BLACK/WHITE EMERGENCY PUMP
PIN 5 - 24A - BLUE/BLACK BRAKE VALVE 108 - YELLOW/BROWN
1
PIN 6 - 26 - BLUE/YELLOW PIN 1 - 26 BLUE/YELLOW
PIN 7 - 30 - RED/GREEN PIN 2 - 02 WHITE (SPLICE # 1)
PIN 8 - 31 - RED/WHITE SPLICE #1
PIN 9 - 32 - GREEN/BLACK MOTOR TORQUE W
1
PIN 10 - 33 - GREEN/WHITE HORN PIN 1 - 45A YELLOW/ORANGE
PIN 11 - 34A - ORANGE/BLACK 49A - GREEN/RED PIN 2 - 02 WHITE (SPLICE # 1)
PIN 12 - 36A - RED/PURPLE 02 - WHITE (SPLICE #1)
02
PIN 13 - 38 - ORANGE/RED
DUMP VALVE RISER UP BOOM UP JIB ENABLE
PIN 14 - 39 - BLACK/RED
A PIN 1 - 21A WHITE/RED PIN 1 - 31 RED/WHITE PIN 1 - 14 BLACK PIN 1 - 34A ORANGE/BLACK
PIN 15 - 40 - BLUE/RED 49 PIN 2 - 02 WHITE (SPLICE #2) PIN 2 - 02 WHITE (SPLICE # 2) PIN 2 - 02 WHITE (SPLICE # 3) PIN 2 - 02 WHITE (SPLICE # 3)
PIN 16 - 41 - BLUE/PURPLE
PIN 17 - 45A - YELLOW/ORANGE
PIN 18 - 49A - GREEN/RED
1 1 1 1
PIN 19 - 65 - YELLOW/PINK RISER DOWN BOOM DOWN PLATFORM ROTATE ENABLE
PIN 20 - 108 - YELLOW/BROWN PIN 1 - 30 RED/GREEN PIN 1 - 13 ORANGE PIN 1 - 36A RED/PURPLE
PIN 21 - 165 - PINK/BLACK PIN 2 - 02 WHITE (SPLICE # 2) PIN 2 - 02 WHITE (SPLICE # 3) PIN 2 - 02 WHITE (SPLICE # 3) X
PIN 22 - 02 - WHITE (SPLICE #1)
PIN 23 - 02 - WHITE (SPLICE #2)
PIN 24 - 02 - WHITE (SPLICE #3) 1 1 1
SPLICE #2 SPLICE #3
MAIN ELECTRICAL HARNESS
1 1 1 1
STEER RIGHT TURRET ROTATE RIGHT PLATFORM LEVEL DOWN TELESCOPE OUT
PIN 1 - 23A BLACK/WHITE PIN 1 - 33 GREEN/WHITE PIN 1 - 40 BLUE/RED PIN 1 - 38 ORANGE/RED
1
PIN 2 - 02 WHITE (SPLICE # 2) 1
PIN 2 - 02 WHITE (SPLICE # 3)
Z
PIN 24 THIS CORNER
STEER LEFT TURRET ROTATE LEFT PLATFORM LEVEL UP TELESCOPE IN
PIN 1 - 24A BLUE/BLACK PIN 1 - 32 GREEN/BLACK PIN 1 - 41 BLUE/PURPLE PIN 1 - 39 BLACK/RED
PIN 2 - 02 WHITE (SPLICE # 2) PIN 2 - 02 WHITE (SPLICE # 2) PIN 2 - 02 WHITE (SPLICE # 2) PIN 2 - 02 WHITE (SPLICE # 3)
M149012AA_S3

194313
3.16 ECU Engine Wiring Diagram (Deutz D2011 Diesel Engine)
A B C D E F G H
00A 00A - L=25.00"
02 02 - L=7.00"
PIN 1 - 02 - WHITE 11 11 - L=13.00"
PIN 2 - 106 - GREEN/PINK 54A 54A - L=9.00"
PIN 3 - 96 - WHITE/GREY
PIN 4 - 76 - BROWN/BLUE
PIN 5 - 74 - GREEN/GREY 57C 57C - L=32.00" W
PIN 6 - PLUGGED
74 74 - L=10.00"
PIN 7 - PLUGGED
PIN 8 - PLUGGED 76 76 - L=10.00"
PIN 9 - PLUGGED 77 77 - L=10.00"
PIN 10 - 105 - GREEN/BROWN 84 84 - L=16.00"
PIN 11 - 104 - GREEN/ORANGE
PIN 12 - PLUGGED
PIN 13 - PLUGGED
90 90 - L=29.00"
PIN 14 - 54A - PURPLE/RED 96 96 - L=16.00" X

PIN 15 - 84 - WHITE/BLACK/PURPLE
PIN 16 - PLUGGED
PIN 17 - 103 - BLACK/PURPLE
PIN 1 - 77 - BROWN/GREY
PIN 4 - 57C - BROWN/GREEN [12 GA.]
99 99 - L=31.00"
PIN 18 - 99 - BLACK/GREY PIN 10 - 11 - WHITE/ORANGE
PIN 19 - PLUGGED 103 103 - L=9.50"
PIN 11 - 00A - WHITE
PIN 20 - PLUGGED 104 104 - L=6.00"
PIN 21 - 90 - RED/GREY
PIN 22 - PLUGGED 105 105 - L=6.00"
PIN 23 - JUMPER TO PIN 24 106 106 - L=6.00"
PIN 24 - JUMPER TO PIN 23 Y
PIN 25 - PLUGGED
M138708AA

194313
3.17 Glow Plug Harnesses (Deutz D2.9L Diesel Engine)
A B C D E F G H
CONNECTOR J5
PIN 1 - 11C
PIN 2 - 11A V
PIN 3 - AA
PIN 4 - PLUGGED
03 03 11B
8 AWG
100
W
11
RELAY CONNECTION DETAIL

TERM 30 - 11B (8GA)
TERM 85 - 11A (18GA)
TERM 86 - 11 (18GA)
11C
11B
11A
TERM 87 - 11C (8GA) X
CONNECTOR P1
SOCKET 1 - 11C (10GA)
SOCKET 2 - 11C (10GA)
J5
4
11-18 BK 11-18 BK
TO 86
3
11A-18 BK 11A-18 BK
TO 85
2
11C-18 RD
1
P1
11C-10 RD Z
2
(+) 11C-10 RD 11C-8 RD

TO 87
1
11B-8 RD 11B-8 RD
TO 30
M165028AB

194313
3.18 Glow Plug Harnesses (Deutz D2011 Diesel Engine)
A B C D E F G H
TO AIR BOX
V
LEFT CYLINDER
RELAY
SOCKET
DETAIL
CENTER CYLINDER RIGHT CYLINDER W
SOCKET #87
54A
11
X
BASE CONTROL
BOX TERMINAL
BLACK - 54A STRIP
WHITE - 11
03
6 AWG
TO ENGINE STARTER
Z
M148653AA1

194313
3.19 Engine Interface Harness (GM Dual Fuel Engine)
A B C D E F G H
PIN 1 - 02 WHITE
PIN 2 - 11 WHITE/ORANGE V
ENGINE CONNECTOR 2
PIN C - 00A WHITE PIN 3 - 54A PURPLE/RED
PIN E - 02 WHITE FUEL PUMP (+) FUEL PUMP (-) PIN 4 - 57A BROWN/GREEN
305
2
300
PIN 5 - PLUGGED
6
PIN J - 78 RED/BLUE 3056 BLACK 3002 WHITE
PIN K - 79 BROWN/PURPLE PIN 6 - 76 BROWN/BLUE
PINS (A,B,D,F,G,H,L,M,N,P,R&S) - N/U PIN 7 - 77 BROWN/GREY
PIN 8 - 78 RED/BLUE
PIN 9 - 79 BROWN/PURPLE W
PIN 10 - 00A WHITE
PIN 11 - PLUGGED
ENGINE CONNECTOR 2
PIN 12 - PLUGGED
BACK VIEW
BACK VIEW
1 12
2 11
DEUTSCH
3 10
4 9
5 8
6 7
X
ENGINE CONNECTOR 1
BACK VIEW
ENGINE CONNECTOR 1 Y
PIN A - 54A PURPLE/RED
PIN B - 77 BROWN/GREY
PIN C - 3002 WHITE
PIN D - 3056 BLACK
PIN F - 57A BROWN/GREEN
PIN G - 76 BROWN/BLUE
PIN H - 11 WHITE/ORANGE
Z
PINS (E,J,K,L,M,N,P,R&S) - N/U
M149481AB_S3

194313
3.20 Platform Harnesses
A B C D E F G H
ORANGE/BLACK (34)
ORANGE/WHITE (35)
WHITE/RED/BLACK (37)
RED/PURPLE (36)
04A
08A
34
35
36
37
02
WHITE (02)
WHITE (02)
BLACK (04A)
WHITE (08A)
JIB / PLATFORM ROTATE VALVE HARNESS X
CAVITY WIRE COLOUR DESCRIPTION

1 34 ORANGE/BLK JIB DOWN
2 02 WHITE (SPLICE 2) GROUND
PLATFORM CONTROL BOX WIRING

1 35 ORANGE/WHITE JIB UP
Y

1 36 RED/PURPLE ROTATE CW
FOOT SWITCH
1 37 WHITE/RED/BLK ROTATE CCW
M167525AA

194313
3.21 Platform Control Cable Harnesses
A B C D E F G H
BASE & PLATFORM CONNECTIONS

POSITION 1 - PURPLE/ BLACK CONTROL CABLE A V
POSITION 2 - RED
POSITION 3 - RED
POSITION 4 - BLUE/ WHITE
POSITION 5 - RED/ YELLOW/ BLACK
POSITION 6 - ORANGE
POSITION 7 - BLACK
POSITION 8 - ORANGE/ BLUE
POSITION 9 - BLACK/ WHITE
POSITION 10 - BLUE/ BLACK
POSITION 11 - BLUE/ YELLOW
POSITION 12 - RED/GREEN
POSITION 13 - RED/WHITE
POSITION 14 - GREEN/ BLACK
POSITION 15 - GREEN/ WHITE MALE W
POSITION 16 - ORANGE/ BLACK
POSITION 17 - ORANGE/ WHITE
POSITION 18 - RED/PURPLE
POSITION 19 - WHITE/RED/BLACK
POSITION 20 - YELLOW/ORANGE
POSITION 21 - YELLOW/PINK
POSITION 22 - PINK/WHITE
POSITION 23 - PINK/PURPLE
POSITION 24 - PINK/BLACK
MALE
BASE & PLATFORM CONNECTIONS

POSITION 1 - WHITE CONTROL CABLE B
POSITION 2 - WHITE
POSITION 3 - WHITE/ ORANGE
POSITION 4 - BLUE
POSITION 5 - WHITE/ BLACK
POSITION 6 - BLUE/ GREEN
POSITION 7 - GREEN
POSITION 8 - ORANGE/ RED Y
POSITION 9 - BLACK/ RED
POSITION 10 - BLUE/ RED
POSITION 11 - BLUE/ PURPLE
POSITION 12 - GREEN/RED
POSITION 13 - YELLOW/PURPLE
POSITION 14 - BROWN/ GREEN
POSITION 15 - YELLOW/BLUE
POSITION 16 - WHITE/BLUE
FEMALE
POSITION 17 - GREEN/GREY
POSITION 18 - BROWN/BLUE
POSITION 19 - RED/BLUE
POSITION 20 - BROWN/PURPLE
POSITION 21 - GREY/BLUE Z
POSITION 22 - BLACK/YELLOW
POSITION 23 - BLUE/WHITE/YELLOW
POSITION 24 - BLUE/WHITE/BLACK FEMALE
M149292AA

194313
3.22 Limit Switch Connections at Base Control Console
A B C D E F G H
W
29A
29A
29
29
59
09
09
09
17
BLACK WHITE BLACK WHITE
BLK/WHT
BLACK
WHITE
BLACK
LS4 LS3 LS2 LS1 Y

FLY BOOM EXTENSION LIMIT SWITCH MAIN BOOM DOWN LIMIT SWITCH RISER DOWN LIMIT SWITCH DIRECTIONAL SENSING LIMIT SWITCH
M153854AD M153855AD M153856AD M119348AB-SM

194313
3.23 Load Sensing Cable Connection (CE & AS)
A B C D E F G H
3
V
2
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
'B' PLUG
8
D11
12
11
10
3
4
5
9
2
6
8
7
1
W
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE
118
60
82
02
02
02
02
'A' PLUG
4
10
11
12
1
7
8
6
2
9
5
4
3
1
5
GREEN/YELLOW
4P-MALE 4P-FEMALE 3P-FEMALE

PLATFORM CONTOL BOX WIRING 4" PIGTAIL
TYP. Z
M152502AA

194313
3.24 All Motion Alarm Connections (CE & AS)
A B C D E F G H
ALARM
PASS WIRES THROUGH
TOP-MOST STRAIN RELIEF
(LOOSEN GLAND FIRST)
W
02-WHITE
20-ORANGE/BLUE X
20
02
02
02
02
02
-WIRE INSTALLATION- Y

194313
3.25 Flashing Amber Light Option
A B C D E F G H
20
02
BLACK - 20 WHITE-02
CONTROL COMPARTMENT BASE CONTROL BOX LAYOUT Y
TO LAMP
CONNECTOR
1
Z

194313
3.26 SGE Wiring Diagram
A B C D E F G H
162A 162B-AJ
Sensor Bar
09A 09B-TBOOM
07A 07B 07C V
E-pump
D04D 7CCR1 - Kill Drive
04D 04E
162A-AJ 20 20E
04-TBOOM delatch 07C NEW DIODE D09-2
4ECR D09-2
7CCR2 - Kill Dump 09 55
Reset
07C
LOW FUEL
Beacon (IF PRESENT)
D09-1
07A 04E
09 76
Amber W
07C Siren
MIL
60 60A NEW DIODE D09-1
07B 07D
7DCR - Kill Engine
07C
Delay on Timer
D07D BASE CONTROLS MODIFICATION -
07C 07D X
PLATFORM CONTROLS MODIFICATION - All Models Models with Deutz D2.9 or TD2.9 Engines
AT1
12A @ START/E-pump 12A 12A ANGLE TRANSDUCER
BASE TOGGLE SW. (WAS 09) & TILT SWITCH
Y
12A 12A 161 (PINK/WH) TO 24 POLE PLUG "B"
12A @ START/E-pump POSITION #21
TO 24 POLE PLUG "A" BASE TOGGLE SW. (WAS 09)
12A 161 (PINK/WH)
POSITION #22
(WAS 09)
59CR
59 02
09 162A
NEW DIODE D162B Z
BASE CONTROLS MODIFICATION - AJ Models BASE CONTROLS MODIFICATION - T Models

M166133AC

194313
3.27 Oil Cooler and 3.5 kW Generator Base Control Console Wiring
A B C D E F G H
V
Base Control Console - Base Control Console -
Oil Cooler Wiring 3.5 kW Generator Wiring
INSERT BLACK WIRE ‘85’ INTO

PLUG ‘B’ - POSITION ‘21’
86A
02 (EXISTING)
86
01CR 49CR
03B
03 W
20A 03B
86CR
-DETAIL A- PLUG B
12 24
TOP VIEW INSERT WHITE WIRE ‘02’ INTO 21
RELAY SOCKET 57ACR 79CR TERMINAL BLOCK ‘02’
03B
86A
86
1 13
INSERT WIRES ‘03B’, ‘86’ & ‘86A’ INTO

EXISTING RELAY BLOCK, PER DETAIL ‘A’ X
09
09
INSERT WIRE ‘09’ INTO

TERMINAL BLOCK ‘09’
02
TO EMERG. PUMP
POWER STUD 03
Y
TO TEMPERATURE SWITCH
CONNECTOR
1
TO COOLER FAN TO GENERATOR

1
CONNECTOR SOLENOID VALVE
1
00 INSTALL UNDER COOLER MOUNTING BOLT
M152418AB_148596AB

194313
3.28 Generator (3.5 kW) Platform Control Box Wiring
A B C D E F G H
V
38 20A 35 20A
08 08 08 08
39 20A 34 20A
S19-LEV S18-TELE S21-JIB

S20-ROT
S22- Remove
W
GEN
04
78
85 04 08C
04 04A 79
04A 04
S48- S10-
S6-EPUMP THROT
KEYWAY TORQ
POSITION
X
SEALING WASHER
04A
85
24
13
21
04A
04
12
1
Z
REMOVE JUMPER
12
1
M152583AA

194313
3.29 Oil Cooler and 12 kW Generator Base Control Console Wiring
A B C D E F G H
V
Oil Cooler Wiring 12kW Generator Wiring
A
TO TERMINAL
BLOCK 87
CONNECT
21B TO PIN 21,
CONNECTOR B
01CR 49CR
03 SEE TOP VIEW
20A 03B
RELAY SOCKET
86CR 57ACR1
W
57ACR 79CR TO TERMINAL

BLOCK ‘09’
03B
86A
86
85
09
87
SECTION A-A
A
SEE TOP VIEW TO TERMINAL
RELAY SOCKET BLOCK 87
09
09
X
TO TERMINAL TO TERMINAL
BLOCK ‘09’ BLOCK 85
TO TERMINAL
TO GENERATOR
SOLENOID BLOCK 85 TO TERMINAL
VALVES BLOCK 02
TO EMERG. PUMP
POWER STUD 03
TO CIRCUIT BREAKER Y
TO TEMPERATURE SWITCH BOX
CONNECTOR
1
87
86A
02 (existing)
TO COOLER FAN
1
02 (existing)
85
CONNECTOR
86
00
09
03B
INSTALL UNDER COOLER MOUNTING BOLT

TOP VIEW
TOP VIEW RELAY SOCKET
RELAY SOCKET
Z
M152418AB_M163088AD

194313
3.30 Generator (12 kW) Platform Control Box Wiring
A B C D E F G H
A3
SPEED A2
A1 CONTROL JOYSTICK
JOYSTICK
S22
GEN
85
04
04A
S20 S19 S18 S21

PLATFORM LEVEL TELE JIB
ROTATE
S9 78
IGNITION
S23 PL2 S4 08
HORN E-STOP
ABCDEFGH 79
04
S10
S48 THROTTLE
TORQUE
S6
E-PUMP
X
57A
08CR CR1
02
57A 85A
85 57A
04A
02
57A
85
CBL
12 24
11 23
10 22
9 21
8 20
7 19
6 18
5 17
4 16
3 15
2 14
1 13
'D'
Y
04A
CBL
02
13 1
14
15
16
17
18
19
20 8
21 9
22 10
23 11
24 12
'C'
7
2
6
3
4
5
Z
M169581AC

194313
3.31 12kW Generator Connection Assembly
A B C D E F G H
GENERATOR WIRING DIAGRAM (REF)
V
LOCATED ON PLATFORM
Z G
WHITE 8 GA W
GREEN 8 GA
Y X RED 8 GA 8 GA JUMPER
BLACK 8 GA
WHITE 8 GA
WHITE 8 GA BLACK 8 GA
RED 8 GA RED 8 GA
BLACK 8 GA
GREEN 8 GA
WELDER CABLE
110V CABLE (REF)
VIEW UNDER GENERATOR COVER WHITE 8 GA GREEN 8 GA
WHITE 8 GA
WHITE 8 GA GREEN 8 GA Z
RED 8 GA
BLACK 8 GA
M166832AA

194313
3.32 Telematics Wiring Diagram
A B C D E F G H
(TELEMATICS)
09CR
09B
03B: BLACK
N/U: WHITE
02
03B
09B
KEY
DETAIL A 8 PIN CONNECTOR X

1 03B
KEY
02
KEY
02 02 2
USE SEALING PLUG FOR ALL UNUSED CONNECTOR, 3 09B
09B
09B
4 KEY
CAVITIES, FOR THE FOLLOWING PINS # 5,6,7,8. 5
6
7
8
03B
Y
TO MASTER DISCCONET
(BATTERY SIDE)
KEY
KEY
02 02
09B
09B
DETAIL A SCALE 4:1

M171106AA_M170989AB

194313
AC 3.33 Load Circuit Wiring
A B C D E F G H
CONNECT TO LOAD
CIRCUIT SOLENOID
1
W
DETAIL "A" USE EXISTING
STRAIN RELIEF
CONNECT TO 57A
ON ENABLE / INGITION D2
1
TOGGLE SWITCH
10
10
10A
162A
57A
01A
29A
21B
99B
10A
99A
104
105
162
165
30
31
32
33
38
39
40
41
55
59
20
21
29
09
09
09
02
02
02
02
02
74
76
13
14
17
79
90
99
S5-
60
57A
IGN.
01
12
02 (WHITE) X
CONNECT TO 21B 21B (BLACK)
TERMINAL BLOCK
D57A
SEPERATE TERMINAL BLOCK 21 AND 29 Y
ADD 21B TERMINAL BLOCK
ADD D21 DIODE FROM TERMINAL

BLOCK 21 TO 21B (NOTE ORIENTATION)
1
D2
Z
21B
21
DETAIL "A"
M194959AB

194313
Notes

194313
AB 3.33 Hydraulic Schematic Diagram
A B C D E F G H I J K L M N O
C7 C6
RISER RISER
CYLINDER CYLINDER
C5 C1
PLATFORM LEVELING JIB LIFT
R
RA2 SLAVE CYLINDER CYLINDER
BOOM ROTATE C4 C3
SAE 04
SWING DRIVE MASTER MAIN BOOM LIFT C2/C11
CYLINDER CYLINDER FLY BOOM EXTENSION
CYLINDER
RA1
M2 PLATFORM ROTARY
ACTUATOR
CV1
BR2
RV9 CB4 CB3
RELIEF VALVE 1000 PSI 1000 PSI CB15 CB14
2500 PSI 3300 PSI 3300 PSI
CB8 CB7 CB13 CB12 3:1 3:1
CB5 3000 PSI 3000 PSI 3000 PSI 3000 PSI
CB6 3500 PSI 4.5:1 4.5:1 1.5:1 1.5:1
3500 PSI 1.5:1
1.5:1 SAE 06 CB11 CB10
1000 PSI 3000 PSI
3:1 4.5:1
SAE 06
EPU
SAE 06
EMERGENCY
POWER UNIT
SV3
SAE 04
SAE 04
CB9
12VDC
M
SAE 04
SAE 04
SAE 04
SAE 04
MOTOR 4000 PSI
OR6 3:1
CV5 S
BULKHEAD #1 TOP OF FLYBOOM - AT TIP
CV6
SAE 06
2B 1B 2A 1A
SAE 08
4H-35 4H-35
UP DOWN
SAE 04
SAE 04
SAE 06
SAE 06
SAE 04
SAE 04
SAE 04
SAE 04
SAE 04
SAE 06
3B 4H-37 4H-36
ST1 ST2 SW1 SW2 S1 S2 PL1 PL2 P1 P2 EXT RET JBP JBT RIGHT LEFT
3A
T3 SV8
4A
MB3 JIB LIFT & PLATFORM ROTATE
OR1 OR2 MANIFOLD
RV8 RV9 0.035" 0.052"
SV4 2750 SV5 2750 SV6
PSI PSI 3H-38
CV4 2H-34A
BOOM
POWER TRACK CARRIER ASSEMBLY

RET JIB
MB2 BRAKE MANIFOLD T

M1 M2
SV7
V2
LOOP 3H-39
FLUSH BOOM 2H-36A
OR5 CV2 EXT PLATFORM
4H-33 4H-32 4H-31 4H-30 4H-14 4H-13
RIGHT LEFT UP DOWN UP DOWN
4H-23A 4H-24A
RIGHT LEFT
SV2
SAE 04
SAE 04
SAE 04
SAE 04
PFC1 4H-41 4H-40
UP DOWN
PR1 OR3
PRESSURE DSV2 DSV3 DSV4 DSV5
REDUCING AUX OR4
VALVE RV7
500 PSI 1750
TEST1 PSI
QD1
CE ONLY
3H-165
DIFF. P
LOCK
TEST4
CV3
CV9 CV10
U
CV7 CV8 CV11 CV12
D
DSV1
3H-65
AXLE
LOCK 2H-21A RV6
DUMP 3100
GLS T1 PSI
AL
LS CV16
T2
3H-45A
2-SPEED
SV1 T3 TEST3 TEST5 TEST2 MB1 MAIN MANIFOLD
2-SPD
SAE 12
T0
3H-26
BRAKE
WITH GENERATOR SAE 08
C8
MB6 PR2 FRONT AXLE
PRESSURE STEERING CYLINDER
REDUCING
VALVE
V1
BRAKE
300 PSI WITHOUT GENERATOR SAE 08
V
SAE 04
OVERRIDE PORT #1
V3
BRAKE SAE 04 STEER SAE 04
HAND RIGHT
PUMP
PORT #5 C13
SAE 04
STEER LEFT
SAE 04 REAR AXLE
DIFF. LOCK
T4
RV4
RELIEF VALVE SAE 04
PORT #10 SAE 04
550 PSI DIFF.LOCK
BR BRG T C12
REAR AXLE SAHR
SAE 04
PORT #2 SAE 04 BRAKE CYLINDER
AXLE LOCK
PORT #6 CB1
SAE 04
2-SPD
SAE 04 SAE 04 5000 PSI
10:1
SAE 04
PORT #4 SAE 04 SAE 06
BRAKE
SAE 04
PORT #3 SAE 04
W
AXLE PRESS. C9/C10
AXLE LOCK-OUT
CYLINDERS
PORT #7
SAE 12 DRIVE SAE 12
REVERSE
PORT #8
SAE 12 DRIVE SAE 12 SAE 06
FORWARD
3H-21 PORT #9 CB2

SAE 08 MOTOR SAE 08 SAE 04 5000 PSI
OR7 DRAIN 10:1
F1 M1
PRESSURE FILTER DRIVE MOTOR
(17.5 CC/1.07 CIR) A
(40.6 CC/2.48 CIR)
P
SAE 10 WITH GENERATOR T6
T S1 D2
B
RV 13
3250 PSI
P3
SAE 10
MB7 LOAD CIRCUIT MANIFOLD

LOAD CIRCUIT OPTION 3H-85
GENERATOR
X
PUMP DISPL
CONTROL
SAE 10
SELECT
4H-15 = REVERSE
4H-16 = FORWARD SAE 08 P2
P4
WITHOUT GENERATOR
T6
IT
CIR T
WITH GENERATOR
AD OU
CU
PFC2 M3
LO
LO WITH
AD
a b
WI IRCU
TP TP P5 CV13
GEN T5
TH IT
C
Mb C2 C1 B
SAE 08
RV10 RV12 T4
V4 3250 PSI 400 PSI
RV2 BYPASS P1
5000 PSI VALVE T3
WITH GENERATOR
DIESEL OR
DUAL FUEL MB5 GENERATOR CONTROL MANIFOLD
ENGINE
T4
3.5KW GENERATOR OPTION T1
SAE 10
SAE 10
P1A OC1
CHARGE
P2 OIL COOLER T2
PUMP SYSTEM PUMP WITH GENERATOR
(13.8 CC/ VIEW OF TANK PORT PHYSICAL LOCATION
Y
SAE 12
RV1 (11 CC/0.66CIR)
0.84 CIR)
WITH GENERATOR
P1 5000 PSI
DRIVE PUMP RV3 (5.7 GPM @ 2000RPM)
(40.6 CC/ 2.48 CIR) 313 PSI w/o 12kW GENERATOR P3
(20.4 GPM @ 2000 RPM) DUAL SYSTEM PUMP
(11 CC/0.66CIR) MAIN
(14 CC/0.84CIR) 3H-85-2
(13 GPM @ 2000RPM) GENERATOR
G1 SELECT
D1 D2 Ma S A
SAE 12
TP
P1
F2
RETURN FILTER
PFC3
WITH GENERATOR
P2 M1 SAE 10
SAE 16
RV11
SAE 12
SAE 16
3000 PSI M4
G2 GM
CV14
3H-85-1
GEN
GENERATOR
SELECT
TM SAE 08
T5 T2 T1
T1 Z
CV15
MB4 GENERATOR CONTROL MANIFOLD
12KW GENERATOR OPTION T4
M167959AD

194313
AD 3.34 Platform Control Console Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine)
A3 JOYSTICK A2 JOYSTICK R
A1
JOYSTICK 04 (YELLOW) POWER RED
04 (RED/YELLOW) POWER RED 02 (WHITE) GROUND BLK
02 (WHITE) GROUND BLK BLACK D-SIGNAL YEL
R (RED/GREEN) R-SIGNAL YL 24 (BLUE/BLACK) LEFT WHT/RED
23 (BLACK/WHITE) RIGHT WHT/YEL
RED (+) POWER 04 (RED/YELLOW)
BLK (-) GROUND 02 (WHITE)
WHT (X) X-SIGNAL RED
BLU (Y) Y-SIGNAL BLUE

S20-ROT JUMPER(08) JUMPER(20A)
S28-DIFF.
S19-LEVEL S18-TELE S21-JIB S
02 165
08
20A
20A
02A 26A
41 20A 38 20A 35 20A
PL5 08
40
08
20A
08
39 20A
08 08
34
08
20A
08
37
36
02 165
A B C D E F G H
- +
PL6
AMB
T
D08
D04
27A
-2
08
02
76
55
S48- S10-
S6-EPUMP TORQ THROT
04
S4-E STOP 01 04
78
60 04 57 S23-HORN 20 04A 59 08
11 04A 04A 01 04
04A
07A 04A
45 79
S26-
49
02 04
U
FUEL 12 10
S9-IGN
02
04
76
55
11
49
02
04
08
04
59
60
V
D04
59
28
57A
128A
128A
79
78
76
60
59
55
38
49
40
39
28
17
16
15
11
02
41
02
165
165
165
D-SIG
24
23
22
21
20
19
18
17
16
15
14
13
26B
24P-MALE (B)
D08-1
165CR
D26A
04A
08A
118
02
02
02
02
04
04
35
34
37
36
59
82
20
60
08
02A
12
11
10
3
4
5
9
2
6
8
7
24P-FEMALE (A)
13
14
15
16
17
18
19
20
21
22
23
24
10
11
12
1
7
8
2
9
4
5
3
04
34
165
31
32
33
34
35
36
37
45
65
08A
07A
07A
23A
24A
01
10
12
13
14
20
26
30
26A
27
35
27CR
36
D20B
27A
37
04
04
20B
20 45
02
X
02
02 04
24 1 04
02 59 02
13 04
D59
25 2 128A
14
08
02
26 3 17
D-SIG
15 24A
27 4
08CR
08A
16
57A
X-SIG 20B
28 5 24
Y-SIG
17 08F
29 6 23
18
02
R-SIG 65
30 7
57
26A
59
19 13
31 8 32
28
20 31
32 9 23A
20A
21 26
33 10
08F
04
16
22 27
14
Y
34 11 15
23
08FCR
33 30
35 12
08
02
BP1
+ 60
27A
_
M168603AC

194313
AD 3.35 Platform Control Console Diagram (46AJ ANSI/CSA - Deutz Diesel Engine)
A1
JOYSTICK 04 (YELLOW) POWER RED
BLK (-)
WHT (X)
GROUND
X-SIGNAL
02 (WHITE)
RED
S20- BASKET
ROTATE JUMPER(08) JUMPER(20A)
S28-DIFF.
PL5 02 165
08
20A
20A
02A 26A
A B C D E F G H
41 20A 38 20A 35 20A
08 08 08 08 08 08
40 20A 39 20A 34 20A
08
37
36
02 165
PL6
D27
D76
D74
- +
AMB
T
D08
27A
08
02
76
55
74
04
S48- S10-
S6-EPUMP TORQ THROT
S4-E STOP
04
S23-HORN I
(8) 01 04 78
04 57
20 04A 59 08
04A 04A 49 04A 07A 01 04
45 79
04A
02 04
U
12 10
S9-IGN
02
04
76
55
74
49
02
04
08
04
59
60
V
D04
59
28
57A
128A
128A
79
78
76
74
60
59
55
38
49
40
39
28
17
16
15
02
41
02
165
165
165
D-SIG
24
23
22
21
20
19
18
17
16
15
14
13
26B
24P-MALE (B)
D08-1
PLUG B
165CR
D26A
04A
08A
118
02
02
02
02
04
04
35
34
37
36
59
82
20
60
08
02A
12
11
10
3
4
9
2
6
8
7
24P-FEMALE (A)
13
14
15
16
17
18
19
20
21
22
23
24
82CR (OPT.)
PLUG A
10
11
12
1
7
8
6
2
9
4
5
3
04
34
165
31
32
33
34
35
36
37
45
65
08A
07A
07A
23A
24A
01
10
12
13
14
20
26
30
26A
27
35
27CR
36
D20B
27A
37
04
04
20B
20 45
02
X
02
02 04
24 1 04
02 59 02
13 04
D59
25 2 128A
14
08
02
26 3 17
D-SIG
15 24A
27 4
08CR
08A
16
57A
X-SIG 20B
28 5 24
Y-SIG
17 08F
29 6 23
18
02
R-SIG 65
30 7
57
26A
59
19 13
31 8 32
28
20 31
32 9 23A
20A
21 26
33 10
08F
16
34
22
11
27
14
Y
15
23
04
08
33 30
35 12
08FCR
02
BP1
+ 60
27A
_
M168576AC

194313
AD 3.36 Platform Control Console Diagram (46AJ & 51AJ CE - Deutz Diesel Engine)
A1
JOYSTICK 162A (YELLOW) POWER RED

S20-BASKET
ROTATE S28-DIFF.
02 165
20A
20A
26C
PL5 41 20C 38 20A 35 20A
02A 26C
26A 26A 26C 26C 26C 26C
D26C
40 39 A
A B C D E F G H 20C 20A 34 20A
26C
37
36
02 165
- +
PL6
AMB T
D27
D76
D74
02B
27A
08
02
76
55
74
04
S48- S10-
S4-E STOP S6-EPUMP TORQ THROT
S23-HORN
04
01 04 78
04 57
162A 04A 59 08B
07A 01 04
45 79
04A
04A 04A
49 04A
02 04 U
12 10
S9-IGN
02
04
76
55
74
49
02
04
V
08 08B 08
D08
59
04 60 60
D04
59
20 20C 20C
D20C
28
162ACR
162A
128A
128A
57A
162A
79
78
76
74
60
59
55
04C
38
49
40
39
28
17
16
15
02
41
02
D-SIG
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE (B)
PLUG B
04
8
D11
04C
02
04A
08A
118
02
02
02
02
04
04
35
34
37
36
59
82
20
60
08
12
11
10
3
5
4
9
2
8
7
1
26
24P-FEMALE (A)
13
14
15
16
17
18
19
26C
20
21
22
23
24
08
26CR
PLUG A
08
02
02
10
11
12
1
7
8
2
9
4
5
3
34
165
31
32
33
34
35
36
37
45
65
165
165
08A
165
07A
07A
23A
24A
01
10
12
13
14
20
26
30
26
35
04
36
D20B
37
165CR
04C
04C
20B
02A
X
20 45
82CR
82
02 04C
24 1
02B
04C
13
02
02 59 02 04C
D59
25 2 128A
02
14
26 3 17
D-SIG
15 24A
27 4
02
08A
X-SIG
16 20B
28 5
27
24
17
27CR
Y-SIG 08F
29 6
27A
23
R-SIG
18 65
30 7 26A
59
19 13
31 8 32
02
28
20 31
32 9
02
23A
20A
21 26
33 10
16
22 27
14 Y
34 11
08
08
15
33
23 30
35 12
08CR
57A
BP3
02
57
+
08F
04
118
02
_
08FCR
08
02
BP1
Z
+ 60
27A
_
M170490AB

194313
AD 3.37 Platform Control Console Diagram (46AJ & 51AJ AS - Deutz Diesel Engine)
A1
JOYSTICK 162A (YELLOW) POWER RED

S20-BASKET
ROTATE
JUMPER(26A) JUMPER(20A)
S28-DIFF.
S
S19-LEVEL S18-TELE S21-JIB
02 165
20A
20A
26C
PL5 41 20A 38 20A 35 20A
02A 26A
26C 26C 26C 26C 26C 26C

A B C D E F G H 40 20A 39 20A 34 20A
26C
37
36
02 165
- +
PL6
AMB T
D27
D76
D74
162A
02B
27A
08
02
76
55
74
04
S48- S10-
S6-EPUMP TORQ THROT
S4-E STOP
S23-HORN 78
04
01 04
20 04B 59 08
04 57
01 04
04B 04B 04B
07A 04B
45 79
49
02 04 U
12 10
S9-IGN
02
04
76
55
74
49
02
26C 20
04
V
D04 08
(2) 59
04 60 60
D04
59
162ACR
162A
28
04C
128A
128A
57A
162A
04C
79
78
76
74
60
59
55
38
49
40
39
28
17
16
15
02
41
02
D-SIG
24
23
22
21
20
19
18
17
16
15
14
13
02
24P-MALE (B)
PLUG B
8
D11
26A
26A
04A
08A
118
02
02
02
02
08
04
04
35
34
37
36
59
82
20
60
08
26C
12
11
10
3
5
4
9
2
8
7
1
26ACR
08
24P-FEMALE (A)
13
14
15
16
17
18
19
20
21
22
23
24
02
02
PLUG A
165
165
165
26B
D08-1
10
11
12
1
7
8
2
9
4
5
3
34
165CR
165
D26A
31
32
33
34
35
36
37
45
65
08A
07A
07A
23A
24A
01
10
12
13
14
20
26
30
26A
02A
35
36
D20B
82CR
37
82
04C
04C
02B
20B
02
X
20 45
02 04C
24 1
02
04C
02 59 02
13 04C
D59
25 2
27
128A
14
27CR
02
26 3
27A
17
D-SIG
15 24A
27 4 08A
X-SIG
16 20B
28 5 24
02
Y-SIG
17 08F
29 6
02
23
R-SIG
18 65
30 7 26A
59
19 13
31 8
08
08
32
28
20 31
32 9
08CR
23A
21
57A
20A 26
33 10
16
22 27
14
Y
34 11 15
33
23 30
35 12
02
57
BP3
08F
+
04
08FCR
08
118
02
_
02
BP1
Z
+ 60
27A
_
M167937AD

194313
3.38 Base Control Console Diagram (46AJ ANSI/CSA - GM Engine)
R
05-14ga
03A-14ga
BP2
01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR PIN 1 - 02 WHITE
00-12ga
03-12ga
02-14ga
108 54A 21A 45A 49A
PIN 2 - 11 WHITE/ORANGE
01A 02 01 00B 09 02 21 02 45 02 45 02 49 02 PIN 3 - 54A PURPLE/RED
03A 02 05 01A 128A
PIN 4 - 57A BROWN/GREEN
CB4 CB3 CB2 CB1 09 01 03A 09 09 128 07
20 02 PIN 5 - PLUGGED
RED BLACK
BACK VIEW PIN 6 - 76 BROWN/BLUE
PIN 7 - PLUGGED
PIN 8 - 78 RED/BLUE
PIN 9 - 79 BROWN/PURPLE
12
11
1
2 PIN 10 - 00A WHITE
S
DEUTSCH
10 3 PIN 11 - PLUGGED
9 4
03 00 03 8 5 PIN 12 - PLUGGED
7 6
BATTERY (B+)
D00B
S3 03 - BLACK 12 GAUGE Ø5/16"
CONNECT TO E-PUMP POWER STUD
E STOP 60CR
S2-KSW TT1
09
03
05 10 60 02
07 02 02
07
00 T
07A 12
54A 00A
07 02
BATTERY (B-)
24P-MALE 'B'
00 - WHITE 12 GAUGE Ø5/16"
CONNECT TO E-PUMP HOUSING
49
128A 12 24
41
11 23
40
128A
10 22
U
PL1
39
PLUG B
79 9 21
38
78 8 20
FAULT
38 28
7 19
1 13
13 76
39 17
6 18
2 14
14
3 15 40 16(BLK)
5 17
+ - 21A 60
HARNESS
4 16 41 15(RED)
23A 59 4 16
5 17 45A 11
24A 57A 3 15
54A 76 6 18 49A 02
26 55 2 14
MAIN
PLUG
7 19 65 02
30 1 13
8 20 108
31
9 21 165
1
2
32
10 22 02-14GA
33
11 23 02-14GA 30 DEUTSCH
34A 165
02-14GA 24 12
V
12 24 26
36A
24A 23 11
3
4
22 10
BACK VIEW
23A
65
20 21 9
24P-FEMALE 45
14 20 8
PLUG A
37
13 19 7
36
18 6
35
12
10 17 5
DRIVE PUMP VALVE
34
07A-14ga 16 4 PIN 1 - 15 RED
33
32
07A-14ga 15
14
3
2
PIN 2 - 02 WHITE
PIN 3 - 02 GREEN
01
31
13 1
PIN 4 - 16 BLACK
36A 24P-FEMALE 'A'
W
S17 S15-
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
36
37
34A
34 34 D34 40 38
10A 10A 10A RESERVED FOR OPTIONS
10
35 35 41 39
10A
D35
36
37
54A
54A
29A
01A
10A
30
31
32
33
38
39
40
41
55
59
20
21
29
01
09
09
02
02
02
02
02
74
76
77
11
13
14
17
60
R7=680
S25-RISER S12-BOOM RESERVED FOR LIMIT SWITCH WIRING X

10
10A
57A
S13-TUR
10A
30
10C 10A
13
10C
S5-
D01A
D10A
31 14 IGN.
10C
32
33
01
12
RESERVED FOR MISC. WIRING

(DIRECTION SWITCH, FUEL LEVEL)
Y
10A 10C
R1=5
YEL
AT1 GREEN
ANGLE
DEUTSCH
4 1
WHITE 3 2
TRANS. BLACK
BACK VIEW
TILT SWITCH TILT SWITCH CONNECTION

PIN 1 - YELLOW PIN 1 - 09 YELLOW
PIN 2 - GREEN PIN 2 - 28 GREEN
Z
PIN 3 - WHITE PIN 3 - 02 WHITE
PIN 4 - BLACK PIN 4 - 128 BLACK/YELLOW
M163579AB

194313
3.39 Base Control Console Diagram (46AJ ANSI/CSA - Kubota WG2503 Engine)
05-14ga R
03A-14ga
BP2
01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR PIN 1 - PLUGGED
00-12ga
03-12ga
02-14ga
108 54A 21A 45A 49A
PIN 2 - 54A PURPLE/RED
01A 02 01 00B 09 02 21 02 45 02 45 02 49 02 PIN 3 - 57A BROWN/GREEN
03A 02 05 01A 128A
PIN 4 - 11 WHITE/ORANGE
CB4 CB3 CB2 CB1 09 01 03A 09 09 128 07
20 02
PIN 5 - 76 BROWN/BLUE
RED BLACK
BACK VIEW PIN 6 - PLUGGED
PIN 7 - 78 RED/BLUE
PIN 8 - 79 BROWN/PURPLE
12 1
PIN 9 - PLUGGED
11 2 PIN 10 - 00A WHITE
DEUTSCH
10 3 PIN 11 - PLUGGED S
9 4
03 00 03 8 5 PIN 12 - PLUGGED
7 6
BATTERY (B+)
D00B
S3 00A
03 - BLACK 12 GAUGE Ø5/16"
E STOP 60CR
TT1 03
09
05 10 60 02
07 02 02
00
07
07A 12 T
54A 00A BATTERY (B-)
07 02
79 78
D78
24P-MALE 'B'
49
128A 12 24
41
128A 11 23
40
10 22
PL1 U
39
PLUG B
79 9 21
38
78 8 20
FAULT
38 28
7 19
1 13
13 76
39 17
6 18
2 14
HARNESS
14
40 16(BLK)
5 17
3 15
+ - 21A 60
41 15(RED)
4 16
4 16
23A 59
45A 11
3 15
5 17
24A 57A
54A 76 49A 02
PLUG
2 14
6 18
MAIN
26 55
65 02
1 13
7 19
30
8 20 108
31
9 21 165
1
2
32
10 22 02-14GA
33
11 23 02-14GA 30 DEUTSCH
34A 165
12 24 02-14GA 26 24 12
36A
24A 23 11
3
4
22 10
65
23A
20 21 9 BACK VIEW V
24P-FEMALE 45
14 20 8
PLUG A
37
13 19 7
36
18 6
35
12
10 17 5
DRIVE PUMP VALVE
34
07A-14ga 16 4 PIN 1 - 15 RED
33
32
07A-14ga 15
14
3
2
PIN 2 - 02 WHITE
PIN 3 - 02 GREEN
01
31
13 1
PIN 4 - 16 BLACK
36A 24P-FEMALE 'A'
D10A
S15-
-1
S17 W
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
36
37
34A
34 34 D34 40 38
10
35 35 41 39
10A
D35
36
37
54A
54A
29A
01A
10A
30
31
32
33
38
39
40
41
55
59
20
21
29
01
09
09
02
02
02
02
02
74
76
11
13
14
17
60
R7=680
S25-RISER S12-BOOM RESERVED FOR LIMIT SWITCH WIRING

10
10A
57A
S13-TUR X
10A
30
10C 10A
13
10C
S5-
D01A
D10A
31 14 IGN.
10C
32
33
01
12

(DIRECTION SWITCH, FUEL LEVEL)
10A 10C Y
R1=5
YEL
AT1 GREEN
ANGLE
DEUTSCH
4 1
WHITE 3 2
TRANS. BLACK
BACK VIEW

Z
M170413AA

194313
AC 3.40 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2011 Diesel Engine)
05-14ga
03A-14ga
R
BP2
01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR
00-12ga
03-12ga
02-14ga
S8 108 01A 54A 21A 45A 128B 49A
DIAGNOSE
01A 02 01 00B 09 02 21 02 45 02 45 02 49 02
03A 02 05 128A
CB3 CB2 CB1 09 01 03A 09 09 128 07

20
RED
02
BLACK
76
R2=250
103
76
03 00 03
S
DEUTZ EDC BATTERY (B+)

S3 HARNESS 03 - BLACK 12 GAUGE Ø5/16"
E STOP 57ACR 60CR 78CR 79CR CONNECT TO E-PUMP POWER STUD
S2-KSW TT1
57B 09B
02
09 103 103
03
05 10 57A 00A 77 60 02 78 02 79 02
54A 09 02 07 90 99
00
07
07A 12
T
77 02
07 02
BATTERY (B-)
D7A
D12 CONNECT TO E-PUMP HOUSING
24P-MALE 'B'
49
128A 12 24
41
128A 11 23
PL2
40
10 22
PL1
39
9 21
79
U
GLOW PLUG B
38
78 8 20
FAULT
38 28
7 19
1 13
13 76
2 14 39 17
14 74 6 18
3 15 40
5 17
+ - + -
HARNESS
21A 60
4 16 41 15(RED)
23A 59 4 16
5 17 45A
24A 57A 3 15
54A 74 54A 76 6 18 49A 02
26 55 2 14
MAIN
PLUG
7 19 65 02
30 1 13
8 20 108
31
9 21 165
1
2
32
10 22 02-14GA
33
11 23 02-14GA 30
DEUTSCH
34A 165
12 24 02-14GA 26 24 12
36A
24A 23 11
3
4
23A 22 10
V
BACK VIEW
65
20 21 9
24P-FEMALE 45
14 20 8
PLUG A
37
13 19 7
36
18 6
35
12
10 17 5
DRIVE PUMP VALVE
34
33
07A-14ga 16 4 PIN 1 -
07A-14ga 15 3
32
01 14 2
31
13 1
D10A
-1
36A 24P-FEMALE 'A'
S17 S15- W
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
36
37
34A
34 34 D34 40 38
10
35 35 41 39
10A
D35
R5=51
36
37
54A
54A
29A
01A
10A
103
30
31
32
33
38
39
40
41
55
59
20
21
29
01
09
09
02
02
02
02
02
74
76
77
11
13
14
17
60
R7=680

10
X
10A
57A
S13-TUR
10A 10E
30
10A 10C
13
S5-
D01A
D10A
31 14 IGN.
10C
32
33
01
12

(GLOWPLUG, FUEL LEVEL)
KEY
54A
X22
106
A
02 104
K
B
Y
105
L
10A 10C YEL 09B
R1=5 AT1 WHITE

ANGLE
DEUTSCH
4 1
BLACK 3 2
TRANS. GREEN
BACK VIEW

PIN 2 - GREEN PIN 2 - 28 GREEN Z
PIN 3 - WHITE PIN 3 -
PIN 4 - BLACK
M163572AE

194313
AC 3.41 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2011 Diesel Engine with Positive Air Shut-Off Option)
05-14ga
03A-14ga
BP2
00-12ga
03-12ga
02-14ga
S8 108 01A 54 21A 45A 128B 49A
DIAGNOSE
01A 02 01 00B 09 02 21 02 45 02 45 02 49 02
03A 02 05 128A
CB3 CB2 CB1 09 01 03A 09 09 128 07

20
RED
02
BLACK
76
R2=250
103 S
76
03 00 03
03
Y DEUTZ EDC
S3
03 SPLICE
(1.5") Z HARNESS BATTERY (B+)

E STOP 57ACR 60CR 78CR 79CR 03 - BLACK 12 GAUGE Ø5/16"
03 S2-KSW TT1 57A
57B
00A 77
09B
02 403A 02 60
09
02 78
103
02 79
103
02
03 CONNECT TO E-PUMP POWER STUD
DO NOT ATTACH 05 10 54A
54A 09 54 07 90 99
403 00 BATTERY (B-) T

07
07A 12 00 - WHITE 12 GAUGE Ø5/16"
77 02 CONNECT TO E-PUMP HOUSING
07 02
D7A
24P-MALE 'B'
F
D12
(22)
49
128A 12 24
41
128A 11 23
PL2
40
10 22
U
PL1
39
79 9 21
GLOW PLUG B
38
78 8 20
FAULT
1 13 38 28
13 76 7 19
2 14 39 17
14 74 6 18
3 15 40
5 17
HARNESS
+ - + - 4 16
21A
41 15(RED)
60
23A 59 4 16
5 17 45A
24A 57A 3 15
54A 74 54A 76 6 18 49A 02
26 55 2 14
MAIN
PLUG
7 19 65 02
30 1 13
8 20 108
31
9 21 165
1
2
32
POSI AIR
(RED)
10 22 02-14GA
33
11 23 02-14GA 30
DEUTSCH
403A
34A 165
02 24 12
02
12 24 02-14GA 26
36A
23 11
402 24A
3
4
23A 22 10
BACK VIEW V
65
20 21 9
24P-FEMALE 45
14 20 8
PLUG A
37
13 19 7
36
18 6
35
12
10 17 5
DRIVE PUMP VALVE
34
33
07A-14ga 16 4 PIN 1 -
07A-14ga 15 3
32
01 14 2
31
13 1
D10A
-1
36A 24P-FEMALE 'A'
S17 S15- F
(19)
H
(2)
D37
D36
-JIB LEVEL S14-TELE W

S16-ROT
36
37
34A
34 34 D34
40 38
10
35 35 D35
41 39
36
37
10A
R5=51
54A
54A
29A
01A
10A
103
30
31
32
33
38
39
40
41
55
59
20
21
29
01
09
09
02
02
02
02
02
74
76
77
11
13
14
17
TO SOLENOID
60
PIN A-BLACK (408) R7=680
PIN B-RED (403A)
PIN C-WHITE (401) S25-RISER S12-BOOM RESERVED FOR LIMIT SWITCH WIRING
10
57A
10A
S13-TUR
30 13
S5-
10A 10E 10A 10C
D01A
IGN. X
D10A
31 14
32
33
10C
12
01
403A
402
403
02
KEY
54A
X22
106
POSITIVE AIR SHUT OFF MODULE 10 PIN CONNECTOR PLUG A
02 104 B
PIN 1 -WHITE (401) PIN 6 -BLUE (403) 105
K
L
PIN 2 -EMPTY PIN 7 -WHITE (02)
09B
PIN 3 -RED (403A) PIN 8 -BLACK(408)
PIN 4 -GREEN (402) PIN 9 -EMPTY
PIN 5 -EMPTY PIN 10 -YELLOW (410) 10A 10C YEL
R1=5 AT1 WHITE
ANGLE
DEUTSCH
4 1
BLACK
Y
3 2
TRANS. GREEN
BACK VIEW

PIN 3 - WHITE PIN 3 -
PIN 4 - BLACK
M195377AB

194313
3.42 Base Control Console Diagram (46AJ & 51AJ CE - Deutz D2011 Diesel Engine)
05-14ga
03A-14ga
R
00-12ga
03-12ga
02-14ga
03
S8 108 01A 54A 21A 45A 128B 49A
DIAGNOSE
01A 02 01 00B 09 02 21 02 45 02 45 02 49 02
03A 02 05 128A
CB3 CB2 CB1 09 01 03A 162A 09 128 07
76
R2=250
103
76
03 00 03
S
DEUTZ EDC BATTERY (B+)
E STOP TT1 57ACR 162BCR 59CR 60CR 78CR 79CR CONNECT TO E-PUMP POWER STUD
S2-KSW 57B 09 09 103 103
03
05 10 57A 00A 162B 01B 02 59 02 60 02 78 02 79 02
54A 01A 162A 07 90 99
77
05
01B 00
07
07A 12
02
09F
T
07 02
BATTERY (B-)
24P-MALE 'B'
D12
D59
07A D07A
12A
162A
49
128A 12 24
41
128A 11 23
PL2
D162
-2 40
10 22
REFER TO
PL1
39
79 9 21
DETAIL C
GLOW PLUG B
38
78 8 20
U
FAULT
38 28
7 19
1 13
13 76
2 14 39 17
14 74 6 18
3 15 40 16
5 17
+ - + - 21A 60
4 16 41 15
23A 59 4 16
5 17 45A
24A 57A 3 15
54A 74 54A 76 6 18 49A 02
26 55 2 14
7 19 65 02
30 1 13
8 20 108
31
9 21 165
1
2
32
10 22 02-14GA
33
11 23 02-14GA 30
DEUTSCH
34A 165
12 24 02-14GA 26 24 12
36A 162
24A 23 11
161
3
4
23A 22 10
65
45
20 21 9
BACK VIEW V
24P-FEMALE 14 20 8
PLUG A
37
13 19 7
36
18 6
35
12
10 17 5
DRIVE PUMP VALVE
34
33
07A-14ga 16 4 PIN 1 - 15 RED
32
07A-14ga 15
14
3
2
PIN 2 - 02 WHITE
PIN 3 - 02 GREEN
01
31
13 1
PIN 4 - 16 BLACK
D10A
-1
24P-FEMALE 'A'
36A
W
S17 S15-
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
36
37
34A
34 34 D34 40 38
10A 10A 10A R5=51 R6=680
RESERVED FOR OPTIONS
35 35 41 39
10A
D35
36
37
R7=680
X
10
10A
57A
S13-TUR D01A
-2
30 13
S5-
09F
DETAIL C
10A 10C 10A 10C
D01A
D10A
31 14 IGN. 1 2 3
10C
4 5 6
32
33
01

12A
(GLOWPLUG, FUEL LEVEL) CONNECTOR (FEMALE)

PIN1 - 05 PURPLE
PIN2 - 77 BROWN
162A
54A
X22
106
PIN3 - 01B PURPLE/BLACK
104
A
B PIN4 - n/a Y
PIN5 - 09F YELLOW
D162
K
105
L
PIN6 - 02 WHITE
162
10A 10C
R1=5
YEL
AT1 WHITE
ANGLE
DEUTSCH
4 1
BLACK 3 2
TRANS. GREEN
BACK VIEW

PIN 1 - YELLOW PIN 1 - 09 YELLOW Z
M170773AC

194313
3.43 Base Control Console Diagram (46AJ & 51AJ AS - Deutz D2011 Diesel Engine)
05-14ga
03A-14ga
BP2
01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR R
00-12ga
03-12ga
02-14ga
S8 108 01A 54A 21A 45A 128B 49A
DIAGNOSE
01A 02 01 00B 09 02 21 02 45 02 45 02 49 02
03A 02 05 128A
SPARE SPARE CB3 CB2 CB1 09 01 03A 162A 09 128 07

20
RED
02
BLACK
76
R2=250
103
76
03 00 03
BATTERY (B+)
DEUTZ EDC S
E STOP 57ACR 59CR 60CR 78CR 79CR
S2-KSW TT1
57B 09 09 103 103
03
05 10 57A 00A 59 02 60 02 78 02 79 02
54A 02 162A 07 90 99
00
07
07A 12
77 02
07 02 BATTERY (B-) T
24P-MALE 'B' 00 - WHITE 12 GAUGE Ø5/16"
D12
07A D07A
12A
162A
49
128A 12 24
41
128A 11 23
PL2
40
10 22
PL1
39
79 9 21
GLOW
38
78 8 20
FAULT
38 28
7 19
PLUG B
1 13
13 76
39 17
6 18
2 14
3 15
14
40 16
74
5 17 U
+ - + - 21A 60
41 15
HARNESS 4 16
23A 59 4 16
5 17 45A
24A 57A 3 15
54A 74 54A 76 6 18 49A 02
26 55 2 14
7 19 65 02
1 13
MAIN
PLUG
30
8 20 108
31
9 21 165
1
2
32
10 22 02-14GA
33
11 23 02-14GA 30 DEUTSCH
34A 165
12 24 02-14GA 26 24 12
36A 162
24A 23 11
3
4
09
22 10
BACK VIEW
23A
65
20 21 9
24P-FEMALE 45
14 20 8
PLUG A
37
19 7
36
13
12 18 6 DRIVE PUMP VALVE V

35
17 5
34
10
07A-14ga 16 4
PIN 1 - 15 RED
33
32
07A-14ga 15 3 PIN 2 - 02 WHITE
31
01 14
13
2
1
PIN 3 - 02 GREEN
PIN 4 - 16 BLACK
24P-FEMALE 'A'
D10A
-1
36A
S17 S15- W
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
36
37
34A
34 34 D34 40 38
10
35 35 41 39
10A
D35
R5=51 R6=680
36
37
162A
54A
54A
29A
01A
10A
103
162
30
31
32
33
38
39
40
41
55
59
20
21
29
01
09
09
02
02
02
02
02
74
76
77
11
13
14
17
60
R7=680

10
10A
X
57A
S13-TUR D01A
-2
10A 10C
30
10A 10C
13
S5-
D01A
D10A
31 14 IGN.
10C
32
33
01
12A

162A
AT1
54A
X22
106
D162
ANGLE
A
Y
BLACK
GREEN
TRANS.
WHITE
YEL
104 B
K
10A 10C
162
105
R1=5
L
TILT SWITCH
DEUTSCH
4 1
PIN 1 - YELLOW 3 2
PIN 2 - GREEN BACK VIEW

PIN 3 - WHITE
PIN 4 - BLACK TILT SWITCH CONNECTION
PIN 1 - 09 YELLOW
PIN 2 - 28 GREEN Z
PIN 3 - 02 WHITE
PIN 4 - 128 BLACK/YELLOW
M163612AC

194313
3.44 Base Control Console Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine)
R
D12
KEY D7A
20 RED
CONNECTOR J1
PIN 1 - 103
PIN 2 - 103A
BP2
05-14ga 20 02 BLACK PIN 3 - 56B
56 09B 02 PIN 4 - 56A
56A PIN 5 - PLUGGED
56B PIN 6 - PLUGGED
01ACR 21CR 45CR1 45CR2 49CR 02
00-12ga
PIN 7 - 203
03-12ga
02-14ga
57A
S8 09B 108 21A 45A 128B 49A 56B 103
103A
PIN 8 - 57A
PIN 9 - PLUGGED
DIAGNOSE
09 77 01A 02 21 02 45 02 45 02 49 02 54 56A
56 02 05 128A
PIN 10 - 74
CB4 CB3 CB2 CB1 09 09 09 09 128 09 56 203
105 PIN 11 - 105
103A 104 PIN 12 - 104
S
R7=250
74
D09
103
-1
CONNECTOR J2
103A SOCKET 1 - 76B
SOCKET 2 - PLUGGED
54
SOCKET 3 - 76A
03 00 03 77
SOCKET 4 - 99
81
SOCKET 5 - 90
76B
SOCKET 6 - JUMPER WITH SOCKET 7
99
S3 90
SOCKET 7 - JUMPER WITH SOCKET 6
SOCKET 8 - 09
76A
SOCKET 9 - 54 BATTERY (B+)
E STOP S2-KSW 60CR 78CR 79CR
09A
09
SOCKET 10 - 81 03 - BLACK 12 GAUGE Ø5/16"
SOCKET 11 - 77
TT1
02 09 99A 99B
SOCKET 12 - 09A
05 10 07A 12
T
76A 76B 02 60 02 54 77 78 02 79 02 02
01A
76 07 01 90 90
03
F NOEM 3 NCLB 1
(6)
4 2
00
54 77
07 02 07 07 BATTERY (B-)
00 - WHITE12 GAUGE Ø5/16"
24P-MALE 'B'
U
49
128A 12 24
41
128A 11 23
40
10 22
39
79 9 21
PLUG B
38
78 8 20
38 28
7 19
1 13
13 76
2 14 39 17
14 74 6 18
40 16(BLK)
5 17
3 15
HARNESS
21A 60
41 15(RED)
57A
4 16
23A 59 4 16
5 17 45A
24A 57A 3 15
49A 02
203
6 18
2 14
09
76
81
203
74
26 55
MAIN
PLUG
7 19 65 02
30 1 13
8 20 108
31
165
V
9 21
32
10 22 02-14GA
33
11 23 02-14GA 30
34A 165
24 12
1
2
12 24 02-14GA 26
36A
24A
23A
23
22
11
10 DEUTSCH
DRIVE PUMP VALVE
65
20 21 9 PIN 1 -
24P-FEMALE 45
14 20 8
3
4
PLUG A
37
19 7
BACK VIEW
13
36
12 18 6
35
10 17 5
34
07A-14ga 16 4
33
07A-14ga 15 3
32
01 14 2
31
13 1
36A
D10A
-1
S17 S15-
D37
D36
-JIB LEVEL S14-TELE
2.1k
120
R5=
R3=
S16-ROT
36
37
34A
2.1k
120
34 34 D34 40 38
R5=
R3=
10A 10A 10A
RESERVED FOR OPTIONS
10
35 35 41 39
10A
D35
36
37
X
29A
01A
10A
30
31
32
33
38
39
40
41
55
59
20
21
29
09
09
09
02
02
02
02
02
74
76
13
14
17
R6=3.9k
60
R6=3.9k
R4=2.2k
R4=2.2k
S25-RISER S12-BOOM
10
10A
57A
S13-TUR RESERVED FOR LIMIT SWITCH WIRING

30 13
S5-
D09
10A 10B 10A 10B

D01A
D10A
IGN.
09A
31 14
10B
32
33
01
12
Y
TILT SWITCH CONNECTION
PIN 1 - 09 YELLOW
PIN 2 - 28 GREEN
104
105
PIN 3 -
09
X22 CONN.
02
10A 10B
R1=6 A - 09
A
AT1
ANGLE B
TRANS.
M164995AE

194313
AD
S9
IGNITION
S2
194313
57 START S4
EMERGENCY KEY SWITCH S3
07A RED 07A EMERGENCY S1 1
STOP BASE/OFF/PLATFORM
POSITION 2-A STOP DISCONNECT
04 RUN SWITCH B1 2
04A 07A 07A RED 07A RT CB1 15 AMP
07 05 05 03 00
POSITION 3-A CTR
A
ENGINE OFF 3
PL3 CB2 15 AMP 03B
10 12 12 RED/YELLOW/BLACK 12 12 LEFT 02 00 00
10
POSITION 5-A 4 BATTERY
10 BLUE/WHITE 10 5
03A CB3 15 AMP 03
PL4 POSITION 4-A
108CR 6
03
M1 7

108 EMERGENCY PUMP

01 01ACR
PURPLE/BLACK 01 01 01A 02 8
POSITION 1-A
09 108 CB4 86CR 9
S6 03B 86A
E-PUMP M
SWITCH TSW1 20A 10 OPTIONAL OIL COOLER
S5 09 86
IGNITION/E-PUMP
20 01 SWITCH 09CR 11
09 02
E-PUMP 01
12
12
04A 04 D01A 03A 54A
ENABLE 13
10A STARTER
10
B
14
04 START 01 00B
15
07CR
57 57A BROWN/GREEN 57A 57A 16
D00B
GEN. POSITION 14-B
08 02 OPTION 00A 17 HOURMETER
54A 00A
TT
08CR 02 57ACR1 TT1 18
HOURMETER ALTERNATOR
07 09 19
D04 D10
04 60
20
S23 60 WHITE/BLUE 60 60 02 02
HORN SWITCH POSITION 16-B TO ENGINE TO ENGINE 21
60CR 49CR STARTER BLOCK
04A 49 GREEN/RED 49 49 02 02 22
POSITION 12-B
H1 23
HORN
00A ENGINE RUNNING
07 49A 02 24
HORN
C
57A
02 02 WHITE 02 02 25 START COMMAND
08
POSITION 1-B
PL5 26
09CR1
08 09 00A 03B
02 27
09B 02
02 02 02 WHITE 02 09 09B
FOOTSWITCH KEY 28 TELEMATICS OPTION
POSITION 2-B TELEMATICS
27A OPTION
TILT D7A 29
OVERLOAD 30
76 76 BROWN/BLUE 76 D12 FS1 LOW
ENGINE FAULT 31
POSITION 18-B FUEL SWITCH
55 55 YELLOW/PURPLE 55
LOW FUEL 32 FUEL LEVEL INDICATOR
POSITION 13-B
BP1 R7=680 ohm 33
54A 76
04B TILT
ALARM 34
60 27A
PL1
D04-1 54A 76 76 35
ENGINE FAULT (MIL)
D
04 ENGINE FAULT
02 27A 36
37
S26 02 27 38
GM Dual Fuel Engine
FUEL SELECT 54A

ENGINE ON (VSW)
SWITCH
27CR 39
60 11 11
11 PROPANE 11 WHITE/ORANGE
40 FUEL SELECT (HI = PROPANE)
POSITION 3-B (LOW = GASOLINE)
41
42
02 43
Refer to 3.51 Interface & Engine Electrical Schematic -
78 44
HIGH IDLE N=2675 RPM
79 45
LOW IDLE N=1600 RPM
E
46
GM EFI DUAL FUEL ENGINE 47
48
S10
THROTTLE 49
SWITCH 78 2000 RPM 78 RED/BLUE 78
08 D08 POSITION 19-B 50
79 1650 RPM 79 BROWN/PURPLE 79
POSITION 20-B 51
52
53
LS4 LS3 LS2
D59 FLY IN LS BOOM DN LS RISER DN LS 54
59 YELLOW/BLUE 59 59 N/C 29A N/C 29 N/C 09
55 BOOM TURRET LIMIT SWITCHES
POSITION 15-B
S48
DRIVE TORQUE 45CR1 56
SWITCH 45 YELLOW/ORANGE 45 45 02
F
59 POSITION 20-A 3H-45 57

45 LOW TORQUE 09 09 45A 45A
MOTOR 2-SPEED VALVE
SUPPR. 58 (COIL ON = HIGH SPEED)
59
D85A-1 S11
FOOT 60
08A SWITCH
61
SUPPR.
62
04 JMPR2 04A D10A 21A 2H-21A
09 09 02 63 DUMP VALVE
WITH OPTIONAL GENERATOR 20 20 20 20 JMPR3
ORANGE/BLUE 21CR 02 64 DUMP VALVE RELAY
REMOVE JMPR2
POSITION 8-A
S22 65
ELECTRICAL SUPPR.
GENERATOR 66
04 04A 2H-85
85 OPTIONAL GENERATOR VALVE
85A 85 GRAY/BLUE 85 02
67
POSITION 21-B
G
68
S28
DIFF LOCK 20 02
D08-1 26B 165 69 OPTIONAL STROBE LIGHT
SWITCH
LB2
D26A 02
165 02A 20 02 70
LOCK OFF ALL MOTION ALARM
165CR BP2 71
165 LOCK ON 165 PINK/BLACK 165 165 3H-165
26A POSITION 24-A DIFFERENTIAL LOCK
SUPPR. 72 (COIL ON = LOCKED)
PL6 73
74
75
OCM-VALVE DRIVER 76
26A 19 7 3H-65 77
65 65 YELLOW/PINK 65 65 02 AXLE LOCK VALVE
POSITION 21-A
08A 16 11 SUPPR. 78 (COIL ON = FLOATING AXLE)
H
27
08 6 79
45CR2
45
04 1 26 80
02
128A BLUE/WHITE/YELLOW 128A AT1
04 2 31 09 ANGLE TRANSDUCER 81
59 59 POSITION 23-B & TILT SWITCH
14 128A 128 02 82
128A 128A BLACK/YELLOW 128A
R4=30 ohm POSITION 22-B 3H-16
04 13 34 16 16 83
16 16 WHITE/BLACK FORWARD DRIVE VALVE
POSITION 5-B 3H-15
23 15 R3=30 ohm 15 15 15 84
BLUE REVERSE DRIVE VALVE
POSITION 4-B 3H-26
10 26 26 85
26 RESISTORS 26 BLUE/YELLOW 02 BRAKE VALVE
BOOM/TUR MAY NOT BE POSITION 11-A
04 X 28 5 N.C. HELD OPEN LS1 SUPPR. 86
20A D20A PRESENT
Vbat Xaxis WITH ENGINE OVER DIRECTION
A1 Y 29 15 17 17 STEERING AXLE SENSING 09 87
17 BLUE/GREEN
BOOM/TURRET Yaxis
POSITION 6-B
JOYSTICK 02 25 88
Gnd
I
32 28 28 28 89
28 GREEN
POSITION 7-B
4 24A 4H-24A 90
24A 24A BLUE/BLACK 24A 02 LEFT STEER VALVE
RISER POSITION 10-A
04 02 24 SUPPR. 91
A3 Vbat Gnd
3.45 Electrical Schematic Diagram (46AJ ANSI/CSA - GM Dual Fuel Engine)
RISER R 30 21 23A 23A 23A 4H-23A 92

23A BLACK/WHITE 02 RIGHT STEER VALVE
JOYSTICK Output
POSITION 9-A
SUPPR. 93
02 94
UP 31 95
10A
DRIVE S25
04 02 96
Vbat Gnd RISER
D 27 10B 97
Output DN 30
A2
DRIVE/STEER 24 17 9 31 31 RED/WHITE 31 31 31 4H-31 98
JOYSTICK Left POSITION 13-A RISER UP VALVE
23 18 12 30 30 RED/GREEN 30 30 30 4H-30 99
Right POSITION 12-A RISER DOWN VALVE
J
100
LT 101
S13
10A 10B
TURRET
RT ROTATE 102
R1=6 ohm
20 32 32 GREEN/BLACK 32 32 32 4H-32
103 TURRET ROTATE LEFT VALVE
POSITION 14-A
35 33 33 GREEN/WHITE 33 33 33 4H-33
104 TURRET ROTATE RIGHT VALVE
POSITION 15-A
105
UP 106
10A
107
S12
10B BOOM LIFT 108
DN
109
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 13 13 4H-13
K
ORANGE 13 BOOM DOWN VALVE

POSITION 6-A 111
33 20A
112
IN
10A S14
TELESCOPE 113
OUT SUPPR.
S18 114
38 38 ORANGE/RED 38 38 38 3H-38
TELESCOPE IN TELESCOPE IN VALVE
RET/EXT 08 POSITION 8-B 115
39 39 BLACK/RED 39 39 39 3H-39
TELESCOPE OUT VALVE
OUT POSITION 9-B
SUPPR. 116
20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 BLUE/PURPLE 41 41 41 4H-41
PLATFORM UP
LEVELING 08 POSITION 11-B 120 PLATFORM LEVEL UP VALVE
40 40 BLUE/RED 40 40 40 4H-40
DN POSITION 10-B 121 PLATFORM LEVEL DOWN VALVE
L
SUPPR.
20A
122
123
36 36 RED/PURPLE 36 36 D36 36A 36A 2H-36A
LT
S20 08 POSITION 18-A 124 PLATFORM ROT. ENABLE VALVE
PLATFORM 37 02 02 4H-36 LT SUPPR.
10A S16
ROTATE RT 125
PLATFORM
SUPPR. ROTATE
126 PLATFORM ROT. LEFT VALVE
02 02 4H-37 RT
20A
D37 127 PLATFORM ROT. RIGHT VALVE
37 WHITE/RED/BLACK 37 37 36A
POSITION 19-A 128
129
SUPPR.
130
35 35 ORANGE/WHITE 35 35 D35 34A 34A 2H-34A
S21 UP 131 JIB ENABLE VALVE
08 POSITION 17-A
JIB 34 02 02 4H-35
UP/DOWN 10A UP
M
DN S17 132
JIB UP/DOWN
SUPPR. 133 JIB UP VALVE
02 02 4H-34
20A DN 134 JIB DOWN VALVE
D34
46AJ ONLY 34 ORANGE/BLACK 34 34 34A
POSITION 16-A 135
136
137
CB5 50 AMP 2H-85-1 138

WHITE WHITE ORANGE 85 02 OPTIONAL 12KW GENERATOR VALVE
139
RED RED RED 3Ø
F
2H-85-2 140
BLACK BLACK BLACK 85 02
141
GREEN GREEN GREEN GREEN OPTIONAL 12KW GENERATOR VALVE
D85 142
110A WHITE
N
143
CB4 15 AMP
110B 110C NOTE: WITH WELDER GENERATOR OPTION HYDRAULIC
F 144
MALE AND FEMALE PLUGS ARE CONNECTED
12KW GENERATOR
145
WELDER OPTION
146
147
148
110A 110A 110A 110V PLATFORM POWER
WHITE
149
110B BLACK 110B 110B
M 150
GND GREEN GND
151
110A HYDRAULIC 152

OPTIONAL 3.5KW GENERATOR
CB6 15 AMP 3.5KW GENERATOR 153
110B 110C
O
F
OPTION 154
NOTE: WITH HYDRAULIC GENERATOR OPTION
MALE AND FEMALE PLUGS ARE CONNECTED 155
M169635AC
Z
T
Y
X
S
R
SKYJACK, Page 97
AD
S9
IGNITION
194313
57 START S4 S2
04 RUN SWITCH B1 2
04C 07A 07A RED 07A RT CB1 15 AMP
07 05 05 03 00
A
POSITION 3-A CTR

ENGINE OFF 3
10 12 12 RED/YELLOW/BLACK 12 LEFT PL3 CB2 15 AMP
12 10 02 00 00
10 BLUE/WHITE 10
03A CB3 15 AMP 03 5
PL4 POSITION 4-A
108CR 6
03
M1 7

01ACR 108 EMERGENCY PUMP
01 PURPLE/BLACK 01 01 01A 02 8
POSITION 1-A
09 108 CB4 86CR 9
S6 03B 86A
E-PUMP M
S5 09 86
IGNITION/E-PUMP
09 02
E-PUMP 01
12
12
04C 04 D01A 03A 54A
ENABLE 13
10A STARTER
B
10
14
04 START 01 00B
15
07CR
D00B
GEN. POSITION 14-B
08 02 OPTION 00A 17 HOURMETER
54A 00A
TT
08CR 02 57ACR1 TT1 18
HOURMETER ALTERNATOR
D10 07 09 19
04 D04 60
20
S23 60 WHITE/BLUE 60 60 02 02
HORN SWITCH POSITION 16-B TO ENGINE TO ENGINE 21
60CR 49CR STARTER BLOCK
04C 49 GREEN/RED 49 49 02 02 22
POSITION 12-B
H1 23
HORN
00A ENGINE RUNNING
07 49A 02 24
C
HORN
57A
02 02 WHITE 02 02 25 START COMMAND
08
POSITION 1-B
PL5 09CR1 26
08 09 00A 03B
27
02
02 02 02 WHITE 02 09 09B
FOOTSWITCH 09B 28 TELEMATICS OPTION
POSITION 2-B KEY TELEMATICS
27A OPTION
TILT 29
D7A
OVERLOAD 30
76 76 BROWN/BLUE 76 D12 FS1 LOW
ENGINE FAULT FUEL SWITCH 31
POSITION 18-B
55 55 YELLOW/PURPLE 55
LOW FUEL 32 FUEL LEVEL INDICATOR
POSITION 13-B
BP1 R7=680 ohm 33
54A 76
04B TILT
ALARM 34
60 27A
PL1
D
D04-1 54A 76 76 35
04 ENGINE FAULT ENGINE FAULT (MIL)
02 27A 36
37
S26 02 27 54A 38
FUEL SELECT ENGINE ON (VSW)
SWITCH
27CR 39
60 11 11
11 PROPANE 11 WHITE/ORANGE
40 FUEL SELECT (HI = PROPANE)
POSITION 3-B (LOW = GASOLINE)
41
42
Refer to 5.9-6 Oscillating Cylinder Bolt Replacement
43
78 44
78+79 ON = HIGH IDLE, N=2000 RPM
79 45
79 ON = LOW IDLE, N=1700 RPM
E
46
D10A-1 D78
KUBOTA EFI DUAL FUEL ENGINE 47
48
S10
THROTTLE 49
POSITION 20-B 51
52
53
LS4 LS3 LS2
POSITION 15-B
S48
YELLOW/ORANGE 45 45
F
SWITCH 45 02
MOTOR 2-SPEED VALVE
59
D85A-1 S11
FOOT 60
08A SWITCH
61
SUPPR.
62
04 JMPR2 04A D10A 21A 2H-21A
WITH OPTIONAL GENERATOR 20 20 ORANGE/BLUE 20 20 JMPR3 21CR 02 64 DUMP VALVE RELAY
REMOVE JMPR2
POSITION 8-A
S22 65
ELECTRICAL SUPPR.
GENERATOR 66
04 04A 2H-85
85 OPTIONAL GENERATOR VALVE
85A 85 GRAY/BLUE 85 02
67
G
POSITION 21-B
68
S28
DIFF LOCK 20 02
D08-1 26B 165 69 OPTIONAL STROBE LIGHT
SWITCH
LB2
D26A 02
165 02A 20 02 70
ALL MOTION ALARM
LOCK OFF
165CR BP2 71
PL6 73
74
75
SCM-VALVE DRIVER 76
26A 7 3H-65 77
08 04 19 65 65 YELLOW/PINK 65 65 02 AXLE LOCK VALVE
POSITION 21-A
H

27
08F 08F 6 79
02 45CR2
45
08FCR 04 1 26 80
02
128A BLUE/WHITE/YELLOW AT1
128A 81
04 2 31 59 59 09 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
14 BLACK/YELLOW 128A 128 02 82
128A 128A 128A
POSITION 22-B 3H-16
04 13 34 WHITE/BLACK 16 16 83
16 16 FORWARD DRIVE VALVE
POSITION 5-B 3H-15
23 15 15 BLUE 15 15 84
REVERSE DRIVE VALVE
POSITION 4-B 3H-26
10 BLUE/YELLOW 26 85
26 26 26 02 BRAKE VALVE
BOOM/TUR POSITION 11-A
20A D20A
A1 Y 29 15 17 BLUE/GREEN 17 STEERING AXLE SENSING 09 87
17
BOOM/TURRET Yaxis
POSITION 6-B
JOYSTICK 02 25 88
I
Gnd
32 28 GREEN 28 28 89
28
POSITION 7-B
4 24A 4H-24A 90
RISER POSITION 10-A
04 02 24 SUPPR. 91
A3 Vbat Gnd
RISER R 30 21 23A BLACK/WHITE 23A 23A 4H-23A 92
23A 02 RIGHT STEER VALVE
JOYSTICK Output
POSITION 9-A
SUPPR. 93
3.46 Electrical Schematic Diagram (46AJ ANSI/CSA - Kubota WG2503 Dual Fuel Engine)
02 94
UP 31 95
10A
DRIVE S25
04 02 96
Vbat Gnd RISER
D 27 10B
DN 30 97
A2 Output
DRIVE/STEER 24 17 9 31 31 RED/WHITE 31 31 31 4H-31
98
JOYSTICK Left POSITION 13-A RISER UP VALVE
23 18 12 30 30 RED/GREEN 30 30 30 4H-30 99
J

100
LT
S13 101
10A 10B
TURRET
RT ROTATE 102
R1=6 ohm
20 32 32 GREEN/BLACK 32 32 32 4H-32
POSITION 14-A
35 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 15-A
105
UP 106
10A
107
S12
10B BOOM LIFT 108
DN
109
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
K
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 6-A 111
33 20A
112
IN
10A S14
TELESCOPE 113
OUT SUPPR.
S18 114
38 38 ORANGE/RED 38 38 38 3H-38
08 POSITION 8-B 115
RET/EXT 39 3H-39
39 39 BLACK/RED 39 39 TELESCOPE OUT VALVE
OUT POSITION 9-B 116
SUPPR.
20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 BLUE/PURPLE 41 41 41 4H-41
PLATFORM UP PLATFORM LEVEL UP VALVE
08 POSITION 11-B 120
LEVELING 40 4H-40
40 40 BLUE/RED 40 40
L
DN POSITION 10-B PLATFORM LEVEL DOWN VALVE

121
SUPPR.
20A
122
123
36 36 RED/PURPLE 36 36 D36 36A 36A 2H-36A
LT
S20 08 POSITION 18-A 124 PLATFORM ROT. ENABLE VALVE
10A S16
ROTATE RT 125
PLATFORM
SUPPR. ROTATE
126 PLATFORM ROT. LEFT VALVE
02 02 4H-37 RT
20A
D37 127 PLATFORM ROT. RIGHT VALVE
37 WHITE/RED/BLACK 37 37 36A
POSITION 19-A 128
129
SUPPR.
130
S21 UP 131 JIB ENABLE VALVE
08 POSITION 17-A
JIB 34 02 02
M
4H-35 UP
UP/DOWN DN 10A 132
S17
JIB UP/DOWN
SUPPR. 133 JIB UP VALVE
02 02 4H-34
20A DN 134 JIB DOWN VALVE
D34
34 ORANGE/BLACK 34 34 34A
POSITION 16-A 135
136
137
CB5 50 AMP 2H-85-1 138

WHITE WHITE ORANGE 85 02 OPTIONAL 12KW GENERATOR VALVE
139
RED RED RED 3Ø
F
2H-85-2 140
141
GREEN GREEN GREEN GREEN
OPTIONAL 12KW GENERATOR VALVE
D85 142
N
110A WHITE
143
CB4 15 AMP
F 144
12KW GENERATOR
145
WELDER OPTION
146
147
148
110A WHITE 110A 110A 110V PLATFORM POWER
149
M 150
GND GREEN GND
151
110A HYDRAULIC 152

O
110B 110C
F
OPTION 154
M170419AC
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S9
IGNITION
57 START S4 S2
194313
04 RUN SWITCH B1 2
04A 07A 07A RED 07A RT CB1 15 AMP
07 05 05 03 00
POSITION 3-A CTR
ENGINE OFF 3
A

12 10 02 00 00
10 BLUE/WHITE 10
03A CB3 15 AMP 03 5
PL4 POSITION 4-A
03B 108CR 6
03
M1 7
108 EMERGENCY PUMP

01ACR

POSITION 1-A
09 108 CB4 86CR 9
S6 03B 86A
E-PUMP S5 M
IGNITION 09 86
/E-PUMP
09 02
E-PUMP 01
12
12
03A 54 57BCR
04A 04 D01A
ENABLE 03 13
10A M STARTER
10
57B
B
X23-ENGINE CONNECTOR 14
04 START 01 00B
15
57ACR PS1
07CR 11 ENGINE OIL PR.
57 57A BROWN/GREEN 57A 57A 57A 00A 00B 00B 16
GEN. POSITION 14-B
08 02 OPTION 17
54A 57B 57B 4
08CR 02 57ACR1 03 18
1 A ALTERNATOR
77 77
D10 07 09 19
04 D04 60 10
11 FU1 20
S23 60 WHITE/BLUE 60 60 02 02 50A
HORN SWITCH POSITION 16-B 21
49CR 11A
60CR
04A 49 GREEN/RED 49 49 02 54ACR 22 COLD START RELAY
POSITION 12-B 11B
H1 54A 23 GLOW PLUGS (3)
HORN
07 49A 02 TO ECU 24
D5.1, PIN 3 HORN
C
25
08
PL5 02 02 WHITE 02 02 26
08 POSITION 1-B
02 02 27
R5=51 ohm ECU
02 02 02 WHITE 02 54A 77 02 HOURMETER
FOOTSWITCH TT CONNECTOR D5.2 28
POSITION 2-B TT1 (LOCATED ON ECU R.H.S.)
D27 27A HOURMETER ENGINE CONTROLLER
TILT 29
00A 16
OVERLOAD 30 ANTI-RESTART
D76 76 76 BROWN/BLUE 76 FS1 LOW
POSITION 18-B
55 55 YELLOW/PURPLE 55 55 02 02 1
LOW FUEL 32
POSITION 13-B
D74 74 74 GREEN/GRAY 74
GLOW PLUG B 106 2 33 DIAGNOSTIC CONNECTOR
POSITION 17-B
04 BP1 03 L 105 10
CB40 X22 34
TILT S40 20A
POSITIVE AIR DIAG PORT
ALARM 27A SHUT OFF 403 104 11
SWITCH 02
K 35
04
D
02 402 REV R7=680 ohm

CONTROLLER 76 A 54A
02 27A 401 54A 36
408
SHUT OFF 410 54A 54A 14 37

SOLENOID 403A
403A
02 PL1
27 38
54A 76
ENGINE FAULT
AIR S.O.
27CR PL40 U 39
02 403A n PL2
-
+
SPEED 74 74 5
SENSOR GLOW PLUG 40
POSITIVE AIR DIAGNOSE 41

SHUT OFF SWITCH
S8 42
OPTION
76 4
54 54A
43
02 403A
S10 103 103 17 44 POSITIVE AIR SHUT OFF VALVE OPTION
THROTTLE D10A-1
403ACR
SWITCH 78 2000 RPM 78 RED/BLUE 78 45
E
46 LOW IDLE RELAY N=1650 RPM

POSITION 20-B 79CR
78 1650RPM
99 18 47 HIGH IDLE RELAY N=2000 RPM
78CR
2000RPM 48
90 21
77CR
77 02 JMPR 23 49
24 50
03B
09 09B 51
09B 02
02 02
D12 KEY
52
02
D7A 53 TELEMATICS OPTION
LS3 LS2 LS2
59 YELLOW/BLUE 59 59 N/C 29A N/C 29 N/C 09 TELEMATICS 02
OPTION 55 BOOM TURRET LIMIT SWITCHES
POSITION 15-B
S48
POSITION 20-A
F
59 3H-45 57
MOTOR 2-SPEED VALVE
59
D85A-1 S11
FOOT 60
08A SWITCH
61
SUPPR.
62
04 JMPR2 04A D10A 21A 2H-21A
WITH OPTIONAL GENERATOR 20 20 ORANGE/BLUE 20 JMPR3
20 21 21CR 02
REMOVE JMPR2 64 DUMP VALVE RELAY
POSITION 8-A
S22 65
ELECTRICAL SUPPR.
GENERATOR 66 OPTIONAL 3.5 KW GENERATOR VALVE
04 04A 2H-85
85A 85 GRAY/BLUE 85 85 02
67
POSITION 21-B
G
68
20 02
69 OPTIONAL STROBE LIGHT
S28 LB2
D08-1 DIFF LOCK
26B 165 SWITCH 20 02 70
ALL MOTION ALARM
D26A 02
165 02A BP2 71
LOCK OFF
165CR 72
PL6 74
75
SCM-VALVE DRIVER 76
26A 3H-65 77
08 04 19 7 65 65 YELLOW/PINK 65 65 02 AXLE LOCK VALVE
POSITION 21-A
27
H
08F 08F 6 79
02 45CR2
45
08FCR 04 1 26 80
02
128A 81
04 2 31 59 59 09 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
128A 128A 128A
POSITION 22-B 3H-16
04 13 34 R4=30 ohm 16 16 83
16 16 WHITE/BLACK FORWARD DRIVE VALVE
POSITION 5-B 3H-15
23 15 R3=30 ohm 15 BLUE 15 15 84
REVERSE DRIVE VALVE
POSITION 4-B 3H-26
BOOM/TUR RESISTORS MAY POSITION 11-A
20B D20B NOT BE
A1 PRESENT SENSING 87
Y 29 15 17 17 BLUE/GREEN 17 STEERING AXLE 09
BOOM/TURRET Yaxis
POSITION 6-B
JOYSTICK 02 25 88
Gnd
I
32 28 GREEN 28 28 89
28
POSITION 7-B
4 24A 4H-24A 90
RISER POSITION 10-A
04 02 24 SUPPR. 91
Vbat Gnd
A3 R 30 21 23A BLACK/WHITE 23A 23A 4H-23A 92
23A 02 RIGHT STEER VALVE
RISER Output
POSITION 9-A
JOYSTICK SUPPR. 93
3.47 Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D2011 Diesel Engine)
02 94
UP 31 95
10A
DRIVE S25
04 02 96
Vbat Gnd RISER
D 27 20C
A2 DN 30 97
Output
DRIVE/STEER
JOYSTICK 24 17 9 31 31 RED/WHITE 31 31 31 4H-31
98
Left POSITION 13-A RISER UP VALVE
23 18 12 30 30 RED/GREEN 30 30 30 4H-30 99
J
100
LT
S13 101
10A 20C
TURRET
RT ROTATE 102
R1=6 ohm
20 32 32 GREEN/BLACK 32 32 32 4H-32
POSITION 14-A
35 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 15-A
105
UP 106
10A
107
S12
20C BOOM LIFT 108
DN
109
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
K
POSITION 6-A 111

33 20A
112
IN
10A S14
TELESCOPE 113
OUT SUPPR.
S18 114
38 38 ORANGE/RED 38 38 38 3H-38
08 POSITION 8-B 115
RET/EXT 39 3H-39
39 39 BLACK/RED 39 39 TELESCOPE OUT VALVE
SUPPR.
20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 BLUE/PURPLE 41 41 41 4H-41
08 POSITION 11-B 120
LEVELING 40 4H-40
40 40 BLUE/RED 40 40
DN POSITION 10-B PLATFORM LEVEL DOWN VALVE
121
L
SUPPR.
20A
122
123
36 36 RED/PURPLE 36 36 D36 36A 36A 2H-36A
LT PLATFORM ROT. ENABLE VALVE
S20 08 POSITION 18-A 124
10A PLATFORM ROT. LEFT VALVE
ROTATE RT 125
SUPPR.
126
02 02 4H-37 RT S16
20A PLATFORM PLATFORM ROT. RIGHT VALVE
D37 127
37 WHITE/RED/BLACK 37 37 36A ROTATE
POSITION 19-A 128
129
SUPPR.
130
S21 UP JIB ENABLE VALVE
08 131
JIB POSITION 17-A
34 02 02 4H-35
UP/DOWN 10A UP
DN 132 JIB UP VALVE
M
SUPPR. DN 133
02 02 4H-34 S17
20A JIB UP/DOWN JIB DOWN VALVE
D34 134
46AJ ONLY 34 ORANGE/BLACK 34 34 34A
POSITION 16-A 135
136
137
CB5 50 AMP 138

2H-85-1 OPTIONAL 12KW GENERATOR VALVE
WHITE WHITE ORANGE 85 02
139
RED RED RED 3Ø
F 140
2H-85-2
141
GREEN GREEN GREEN GREEN OPTIONAL 12KW GENERATOR VALVE
142
110A WHITE D85
N
143
CB4 15 AMP
110B 110C NOTE: WITH WELDER GENERATOR OPTION HYDRAULIC 144
F
12KW GENERATOR 145
WELDER OPTION
146
147
148
110V PLATFORM POWER
110A WHITE 110A 110A 149
M 150
GND GREEN GND
151
152
110A HYDRAULIC OPTIONAL 3.5KW GENERATOR
153
CB6 15 AMP 3.5KW GENERATOR
O
110B 110C
F
OPTION 154
155
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IGNITION
57 START S4 S2 S1 03B
07A RED DISCONNECT
194313
07A BASE/OFF/PLATFORM EMERGENCY 1
STOP SWITCH
POSITION 2-A STOP
04 RUN B1 2
04A 07A 07A RED 07A RT CB1 15 AMP B+
07 05 05 03 00
POSITION 3-A
ENGINE OFF 03B 3
10 12 12 RED/YELLOW/BLACK 12 LEFT PL3
12
A
POSITION 5-A 02 CB2 15 AMP 4 BATTERY

10 00 00
10 BLUE/WHITE 10 5
PL4 POSITION 4-A
CB3
01ACR 15A 108CR 6
01 PURPLE/BLACK 01 01 01A 02
56 03
POSITION 1-A M1 7
09 108 108 EMERGENCY PUMP
D01A
8

9
S6 54 77 CB4 86CR
E-PUMP 03B 86A
SWITCH M 10 OPTIONAL OIL COOLER
S5 77CR
IGNITION/E-PUMP 20A
20 01 SWITCH 11
E-PUMP 01
TSW1 12
12 09 86
04A 04
ENABLE 13
10A STARTER
10 02
14
B
04 START
15

GEN. POSITION 14-B
08 02 OPTION 17
08CR 57ACR1
02 18
07 09 03 00 19
04 D04 60 D10 TO ENGINE TO ENGINE
STARTER POST GROUND 20
S23 60 WHITE/BLUE 60 60 02 02
B+ 00 21
HORN SWITCH POSITION 16-B
60CR 49CR TO TO
04A 49 GREEN/RED 49 49 02 ECU ECU 22
SEE ENGINE DETAIL
POSITION 12-B
H1 ON SHEET 2 23
HORN
02 02 WHITE 02 07 49A 02 24
POSITION 2-B
25
C
08
02 02 WHITE 02 DIAGNOSE
PL5 POSITION 1-B SWITCH 26
08 S8
103 27
1
FOOTSWITCH 02 02 103A 28
2
D27 27A FS1 LOW 56 56B

TILT
3
FUEL SWITCH 29
55 02
OVERLOAD 56ACR 30 FUEL PUMP RELAY
56A
4
D76 76 76 BROWN/BLUE 76
ENGINE FAULT 54 31
POSITION 18-B
55 55 YELLOW/PURPLE 55 PL4 LOW FUEL 09
LOW FUEL 32
5
+
POSITION 13-B -
6
GLOW PLUG 33
POSITION 17-B 203
7
04 BP1
34
TILT 57A
8
ALARM 27A
X22 35
04
9
DIAGNOSTIC R3=
02 27A PL6 PREHEAT 74 36 PREHEAT/GLOW PLUG INDICATOR
D
PORT 120
10
09 09 ohm - 105
A G 105 37 DIAGNOSTIC CONNECTOR
02 B H 104 104
11 12
02 27 38
27CR 76ACR 39
PL3 MIL 09 76A 76B 76B
1
40
+
-
2
Deutz D2.9L Engine
76A 41
3
76 02 99 42
4
S10 90
5
THROTTLE 43
D10A-1
SWITCH 78 2000 RPM 78 RED/BLUE 78 JMPR
6
79CR
1750 RPM 44
08 D08 POSITION 19-B
79 79
7
79 1750 RPM 79 BROWN/PURPLE

R6= 45 LOW IDLE RELAY N=1750 RPM
POSITION 20-B 09
8
3.9k
90 99B ohm R4= 54 46
9
2.2k
ohm
Refer to 3.53 Interface & Engine Electrical Schematic -
78CR PL8 W.I.F. 81

E
10
2000 RPM 47 WATER IN FUEL INDICATOR

+
-
78
R5= 48 HIGH IDLE RELAY N=2000 RPM
2.1k H.M. 77
ohm TT1
+
90 99A D09 - 09A 49 HOURMETER

11 12
50
51
09
52
02 53
LS3 LS2 LS2
POSITION 15-B
S48
F
MOTOR 2-SPEED VALVE

D09 09CR SUPPR. 58 (COIL ON = HIGH SPEED)
09 09 -1 77 03B 59
D85A-1 S11 02
09B
FOOT 09 09 09B 60 TELEMATICS OPTION
KEY
08A SWITCH
61
D7A
TELEMATICS SUPPR.
OPTION 62
04 JMPR2 04A D10A D12 21A 2H-21A
20 20 ORANGE/BLUE 20 20 JMPR3 21 21CR 02 64 DUMP VALVE RELAY
POSITION 8-A
D21 21B 3H-21B 02
WITH OPTIONAL GENERATOR 65 OPTIONAL LOAD CIRCUIT VALVE
REMOVE JMPR2 D57A D85-1
66
SUPPR.
S22
ELECTRICAL SUPPR. 67
GENERATOR
AH
04 04A 2H-85
85 GRAY/BLUE 85 68 OPTIONAL 3.5 KW GENERATOR VALVE
85A 85A 85 02
G
POSITION 21-B
69
20 02 70
S28 LB2 71 OPTIONAL STROBE LIGHT
D08-1 DIFF LOCK
26B 165 SWITCH 20 02
72
D26A 02 ALL MOTION ALARM
165 02A BP2
LOCK OFF 73
165CR
165 LOCK ON 165 PINK/BLACK 165 165 3H-165 74
26A POSITION 24-A
SUPPR. DIFFERENTIAL LOCK
75 (COIL ON = LOCKED)
PL6
76
R7=250 ohm 77
SCM-VALVE DRIVER
78
26A 3H-65
08 04 19 7 65 65 YELLOW/PINK 65 65 02 79 AXLE LOCK VALVE
POSITION 21-A
H
08A 16 11 27 45CR2 SUPPR. (COIL ON = FLOATING AXLE)

45 80
02 08F 08F 6
81
AT1
08FCR 04 1 26 02 09
128B ANGLE TRANSDUCER 82
128A BLUE/WHITE/YELLOW 128A 128A & TILT SWITCH
04 2 31 59 59 POSITION 23-B 83
14 128A 128A BLACK/YELLOW 128A 02
84
POSITION 22-B 3H-16
04 13 34 16 16 WHITE/BLACK 16 16
85
POSITION 5-B 3H-15 FORWARD DRIVE VALVE
23 15 15 BLUE 15 15
86
POSITION 4-B REVERSE DRIVE VALVE
3H-26
10 26 26 BLUE/YELLOW 26 26 02 87
POSITION 11-A BRAKE VALVE
BOOM/TUR LS1 SUPPR.
04 X 28 5 20A D20A N.C. HELD OPEN
Vbat Xaxis WITH ENGINE OVER DIRECTION 88
A1 Y 29 15 17 17 BLUE/GREEN 17 STEERING AXLE SENSING 09
BOOM/TURRET Yaxis 89
POSITION 6-B
JOYSTICK 02 25
I
Gnd 90
32 28 28 GREEN 28 28
91
POSITION 7-B
4 24A 24A 24A 24A 4H-24A
BLUE/BLACK 02 92
RISER POSITION 10-A LEFT STEER VALVE
04 02 24 SUPPR.
Vbat Gnd 93
A3 R 30 21 23A 23A BLACK/WHITE 23A 23A 4H-23A 02
Output 94
3.48 Electrical Schematic Diagram (46AJ ANSI/CSA - Deutz D2.9L Diesel Engine)
RISER RIGHT STEER VALVE

POSITION 9-A
JOYSTICK SUPPR.
95
02
96
UP 31
10A 97
DRIVE S25
04 02
Vbat Gnd RISER
98
D 27 20C
A2 DN 30
Output 99
DRIVE/STEER
JOYSTICK 24 17 9 31 31 RED/WHITE 31 31 31 4H-31
Left POSITION 13-A 100
23 18 12 30 4H-30 RISER UP VALVE
30 30 RED/GREEN 30 30
Right
J
POSITION 12-A 101

RISER DOWN VALVE
102
LT
S13
10A 20C 103
TURRET
RT ROTATE
R1=6 ohm 104
20 32 32 GREEN/BLACK 32 32 32 4H-32
POSITION 14-A 105 TURRET ROTATE LEFT VALVE
35 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 15-A 106 TURRET ROTATE RIGHT VALVE
107
UP
10A 108
S12 109
20C BOOM LIFT
DN 110
22 14 14 BLACK 14 14 14 4H-14 111

POSITION 7-A BOOM UP VALVE
K
8 13 13 ORANGE 13 13 13 4H-13 112

POSITION 6-A BOOM DOWN VALVE
33 20A 113
IN 114
10A S14
TELESCOPE SUPPR.
OUT 115
S18 38 38 38 3H-38
IN 38 ORANGE/RED 38 116
TELESCOPE
08 POSITION 8-B TELESCOPE IN VALVE
RET/EXT 39 3H-39
39 39 BLACK/RED 39 39 117
OUT POSITION 9-B TELESCOPE OUT VALVE
SUPPR.
20A 118
UP 41 S15 119
10A
PLATFORM
DN 40 SUPPR. 120
LEVELING
S19 41 41 41 41 4H-41
UP 41 BLUE/PURPLE 121
PLATFORM
08 POSITION 11-B PLATFORM LEVEL UP VALVE
LEVELING 40 4H-40
40 40 BLUE/RED 40 40 122
DN
L
POSITION 10-B PLATFORM LEVEL DOWN VALVE

SUPPR. 123
20A
124
36 36 RED/PURPLE 36 36 D36 36A 36A 2H-36A 125

LT
S20 08 POSITION 18-A PLATFORM ROT. ENABLE VALVE
PLATFORM 37 02 02 4H-36 LT SUPPR. 126
10A
ROTATE RT PLATFORM ROT. LEFT VALVE
127
SUPPR.
02 02 4H-37 RT S16 128
20A PLATFORM
D37 PLATFORM ROT. RIGHT VALVE
129
POSITION 19-A
130
SUPPR. 131
35 35 ORANGE/WHITE 35 35 D35 34A 34A 2H-34A 132

S21 UP
08 POSITION 17-A JIB ENABLE VALVE
JIB 34 02 02 133
4H-35 UP
M
UP/DOWN DN 10A
JIB UP VALVE
134
SUPPR. DN
02 02 4H-34 S17 135
20A JIB UP/DOWN
D34 JIB DOWN VALVE
46AJ ONLY 34 ORANGE/BLACK 34 34 34A 136
POSITION 16-A
137
138
139
CB5 50 AMP 2H-85-1
WHITE WHITE ORANGE 85 02 140
RED RED RED 3Ø 141
F
2H-85-2 142
GREEN GREEN GREEN GREEN 143

D85
110A WHITE 144
N
CB4 15 AMP 145

F
12KW GENERATOR
WELDER OPTION 147
148
149
150
110A WHITE 110A 110A 110V PLATFORM POWER
151
M
152
GND GREEN GND
153
110A HYDRAULIC 154

O
110B 110C
F
OPTION
M169636AH
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AD
S9 CI
IGNITION 03 00 1
57 START S4 S2 V CHARGE INDICATOR
194313
EMERGENCY KEY SWITCH S3 2
07A RED 07A EMERGENCY S1
3
04 RUN SWITCH B1
04A 07A 07A RED 07A 07A RT CB1 15 AMP
07 05 05 03 00 4 BATTERY
POSITION 3-A CTR
A
ENGINE OFF
12 10 02 00 00 5
POSITION 5-A
10 BLUE/WHITE 108CR 6
10
03A CB3 15 AMP 03 03
PL4 POSITION 4-A
M1 7
D07A 01ACR 108 EMERGENCY PUMP

POSITION 1-A
09 108 CB4 86CR 9
S6 03B 86A
E-PUMP D12 M
TSW1 10 OPTIONAL OIL COOLER
SWITCH S5 09 86 20A
IGNITION/E-PUMP
162A 01 SWITCH 09CR 11
09 02
E-PUMP 01
12
12A
03A 54A 57BCR
04A 04 D01A
ENABLE 03 13
10A M STARTER
10
57B 14
B
X23-ENGINE CONNECTOR
04 START 01 00B
15
57ACR PS1
07CR ENGINE OIL PR.
57 57A BROWN/GREEN 57A 57A 00A 00B 11 00B
57A 16
GEN. POSITION 14-B
08 02 OPTION 17
54A 57B 57B 4
08CR 02 57ACR1 03 18
1 A ALTERNATOR
77 77
07 09 19
04 D04 60 D10 10
11 FU1 20
S23 60 WHITE/BLUE 60 60 02 02 50A
49CR 11A
60CR
POSITION 12-B 11B
HORN
49A 02 TO ECU 24
C
07
D5.1, PIN 3 HORN
25
08
PL5 02 02 WHITE 02 02 26
08 POSITION 1-B
27
R5=51 ohm ECU
02 02 02 WHITE 02 54A 77 HOURMETER
FOOTSWITCH CONNECTOR D5.2 28
POSITION 2-B (LOCATED ON ECU R.H.S.)
D27 27A ENGINE CONTROLLER
TILT 29
02B 00A 16
POSITION 18-B
55 55 YELLOW/PURPLE 55 55 02 02 1
LOW FUEL 32
POSITION 13-B
POSITION 17-B
04 BP1 105
D
X22 L 10 34
TILT
DIAG PORT
60 ALARM 27A K 104 11 35
04
R7=680 ohm 54A
02 27A 54A 76 A 36
54A 54A 14 37
02 PL1
27 38
54A 76
ENGINE FAULT
82 02 27CR 39
PL2
BP3 82CR 74 74 5
GLOW PLUG 40
D118 OVERLOAD
118 ALARM 02 DIAGNOSE 41
SWITCH
PLATFORM LOAD SENSOR S8 42
76 4
43
E
118 4 1 60
103 103 17 44
82 5 7 02 02
45
162 3 2 161 161 PINK/WHITE 161 JMPR4 09 79
POSITION 22-A 79CR
78 1650RPM
78CR
162 PINK/PURPLE 162 2000RPM
90 21 48
POSITION 23-A
JMPR 23 49
S10
THROTTLE D10A-1 24 50
79 1650 RPM 79 BROWN/PURPLE 79 02 02
POSITION 20-B 52
162
53 LOAD SENSOR RESISTOR
LS3 LS2 LS2
F
R6=680 ohm
SUPPR FLY IN LS BOOM DN LS RISER DN LS 54
POSITION 15-B
S48
MOTOR 2-SPEED VALVE
59
D85A-1 S11
59 59CR
FOOT 59 60
08A SWITCH
09 09 162A 61
SUPPR.
D162 D01A-2 62
04 JMPR2 04A D10A 21A 2H-21A
162A 162A 162A 02 63 DUMP VALVE
G

20 21 21CR 02 DUMP VALVE RELAY
REMOVE JMPR2 64
POSITION 8-A
S22 65
ELECTRICAL SUPPR.
GENERATOR D59 D162-2 66
04 04A 2H-85
85A 85 GRAY/BLUE 85 85 02 OPTIONAL GENERATOR VALVE
67
POSITION 21-B
68
20 02
S28 LB2
DIFF LOCK
04 165 SWITCH 20 02 70
OPTIONAL ALL MOTION ALARM
02
165 02A BP2 71
LOCK OFF
165CR 72
26C POSITION 24-A DIFFERENTIAL LOCK
H
01A 01B
PL6 74
08 04 75
162B 02
SCM-VALVE DRIVER 76
26ACR 162BCR
26 3H-65 77
02 26 10 7 65 65 YELLOW/PINK 65 65 02 AXLE LOCK VALVE
POSITION 21-A (COIL ON = FLOATING AXLE)
26C 08 08A 16 11 SUPPR. 78
27
driving=open
stopped=closed 08F 6 79
02 08F 45CR2
45
08FCR 04C 1 26 80
02
128A 81
04C 2 31 59 59 09 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
128A 128A 128A
POSITION 22-B
I
3H-16 83
04C 13 34 16 16 WHITE/BLACK 16 16 FORWARD DRIVE VALVE
162A 02 POSITION 5-B 3H-15
23 15 15 BLUE 15 15 84
REVERSE DRIVE VALVE
162ACR POSITION 4-B 3H-26 85
26 BLUE/YELLOW 26 26 02 BRAKE VALVE
20B D20B
Vbat Xaxis WITH ENGINE OVER DIRECTION 05
3.49 Electrical Schematic Diagram (46AJ & 51AJ CE - Deutz D2011 Diesel Engine)
A1 Y 29 15 17 BLUE/GREEN 17 STEERING AXLE SENSING 09 09 TT1 87

17 77 H-1
BOOM/TURRET Yaxis TT HOURMETER
POSITION 6-B
JOYSTICK 02 25 01B C1 88
C-1
D20C
Gnd C COUNTER
09F RC-1 89
32 28 28 GREEN 28 28
02
POSITION 7-B
4 24A 4H-24A 90
RISER POSITION 10-A
04 02 24 SUPPR. 91
Vbat Gnd
A3
R 30 21 23A BLACK/WHITE 23A 23A 4H-23A 92
RISER 23A 02 RIGHT STEER VALVE
Output
JOYSTICK POSITION 9-A
J
SUPPR. 93
162A BLUE/WHITE/BLACK 162A 94

POSITION 24-B
02 UP 31 95
10A
DRIVE S25
162A 02 96
Vbat Gnd RISER
D 27 20C
DN 30 97
A2 Output
DRIVE/STEER 24 9 31 31 RED/WHITE 31 31 4H-31
17 31 98
JOYSTICK Left RISER UP VALVE
POSITION 13-A
23 18 12 30 30 RED/GREEN 30 30 30 4H-30 99
100
LT
S13 101
10A 20C
TURRET
RT ROTATE 102
R1=6 ohm
K
20 32 32 GREEN/BLACK 32 32 32 4H-32
POSITION 14-A
35 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 15-A
105
UP 106
10A
107
S12
20C BOOM LIFT 108
DN
109
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 6-A 111
26A 19 33 20A
112
IN
L
10A S14
S18 TELESCOPE 113
TELESCOPE OUT SUPPR.
RET/EXT 114
38 38 ORANGE/RED 38 38 38 3H-38
IN TELESCOPE IN VALVE
26C POSITION 8-B 115
39 39 BLACK/RED 39 39 39 3H-39
TELESCOPE OUT VALVE
SUPPR.
26C 20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 BLUE/PURPLE 41 41 41 4H-41
26A POSITION 11-B 120
LEVELING 40 4H-40
40 40 BLUE/RED 40 40
DN POSITION 10-B PLATFORM LEVEL DN VALVE
121
26A SUPPR.
20C
122
M
123
LT 36 RED/PURPLE 36 36 D36 36A 36A 2H-36A
36 PLATFORM ROT. ENABLE VALVE
S20 26C 124
37 POSITION 18-A
PLATFORM 02 02 4H-36 LT SUPPR.
ROTATE RT 10A PLATFORM ROT. LEFT VALVE
125
SUPPR.
126
02 02 4H-37 RT S16
26C 20A PLATFORM ROT. RIGHT VALVE
PLATFORM
D37 127
POSITION 19-A 128
SUPPR.
129
UP 35 35 ORANGE/WHITE 35 35 D35 34A 34A 2H-34A
S21 26C 130
JIB 34 POSITION 17-A
UP/DOWN 02 02 4H-35 UP
DN 10A 131 JIB ENABLE VALVE
SUPPR. DN 132
N
02 02 4H-34 S17
26C 20A JIB UP/DOWN 133 JIB UP VALVE
D34
POSITION 16-A 134 JIB DOWN VALVE
135
136
137
HYDRAULIC 138
GENERATOR 139
OPTIONAL GENERATOR
OPTION 140
110A 110A 110A 110A 141

WHITE
110B CB6 15 AMP 142 110V PLATFORM POWER
O
BLACK 110B 110B 110B 110C

M F
GND GREEN GND 143
M170600AB
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AD
S9 CI
IGNITION 03 00 1
S4 S2 V CHARGE INDICATOR
194313
57 START S3
EMERGENCY KEY SWITCH 2
07A RED 07A EMERGENCY S1
3
04 RUN SWITCH B1
04A 07A 07A RED 07A 07A RT CB1 15 AMP
07 05 05 03 00 4 BATTERY
POSITION 3-A
A
ENGINE OFF CTR

12 10 02 00 00 5
POSITION 5-A
10 BLUE/WHITE 108CR 6
10
03A CB3 15 AMP 03 03
PL4 POSITION 4-A
M1 7
D07A 01ACR 108 EMERGENCY PUMP

POSITION 1-A
09 108 CB4 86CR 9
S6 03B 86A
E-PUMP D12 M
TSW1 10 OPTIONAL OIL COOLER
SWITCH S5 09 86 20A
IGNITION/E-PUMP
09 02
E-PUMP 01
12
12A
03A 54A 57BCR
04A 04 D01A
ENABLE 03 13
10A M STARTER
10
57B 14
B
X23-ENGINE CONNECTOR
04 START 01 00B
15
57ACR PS1
07CR 11 ENGINE OIL PR.
57 57A BROWN/GREEN 57A 57A 57A 00A 00B 00B 16
GEN. POSITION 14-B
08 02 OPTION 17
54A 57B 57B 4
08CR 02 57ACR1 03 18
1 A ALTERNATOR
77 77
07 09 19
04 D04 60 D10 10
11 FU1 20
S23 60 WHITE/BLUE 60 60 02 02 50A
49CR 11A
60CR
POSITION 12-B 11B
HORN
TO ECU
C
07 49A 02 24
D5.1, PIN 3 HORN
25
08
PL5 02 02 WHITE 02 02 26
08 POSITION 1-B
27
R5=51 ohm ECU
02 02 02 WHITE 02 54A 77 02 HOURMETER
FOOTSWITCH TT CONNECTOR D5.2 28
POSITION 2-B TT1 (LOCATED ON ECU R.H.S.)
D27 27A HOURMETER ENGINE CONTROLLER
TILT 29
02B 00A 16
POSITION 18-B
55 55 YELLOW/PURPLE 55 55 02 02 1
LOW FUEL 32
POSITION 13-B
POSITION 17-B
04 BP1
D
X22 L 105 10 34
TILT
DIAG PORT
60 ALARM 27A K 104 11 35
04
R7=680 ohm 54A
02 27A 54A 76 A 36
54A 54A 14 37
02 PL1
27 38
54A 76
ENGINE FAULT
82 02 27CR 39
PL2
BP3 82CR 74 74 5
GLOW PLUG 40
D118 OVERLOAD
118 ALARM 02 DIAGNOSE 41
SWITCH
PLATFORM LOAD SENSOR S8 42
76 4
43
E
118 4 1 60
103 103 17 44
82 5 7 02 02
45
162 3 2 161 161 PINK/WHITE 161 JMPR4 09 79
POSITION 22-A 79CR
78 1650RPM
78CR
162 PINK/PURPLE 162 2000RPM
90 21 48
POSITION 23-A
JMPR 23 49
S10
THROTTLE D10A-1 24 50
79 1650 RPM 79 BROWN/PURPLE 79 02 02
POSITION 20-B 52
162
53 LOAD SENSOR RESISTOR
LS3 LS2 LS2
F
R6=680 ohm
POSITION 15-B
S48
MOTOR 2-SPEED VALVE
59
D85A-1 S11
59CR
FOOT 59 60
08A SWITCH
09 09 162A 61
SUPPR.
D162 D01A-2 62
04 JMPR2 04A D10A 21A 2H-21A
162A 162A 162A 02 63 DUMP VALVE
G

20 21 21CR 02 DUMP VALVE RELAY
REMOVE JMPR2 64
POSITION 8-A
S22 65
ELECTRICAL SUPPR.
GENERATOR 66
04 04A 2H-85
85A 85 GRAY/BLUE 85 85 02 OPTIONAL GENERATOR VALVE
67
POSITION 21-B
68
20 02
S28 LB2
D08-1 DIFF LOCK
26B 165 SWITCH 20 02 70
OPTIONAL ALL MOTION ALARM
D26A 02
165 02A BP2 71
LOCK OFF
165CR 72
H
PL6 74
75
26ACR SCM-VALVE DRIVER 76
26A 02
26A 3H-65 77
26C 08 08 04 19 7 65 65 YELLOW/PINK 65 65 02 AXLE LOCK VALVE
POSITION 21-A (COIL ON = FLOATING AXLE)
08A 16 11 SUPPR. 78
27
08F 6 79
02 08F 45CR2
45
08FCR 26 80
02
128A 81
04 04C 04C 1 31 59 59 09 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
04C 2 14 BLACK/YELLOW 128A 128 02 82
128A 128A 128A
POSITION 22-B 3H-16 83
I
02 162A 34 16 16 WHITE/BLACK 16 16 FORWARD DRIVE VALVE

POSITION 5-B 3H-15
162ACR 04C 13 23 15 15 15 15 84
BLUE REVERSE DRIVE VALVE
POSITION 4-B 3H-26
20B D20B
3.50 Electrical Schematic Diagram (46AJ & 51AJ AS - Deutz D2011 Diesel Engine)
A1 Y 29 15 17 BLUE/GREEN 17 STEERING AXLE SENSING 09 87

17
BOOM/TURRET Yaxis
POSITION 6-B
JOYSTICK 02 25 88
Gnd
32 28 GREEN 28 28 89
28
POSITION 7-B
4 24A 4H-24A 90
RISER POSITION 10-A
04 02 24 SUPPR. 91
Vbat Gnd
A3
R 30 21 23A BLACK/WHITE 23A 23A 4H-23A 92
RISER 23A 02 RIGHT STEER VALVE
Output
JOYSTICK POSITION 9-A
J
SUPPR. 93
162A BLUE/WHITE/BLACK 162A 94

POSITION 24-B
02 UP 31 95
10A
DRIVE S25
162A 02 96
Vbat Gnd RISER
D 27 20C
DN 30 97
A2 Output
DRIVE/STEER 24 9 31 31 RED/WHITE 31 31 4H-31
17 31 98
JOYSTICK Left RISER UP VALVE
POSITION 13-A
23 18 12 30 30 RED/GREEN 30 30 30 4H-30 99
100
LT
S13 101
10A 20C
TURRET
RT ROTATE 102
R1=6 ohm
20 32 32 32 32 4H-32
K
GREEN/BLACK 32 103 TURRET ROTATE LEFT VALVE

POSITION 14-A
35 33 33 GREEN/WHITE 33 33 33 4H-33
POSITION 15-A
105
UP 106
10A
107
S12
20C BOOM LIFT 108
DN
109
22 14 14 BLACK 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 ORANGE 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 6-A 111
33 20A
112
IN
10A S14
L
S18 TELESCOPE 113

TELESCOPE OUT SUPPR.
RET/EXT 114
38 38 ORANGE/RED 38 38 38 3H-38
IN TELESCOPE IN VALVE
39 39 BLACK/RED 39 39 39 3H-39
TELESCOPE OUT VALVE
SUPPR.
26C 20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 BLUE/PURPLE 41 41 41 4H-41
LEVELING 40 4H-40
40 40 BLUE/RED 40 40
DN POSITION 10-B PLATFORM LEVEL DN VALVE
121
26C SUPPR.
20A
122
M
123
LT 36 RED/PURPLE 36 36 D36 36A 36A 2H-36A
36 PLATFORM ROT. ENABLE VALVE
S20 26C 124
37 POSITION 18-A
PLATFORM 02 02 4H-36 LT SUPPR.
ROTATE RT 10A PLATFORM ROT. LEFT VALVE
125
SUPPR.
126
02 02 4H-37 RT S16
26C 20A PLATFORM ROT. RIGHT VALVE
PLATFORM
D37 127
POSITION 19-A 128
SUPPR.
129
UP 35 35 ORANGE/WHITE 35 35 D35 34A 34A 2H-34A
S21 26C 130
JIB 34 POSITION 17-A
UP/DOWN 02 02 4H-35 UP
DN 10A 131 JIB ENABLE VALVE
SUPPR. DN 132
N
02 02 4H-34 S17
26C 20A JIB UP/DOWN 133 JIB UP VALVE
D34
POSITION 16-A 134 JIB DOWN VALVE
135
136
137
HYDRAULIC 138
GENERATOR 139
OPTIONAL GENERATOR
OPTION 140
110A 110A 110A 110A 141

WHITE
110B CB6 15 AMP 142 110V PLATFORM POWER
BLACK 110B 110B 110B 110C
O
M F
GND GREEN GND 143
M169638AB
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194313
GM EFI DUAL FUEL ENGINE
A
ECU1
R (TAN/DK GREEN)
8 (TAN/DK GREEN) AUX ANA PD 1 1 ECU
(TWIST WIRES 10 TURNS (360 DEG)/FOOT FULL LENGTH)

P (RED/BLACK)
25 (RED/WHITE) SPEED + 2
N (RED/WHITE)
26 (RED/BLACK) SPEED - 3
CONNECTOR 2
M (TAN/BLACK)
44 (TAN/BLACK) AUX DIG 3 4
B
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)
C
78 (WHITE/BROWN) PWM 5 RECIRC 10
78 J (GRAY/ORANGE)
52 (GRAY/ORANGE) GOV 2 11 1650 RPM
79 K (GRAY/DK BLUE)
51 (GRAY/DK BLUE) GOV 1 12 2000 RPM
00A C (BROWN/WHITE)
77 (BROWN/WHITE) PWM 5 13
02 E (BLACK)
69 (BLACK) GND TEMP 14
S (PINK/DK GREEN)
81 (BLACK) GND TEMP 15
D
CPS1
A (UNUSED)
A 22 (WHITE/PURPLE) CRANK - 16
B 21 (PURPLE/WHITE) CRANK + 17
CPS2
A 23 (GRAY/BROWN) CAM+ 18 CAMSHAFT
B 24 (PURPLE/ORANGE) CAM- 19
C 20
E
GI1-1
61 (BROWN/LT BLUE) INJ 1 LS 21
GI1-4
63 (BROWN/YELLOW) INJ 3 LS 22
GI1-2
64 (BROWN/WHITE) INJ 4 LS 23
GI1-3
62 (BROWN/LT GREEN) INJ 2 LS 24
IGC1
(YELLOW) A 25
F
B 26
IGM1
D B 31 (YELLOW) SPK COIL 1A 27
A C 28
OXS1
C D 72 (BLACK/WHITE) EGOH 1 29
PRE-CAT
B A 1 (DK GREEN/ORANGE) EGO 1 30

(RED) (PINK/DK GREEN) OXS2
G
A B 2 (DK GREEN/WHITE) EGO 2 31

POST-CAT
F10
C D 73 (BLACK/YELLOW) EGOH 2 32
FUSE 15A
IGNITION
71 (WHITE/LT BLUE) RELAY 33
2002CR
F8
79 (RED/TAN) VBAT 34
FUSE 20A
ECM
TPS1
B A 40 (TAN/WHITE) ECT 36
H
TPS2
B A 41 (WHITE/RED) EGT 37
SENSOR
MS1
1 2 39 (YELLOW/GRAY) IAT 38
3 4 7 (LT GREEN) MAP 39

RA1
2 1 83 (TAN/ORANGE) DBW - 40 THROTTLE
ACTUATOR
3 4 82 (PINK/WHITE) DBW + 41
I
1 (BLACK/LT GREEN)
5 6 (LT BLUE/DK BLUE) TPS 2 42
3.51 Interface & Engine Electrical Schematic - GM Dual Fuel Engine
2 (LT GREEN/RED)
6 5 (PURPLE/LT BLUE) TPS 1 43
3 (DK GREEN)
55 (DK GREEN) PC TX
DIAGNOSTIC
44
(RED/LT BLUE)
4 (ORANGE)
56 (ORANGE) PC RX 45
PRV1 F9 GPS1
8 (BLUE/WHITE) GASOLINE
1 7 A B 48 (LT GREEN/WHITE) (FRT) AUX ANA PU 3 46
FUSE 10A
J
7 (BLUE/PINK) EPR
3 C D 54 (WHITE/LT GREEN) (FRP) AUX AND PUD 1 47 PROPANE
2 6 13 (WHITE/ORANGE) CAN TERM + 48

(WHITE)
P (BLUE/WHITE)
14 (BLUE/PINK) CAN 1 + 49
N (BLUE/PINK)
15 (BLUE/WHITE) CAN 1 - 50
L (BLACK/LT GREEN)
20 (BLACK/LT GREEN) 5V RTN 51
CONNECTOR 1
K
M (LT GREEN/RED)
19 (LT GREEN/RED) 5V EXT 1 52
S (LT GREEN/PURPLE)
49 (LT GREEN/PURPLE) 5V EXT 2 53
R (LT GREEN/BLACK)
50 (LT GREEN/BLACK) 5V RTN 54
K (DK BLUE/ORANGE)
9 (DK BLUE/ORANGE) FPP1 55
J (PURPLE/YELLOW)
10 (PURPLE/YELLOW) FPP2/IVS 56
E (DK BLUE)
L
88 (DK BLUE) AUX PWM 1 57

SWITCH
3002 C (BLACK/RED)
FP 86 (BLACK/RED) AUX PWM 3 58
(PINK/YELLOW) (RED)
OPS1
85 (PINK/YELLOW) AUX PWM 3 RECIR 59
SWITCH
3056 F11
D (PINK/YELLOW)
53 (LT BLUE) OIL PRES 60
FUSE 15A SWITCH
00A FUEL PUMP
84 (TAN/BLACK) FPUMP 61
RELAY
56CR 2P-56
57A
75 (WHITE/BLACK) EGOH 4 62
M
SOLENOID
11 H (TAN/BROWN)
42 (TAN/BROWN) AUX DIG 1 63
76 76 G (GREEN/YELLOW)
80 (GREEN/YELLOW) MIL 64
LIGHT
57ACR
57A F (LT BLUE/PINK)
89 (PINK/BLACK) (STARTER) AUX PWM4 65
F7 (WHITE)
54A 54A A (PINK)
45 (PINK/TAN) VSW 66
FUSE 5A
F12 32BCR
VSW
67
FUSE 15A SOLENOID
N
11 STARTER
M 68
EL. MOTOR
(RED/TAN)
B (PURPLE) 69
(RED)
02 70
F13 S IG
78 71
G
FUSE 60A
79 ALTERNATOR
72
TO MAIN TO BATTERY
O
DISCONNECT GROUND
M169635AC-2
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AB
194313
A
KUBOTA EFI DUAL FUEL ENGINE

ECU1
R (ORANGE/YELLOW)
12 (ORANGE/YELLOW) AUX ANA PD 1 1 ECU
(TWIST WIRES 10 TURNS (360 DEG)/FOOT FULL LENGTH)
P (RED/BLACK)
29 (RED/WHITE) SPEED + 2
N (RED/WHITE)
30 (RED/BLACK) SPEED - 3
B
CONNECTOR VIC2
M (TAN/DK GREEN)
41 (TAN/DK GREEN) AUX DIG 3 4
L (TAN/RED)
50 (TAN/RED) AUX DIG 2 5
H (DK BLUE/YELLOW)
40 (DK BLUE/YELLOW) AUX ANA PU 3 6
G (YELLOW/DK BLUE)
39 (YELLOW/DK BLUE) AUX ANA PU 2 7
F (TAN)
85 (TAN) AUX PWM1 8
D (GRAY)
C
43 (GRAY) TACH 9
B (WHITE/BROWN)
83 (WHITE/BROWN) AUX PWM5 RECIRC 10
78 J (GRAY/RED)
42 (GRAY/RED) (GOV 2) AUX DIG 4 11 1700 RPM
79 K (GRAY/DK BLUE)
34 (GRAY/DK BLUE) GOV 1 12 2675 RPM
00A C (BROWN/WHITE)
84 (BROWN/WHITE) AUX PWM5 13 ENGINE RUNNING
3000 E (BLACK)
69 (BLACK) GROUND 14
D
S (PINK/DK GREEN)
81 (BLACK) GROUND 15
CPS1
A (UNUSED) CRANKSHAFT
1 26 (WHITE/PURPLE) CRANK - 16
POSITION SENSOR
2 25 (PURPLE/WHITE) CRANK + 17
CPS2
1 28 (PURPLE/ORANGE) CAM- 18 CAMSHAFT
POSITION SENSOR
2 27 (GRAY/BROWN) CAM+ 19
KS
E
1 52 (BLACK) KNK1- 20 KNOCK SENSOR
2 51 (BLACK/YELLOW) KNK1+ 21
GI1
64 (BROWN/LT BLUE) INJ 1 LS 22 GAS INJECTOR
CYLINDER #1
GI2
65 (BROWN/LT GREEN) INJ 2 LS 23 GAS INJECTOR
CYLINDER #3
GI3
66 (BROWN/YELLOW) INJ 3 LS 24 GAS INJECTOR
CYLINDER #4
GI4
67 (BROWN/WHITE) INJ 4 LS 25 GAS INJECTOR
F
CYLINDER #2
SC1
1 2 1 (YELLOW) SPK COIL 1A 26 SPARK COIL
CYLINDER #1
SC4
1 2 2 (YELLOW/BLACK) SPK COIL 1B 27 SPARK COIL
CYLINDER #4
SC3
1 2 3 (YELLOW/RED) SPK COIL 2A 28 SPARK COIL
CYLINDER #3
4 (BLACK) SPARK GND 29

SC2
1 2 5 (YELLOW/WHITE) SPK COIL 2B 30 SPARK COIL
CYLINDER #2
G
OXS1
A B 21 (DK GREEN/ORANGE) EGO 1 31 OXYGEN SENSOR
PRE-CAT
C D 62 (BLACK/WHITE) EGOH 1 32
(RED) (PINK/DK GREEN) OXS2
A B 22 (DK GREEN/WHITE) EGO 2 33 OXYGEN SENSOR
POST-CAT
F10 A
C D 61 (BLACK/YELLOW) EGOH 2 34 POWER RELAY
FUSE 15A
IGNITION
73 (WHITE/LT BLUE) RELAY 35
2002CR
F8
H
FUSE 10A
ECM TPS1
(BLACK) A (BLACK/LT GREEN) D
1 2 37 (TAN/WHITE) ECT 37 ENGINE COOLANT
00A TEMPERATURE SENSOR
GPS1
(GREEN/WHITE) B (LT GREEN/WHITE)
1 2 38 (LT GREEN/WHITE) (FRT) AUX ANA PU1 38 GASOLINE
57A PRESSURE SENSOR
(WHITE) D (WHITE/LT GREEN)
3 4 13 (WHITE/LT GREEN) (FRP) AUX ANA PD2 39
TA1
(GREEN/RED) C (LT GREEN/RED)
2 1 82 (TAN/ORANGE) DBW - 40 THROTTLE
ACTUATOR
76
C
3 4 80 (PINK/WHITE) DBW + 41
I
5 48 (LT BLUE/DK BLUE) TPS 2 42

54A
6 47 (PURPLE/LT BLUE) TPS 1 43

3.52 Interface & Engine Electrical Schematic - Kubota WG2503 Dual Fuel Engine
44
11 (PINK/DK GREEN) MS1
C A 36 (YELLOW/GRAY) IAT 45 M.A.P. SENSOR
DEPR1 F9
8 (BLUE/WHITE)
5 3 B D 23 (LT GREEN) MAP 46
FUSE 5A
DEPR
J
7 (DK BLUE/PINK) PROPANE DIRECT

2 6 47
ELECTRONIC PRESSURE
DIAGNOSTIC
78
REGULATOR
1 4 48
DIAGNOSTIC DISPLAY
79
(WHITE)
54A CAN L P (BLUE/WHITE)
2 4 14 (DK BLUE/PINK) CAN 1 + 49
3000 CAN H N (DK BLUE/PINK)

1 3 15 (BLUE/WHITE) CAN 1 - 50
L (BLACK/LT GREEN)
20 (BLACK/LT GREEN) 5V RTN 1 51
M (LT GREEN/RED)
19 (LT GREEN/RED) 5V EXT 1 52
K
S (LT GREEN/PURPLE)
31 (LT GREEN/PURPLE) 5V EXT 2 53
CONNECTOR VIC1
R (LT GREEN/BLACK)
32 (LT GREEN/BLACK) 5V RTN 2 54
K (DK BLUE/ORANGE)
53 (DK BLUE/ORANGE) FPP1 55
J (PURPLE/YELLOW)
54 (PURPLE/YELLOW) FPP2 IVS 56
E (DK BLUE) MAIN ENGINE

87 (DK BLUE) AUX PWM 2 57
SWITCH
L
3002 C (BLACK/RED)
FP 90 (BLACK/RED) AUX PWM 3 58 FUEL PUMP
(PINK/YELLOW) (RED)
OPS1
89 (PINK/YELLOW) AUX PWM 3 REC 59 ENGINE START
SWITCH
3056 F11
D (PINK/YELLOW) OIL PRESSURE
35 (LT BLUE) OIL PRES 60
FUSE 15A SWITCH
FUEL PUMP
78 (TAN/BLACK) (FPUMP) AUX PWM6 61 FUEL PUMP
RELAY
56CR 2P-56
77 (WHITE/BLACK) LOCK OFF 62 PROPANE LOCKOFF
SOLENOID
11 H (DK GREEN/PURPLE)
49 (DK GREEN/PURPLE) (FUEL SEL) AUX DIG 1 63 GAS/PROPANE
M
SELECTOR SWITCH
76 G (GREEN/YELLOW) CHECK ENGINE
74 (GREEN/YELLOW) MIL 64
LIGHT
57ACR
57A F (LT BLUE/PINK)
72 (PINK/BLACK) (STARTER) AUX PWM4 65 STARTER RELAY
F7 (WHITE)
54A A (PINK)
44 (PINK/TAN) VSW 66
FUSE 5A
F12 32BCR
VSW
67 ENGINE STARTER
FUSE 15A SOLENOID
STARTER
M 68 ENGINE STARTER
EL. MOTOR
N
(RED/TAN)
B (PURPLE) 69
(RED)
70
F13 2 3
G 71 ALTERNATOR
FUSE 60A
ALTERNATOR
72
TO MAIN TO BATTERY
DISCONNECT GROUND
O
M170419AB-2
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AB
194313
A

TO BATTERY TO BATTERY
B+ POST B- POST
B
B+-12 RD
00-18 WH
00-12 WH
FU1
30A A02-16 WH
2
A32-16 BK
32
A03-16 WH
3
A46-16 BK
46
A04-16 WH
4
A05-16 BK
5
A16-16 WH
16
A33-16 BK
C
33
A18-16 WH
18
A48-16 BK
48
A37-18 WH
37
A52-18 BK
52
A53-18 RD
53
A38-18 RD
38
A39-18 WH
39
A54-18 BK D2.1 - 60 PIN

54
7
A07-18 BK TO ECU
D
A19-16 BK
19
A20-16 WH
20
A23-18 BK
23
(-) 00-16 WH
A24-18 BK
24
FUEL
PUMP FP A25-18 BK
25
(+) 56B-16 BK
A26-18 BK
26
A27-18 BK
27
A28-18 BK
28
A29-18 BK
29
L L1
A35-18 BK
E
35
WATER IN 201-18 WH
A40-18 BK
40
FUEL SWITCH 200-18 BK

A43-18 BK
43
A44-18 BK
44
A45-18 BK
45
K01-14 RD
1
F
K01-12 RD K01-14 RD
3
K01-14 RD
5
SPLK01
00-14 WH
2
00-12 WH 00-14 WH
4
00-14 WH
6
SPL00
204-18 RD
103-18 BK SPL103 103-18 BK
13 15
1
103A-18 WH 103A-18 WH
2
19
56B-16 BK K22-18 BK
3
22
56A-18 WH 56A-18 WH
4
G
84-18 WH (T-ONLY) 84-18 WH
5
CONNECTOR P1
K28-18 BK
6
26 27 28
203-18 BK SPL203 203-18 BK
7
TO CONTROL PANEL.
57A-16 BK 57A-16 BK
8
SEE MACHINE
K44-18 BK
29 35 44
ELEC. SCHEMATIC.
74-18 WH 74-18 WH
9 10
105-18 WH 105-18 WH
48 53
104-18 BK
11 12
201-18 WH
57
K61-18 BK
H
200-18 BK
61 64
D2.2 - 94 PIN
76A-18 WH
TO ECU
103-18 BK
65 68
96-18 WH
76A-18 WH 76-18 BK
1
96-18 WH (T-ONLY) K73-18 BK
2
76-18 BK 99-18 WH
3
69 70 73 74
99-18 WH 104-18 BK
4
90-18 BK 90-18 BK
5
75 80
CONNECTOR P2
K22-18 BK (46AJ ONLY)
6
K82-18 BK
I
K85-18 BK
TO CONTROL PANEL.
202-18 WH (46AJ ONLY) SPL202 202-18 WH
3.53 Interface & Engine Electrical Schematic - Deutz D2.9L Engine
SEE MACHINE 7
09-16 BK 09-16 BK
8
ELEC. SCHEMATIC.
54-18 BK 54-18 BK
81-18 WH 81-18 WH
9 10
82 85 87 88 90 92
77-18 WH 77-18 WH
71
09A-18 BK
11 12
J
K
K82-18 BK
203-18 BK
K28-18 BK
K61-18 BK
K44-18 BK
K85-18 BK
A40-18 BK
A27-18 BK
A24-18 BK
A32-16 BK
A46-16 BK
A05-16 BK
A33-16 BK
A48-16 BK
A52-18 BK
A54-18 BK
A28-18 BK
A25-18 BK
A26-18 BK
A43-18 BK
A44-18 BK
A29-18 BK
A19-16 BK
204-18 RD
K73-18 BK
A07-18 BK
A53-18 RD
A38-18 RD
202-18 WH
A02-16 WH
A03-16 WH
A04-16 WH
A16-16 WH
A18-16 WH
A37-18 WH
A39-18 WH
A20-16 WH
L
A23-18 BK
A35-18 BK
A45-18 BK
X17.1-62 PIN
61 38 41 40 19 20 35 62 37 42 14 13 9 1 15 21 2 3 24 17 32 31 25 28 29 22 23 26 27 50 46 51 47 48 1 2 3 4 4 3 2 1
AT ENGINE
L L2
11 11A
COOLANT
11CR LEVEL
SENSOR
2 1 1 2 3 4 3 1 2 1 2 3 4 1 2 3 4 5 4 3 2 1 11B 11C GP1
U U U U U U U
n n n P P p&t° P M
FUEL FUEL ACTUATOR FUEL FUEL FU2
GP2
M
INJ. INJ. MPROP INJ. INJ. ENGINE ENGINE COOLING FUEL LOW FUEL BOOST OIL 100A 11C
CYL.3 CYL.2 CYL.1 CYL.4 SPEED SPEED TEMPERATURE PRESSURE RAIL PRESSURE & PRESSURE 03
SENSOR SENSOR SENSOR SENSOR PRESS. TEMPERATURE SENSOR EXHAUST GAS
CAMSHAFT CRANKSHAFT SENSOR SENSOR RECIRCULATION
VALVE (EGR) 11C GP3
11C GP4
START STARTER
RELAY
STARTER
SOLENOID
TO S1 BATTERY TO BATTERY
03 00
DISCONNECT SW. B- POST
M
N
B+ G
3
D+
09A
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3.54 Engine Harness - Deutz D2.9L
D2.2 - 94 PIN 1 3 5 2 4 6 13 15 19 22 26 27 28 29 35 44 48 53 57 61 64 65 68 69 70 73 74 75 80 82 85 87 88 90 92 71 7 8 9 10 11 12 14 16 17 18 20 21 23 24 25 30 31 32 33 34 36 37 38 39 40 41 42 43 45 46 47 49 50 51 52 54 55 56 58 59 60 62 63 66 67 72 76 77 78 79 81 83 84 86 89 91 93 94
TO ECU
103A-18 WH
56A-18 WH
76B-18 WH
201-18 WH
R
202-18 WH
105-18 WH
76A-18 BK
K73-18 BK
K01-14 RD
K01-14 RD
K01-14 RD
204-18 RD
57A-16 BK
K22-18 BK
K28-18 BK
K44-18 BK
K85-18 BK
203-18 BK
200-18 BK
K61-18 BK
K82-18 BK
103-18 BK
103-18 BK
104-18 BK
74-18 WH
99-18 WH
81-18 WH
77-18 WH
00-14 WH
00-14 WH
00-14 WH
09-16 BK
90-18 BK
54-18 BK
SPL103
SPL202
P4
203-18 BK
SPL203
1
SPLK01 SPL00 202-18 WH
2 TO COOLANT
204-18 RD
3 SENSOR
4
K01-12 RD
00-12 WH
D
09A-18 BK
TO ALTERNATOR
S
60
59
58
57
60
59
56
55
58
57
54
56
53
T
55
52
K82-18 BK
51
51
K44-18 BK
50
50
49
49
K85-18 BK
46
47
A45-18 BK
45
45
A44-18 BK A44-18 BK
26
44
A43-18 BK A43-18 BK
43
23
42
44
41
43
A40-18 BK A40-18 BK
40
28
U
39
36
A35-18 BK
35
36
31 34
34
33
30
30
A29-18 BK A29-18 BK
29
27
A28-18 BK A28-18 BK
28
24
A27-18 BK A27-18 BK
29
27
A26-18 BK A26-18 BK
X17.1 - 62 PIN
26
25
D2.1 - 60 PIN A25-18 BK A25-18 BK
31
25
TO ENGINE
A24-18 BK A24-18 BK
TO ECU
22
24
A23-18 BK V
23
18
K61-18 BK
22
17
21
16
A20-16 WH A20-16 WH
20
48
A19-16 BK A19-16 BK
19
47
17
12
11
15
10
14
13
8
12
7
W
11
6
10
5
4
9
K73-18 BK
8
3
A07-18 BK A07-18 BK
32
7
K28-18 BK
6
2
A54-18 BK A54-18 BK
21
54
A39-18 WH A39-18 WH
39
15
A38-18 RD A38-18 RD
38
1
A53-18 RD A53-18 RD
53
9
A52-18 BK A52-18 BK
13
52
A37-18 WH A37-18 WH X
37
14
A48-16 BK A48-16 BK
48
42
A18-16 WH A18-16 WH
18
37
A33-16 BK A33-16 BK
33
62
A16-16 WH A16-16 WH
16
35
A05-16 BK A05-16 BK
20
5
A04-16 WH A04-16 WH
19
4
A46-16 BK A46-16 BK
46
40
A03-16 WH A03-16 WH
41
3
A32-16 BK A32-16 BK
32
38
A02-16 WH A02-16 WH
61
Y
2
1
P6
B
30A
103A-18 WH
76B-18 WH
201-18 WH
56A-18 WH
105-18 WH
76A-18 BK
09A-18 BK
200-18 BK
57A-16 BK
99-18 WH
81-18 WH
77-18 WH
56B-16 BK
103-18 BK
203-18 BK
104-18 BK
56B-16 BK
202-18 WH
74-18 WH
00-16 WH
00-18 WH
00-12 WH
90-18 BK
09-16 BK
54-18 BK
B+-12 RD
K22-18 BK
A23-18 BK
A35-18 BK
A45-18 BK
Z
1 2 3 4 5 6 7 8 9 10 11 12 2 1 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4
(+) (-) B- B+
P1 P3 P2 P5
TO FUEL PUMP TO BATTERY TO CTRL PNL TO WATER SENSOR TO CTRL PNL TO PRE-HEAT
M165020AB-1

194313
Section 4
TROUBLESHOOTING INFORMATION
Table of Contents
Introduction...............................................................................................................................................................109
4.1 Electrical System

4.1-1 All Controls Inoperative..................................................................................................................................110
4.1-2 No Power To Platform.....................................................................................................................................110
4.1-3 No Power to Base...........................................................................................................................................111
4.1-4 Engine Will Not Crank from Base...................................................................................................................111
4.1-5 Engine Will Not Crank from Platform..............................................................................................................111
4.1-6 Engine Will Not Crank from Platform or Base (Deutz Diesel D2.9L...............................................................112
4.1-7 Engine Cranks but Will Not Start (Deutz Diesel D2.9L).................................................................................112
4.1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011).............................................................113
4.1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011).................................................................................113
4.1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel)........................................................114
4.1-11 Engine Cranks but Will Not Start (GM Dual Fuel)........................................................................................115
4.1-12 Glow Plug Circuit Inoperative (Deutz Diesel D2011 Engine).......................................................................117
4.1-13 All Controls Inoperative from Base Console................................................................................................117
4.1-14 No Main Boom Down, Riser Down or Turret Rotate from Base Control Console........................................118
4.1-15 No Boom Up from Base Control Console.....................................................................................................118
4.1-16 No Boom Down from Base Control Console................................................................................................118
4.1-17 No Riser Up from Base Control Console......................................................................................................119
4.1-18 No Riser Down from Base Control Console..................................................................................................119
4.1-19 No Turret Rotate Left from Base Control Console........................................................................................119
4.1-20 No Turret Rotate Right from Base Control Console.....................................................................................120
4
4.1-21 No Telescope Retract from Base Control Console......................................................................................120
4.1-22 No Telescope Extend from Base Control Console.......................................................................................120
4.1-23 No Platform Rotate Left from Base Control Console...................................................................................121
4.1-24 No Platform Rotate Right from Base Control Console.................................................................................121
4.1-25 No Jib Up from Base Control Console.........................................................................................................122
4.1-26 No Jib Down from Base Control Console.....................................................................................................122
4.1-27 No Manual Platform Level Up from Base Control Console...........................................................................123
4.1-28 No Manual Platform Level Down from Base Control Console......................................................................123
4.1-29 All Controls Inoperative from Platform Control Console..............................................................................124
4.1-30 No Boom Up from Platform Control Console...............................................................................................125
4.1-31 No Boom Down from Platform Control Console..........................................................................................125
4.1-32 No Riser Up from Platform Control Console................................................................................................126
4.1-33 No Riser Down from Platform Control Console...........................................................................................126
4.1-34 No Turret Left from Platform Control Console..............................................................................................127
4.1-35 No Turret Right from Platform Control Console...........................................................................................128
4.1-36 No Toggle Switch Functions from Platform Control Console.......................................................................128
4.1-37 No Telescope In from Platform Control Console...........................................................................................128
4.1-38 No Telescope Out from Platform Control Console........................................................................................129
4.1-39 No Platform Rotate Left from Platform Control Console...............................................................................129
4.1-40 No Platform Rotate Right from Platform Control Console...........................................................................130
4.1-41 No Jib Up from Platform Control Console...................................................................................................131
4.1-42 No Jib Down from Platform Control Console...............................................................................................131
4.1-43 No Manual Platform Level Up from Platform Control Console....................................................................132
4.1-44 No Manual Platform Level Down from Platform Control Console................................................................133
4.1-45 Throttle Inoperative, Mid and High (Deutz D2.9L only).................................................................................133

194313
Service and Maintenance Section 4 - Troubleshooting Information
Table of Contents (Continued)

4.1-46 Mid Throttle Inoperative.................................................................................................................................134
4.1-47 High Throttle Inoperative...............................................................................................................................135
4.1-48 Brake will not Release...................................................................................................................................135
4.1-49 Differential Lock will not Engage..................................................................................................................136
4.1-50 Differential Lock Engages Momentarily but will not stay Engaged.............................................................136
4.1-51 No Drive and Steer.......................................................................................................................................137
4.1-52 No Forward Drive..........................................................................................................................................137
4.1-53 No Reverse Drive..........................................................................................................................................137
4.1-54 No High Speed Drive....................................................................................................................................138
4.1-55 No Elevated Drive.........................................................................................................................................139
4.1-56 No Left Steer.................................................................................................................................................139
4.1-57 No Right Steer..............................................................................................................................................140
4.1-58 Direction Sensing Inoperative......................................................................................................................140
4.2 Hydraulic System

4.2-1 All Controls Inoperative...................................................................................................................................141
4.2-2 All Boom Functions Inoperative.......................................................................................................................141
4.2-3 No Main Boom Up...........................................................................................................................................141
4.2-4 No Main Boom Down......................................................................................................................................141
4.2-5 No Riser Boom Up...........................................................................................................................................142
4.2-6 No Riser Boom Down......................................................................................................................................142
4.2-7 Riser Boom Down Jerky..................................................................................................................................142
4.2-8 No Turret Rotate Left........................................................................................................................................143
4.2-9 No Turret Rotate Right.....................................................................................................................................143
4.2-10 No Boom Extend...........................................................................................................................................144
4.2-11 No Boom Retract...........................................................................................................................................144
4.2-12 No Jib Up.......................................................................................................................................................144
4.2-13 No Jib Down..................................................................................................................................................144
4.2-14 No Platform Rotation Right............................................................................................................................145
4.2-15 No Platform Rotation Left...............................................................................................................................145
4.2-16 Platform will not Level Down Manually..........................................................................................................145
4.2-17 Platform will not Level Up Manually...............................................................................................................146
4.2-18 Brake will not Release...................................................................................................................................146
4.2-19 Brake will not Engage....................................................................................................................................147
4.2-20 Differential Lock will not Engage...................................................................................................................147
4.2-21 No Drive Forward or Reverse........................................................................................................................147
4.2-22 No Forward Drive...........................................................................................................................................147
4.2-23 No Reverse Drive...........................................................................................................................................148
4.2-24 No High Speed Drive.....................................................................................................................................148
4.2-25 No Right Steer...............................................................................................................................................148
4.2-26 No Left Steer..................................................................................................................................................148
4.2-27 Axle Will Not Oscillate....................................................................................................................................148
4.2-28 Axle Will Not Lock..........................................................................................................................................149
4.3 Load Sensing System - CE

4.3-1 Green Power LED is not Flashing...................................................................................................................150
4.3-2 Load Cell red Alarm LED is ON (with platform empty)...................................................................................150
4.3-3 Red Error LED is ON........................................................................................................................................150
4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)..........................................................................150
4.3-5 Platform Indicator Light does not turn ON......................................................................................................150
4.3-6 Audible Alarm does not turn ON.....................................................................................................................150
4.3-7 Boom and Drive Functions are Enabled (with boom extended).....................................................................150

194313
Section 4 - Troubleshooting Information Service and Maintenance
Introduction
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble
occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num-
ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it. See example below for clarification.
1. Probable Cause
-- Remedy

194313
NOTE
All tests should be performed with boom over non-steering axle.
4.1 Electrical System
4.1-1 All Controls Inoperative

1. Battery disconnected or discharged.
-- Connect battery or recharge.
2. Loose or broken B+ cable from battery to battery disconnect switch S1.
-- Check continuity. Replace if defective.
3. Open or defective battery disconnect switch S1.
-- Close switch. Replace if defective.
4. Loose or broken wire #03 from battery disconnect switch S1 to circuit breaker CB1.
5. Circuit breaker CB1 tripped or defective.
-- Reset breaker, check for defective wiring. Replace if defective.
6. Loose or broken wire #05 from circuit breaker CB1 to base emergency stop switch S3.
7. Open or defective base emergency stop switch S3.
8. Loose or broken wire #07 from base emergency stop switch S3 to base key S2.
9. Open or defective key select switch S2.
10. Loose or broken wire #60 from base terminal block to relay 60CR.
11. Loose or broken wire #07 from base emergency stop switch S3 to relay 60CR.
12. Loose or broken wire #02 from relay 60CR to base terminal block.
13. Defective relay 60CR.
-- Check relay. Replace if defective.
15. Loose or broken wire #02 from base terminal block to circuit breaker CB2.
-- Reset breaker, check for defective wiring. Replace if defective.
17. Loose or broken wire #00 from circuit breaker CB2 to battery negative.
4.1-2 No Power To Platform

1. Open or defective key select switch S2.
2. Loose or broken wire #07A from key select switch S2 to plug A pins # 2 & 3 in base control console.
3. Loose or broken wire #07A from plug A pins # 2 & 3 in platform control console to platform emergency
stop switch S4.
4. Open or defective platform emergency stop switch S4.
-- Check switch. Replace if defective.
5. Loose or broken wire #04 from platform emergency stop switch S4 to Ignition/E-pump switch S6

194313
4.1-3 No Power to Base

1. Open or defective base key switch S2.
-- Select base position on key switch. Check continuity through base key switch. Replace if
defective.
2. Loose or broken wire #12 from base key switch S2 to Ignition/E-pump switch S5.
3. Loose or broken wire #12 from base key switch S2 to base connector plug A pin #5.
4. Loose or broken wire #12 in boom cable A or its connectors.
-- Check for continuity between pins #5 on cable A. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
5. Loose or broken wire #12 from plug A pin #5 to emergency stop switch S4 in platform control console.
6. Open or defective emergency stop switch S4.
-- Check switch is in on position. Check continuity through switch. Replace if defective.
7. Loose or broken wire #10 from emergency stop switch S4 to plug A pin #4.
9. Loose or broken wire #10 from plug A pin #4 to base terminal block.
10. Open or defective diode D10.
-- Check diode. Replace if defective.
11. Loose or broken wire #10 from base terminal block to Ignition/E-pump (enable) switch S5.
12. Open or defective Ignition/E-pump (enable) switch S5.
-- Check switch. Replace if defective
4.1-4 Engine Will Not Crank from Base

1. Loose or broken wire #57A from base start switch S5 to relay 57ACR (Deutz D2011 and GM 3.0l engines).
2. Defective base start switch S5.
-- Check start switch. Replace if defective.
4.1-5 Engine Will Not Crank from Platform
NOTE
Engine will not crank from platform with footswitch depressed.
1. Loose or broken wire #4 from emergency stop switch S4 to start switch S6.
2. Defective start switch S6.
-- Check continuity through switch. Replace if defective.
3. Loose or broken wire #57 from start switch S6 to relay 08CR.
-- Check continuity through contacts of relay. Replace if defective.
5. Loose or broken wire #57A from relay 08CR to plug B pin #14.

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6. Loose or broken wire #57A in boom cable B or its connectors.

-- Check for continuity between pin #14 on cable B. Check for loose or corroded connections
on cable connectors. Replace if wire is defective.
7. Loose or broken wire #57A from plug B pin #14 to relay 57ACR in base control console (Deutz D2011,
GM 3.0L) or to base start switch S5 (Deutz TD2.9L).
4.1-6 Engine Will Not Crank from Platform or Base (Deutz Diesel D2.9L
1. Loose or broken wire #57A from base start switch S5 to 12 pin connector (J1) pin 8.
2. Loose or broken wire #57A from 12 pin connector (P1) pin 8 to 94 pin ECU connector, pin 35 .
3. Loose or broken B+ wire from battery B+ to ECU fuse connector P6 pin A .
4. ECU 30A fuse open or defective.
-- Check for defective wiring. Replace if defective. Replace fuse.
5. Loose or broken wire #K01 from ECU fuse connector P6 pin B to 94 pin ECU connector 3 places pins
1, 3, and 5.
5. Loose or broken ground wire #00 from battery B- to 94 pin ECU connector 3 places pins 2, 4, and 6.
4.1-7 Engine Cranks but Will Not Start (Deutz Diesel D2.9L)
1. Loose or broken wire #54 from 94 pin ECU connector, pin90 to 12 pin connector (P2), pin 9.
2. Loose or broken wire #54 from 12 pin connector (J2) pin 9 to relay 56ACR.
3. Loose or broken wire #03 to circuit breaker CB3.
-- Reset breaker, check for defective wiring. Replace if defective
5. Loose or broken wire #56 from CB3 to relay 56ACR.
6. Loose or broken wire #56A from relay 56ACR to 12 pin connector (J1) pin 4.
7. Loose or broken wire #56A from 12 pin connector (P1) pin 4 to 94 pin ECU connector, pin 26.
8. Loose or broken wire #56B from relay 56ACR to 12 pin connector (J1) pin 3.
9. Defective relay 56ACR.
-- Check continuity through contacts of relay. Replace if defective.
10. Loose or broken wire #56B from 12 pin connector (P1) pin 3 to fuel pump.
11. Loose or broken ground wire #00 from fuel pump to battery B-.
12. Engine pre-heat circuit inoperative.
-- Refer to Engine manufacturer’s manual to diagnose.
NOTE
For other engine related problems, consult engine manufacturer’s
manual.

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4.1-8 Engine Will Not Crank from Platform or Base (Deutz Diesel D2011)
1. Loose or broken wire #57A at relay 57ACR (2 places).
-- Check for connections at relay. Check for voltage on relay (2 places).
2. Loose or broken wire #57A from relay 57ACR to relay 57BCR.
3. Loose or broken wire #00A from X23 engine connector pin #11 to relay 57ACR.
4. Loose or broken wire #00A from X23 engine connector pin #11 to engine oil pressure switch.
7. Loose or broken wire #03A from circuit breaker CB3 to relay 09CR.
8. Tripped or defective circuit breaker CB3.
-- Reset circuit breaker. Check continuity through circuit breaker. Replace if defective.
9. Loose or broken wire #3 from circuit breaker CB3 to turret harness plug pin #2.
12. Loose or broken wire #54A from relay 09CR to base terminal block.
13. Loose or broken wire #54A from base terminal block to relay 57BCR1.
14. Defective contacts in relay 57BCR1.
-- Check continuity between wires #54A and #57C when cranking. If no continuity, replace relay.
15. Loose or broken wire #57C from relay 57BCR1 to X23 engine connector pin #4.
16. Loose or broken wire #57C from X23 engine plug to start solenoid 57CCR.
17. Loose or broken starter cable #03 from disconnect switch S1 to start solenoid 57CCR.
18. Defective start solenoid 57CCR.
-- Check solenoid. Replace if defective.
19. Defective starter motor.
-- Check starter motor. Replace if defective.
4.1-9 Engine Cranks but Will Not Start (Deutz Diesel D2011)
1. Loose or broken wire #57B from relay 57ACR to relay 57BCR (2 places).
-- 57BCR maintains power for start circuit before engine starts and after oil pressure switch opens
to relay 57BCR1. Check wire #57B for continuity. Replace if defective.
2. Loose or broken wire #57A from relay 57ACR to relay 57BCR.
3. Loose or broken wire #02 from base terminal block to relay 57BCR.
4. Defective relay 57BCR.
5. Glow plug circuit not operating.
-- See “Glow Plug Circuit Inoperative” in this section.

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6. No fuel in fuel tank or fuel line obstructions.

-- Check fuel level and flow through lines. Fill or repair if necessary.
NOTE
For other engine related problems, consult engine manufacturer’s
manual.
4.1-10 Engine Will Not Crank from Platform or Base Control (GM Dual Fuel)
1. Loose or broken wire #54A from base terminal block TB1 to engine harness plug.
2. Loose or broken wire #54A from engine harness plug to GM engine connector 1.
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 fuse. Replace if defective.
8. Loose or broken red/tan wire from fuse F8 to ECU connector pin #60 and pin #79.
9. Loose or broken black wire from engine ground to ECU connector pin #69 and #81.
10. Loose or broken light blue/pink wire from GM engine connector 1 to relay 57ACR.
11. Loose or broken pink/black wire from ECU connector pin #89 to relay 57ACR.
13. Loose or broken red wire from battery positive to starter fuse F12.
15. Loose or broken red/tan wire from fuse F12 to relay 57ACR.
16. Loose or broken white wire from relay 57ACR to start solenoid 32BCR.
17. Defective starter solenoid 32BCR.
-- Check solenoid. Replace if defective.
18. Loose or broken battery cable from starter solenoid 32BCR to starter motor.
19. Defective starter motor.
-- Check motor. Repair or replace if defective.

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4.1-11 Engine Cranks but Will Not Start (GM Dual Fuel)
NOTE
For additional engine troubleshooting refer to diagnostic trouble codes
for use with the check engine light.
1. Loose or broken red wire from battery positive to relay 2002CR.

2. Loose or broken red/tan wire from ECU fuse F8 to relay 2002CR.
3. Loose or broken white/ light blue wire from ECU connector pin #71 to relay 2002CR.
5. Loose or broken pink/dark green wire from relay 2002CR to ignition fuse F10.
7. Loose or broken pink/dark green wire from fuse F10 to ignition coil IGC1 pin #A.
8. Loose or broken yellow wire from ignition coil IGC1 pin #B to ignition module IGM1.
9. Defective ignition coil IGC1.
-- Check coil for spark. Replace if defective.
10. Loose or broken pink/dark green wire from fuse F10 to ignition module IGM1 pin #A.
11. Loose or broken black wire from ignition module IGM1 pin #C to engine ground.
12. Loose or broken yellow wire from ignition module IGM1 pin #B to ECU connector pin #31.
13. Defective ignition module IGM1.
-- Check module for operation. Replace if defective.
14. Loose or broken pink/dark green wire from fuse F10 to gas injectors GI-1, GI-2, GI-3 and GI-4.
15. Loose or broken pink/white wire from ECU connector pin #82 to throttle actuator RA1.
16. Loose or broken tan/orange wire from ECU connector pin #83 to throttle actuator RA1.
17. Loose or broken light green/red wire from ECU connector pin #19 to throttle actuator RA1.
18. Loose or broken black/light green wire from ECU connector pin #20 to throttle actuator RA1.
19. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA1.
20. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA1.
Fuel Related Problems

(Gasoline Only)
21. Loose or broken pink/tan wire from fuse F7 to fuel pump relay 56CR.
22. Loose or broken red wire from battery positive to fuel pump relay 56CR.

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23. Loose or broken tan/black wire from ECU connector pin #84 to fuel pump relay 56CR.
24. Defective fuel pump relay 56CR.
25. Loose or broken pink/yellow wire from fuel pump relay 56CR to fuse F11.
27. Loose or broken pink/yellow wire from fuse F11 to fuel pump FP.
28. Defective fuel pump FP.
-- Check fuel pump by putting 12 volts and a ground to it. Replace if defective.
29. Loose or broken wire #3002 from fuel pump FP to GM engine connector 1.
30. Loose or broken black/red wire from GM engine connector to ECU connector pin #86.
(Propane Only)
NOTE
The fuel select switch is defaulted to gasoline. The engine will run on
gasoline if propane is selected from the switch and either the switch
is bad or a wire is loose or broken from the switch. This is providing
there is nothing wrong on the gasoline side of the system. Disconnect
fuel pump to test propane side.
31. Loose or broken wire #60 from platform terminal block to fuel select switch S26.
32. Defective fuel select switch S26.
-- Check switch. Replace if defective.
33. Loose or broken wire #11 from fuel select switch S26 to plug B pin #15 in platform control console.
34. Loose or broken wire #11 in boom cable B or its connectors.
-- Check continuity between pins #15 on cable B. Check for loose or corroded connections on
35. Loose or broken wire #11 from plug B pin #15 to engine harness plug.
36. Loose or broken wire #11 from engine harness plug to GM engine connector 1.
37. Loose or broken tan/brown wire from GM engine connector 1 to ECU connector pin #42.
38. Loose or broken pink/tan wire from fuse F7 to propane lock off 2P-56.
39. Loose or broken white/black wire from ECU connector pin #75 to propane lock off 2P-56.
40. Defective propane lock off 2P-56.
-- Check lock off. Replace if defective.
41. Loose or broken pink/dark green wire from fuse F10 to fuse F9.
43. Loose or broken red/light blue wire from fuse F9 to propane regulator PRV1.
44. Loose or broken black wire from engine ground to propane regulator PRV1.

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4.1-12 Glow Plug Circuit Inoperative (Deutz Diesel D2011 Engine)

1. Defective glow plug fuse FU1 50 amp.
2. Loose or broken wire #03 from start solenoid 57CCR to fuse holder FU1.
3. Loose or broken wire #11A from fuse holder FU1 to relay 54ACR.
4. Loose or broken wire #11B from relay 54ACR to glow plugs.
5. Loose or broken wire #54A from base terminal strip to relay 54ACR.
6. Loose or broken wire #11 from base terminal block to relay 54ACR.
8. Defective glow plugs.
-- Check glow plugs. Replace if defective.
NOTE
For other glow plug related problems, consult engine manufacturer’s
manual.
4.1-13 All Controls Inoperative from Base Console

1. Loose or broken wire #10 from base emergency stop switch S3 to base ignition/pump switch S5.
2. Defective ignition/pump switch S5.
-- Check continuity through switch when activated. Replace if defective.
3. Loose or broken wire #10A from ignition/pump switch S5 to base terminal block.
4. Loose or broken wire #10A from base terminal block to diode D10A.
5. Open or defective diode D10A.
6. Loose or broken wire #20 from diode D10A to base terminal block.
7. Missing or broken terminal block jumper between wire #20 and #21.
-- Check for jumper. Replace if missing or broken.
NOTE
Jumper is removed if equipped with generator option.
10. Loose or broken wire #09 from base terminal block to relay 21CR. (ANSI/CSA)
11. Loose or broken wire #09 from base terminal block to relay 59CR. (CE)
12. Loose or broken wire #162A from relay 59CR to base terminal block. (CE)
13. Loose or broken wire #162A from base terminal block to relay 21CR. (CE)

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NOTE
For further CE troubleshooting refer to Load Sensing System.

15. Loose or broken wire #21A from relay 21CR to main harness plug pin #3.
16. Loose or broken wire #21A from main harness plug pin #3 to dump valve 2H-21A.
17. Loose or broken wire #02 from dump valve 2H-21A to main harness plug.
18. Defective dump valve coil 2H-21A.
-- Check continuity and resistance through coil. Replace if defective.
4.1-14 No Main Boom Down, Riser Down or Turret Rotate from Base Control
Console
1. Loose or broken wire #10A from base terminal block to resistor R1.
2. Open resistor R1.
-- Check resistor for 6 ohms. If no resistance found, replace resistor.
3. Loose or broken wire #10B from resistor R1 to turret rotate switch S13, boom down switch S12 and
riser down switch S25.
4.1-15 No Boom Up from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to boom switch S12.
2. Defective boom switch S12.
-- Check continuity through switch while activating up function between wires #10A and #14.
Replace switch if no continuity.
3. Loose or broken wire #14 from boom switch S12 to base terminal block.
4. Loose or broken wire #14 from base terminal block to main harness plug pin #2.
5. Loose or broken wire #14 from main harness plug pin #2 to boom up valve 4H-14.
6. Loose or broken wire #02 from main harness plug to boom up valve 4H-14.
7. Defective boom up coil 4H-14.
4.1-16 No Boom Down from Base Control Console

1. Loose or broken wire #10B from resistor R1 to boom down switch S12.
2. Defective boom switch S12.
-- Check continuity through switch while activating down function between wires #10B and #13.
If no continuity found, replace switch.
3. Loose or broken wire #13 from boom down switch S12 to base terminal block.

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5. Loose or broken wire #13 from main harness plug pin #1 to boom down valve 4H-13.
6. Loose or broken wire #02 from main harness plug to boom down valve 4H-13.
7. Defective boom down coil 4H-13.
4.1-17 No Riser Up from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to riser switch S25.
2. Defective riser switch S25.
-- Check continuity through switch while activating up function between wires #10A and #31.
Replace switch if no continuity.
3. Loose or broken wire #31 from riser switch S25 to base terminal block.
5. Loose or broken wire #31 from main harness plug pin #8 to riser up valve 4H-31.
6. Loose or broken wire #02 from main harness plug to riser up valve 4H-31.
7. Defective boom up coil 4H-31.
4.1-18 No Riser Down from Base Control Console

1. Loose or broken wire #10B from resistor R1 to riser down switch S25.
2. Defective riser switch S25.
-- Check continuity through switch while activating down function between wires #10B and #30.
3. Loose or broken wire #30 from riser down switch S25 to base terminal block.
5. Loose or broken wire #30 from main harness plug pin #7 to riser down valve 4H-30.
6. Loose or broken wire #02 from main harness plug to riser down valve 4H-30.
7. Defective riser down coil 4H-30.
4.1-19 No Turret Rotate Left from Base Control Console

1. Loose or broken wire #10B from resistor R1 to turret rotate switch S13.
2. Defective turret rotate switch S13.
-- Check continuity through switch while activating rotate left function between wires #10B and
#32. If no continuity found, replace switch.
3. Loose or broken wire #32 from turret rotate switch S13 to base terminal block.

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5. Loose or broken wire #32 from main harness plug pin #9 to turret rotate left valve 4H-32.
6. Loose or broken wire #02 from main harness plug to turret rotate left valve 4H-32.
7. Defective turret rotate left valve coil 4H-32.
4.1-20 No Turret Rotate Right from Base Control Console

1. Loose or broken wire #10B from resistor R1 to turret rotate switch S13.
2. Defective turret rotate switch S13.
-- - Check continuity through switch while activating rotate right function between wires #10B
and #33. If no continuity found, replace switch.
3. Loose or broken wire #33 from turret rotate switch S13 to base terminal block.
5. Loose or broken wire #33 from main harness plug pin #10 to turret rotate right valve 4H-33.
6. Loose or broken wire #02 from main harness plug to turret rotate right valve 4H-33.
7. Defective turret rotate right valve coil 4H-33.
4.1-21 No Telescope Retract from Base Control Console

1. Loose or broken wire #10A from ignition/enable switch S5 to telescope switch S14.
2. Defective telescope switch S14.
-- - Check continuity through switch while activating retract function between wires #10A and
3. Loose or broken wire #38 from telescope switch S14 to base terminal block.
5. Loose or broken wire #38 from main harness plug pin #13 to telescope retract valve 3H-38.
--
6. Loose or broken wire #02 from main harness plug to telescope retract valve 3H-38.
7. Defective telescope retract valve coil 3H-38.
-- Check continuity and resistance through coil. Replace if defective
4.1-22 No Telescope Extend from Base Control Console

1. Loose or broken wire #10A from ignition/enable switch S5 to telescope switch S14.
Check continuity. Replace if defective.
-- Check continuity through switch while activating extend function between wires #10A and #39.
3. Loose or broken wire #39 from telescope switch S14 to base terminal block.

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5. Loose or broken wire #39 from main harness plug pin #14 to telescope extend valve 3H-39.
6. Loose or broken wire #02 from main harness plug to telescope extend valve 3H-39.
7. Defective telescope extend valve coil 3H-39.
4.1-23 No Platform Rotate Left from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to platform rotate switch S16.
2. Defective platform rotate switch S16.
-- Check continuity through switch while activating rotate left function between wires #10A and
4. Loose or broken wire #36A from diode D36 to main harness plug pin #12.
5. Loose or broken wire #36A from main harness plug pin #12 to platform rotate enable valve 2H-36A.
6. Loose or broken wire #02 from main harness plug to platform rotate enable valve 2H-36A.
7. Defective platform rotate enable valve 2H-36A.
8. Loose or broken wire #36 from platform rotate switch S16 to base connector plug A pin #18.
-- Check for continuity between pins #18 on cable A. Check for loose or corroded connections
10. Loose or broken wire #36 plug A pin #18 to platform terminal block.
11. Loose or broken wire #36 from platform terminal block to platform rotate left valve 4H-36.
12. Loose or broken wire #02 from platform terminal block to platform rotate left valve 4H-36.
13. Defective platform rotate left valve coil 4H-36.
4.1-24 No Platform Rotate Right from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to platform rotate switch S16.
-- Check continuity through switch while activating rotate right function between wires #10A and

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8. Loose or broken wire #37 from platform rotate switch S16 to base connector plug A pin #19.
10. Loose or broken wire #37 plug A pin #19 to platform terminal block.
11. Loose or broken wire #37 from platform terminal block to platform rotate right valve 4H-37.
12. Loose or broken wire #02 from platform terminal block to platform rotate right valve 4H-37.
13. Defective platform rotate right valve coil 4H-37.
4.1-25 No Jib Up from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to jib switch S17.
2. Defective jib up switch S17.
-- Check continuity through switch while activating jib up function between wires #10A and #35.
5. Loose or broken wire #34A from main harness plug pin #11 to jib enable valve 2H-34A.
6. Loose or broken wire #02 from main harness plug to jib enable valve 2H-34A.
7. Defective jib enable valve 2H-34A.
8. Loose or broken wire #35 from jib up switch S17 to base connector plug A pin #17.
10. Loose or broken wire #35 from plug A pin #17 to platform terminal block.
11. Loose or broken wire #35 from platform terminal block to jib up valve 4H-35.
12. Loose or broken wire #02 from platform terminal block to jib up valve 4H-35.
13. Defective jib up valve coil 4H-35.
4.1-26 No Jib Down from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to jib switch S17.

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2. Defective jib down switch S17.

-- Check continuity through switch while activating jib down function between wires #10A and#34.
8. Loose or broken wire #34 from jib down switch S17 to base connector plug A pin #16.
10. Loose or broken wire #34 from plug A pin #16 to platform terminal block.
11. Loose or broken wire #34 from platform terminal block to jib down valve 4H-34.
12. Loose or broken wire #02 from platform terminal block to jib down valve 4H-34.
13. Defective jib down valve coil 4H-34.
4.1-27 No Manual Platform Level Up from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to platform level switch S15.
2. Defective platform level switch S15.
-- Check continuity through switch while activating level up function between wires #10A and#41.
If no continuity found replace switch.
3. Loose or broken wire #41 from platform level switch S15 to base terminal block.
4. Loose or broken wire #41 from base terminal block to main harness pin plug pin#16.
5. Loose or broken wire #41 from main harness pin plug pin#16 platform level up valve 4H-41.
6. Loose or broken wire #02 from turret harness pin plug platform level up valve 4H-41.
7. Defective platform level up valve coil 4H-41.
4.1-28 No Manual Platform Level Down from Base Control Console

1. Loose or broken wire #10A from ignition/pump switch S5 to platform level switch S15.
2. Defective platform level switch S15.
-- Check continuity through switch while activating level down function between wires #10A
and#40. If no continuity found replace switch.
3. Loose or broken wire #40 from platform level switch S15 to base terminal block.
4. Loose or broken wire #40 from base terminal block to main harness pin plug pin#15.

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5. Loose or broken wire #40 from main harness pin plug pin#16 platform level down valve 4H-40.
6. Loose or broken wire #02 from turret harness pin plug platform level down valve 4H-40.
7. Defective platform level down valve coil 4H-40.
4.1-29 All Controls Inoperative from Platform Control Console

1. Open or defective emergency stop switch S4.
-- Pull emergency switch out. Check continuity through switch. Replace if defective.
2. Loose or broken wire #4A from emergency stop switch S4 to platform start switch S9.
3. Loose or broken wire #4 platform start switch S9 to platform terminal block.
4. Loose or broken pin jumper between #04 and #04A on platform terminal block (without generator
option only).
5. Loose or broken wire #04 from platform terminal block to generator switch S22 (generator option only).
6. Generator switch S22 in generator mode or is open or defective (generator option only).
-- Select OFF mode on generator switch. Check continuity through switch from #04 to #04A.
Replace if defective.
7. Loose or broken wire #04A from generator switch S22 to platform terminal block (generator option only).
8. Loose or broken wire #04A from platform terminal block to footswitch S11.
9. Open or defective footswitch S11.
-- Check continuity through switch while activating footswitch function between wires #04A and
#08A. If no continuity found replace switch.
10. Loose or broken wire #08A from footswitch S11 to valve driver pin #16.
11. Loose or broken wire #04 from platform terminal block to valve driver pin #1, 2 & 13.
12. Loose or broken wire #02 from platform terminal block to valve driver pin #24, 25 & 26.
13. No output on pin #6 of the valve driver to wire #08.
-- Check pin #6 for 12 volts. If no voltage present with foot on footswitch check section 5 for
OCM pin voltage reference.
14. Loose or broken wire #04 from platform terminal block to diode D04.
16. Loose or broken wire #60 from diode D04 to platform terminal block.
17. Loose or broken wire #60 from platform terminal block to plug B pin #16 in platform control console.
-- Check for continuity between pins #16 on cable B. Check for loose or corroded connections
19. Loose or broken wire #60 from plug B pin #16 to base terminal block.

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4.1-30 No Boom Up from Platform Control Console

1. Loose or broken wire #04 from platform terminal block to joystick controller A1.
3. No output on y-axis of joystick controller A1.
-- Refer to joystick test procedure in section 5.
4. Loose or broken wire “Y” from joystick controller A1 to valve driver pin #29.
-- Check pin #22 for minimum 3.5 volts. If no voltage present with foot on footswitch check section
5 for OCM pin voltage reference.
7. Loose or broken wire #14 from valve driver pin #22 to plug A pin #7 in platform control console.
9. Loose or broken wire #14 from base connector plug A pin #7 to base terminal block.
11. Loose or broken wire #14 from main harness plug pin #2 to boom up valve 4H-14.
12. Loose or broken wire #02 from main harness plug to boom up valve 4H-14.
13. Defective boom up valve coil 4H-14.
4.1-31 No Boom Down from Platform Control Console

3. No output on y-axis of joystick controller A1.
4. Loose or broken wire “Y” from joystick controller A1 to valve driver pin #29.

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11. Loose or broken wire #13 from main harness plug pin #1 to boom down valve 4H-13.
12. Loose or broken wire #02 from main harness plug to boom down valve 4H-13.
13. Defective boom down valve coil 4H-13.
4.1-32 No Riser Up from Platform Control Console

3. No output on R signal from joystick controller A3.
4. Loose or broken wire “R” from joystick controller A3 to valve driver pin #30.
-- Check pin #9 for minimum 3 volts. If no voltage present with foot on footswitch check section
11. Loose or broken wire #31 from main harness plug pin #8 to riser up valve 4H-31.
12. Loose or broken wire #02 from main harness plug to riser up valve 4H-31.
13. Defective riser up valve coil 4H-31.
-- Check continuity and resistance through coil. Replace if defective
4.1-33 No Riser Down from Platform Control Console

3. No output on R signal from joystick controller A3.
4. Loose or broken wire “R” from joystick controller A3 to valve driver pin #30.

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11. Loose or broken wire #30 from main harness plug pin #7 to riser down valve 4H-30.
12. Loose or broken wire #02 from main harness plug to riser down valve 4H-30.
13. Defective riser down valve coil 4H-30.
4.1-34 No Turret Left from Platform Control Console

3. No output on x-axis of joystick controller A1.
4. Loose or broken wire “X” from joystick controller A1 to valve driver pin #28.
11. Loose or broken wire #32 from main harness plug pin #9 to turret left valve 4H-32.
12. Loose or broken wire #02 from main harness plug to turret left valve 4H-32.
13. Defective turret left valve coil 4H-32.

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4.1-35 No Turret Right from Platform Control Console

3. No output on x-axis of joystick controller A1.
4. Loose or broken wire “X” from joystick controller A1 to valve driver pin #28.
11. Loose or broken wire #33 from main harness plug pin #10 to turret right valve 4H-33.
12. Loose or broken wire #02 from main harness plug to turret right valve 4H-33.
13. Defective turret right valve coil 4H-33.
4.1-36 No Toggle Switch Functions from Platform Control Console

1. Loose or broken wire #8 from platform terminal block to toggle switches.
2. Loose or broken wire #20A from toggle switches to valve driver pin #33.
4.1-37 No Telescope In from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to telescope switch S18.
-- Check continuity through switch while activating in function between wires #08 and #38.
3. Loose or broken wire #20A from telescope switch S18 to valve driver pin #33.
5. Loose or broken wire #38 from telescope switch S18 to plug B pin #8 in platform control console.

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-- Check for continuity between pins #8 on cable B. Check for loose or corroded connections on
7. Loose or broken wire #38 from base connector plug B pin #8 to base terminal block.
9. Loose or broken wire #38 from main harness plug pin #13 to telescope in valve 4H-38.
10. Loose or broken wire #02 from main harness plug to telescope in valve 4H-38.
11. Defective telescope in valve coil 4H-38.
4.1-38 No Telescope Out from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to telescope switch S18.
-- Check continuity through switch while activating out function between wires #08 and #39.
3. Loose or broken wire #20A from telescope switch S18 to valve driver pin #33.
5. Loose or broken wire #39 from telescope switch S18 to plug B pin #9 in platform control console.
9. Loose or broken wire #39 from main harness plug pin #14 to telescope out valve 4H-39.
10. Loose or broken wire #02 from main harness plug to telescope out valve 4H-39.
11. Defective telescope out valve coil 4H-39.
4.1-39 No Platform Rotate Left from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to platform rotate switch S20.
-- Check continuity through switch while activating rotate left function between wires #08 and #36.
3. Loose or broken wire #20A from platform rotate switch S20 to valve driver pin #33.
5. Loose or broken wire #36 from platform rotate switch S20 to platform terminal block.

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6. Loose or broken wire #36 or #02 from platform terminal block to rotate left valve 4H-36.
7. Defective rotate left valve coil 4H-36.
8. Loose or broken wire #36 from platform terminal block to plug A pin#18 in platform control console.
10. Loose or broken wire #36 from base connector plug A pin #18 to base platform rotate switch S16.
11. Defective base platform rotate switch S16.
-- Check continuity through switch while activating rotate left function between wires #10A and
4.1-40 No Platform Rotate Right from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to platform rotate switch S20.
-- Check continuity through switch while activating rotate right function between wires #08 and
#37.
3. Loose or broken wire #20A from platform rotate switch S20 to valve driver pin #33.
5. Loose or broken wire #37 from platform rotate switch S20 to platform terminal block.
6. Loose or broken wire #37 or #02 from platform terminal block to rotate right valve 4H-37.
7. Defective rotate right valve coil 4H-37.
10. Loose or broken wire #37 from base connector plug A pin #19 to base platform rotate switch S16.
11. Defective base platform rotate switch S16.
-- Check continuity through switch while activating rotate right function between wires #10A and

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4.1-41 No Jib Up from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to jib switch S21.
2. Defective jib up switch S21.
-- Check continuity through switch while activating jib up function between wires #08 and #35.
3. Loose or broken wire #20A from jib switch S21 to valve driver pin #33.
5. Loose or broken wire #35 from jib switch S20 to platform terminal block.
6. Loose or broken wire #35 or #02 from platform terminal block to jib up valve 4H-35.
10. Loose or broken wire #35 from base connector plug A pin #17 to base jib up switch S17.
11. Defective base jib up switch S17.
-- Check continuity through switch while activating jib up function between wires #10A and #35.
4.1-42 No Jib Down from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to jib switch S21.
2. Defective jib down switch S21.
-- Check continuity through switch while activating jib down function between wires #08 and #34.

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3. Loose or broken wire #20A from jib switch S21 to valve driver pin #33.
5. Loose or broken wire #34 from jib switch S20 to platform terminal block.
6. Loose or broken wire #34 or #02 from platform terminal block to jib down valve 4H-34.
10. Loose or broken wire #34 from base connector plug A pin #16 to base jib down switch S17.
11. Defective base jib down switch S17.
-- Check continuity through switch while activating jib down function between wires #10A and
4.1-43 No Manual Platform Level Up from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to platform leveling switch S19.
2. Defective platform leveling switch S19.
-- Check continuity through switch while activating level up function between wires #08 and #41.
3. Loose or broken wire #20A from platform leveling switch S19 to valve driver pin #33.
5. Loose or broken wire #41 from platform leveling switch S19 to plug B pin #11 in platform control console.

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9. Loose or broken wire #41 from main harness plug pin #16 to level up valve 4H-41.
10. Loose or broken wire #02 from main harness plug to level up valve 4H-41.
11. Defective level up valve coil 4H-41.
4.1-44 No Manual Platform Level Down from Platform Control Console

1. Loose or broken wire #08 from platform terminal block to platform leveling switch S19.
2. Defective platform leveling switch S19.
-- Check continuity through switch while activating level down function between wires #08 and #40.
3. Loose or broken wire #20A from platform leveling switch S19 to valve driver pin #33.
5. Loose or broken wire #40 from platform leveling switch S19 to plug B pin #10 in platform control console.
9. Loose or broken wire #40 from main harness plug pin #15 to level down valve 4H-40.
10. Loose or broken wire #02 from main harness plug to level down valve 4H-40.
11. Defective level down valve coil 4H-40.
4.1-45 Throttle Inoperative, Mid and High (Deutz D2.9L only)

1. Loose or broken wire #90 from base terminal block to connector J2 pin #5.
2. Loose or broken wire #90 from connector P2 pin #5 94 pin ECU connector pin 80.
3. Loose or broken wire #99 from base terminal block to connector J2 pin 4
4. Loose or broken wire #99 from connector P2 pin 4 to 94 pin ECU connector pin 74
5. Resistor R4 open or poor connection at base terminal block.
-- Measure resistance (1KΩ) between 99 and 99A. Check connections. Replace if defective.
-- Measure resistance (3.3KΩ) between 99A and 99B. Check connections. Replace if defective.
-- Measure resistance (3.9KΩ) between 99B and 90. Check connections. Replace if defective.

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4.1-46 Mid Throttle Inoperative

1. Loose or broken wire #08 from platform terminal block to throttle switch S10.
2. Defective throttle switch S10.
-- Check continuity through switch while activating mid throttle function between wires #08 and
#79. If no continuity found replace switch.
3. Loose or broken wire #79 from throttle switch S10 to plug B pin #20 in platform control console.
4. Loose or broken wire #79 in Cable B or its connectors.
(Deutz D2.9L Diesel Only)

5. Loose or broken wire #79 from base plug B pin #20 to relay 79CR.
8. Loose or broken wire #99B from relay 79CR to base terminal block.
(Deutz D2011 Diesel Only)

7. Loose or broken wire #99 from relay 79CR to ECU connector pin #18.
9. Loose or broken wire #103 from base terminal block to ECU connector pin #17.
(GM Engine Only)

11. Loose or broken wire #79 from base plug B pin #20 to engine harness plug.
-- Check continuity. Replace if defective
12. Loose or broken wire #79 from engine harness plug to GM engine connector 2.
13. Loose or broken gray/dark blue wire from GM engine connector to ECU connector pin #51.
14. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA1.
15. Defective throttle actuator RA1.
-- Check actuator. Replace if defective.

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4.1-47 High Throttle Inoperative

1. Loose or broken wire #08 from platform terminal block to throttle switch S10.
2. Defective throttle switch S10.
-- Check continuity through switch while activating high throttle function between wires #08 and
3. Loose or broken wire #78 from throttle switch S10 to plug B pin #19 in platform control console.
4. Loose or broken wire #78 in Cable B or its connectors.
(Deutz D2.9L Diesel Only)

8. Loose or broken wire #99A from relay 78CR to base terminal block.
(Deutz D2011 Diesel Only)

7. Loose or broken wire #90 from relay 78CR to ECU connector pin #21.
9. Loose or broken wire #103 from base terminal block to ECU connector pin #17.
4.1-48 Brake will not Release

1. No output on pin #10 from valve driver to wire #26 when operating a drive function.
2. Loose or broken wire #26 from valve drive pin #10 to plug A pin #11 in platform control console.
3. Loose or broken wire #26 in Cable A or its connectors.
4. Loose or broken wire #26 from base plug A pin #11 to main harness plug pin #6.
5. Loose or broken wire #26 or #02 from main harness plug to brake valve 3H-26.
6. Defective brake valve coil 3H-26.

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4.1-49 Differential Lock will not Engage
NOTE
Differential Lock cannot be engaged if a drive function has been
selected.
1. No output on pin #19 from valve driver to wire #26A.

-- Check pin #19 for 12 volts when drive in neutral position. If no voltage present make sure drive
joystick output “D” is between 4.2 and 4.8 volts.
2. Loose or broken wire #26A from valve drive pin #19 to differential lock switch S28.
3. Loose or broken wire #165 from differential lock switch S28 to plug A pin #24 in platform control console.
4. Loose or broken wire #165 in Cable A or its connectors.
5. Loose or broken wire #165 from base plug A pin #24 to main harness plug pin #21.
6. Loose or broken wire #165 or #02 from main harness plug to differential lock valve 3H-165.
7. Defective differential lock valve coil 3H-165.
4.1-50 Differential Lock Engages Momentarily but will not stay Engaged
NOTE
Differential Lock will engage without light being illuminated. Check
bulb.
1. Loose or broken wire #26A at diode D26A.

2. Open or defective diode D26A.
3. Loose or broken wire #26B from diode D26A to relay 165CR.
4. Loose or broken wire #165 from differential lock switch S28 to relay 165CR. (2 places)
-- Check for 12 volts on wire #165 (2 places) while activating differential lock at relay 165CR.
6. Loose or broken wire #02 from platform terminal block to differential lock switch S28.
7. Loose or broken wire #02A from differential lock switch S28 to relay 165CR.
8. Loose or broken wire #08 from platform terminal block to diode D08-1.
9. Open or defective diode D08-1.
10. Loose or broken wire #26B from diode D08-1 to relay 165CR.

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4.1-51 No Drive and Steer
NOTE
Aerial platform will not drive or steer if it is tilted and off limit switches.
1. Loose or broken wire #162A from base terminal block to base plug B pin #24. (CE only)
2. Loose or broken wire #162A in Cable B or its connectors. (CE only)
3. Loose or broken wire #162A from plug B pin #24 in platform control console to drive joystick A2. (CE
only)
NOTE
For further CE troubleshooting refer to Load Sensing System.
4. Loose or broken wire #04 from platform terminal block to drive joystick A2.
5. Loose or broken wire #02 from platform terminal block to drive joystick A2.
4.1-52 No Forward Drive

1. No output on “D” when forward is selected on drive joystick A2.
-- See drive joystick test procedure in section 5.
2. Loose or broken wire ”D-signal” from drive joystick A2 to valve driver pin #27.
3. No output from valve driver pin #34 to wire #16.
-- 5 for OCM pin voltage reference.
4. Loose or broken wire #16 from valve driver pin #34 to plug B pin #5 in platform control console.
5. Loose or broken wire #16 in cable B or its connectors.
6. Loose or broken wire #16 from base plug B pin #5 to forward drive valve 3H-16.
7. Loose or broken wire #02 from base terminal block to forward drive valve 3H-16.
8. Defective forward drive valve coil 3H-16.
4.1-53 No Reverse Drive

1. No output on “D” when reverse is selected on drive joystick A2.
-- See drive joystick test procedure in section 5.
2. Loose or broken wire ”D-signal” from drive joystick A2 to valve driver pin #27.
3. No output from valve driver pin #23 to wire #15.
4. Loose or broken wire #15 from valve driver pin #23 to plug B pin #4 in platform control console.

194313

6. Loose or broken wire #15 from base plug B pin #4 to reverse drive valve 3H-15.
7. Loose or broken wire #02 from base terminal block to reverse drive valve 3H-15.
8. Defective reverse drive valve coil 3H-15.
4.1-54 No High Speed Drive
NOTE
Aerial platform must be level and boom must be fully retracted and
horizontal or below.
1. Loose or broken wire #09 from base terminal block to limit switch LS2.
2. Open or defective limit switch LS2.
-- Ensure boom is horizontal or below and fully retracted. Adjust switch if required. Check continuity
through switch. Replace if required.
3. Loose or broken wire #29 from limit switch LS2 to base terminal block.
-- Ensure boom is fully retracted and horizontal or below. Adjust switch if required. Check continuity
through switch. Replace if defective.
6. Loose or broken wire #29A from limit switch LS3 to base terminal block.
7. Loose or broken wire #29A from base terminal block to limit switch LS4.
-- Ensure boom is fully retracted and horizontal or below. Adjust switch if required. Check continuity
through switch. Replace if defective.
10. Loose or broken wire #59 from base terminal block to plug B pin #15.
12. Loose or broken wire #59 from plug B pin #15 to platform terminal block.
13. Loose or broken wire #59 from platform terminal block to valve driver pin #31.
14. Defective valve driver channel input for high drive enable.
-- See section 5 for OCM pin voltage reference.
15. Loose or broken wire #59 from platform terminal block to torque switch S48.
16. Open or defective torque switch S48.
-- Check continuity through switch while activating low torque function between wires #59 and

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17. Loose or broken wire #45 from torque switch S48 to plug A pin #20 in platform control console.
18. Loose or broken wire #45 in cable A or its connectors.
19. Loose or broken wire #45 from plug A pin #20 to relay 45CR1.
20. Loose or broken wire #09 from base terminal block to relay 45CR1.
21. Loose or broken wire #02 from relay 45CR1 to base terminal block.
22. Defective relay 45CR1.
23. Loose or broken wire #45A from relay 45CR1 to main harness plug pin #17.
24. Loose or broken wire #45A or #02 from main harness plug to 2 speed valve 3H-45A.
25. Defective 2 speed valve 3H-45A.
4.1-55 No Elevated Drive
NOTE
Aerial platform must be level to drive elevated.
1. Loose or broken wire #09 or #02 from base terminal block to level sensor TS1.
2. Misadjusted, no output or defective level sensor TS1.
-- Adjust level sensor if required. Check for 12 volts on wire #28. If no voltage present with level
sensor adjusted or if defective, replace level sensor.
3. Loose or broken wire #28 from level sensor TS1 to plug B pin #7.
5. Loose or broken wire #28 from plug B pin #7 to platform terminal block.
6. Loose or broken wire #28 from platform terminal block to valve driver pin #32.
4.1-56 No Left Steer

1. Loose or broken wire #24 from drive joystick A2 to valve driver pin #17.
2. No output from valve driver pin #4 to wire #24A.
3. Loose or broken wire #24A from valve driver pin #4 to plug A pin #10 in platform control console.
4. Loose or broken wire #24A in boom cable A or its connectors.
5. Loose or broken wire #24A from base plug A pin #10 to main harness plug pin #5.

194313
6. Loose or broken wire #24A or #02 from main harness plug to left steer valve 4H-24A.
7. Defective left steer valve coil 4H-24A.
4.1-57 No Right Steer

1. Loose or broken wire #23 from drive joystick A2 to valve driver pin #18.
2. No output from valve driver pin #21 to wire #23A.
3. Loose or broken wire #23A from valve driver pin #21 to plug A pin #9 in platform control console.
4. Loose or broken wire #23A in boom cable A or its connectors.
5. Loose or broken wire #23A from base plug A pin #9 to main harness plug pin #4.
6. Loose or broken wire #23A or #02 from main harness plug to right steer valve 4H-23A.
7. Defective right steer valve coil 4H-23A.
4.1-58 Direction Sensing Inoperative

-- Adjust limit switch if required. Check continuity through switch. Replace if defective.
4. Loose or broken wire #17 from base terminal block to base plug B pin #6.
6. Loose or broken wire #17 from platform plug B pin #6 to valve driver pin #15 in platform control console.
7. Defective valve driver channel input for direction sense enable.
-- See section 5 for test procedure on valve driver.

194313
4.2 Hydraulic System
4.2-1 All Controls Inoperative

1. Broken or defective drive pump shaft or coupling.
-- Check pump shaft and coupling. Replace if defective.
2. Hydraulic oil level low.
-- Check oil level. Fill to proper level.
4.2-2 All Boom Functions Inoperative

1. Open or defective dump valve 2H-21A.
-- Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as
required.
2. Stuck or defective relief valve RV6.
-- Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required.
3. Stuck or defective Inlet Compensator/ differential sensing valve DSV1.
-- Check O-rings and clean valve. Check operation of valve. Repair or replace valve as required.
4. System pump P2 defective.
-- Test pump with flow meter. Replace if defective.
5. Plugged or defective high pressure filter F1.
-- Check filter. Replace if plugged or defective.
4.2-3 No Main Boom Up

1. Stuck or defective lift up valve 4H-14.
-- Clean valve. Check operation of valve. Repair or replace valve as required.
2. Stuck or defective shuttle valve SV6.
required.
3. Stuck or defective check valve CV10.
4. Stuck or defective differential sensing valve DSV4.
required.
5. Stuck or defective counterbalance valve CB9.
-- Clean valve. Check O-rings on valve. Repair or replace valve as required.
6. Defective lift cylinder C3.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective.
4.2-4 No Main Boom Down

1. Stuck or defective lift down valve 4H-13.
required.
4. Stuck or defective differential sensing valve DSV4.
required.
6. Defective lift cylinder C3.

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4.2-5 No Riser Boom Up

1. Stuck or defective riser up valve 4H-31.
required.
required.
5. Stuck or defective differential pressure sensing valve DSV3.
required.
6. Stuck or defective counterbalance valve CB5 or CB6.
7. Defective riser cylinder C6 or C7.
4.2-6 No Riser Boom Down

1. Stuck or defective riser down valve 4H-30.
required.
3. Plugged or defective orifice OR6.
-- Check orifice. Replace if plugged or defective.
required.
required.
8. Stuck or defective counterbalance valve CB5 or CB6.
9. Defective riser cylinder C6 or C7.
4.2-7 Riser Boom Down Jerky

1. Stuck open or defective check valve CV5.
2. Stuck or incorrectly set counterbalance valve CB5 or CB6.
required.

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4.2-8 No Turret Rotate Left

1. Stuck or defective rotate left valve 4H-32.
required.
-- Set valve to specifications. Check o-rings and clean valve. Repair or replace valve as required.
required.
required.
8. Turret rotate brake BR2 not releasing.
-- Inspect brake for worn seals or broken components. Repair and replace as necessary.
9. Worn or defective swing drive motor RA2.
4.2-9 No Turret Rotate Right

1. Stuck or defective rotate right valve 4H-33.
required.
required.
required.
8. Turret rotate brake BR2 not releasing.
-- Inspect brake for worn seals or broken components. Repair and replace as necessary.
9. Worn or defective swing drive motor RA2.

194313
4.2-10 No Boom Extend

1. Stuck or defective boom extend valve 3H-39.
2. Plugged, incorrectly adjusted or defective orifice OR3.
3. Stuck in the shifted position or defective boom retract valve 3H-38.
6. Defective extension cylinder C2.
4.2-11 No Boom Retract

1. Stuck or defective boom retract valve 3H-38.
5. Defective extension cylinder C2.
-- Check seals on cylinder. Replace as necessary. Replace cylinder if defective
4.2-12 No Jib Up
1. Stuck or defective jib enable valve 2H-34A.
required.
required.
5. Stuck or defective jib up valve 4H-35.
7. Defective jib cylinder C1.
4.2-13 No Jib Down

1. Stuck or defective jib enable valve 2H-34A.
required.
required.

194313

5. Stuck or defective jib down valve 4H-34.
7. Defective jib cylinder C1.
4.2-14 No Platform Rotation Right

1. Stuck or defective platform rotate enable valve 2H-36A.
required.
required.
5. Stuck or defective platform rotate right valve 4H-37.
7. Defective rotary actuator RA1.
-- Check actuator. Repair or replace as necessary.
4.2-15 No Platform Rotation Left

1. Stuck or defective platform rotate enable valve 2H-36A.
required.
required.
5. Stuck or defective platform rotate left valve 4H-36.
7. Defective rotary actuator RA1.
-- Check actuator. Repair or replace as necessary.
4.2-16 Platform will not Level Down Manually

2. Stuck or defective platform level down valve 4H-40.
required.

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required.
required.
9. Defective leveling cylinder C4 or slave cylinder C5.
4.2-17 Platform will not Level Up Manually

2. Stuck or defective platform level up valve 4H-41.
required.
required.
required.
-- Clean valve. Check Check operation of valve. Repair or replace valve as required.
9. Defective leveling cylinder C4 or slave cylinder C5.
4.2-18 Brake will not Release

required.
2. Defective or misadjusted pressure reducing valve PR1.
3. Stuck or defective brake valve 3H-26.
required.
required.
5. Defective or misadjusted relief valve RV4.

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6. Stuck or defective brake release override valve V1.

7. Bypassing or defective brake hand pump V3.
8. Bypassing or defective brake cylinder C12.
4.2-19 Brake will not Engage

1. Brake cylinder defective.
-- Check cylinders. Repair or replace as necessary.
2. Brake valve 3H-26 stuck in shifted position.
-- Check valve. Replace if defective.
3. Brake inside axle out of adjustment.
-- See section 5 for brake adjustment procedure.
4.2-20 Differential Lock will not Engage

required.
2. Defective or misadjusted pressure reducing valve PR1.
3. Stuck or defective differential lock valve 3H-165.
required.
4. Bypassing or defective differential lock cylinder C13.
4.2-21 No Drive Forward or Reverse

1. Brake not releasing.
-- See “brake will not release” in this section.
2. Defective or misadjusted charge pump relief valve RV3.
3. Plugged or defective charge pump filter F1.
-- -Check filter. Replace if plugged or defective.
4. Worn charge pump P1A.
-- Check pump. Replace if defective.
5. Defective pump displacement control 4H-15 and 4H-16.
-- Check control. Replace if defective.
6. Open bypass valve V4.
-- Close bypass valve.
7. Worn drive pump P1.
8. Worn or defective drive motor M1.
-- Check motor. Replace if defective.
4.2-22 No Forward Drive

1. Defective pump displacement control 4H-16.
2. Defective or misadjusted drive relief valve RV1.
-- See section 5 for drive pump set up procedures.
3. Drive pump servo stuck or not shifting.

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4.2-23 No Reverse Drive

1. Defective pump displacement control 4H-15.
2. Defective or misadjusted drive relief valve RV2.
-- See section 5 for drive pump set up procedures.
3. Drive pump servo stuck or not shifting.
4.2-24 No High Speed Drive

1. Stuck or defective 2 speed valve 3H-45.
required.
2. Defective shift spool in drive motor M1.
-- Check motor. Repair or replace if necessary.
4.2-25 No Right Steer

1. Plugged, incorrectly adjusted or defective priority flow control PFC1.
-- Check operation. Set flow rate to 1.25 GPM @ 2000 psi. Replace if plugged or defective.
2. Stuck or defective right steer valve 4H-23A.
3. Defective steer cylinder C8.
4.2-26 No Left Steer

1. Plugged, incorrectly adjusted or defective priority flow control PFC1.
-- Check operation. Set flow rate to 1.25 GPM @ 2000 psi. Replace if plugged or defective.
2. Stuck or defective left steer valve 4H-24A.
3. Defective steer cylinder C8.
4.2-27 Axle Will Not Oscillate
NOTE
Axle will only oscillate when boom is fully retracted and is horizontal
or below.
1. Stuck or defective axle lockout valve 3H-65.

-- Clean valve. Replace if defective.
2. One or more counterbalance valves (CB1 or CB2) failed to shift or is defective.

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4.2-28 Axle Will Not Lock
NOTE
Axle is in constant float if boom is fully retracted and is horizontal
or below.
1. Axle lockout valve 3H-65 is stuck in shifted position or is defective.

required.
2. Bypassing or defective axle lock cylinders C9 and C10.
3. Counterbalance valves (CB1 or CB2) out of adjustment or are defective.

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4.3 Load Sensing System - CE
4.3-1 Green Power LED is not Flashing

1. Loose or broken wires #60 and #02 at platform terminal block.
-- Check for connections. Check for voltage (12V).
2. Load cell has lost its calibration.
-- Refer to calibration procedure for recalibration of load cell.
4.3-2 Load Cell red Alarm LED is ON (with platform empty)

1. Load cell has lost its calibration.
-- Refer to calibration procedure for recalibration of load cell.
4.3-3 Red Error LED is ON

1. Open safety contact circuit.
-- Check for connections with wires #161 and #162A at platform terminal block and base terminal block.
Check resistor R6 for 680 ohms.
4.3-4 Load Cell red Alarm LED is OFF (with platform overloaded)
1. Open safety contact circuit.
-- Check for connections with wires #161 and #162 at platform terminal block and base terminal block.
Check resistor R6 for 680 ohms.
4.3-5 Platform Indicator Light does not turn ON

1. Defective lamp.
-- Check lamp. Replace if defective.
3. Load cell circuit not operating.
-- Check for connections with wire #02B at pilot light strip and relay 82CR, and wire #82 at platform
terminal block and relay 82CR.
4. Defective load cell.
-- Defective if 0V is measured between wire #82 and #02 from platform terminal block.
4.3-6 Audible Alarm does not turn ON

1. Defective alarm BP3.
-- Check alarm. Replace if defective.
3. Load cell circuit not operating.
-- Check for connections with wires #02 and #118 at platform terminal block.
4. Defective load cell.
-- Defective if 0V is measured between wire #118 and #02 from platform terminal block.
4.3-7 Boom and Drive Functions are Enabled (with boom extended)
1. “Fly IN” limit switch LS3 is not operating properly.
-- Check for voltage (0V) between wires #59 and #02 from platform terminal block. If 12V is measured,
check for proper actuation of limit switch. Readjust limit switch if necessary.
2. Defective load cell. Safety contact remains closed.
-- Check for voltage (0V) between wires #162 and #02 from base terminal block. Defective if 12V is
measured.

194313
Section 5
PROCEDURES
Table of Contents
General......................................................................................................................................................................153
Safety and Workmanship..........................................................................................................................................153
Platform
5.1-1 Human Machine Interface (HMI)....................................................................................................................153
5.1-2 User Interface Keys........................................................................................................................................154
5.1-3 How to Select Functionality............................................................................................................................156
5.1-4 How to View OCM Operation.........................................................................................................................157
5.1-5 How to Unlock and Modify OCM Settings.....................................................................................................158
5.1-6 OCM Pin Voltage Reference..........................................................................................................................159
5.1-7 Platform Controller Voltage References.........................................................................................................162
Boom
5.2-1 Check Wear Pads...........................................................................................................................................164
5.2-2 Shimming Wear Pads.....................................................................................................................................164
5.2-3 Cable Carrier Repair.......................................................................................................................................164
5.2-4 Master Cylinder Replacement........................................................................................................................164
Turret
5.3-1 High Pressure Filter Replacement.................................................................................................................166
5.3-2 Check Swing Drive Motor Gearbox Oil..........................................................................................................166
5.3-3 Turret Rotation Gear Backlash Adjustment....................................................................................................166
5.3-4 Swing Drive Motor Removal...........................................................................................................................167
5.3-5 Swing Drive Motor Replacement...................................................................................................................168
5.3-6 Swing Drive Brake and Gearbox Oil Replacement........................................................................................168
5.3-7 Battery Replacement......................................................................................................................................168
5.3-8 Bolt Torque Procedure...................................................................................................................................169
5.3-9 Electronic Tilt Switch Setup Procedure..........................................................................................................170
5.3-10 Check Rotation Bearing for Axial Wear........................................................................................................173
Deutz Diesel Engine

5.4-1 Engine Oil and Filter Replacement................................................................................................................174
5.4-2 Fuel Filter Replacement.................................................................................................................................175
5.4-3 Air Filter Replacement....................................................................................................................................175
5.4-4 Check Engine Belt..........................................................................................................................................175
5.4-5 Check Oil Cooler............................................................................................................................................175
GM Dual Fuel Engine

5.5-1
5.5-2
5.5-3
GM Map and IAT Sensor (3.0L GM Engine)..................................................................................................176
LPG Temperature Sensor (3.0L GM Engine).................................................................................................177
Throttle Actuator (3.0L GM Engine)...............................................................................................................178
5
5.5-4 Engine Coolant Temperature Sensor (3.0L GM Engine)...............................................................................179
5.5-5 ECU Pin Reference Chart (3.0L GM Engine).................................................................................................180
5.5-6 Fuse Block Layout (3.0L GM Engine)............................................................................................................181

194313
Service and Maintenance Section 5 - Procedures
Table of Contents
Kubota WG2503 Dual Fuel Engine

5.6-1 Engine Parameter Display (KAntrak 1700)....................................................................................................182
5.6-2 Diagnostic Trouble Codes..............................................................................................................................183
5.6-3 ECU Pin Reference Chart (Kubota WG2503).................................................................................................188
5.6-4 Fuse Box (Kubota WG2503)...........................................................................................................................189
5.6-5 MAP Sensor (Kubota WG2503)......................................................................................................................190
5.6-6 IAT Sensor (Kubota WG2503)........................................................................................................................190
5.6-7 ECT (Kubota WG2503)...................................................................................................................................191
5.6-8 TPS & Engine Speed (Kubota WG2503)........................................................................................................191
5.6-9 Fuel Temperature Sensor (Kubota WG2503).................................................................................................192
5.6-10 Oil Pressure Sensor (Kubota WG2503)........................................................................................................192
Hydraulic Tank
5.7-1 Hydraulic Oil Replacement............................................................................................................................193
5.7-2 Hydraulic In-tank Filter Replacement.............................................................................................................193
Manifold and Hydraulic Pumps

5.8-1 Hydraulic Brake Pressure Adjustment...........................................................................................................194
5.8-2 Hydraulic System Relief Valve Adjustment....................................................................................................195
5.8-3 Riser Down Relief Valve Adjustment..............................................................................................................195
5.8-4 Turret Rotate Relief Valve Adjustment............................................................................................................196
5.8-5 Platform Level Relief Valve Adjustment..........................................................................................................196
5.8-6 Test Charge Pump Pressure on Drive Pump.................................................................................................197
5.8-7 Test Forward Drive Pressure on Drive Pump.................................................................................................197
5.8-8 Test Reverse Drive Pressure on Drive Pump.................................................................................................198
Axles
5.9-1 Rear Axle Oil Replacement............................................................................................................................198
5.9-2 Front Axle Oil Replacement............................................................................................................................198
5.9-3 Check Torque Hub Oil Level..........................................................................................................................199
5.9-4 Check Axle Gearbox Oil Level........................................................................................................................199
5.9-5 Axle Gearbox Oil Replacement......................................................................................................................199
5.9-6 Oscillating Cylinder Bolt Replacement...........................................................................................................200
5.9-7 Oscillating Cylinder Replacement..................................................................................................................200
5.9-8 Bleeding Oscillating Axle Cylinders...............................................................................................................202
5.9-9 Pin Brake Adjustments...................................................................................................................................202
Grease Points
5.10-1 Lubrication.....................................................................................................................................................204
Options
5.11-1 Load Sensing System - CE............................................................................................................................206

194313
Section 5 - Procedures Service and Maintenance
General
The following information is provided to assist you in the use and application of servicing and maintenance procedures
contained in this chapter.
Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support
is provided.
Platform
5.1-1 Human Machine Interface (HMI)
Maintaining proper calibration is essential for good performance of the aerial platform.
1. Ensure aerial platform is on a firm level surface, and is in stowed position and engine is off.
2. On base control, turn base/off/platform key switch to “ ” platform position.
3. Pull out ” ” emergency stop button.
WARNING
Ensure that you maintain three points of contact to mount/dismount platform.
4. Enter platform and close gate.

WARNING
DO NOT operate any control on platform control console without proper fall protection secured to
designated location in platform. Failure to avoid this hazard could result in death or serious injury!
WARNING
Ensure that there are no personnel or obstructions in test area and that there is sufficient room
for boom to swing.
5. At platform control, open the cover of the console to access the OCI-1 console.
The OCI-1 has an integrated multi segment, two line display with membrane keys that allow it to be used as the
main interface to system controls and adjustments. the Human Machine Interface (referred to as the HMI) will serve
as your window into the application software to allow the operator to monitor/adjust the following information;
- Active Function Being Used

- Part Number and Serial Number
- Restore the Factory Default Settings
- Output Calibrations (Tresh, Max, Ramp.etc)
- I-O Status
- CANBus Status

194313
5.1-2 User Interface Keys
MENU 1.0-1 <MENU> enters a new menu screen and/or

1.0 SELECT
1.0-2 <SELECT> select the flashing item.
1.1-1 <MINUS> decreases an adjustable parameter such as

---- ramp time.
1.1
1.1-2 <DOWN> selects the previous item in the current menu’s
list.
1.2-1 <PLUS> increases an adjustable parameter.

1.2
1.2-2 <UP> selects the next item in the current menu’s list.
+
1.3-1 <SAVE> saves the new data to EEPROM (permanent
1.3 SAVE
memory storage).
---- Simultaneously press <UP> and <DOWN> will reset the HMI to
1.4
menu screen 0.
+
OCM Character Functions Charts
OCM Keypad Function Attribute

Keys Short Form THRESH Threshold
Menu/Select (M/S) RAMPDN Ramp Down
▼/- (-) RAMPUP Ramp Up
▲/+ (+) LOWRNG Low Range
Save/Exit (S/E) MAXOUT Maximum Output
60584AA
OCM Function (Channel) Names

DRIVE REV Fn01A Drive Reverse
DRIVE FWD Fn01B Drive Forward
CHAN 2A Fn02A Brakes
CHAN 2B Fn02B Differential Lock Enable
BOOM DOWN Fn03A Main Boom Down
BOOM UP Fn03B Main Boom Up
ROTATE L Fn04A Turret Rotate Left
ROTATE R Fn04B Turret Rotate Right
RISER DN Fn05A Riser Down
RISER UP Fn05B Riser Up
RISER UP Fn06A Virtual channel
RISER UP Fn06B Virtual channel
129AB

194313
OCM Operating Values Chart
Input (Analog) Expected Value Description

AI 1 0.5V to 8.5V Drive Controller
AI 2 0.5V to 8.5V Turret Rotate Controller
AI 3 0.5V to 8.5V Boom Elevation Controller
AI 4 0.5V to 8.5V Riser Controller
AI 7 1.0V to 5.0V Torque Mode (Angle Sensor)
Input (Digital) Expected Value Description
DI 1 0 or 1 Drive Direction Reverse Limit Switch
DI 2 0 or 1 Footswitch Actuated
DI 3 0 or 1 Steer Left Rocker Switch
DI 4 0 or 1 Steer Right Rocker Switch
DI 5 0 or 1 Boom Function Toggle Switch Enabled
DI 6 0 or 1 5 Degree Tilt Switch
DI 11 0 or 1 High Speed Drive Enable Limit Switch
Output (PWM) Expected Value Description
PWM 1 13% - 80% Drive Reverse
PWM 2 13% - 80% Drive Forward
PWM 3 0% or 100% Brake (Energized to Release)
PWM 4 0% or 100% Differential Lock Enable
PWM 5 27% - 45% Main Boom Down
PWM 6 27% - 55% Main Boom Up
PWM 7 30% - 50% Turret Rotate Left
PWM 8 30% - 50% Turret Rotate Right
PWM 9 50% - 55% Riser Down
PWM 10 28% - 70% Riser Up
Output (Digital) Expected Value Description

DOUT 1 0 or 1 Steer Left
DOUT 2 0 or 1 Load Sense Enable
DOUT 3 0 or 1 Footswitch Actuated Indicator
DOUT 4 0 or 1 Axle Lock (0=enabled)
DOUT 7 0 or 1 Tilt Alarm Indicator
DOUT 8 0 or 1 Steer Right
128AC

194313
5.1-3 How to Select Functionality AC
STARTING MODE: NO CONFIG 

SCREEN FUNCTIONS OFF +
ENTER PASSWORD MENU UNLOCK SETUP?  SOFTWARE REVISION

0** SELEC PRESS SELECT + MODEL SERIAL NUMBER
0 (FLASHING) (FLASHING)
5X 1X
 ENTER PASSWORD MENU ENTER PASSWORD  ENTER PASSWORD
+ 5** SELECT 50** + 51**
5 (FLASHING) 0 (FLASHING) 1 (FLASHING)
9X
SETUP UNLOCKED MENU ENTER PASSWORD  ENTER PASSWORD MENU
PRESS – OR + SELECT 519 + 510 SELECT
(FLASHING) 9 (FLASHING) 0 (FLASHING)
 SET DRIVE TIMER  SET B BOUNDARY  SET LRNG B&C 

+ PRESS SELECT + PRESS SELECT + PRESS SELECT +
(FLASHING) (FLASHING) (FLASHING)
TO SELECT
MODEL
 MODE: CONFIG SAVE MENU SELECT MODEL #
 PRESS SELECT
– FUNCTIONS OFF EXIT SELECT
+ (FLASHING)
RESTORE DEFAULTS  SELECT MULTIFNCT MENU SELECT MULTIFNCT

(FLASHING) – PRESS SELECT SELECT STD LTD
(FLASHING) (FLASHING)
SAVE
NOTE
EXIT
STD Machines for the North American market (ANSI/CSA models) USE THE CHART TO THE
LTD Machines for the European market (CE models) LEFT TO DETERMINE THE
FUNCTIONALITY REQUIRED
FOR YOUR MACHINE.
PRESS SAVE/EXIT WHEN
THE FUNCTIONALITY FOR
YOUR MACHINE
Recycle power to the OCM with E‐Stop to re‐enable password protection. CONFIGURATION IS
If the OCM is inactive for more than 5 minutes, password must be re‐entered. FLASHING.

194313
5.1-4 How to View OCM Operation

As a joystick or toggle switch is being activated, the OCM screen will display the active function and % output.
Also, the following procedure will allow monitoring of all input and output channels:
CE Models MODE= XX/XX LTD

STARTING FUNCTIONS OFF
SCREEN
OR
ANSI/CSA MODE= XX/XX STD

Models FUNCTIONS OFF
SAVE
▬▬▬▬ ▲ MENU
ADJUST
EXIT ▬▬▬ ▬▬▬▬
(FLASHING)
┼ SELECT
IO TEST
(FLASHING)
SAVE
▬▬▬▬
EXIT
MENU
▬▬▬▬
SELECT
▲ ▲
Di1 to Di5 Di6 to Di10 Di11 to Di12
▬▬▬ ▬▬▬
DISPLAYED DISPLAYED DISPLAYED
MENU ┼ ┼
▬▬▬▬
SELECT
▲ ▲
Ai1 to Ai3 Ai4 to Ai6 Ai7
▬▬▬ ▬▬▬
┼ ┼
MENU
▬▬▬▬ SAVE
SELECT ▬▬▬▬
EXIT
▲
Do1 to Do5 Do6 to Do8
▬▬▬
DISPLAYED DISPLAYED
MENU ┼
▬▬▬▬
SELECT
▲ ▲ ▲
PWM3 to PWM4 PWM5 to PWM6
PWM1 to PWM2 ▬▬▬ ▬▬▬ ▬▬▬
DISPLAYED DISPLAYED
DISPLAYED ┼ ┼ ┼
▲ ▲
PWM11 to PWM12 PWM9 to PWM10 PWM7 to PWM8
▬▬▬ ▬▬▬
┼ ┼
MENU
▬▬▬▬
SELECT MENU
VDD POWER SUPPLY 8V SENSOR SUPPLY
▬▬▬▬
VALUE = VOLTAGE VALUE = VOLTS
SELECT
See OCM Operating Values Chart on page 155 for operating valves for the previous observations.

194313
5.1-5 How to Unlock and Modify OCM Settings
CE Models MODE= XX/XX LTD

FUNCTIONS OFF
▲
STARTING OR ▬▬▬
SCREEN ┼
ANSI/CSA MODE= XX/XX STD
Models FUNCTIONS OFF
MENU UNLOCK SETUP? ▲

▬▬▬▬ PRESS SELECT ▬▬▬ SOFTWARE REVISION
SELECT ┼ MODEL SERIAL NUMBER
(FLASHING)
7X 5X
ENTER PASSWORD ENTER PASSWORD MENU ENTER PASSWORD
▲ ▲
0**
▬▬▬ 7** ▬▬▬▬ 70* ▬▬▬
0 (FLASHING) ┼ 7 (FLASHING) SELECT 0 (FLASHING) ┼
5X
MENU ENTER PASSWORD ▲ ENTER PASSWORD MENU ENTER PASSWORD
▬▬▬▬ 755 ▬▬▬ 750 ▬▬▬▬ 75*
SELECT 5 (FLASHING) ┼ 0 (FLASHING) SELECT 5 (FLASHING)
SETUP UNLOCKED Increases

PRESS - OR + SAVE Value
(FLASHING) ▬▬▬▬
▲
EXIT
▬▬▬
▲ ┼
▬▬▬ ▬
ONCE THE VALUE HAS
┼ ▬▬▬ XXXX XX (XXXXXX)
BEEN ADJUSTED WITHIN
▼ Fn0XX VALUE = % or SEC
THE PARAMETER OF THE
SET DRIVE TIMER FUNCTION SELECTED, Decreases (FLASHING)
PRESS SELECT YOU MAY CONTINUE TO Value
(FLASHING) ANOTHER ADJUSTABLE MENU
PARAMETER OR SAVE/ ▬▬▬▬
EXIT ALL THE WAY OUT ▲
SAVE SELECT
▬▬▬
▬▬▬▬ TO THE START SCREEN
┼
EXIT XXXX XX
(THRESH/MAXOUT/
MODE: XXXXX TOGGLE LOWRNG/RAMPUP/RAMPDN)
FUNCTIONS OFF Fn0XX VALUE= %
DISPLAYED ▬ (FLASHING)
XXXX XX (THRESH)
▬▬▬
Fn0XX VALUE= %
MENU ▼
▬▬▬▬ (FLASHING)
SELECT
(DRIVE REV) THRESH Fn01A VALUE= %
ADJUST MENU + (DRIVE FWD) THRESH Fn01B VALUE= %
(FLASHING) ▬▬▬▬ + (CHAN 2A) THRESH Fn02A VALUE= %
SELECT + (CHAN 2B) THRESH Fn02B VALUE= %
MENU + (BOOM DOWN) THRESH Fn03A VALUE= %
▬▬▬▬ + (BOOM UP) THRESH Fn03B VALUE= %
SELECT TOGGLE ++ (ROTATE L) THRESH Fn04A VALUE= %
+ (ROTATE R) THRESH Fn04B VALUE= %
(DRIVE REV) THRESH ▲ (DRIVE FWD) THRESH ▲ +
(RISER DOWN) THRESH Fn05A VALUE= %
Fn01A VALUE= % ▬▬▬ Fn01B VALUE= % ▬▬▬ +
+ (RISER UP) THRESH Fn05B VALUE= %
(FLASHING) ┼ (FLASHING) ┼
(LR REV) THRESH Fn06A VALUE= %
(LR FWD) THRESH Fn06B VALUE= %
(FLASHING)
Recycle power to the OCM with the E-Stop to re-enable password protection.
If the OCM is inactive for more than 5 minutes, password must be re-entered.

194313
5.1-6 OCM Pin Voltage Reference
1 12
13 23
24 35
All voltages given are with OCM controller at maximum % adjustable settings.
All voltages should be tested with key on, engine off and foot switch depressed.
All tests should be performed with platform over drive axle, boom fully stowed and on flat level surface.
Pin 1 - 12 volt input from wire 4.

Test between pin 1 and 02 wire.

Pin 3 - Not used.
Pin 4 - 12 Volt output on wire 24A to left steer valve 4H-24A

Pin 5 - 12 volt output on wire 20 to dump valve relay 21CR.

Test between pin 5 and 02 wire while selecting a function.
Pin 6 - 12 volt output on wire 08 to toggle switch boom functions. (Foot switch activated)
Pin 7 - 12 volt output on wire 65 to axle lock valve 3H-65.

Pin 8 - Boom down selected. Proportional output on wire 13 to boom down valve 4H-13.
0 volts to 5.5 volts depending on position of joystick. Threshold= 1.0 volt.
Test between pin 8 and 02 wire while operating boom down.
Pin 9 - Riser up selected. Proportional output on wire 31 to riser up valve 4H-31.

0 volts to 7.5 volts depending on position of joystick. Threshold= 2.8 volts.
Test between pin 9 and 02 wire while operating boom down.
Pin 10 - 12 volt output on wire 26 brake valve 3H-26. 12V=Drive selected


194313
Pin 11 - 12 volt output on wire 27 to tilt alarm relay 27CR.

Test between pin 11 and 02 wire
Pin 12 - Riser down selected. Proportional output on wire 30 to riser down valve 4H-30.
. Test between pin 12 and 02 wire.

Pin 14 - Variable input from wire 128A.

1 volt to 5 volts depending on angle of machine.
1 volt = Level
Pin 15 - Turret position. 12 volt input from limit switch LS1 on wire 17.
0 volts= Platform over drive axle.
12 volts= Platform over steer axle.
Test between 15 and 02 wire.
Pin 16 - Foot switch activated. 12 volt input from wire 08A.

Pin 17 - Left steer selected. 12 volt input from wire 24.

Pin 18 - Right steer selected. 12 volt input from wire 23.

Pin 19 - 12 Volt output on wire 26A to differential lock switch.

Pin 20 - Turret rotate left selected. Proportional output on wire 32 to turret rotate left valve 4H-32.
Test between pin 20 and 02 wire while operating turret rotate left.
.
Pin 21 - 12 Volt output on wire 23A to right steer valve 4H-23A
Pin 22 - Boom up selected. Proportional output on wire 14 to boom up valve 4H-14.

0 volts to 6.5 volts depending on joystick position. Threshold= 3.2 volts.
Test between pin 22 and 02 wire while operating boom up.
Pin 23 - Reverse drive selected. Proportional output on wire 15 to reverse drive valve 3H-15.
Test between pin 23 and 02 wire while operating reverse drive.
Pin 24 - Battery negative. Wire 02.

194313
Pin 27 - Accelerator input. Wire D from drive joystick controller.

Neutral position= 4.2 volts to 4.8 volts.
Forward function= 4.9 volts to 8.5 volts.
Reverse function= 4.1 volts to .5 volts.
Pin 28 - Turret rotate input. Wire X from boom joystick controller.

Rotate right function= 4.9 volts to 8.5 volts.
Rotate left function= 4.1 volts to .5 volts.
Pin 29 - Boom elevation input. Wire Y from boom joystick controller.

Boom up function= 4.9 volts to 8.5 volts.
Boom down function= 4.1 volts to .5 volts.
Pin 30 - Riser input. Wire R from riser joystick controller.

Boom up function= 4.9 volts to 8.5 volts.
Boom down function= 4.1 volts to .5 volts.
Pin 31 - 12 volt input from LS2 boom/riser elevation limit switch and LS3 telescope limit switch on wire 59.
12 volts= full speed. 0 volts= creep speed (one or more limit switches open).
Pin 32 - 12 volt input from angle sensor on wire 28. 12V=<5%

Pin 33 - Toggle switch boom function enable. 12 volt input from wire 20A.
Pin 34 - Forward drive selected. Proportional output on wire 16 to forward drive valve 3H-16.
Test between pin 34 and 02 wire while operating forward drive.
Pin 35 - Turret rotate right selected. Proportional output on wire 33 to turret rotate right valve 4H-33.
Test between pin 10 and 02 wire while operating turret rotate right.

194313
5.1-7 Platform Controller Voltage References
Boom/Turret (A1) Controller

Boom Up
12 Volts
Y
RED (+) POWER 04 RED/YEL
Neutral BLK(-) GROUND 02 WHT
Turret Rotate Left Position Turret Rotate Right WHT(X) X-SIGNAL RED
X 4.2 - 4.8 Pin 28
Volts
BLU(Y) Y-SIGNAL BLU
Pin 29
OCM
Reference
Analog Input
Boom Down AI 3
Reference
Analog Input Turret Rotation (X axis) Boom Elevation (Y axis)
AI 2
Neutral Position = 4.2 - 4.9 Volts Neutral Position = 4.2 - 4.8 Volts
Right = 4.9 - 8.5 Volts @ full stroke Up = 4.9 - 8.5 Volts @ full stroke
Left = 4.1 - 0.5 Volts @ full stroke Down = 4.1 - 0.5 Volts @ full stroke

194313
5.1-7 Platform Controller Voltage References (Cont’d)

Drive (A2) Controller
12 Volts
Drive Forward
04 YEL POWER RED
02 WHT GROUND BLK

Neutral
BLK D‐SIGNAL YEL Position
Pin 27
4.2 ‐ 4.8
24 BLU/BLK LEFT WHT/RED Volts
Pin 17
23 BLK/WHT RIGHT WHT/YEL
Pin 18
OCM
Drive Reverse
Reference
Analog Input
AI 1
12 Volts 12 Volts Neutral Position = 4.2 ‐ 4.8 Volts

Left Steer Right Steer Forward = 4.9 ‐ 8.5 Volts @ full stroke
Selected Selected Reverse = 4.1 ‐ 0.5 Volts @ full stroke
Riser (A3) Controller

Riser Up
04 RED/YEL POWER RED

Neutral
02 WHT GROUND BLK Position
4.2 ‐ 4.8
R RED/GRN R‐SIGNAL YEL Volts
Pin 30
OCM Reference
Analog Input
AI 4
RiserDown
Neutral Position = 4.2 ‐ 4.8 Volts

12 Volts Forward = 4.9 ‐ 8.5 Volts @ full stroke
Reverse = 4.1 ‐ 0.5 Volts @ full stroke

194313
Boom 5.2-3 Cable Carrier Repair

The cable carrier can be repaired by simply using a
5.2-1 Check Wear Pads screwdriver. Each crossbar can be snapped off from
1. Ensure aerial platform is on a firm level either side of the chain either by hand or by using the
surface and is in stowed position. screwdriver as a lever. New crossbars may be installed
2. Start engine from base control console. by snapping links together.
3. Raise main boom to a comfortable working

height (chest high), and then extend fly
boom approximately 1 foot (30 cm).
Female Side
4. Measure the thickness of each wear pad and
replace wear pad if it is less than 7/16 inches
(11 mm)
5. If wear pad is within specified thickness,
shim as necessary.
Male Side
5.2-2 Shimming Wear Pads
1. Ensure aerial platform is on a firm level
surface and is in stowed position. Crossbar
2. Raise main boom to a comfortable working
height (chest high) and extend fly boom until Cable Carrier Assembly
wear pad are accessible.
3. Loosen wear pad fasteners. 5.2-4 Master Cylinder Replacement
4. Shim as necessary to obtain zero to
1/32”clearance and zero drag. 1. Ensure aerial platform is parked on a firm
and level surface.
WARNING
Fly Boom
Ensure that there is sufficient room for
boom to swing and elevate.
WARNING
Be aware of overhead obstructions
1/32” Feeler or other possible hazards around the
Gauge
machine when lifting.
2. By using the base controls, position the

Shim machine as below to allow for easy work
Wear Pad access to the basket/jib boom and the
master cylinder.
Shim & Feeler Gauge
5. Extend and retract fly boom through the

entire range of motion and observe for loose
points.
NOTE
Always maintain squareness between the
boom’s outer and inner tubes.
Machine Setup Position 1

194313
6. Remove the hydraulic hoses and fittings on
the master cylinder. Replace any worn or
Master Cylinder damaged component.
7. Disconnect the master cylinder from the main
boom by removing the connecting pin, see
below. Store all parts aside for reuse.
Master Cylinder
Connecting Pin
Machine Setup Position 2
3. Turn main disconnect switch to “ ” off position.

Lock the switch to prevent unauthorized use
during this procedure.
Master Cylinder
NOTE
Connecting Pin
Ensure the all components are secured
before lifting or removing
4. Using straps, secure the main boom on a Master Cylinder Removal

suitable lifting equipment such as a crane.
8. Install the new master by installing the cylinder
5. Secure the master cylinder with straps. For pins as shonw above. Secure the keeper
example see below. pin and the bolt with Loctile 242 (Blue) or
equivalent.
7. Install the hydraulic hoses and fittings on the

master cylinder.
Master Cylinder Secured with Straps
CAUTION
Label all electrical cables and hydraulic
hoses before removal
CAUTION
To p r e v e n t h y d r a u l i c s y s t e m
contaminations, cap all hydraulic hoses
and fittings after removal.

194313
Turret 5.3-3 Turret Rotation Gear Backlash

Adjustment
5.3-1 High Pressure Filter Replacement Adjusting the backlash clearance will allow proper
1. Turn engine off. mating between the turret rotation gear and the swing
2. Place a suitable container under filter. drive motor gear.
WARNING
Head
Ensure that there are no personnel or
obstructions in test area and there is suffi-
cient room for boom to swing and elevate.
Housing Filter
Swing Drive
Motor
Bolt Mount Fastener
High Pressure Filter Adjustment

Bolt & Nut
3. Using a 30 mm box wrench, loosen bolt and
remove high pressure filter housing from
filter head.
4. Remove high pressure filter from filter head
and install a new high pressure filter.
5. Apply hydraulic oil to the o-ring on the high
pressure filter housing.
6. Reinstall filter and re-tighten bolt. Swing Drive Assembly
NOTE
The adjustment of the backlash must be
5.3-2 Check Swing Drive Motor Gearbox
performed on a flat level surface.
Oil
1. Remove gearbox fill plug.
surface.
2. Check oil level (oil level should be slightly
below the plug, see below). Add oil if needed.
For oil specification, Refer to section 2. WARNING
Operator must lock the turret to base
to prevent the turret from spinning
spontaneously.
Fill to here
Turret Lock Pin

Gearbox Fill Port
Base
Turret Lock Pin

194313
2. Lock the turret to base with the turret lock

WARNING
pin.
3. Raise riser boom to access the swing drive Operator must lock the turret to base
motor. to prevent the turret from spinning
spontaneously.
4. Support the boom with an overhang crane.
Do not lift the boom.
5. Turn main disconnect switch to “ ” off
position.
6. Loosen mounting fasteners on the swing
drive motor.
7. Pull the swing drive motor towards the center Turret Lock Pin
of turret as close as possible. (this will push Base
the rotation gear into the rotation bearing)
8. Loosen lock nut on adjustment bolt.
Turret Lock Pin
9. Tighten adjustment bolt clockwise until it
contacts the plate of gearbox. 2. Lock the turret to base with the turret lock
10. Tu r n a d j u s t m e n t b o l t 1 / 2 t u r n pin.
counterclockwise, then tighten lock nut on 3. Raise riser boom to access the swing drive
adjustment bolt. motor.
11. Push the swing drive motor towards 4. Support the boom with an overhang crane.
the counterweight until it contacts the Do not lift the boom.
adjustment bolt.
5. Turn main disconnect switch to “ ” off
12. Tighten mounting fasteners on swing drive position.
motor.
6. Remove mid-turret cover.
13. Unlock the turret lock pin.
7. Label the hydraulic hoses connected to
14. Turn main disconnect switch to “ ” ON swing drive and then remove hoses from
position. motor. Plug hoses and fittings to prevent
15. Rotate turret through an entire rotation and hydraulic contamination.
check for a smooth rotation of the turret. 8. Loosen adjustment bolt and remove
16. Adjust adjustment bolt until smooth rotation mounting fasteners fromm the swing drive
of the turret is achieved. motor.
17. Unsecure riser boom and lower boom. 9. use a lift device to remove swing drive motor
out away from turret and place it aside.
5.3-4 Swing Drive Motor Removal Lift Lugs
The swing drive motor is located near the center of the
turret, underneath the riser/main boom.
WARNING
Ensure that there are no personnel or
obstructions in test area and there is suffi-
cient room for boom to swing and elevate.

surface.
Swing Drive Lift Lugs

194313
5.3-5 Swing Drive Motor Replacement 5.3-7 Battery Replacement

1. Refer to procedure 5.3-4 Swing Drive Motor 1. Turn main disconnect switch to “ ” off
Removal. position.
2. Use a lift device to position new swing drive
motor onto turret and loosely bolt swing Anchor Plate
drive motor to turret. and Nuts
3. Refer to step 7 to 18 of procedure 5.3-3
Turret Rotation Gear Backlash Adjustment Rods
to complete this procedure.
5.3-6 Swing Drive Brake and Gearbox Oil Battery

Replacement
Periodic replacement of the motor/brake oil is essential Battery Pad
to good motor performance.
1. Refer to procedure 5.3-4 Swing Drive Motor Battery Assembly

Removal.
2. Remove plug and drain old oil from the brake 2. Unlock and swing out engine tray from turret.
motor.
3. Remove positive and negative connector
from battery.
4. Remove the battery.
Gearbox Fill 5. Replace battery pad if needed.
Port 6. Replace and secure the new battery.
Brake 7. Clean terminal posts and clamps of battery,
Drain/Fill Gearbox Drain and apply acid-free and acid-resistant
Port Port grease.
8. Re-connect battery with the positive and
negative connector cables. (Ensure the
clamps make good contact)
Gearbox Ports 9. Swing back and lock engine tray.
3. Refill brake motor with new oil and plug the

port. For oil specification, Refer to Section 2.
4. Remove plug and drain old oil from gearbox.
5. Refill gearbox with new oil and plug the port.
For oil specification, Refer to Section 2.
6. Use a lift device to position swing drive motor
onto turret and loosely bolt swing drive to
turret.
7. Refer to step 7 to 18 of procedure Refer
to 5.3-3 Turret Rotation Gear Backlash
Adjustment to complete this procedure.

194313
5.3-8 Bolt Torque Procedure Turret Rotation Gear Bolt Torque Sequence
Maintaining proper torque is essential to safe aerial 1. Ensure aerial platform is on a firm level
platform operation. Improper bolt torque could result surface and is in stowed position.
in an unsafe operating condition and component dam- 2. Turn main power disconnect switch to off
age. position.
3. Set the torque wrench to 85 ft.lb and tighten
Rotary Actuator Bolt Torque Sequence
mounting bolts in a cross pattern sequence.
surface and is in stowed position. 1 5
16 9
2. Turn main power disconnect switch to off
17
position. 12
3. Set the torque wrench to 17 ft.Ib and tighten 8 13
mounting bolts in a cross pattern sequence.

4 3
1 1 5
16 9
8 18 7
5
12 17
14 11
8 13
15
4 3 10
6 2
4 3
Bolt Torque Sequence
6
7
18 Outer Ring Gear 7
2 4. Set torque wrench to 170 ft.Ib 11 and tighten

14 17 18 10
Bolt Torque Sequence mounting bolts
6
16with the 11 same sequence.
12
5 22 15
5. Repeat step4
10
3-4 6for bolt
2 torque sequence
23
inner ring gear.
21
20 1
4. Set torque wrench to 35 ft.Ib and tighten 19 2
mounting bolts with the same sequence. 9
8 13
3
7 15 14
5. Torque the center bolt to 480 ft.lb. 17 18 10
16 11
6 12
5 22
4 23
21
20 1
19 2
9 3
8 13
7 15 14
Bolt Torque Sequence

Inner Ring Gear

194313
5.3-9 Electronic Tilt Switch Setup 7. Install new switch to mount and connect switch
Procedure plug to 4 pin connector.
The following information is supplied for replacement
NOTE
or reprogramming of the electronic tilt switch. Also
The tilt circuit is only powered when
included are test and verification instructions. Follow
controls are powered up.
the appropriate procedures below.
Tilt Switch Replacement 8. Turn main disconnect switch to “ ” ON position.
9. Turn base/off/platform key switch to “ ” base

Y AXIS position.
X AXIS
10. Pull out “ ” all emergency stop buttons.
11. Verify switch is powered. (Red or green LED will

be continually blinking)
Red LED Red LED

Green LED Green LED
12. Program the Tilt Switch

1. Ensure aerial platform is parked on a firm level
a. Press and release the set up button 3 times.
surface.
Observe LED flash codes as shown below.
2. Fully lower platform and retract fly boom.
3. Chock or block wheels to keep the aerial platform b. Only the red LED will
Red LED
from rolling forward or backward. blink for 4 seconds.
Green LED
4. Push in “ ” emergency stop buttons and turn

main power disconnect switch to “ ” off position. c. B o t h L E D s w i l l
flash for 1 second.
5. Disconnect tilt switch from 4 pin connector. Red LED
Results: The switch is
Green LED
NOTE learning the new zero
Ensure part number of old and new tilt position.
switch are the same.

d. Both LEDs will turn
6. Remove old tilt switch from mount. on solid for 1 second.
Red LED
Results: The new zero
Green LED
position has been
learned.

194313
e. The green LED will flash and then the Reprogramming Existing Tilt Switch
red LED will turn on solid for 2 seconds.
Results: The switch is verifying the new zero Set up button is located on this
position. Light Indicators face next to harness
Red LED Red LED

Green LED Green LED R
Gre ed LE
en D
LE
D

f. The green LED
will turn on solid.
Red LED
Results: The switch
Green LED
is ready for normal
operation.
13. Turn main power disconnect switch to “ ” off 1. Ensure aerial platform is parked on a firm level
position surface.
14. Push in “ ” emergency stop buttons. 2. Fully lower platform and retract fly boom.
15. Remove chock or wheel blocks. 3. Chock or block wheels to keep the aerial platform
from rolling forward or backward.
16. Proceed to Test and Verify Tilt Circuit.
NOTE
The tilt circuit is only powered when
controls are powered up.
4. Turn main disconnect switch to “ ” ON position.
5. Pull out “ ” all emergency stop buttons.
6. Turn base/off/platform key switch to “ ” base

position.
7. Verify switch is powered. (Red or green LED will

be continually blinking)
Red LED Red LED

Green LED Green LED
8. Reprogram the Tilt Switch

a. P r e s s a n d h o l d
the set up button
Red LED
for 3 seconds.
Green LED
Results: Both LEDs
will be OFF.

194313
9. Turn main power disconnect switch to “ ” off

position.
b. Both LEDs will flash. Red LED
Green LED
10. Push in “ ” emergency stop buttons.
11. Remove chock or wheel blocks.

IMPORTANT
Step “c” must be completed within 12. Proceed to Test and Verify Tilt Circuit.
a 5 second period or the switch will
automatically exit program mode and
return to normal operation using previously
stored data. Test and Verify Tilt Circuit
c. Press and release set up button 3 times. Set up button is located on this
Light Indicators face next to harness
d. If 5 second period has expired prior
completion, repeat Step “a”, “b” and “c”.

e. O b s e r v e p r o g r a m R
Gre ed LE
en D
LE
delay / stabilization D
Red LED
time. (Only the red
Green LED
LED will blink for 4
seconds)

f. Both LEDs will
flash for 1 second. Operations of Tilt Switch
Red LED
Results: The switch is The following describes the LED’s and what they
Green LED
learning the new zero indicate.
position.
Illuminated whenever both tilt

axes are within the specified
g. Both LEDs will turn degrees of the zero/ home
on solid for 1 second. Green LED learned position.
Red LED
Results: The new Flashes when transitioning in or
Green LED
zero position has been out of tilt angle limits, but built in
learned. time delay has not fully occurred.
Illuminated whenever tilt on one
h. The green LED will flash and then the or more axes is more than the
red LED will turn on solid for 2 seconds. Red LED
specified degrees out from the
Results: The switch is verifying the new zero zero/ home position.
position. On together, no blinking when
Green & Red LED
fault detected.
Red LED Red LED

Green LED Green LED Tilt Circuit Test
1. Refer to the Operating Manual’s Test Tilt Sensor

i. The green LED procedure within Functions Tests.
will turn on solid.
Red LED
Results: The switch
Green LED
is ready for normal
operation.

194313
5.3-10 Check Rotation Bearing for Axial

Wear
1. Position the boom so that it is centered
over the front drive and steer axle and is
horizontal with the ground.
2. Extend the boom to its full extension length.
3. Mount a dial indicator on the chassis. Place
the dial indicator set directly under the
boom, close to the bearing teeth. Make sure
to allow clearance as the turret assembly
rotates.
4. Position the indicator arm or shaft so that
the pointer touches the bottom surface of
the turret weldment.
TURRET
CHASSIS
Check Axial Wear of the Rotation Bearing
5. Zero the dial indicator.

6. Rotate the turret 180° in the clockwise
direction until the boom is centered over
the rear axle. (Rotating the turret in the
counterclockwise direction will cause the
rotation gearbox pinion to impact the dial
indicator).
7. If, when you are rotating the turret, the boom
needs to be retracted or raised to avoid
obstacles, be sure to again fully extend
and level the boom when it is positioned
over the rear axle. Do not be concerned
with any dial indicator readings as the turret
assembly rotates.
8. With the boom assembly rotation stopped
and the boom centered over the rear axle,
read the dial indicator and record the
reading. This reading is the total amount of
axial movement in the bearing assembly. If
this reading is 0.100” (2.54 mm) or greater,
the rotation bearing should be removed and
replaced.

194313
Deutz Diesel Engine 5. Remove oil filter and catch any escaping oil.
Maintaining the engine components is essential to good 6. Clean the filter mounting surface on engine.
performance and service life of the aerial platform.
7. Add clean engine oil to new oil filter.
8. Apply a thin layer of engine oil to the new oil
5.4-1 Engine Oil and Filter Replacement filter gasket.
Periodic replacement of the engine oil and filter is 9. Install filter and tighten it by hand.
essential to good engine performance. 10. Install oil drain plug with new seal ring and
tighten firmly.
NOTE
11. Refill engine with new oil as per specifications
Perform this operation after warming the
(Refer to engine manual).
engine to normal operating temperature.
12. Clean up any oil that may have spilled during
this procedure.
CAUTION
13. Start engine from base control console and
Beware of hot engine components. allow engine to run for 30 seconds then stop
Contact with hot engine components the engine.
may cause severe burns.
14. Check for oil leakage.
CAUTION 15. Check engine oil level on dipstick and add
oil if needed.
When draining hot oil, there is a risk of
NOTE
scalding. Do not let used oil run into
Refer to your national/local regulations
the soil, rather collect it in a container.
on how to dispose of used filter and oil.
Dispose of this in accordance with en-
vironmental regulations.

surface.
2. Allow engine to warm up.
3. Place suitable container under engine.
4. Remove oil drain plug and allow all engine
oil to drain into container.

194313
5.4-2 Fuel Filter Replacement 5.4-4 Check Engine Belt

1. Place suitable container under engine filter. The aerial platform will not operate properly with a
2. Remove fuel filter and catch any escaping loose or defective belt. Continuous usage may cause
fuel. component damage.
3. Clean any dirt from filter carrier sealing
surface. WARNING
4. Apply a thin layer of oil or diesel fuel to Do not inspect while the engine is run-
rubber gasket of new fuel filter. ning. Remove the key to secure from
operation.
5. Install fuel filter and tighten it by hand then
tighten filter cartridge with final half-turn.
CAUTION
6. Use the fuel hand pump to pump fuel into
filter. Beware of hot engine components.
7. Clean up any fuel that may have spilled Contact with hot engine components
during this procedure. may cause severe burns.
8. Check for fuel leakage. 1. Inspect the engine belt for:
• cracking
NOTE • glazing
Refer to your national/local regulations • separation
on how to dispose of used filter and oil. • breaks
2. For correct tension of engine belt, refer to

engine manual.
5.4-3 Air Filter Replacement
Engine specifications require that this procedure be
performed more often if dusty conditions exist.
5.4-5 Check Oil Cooler
1. Remove cover from the side of engine.
CAUTION
2. Inspect oil cooler for leaks and physical
Perform this procedure with the engine damage.
off.
3. Clean oil cooler of any kind of debris.
1. Remove end cap from air filter canister. 4. Reinstall cover.
2. Remove both filters from inside of canister.
3. Use a dry cloth to clean inside of canister
and gasket.
4. Insert two new filters to inside of canister.
5. Reinstall end cap to canister.

194313
GM Dual Fuel Engine

Maintaining the engine components is essential to good performance and service life of the aerial platform.
5.5-1 GM Map and IAT Sensor (3.0L GM Engine)
BLK/LT GRN
1 SENSOR GROUND
YEL/GRY 5 VOLTS
2 INTAKE AIR TEMPERATURE SIGNAL (IAT)
LT GRN/RED
3 5 VOLTS
4 LT GRN
MANIFOLD ABSOLUTE PRESSURE SIGNAL
(MAP)
IAT Sensor Resistance

TEMPERATURE TOLERANCE ±10%
°F OHMS
248 110
239 125
221 162
203 214
185 284
167 383
149 522
131 721
104 1,200
77 2,063
50 3,791
23 7,419
-4 15,614
-22 26,854
-31 35,763
-40 48,153
60597AA

194313
5.5-2 LPG Temperature Sensor (3.0L GM Engine)
A WHITE/RED
5 VOLTS
BLK/LT GREEN
B
SENSOR GROUND
TEMPERATURE SENSOR
Temperature Sensor RESISTANCE
Resistance
DEGREES F OHMS
220 153.7
200 214.6
190 255.4
180 305.5
170 367.3
160 444.1
140 660.6
120 1008
100 1582
80 2554
70 3284
60 4259
40 7357
20 13214
0 24705
-20 48300
-40 99318
60596AA

194313
5.5-3 Throttle Actuator (3.0L GM Engine)
DBW+ PNK/WHT
4
MOTOR
DBW- TAN/ORG
1
TPS1 SIGNAL PPL/LT BLU

6
SENSOR GROUND BLK/LT GRN

2
TPS1 SIGNAL LT BLU/DK BLU

5
5 VOLTS
3 LT GRN/RED

194313
5.5-4 Engine Coolant Temperature Sensor (3.0L GM Engine)
A TAN/WHITE
5 VOLTS
BLK/LT GREEN
B
SENSOR GROUND
TEMPERATURE SENSOR
Temperature Sensor RESISTANCE
Resistance
F OHMS
242.4 101
231.9 121
211.6 175
201.4 209
181.9 302
163.1 434
144.9 625
127.4 901
102.4 1,556
78.9 2,689
49.9 5,576
23.5 11,562
-5.7 28,770
-21.7 49,715
-30.8 71,589
-40 99,301
60595AA

194313
5.5-5 ECU Pin Reference Chart (3.0L GM Engine)
61 75 76 90
31 45 46 60 LOCK TAB
1 15 16 30
Diagnostics 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
17 EMPTY 62 BRN/LT GRN To injector #3
18 EMPTY 63 BRN/YEL To injector #4
19 LT GRN/RED 5 volt + from ECU to sensors 64 BRN/WHT To injector #2
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 GRY/BRN +V from camshaft position sensor 68 EMPTY
24 PPL/ORN -V from camshaft position sensor 69 BLK Ground from engine block
25 RED/WHT Not used 70 EMPTY
26 RED/BLK Not used 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 igition module 76 EMPTY
32 EMPTY 77 BRN/WHT Not used
33 EMPTY 78 WHT/BRN Not used
34 EMPTY 79 RED/TAN Battery positive
35 EMPTY 80 GRN/YEL To check engine light (MIL)
36 EMPTY 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 TPS1 85 PNK/YEL Fuel pump excite wire
41 WHT/RED Output to TPS2 86 BLK/RED Negative supply to fuel pump
42 TAN/BRN Propane selected 87 TAN Not used
43 TAN/RED Not used 88 DK BLU Not used
44 TAN/BLK Not used 89 PNK/BLK Negative supply to starter relay 57ACR
45 PNK/TAN 12 volt input 90 EMPTY
60594AB

194313
5.5-6 Fuse Block Layout (3.0L GM Engine)
2002CR 56CR 57ACR

POWER FUEL STARTER
RELAY PUMP RELAY
RELAY
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

194313
Kubota WG2503 Dual Fuel Engine 2. Dual Screen. This mode is used to monitor two
Maintaining the engine components is essential to good parameters at a time. The screen also displays
performance and service life of the aerial platform. the associated parameter icon and units.
5.6-1 Engine Parameter Display (KAntrak

1700)
3. Multi Screen. This mode is used to monitor a list
KAntrak 1700 display allows users to easily monitor of four(4) parameters selected by the user. Every
diagnostic trouble codes or critical engine faults such item is listed with its associated icon and units.
as oil pressure and water temperature as well as
providing an alarm system to alert the user when the 4. DTC Screen. This mode is used to display Data
ECU (Engine Control Unit) detects an engine fault. Trouble Codes.
Diagnostic Trouble Codes (DTC)
Diagnostic Trouble Codes (DTCs) are manufacturer’s

codes to indicate specific engine malfunction. These
codes will appear on the KAntrak screen whenever
an engine malfunction occurs. For DTCs, see 5.6-2
Diagnostic Trouble Codes.
Selecting DTC Screen

The DTC Screen mode is used to display Data Trouble
Codes. The header contains the total active/inactive
faults, the associated SPN (Suspect Parameter
Number) and FMI (Failure Mode Identifier), as well as
the OCC (number of occurences).
1. To access the DTC Screen, select the “ ” tool

to access the Settings Menu.
Menu Browsing
2. On the Display Mode option, select Dtc.
The KAntrak 1700 unit has only three (3) buttons for
different features selection on its dynamic style menu
3. To display the DTC detailed info, select the “?”
system. These buttons, located at the bottom of the
function. A detailed screen of the selected DTC
unit, are used to navigate on the menu.
including the SPN description (Header), the FMI
Description (Header), the fault status (Status),
During normal operation, the buttons have no specific
the SPN Number (SPN), the FMI Number (FMI),
functions. When pressing any button once, a dynamic
the total number of occurrences (OCC) and the
pop-up menu appears which contains some function
related node source address (SRC) will then
icons aligned above the associated buttons. The
appear.
user selects the required function from the displayed
menu. When a fault occurs, the amber light on top of 4. Note the SPN Number on the display and check
the KAntrak unit and the Check Engine Indicator Light it against the list found in 5.6-2 Diagnostic
on the Engine Control Console illuminate and will stay Trouble Codes. Look for the Detected Item/
on until the fault is corrected. Hardware information and correct the error. Once
the fault is fixed, the amber lights on KAntrak unit
Display Modes and on Engine Control Console will turn off.
KAntrak 1700 unit has four display modes and can be
accessed through the Setting Menu by selecting the 5. To exit from DTC Screen, select “ ” tool to
“ ” tool. continue browsing for other parameters. The
1. Single Screen. This mode is used to monitor one menu will be hidden after a few seconds.
parameter at a time. The screen also displays the
associated parameter icon, the description, the
units and a bar graph.

194313
5.6-2 Diagnostic Trouble Codes
(J1939) (J1939)
DTC Detected Item/Hardware
SPN FMI
16 636 8 ‐Mechanical Misalignment between cam and crank
87 94 1 ‐Fuel Pressure Abormality (Low Side)
88 94 0 ‐Fuel Pressure Abormality (High Side)
‐Sensor/Wiring Harness Open/Short To Ground
91 94 4
‐Sensor Malfunction
‐Sensor/Wiring Harness Short To Power
92 94 3
107 106 4
108 106 16
111 105 15 ‐Intake air temperature abnormality (High Side Stage 1)
112 105 4
113 105 3
116 110 15 ‐Engine Coolant Temperature Abnormality (High Side Stage 1)
‐Sensor/Wiring Harness Short To Ground
117 110 4
118 110 3
121 51 1 ‐Throttle Position Sensor Malfunction
122 51 4 ‐Throttle Position Sensor 1 Signal Voltage Low
123 51 3 ‐Throttle Position Sensor 1 Signal Voltage High
127 105 0 ‐Intake Air Temperature Higher Than Expected Stage 2
‐Open feed circuit to O2 heater
‐Open heater ground circuit
134 3217 5 ‐Open or shorted to ground O2 signal wire
‐Open sensor ground (5Vrtn1)
‐Inoperative sensor
‐Open feed circuit to O2 heater
‐Open heater ground circuit
154 3227 5 ‐Open or shorted to ground O2 signal wire
‐Open sensor ground (5Vrtn1)
‐Inoperative sensor
‐Exhaust leaks upstream or near the HEGO sensor
‐reduced fuel supply pressure to the fuel injection system
‐a inoperative sensor
171 4237 0
‐an injector that is stuck closed or dirty
‐weak spark or lack of spark to a cylinder
‐a MAP sensor that indicates pressure tjat is lower that the true pressure
‐An inoperative O2 sensor
172 4237 1
‐High fuel supply pressure or temperature
‐Operating in a frigid atmosphere
182 174 4
‐Sensor out of calibration

194313
5.6-2 Diagnostic Trouble Codes (continued)
(J1939) (J1939)
SPN FMI
‐Operating in a hot environment
183 174 3
‐Sensor out of calibration
217 110 0 ‐Engine Coolant Temperature Exceeds Stage 2
‐Engine over speed condition, stuck throttle, large vacuum leak into intake manifold
219 515 15
after throttle blade
221 51 51 ‐Throttle Position Sensor Malfunction
‐Throttle position sensor circuit in the harness short to ground
222 3673 4
‐Throttle position sensor malfunction
‐Throttle position sensor circuit in the harness short to power
223 3673 3
‐Throttle position sensor malfunction
‐Loss of 12.0 V feed to injector
261 651 5 ‐Open injector coil
‐Open or shorted to ground injector driver circuit in engine harness
‐Injector coil shorted internally

262 651 6
‐Injector driver circuit shorted to voltage between injector and ECM


265 652 6


268 653 6


271 654 6
‐Knock signal abnormality (High Side)
326 731 2
‐Sensor/wiring harness open/short to power
327 731 4
‐Sensor malfunction
336 636 2 ‐Crank+ or Crank‐ circuits in wrong connector terminal slot
‐Loss of sensor feed
337 636 4 ‐Open sensor ground
‐Open or shorted to ground sinal wire

194313
(J1939) (J1939)
SPN FMI
‐Cam+ or Cam‐ circuits in wrong connector terminal slot
‐Loss of feed voltage to Cam sensor
‐Loss of sensor feed
341 723 2
‐Open sensor ground
‐Open or shorted to ground signal wire
‐Sensor malfunctioning
‐Loss of feed voltage to Cam sensor
342 723 4 ‐Loss of signal or ground circuits
‐Faulty sensor
359 n/a n/a n/a
420 3050 n/a n/a
524 100 1 ‐Low Oil Pressure
‐Wiring harness open/short/damage
562 168 17
‐Battery abnormality
563 168 15 ‐System voltage abnormality (High Side)
‐Faulty ECU
601 628 13
‐ROM Malfunction
604 630 12 ‐ Faulty ECU
606 629 31 ‐Faulty ECU
‐Open coil in relay
627 1348 5
‐Open in relay driver circuit in engine harness
‐Relay pull in coil shorted internally
628 1347 5
‐Relay driver circuit shorted to ground in wire harness
‐Shorted relay pull in coil
629 1347 6
‐Relay driver circuit shorted to voltage in wire harness
‐Wiring harness short to ground
642 1079 4
‐ECM malfunction
‐Wiring harness short to 12.0 V power
643 1079 3
‐ECM malfunction
‐Wiring harness short to ground
652 1080 4
‐ECM malfunction
‐Wiring harness short to 10.0 V power
653 1080 3
‐ECM malfunction
‐Short to ground in relay pull in coil
686 1485 4
‐Short to ground in relay driver circuit in wire harness
‐Shorted relay pull in coil
687 1485 3 ‐Relay driver circuit shorted to voltage in wire harness
‐Power Relay Error
1111 515 16 ‐Engine overspeed condition, faulty Crank sensor or input
1112 515 0 ‐Engine overspeed condition, faulty Crank sensor or input
•exhaust leaks upstream or near the HEGO sensor
• reduced fuel supply pressure to the gaseous fuel control system
1151 4236 0
• a fuel supply or manifold leak
• a non‐responsive HEGO sensor

194313
(J1939) (J1939)
SPN FMI
• high fuel supply pressure to the gaseous fuel control or faulty pressure regulator
1152 4236 1
• exhaust leaks upstream or near the HEGO sensor

1153 4236 0
1154 4236 1
1155 4236 0 • reduced fuel supply pressure
• an injector that is stuck closed
• high fuel supply pressure to the fuel injection system
1156 4236 1 • a non‐responsive HEGO sensor
• an injector that is stuck open
1161 4237 0
1162 4237 1

1163 4237 0
1164 4237 1
1165 3050 11 n/a
1166 3050 11 n/a
1173 520620 31 n/a
1612 629 31 • Faulty ECU
1613 629 31 • Faulty ECU
1614 629 31 • Faulty ECU
1615 629 31 • Faulty ECU
1616 629 31 • Faulty ECU
2111 51 7 • TPS malfunction
• Wiring harness open/short/damage
2115 51 0 • FPP malfunction
• IVS malfunction

194313
(J1939) (J1939)
SPN FMI
• IVS malfunction
2122 91 3
• FPP malfunction
2123 91 3
• FPP malfunction
2127 29 4
• FPP malfunction
2128 29 3
• FPP malfunction
• IVS malfunction
• IVS malfunction
• a short to ground or open circuit in the harness
2300 1268 5
• an open internal to the primary coil
• a short to power in the harness
2301 1268 6
• a short internal to the primary coil
2303 1269 5
2304 1269 6
2306 1270 5
2307 1270 6
2309 1271 5
2310 1271 6

194313
5.6-3 ECU Pin Reference Chart (Kubota WG2503)
B A
90 76 75 61
60 46 45 61
30 16 15 1
Pin Wire Colour Description Pin Wire Colour Description

1 YELLOW 18 SPK_COIL 1A 46 BLANK AUX ANA PUD 1
2 YELLOW/BLACK 18 SPK_COIL 1B 47 PURPLE/LT_BLUE 18 TPS 1
3 YELLOW/RED 18 SPK_COIL 2A 48 LT_BLUE/DK_BLUE 18 TPS 2
4 BLACK 16 SPK_GRND 49 DK_GREEN/PURPLE 18 AUX DIG 1
5 YELLOW/WHITE 18 SPK_COIL 2B 50 TAN/RED 18 AUX DIG 2
6 BLANK SPK_COIL 3A 51 BLACK/YELLOW 18 KNK1 +
7 BLANK SPK_COIL 3B 52 BLACK 18 KNK1 ‐
8 BLANK EGO_3 53 DK_BLUE/ORANGE 18 FPP1
9 ‐ ‐ 54 PURPLE/YELLOW 18 FPP2 IVS
10 ‐ ‐ 55 BLANK VRELAY
11 ‐ ‐ 56 ‐ ‐
12 ORANGE/YELLOW 18 AUX ANA PD1 57 BLANK KNK2 +
13 WHITE/LT_GREEN 18 AUX ANA PD2 58 BLANK KNK2 ‐
14 DK BLUE‐PINK 18 CAN 1 + 59 BLANK VBAT PROT
15 BLUE/WHITE 18 CAN 1 ‐ 60 RED/TAN 16 VBAT
16 ‐ ‐ 61 BLACK/YELLOW 18 EGOH 2
17 ‐ ‐ 62 BLACK/WHITE 18 EGOH 1
18 BLANK AUX ANA PUD3 63 BLANK UEGOC
19 LT_GREEN/RED 18 5 V EXT 1 64 BROWN/LT_BLUE 18 INJ1 LS
20 BLACK/LT_GREEN 18 5 V RTN 1 65 BROWN/LT_GREEN 18 INJ2 LS
21 DK_GREEN/ORANGE 18 EGO 1 66 BROWN/YELLOW 18 INJ3 LS
22 DK_GREEN/WHITE 18 EGO 2 67 BROWN/WHITE 18 INJ4 LS
23 LT_GREEN 18 MAP 68 BLANK INJ5 LS
24 BLANK AUX ANA PUD3 69 BLACK 16 GROUND
25 PURPLE/WHITE 18 CRANK + 70 BLANK INJ6 LS
26 WHITE/PURPLE 18 CRANK ‐ 71 BLANK AUX PWM8
27 GRAY/BROWN 18 CAM + 72 PINK/BLACK 18 STARTER
28 PURPLE/ORANGE 18 CAM ‐ 73 WHITE/LT_BLUE 18 RELAY
29 RED/WHITE 18 SPEED + 74 GREEN/YELLOW 18 MIL
30 RED/BLACK 18 SPEED ‐ 75 BLANK EGOH_3
31 LT_GREEN/PURPLE 18 5 V EXT 2 76 BLANK AUX PWM7
32 LT_GREEN/B;ACK 18 5 V RTN 2 77 WHITE/BLACK 18 LOCK OFF
33 BLANK PULSE_IN 78 TAN/BLACK 18 AUX PWM6
34 GRAY/DK_BLUE 18 GOV 1 79 RED/TAN 16 VBAT
35 LT_BLUE 18 OIL PRESSURE 80 PINK/WHITE 18 DBW +
36 YELLOW/GRAY 18 IAT 81 BLACK 16 GROUND
37 TAN/WHITE 18 ECT 82 TAN/ORANGE 18 DBW ‐
38 LT_GREEN/WHITE 18 AUX ANA PU1 83 WHITE/BROWN 16 AUX OWM5 REC
39 YELLOW/DK_BLUE 18 AUX ANA PU2 84 BROWN/WHITE 16 AUX PWM5
40 DK_BLUE/YELLOW 18 AUX ANA PU3 85 TAN 16 AUX PWM1
41 TAN/DK_GREEN 18 AUX DIG 3 86 BLANK AUX PWM4
42 GRAY/RED 18 AUX DIG 4 87 DK_BLUE 18 AUX PWM2
43 GRAY 18 TACH 88 BLANK AUX PWM4 REC
44 PINK/TAN 18 VSW 89 PINK/YELLOW 16 AUX PWM3 REC
45 BLANK AUX ANA PUD 2 90 BLACK/RED 16 AUX PWM3 REC

194313
5.6-4 Fuse Box (Kubota WG2503)
Fuel Pump Starter Relay

Power Relay
Relay 85
2 4 1 2 4 1
30 87A 87
5 5
86
3 3
15 A Fuse 15 A Fuse
15 A Fuse 5 A Fuse
10 A Fuse 5 A Fuse
RED 8 1 ALTERNATOR 60A 10 RED 8
PINK/TAN 18 2 VSW 5A 11 PINK 18
RED/TAN 16 3 ECM 10A 12 RED 16
13 RED 14
PINK/
RED/TAN 16 4 IGNITION 15A 14
DK_GREEN 16
15 PINK/
DK_GREEN 16
WHITE/ PINK/
5 16
LT_BLUE 18 DK_GREEN 16
17 PINK/
POWER RELAY DK_GREEN 18
18 PINK/
STARTER RELAY DK_GREEN 18
LT_BLUE/ 6 DEPR 5A 19 PINK/
PINK 18 DK_GREEN 18
20 RED/TAN 12
21 RED/TAN 12
PINK/BLACK 18 7 STARTER 15A 22 RED 12
23 WHITE 12
PINK/TAN 18 8 24 RED 16
PINK/
25
YELLOW 16
PINK/
26
YELLOW 16
TAN/BLACK 18 9 FUEL_PUMP 15A PINK/
27
YELLOW 16
FUEL_PUMP RELAY

194313
5.6-5 MAP Sensor (Kubota WG2503)
ECM
TAMP Sensor
V
B 19 5v
5V ext 1
V
D 23
MAP Signal
C 20
5V rtn 1
5.6-6 IAT Sensor (Kubota WG2503)
ECM
TAMP Sensor V
IAT
A 36 5v
Thermistor
D 20 5V rtn 1

194313
5.6-7 ECT (Kubota WG2503)

ECM
ECT Sensor V
A ECT 5v
37
B 20 5V rtn 1
Thermistor
5.6-8 TPS & Engine Speed (Kubota WG2503)
Electronic Throttle Body ECM
DBW+
+ 80
Motor H-Bridge
- 82 DBW-
TPS1 5V ext 1
19 5v
TPS1
47 V
TPS2 20 5V rtn 1
TPS2
48 V
5V ext 1
19 5v

194313
5.6-9 Fuel Temperature Sensor (Kubota WG2503)
ECM
FP/FT Sensor
V
5V ext 1
19 5v
V
FRP Signal
13
5V rtn 1
20
V
FRP Signal
38 5v
5.6-10 Oil Pressure Sensor (Kubota WG2503)
Oil Pressure Switch ECM
+5V
35 Pressure Voltage

194313
Hydraulic Tank 5.7-2 Hydraulic In-tank Filter Replacement

Maintaining the hydraulic components and hydraulic oil
at the proper level are essential to good performance 1. Ensure aerial platform is on a firm level
and service life of the aerial platform. surface, is in stowed position and engine is
off.
5.7-1 Hydraulic Oil Replacement Cap

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

194313
Manifold and Hydraulic Pumps WARNING

5.8-1 Hydraulic Brake Pressure Ensure that there are no personnel or
Adjustment obstructions in test area and there is suf-
ficient room for forward or reverse travel.
Maintaining accurate hydraulic brake pressure is
important when it comes to safe aerial platform 6. Start engine from platform control console
operation. and extend boom slightly to achieve low
speed drive.
1. Ensure aerial platform is on a firm level 7. Drive aerial platform forward or reverse.
surface and is in stowed position. Pressure gauge reading should be 550 psi.
2. Locate BR port on the brake valve assembly. Stop the aerial platform. Follow the next
steps for adjusting relief valve pressure
BR Port
if needed. If no adjustment is required
PR1 continue to step 10.
Pressure Reducing
8. Locate brake pressure relief valve RV4 and
Valve
loosen the lock nut.
V1
Release Override 9. Turn the adjusting stem on pressure
relief valve RV4 ¼ of a revolution at a
time clockwise to increase pressure or
counterclockwise to decrease pressure.
RV4 Drive aerial platform forward or reverse, note
Pressure Relief Valve pressure and stop the aerial platform.
10. Repeat step 8 until brake pressure is
V3 achieved (550 psi) then tighten lock nut on
Brake Hand Pump brake system pressure relief valve RV4.
Brake Manifold 11. Locate brake system pressure reducing valve
PR1 and turn valve gently counterclockwise
3. Connect a pressure gauge (1000 psi) to
to initial position.
BR port.
12. Drive aerial platform forward or reverse.
4. Remove the wiring from three valves:
Pressure gauge reading should be 500 psi.
differential lock valve wire numbers 165 and
02, axle lockout valve wires 65 and 02, as 13. Stop aerial platform and adjust pressure
well as two speed valve wires 45A and 02. reducing valve PR1 1/4 turn at a time by
Mark the valves to ensure you put the wiring turning either clockwise to increase pressure
back in the correct positions later. or counterclockwise to decrease pressure.
14. Repeat step 11 and 12 until brake pressure
CAUTION
is achieved (500 psi) then tighten lock nut on
Failure to remove the wiring may cause brake system pressure reducing valve PR1.
damage to components downstream. 15. Reinstall the wiring in the same positions it
was removed from in step 4.
5. Locate brake system pressure reducing 16. Test the brake, differential lockout, and two
valve PR1. Loosen lock nut and turn speed functions.
adjustment stem gently clockwise 2 full
turns.
CAUTION
Valve damage will occur if tightened
too much.

194313
5.8-2 Hydraulic System Relief Valve 5.8-3 Riser Down Relief Valve Adjustment
Adjustment
1. Locate Test 5 Port on main manifold.
1. Locate Test 1 Port on main manifold and 2. Connect a pressure gauge (5000 psi) to
remove the cap. Test 5 port.
2. Connect a pressure gauge (5000 psi) to RV8
Test 1 port. Riser Down
RV6 Relief Valve
System
Relief Valve
TEST 5
Port
TEST 1
Port Main Manifold
3. Start engine from base control console and

Main Manifold
let it run for 2-5 minutes.
3. Start engine from base control console and 4. Raise main boom to ensure basket will not
let it run for 2-5 minutes. contact the ground.
4. Steer fully to one direction and then check 5. Fully lower riser and check reading on
reading on gauge. Pressure should be gauge. Pressure should be 2750 psi. Follow
3100 psi. Follow the next steps for adjusting the next steps for adjusting pressure if
pressure if needed. needed.
5. Locate system relief valve RV6. 6. Locate riser down relief valve RV8.
6. Loosen lock nut on system relief valve 7. Loosen lock nut on system relief valve RV8.
RV6. Turn the adjusting stem clockwise to Turn adjusting stem clockwise to increase
increase pressure and counterclockwise to pressure and counterclockwise to decrease
decrease pressure. pressure.
7. Tighten lock nut on system relief valve RV6 8. Tighten lock nut on system relief valve RV8
once 3100 psi is observed on the gauge. once 2750 psi is observed on the gauge.
(You must steer fully in one direction to (You must fully lower riser to activate
activate pressure reading on gauge.) pressure reading on gauge.)

194313
5.8-4 Turret Rotate Relief Valve 5.8-5 Platform Level Relief Valve
Adjustment Adjustment
1. Locate Test 5 Port on main manifold. 1. Locate Test 5 Port on main manifold.
2. Connect a pressure gauge (5000 psi) to 2. Connect a pressure gauge (5000 psi) to
Test 5 port. Test 5 port.
RV9
Platf. Levelling
Relief Valve
TEST 5 TEST 5
Port Port
RV7 Main Manifold

Turret Rotation
Relief Valve 3. Start engine from base control console and
let it run for 2-5 minutes.
Main Manifold
4. Raise main boom to ensure basket will not
3. Start engine from base control console and contact the ground.
let it run for 2-5 minutes. 5. Fully raise or lower platform level and check
4. Raise main boom to ensure basket will not reading on gauge. Pressure should be 2750
contact the ground. psi. Follow the next steps for adjusting
5. Engage the turret transport lock. pressure if needed.
6. Attempt to rotate turret. Pressure should be 6. Locate platform leveling relief valve RV9.
1400 psi. Follow the next steps for adjusting 7. Loosen lock nut on platform level relief
pressure if needed. valve RV9. Turn adjusting stem clockwise
7. Locate turret rotate relief valve RV7. to increase pressure and counterclockwise
to decrease pressure.
8. Loosen lock nut on turret rotate relief valve
RV7. Turn adjusting stem clockwise to 8. Tighten lock nut on platform level relief
increase pressure and counterclockwise to valve RV9 once 2750 psi is observed on the
decrease pressure. gauge. (You must fully raise or lower platform
level to activate pressure reading on gauge.)
9. Tighten lock nut on turret rotate relief valve
RV7 once 1400 psi is observed on the
gauge. (You must activate turret rotate to
obtain pressure reading on gauge.)
10. Disengage turret transport lock.

194313
5.8-6 Test Charge Pump Pressure on Drive 5.8-7 Test Forward Drive Pressure on
Pump Drive Pump
NOTE
1. Locate test port TP3 on drive pump. Make sure charge pump pressure test is
2. Connect a pressure gauge (600 psi) to test completed first.
port.
1. Locate test port TP1 on the drive pump.
2. Connect a pressure gauge (10000 psi) to
RV10 test port TP1.
Charge Pump
Relief Valve
TP3
Charge
Pressure
Test Port
TP1
Drive Pump - TP3
3. Start engine from base control console.
WARNING Drive Pump - TP1
Do not activate any controls during 3. Start engine from platform control console.
procedure to protect gauge. 4. Unplug brake solenoid power cable (26) on
brake valve.
4. Check reading on gauge (standard pressure 5. Activate drive function slowly forward with
should be 313 ±10% psi.) engine at high speed. Wheels should not
5. Replace charge pump relief valve RV3 if turn.
pressure is not achieved. NOTE
6. Repeat steps 2, 3, and 4 after charge pump Activating drive function too fast will stall
relief valve is replaced. the engine.
7. if pressure still not in range, repair or replace
the pump as necessary. 6. Check reading on gauges Standard
pressure should be 5000 psi. Go to step 8
if pump pressure is achieved.
7. Replace pump if pressure is not achieved.
8. Turn engine off.
9. Remove pressure gauge from port, cap
the port and re-plug brake solenoid power
cable.

194313
5.8-8 Test Reverse Drive Pressure on Drive Axles

Pump
NOTE 5.9-1 Rear Axle Oil Replacement
Make sure charge pump pressure test is
completed first. 1. Ensure aerial platform is on a firm level
surface and is in stowed position.
1. Locate test port TP2 on the drive pump. 2. Turn main power disconnect switch to off
2. Connect a pressure gauge (10000 psi) to position.
test port TP2. 3. Place suitable container under the axle
4. Remove fill plug.
5. Remove all three drain plugs to allow oil to
drain into container.
FIll Port
Check Port
TP2 Drain Ports

Rear Axle (shown)
Drive Pump - TP2
6. Reinstall all drain plugs.
3. Start engine from platform control console. 7. Remove check plug.
4. Unplug brake solenoid power cable (26) on
brake valve. NOTE
5. Activate drive function slowly reverse with Axle is filled when oil is leaking from the
engine at high speed. Wheels should not check port.
turn.
NOTE 8. Refill axle with new oil as per specifications.
Activating drive function too fast will stall (Refer to Section 2)
the engine. 9. Reinstall both fill and check plugs.
6. Check reading on gauges Standard

pressure should be 5000 psi. Go to step 8 5.9-2 Front Axle Oil Replacement
if pump pressure is achieved.
7. Replace pump if pressure is not achieved. 1. Ensure aerial platform is on a firm level
8. Turn engine off. surface and is in stowed position.
9. Remove pressure gauge from port, cap 2. Turn main power disconnect switch to off
the port and re-plug brake solenoid power position.
cable. 3. Place suitable container under the axle.

194313
5. Remove drain plug to allow oil to drain into 5.9-4 Check Axle Gearbox Oil Level
container. 1. Remove plug 1 from gear box.
2. Check oil level. Oil level should be even with

the bottom of plug hole 1. Add oil if needed.
For oil specification, Refer to Section 2.
Fill/Check Port
Drain Port
Front Axle
6. Reinstall drain plug. 1

Gearbox
NOTE
Axle is filled when oil is leaking from the
check port. 5.9-5 Axle Gearbox Oil Replacement
7. Refill axle with new oil as per specifications. surface and is in stowed position.
(Refer to Section 2) 2. Turn main power disconnect switch to off
8. Reinstall fill/check plug. position.
3. Place suitable container under the gearbox.
5.9-3 Check Torque Hub Oil Level 5. Remove drain plug to allow oil to drain into
1. Drive the aerial platform to rotate the hub
container.
until the plug is located at 90 degrees.
2. Remove the plug and check the oil level.

The oil level should be even with the bottom
of the plug hole. Add oil if needed. For oil
specification, Refer to Section 2.
Fill/Check Port Drain Port

Gearbox
6. Reinstall drain plug.
Drive Torque Hub
Fill and Check Drain NOTE
Gearbox is filled when oil is leaking from
the check port.
7. Refill gearbox with new oil as per

specifications. (Refer to Section 2)
8. Reinstall fill/check plug.

194313
5.9-6 Oscillating Cylinder Bolt 5.9-7 Oscillating Cylinder Replacement

Replacement
NOTE
If upon inspection it is determined that the oscillating The oscillating axle cylinder weighs approximately 43
cylinder bolts have missing or damaged torque seal, lbs [19.5 kg], so a second person to assist with the
the affected bolts must be replaced. If replacing removal and replacement would be helpful.
more than one bolt, do so one at a time to prevent the
cylinder from shifting. 1. Wedge a block of wood between the front axle and
the chassis, to prevent the axle from oscillating
1. Remove the affected bolt. during the procedure.
2. Clean the cylinder’s corresponding internal

threaded hole thoroughly.
3. Replace the removed bolt with a new 0.5”-13 x

2.25” grade 8 bolt, applying liquid blue Loctite 242
or 243 to the bottom half of the bolts.
4. Hand tighten the bolt.
5. Torque the new bolt to 80 ft-lbs.
6. Apply a line of torque seal to each new bolt

extending from the bolt head over the washer and
to the chassis wall.
2. Remove and set aside the base cover from the

oscillating axle end of the chassis.

194313
3. With a rag in hand to catch any leaking oil, slowly 7. Adjust the oscillating cylinder position until there
loosen the bleeder screw to release any trapped is continuous contact between the cylinder
air within the cylinder, then tighten it again. Slowly mounting surface and the mounting plate, and
loosen the oscillating axle cylinder hoses to between the mounting plate and the cylinder
release the pressure, then disconnect them fully, shoulder, with no gaps. Torque the bolts to 80
being sure to plug the hose ends. ft-lbs [108 Nm].
4. Remove, cap, and set aside the cylinder fittings,

ensuring they stay clean.
No gaps
5. Remove and throw away the bolts and washers 8. Apply a line of torque seal to each bolt extending
securing the cylinder to the chassis. Lift the from the bolt head over the washer and to the
cylinder away. chassis wall.
6. Lift a new cylinder into place and install new bolts
(0.5”-13 x 2.25” grade 8) and 0.50” hardened
washers, applying liquid blue Loctite 242 or 243
to the lower half of the bolts before installing them.
Hand tighten the bolts.
9. Reinstall the cylinder fittings, torquing the larger

one to 24 ft-lbs [33 Nm] and the smaller one to
15 ft-lbs [20 Nm].

194313
10. Remove the plugs and reconnect the hoses to 5.9-9 Pin Brake Adjustments
the cylinder fittings, torquing the larger hose end
to 21 ft-lbs [28 Nm] and the smaller hose end to
12 ft-lbs [16 Nm].
11. Reinstall the base cover and remove the block

of wood.
12. Turn the aerial platform on and let it run for a few
minutes to pressurize the cylinder, then turn it
off again.
13. Check the oil level using the hydraulic tank sight
gauge. Add more hydraulic oil if needed.
14. Bleed the cylinder (refer to the next procedure). 1. To manually release the brake give a light
blow to the external ring of the check unit.
5.9-8 Bleeding Oscillating Axle Cylinders

If the axle oscillation system is not operating properly,
the stability of the aerial platform is compromised and
it may tip over.
Items you will need before starting:

• oil container
• hose (to reach from bleeders to bucket)
1. Locate a bleeder on either side of the

oscillating axle cylinder.
2. Connect a hose to the bleeder nipple.
3. Start the engine and slowly open the bleeder
2. To adjust the idle elimination loosen jam nut
to allow the oil to flow in a continuous
and back out adjustment stem a few turns.
stream.
4. Close the bleeder.
5. Repeat the procedure with the other
oscillating axle cylinder.
3. Apply a 2lb. force (1Kg) in the direction of

brake application and turn adjusting stem
so that it touches the stop.

194313
4. Tighten the Jam nut. Repeat this procedure 7. Release the pressure from the cylinder
for the other side. and check that the rod returns and stops
in a position where it projects out from the
cylinder head by 3/16” (5mm).
5. On the Cylinder side ensure that there is

some clearance between the cylinder and
the lever “A” with the lever against the stop. 8. If adjustment is needed loosen the jam
nut, pressurize the cylinder and turn the
adjustment stem. Repeat step 7 and
tighten jam nut when correct adjustment
is obtained.
6. Introduce pressure into the cylinder and

ensure that the check unit engages.

194313
Grease Points
5.10-1 Lubrication
Maintaining proper lubrication is essential for good performance and service life of the aerial platform. If the bearing
and gear of the aerial platform are improperly greased, it could result in component damage.
WARNING
Ensure that there are no personnel or obstructions in maintenance area and there is
sufficient room for boom to swing.
Grease Turret Rotation Bearing

1. Ensure aerial platform is on a firm level surface and is in stowed position.
2. Raise the Riser and Main boom to access the grease line located near turret lock pin.
3. Pump grease into the turret rotation bearing and continue pumping until new lube appears continuously
around the grease seal lip. (Refer to the Race column in the Table below)
4. Rotate the turret in increments of 4 to 5 inches (10 to 13 cm) at a time, and repeat step 3 until the entire
bearing has been greased.
Grease Turret Rotation Gear

1. Apply grease to each tooth of the drive gear, located under the turret. (Refer to the Gear column in the
Table below)
GREASE
Recommended Grease Type

Model
Race Gear
Mobil Mobillux EP2 Mobil Mobiltac C
SJ40T & 45T Texaco Multifax EP2 Texaco Crater 2X or 3X
SJ61T & 66T Sun Prestige 742 EP Sun Gear Compound 407
SJ46A/AJ & 51AJ Shell Alvania EP2 Shell Cardium EP
Exxon Ronex WB Exxon Surrett Fluid 30
Turret Swing Drive Motor
To Turret Rotation Bearing
Turret Rotation Gear

194313
Grease Drive Axle

1. Ensure aerial platform is on a firm level surface and is in stowed position.
2. Open axle cover plate and locate grease fitting. (see diagram below)
3. Pump grease into the grease fittings. (Refer to the Table below)
Grease Drive Shaft

1. Locate the grease fittings on the drive shaft and pump grease. (Refer to the Table below)
*GREASE
Model Recommended Grease Type
Mobil Mobillux EP2

SJ40T & 45T Texaco Multifax EP2
SJ61T & 66T Sun Prestige 742 EP
SJ46A/AJ & 51AJ Shell Alvania EP2
Exxon Ronex WB
* Refer to Service and Maintenance manual for greasing

frequency and procedures.
Grease Fitting
*GREASE Grease Fitting
Grease Fitting Model Recommended Grease Type
Mobil Mobiltac C
SJ40T & 45T Texaco Crater 2X or 3X
SJ61T & 66T Sun Gear Compound 407
SJ46A/AJ & 51AJ Shell Cardium EP
Exxon Surrett Fluid 30
* Refer to Service and Maintenance manual for greasing

Grease frequency
Fitting and procedures.
Grease Fitting
Drive Axle

194313
Options
5.11-1 Load Sensing System - CE

The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The deck
steel structure is isolated from the aerial platform. The load cell is permanently bolted between the deck and the
rotary actuator mount. The load cell will only respond to the vertical component of the load in the platform. There
are four external bolted connections that serve as a redundant back up system for the load cell connection. The
system is first calibrated with an empty platform to set the tare weight to zero. The following steps of the process
set the overload limit as regulated by applicable safety standards for Mobile Elevated Work Platforms.
Aerial Platform
(Rotary Actuator Mount)
Error LED
Alarm LED Deck
Interface Connector
Zero/Tare LED
Power LED
External Bolts Load Cell Permanent Bolts
Bottom View of Deck
Load Cell
LED Display
“T” Label
Overload Light
“4” Button
Platform Control Console

Indicator Module “Teach in” Handset
(Service only)
Error LED - Continously on when system error
Alarm LED - Continously on when platform is overload or has base contact
Interface Connector - Storage of limit valve (“Teach in” handset connects here)
Orange LED - Continously on when tare value is zero ± 15kg
Green LED - Flashes slowly on when system powered and calibrated
NOTE
When power is turned on and after a four second time period elapses, the overload light and audible
alarm will pulse two times. This indicates the system is active and there are no faults.

194313
Verify Proper Operation of the Load Sensing System
Overload Status Chart
Indicator Load Cell Audible Aerial Platform

Weight
Light LED Display Alarm Functions
Error - OFF Error - OFF

Alarm - OFF Alarm - ON (red)
Error - OFF
Zero/Tare - ON (orange) Error - OFF
Zero/Tare - OFF
Alarm
Power -- OFF
FLASHING (green) Alarm
Power -- ON (red) (green)
FLASHING
(Zero) OFF Zero/Tare - ON (orange) Zero/Tare
OFF - OFF ENABLED
Power - FLASHING (green) Power - FLASHING (green)
Error - OFF
Alarm - FLASHING (red)
Error - OFF
Zero/Tare - OFF
Alarm
Power -- FLASHING
FLASHING (red)
(green)
Zero/Tare
Error - OFF- OFF Error - OFF
(Work Mode Power--OFF
Alarm FLASHING (green) Alarm - ON (red)
@ 244+) FLASHING Zero/Tare - ON (orange) PULSING
Zero/Tare - OFF
Power - FLASHING (green) Power - FLASHING (green) DISABLED
Error - OFF
Alarm - FLASHING (red)
Zero/Tare - OFF
(Travel Mode Power - FLASHING (green)
@ 244+) FLASHING PULSING ENABLED
1. Ensure aerial platform is on firm level ground.
2. Fully “ ” retract and “ ” lower boom.

3. Turn engine “ ” off.
4. Ensure both “ ” emergency stops are pulled out and platform engine enable switch is in “ ” on
position.
Result: Overload indicator light and audible alarm will pulse two times.
5. Ensure platform is unloaded and is free from any surface contact.
Result: Green power LED is flashing, orange LED is ON, red alarm LED is OFF and red error LED is
OFF.
6. Place a 244kg load on platform.
Result: Platform indicator light is flashing, load cell red alarm LED is ON, and audible alarm is pulsing.
7. On base control console, start engine and extend boom by > 300mm.
Result: All drive and boom function are disabled.
8. Remove load from platform.
Result: All drive and boom function are enabled and all warning indicators are OFF.
NOTE
Refer to section 4 for load sensing system troubleshooting.

194313
Calibration of Load Sensing System (with “Teach In” Handset)
WARNING
Do not interrupt system power and rest your hand or foot on platform during this procedure.
1. Ensure aerial platform is on firm level ground.
2. Fully “ ” retract and “ ” lower boom.

3. Turn engine “ ” off.
4. Ensure both “ ” emergency stops are pulled out and platform engine enable switch is in “ ” on
position.
Result: Overload indicator light and audible alarm pulse two times.
5. Ensure platform is unloaded and is free from any surface contact.
6. Remove cap from load cell interface connector.
7. Connect “Teach in” handset to interface connector.
Result: The “T” label on handset will flash at a high frequency of 5Hz. If not, recheck that power is on
and handset is properly connected.
WARNING
Do not disconnect handset at any point of the following steps until instructed.
8. On “Teach in” handset, depress “4” button for four seconds.

Result: The “T” label on handset will light on constantly and then flash at a lower frequency of 1.25Hz.
9. Add a test load of 244kg onto the center of platform.
10. Depress “4” button for four seconds.
Result: The “T” label on handset will go from flashing to constantly on.
11. Disconnect “Teach in” handset from interface connector.
12. Wait for four seconds and then add a test load exceeding 244kg to test load sensing system.
Result: On platform control console, the overload light will flash and an audible alarm will pulse.
13. Remove test load from platform.
Result: Green power LED is flashing, orange LED is ON, red alarm LED is OFF, audible alarm is OFF
and red error LED is OFF.
14. Re-cap interface connector and place provided “calibrated” label over interface connector.

194313
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SERVICE MANUAL

194313AC October 2015

SJ46AJ & SJ51AJ: 95 001 105 & Above

Please refer to the website (www.skyjack.com) for older Serial Numbers.

Skyjack Service Center Parts & Service (Europe)

Parts (North America) Skyjack Brasil

Section 1 - Scheduled Maintenance

Section 2 - Maintenance Tables

Section 3 - System Component Identification and Schematics

Articulating Boom Series December 2007

Articulating Boom Series

Operator’s Responsibility for Maintenance

Service and Maintenance

Scheduled Maintenance Inspections and Function Tests

Articulating Boom Series December 2007

Aerial Platform Definition

Service & Maintenance

Service Policy and Warranty

Operator Safety Reminders, Warnings, and Precautions

Articulating Boom Series

Maintenance and Inspection Schedule Maintenance and Service Safety Tips

Articulating Boom Series December 2007

Hydraulic System & Component 7. All hydraulic components must be disassembled

6. When removing any hydraulic component, be sure

Articulating Boom Series

About this Section Maintenance Instructions

• Repair any damaged or malfunction components

Articulating Boom Series December 2007

Table 1.1 Owner’s Annual Inspection Record

Model Number: _________________ Serial Number:__________________

* 20__ 20__ 20__ 20__ 20__ 20__ 20__ 20__ 20__

Articulating Boom Series

Pre-Delivery/Maintenance Inspection Checklist

Serial Number: Product Owner:

Hourmeter Reading: Product User:

Items for Inspection P F R N/A Items for Inspection P F R N/A

Owner: ________________________________________________ / _____________________________________________ / ___________________________________________________

User: _________________________________________________ / _____________________________________________ / ___________________________________________________

Note: Visit skyjack.com for a printable copy of this form. 167834AA

Articulating Boom Series December 2007

1.1 Scheduled Maintenance Inspections Hydraulic

1.1-2 Labels (B)

Articulating Boom Series

1.1-3 Limit Switches (B)

1.1-4 Engine Compartment WARNING

3. Ensure all battery connections are tight.

Articulating Boom Series December 2007

4. If applicable, check battery fluid level. -- For brake/motor oil replacement

• Charge Indicator - CE (B)

• Swing Drive Motor (B,C)

Articulating Boom Series

• Muffler and Exhaust (B) • Engine Air Filter (B,C)

Articulating Boom Series December 2007

Brake Manifold Main Manifold

1.1-5 Control Compartment • Hydraulic In-Tank Filter (B,C)

Articulating Boom Series

Brake Manifold Main Manifold

• Fuel Tank (B,C) • Fuel Leaks (B)

-- Ensure fuel tank, shutoff valve (if

Articulating Boom Series December 2007

1.1-6 Base • Oscillating Cylinder Assembly (B,C)

• Rotary Manifold (B) -- Visually inspect the heads of the oscillating

• Steer Linkage (B)

Articulating Boom Series

Model Number: _ Serial Number:__

* 20 20 20 20 20 20 20 20 20__

Owner: __________________________ / _ / _____________________________

User: ___________________________ / _ / _____________________________