SKYJACK SJ46 Service M

SERVICE
MANUAL
SJ46 AJ+, SJ46 AJ, SJ51 AJ
ARTICULATING BOOMS
229042AFA
January 25 2024
ANSI/CSA, CE, AS
This manual is for MEWPs with serial numbers:
SJ46 AJ+: A301 000 001 - A301 999 999
SJ46 AJ: B301 000 001 - B301 999 999
SJ51 AJ: B301 000 001 - B301 999 999
Please refer to the website (www.skyjack.com) for contact

information, other serial numbers, the most recent technical
manuals, animations, and USB software.
The original instructions are in English.

THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.
The Safety Alert Symbol identifies important safety

messages on MEWPs, safety signs in manuals or
elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
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 MEWP.
SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042AFA

3
Notes
229042AFA SJ46 AJ+, SJ46 AJ, SJ51 AJ

4
Table of Contents
Section 1 – Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Read and Heed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-1 MEWP and Mobile Elevating Work Platform Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-2 Purpose of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-3 Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-4 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-5 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1-6 Operator Safety Reminders, Warnings and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-1 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-2 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-3 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-4 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-5 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2-6 Hydraulic Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2-7 Railing Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3-1 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3-2 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Pre-Delivery/Maintenance Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-2 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-3 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-4 Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-5 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6-6 Control Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6-7 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6-8 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.6-9 Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6-10 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.1 Standard Hose Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Torque Specifications for Fasteners (US Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.3 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.5 MEWP Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.6 Axle Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.7 Axle Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.8 Maximum Platform Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.9 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.10 Floor Loading Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.11 Hydraulic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.12 Hydraulic & Gear Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.13 Specifications & Features - Dimensions & Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.14 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.15 Reach & Dimension Diagrams - SJ46 AJ+ ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.16 Reach & Dimension Diagrams - SJ46 AJ CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.17 Reach & Dimension Diagrams - SJ51 AJ CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.18 Axle Oscillation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 53

3.1 Electrical Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2 Hydraulic Symbol Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 Wire Number and Colour Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.4 Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Electrical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.6 Brake Manifold Components and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.7 Rotary Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.8 Drive and System Pump Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.9 Drive and System Pump Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.10 Drive Motor Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.11 Jib Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.12 Pressure Reducing Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.13 Main Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.14 Generator Control Valve and Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.15 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.16 Main Harness and Fuel Level Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.17 Interface Harness - Deutz D2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.18 Interface Harness - Deutz D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.19 Engine Interface Harness - Deutz D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.20 Interface Harness - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.21 ECU Engine Wiring Diagram - Deutz D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.22 Glow Plug Harnesses - Deutz D2.9L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.23 Glow Plug Harnesses - Deutz D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.24 Platform Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.25 Platform Control Cables - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6
3.26 Limit Switch Connections - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.27 Limit Switch Connections - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.28 Load Sensing Cable Connections - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.29 All Motion Alarm Connections - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.30 Flashing Amber Light Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.31 SGE Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.32 SGE Connections - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.33 Moba Load Cell Connections - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.34 Footswitch Connections - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.35 CANbus Cable Connections - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.36 Power Cable Connections - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.37 Oil Cooler and 3.5 kW Generator Base Control Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.38 Generator (3.5 kW) Platform Control Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.39 Oil Cooler and 12 kW Generator Base Control Box Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.40 Generator (12 kW) Platform Control Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.41 12kW Generator Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.42 Load Circuit Wiring - SJ46 AJ+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.43 Hydraulic Schematic - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.44 Hydraulic Schematic - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.45 Platform Control Box Wiring - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.46 Platform Control Box Wiring - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.47 Platform Control Box Wiring - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.48 Base Control Box Wiring - ANSI/CSA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.49 Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option . . . . . . . . . . . . . . . . . . . . . 109
3.50 Base Control Box Wiring - CE Deutz D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.51 Base Control Box Wiring - CE Deutz D2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.52 Base Control Box Wiring - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.53 Electrical Schematic - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.54 Electrical Schematic - CE with Deutz D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.55 Electrical Schematic - CE with D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.56 Electrical Schematic - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.57 Interface & Engine Electrical Schematic - Deutz D2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.58 Interface & Engine Electrical Schematic - Deutz D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.59 Engine Electrical Schematic - Deutz D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.60 Interface & Engine Electrical Schematic - Kubota WG2503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Electrical System - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2-1 All Controls are Inoperative from the Base or Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2-2 All Controls are Inoperative from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.2-3 The Engine will not Crank from the Base or Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.2-4 The Engine will not Crank from the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

7
4.2-5 The Engine will not Crank from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2-6 The Boom Controls are Inoperative (Drive Operates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2-7 No Boom Up from the Base or Platform Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2-8 No Boom Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2-9 No Boom Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2-10 No Boom Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2-11 No Boom Down from the Base Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2-12 No Boom Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2-13 No Turret Rotate Right from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2-14 No Turret Rotate Right from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2-15 No Turret Rotate Right from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2-16 No Turret Rotate Left from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2-17 No Turret Rotate Left from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2-18 No Turret Rotate Left from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2-19 No Riser Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2-20 No Riser Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2-21 No Riser Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2-22 No Riser Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2-23 No Riser Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2-24 No Riser Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2-25 No Telescope Out from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2-26 No Telescope Out from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2-27 No Telescope Out from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2-28 No Telescope In from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2-29 No Telescope In from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2-30 No Telescope In from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2-31 No Platform Level Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2-32 No Platform Level Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2-33 No Platform Level Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2-34 No Platform Level Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2-35 No Platform Level Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2-36 No Platform Level Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . 133
4.2-38 No Platform Rotate Right from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.2-39 No Platform Rotate Right from the Base Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.2-40 No Platform Rotate Right from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.2-41 No Platform Rotate Left from the Base or Platform Consoles. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.2-42 No Platform Rotate Left from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.2-43 No Platform Rotate Left from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.2-44 No Jib Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.2-45 No Jib Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.2-46 No Jib Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.2-47 No Jib Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

8
4.2-48 No Jib Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.2-49 No Jib Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2-50 No Drive or Steer Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2-51 No Forward or Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2-52 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.2-53 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2-54 The Brake will not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2-55 No Left Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2-56 No Right Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2-57 The Directon Sensing is Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.2-59 The Overload Indicator Light does not Turn On when the Platform is Overloaded . . . . . . . . . . . 140
4.2-60 The Audible Alarm does not Turn On with the Platform Overloaded . . . . . . . . . . . . . . . . . . . . . . 140
4.3 Electrical System - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3-1 All Controls are Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3-2 No Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.3-3 Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.3-4 Engine Cranks but Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3-5 Glow Plug Circuit Inoperative - Deutz D2011 diesel engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.3-6 All Base Control Console Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.3-7 No Movement from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.3-8 All Controls Inoperative From Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.3-9 Throttle Inoperative, Mid and High - Deutz D2.9L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.3-10 Mid Throttle Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.3-11 High Throttle Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.3-12 Brake will not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.3-13 Differential Lock will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3-14 Differential Lock Engages Momentarily but will not stay Engaged . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3-15 No Drive and Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.3-16 No High Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.3-17 No Elevated Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.3-18 Direction Sensing Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.4 Load Sensing System - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-1 Green Power LED is not Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-2 Load Cell red Alarm LED is ON (with platform empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-3 Red Error LED is ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-4 Load Cell red Alarm LED is OFF (with platform overloaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-5 Platform Indicator Light does not turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-6 Audible Alarm does not turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4-7 Boom and Drive Functions are Enabled (with boom extended) . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.5 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.5-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9
4.5-2 All Boom Functions Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.5-3 No Main Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.5-4 No Main Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.5-5 No Riser Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.5-6 No Riser Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.5-7 Riser Boom Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.5-8 No Turret Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.5-9 No Turret Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.5-10 No Boom Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.5-11 No Boom Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.5-12 No Jib Up - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.5-13 No Jib Up - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.5-14 No Jib Down - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.5-15 No Jib Down - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.5-16 No Platform Rotation Right - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.5-17 No Platform Rotation Right - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.5-18 No Platform Rotation Left - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.5-19 No Platform Rotation Left - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.5-20 Platform will not Level Down Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.5-21 Platform will not Level Up Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.5-22 Brake will not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.5-23 Brake will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.5-24 Differential Lock will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.5-25 No Drive Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.5-26 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.5-27 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.5-28 No High Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.5-29 No Right Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.5-30 No Left Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.5-31 Axle Will Not Oscillate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.5-32 Axle Will Not Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
5.2 System Control Modules (OCM/SCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.2-1 User Interface Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.2-2 OCM Character Functions Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.2-3 OCM Function Channel Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.2-4 OCM Operating Values Chart - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
5.2-5 How to Select OCM Functionality - CE & AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.2-6 How to View OCM Operation - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.2-7 How to Unlock and Modify OCM Settings - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

10
5.2-8 OCM Pin Voltage Reference - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.2-9 SCM Pin Reference - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5.2-10 Check I/O Error - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.2-11 How to Unlock and Modify the SCM - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
5.2-12 SCM Select Model - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.2-13 SCM Weight Calibration - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.2-14 SCM Weight Calibration Flowchart - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.2-15 CAN Bus Communication Check - ANSI/CSA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5.3 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.3-1 Fly Boom Switch Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.3-2 Platform Controller Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5.3-3 Replace the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.4 Load Sensing System - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.4-1 Load Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.4-2 Verify Proper Operation of the Load Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.4-3 Calibration of Load Sensing System (with “Teach In” Handset) . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.5 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.5-1 Check Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.5-2 Shim Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.5-3 Cable Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.5-4 Rotary Actuator Bolt Torque Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.5-5 Master Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5.5-6 Limit Switch Locations - SJ46 AJ+ ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.5-7 Limit Switch Locations - SJ46 AJ & SJ51 AJ CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
5.6 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.6-1 Check and Replace the High Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.6-2 Turret Rotation Gear Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.6-3 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.6-4 Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.7 Deutz Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5.7-1 Replace Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5.7-2 Replace the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.7-3 Replace the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.7-4 Check the Engine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.7-5 Check the Oil Cooler (Deutz D2011 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.7-6 Retrieve Engine Fault Codes - Deutz D2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5.7-7 Deutz D2.9L Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5.8 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.8-1 Hydraulic Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.8-2 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.9 Kubota WG2503 Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
5.9-1 Engine Parameter Display (KAntrak 1700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
5.9-2 Kubota WG2503 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

11
5.9-3 ECU Pin Reference Chart (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
5.9-4 Fuse Box (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
5.9-5 MAP Sensor (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5.9-6 IAT Sensor (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5.9-7 ECT (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5.9-8 TPS & Engine Speed (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5.9-9 Fuel Temperature Sensor (Kubota WG2503) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
5.9-10 Oil Pressure Sensor (Kubota WG2503). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
5.10 Manifold and Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
5.10-1 Hydraulic Brake Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
5.10-2 Hydraulic System Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.10-3 Riser Down Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.10-4 Turret Rotate Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.10-5 Platform Level Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.10-6 Test Charge Pump Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.10-7 Test Forward Drive Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.10-8 Test Reverse Drive Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
5.11 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5.11-1 Change the Oil in the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5.11-2 Check the Oil Level in the Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5.11-3 Change the Oil in the Torque Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5.11-4 Check the Oil Level in the Axle Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.11-5 Change the Oil in the Axle Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.11-6 Oscillating Cylinder Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.11-7 Oscillating Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.11-8 Bleed the Oscillating Axle Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
5.11-9 Test the Oscillating Axle Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
5.11-10 Pin Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
5.11-11 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.12 Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.12-1 Grease the Turret Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.12-2 Grease the Turret Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.12-3 Grease the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5.12-4 Grease the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5.13 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5.13-1 Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5.13-2 Generator Frequency/Voltage Check & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

12
Section 1 – Scheduled Maintenance
1.1 Read and Heed 1.1-5 Service Policy and Warranty
Skyjack warrants each new product to be free of
Skyjack is continuously improving and expanding
defective parts and workmanship for the first 2 years
product features on its equipment, therefore,
or 3000 hours, whichever occurs first. Any defective
specifications and dimensions are subject to change
part will be replaced or repaired by your local Skyjack
without notice.
dealer at no charge for parts or labor. In addition,
all products have a 5 year structural warranty.
1.1-1 MEWP and Mobile Elevating Work Contact the Skyjack Service Department for warranty
Platform Definition statement extensions or exclusions.
A mobile device that has a positionable platform
supported from ground level by a structure. 1.1-6 Operator Safety Reminders,
Warnings and Precautions
1.1-2 Purpose of Equipment Operator safety is Skyjack’s priority. The operator
The Skyjack Articulated Boom Series MEWPs are should comply with all applicable safety-related
designed to transport and raise personnel, tools and reminders, warnings and precautions found in
materials to overhead work areas. the Operating Manual. They should be read and
understood completely before operating the MEWP.
1.1-3 Use of Equipment
The MEWP is a highly maneuverable, mobile work
station. Work platform elevation and elevated driving
must only be done on a firm, level surface.
1.1-4 Manual
Operating Manual: The operating manual is
considered a fundamental part of the MEWP. 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 MEWP 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.

13
Section 1 – Scheduled Maintenance Maintenance and Service
1.2 Maintenance and Service 1.2-4 Maintenance and Service Safety

Tips
1.2-1 Maintenance and Inspection Maintenance and repair should only be performed by
Schedule personnel who are trained and qualified to service this
MEWP.
The actual operating environment of the work platform
governs the use of the maintenance schedule. The All maintenance and service procedures should be
inspection points covered in Table 1.2. Maintenance performed in a well lighted and well ventilated area.
and lnspection Checklist, indicates the areas of the Anyone operating or servicing this MEWP must read
MEWP to be maintained or inspected and at what and completely understand all operating instructions
intervals the maintenance and inspections are to be and safety hazards in this manual and operating
performed. manual.
All tools, supports and lifting equipment to be used
1.2-2 Owner’s Annual Inspection Record must be of proper rated load and in good working
It is the responsibility of the owner to arrange quarterly order before any service work begins. Work area
and annual inspections of the MEWP. The Owner’s should be kept clean and free of debris to avoid
Annual lnspection Record (1.4 Owner’s Annual contaminating components while servicing.
Inspection Record) is to be used to record the date
Ensure personnel are clear from under unsupported
of the inspection, owner’s name, and the person
components/systems that are at risk of movement
responsible for the inspection of the work platform.
during maintenance.
1.2-3 Replacement Parts All service personnel must be familiar with employer
and governmental regulations that apply to servicing
Use only original replacement parts. Parts such
this type of equipment.
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect Keep sparks and flames away from all flammable or
stability of the MEWP and must not be used without combustible materials.
manufacturer’s consent. Properly dispose of all waste material such as
All replacement tires must be of the same size and lubricants, rags, and old parts according to the
load rating as originally supplied tires; to maintain relative law provisions obtaining in the country.
safety and stability of MEWP. Before attempting any repair work, disconnect the
Consult Skyjack’s Service Department for optional main power conenctors.
tires specifications and installation. Keep personnel clear of components, systems or
unsupported loads that may move unexpectedly
WARNING during maintenance procedures.
Any unit that is damaged or not operating properly Preventive maintenance is the easiest and least
must be immediately tagged and removed from expensive type of maintenance.
service until proper repairs are completed.

14
Maintenance and Service Section 1 – Scheduled Maintenance
1.2-5 Hydraulic System & Component 7. All hydraulic components must be disassembled
Maintenance and Repair in spotlessly clean surroundings. During
disassembly, pay particular attention to
The following points should be kept in mind when the identification of parts to assure proper
working on the hydraulic system or any component: reassembly. Clean all metal parts in a clean
mineral oil solvent. Be sure to thoroughly clean
WARNING all internal passages. After the parts have been
Escaping fluid from a hydraulic pressure leak can dried thoroughly, lay them on a clean, lint-free
damage your eyes, penetrate the skin and cause surface for inspection.
serious injury. Use proper personal preotection at 8. Replace all O-rings and seals when overhauling
all times. any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
1. Any structure has limits of strength and amounts of petroleum jelly to hold O-rings in
durability. To prevent failure of structural parts of place during assembly.
hydraulic components, relief valves which limit 9. Be sure to replace any lost hydraulic oil when
pressure to safe operating values are included in completing the installation of the repaired
the hydraulic circuits. component, and bleed any air from the system
2. Tolerance of working parts in the hydraulic when required.
system is very close. Even small amounts of dirt 10. All hydraulic connections must be kept tight. A
or foreign materials in the system can cause loose connection in a pressure line will permit
wear or damage to components, as well as the oil to leak out or air to be drawn into the
general faulty operation of the hydraulic system. system. Air in the system can cause damage
Every precaution must be taken to assure to the components and noisy or erratic system
absolute cleanliness of the hydraulic oil. operation.
3. Whenever there is a hydraulic system failure
which gives reason to believe that there are 1.2-6 Hydraulic Maintenance Hints
metal particles or foreign materials in the system, Three simple maintenance procedures have the
drain and flush the entire system and replace the greatest effect on the hydraulic system performance,
filter cartridges. A complete change of oil must efficiency and life. Yet, the very simplicity of them may
be performed under these circumstances. be the reason they are so often overlooked. They are
4. Whenever the hydraulic system is drained, simply these:
check the magnets in the hydraulic reservoir for 1. Change filters annually. The filters will need
metal particles. If metal particles are present, to be changed more often depending on the
flush the entire system and add a new change operating conditions. Dirty, dusty, high moisture
of oil. The presence of metal particles also may environments may cause the hydraulic system
indicate the possibility of imminent component to be contaminated more quickly.
failure. A very small amount of fine particles is
normal. 2. Maintain a sufficient quantity of clean hydraulic
oil of the proper type and viscosity in the
5. All containers and funnels used in handling hydraulic reservoir.
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic 3. Keep all connections tight.
oil reservoir, and fill the reservoir only through
the filter opening. The use of cloth to strain the
oil should be avoided to prevent lint from getting
into the system.
6. When removing any hydraulic component,
be sure to cap and tag all hydraulic lines
involved. Also, plug the ports of the removed
components.

15
Section 1 – Scheduled Maintenance Maintenance and Service
1.2-7 Railing Maintenance and Repair

Skyjack MEWPs have been designed to ensure
compliance with the relevant design standards
applicable for that particular unit at the time of
manufacture. As such, any repairs made to the
guardrail or basket structure need to ensure this
compliance is not compromised and must return the
structure to its original condition.
Any damage must be repaired by returning the railing
assembly to its undamaged state. Damage includes,
but is not limited to, the items listed below:
▪ bent/deformed guardrail sections
▪ cracks or broken welds in railing sections
▪ damaged pin connections
▪ missing pins or broken pin lanyards
▪ missing railing hardware
▪ loose or missing parts
▪ additional holes in guardrail sections other than
those approved by Skyjack
Additionally, the guardrails must be properly
positioned and secured, and the entry gate must be
in good working order.
The strength of the guardrail system, and therefore
its ability to provide fall protection for platform
occupants, depends upon the design being secure
and undamaged.
Skyjack railings are designed for modular
replacement, and Skyjack recommends replacement
of any damaged railing section. Skyjack-approved
replacement parts will meet this requirement.

16
Scheduled Maintenance Section 1 – Scheduled Maintenance
1.3 Scheduled Maintenance 1.3-3 Maintenance Instructions

This manual consists of four schedules to be done
This section contains the maintenance and inspection
for maintaining on a MEWP. Inspection schedule
schedule that is to be performed.
frequency is shown below:
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for Issue or Symptom
checks and replacements.
PDI/Frequent B Perform PDI prior to each
1.3-1 Service Bulletins delivery, or Frequent
Before performing any scheduled maintenance Inspection every 200 days
inspection procedure, refer to service bulletins found or 200 hours.
in our web site: www.skyjackinc.com for updates
Annual B+C Perform Scheduled
related to service and maintenance of this MEWP.
Maintenance Inspections
every year.
1.3-2 Maintenance and Inspection
Death or injury can result if the MEWP is not kept in Additional * Perform at time sensitive
good working order. Inspection and maintenance maintenance intervals.
should be performed by competent personnel who
are trained and qualified on maintenance of this ▪ Make copies of the maintenance and inspection
MEWP. checklist to be used for each inspection.
▪ Check the schedule on the checklist for the type
WARNING of inspection to be performed.
Failure to perform each procedure as presented ▪ Place a check in the appropriate box after each
and scheduled may cause death, serious injury or inspection procedure is completed.
substantial damage. ▪ Use the maintenance and inspection checklist
and step-by-step procedures in Section 1 to
perform these inspections.
NOTE If any inspection receives a fail, tag and remove
Preventive maintenance is the easiest and least
▪
the MEWP from service.
expensive type of maintenance.
▪ If any MEWP component(s) has been repaired,
▪ Unless otherwise specified, perform each an inspection must be performed again before
maintenance procedure with the MEWP in the removing the tag. Place a check in the repair
following configuration: column.
▪ MEWP parked on a flat and level surface Legend
▪ Disconnect the batteries by disconnecting the Pass P
main power connectors.
▪ Repair any damaged or malfunction Fail F
components before operating MEWP.
Repaired R
▪ Keep records on all inspections.
Not applicable N/A

17
Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record
Table 1.4 Owner’s Annual Inspection Record
Inspection
Date
Inspector
Signature
WARNING
Do not use the MEWP if there is no inspection
recorded in the last 13 months. If you do not obey,
there is a risk of death or serious injury.
IMPORTANT
The Owner’s annual inspection record is located
on the scissor assembly. It must be filled out after
an annual inspection has been completed. Do
not use the MEWP if an inspection has not been
recorded in the last 13 months.

18
Pre-Delivery/Maintenance Inspection Checklist Section 1 – Scheduled Maintenance
1.5 Pre-Delivery/Maintenance Inspection Checklist
Frequent/Periodic/Annual/PDI Checklist
Articulating Booms and Telescopic Booms
Serial Number: Starting with serial number A000 000 000 or B000 000 000 and above Product Owner:
Product User:
Model: Date/Time:
Hourmeter Reading: Inspection Type (Choose one): Pre-delivery Frequent Periodic Annual
Use this table for pre-delivery inspections (PDI) before each rental, lease or sale and as an instruction for all frequent inspections and annual inspections.
Refer to the operation and service manuals for inspection instructions (for example, visual inspection and function tests, torque specs, engine oil, chain
inspection intervals, and more).
B - Do the pre-delivery inspection before the machine is sent out or during the frequent inspections at 200 days or 200 hour P - Pass
Inspection Type Schedule
intervals. For more instructions, refer to the operation and service manuals. N/A - Not Applicable
PDI/Frequent/Periodic B
C - Do the scheduled maintenance Inspections each year. For more instructions, refer to the service manual.
Annual B+C
Put a check mark in the “Pass” column as you meet the requirements of the inspection for each item. Add a comment if the item does not pass inspection.
Items for Inspection P N/A Items for Inspection P N/A
Service Bulletins. Make sure there are no open service bulletins. B Axles. Correctly attached and no missing components. Tight fittings and hoses
B
and no leaks. Make sure the axles and drive shaft are lubricated.
Annual Inspection. Make sure you complete it within 13 months. B
Axles. Do a check of the brakes. Lubricate the axles and drive shaft. C
Labels. In place, correctly attached and you can read them. B
Oscillating Cylinders. Correctly attached and no missing components. Tight
Limit Switches. Correctly installed and no obstructions or damage. B B
fittings and hoses and no leaks.
ENGINE COMPARTMENT Oscillating Cylinders. Correctly attached and no missing components. Tight
C
Main Power Disconnect Switch. Cables and switch tight and in working order. B fittings and hoses and no leaks. Do a check of the mounting bolts torque seal.
Battery. No damage, tight connections and sufficient fluid levels. Clean Steer Cylinder. Correctly attached and no missing components. Tight fittings
B B
terminals and cable ends. and hoses and no leaks.
Swing Drive. Tight fittings, hoses and bolts. No damage, missing components Steer Linkage. No damage/wear or missing components. B
B
or leaks. Wheel/Tire Assembly. Do a check of all tires for damage, wear and
B
Hydraulic Pump and Motor. Tight fittings, hoses and bolts. No damage, correctly aligned.
B
missing components or leaks. Wheel/Tire Assembly. No loose bolts. Wheel nuts torqued as recommended. C
Engine and Components. Do a check of the engine and components for any PLATFORM
loose, missing, damaged, or failed items. Do a check of the oil and coolant
B
levels. Make sure you do not exceed the recommended oil and coolant change Raillings and Gates. Correctly attached and no damage or missing
B
intervals. components.
Air Filter. Do a check of the filter. Replace the air filter if necessary. C Platform Floor. Correctly attached and no damage or missing components. B
Fuel Filter. Do a check of the filter. Replace the fuel filter if necessary. C Footswitch. Correctly attached. Operates correctly with no modifications. B
Radiator. Do a check of the coolant condition and replace if necessary. C Fall-Protection Anchorage. Anchorages are correctly attached and no damage. B
CONTROL COMPARTMENT AC Power Socket. No obstructions, dirt, or damage. B
Turret Transportation Lock. Unlocked and no damage or missing Platform Control Console. Operate the switches and make sure they all
B B
components. operate correctly. No damage or missing components.
Base Control Console. Operate the switches and make sure they all operate Manual Storage Box. Manuals and documents are in storage box, in good
B B
correctly. No damage or missing components. condition, and you can read them.
Hydraulic Tank. Filler cap closed tightly and no damage or leaks. B BOOM
Hydraulic Oil. Level between min. and max. marks. B Rotary Actuator. No damage or missing components. Tight fittings, hoses and
B
bolts and no leaks.
Hydraulic Oil. Do a check and replace oil and filters if necessary. C
Jib. No damage or missing components. Tight hoses and bolts and no leaks. B
Hydraulic Return Filter. Correctly attached and no damage, missing
B
components or leaks. Boom. No damage or missing components. No deformation or cracks in welds.
B
Tight fittings, hoses, bolts, and pins. No leaks.
Hydraulic Return Filter. Do a check of the filter. Replace the filter if necessary. C
Cable Track. No damage or missing components. B
Manifolds. Tight fittings and hoses and no damage or leaks. Tight wire
B
connections, no missing components and correctly working valves. Wear Pads. No damage, wear or missing components. Fasteners tight. B
High-pressure Filter. Do a check of the filter. Replace the filter if necessary. Riser. No damage or missing components. No deformation or cracks in welds.
B
Tight fittings, hoses, bolts, and pins. No leaks.
Emergency Power Unit. Tight fittings and hoses. No leaks. Tight wire
B
connections and no damage or missing components. Cylinders. No damage or missing components. Tight fittings and hoses and no
B
leaks. Pins and bushing are tight and correctly installed.
Fuel Tank and Lines. Filler cap, tank, fittings and hoses are closed tightly and
B
no damage or leaks. Control Cables and Hoses. No damage or missing components. No leaks. B
BASE Wire Ropes. No damage or missing components. Tight jam nuts. No spring
B
gaps. Do not exceed the inspection interval.
Base Weldment. No deformation or cracks. B
OPTIONAL EQUIPMENT
Rotary Manifold. Tight fittings and hoses, and no leaks. B
Special Options and Approved Attachments. Correctly attached and no
Turret Rotation Motor/Gear. Tight fittings, hoses and bolts. No damage, B
B damage or missing components.
missing components or leaks. Make sure the gears are lubricated.
Function Tests. Refer to the operating manual for your serial number for PASS
Turret Rotation Motor/Gear. Lubricate the gears. C
information on how to run these tests. FAIL
199342AB
Comments:
The undersigned has made sure that all areas in the list have received an inspection.
The undersigned has told the machine owner of all inconsistencies in the inspection and corrected them before machine operation.
Owner: Print Name Signature Date (DD/MM/YY)
User: Print Name Signature Date (DD/MM/YY)

19
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections
1.6 Scheduled Maintenance 1.6-2 Hydraulic

Do a check on these areas and make sure there are
Inspections no signs of leakage:
Do an inspection of the MEWP in this sequence. ▪ Hydraulic tank filter, fittings, hoses, emergency-
power unit, turret and base surface
WARNING ▪ Engine compartment fittings, hoses, primary
Do not operate a MEWP until all malfunctions have pump, filter, turret and base surface
been corrected. If you do not obey, there is a risk ▪ All hydraulic cylinders
of death or serious injury. ▪ All hydraulic manifolds
▪ The ground area below the MEWP.
WARNING
1.6-3 Labels
Turn the main power disconnect switch to the
off position before you do the visual and daily (B) Refer to the labels section in the Operating
maintenance inspections. If you do not obey, there Manual. Make sure all the labels are in the correct
is a risk of death or serious injury. location, are in good condition, and you can read
them.
1.6-1 Electrical 1.6-4 Limit switches

Do a check on these areas for chafed, corroded, and
loose wires: (B) Do an inspection of all limit switches 1 located
inside the turret and on the boom. Inspect for the
▪ Boom to platform cable harness following:
▪ Engine compartment electrical panel
▪ Broken or missing actuator arms
▪ Engine wiring harness
▪ Missing fasteners
▪ Rotary manifold wiring
▪ Loose wiring.

20
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance
1.6-5 Engine Compartment B - Frequent Inspection

Do the inspection that follows: 1. Do an inspection of the battery case for damage.
Make sure all compartment latches are latched tightly

▪ Clean the battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
and in good condition.
brush.
1 Main power disconnect switch (B) 2. Make sure all the battery connections are tight.
▪ Turn the main power disconnect switch to the 3. If applicable, check the battery fluid level.
off position.
▪ If the plates do not have a minimum 13 mm
▪ Make sure the switch rotates and stays in the (1/2 inch) of solution above them, add distilled
on and off position. or demineralized water.
▪ Make sure the cables are not loose. ▪ Replace the battery if it is damaged or cannot
2 Battery (B) hold a lasting charge.
WARNING WARNING
Explosion hazard. Keep flames and sparks away. Only use original or manufacturer-approved parts
Do not smoke near the batteries. If you do not and components for the MEWP. If you do not obey,
obey, there is a risk of death or serious injury. there is a risk of death, serious injury, or machine
damage.
WARNING
Corrosion hazard. Do not touch battery acid. Wear
the correct PPE. If the battery acid touches you,
immediately flush the area with cold water and get
medical aid.

21
3 Hydraulic pump and motor (B) 6 Muffler and exhaust (B)

▪ Make sure there are no loose or missing parts. ▪ Make sure that the muffler and exhaust
▪ Make sure there is no visible damage. systems are correctly attached with no visible
damage.
▪ Make sure all bolts are correctly tightened.
Engine fuel leaks (B,C)
▪ Make sure all fittings and hoses are correctly
tightened and there are no hydraulic leaks. ▪ Make sure that there no fuel leaks at the
4 High-pressure filter (B,C) engine.
▪ Make sure there is no visible damage.
▪ Make sure the housing is attached and tight.
▪ Make sure there is no visible damage or WARNING
hydraulic leaks.
Explosion or fire hazard. Do not smoke near the
C - Annual Inspection
fuel system. If you do not obey, there is a risk of
▪ For the filter element replacement procedure, death or serious injury.
refer to 5.6-1 Check and Replace the High
Pressure Filter.
Engine fuel filter (B,C)
Engine and Components

▪ Make sure there are no loose or missing parts.
▪ Make sure there is no visible damage.
5 Engine pivot tray (B) C - Annual Inspection
▪ Make sure there are no loose or missing parts. ▪ For the engine fuel filter replacement
▪ Make sure there is no visible damage. procedure, refer to the engine manual.
▪ Make sure that the engine is correctly attached
to the pivot tray.
▪ Make sure the tray-securing bolt is in place.

22
7 Radiator (B, C) 9 Air filter (B,C)

▪ Make sure there are no loose or missing parts. ▪ Make sure there are no loose or missing parts.
▪ Make sure there is no visible damage. ▪ Make sure there is no visible damage.
▪ Make sure that the radiator is correctly ▪ Squeeze the lips of the vacuator valve to
attached to the engine tray. remove the dirt and dust.
▪ Check the coolant level and add more if ▪ Do an inspection of the service indicator on
necessary. the air cleaner. Replace the filter element if
C - Annual Inspection necessary.
▪ Check the coolant strength. For B - Frequent Inspection
recommended coolant change intervals, refer ▪ For the engine air filter maintenance
to the engine manual. procedure, refer to the engine manual.
8 Engine oil level (B) ▪ For the engine air filter replacement procedure,
refer to the engine manual.
WARNING
Burn hazard. Do not touch hot engine components
without the correct PPE. Let the engine cool before
you do an inspection or servicing. If you do not
obey, there is a risk of death or serious injury.
▪ Use the dipstick to check the oil level.

▪ The oil level must be between the marks L
(low) and H (high). Add oil if it is necessary.
Refer to 2.14 Engine Specifications.
B - Frequent Inspection
▪ For recommended oil change intervals, refer to
the engine manual.

23
4 5
3 2
1.6-6 Control Compartment C - Annual Inspection

Do the inspection that follows: ▪ For the hydraulic oil replacement procedure,
refer to 5.8-1 Hydraulic Oil Replacement.
Make sure all compartment latches are latched tightly 4 Hydraulic Return Filter (B,C)
and in good condition.
1 Turret transportation lock (B)
▪ Make sure the filter element is attached and
tight.
▪ Make sure the turret transportation lock is ▪ Make sure there is no visible damage or
unlocked. hydraulic leaks.
▪ Make sure there are no loose or missing parts. C - Annual Inspection
▪ Make sure there is no visible damage ▪ For the hydraulic tank filter replacement
2 Base Control Console (B) procedure, refer to 5.8-2 Hydraulic Filter
Replacement.
▪ Make sure there are no loose or missing parts. 5 Manifolds (B)
▪ Make sure there is no visible damage, and all
the switches are in their off/neutral positions. ▪ Make sure all fittings and hoses are correctly
tightened.
3 Hydraulic Tank (B)
▪ Make sure there is no indication of hydraulic
▪ Make sure the hydraulic filler cap closes leakage.
tightly.
▪ Make sure there are no loose wires or missing
▪ Make sure there is no visible damage or fasteners.
hydraulic leaks.
Hydraulic Oil (B, C)
▪ Make sure the boom is in the stowed position.
▪ Do a check on the gauge on the side of the
hydraulic oil tank. The hydraulic oil level must
be at or a small distance above the top mark
of the gauge. Add oil if it is necessary. Refer to
2.12 Hydraulic & Gear Oils.

24
7 Emergency Power Unit (B)

WARNING
▪ Make sure there are no loose or missing parts.
Environmental hazard. Immediately remove
▪ Make sure there are no loose wires or missing gasoline, diesel fuel, engine oil, and hydraulic
fasteners.
fluid spills and leaks with rags. Discard these
▪ Make sure there is no visible damage. rags in accordance with national, state/provincial/
▪ Make sure all the fittings and hoses are territorial, and local regulations. Spilled fluids can
correctly tightened and there are no hydraulic damage the environment. When spilled fluids go
leaks. into the water (for example, a sewage system,
8 Fuel Tank and Lines (B) streams, rivers, or other surface water), they can
kill aquatic life.
IMPORTANT
Before you use the MEWP, make sure there is
sufficient fuel for the estimated task.
DANGER
Explosion or fire hazard. Do not smoke near the
fuel system. If you do not obey, there is a risk of
death or serious injury.
▪ Make sure that the fuel filler cap closes tightly.

▪ Make sure there is no visible damage to the
tank, gauge, hoses, or fittings.
▪ Make sure there is no indication of fuel
leakage from the tank, gauge, hoses, fittings,
pump, and filter.

25
6 3
1
3
2 5
1.6-7 Base 4 Brake Cylinder (B)

1 Base weldment (B) ▪ Make sure there are no loose or missing parts.
▪ Make sure there are no visible cracks in ▪ Make sure all the fittings and hoses are
welds or structure and there are no signs of correctly tightened and there are no hydraulic
deformation. leaks.
2 Turret rotation motor and gear (B,C) 5 Steer cylinder (B)
▪ Make sure there are no loose or missing parts. ▪ Make sure there are no loose or missing parts.
▪ Make sure there is no visible damage. ▪ Make sure all the fittings and hoses are
C - Annual Inspection correctly tightened and there are no hydraulic
▪ For the lube procedure, refer leaks.
3 Axles (B,C) 6 Steer linkage (B)
▪ Make sure the front and rear axles are ▪ Make sure there are no loose or missing parts.
correctly attached. ▪ Make sure the tie rod end studs are locked
▪ Make sure there are no loose or missing parts. and there is no visible damage.
▪ Make sure all the fittings and hose connections
are tight.
▪ Make sure there is no sign of hydraulic
leakage.
▪ Check the brakes annually. Refer to the
procedure 5.11-11 Brake Inspection.

26
7 Oscillating cylinders (B,C) 8 Wheel/tires (B,C)

▪ Make sure the oscillating cylinders are ▪ Do a check on all tire treads and sidewalls for
correctly attached, and there are no visible cuts, cracks, holes, and unusual wear.
spaces. ▪ Do a check on each wheel for damage, and
▪ Make sure there are no loose or missing parts. cracked welds.
▪ Make sure all the fittings and hose connections ▪ Do a check on each lug nut for the correct
are tight. torque to make sure they are not loose.
▪ Make sure there is no sign of hydraulic ▪ Make sure the wheels are correctly aligned
leakage. vertically and horizontally.
▪ Do a check of the heads of the oscillating ▪ Make sure there are no loose or missing parts.
cylinder mounting bolts to make sure the ▪ Make sure there is no visible damage.
torque seal is visible and undamaged. If the
B - Frequent Inspection
torque seal is damaged or is missing, remove
and replace the affected bolts. Refer to 5.11-6 ▪ For proper torque information, refer to 2.5
MEWP Torque Specifications.
Oscillating Cylinder Bolt Replacement.
WARNING
NOTE
The oscillating axle is locked when the MEWP is Do not use tires other than the tires that Skyjack
in the elevated travel position or at the elevated specifies for this MEWP. Do not mix different types
travel speed. Refer to 2.18 Axle Oscillation of tires or use tires that are not in good condition.
Diagram. Only replace the tires with the same types that are
approved by Skyjack. The use of other tires can
make the MEWP less stable. If you do not obey,
there is a risk of death or serious injury.
Refer to 2.9 Tire Specifications.

27
7 6
1
3
2 4
9
8
1.6-8 Platform 7 Platform control console (B)

1 2 Railings and gates ▪ Make sure all switches and controllers are in
▪ Make sure there are no loose or missing parts, the neutral position.
and there is no visible damage. ▪ Make sure there are no loose or missing parts,
▪ Make sure the fasteners are correctly installed. and there is no visible damage.
▪ Make sure the platform railings 1 are in the 8 Manual storage box (B)
correct position. ▪ Make sure that the operation manual and
▪ Make sure the gates or drop bars 2are in other important documents are in the manual
good condition and operate correctly. storage box.
3 MEWP floor ▪ Make sure that the documents are in good
condition, and you can read them.
▪ Make sure the MEWP floor is solid and there is
no visible damage. ▪ Always put the manuals and other documents
back in the storage box after use.
4 Footswitch
9 Load Cell - CE & AS (B)
▪ Make sure the footswitch is in good working
order and has not been tampered with, ▪ Make sure there are no loose or missing parts,
disabled or blocked. and there is no visible damage.
▪ Make sure the fasteners are correctly installed.
5 Fall-protection anchorages
▪ Make sure the cables are in good condition.
▪ Make sure that the fall-protection anchorages Make sure the cable connections are tight.
are correctly installed. ▪
▪ Make sure there is no debris lodged between
▪ Make sure there is no visible damage. the platform and the boom adaptor.
6 AC power socket
▪ Make sure that the socket is free of dirt or
blockages.

28
2 4
1
8
7
1.6-9 Boom Assembly 5 Wear Pads (B)

1 Rotary actuator ▪ All fasteners are correctly tightened.
▪ There are no loose or missing parts, and there ▪ There are no loose or missing parts, and there
is no visible damage. is no visible damage to the wear pads.
▪ All fasteners are correctly tightened. 6 Riser (B)
▪ All hoses are correctly tightened and there is ▪ There are no loose or missing parts.
no sign of hydraulic leakage.
▪ There is no visible damage.
2 Jib (B)
▪ All fasteners and pins are correctly tightened.
▪ There are no loose or missing parts, and there ▪ There are no visible cracks in welds
is no visible damage. or structure and there are no signs of
▪ All fasteners are correctly tightened. deformation.
▪ All hoses are correctly tightened and there is 7 Cylinders (B)
▪ Make sure the cylinders are correctly installed.
3 Boom (B)
▪ Make sure there is no indication of leaks or
▪ There are no loose or missing parts, and there damage.
is no visible damage. ▪ Make sure all pins and bushings are secure
▪ All fasteners are correctly tightened. and properly tightened.
▪ All hoses are correctly tightened and there is 8 Control Cables and Hoses (B)
▪ There are no loose or missing parts, and there
▪ Make sure there are no visible cracks in is no visible damage.
welds or structure and there are no signs of
▪ All hoses are correctly tightened and there is
deformation.
4 Cable Track (B)
is no visible damage.

29
1 2 4 5
3 6 7
1.6-10 Optional equipment 4 Cold or arctic weather package

(B) Do the inspection that follows, and make sure: ▪ The heater plugs are correctly attached with
1 Generator no visible damage.
▪ There is no sign of engine oil leakage.
is no visible damage. 5 Tool tray
▪ All hoses are correctly tightened and there is ▪ The tray is correctly attached with lock-pins,
no sign of hydraulic leakage. and there is no visible damage.
2 Flashing amber light 6 Glazier
▪ The lamp is correctly attached, and there is no ▪ There are no loose or missing parts, and there
visible damage. is no visible damage.
3 Welder 7 Pipe rack
▪ The welder and the welder tray are correctly ▪ There are no loose or missing parts, and there
attached. is no visible damage.
is no visible damage.
▪ There are no loose wires or missing fasteners.

30
Function Tests Section 1 – Scheduled Maintenance
1.7 Function Tests

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

perform a pre-operation inspection and a series
of function tests again before putting the MEWP
into service.
▪ Prior to performing function tests, be sure to
read and understand the “Start Operation”
section of the operating manual.
▪ For function tests that are to be performed,
please refer to the operating manual that
corresponds to the correct serial number.
Found there are detailed instructions for which
tests to perform, as well as how to properly and
successfully perform them.
NOTE
The all-function motion alarm should sound while
operating any boom and drive function.

31
Notes

32
Section 2 – Maintenance Tables and
Diagrams
Table 2.1 Standard Hose Numbering System
H1104 0081 2
FITTING LENGTH IN FRACTIONS

ARRANGEMENT LENGTH OF HOSE IN (1/4" INCREMENTS)
(See Schedule Below) WHOLE INCHES 1=1/4"
HOSE SIZE
2=1/2"
(See Chart Below)
3=3/4"
Using the number above as an example,

H1104 0081 2, this hose requires a 37° JIC female NOTE
swivel fitting on one end, and a medium length 90° JIC Hose ends and hose must be from same
female swivel fitting for the other end. The hose must manufacturer per S.A.E. J1273 Nov. ‘91, Sections
meet or exceed the S.A.E. 100R13 hose specification, 3.10 and 4.2. Hose ends and hose must be of the
and be a total of 81-1/2" long. 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"
Fitting Arrangement Schedule

S.A.E.
Hose Prefix Hose End Fitting Hose End Fitting
Hose 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

33
Section 2 – Maintenance Tables and Diagrams Standard Hose Numbering System
Hose S.A.E. Hose

Hose End Fitting Hose End Fitting
Prefix Specification
H15 REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI
H16 NO FITTING NO FITTING 100R4
H17 NO FITTING NO FITTING 300 PSI
H18 REUSABLE, FEMALE, 37° JIC, SWIVEL NO FITTING 300 PSI
H19 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R13
H20 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R4
H21 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R2AT
H22 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R2AT
H23 FEMALE, LONG 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R2AT
H24 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R13
H30 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H32 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H57 SHORT 45°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H58 FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H59 MEDIUM 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H66 FEMALE, 37° JIC, SWIVEL NO FITTING 100R4
H71 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15

34
Torque Specifications for Fasteners (US Imperial) Section 2 – Maintenance Tables and Diagrams
Table 2.2 Torque Specifications for Fasteners (US Imperial)

Torque SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8
Size Size
Type 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
ft-lb 170 125 430 320 600 460
(in-lb) (27) (21) (43) (32) (60) (45) 7/8-9
10-24 Nm 230 169 583 434 813 624
Nm 3.1 2.4 4.9 3.6 6.8 5.1
ft-lb 180 140 470 360 660 500
(in-lb) (31) (23) (49) (36) (68) (51) 7/8-14
10-32 Nm 244 190 637 488 895 678
Nm 3.5 2.6 5.5 4.1 7.7 5.8
ft-lb 250 190 640 480 900 680
(in-lb) ft-lb (66) (50) 8 (75) 12 9 1-8
1/4-20 Nm 339 258 868 651 1220 922
Nm 7.5 5.6 11 8.5 16 12
ft-lb 270 210 710 530 1000 740
(in-lb) ft-lb (76) (56) 10 (86) 14 10 1-12
1/4-28 Nm 366 285 963 719 1356 1003
Nm 8.6 6.3 14 9.7 19 14
ft-lb 280 210 730 540 1020 760
ft-lb 11 8 17 13 25 18 1-14
5/16-18 Nm 380 285 990 732 1383 1030
Nm 15 11 23 18 34 24
ft-lb 350 270 800 600 1280 960
ft-lb 12 9 19 14 25 20 1 1/8-7
5/16-24 Nm 475 366 1085 813 1735 1302
Nm 16 12 26 19 34 27
ft-lb 400 300 880 660 1440 1080
ft-lb 20 15 30 23 45 35 1 1/8-12
3/8-16 Nm 542 407 1193 895 1952 1464
Nm 27 20 41 31 61 47
ft-lb 500 380 1120 840 1820 1360
ft-lb 23 17 35 25 50 35 1 1/4-7
3/8-24 Nm 678 515 1519 1139 2468 1844
Nm 31 23 47 34 68 47
ft-lb 550 420 1240 920 2000 1500
ft-lb 32 24 50 35 70 55 1 1/4-12
7/16-14 Nm 746 569 1681 1247 2712 2034
Nm 43 33 68 47 95 75
ft-lb 670 490 1460 1100 2380 1780
ft-lb 36 27 55 40 80 60 1 3/8-6
7/16-20 Nm 908 664 1979 1491 3227 2413
Nm 49 37 75 54 108 81 ft-lb 750 560 1680 1260 2720 2040
ft-lb 50 35 75 55 110 80 1 3/8-12
1/2-13 Nm 1017 759 2278 1708 3688 2766
Nm 68 47 102 75 149 108 ft-lb 870 650 1940 1460 3160 2360
1 1/2-6
ft-lb 55 40 90 65 120 90 Nm 1180 881 2630 1979 4284 3200
1/2-20
Nm 75 54 122 88 163 122 ft-lb 980 730 2200 1640 3560 2660
1 1/2-12
Nm 1329 990 2983 2224 4827 3606
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. Refer to the specific 1374AB
thread locker manufacturer’s instructions for specific torque adjustments.

35
Section 2 – Maintenance Tables and Diagrams Torque Specifications for Fasteners (Metric)
Table 2.3 Torque Specifications for Fasteners (Metric)

Torque 8.8 10.9
Size
Type 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
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. 1375AC
Refer to the specific thread locker manufacturer’s instructions for specific torque adjustments.

36
Torque Specifications for Hydraulic Couplings & Hoses Section 2 – Maintenance Tables and Diagrams
Table 2.4 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
1276AA

37
Section 2 – Maintenance Tables and Diagrams MEWP Torque Specifications
Table 2.5 MEWP 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
Rotation Gear BOLT, Hex head (5/8"-11 x 2.75", Grade 8) 170 230
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 (SJ46A / SJ51AJ) 300 407
Extension
ROD NUT (SJ46AJ) 150 203
GLAND 450-500 610-678
Master
ROD NUT 350 475
Slave GLAND & ROD NUT 350 475
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
Riser ROD NUT & 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 45, Grade 10.9 \ ZP) 200 271
Load Cell Mounting (CE)
BOLT, Hex head (1/2"-13 x 2.5", Grade 8) 80 108
1402AC

38
Axle Torque Specifications Section 2 – Maintenance Tables and Diagrams
Table 2.6 Axle 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
Coarse 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
1373AA
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
locking. Before using it, completely remove any lubricant by using the specific activator.
Loctite 270
▪ Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength
locking. Before using it, completely remove any lubricant by using the specific activator. To remove parts,
it may be necessary to heat them at 80˚C approx.

39
Section 2 – Maintenance Tables and Diagrams Axle Maintenance Intervals
Table 2.7 Axle Maintenance Intervals
Operation Component Frequency Lubricants

Differential monthly
Check Levels Planetary reduction every 200 hours SAE 80W-90 API GL-5
Gear box monthly
Differential every 800 hours *
Planetary reduction every 1000 hours *
Oil Change Self-locking differential gear every 700 hours * & SAE 80W-90 API GL-5
once at 50 hours after every
Gear box
1000 hours
Gear box screws/bolts every 200 hours
Tighten N/A
Wheel Nuts every 200 hours
Operation Member Conditions Frequency Lubricants

Normal work monthly
Grease Articulations MOLIKOTE
Awkward work weekly
Gear Oil Gear Box Central Housing Hubs (each)

5.5 L (5.8 qt) front
Maximum Oil Capacities 2.4 L (2.5 qt) 0.9 L (0.9 qt)
7.5 L (7.9 qt) rear
*Initially after 100 working hours 2238AA-2

& when it starts sounding noisy
NOTE
1 Nm = 0.7376 ft-lb
40
Maximum Platform Capacity Section 2 – Maintenance Tables and Diagrams
Table 2.8 Maximum Platform Capacity

SJ46 AJ+ ANSI/CSA SJ46 AJ & SJ51 AJ
without attachment with attachment CE & AS
300 kg (660 lb) 272 kg (600 lb) 227 kg (500 lb)
Total Capacity*
2 Persons 1 Person 2 Persons
Maximum Wind 12.5 m/s (28 mph) 12.5 m/s (28 mph) 12.5 m/s (28 mph)
Maximum Side Force 400 N (90 lb) 200 N (45 lb) 400 N (90 lb)
Tilt Switch Cutout
5° x 5° 5° x 5° 5° x 5°
Side-to-side x front-to-back
2043AB
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 the slope increases to above 45%, the forward drive is disabled but reverse drive remains
active.
Table 2.9 Tire Specifications
Model Type Brand Size Ply Rating

Solid
SJ46 AJ+ ANSI Trelleborg Brawler HPS 31x10-20 N/A
Solid non-marking
Foam Carlisle TR-501 12x16.5 10
SJ46 AJ CE & AS
Foam non-marking OTR 315/55D20 12
2091AA
WARNING
Do not use tires other than those specified for this machine. Do not mix different types of tires. Tires other
than those specified can adversely affect stability. Failure to operate with matched, approved tires in good
condition can result in death or serious injury. Replace tires with the exact, Skyjack-approved types only.
IMPORTANT
For the proper functioning 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 the overall
mobility of the MEWP.

41
Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure
Table 2.10 Floor Loading Pressure

Gross MEWP Total MEWP Load
Model Weight Wheel LCP OUP
kg lb kg lb kPa psi kPa psf
SJ46 AJ+ ANSI 6000 13,200 3000 6,600 1090 158 10 209
SJ46 AJ CE & AS 7180 15,830 3527 7,775 827 120 10.9 227
SJ51 AJ CE & AS 7543 16,630 3842 8,470 917 133 11.4 239
2038AA
▪ Gross MEWP Weight = Weight + platform capacity

LCP – Locally Concentrated Pressure – is a measure of how hard the MEWP 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.
▪ OFL – Overall Floor Load – is a measure of the average load the MEWP 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.
▪ The welder option will add approximately 158.8 kg (350 lb) to total MEWP weight and 79.4 kg (175 lb) to
the max. wheel load.
NOTE:
The LCP or OFL 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 Floor Load (OFL)

Foot Print Area identified by test Base Area = Length x Width
Wheel Load Weight of MEWP + Capacity
LCP = OFL =
Foot Print Area Base Area
Foot Print Area
Base Width
Base Length

42
Hydraulic Specifications Section 2 – Maintenance Tables and Diagrams
Table 2.11 Hydraulic Specifications

Description Metric US
Pumps
Displacement - 2000 rpm 46 CC 2.8 CIR 24.3 gpm @ 2000 rpm
Drive Pump Pressure 345 bar 5000 psi

Drive Pump
Charge Pump Displacement 13.9 CC 0.85 CIR
Charge Pump Pressure 22 bar 313 psi
Displacement - Static 11 CC 0.67 CIR / 5.8 gpm @ 2000 rpm

System Pump
System Pump Pressure 207 bar 3000 psi
Filters
Charge Pump Filter Max. Operating Pressure 9 µm/35 50 psi
High Pressure Filter Max. Operating Pressure 10 µm/25 87 psi
Return Filter Max. Operating Pressure 10 µm/40 22 psi

Motors
Displacement - Low 21 CC 1.55 CIR

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

Swing Motor
Maximum Swing Pressure 121 bar 1750 psi
Cylinders
Bore 5.1 cm 2 in.
Rod Diameter 3.2 cm 1.25 in.

Extension Cylinder
Stroke 1.7 m 67 in.
Maximum Boom Pressure 207 bar 3000 psi
Bore 10.2 cm 4 in.

Main Lift Cylinder
Stroke 64.6 cm 25.44 in.
Maximum Lift Pressure 207 bar 3000 psi
Bore 6.4 cm 2.5 in.
Riser Cylinder Stroke 92 cm 36.21 in.
Maximum Lift Pressure 207 bar 3000 psi
Maximum Lower Pressure 190 bar 2750 psi
Steering Cylinder Maximum Steering Pressure 207 bar 3000 psi
2039AB

43
Section 2 – Maintenance Tables and Diagrams Hydraulic & Gear Oils
Table 2.12 Hydraulic & Gear Oils

SJ46 AJ+ SJ46 AJ & SJ51 AJ
Description Temperature Range
ANSI/CSA CE & AS
Hydraulic Oil Cooler Option 38°C to 45°C (100°F to 115°F) Oil cooler option recommended
Shell Tellus T46,
Standard Hydraulic Oil -26°C to 38°C (-15°F to 100°F) Petro-Canada ATF D3M
Petro-Canada Hydrex MV46
Esso/Mobil UNIVIS HVI 26, Esso/Mobil UNIVIS HVI 26,
Arctic Hydraulic Oil -40°C to 38°C (-40°F to 100°F)
Petro-Canada Hydrex Extreme Petro-Canada Hydrex Extreme
Biodegradable Hydraulic Oil -29°C to 32°C (-20°F to 90°F) Shell Naturelle HF-E 46
Hydraulic Tank Capacity 170 L (45 gal) 170 L
Standard Gear Oil -29°C to 45°C (-20°F to 115°F) SAE 80W-90 API GL5
Arctic Gear Oil -40°C to 45°C (-40°F to 115°F) Duratran XL Synthetic Oil
Gear Oil Capacity 38 L (10 gal) 38 L

2069AB

44
Specifications & Features - Dimensions & Speeds Section 2 – Maintenance Tables and Diagrams
Table 2.13 Specifications & Features - Dimensions & Speeds

SJ46 AJ+ ANSI/CSA SJ46 AJ CE & AS SJ51 AJ CE & AS
Height & Reach
Working Height 15.93 m 52' 3-1/4" 16.10 m 17.55 m
Platform Elevated Height 14.10 m 46' 3-1/4" 14.10 m 15.55 m
Drive Height Driveable at all heights
Horizontal Reach - Maximum 7.54 m 24' 8-3/4" 7.54 m 9.03 m
Horizontal Reach at Max Height 2.47 m 8' 1" 2.47 m 2.86 m
Tailswing 0 0 0 0
Up and Over Clearance - Platform 7.53 m 24' 8-3/4" 7.53 m 7.53 m
Up and Over Clearance - Main Boom 7.45 m 24' 5-1/4" 7.45 m 7.45 m
Platform
0.76 x 1.52 m 30" x 60" 0.76 m x 1.52 m 0.76 m x 1.52 m
Platform Size
0.76 x 1.83 m 30" x 72" 0.76 m x 1.83 m 0.76 m x 1.83 m
Platform Rotation 178° 178° 178° 178°
Platform Height - Stowed 0.28 m 11" 0.25 m 0.25 m
Platform Height - Overall 1.35 m 53" 1.33 m 1.33 m
Railing Height - Platform 1.11 m 44" 1.10 m 1.10 m
Dimensional Data
Height - Stowed 2.06 m 6' 9" 2.06 m 2.06 m
Length - Stowed 6.35 m 20' 10" 6.35 m 7.10 m
Width 2.29 m 7' 6" 2.29 m 2.29 m
Wheelbase 2.03 m 6' 8" 2.03 m 2.03 m
Ground Clearance - Chassis 0.39 m 15-1/4" 0.39 m 0.39 m
Ground Clearance - Axle 0.33 m (front) 13" (front) 0.27 m (rear) 0.27 m (rear)
Axle Oscillation 0.09 m 3"-5/8 0.09 m 0.09 m
Turning Radius - Inside 1.50 m 4' 11-1/4" 1.50 m 1.50 m
Turning Radius - Outside 4.34 m 14' 3" 4.34 m 4.34 m
Turret Rotation 355° 355° 355° 355°
Lift Capacity
Max Lift Capacity without attachment 300 kg 660 lb 227 kg 227 kg
Max Persons without Attachment 2 2 2 2
Max Lift Capacity with attachment 272 kg 600 lb 227 kg 227 kg
Max Persons with Attachment 1 1 2 2
Jib
Jib Length - Stowed 1.42 m 55-3/4" 1.42 m 1.42 m
2041AD

45
Section 2 – Maintenance Tables and Diagrams Specifications & Features - Dimensions & Speeds
Table 2.13 Specifications & Features - Dimensions & Speeds

SJ46AJ ANSI/CSA SJ46AJ CE & AS SJ51AJ CE & AS
Performance & Speeds
Gradeability - Maximum 40% 40% 40%
7.7 km/h (Deutz D2011) 7.7 km/h (Deutz D2011)

Drive Speed - Stowed/Low Torque 7.7 km/h 4.8 mph
4.0 km/h (Deutz D2.2) 4.0 km/h (Deutz D2.2)
2.9 km/h (Deutz D2011) 2.9 km/h (Deutz D2011)
Drive Speed - Stowed/High Torque 2.9 km/h 1.8 mph
1.3 km/h (Deutz D2.2) 1.3 km/h (Deutz D2.2)
Drive Speed - Elevated 0.58 km/h 0.36 mph 0.58 km/h 0.58 km/h
Turret Rotation 70-90 seconds 90-110 seconds 90-110 seconds
Platform Rotation 5-9 seconds 15-25 seconds 15-25 seconds
26-32 seconds (CE) 26-32 seconds (CE)

Boom Up 29-32 seconds
23-29 seconds (AS) 23-29 seconds (AS)
26-32 seconds (CE) 26-32 seconds (CE)
Boom Down 27-30 seconds
23-29 seconds (AS) 23-29 seconds (AS)
Boom Extend 10-16 seconds 8-14 seconds 12-18 seconds
Boom Retract 25-30 seconds 16-21 seconds 23-29 seconds
Riser Up 24-30 seconds 23-29 seconds 23-29 seconds
Riser Down 30-35 seconds 28-34 seconds 28-34 seconds
Jib Up 18-24 seconds 34-44 seconds 34-44 seconds
Jib Down 10-16 seconds 18-28 seconds 18-28 seconds
Weight
6 500 kg (CE)
Weight with Foam Tires - No Options 6 000 kg 13,200 lb 7 300 kg
6 400 kg (AS)
Electrical
System Voltage 12 volt DC 12 volt DC 12 volt DC
Battery Type Lead / Acid Lead / Acid Lead / Acid
2041AC-1

46
Engine Specifications Section 2 – Maintenance Tables and Diagrams
Table 2.14 Engine Specifications

SJ46 AJ+, SJ46 AJ & SJ51 AJ
RPM Settings 900 Low / 1600 / 2600 High
Horsepower @ 2600 rpm (intermittent) 55.4 kW / 75 hp
Fuel Type Diesel
Deutz TD2.9L
Fuel Tank Capacity 47 gal (170.3 L)

Standard Oil Factory Fill 0°F to 115°F (-18°C to 45°C) SAE 15W-40 API CF/CG/CH-6
Cold Lube Oil Option -20°F to 90°F (-29°C to 32°C) SAE 0W-30 API CF/CG/CH-6
Arctic Lube Oil Option -40°F to 115°F (-40°C to 45°C) SAE 0W-40 API CF/CG/CH-6
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)
Lube Oil Sump Capacity 2.64 gal (10.0 L)
Horsepower @ 2300 rpm (intermittent) 18.4.4 kW / 25 hp
Fuel Type Diesel
Deutz D2.2

Standard Coolant -40°F to 115°F (-40°C to 45°C) Delo 50/50 Extended Life Coolant
Coolant Capacity 2.75 gal (10.4 L)
Horsepower @ 2600 rpm (intermittent) 48 kW / 65 hp
Deutz D2011
Fuel Type Diesel

Cold Lube Oil Option -20°F to 90°F (-29°C to 32°C) SAE 0W-30 API CF/CG/CH-6
Arctic Lube Oil Option -40°F to 115°F (-40°C to 45°C) SAE 0W-40 API CF/CG/CH-6
Gross Intermittent HP 45.5 kW / 61 Hp
Kubota WG2503
Fuel Type Gasoline/Propane

Standard Lube Oil -40°F to 115°F (-40°C to 45°C) SAE 5W-30 API CF/CG/CH-6
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)
Lube Oil Sump Capacity 2.5 gal (9 L)
2042AA

47
Section 2 – Maintenance Tables and Diagrams Reach & Dimension Diagrams - SJ46 AJ+ ANSI/CSA
Table 2.15 Reach & Dimension Diagrams - SJ46 AJ+ ANSI/CSA

METERS (FEET)
16.76
(55)
15.24
(50)
13.72
(45)
12.19
(40)
10.67
(35)
9.14
(30)
7.62
(25)
6.10
(20)
4.57
(15)
3.05
(10)
1.52
(5)
-1.52
(-5)
-3.05
(-10)
-3.05 -1.52 0 1.52 3.05 4.57 6.10 7.62 9.14 10.67
(-10) (-5) (5) (10) (15) (20) (25) (30) (35)
1.52 m/1.83 m
[60 in/72 in]
175°
0.76 m
[30 in]
2.47 m
[8 ft 1 in] C
7.54 m
A
[24 ft 8.75 in]
8.33 m A 1.14 m C 0.08 m
[23 ft 4 in] [45 in] [3.2 in]
A
75°
15.93 m 2.29 m
[52 ft 3.25 in] [7 ft 6 in]
14.10 m
B 1.50 m
75°
[46 ft 3.25 in] [4 ft 11.25 in]
B
2.7 m
[106.5 in]
70°
43.716
25.404
6.500
1.42 m
7.53 m [55.75 in]
7.45 m
[24 ft 8.75 in]
[24 ft 5.25 in]
6.35 m
[20 ft 10 in]
5.15 m
[16 ft 10 in]
4.34 m
[14 ft 3 in ]
355°
2.06 m
[6 ft 9 in] D
C
2.03 m B E
[6 ft 8 in]
A A 0.33 m B 0.39 m C 1.11 m D 1.35 m E 0.28 m
[13 in] [15.25 in] [44 in] [53 in] [11 in]

48
Reach & Dimension Diagrams - SJ46 AJ CE & AS Section 2 – Maintenance Tables and Diagrams
Diagram 2.16 Reach & Dimension Diagrams - SJ46 AJ CE & AS

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)
-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)

49
Section 2 – Maintenance Tables and Diagrams Reach & Dimension Diagrams - SJ51 AJ CE & AS
Diagram 2.17 Reach & Dimension Diagrams - SJ51 AJ CE & AS

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)
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)

50
Axle Oscillation Diagram Section 2 – Maintenance Tables and Diagrams
Table 2.18 Axle Oscillation Diagram
WARNING
Do not raise the platform in work mode if the MEWP it is not on a firm level surface.
Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max.
Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max.
Axle oscillation locked (work mode) - drive speed 0.8 km/h (0.5 mph) max.

51
Notes

52
Section 3 – System Component
Identification and Schematics

53
Section 3 – System Component Identification and Schematics Electrical Symbol Chart
Table 3.1 Electrical Symbol Chart
CIRCUITS CROSSING
NO CONNECTION TT HOURMETER KEY SWITCH LIMIT SWITCH
CIRCUITS CAM OPERATED

LIGHT FOOT SWITCH
CONNECTED LIMIT SWITCH
HYDRAULIC LIMIT SWITCH

BATTERY TOGGLE SWITCH
VALVE COIL N.O
PROPORTIONAL ANGLE LIMIT SWITCH

GROUND HYDRAULIC TRANSDUCER N.O HELD
VALVE COIL & TILT SWITCH CLOSED
ELECTRIC TEMPERATURE LIMIT SWITCH

FUSE M MOTOR SWITCH N.C.
CIRCUIT SINGLE POLE LIMIT SWITCH

BREAKER HORN SINGLE THROW N.C HELD OPEN
RELAY
SINGLE POLE
VOLT METER
V PUSH BUTTON DOUBLE THROW BEEPER
RELAY
DOUBLE POLE
CAPACITOR ROTARY SWITCH DOUBLE THROW DIODE
RELAY
DOUBLE POLE
EMERGENCY SINGLE THROW
POTENTIOMETER STOP BUTTON RELAY
TRIPLE POLE
RESISTOR DOUBLE THROW
RHEOSTAT
RELAY

54
Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics
Table 3.2 Hydraulic Symbol Chart
THREE POSITION
FIXED
FOUR WAY
LINE CROSSING
A B
SHUTTLE VALVE
PT
DISPLACEMENT
CLOSED CENTER
PUMP
OPEN PORT
VARIABLE CUSHION
LINE JOINED DISPLACEMENT PRESSURE
SWITCH CYLINDER
PUMP
MAIN LINES MOTION DOUBLE ACTING

HAND PUMP CYLINDER
Solid CONTROL VALVE
DOUBLE ACTING
PILOT LINES OIL COOLER FLOW DIVIDER DOUBLE
Dashed COMBINER RODDED
CYLINDER
HYDRAULIC COUNTER BRAKE

VELOCITY FUSE
TANK BALANCE VALVE CYLINDER
SPRING APPLIED
HYDRAULIC
VALVE COIL HYDRAULIC
FILTER WITH RELIEF VALVE RELEASED
BYPASS
BRAKE
TWO POSITION
ELECTRIC PRESSURE TWO WAY ROTARY
M MOTOR REDUCING NORMALLY ACTUATOR
VALVE OPEN VALVE
TWO POSITION
PRESSURE TWO WAY
ENGINE
TRANSDUCER NORMALLY SERVO
CLOSED VALVE
BI DIRECTIONAL
TWO POSITION
HYDRAULIC FIXED ORIFICE THREE WAY VALVE
MOTOR
VARIABLE
DISPLACEMENT ADJUSTABLE TWO POSITION
HYDRAULIC MOTOR FLOW CONTROL THREE WAY VALVE
SERIES PARALLEL THREE POSITION

FOUR WAY
B
HYDRAULIC CHECK VALVE

A B
PT
MOTOR CLOSED CENTER

A
CLOSED PORT

55
Section 3 – System Component Identification and Schematics Wire Number and Colour Chart
3.3 Wire Number and Colour Chart

Wire No. Wire Colour Wire No. Wire Colour
B+ GREEN/PURPLE 38 ORANGE/RED
0 WHITE 39 BLACK/RED
1 PURPLE/BLACK 40 BLUE/RED
2 WHITE 41 BLUE/PURPLE
3 GREEN/PURPLE 42 PINK
4 RED/YELLOW 45 YELLOW/ORANGE
5 PURPLE 49 GREEN/RED
7 RED 55 YELLOW/PURPLE
9 YELLOW 57 BROWN/GREEN
10 BLUE/WHITE 59 YELLOW/BLUE
11 WHITE/ORANGE 65 YELLOW/PINK
12 RED/BLACK/YELLOW 68 GREY
13 ORANGE 74 GREEN/GREY
14 BLACK 76 BROWN/BLUE
15 BLUE 77 BROWN/GREY
16 WHITE/BLACK 85 GREY/BLUE
17 BLUE/GREEN 108 YELLOW/BROWN
20 ORANGE/BLUE 118 PURPLE/PINK
21 WHITE/RED 119 PURPLE/YELLOW
23 BLACK/WHITE 120 GREY/BROWN
24 BLUE/BLACK 121 GREY/RED
26 BLUE/YELLOW 122 GREY/YELLOW
28 GREEN 128 BLACK/YELLOW
29 GREY/ORANGE(BLACK) 165 PINK/BLACK
30 RED/GREEN CANH BLACK
31 RED/WHITE CANL WHITE
32 GREEN/BLACK CAN2H(C-OPEN) YELLOW
33 GREEN/WHITE CAN2L(C-OPEN) GREEN
34 ORANGE/BLACK CANH(J1939) BLACK
35 ORANGE/WHITE CANL(J1939) WHITE
36 RED/PURPLE CANH WHITE
37 WHITE/RED/BLACK CANL BLACK
This table is a wire number/colour reference for all electrical drawings and schematics. 2178AA
All wire numbers retain their original colour coding; for example if wire 7 is red, wires 7A, 7B,
and 7C are also red.

56
Hydraulic Parts List Section 3 – System Component Identification and Schematics
3.4 Hydraulic Parts List

Index Skyjack
Description
No. Part No.
2H-21A 166039 VALVE (Dump)
2H-42 231438 VALVE, Proportional
3H-21 195036 VALVE, Control (Load Circuit)
3H-26 159827 VALVE, Control (Brake Release)
3H-38 166037 VALVE, Control (Boom Retract)
3H-39 166037 VALVE, Control (Boom Extend)
3H-45A 159827 VALVE, Control (2 Speed Motor)
3H-65 159827 VALVE, Control (Axle Lockout)
3H-85 168448 VALVE, Generator Bypass (3.5kW Generator)
3H-85-1 N/A VALVE, Generator (12kW Generator Option)
3H-85-2 N/A VALVE, Generator (12kW Generator Option)
3H-165 159827 VALVE, Control (Differential Lock)
4H-13 166041 VALVE, Control (Main Boom Lift Down)
4H-14 166041 VALVE, Control (Main Boom Lift Up)
4H-15 N/A VALVE, Control (Drive Pump Control)
4H-16 N/A VALVE, Control (Drive Pump Control)
4H-23A 158186 VALVE, Control (Steering Left)
4H-24A 158186 VALVE, Control (Steering Right)
4H-30 166041 VALVE, Control (Riser Down)
4H-31 166041 VALVE, Control (Riser Up)
4H-32 166041 VALVE, Control (Turret Rotate Left)
4H-33 166041 VALVE, Control (Turret Rotate Right)
4H-34 166036 VALVE, Control (Jib Down)
4H-35 166036 VALVE, Control (Jib Up)
4H-36 166036 VALVE, Control (Platform Rotate Left)
4H-37 166036 VALVE, Control (Platform Rotate Right)
4H-40 166036 VALVE, Control (Platform Level Down)
4H-41 166036 VALVE, Control (Platform Level Up)
C1 218750 CYLINDER (Jib)
C2 148712 CYLINDER (Fly Boom) (46AJ)
C3 148711 CYLINDER (Main Boom Lift)
C4 148715 CYLINDER (Platform Level, Master)
C5 148716 CYLINDER (Platform Level, Slave)
C6 148710 CYLINDER (Riser Lift)
C7 148710 CYLINDER (Riser Lift)
C8 N/A CYLINDER (Steer)
C9 212871 RAM (Axle Lockout)
C10 212871 RAM (Axle Lockout)
C11 148713 CYLINDER (Fly Boom) (51AJ)
C12 N/A CYLINDER (Brake)
C13 N/A CYLINDER (Differential Lock)
CB1 212872 VALVE, Counterbalance (Axle Lockout)
CB2 212872 VALVE, Counterbalance (Axle Lockout)
CB3 220533 VALVE, Counterbalance (Swing Drive)
CB4 220533 VALVE, Counterbalance (Swing Drive)

57
Section 3 – System Component Identification and Schematics Wire Number and Colour Chart

Index Skyjack
Description
No. Part No.
CB5 149488 VALVE, Counterbalance (Riser Down)
CB6 149488 VALVE, Counterbalance (Riser Down)
CB7 149228 VALVE, Counterbalance (Platform Level, Slave)
CB8 149228 VALVE, Counterbalance (Platform Level, Slave)
CB9 152326 VALVE, Counterbalance (Boom Lift)
CB10 149228 VALVE, Counterbalance (Fly Boom Extend)
CB11 141453 VALVE, Counterbalance (Fly Boom Retract)
CB12 149372 VALVE, Counterbalance (Jib)
CB13 149372 VALVE, Counterbalance (Jib)
CB14 141399 VALVE, Counterbalance (Rotary Actuator)
CB15 141399 VALVE, Counterbalance (Rotary Actuator)
CP1 231437 PLUG, Cavity
CV1 N/A VALVE, Check (EPU)
CV2 171413 VALVE, Check (Brake Manifold)
CV3 166064 VALVE, Check (Main Control)
CV4 159817 VALVE, Check (Double, Piloted, Platform Level)
CV5 163183 VALVE, Check (Riser)
CV6 163182 VALVE, Check (Riser)
CV7 166067 VALVE, Check (LS)
CV13 N/A VALVE, Check (Generator 3.5kW)
CV14 N/A VALVE, Check (Generator 12kW)
CV15 N/A VALVE, Check (Generator 12kW)
CV16 168243 VALVE, Check (2 SPD)
DSV1 166059 VALVE, System Load Sense (Differential Sensing Valves)
DSV2 166062 VALVE, Differential Sensing (Boom Rotate)
DSV3 166063 VALVE, Differential Sensing (Riser)
DSV4 166063 VALVE, Differential Sensing (Main Lift)
DSV5 166062 VALVE, Differential Sensing (Jib/Platform Rotate)
EPU 160923 PUMP, Emergency Power Unit
F1 161932 FILTER, High Pressure
F2 161934 FILTER, Return
M1 161964 MOTOR, Drive
M2 N/A MOTOR, Swing
M3 N/A MOTOR, Generator - 3.5kW Generator Option
M4 N/A MOTOR, Generator - 12kW Generator Option
MB1 162495 MANIFOLD, Main
MB2 168642 MANIFOLD, Brake
MB3 231501 MANIFOLD, Jib
MB4 169526 MANIFOLD, Generator 12 kW
MB5 169390 MANIFOLD, Generator 3.5 kW
MB7 208620 MANIFOLD, Load Circuit

58
Wire Number and Colour Chart Section 3 – System Component Identification and Schematics

Index Skyjack
Description
No. Part No.
OC1 160800 COOLER, Oil (Oil Cooler Option)
OR1 167353 ORIFICE, Main Control (Platform Rotate)

OR2 167352 ORIFICE, Main Control (Jib)
OR3 166056 ORIFICE, Main Control (Boom Extend)
OR4 166057 ORIFICE, Main Control (Platform Level)
OR5 171420 ORIFICE, Brake Manifold (Loop Flush)
OR6 163710 ORIFICE, Riser Down (0.067”)
OR7 195033 VALVE, Needle (Load Circuit)
P1/P1A 170599 PUMP, Drive - Deutz D2.9L, Deutz D2011, Kubota, GM
P1/P1A 228717 PUMP, Drive - Deutz D2.2
P2 161963 PUMP, System
P3 162330 PUMP, System - with 12 kW Generator
PFC1 166055 CONTROL, Priority Flow (Steer)
PFC2 169407 CONTROL, Priority Flow (Generator 3.5kW)
PFC3 N/A CONTROL, Priority Flow (Generator 12kW)
PR1 168754 VALVE, Pressure Reducing
QD1 122420 DISCONNECT, Quick
RV1 N/A VALVE, Relief (Drive Pump)
RV2 N/A VALVE, Relief (Drive Pump)
RV3 N/A VALVE, Relief (Charge Pump)
RV5 N/A VALVE, Relief (EPU)
RV6 166043 VALVE, Relief (Main Control)
RV7 168975 VALVE, Relief (Boom Rotate)
RV8 166044 VALVE, Relief (Riser Down)
RV9 159809 VALVE, Relief (Platform Level)
RV10 195600 VALVE, Relief (3.5 kW Generator Option)
RV11 209466 VALVE, Relief (12 kW Generator Option)
RV12 195596 VALVE, Relief (3.5 kW Generator Option)
RV13 195035 VALVE, Relief (Load Circuit)
RV15 209468 VALVE, Relief (Load Circuit)
RV16 209466 VALVE, Relief (12 kW Generator Option)
SV1 141414 SHUTTLE VALVE, Brake Manifold (LS)
SV2 166054 SHUTTLE VALVE, Brake Manifold (M1 / M2)
SV3 N/A SHUTTLE VALVE, Swing Drive
SV4 166054 SHUTTLE VALVE, Main Manifold (Swing)
SV5 166054 SHUTTLE VALVE, Main Manifold (Riser)
SV6 166054 SHUTTLE VALVE, Main Manifold (Boom Lift)
SV7 166054 SHUTTLE VALVE, Main Manifold (Platform Level)
SV8 166054 SHUTTLE VALVE, Main Manifold (Platform Level)
V1 141436 VALVE, Control (Brake Release Override)
V2 166053 VALVE, Control (Loop Flush)
V3 159831 HAND PUMP (Brake Release)
V4 N/A VALVE, Control (Bypass Towing)

59
Section 3 – System Component Identification and Schematics Electrical Parts List
3.5 Electrical Parts List

SUPPLY (B+) (Common)
Control (B+)
CONTROL (B+)
1
Normally
Supply (B+)
3 5 4 Closed GROUND (B-)
(Common)
Contact
2
Normally Open Contact Ground (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Description
No. Part No.
01ACR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console) (ANSI)
01ACR 127131 RELAY, 12 Volt 40 Amp (Base control console - E-pump) (CE & AS)
04ACR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console)
07CR 127131 RELAY, 12 Volt 40 Amp (Base control console - E-pump/Enable)
08CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Footswitch/Starter interlock)
09CR 127131 RELAY, 12 Volt 40 Amp (Engine power on)
21CR 127131 RELAY, 12 Volt 40 Amp (Base control console - Dump valve)
27CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Tilt alarm)
45CR1 127131 RELAY, 12 Volt 40 Amp (Base control console - 2-SPD motor)
45CR2 127131 RELAY, 12 Volt 40 Amp (Base control console - 2-SPD motor controller)
49CR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console) (ANSI)
49CR 127131 RELAY, 12 Volt 40 Amp (Base control console - Horn) (CE & AS)
57ACR 127131 RELAY, 12 Volt 40 Amp (Base control console - Engine Start)
57DCR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console)
59CR 127131 RELAY, 12 Volt 40 Amp (Base control console - Overload sensor) (CE & AS)
60CR 127131 RELAY, 12 Volt 40 Amp (Base control console - System power)
78CR 127131 RELAY, 12 Volt 40 Amp (Base control console - High idle)
79CR 127131 RELAY, 12 Volt 40 Amp (Base control console - Low idle)
82CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Load sensing alarm)
165CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Differential lock)
403ACR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console - Positive air shut-off option) (ANSI)
2H-21A 159819 COIL, 12 Volt (Dump valve)
2H-34A 159821 COIL, 12 Volt (Jib enble valve)
2H-36A 159821 COIL, 12 Volt (Platform rotate enble valve)
3H-26 159827 COIL, 12 Volt (Brake valve)
3H-45 159827 COIL, 12 Volt (Motor 2-speed valve)
3H-65 159827 COIL, 12 Volt (Axle lock valve)
3H-165 159827 COIL, 12 Volt (Differential lock valve)

60
Electrical Parts List Section 3 – System Component Identification and Schematics

Index Skyjack
Description
No. Part No.
4H-13 159819 COIL, 12 Volt (Boom down valve)
4H-14 159819 COIL, 12 Volt (Boom up valve)
4H-23A 159819 COIL, 12 Volt (Right steer valve)
4H-24A 159819 COIL, 12 Volt (Left steer valve)
4H-30 159819 COIL, 12 Volt (Riser down valve)
4H-31 159819 COIL, 12 Volt (Riser up valve)
4H-32 159819 COIL, 12 Volt (Left turret rotate valve)
4H-33 159819 COIL, 12 Volt (Right turret rotate valve)
4H-34 159821 COIL, 12 Volt (Jib down valve)
4H-35 159821 COIL, 12 Volt (Jib up valve)
4H-36 159821 COIL, 12 Volt (Platform left rotate valve)
4H-37 159821 COIL, 12 Volt (Platform right rotate valve)
4H-38 159821 COIL, 12 Volt (Boom retract valve)
4H-39 159821 COIL, 12 Volt (Boom extend valve)
4H-40 159821 COIL, 12 Volt (Platform level down valve)
4H-41 159821 COIL, 12 Volt (Platform level up valve)
A1 138224 JOYSTICK (Fly boom/Turret)
A2 138225 JOYSTICK (Drive/Steer)
A3 148707 JOYSTICK (Riser boom)
AT1 149426 ANGLE TRANSDUCER
B1 144676 BATTERY, 12V (Wet)
BP1 103057 BEEPER, 4-28 VDC Slow pulsing (Platform control console)
BP2 103056 BEEPER, 7.5-16 VDC (Base control console) (ANSI/CSA & AS)
BP3 144387 ALARM, Overload (CE & AS)
CB1 117325 CIRCUIT BREAKER (15 Amp)
CI 152323 INDICATOR, Charge
DXX 102921 DIODE
FU1 138848 FUSE, 50 Amp
FS1 138230 SWITCH, Low fuel
H1 146652 HORN, 12 Volt
LS1 122007 SWITCH, Limit (Direction sensing)
LS2 111356 SWITCH, Limit (Riser down)
LS3 161582 SWITCH, Limit (Boom down)
LS4 160018 SWITCH, Limit (Fly in)
M1 706921 PUMP, Emergency
PL1 148971 LIGHT, Pilot (Engine fault)
PL2 148972 LIGHT, Pilot (Glow plug)
PL3 147229 LED BLOCK, Red (12 volts) (Base control console)
PL4 147229 LED BLOCK, Red (12 volts) (Platform control console)
PL5 138229 MODULE, Upper indicating
PL6 148971 LIGHT, Pilot (Platform control console)

61
Section 3 – System Component Identification and Schematics Electrical Parts List
Index Skyjack
Description
No. Part No.
QD1 122420 QUICK DISCONNECT (CE & AS)
R1 231426 RESISTOR, 13 mohm 1/4 W
R2 151643 RESISTOR, 250 ohm 1 W
R3 163021 RESISTOR, 120 ohm 1/2 W
R4 164859 RESISTOR, 2.2k ohm 1/2 W
R5 143952 RESISTOR, 51 ohm 2 W (Deutz D2011 and Kubota)
164858 RESISTOR, 2.1k ohm 1/2 W (Deutz D2.9L)
R6 164857 RESISTOR, 3.9k ohm 1/2 W
R7 144492 RESISTOR, 680 ohm 1 W (Deutz D2.9L)
151643 RESISTOR, 250 ohm 1 W (Deutz D2011 and Kubota)
S1 119725 SWITCH, Main power disconnect
S2 138277 KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA, AS Deutz D2011)
164949 KEYSWITCH, Base/Off/Platform (Base control) (ANSI/CSA Deutz D2.9L)
144366 KEYSWITCH, Base/Off/Platform (Base control) (CE)
S3 147053 N.C. CONTACT, Emergency stop (Base control console)
S4 147053 N.C. CONTACT, Emergency stop (Platform control console)
S5 138278 SWITCH, Ignition/emergency pump toggle (Base control console)
S6 138278 SWITCH, Ignition/emergency toggle (Platform control console)
S8 102853 SWITCH, Diagnose toggle (Base control console) (Deutz engine)
S9 124446 SWITCH, Ignition (Platform control console)
S10 115574 SWITCH, Throttle toggle (Platform control console)
S11 138721 ASSEMBLY, Footswitch
S12 138278 SWITCH, Boom up/down toggle (Base control console)
S13 102853 SWITCH, Turret rotate toggle (Base control console)
S14 102853 SWITCH, Telescope in/out toggle (Base control console)
S15 102853 SWITCH, Platform leveling toggle (Base control console)
S16 102853 SWITCH, Platform rotate toggle (Base control console)
S17 102853 SWITCH, Jib up/down toggle (Base control console)
S18 138278 SWITCH, Telescope in/out toggle (Platform control console)
S19 138278 SWITCH, Platform leveling toggle (Platform control console) (ANSI/CSA)
S20 138278 SWITCH, Platform rotate toggle (Platform control console)
S21 138278 SWITCH, Jib up/down toggle (Platform control console)
S23 147054 N.O. CONTACT, Horn (Platform control console)
S25 138278 SWITCH, Riser boom up/down toggle (Base control console)
S26 115574 SWITCH, Fuel select (Platform control console) (GM engine)
S28 148998 SWITCH, Differential (Platform control console)
S48 115747 SWITCH, Drive torque toggle (Platform control console)
SMB1-105 218381 MODULE, Master
SMB1-106 218382 MODULE, Slavew
TT1 103336 HOUR METER
X22 138576 PORT, Diagnose (Deutz engine)
X23 138574 CONNECTOR, Engine (Deutz engine)

62
Brake Manifold Components and Ports Section 3 – System Component Identification and Schematics
3.6 Brake Manifold Components and Ports
3H-65
Axle Lock Valve
3H-45
2 Speed Valve
3H-26
Brake Valve
3H-165
Differential Lock
Valve
AL
To Rotary Manifold
D
To Rotary
BRG Manifold
To Rotary
Manifold
V1 T
Brake Release To Hydraulic
Override Valve Tank
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

63
Section 3 – System Component Identification and Schematics Rotary Manifold Ports
3.7 Rotary Manifold Ports
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

64
Drive and System Pump Ports Section 3 – System Component Identification and Schematics
3.8 Drive and System Pump Ports
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

65
Section 3 – System Component Identification and Schematics Drive and System Pump Ports
3.9 Drive and System Pump Ports
For machines with the 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)

66
Drive Motor Ports Section 3 – System Component Identification and Schematics
3.10 Drive Motor Ports
L1
To Rotary Manifold
B
To Rotary Manifold
A
X1 To Rotary Manifold
To Rotary Manifold

67
Section 3 – System Component Identification and Schematics Jib Valve Ports
3.11 Jib Valve Ports
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

68
Pressure Reducing Valve Ports Section 3 – System Component Identification and Schematics
3.12 Pressure Reducing Valve Ports
1
To Rotary Manifold Port 6
3
To Hydraulic Tank
2
To Brake Manifold
2SPD Port

69
Notes

70
3.13 Main Manifold Ports
A B C D E F G H
GP1/TEST 1
TEST 3
Note: the first port name is GP2/TEST 5 V

for ANSI/CSA manifolds, LS/TEST 2
the second port name is for
CE & AS manifolds. TEST 4
ANSI/CE&AS
LB/P2
To Lift Cylinder
T/JBT
To Jib Valve
PP/JBP
X
To Jib Valve
EA/EXT
To Boom Extension Cylinder
P
EB/RET To High Pressure Filter
To Boom Extension Cylinder
PLA/PL1
To Master Cylinder AUX
To Emergency Power Unit Y
LA/P1
To Lift Cylinder
PLB/PL2
To Master Cylinder
SB/ST2 T3
RSB/S2 To Brake Manifold
To Rotary Manifold
To Riser Cylinder
RSA/S1 SA/ST1
To Riser Cylinder To Rotary Manifold Z
RA/SW1 RB/SW2
To Swing Drive Motor To Swing Drive Motor
M167494AC-1

71
3.13 Main Manifold Electrical Components
A B C D E F G H
4H-40
2H-34A Platform Leveling Valve
Jib Boom Valve 3H-38
V
CE & AS Boom Retract Valve
4H-41
Platform Leveling Valve
3H-39 4H-32
Boom Extend Valve Turret Rotate Left Valve
4H-30
Riser Down Valve
2H-36A 4H-33
Platform Rotate Valve Turret Rotate Right Valve
CE & AS
W
2H-42 4H-31
Platform Rotate Valve Riser Up Valve
ANSI/CSA
4H-24A
4H-13 Left Steer Valve
Boom Down Valve
4H-14 Y
4H-23A
Boom Up Valve Right Steer Valve
2H-21A
Dump Valve Z
M167494AC-2

72
3.13 Main Manifold Hydraulic Components
A B C D E F G H
OR2 (CE & AS) CV4 OR4

CP1 (ANSI/CSA) OR3 Check Valve
DSV5 DSV4 V
Differential Sensing Valve 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
M167494AC-3

73
3.14 Generator Control Valve and Manifold
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
LS 3H-85 X
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

74
3.15 Major Components
A B C D E F G H
Upper SCM controller SMB1-106

(inside the control box)
Platform control box
W
Serial plate
ECU
Load cell
Y
(under the platform)
Main disconnect switch

(in front of the battery) Z
Emergency power
unit Lower SCM controller SMB1-105
Base control box (inside the control box)
M68935AA

75
3.16 Main Harness and Fuel Level Switch Harness
A B C D E F G H
PIN 24 THIS CORNER PIN 1 - 13 - ORANGE PIN 13 - 38 - ORANGE/RED

PIN 2 - 14 - BLACK PIN 14 - 39 - BLACK/RED
PIN 3 - 21A - WHITE/RED PIN 15 - 40 - BLUE/RED
PIN 4 - 23A - BLACK/WHITE PIN 16 - 41 - BLUE/PURPLE Fuel Level Switch Harness V
PIN 5 - 24A - BLUE/BLACK PIN 17 - 45A - YELLOW/ORANGE
PIN 6 - 26 - BLUE/YELLOW PIN 18 - 49A - GREEN/RED
1
PIN 7 - 30 - RED/GREEN PIN 19 - 65 - YELLOW/PINK
PIN 8 - 31 - RED/WHITE PIN 20 - 108 - YELLOW/BROWN [14 GA.]
PIN 9 - 32 - GREEN/BLACK PIN 21 - 165 - PINK/BLACK SOCKET 1 - BLACK
PIN 10 - 33 - GREEN/WHITE PIN 22 - 02 - WHITE (SPLICE #1) [14 GA.] SOCKET 2 - WHITE
PIN 11 - N/U PIN 23 - 02 - WHITE (SPLICE #2) [14 GA.]
PIN 12 - 42 - PINK PIN 24 - 02 - WHITE (SPLICE #3) [14 GA.]
HORN
W
49
A
49A - GREEN/RED
02 - WHITE (SPLICE #1)
02
DIFFERENTIAL LOCK VALVE
PIN 1 - 165 PINK/BLACK
PIN 2 - 02 WHITE
1
AXLE LOCK VALVE
PIN 1 - 65 YELLOW/PINK
PIN 2 - 02 WHITE
1
108 EMERGENCY PUMP
108 - YELLOW/BROWN
BRAKE VALVE 14 GA.
1
PIN 1 - 26 BLUE/YELLOW
PIN 2 - 02 WHITE X
STEER LEFT DUMP VALVE
1
PIN 1 - 24A BLUE/BLACK PIN 1 - 21A WHITE/RED MOTOR TORQUE
1
PIN 1 - 45A YELLOW/ORANGE
1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE (SPLICE #2)
PIN 2 - 02 WHITE
STEER RIGHT
PIN 23A
1 - BLACK/WHITE
1
PIN 2 - 02 WHITE
TURRET ROTATE LEFT RISER UP

PIN 1 - 32 GREEN/BLACK
1
PIN 1 - 31 RED/WHITE
1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE

TURRET ROTATE RIGHT RISER DOWN
PIN 1 - 33 GREEN/WHITE
1
PIN 1 - 30 RED/GREEN
1

Y
PLATFORM LEVEL UP BOOM UP
PIN 1 - 41 BLUE/PURPLE
1
PIN 1 - 14 BLACK
1

PLATFORM LEVEL DOWN BOOM DOWN
PIN 1 - 40 BLUE/RED
1
PIN 1 - 13 ORANGE
1
TELESCOPE IN
PIN 1 - 39 BLACK/RED
1
PIN 2 - 02 WHITE
TELESCOPE OUT FLOW ENABLE Z
PIN 1 - 38 ORANGE/RED PIN 1 - 42
1
M149012AA_S3

76
3.17 Interface Harness - Deutz D2.9L
A B C D E F G H
TO X22
T0 RELAY T0 RELAY CONNECTOR
56ACR 76ACR
H
G
A
B
R= 120 ohm
56B
76
76A
56
56A
76B
02
54
TO BASE BOX SP105 V
105
104
09
02
ENCLOSURE TO ENGINE
SP104 HARNESS
56(FROM CB3) 103
1
56ACR 76ACR 103 103A
2
103A 56B
NOTE:
3
56A 76A
54 76B
84 56A
The relays are mounted
4
to the outside of the base 76 74 84
5
56B
control box. 09 SP09 SPCANH CANH
6
56 02
02 SP02 R= 120
7
T0 RELAY 57A SPCANL 57A
T0 RELAY W
8
76ACR CANL
56ACR
9
74
10
105
11
104
12
56B
76
56
02
56A
76A
76B
54
96 76B
1
76 96
2
81 76A
3
77(ENGINE RUN= GND)
4
68
5
X
6
CANH JMPR
7
CANL
68
8
54
9
81
10
77(ENGINE RUN= GND)
11
D09 09A
12
CONNECTOR J1 CONNECTOR J3
PIN 1 - 56 (14GA) PIN 1 - 103
PIN 2 - 103 PIN 2 - 103A
PIN 3 - 103A
PIN 4 - 84
PIN 3 - 56B (14GA)
PIN 4 - 56A Y
PIN 5 - 74 PIN 5 - 84
PIN 6 - 09 PIN 6 - CANH
PIN 7 - 02 PIN 7 - PLUGGED
PIN 8 - 57A
PIN 9 - PLUGGED
J1 SPCANH
SPCANL
J3 PIN 8 - 57A
R=120Ω PIN 9 - CANL
PIN 10 -PLUGGED PIN 10 - 74
SPL09
SPL104
SPL02
SPL105
CONNECTOR J2
SOCKET 1 - 76B
J2 D09
J4 SOCKET 2 - 96
SOCKET 3 - 76A
SOCKET 4 - PLUGGED
CONNECTOR J2 SOCKET 5 - PLUGGED
SOCKET 1 - 96 SOCKET 6 - JUMPER WITH SOCKET 7
SOCKET 2 - 76 SOCKET 7 - JUMPER WITH SOCKET 6
SOCKET 3 - 81 SOCKET 8 - 68
SOCKET 4 -77(Engine run=GND) SOCKET 9 - 54
SOCKET 5 - 68 SOCKET 10- 81
SOCKET 11- 77
Z
SOCKET 6 - PLUGGED
SOCKET 7 - CANH X22 CONN SOCKET 12 - 09A
SOCKET 8 - CANL A - 09
SOCKET 9 - PLUGGED B - 02
SOCKET 10 -PLUGGED G - 105
SOCKET 11 -PLUGGED H - 104
SOCKET 12 -PLUGGED
M218405AE

77
3.18 Interface Harness - Deutz D2011
A B C D E F G H
TO BASE BOX
T0 RELAY
56ACR
T0 RELAY
57ACR
T0 RELAY
68CR
T0 RELAY
00ACR
TO ENGINE
ENCLOSURE HARNESS
00A
02
02
02
68A
09
09
54A
68
57B
02
54A
57A
56
77
54A
56(FROM CB3) SP54A_2 54A
1
103 SP02B
02 V
2
76 00A(ENGINE RUN= GND)
3
84 57B
4
74 SP54A_3 D54A 77A
5
09 SP09 103
6
NOTE:
The relays are mounted
56ACR 57ACR 68CR 00ACR 02 SP02A SP02 76
7
to the outside of the base 09 57A 68 09 77 57A 74
8
02 02 02 00A
control box. 54A SP54A_1
9
84
9
57B 68A 104
10
54A
54A 02 SP09A 105
11
56 54A
106
12
T0 RELAY T0 RELAY T0 RELAY T0 RELAY W
96 68A
56ACR 57ACR 68CR 00ACR
1
76 SP76 96
2
CANH
3
R= 120
77(ENGINE RUN= GND) CANL
57B
54A
54A
68A
56
54A
4
57A
77
02
09
02
00A
02
02
68
09
68 11
5
11
6
CANH
7
7
CANL
8
8
9
10
11
X
12
104
106
105
09
X22
A
B
K
L
DIAG PORT
CONNECTOR J1 CONNECTOR J3
PIN 1 - 56 PIN 1 - 56
PIN 2 - 103 PIN 2 - 02
PIN 3 - PLUGGED PIN 3 - 00A(GND)
PIN 4 - 84 PIN 4 - 57B
PIN 5 - 74 PIN 5 - 77
PIN 6 - 09 PIN 6 - 103
PIN 7 - 02 PIN 7 - 76
PIN 8 - 57A PIN 8 - 74
PIN 9 - 54A PIN 9 - 84
Y
J1 D54A J3
SPL54A_1 SPL02B
SPL02A
SPL54A_2 CONNECTOR J2
SPL02
SPL09
SPL54A_3
SOCKET 1 - 68A
SOCKET 2 - 96
SOCKET 3 - CANH
SOCKET 4 - CANL
J2 SPL76
SPCANH
SPCANL
J4 SOCKET 5 - 11
R=120Ω SOCKET 6 - PLUGGED
SOCKET 7 - PLUGGED
SOCKET 8 - PLUGGED
SOCKET 9 - PLUGGED
CONNECTOR J2 SOCKET 10- PLUGGED
SOCKET 1 - 96 SOCKET 11- PLUGGED
SOCKET 2 - 76 SOCKET 12 - PLUGGED
SOCKET 3 - PLUGGED
SOCKET 4 -77(Engine run=GND) X22 CONN
Z
SOCKET 5 - 68 A - 09
SOCKET 6 - PLUGGED B - 106
SOCKET 7 - CANH K - 104
SOCKET 8 - CANL L - 105
SOCKET 9 - PLUGGED
SOCKET 10 -PLUGGED
SOCKET 11 -PLUGGED
SOCKET 12 -PLUGGED
M218415AF-1

78
3.19 Engine Interface Harness - Deutz D2.2
A B C D E F G H
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 54 76 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 55 56 58 59 60 62 63 66 67 72 77 78 79 81 83 84 86 89 91 93 94
TO ECU
CAN L-18 WH
CAN H-18 BK
103A-18 WH
56A-18 WH
201-18 WH
76B-18 WH
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
203-18 BK
K44-18 BK
K61-18 BK
200-18 BK
K82-18 BK
K85-18 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
ohm
R4=
120
SPL103
SPL202
SPLK01 SPL00
203-18 BK
202-18 WH
P4
1
V
2 TO COOLANT
204-18 RD
3 SENSOR
4
K01-12 RD
00-12 WH
D
09A-18 BK
TO ALTERNATOR
60
X17.1
59
58
57
60
59
56
58
55
57
54
56
53
55
52
K82-18 BK
51
51
K44-18 BK
202,
203,
50
50
204
49
49
K85-18 BK
P4
47
46
09A
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
P5
39
36
A23,
A35,
A45
A35-18 BK
35
36
34
34
00
31
33
09A
P6
30
30
A29-18 BK A29-18 BK
29
27
86C
A28-18 BK A28-18 BK
28
24
86B
A27-18 BK A27-18 BK
29
27
SPL09A
A26-18 BK A26-18 BK
X17.1 - 62 PIN
26
25
D2.1 - 60 PIN A25-18 BK A25-18 BK
00
31
25
TO ENGINE
B-
TO ECU A24-18 BK A24-18 BK
22
24
00
A23-18 BK
B+
23
18
B-
K61-18 BK
X
22
17
B+
21
16
A20-16 WH A20-16 WH
20
48
A19-16 BK A19-16 BK
19
47
P7
(30A)
17
12
A15-18 BK
11
15
B+
10
14
86B
13
B+
8
12
7
11
6
P3
200,
201
10
5
P8
(40A)
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
00 A38-18 RD A38-18 RD
38
1
A53-18 RD A53-18 RD
53
9
56B
A52-18 BK A52-18 BK
52
13
A37-18 WH A37-18 WH
Y
37
14
A48-16 BK A48-16 BK
48
42
SPL202
A18-16 WH A18-16 WH
37
18
A33-16 BK A33-16 BK
SPL203
33
62
A16-16 WH A16-16 WH
35
16
A05-16 BK A05-16 BK
20
P2
A04-16 WH A04-16 WH
19
4
46
40
SPL103
41
3
A32-16 BK A32-16 BK
32
38
A02-16 WH A02-16 WH
61
2
P8 P7
1
86B-10 RD
40A
30A
B+-10 RD
P1
SPL09A
SPLK01
SPL00
CAN L-18 WH
CAN H-18 BK
103A-18 WH
76B-18 WH
202-18 WH
201-18 WH
56A-18 WH
105-18 WH
76A-18 BK
09A-18 BK
86C-10 RD
200-18 BK
K22-18 BK
56B-14 RD
A15-18 BK
57A-16 BK
86C-10 RD
99-18 WH
81-18 WH
77-18 WH
86B-10 RD
56B-14 RD
103-18 BK
104-18 BK
09A-18 BK
00-10 WH
74-18 WH
00-14 WH
00-12 WH
00-10 WH
00-18 WH
00-14 WH
00-18 WH
90-18 BK
09-16 BK
54-18 BK
B+-10 RD
B+-12 RD
A23-18 BK
A35-18 BK
A45-18 BK
Z
D2.1
D2.2
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 1 2 3 4
(+) (-) B- B- B+ 85 86 87 30
P1 P3 P2 P6 P5
TO FUEL PUMP TO BATTERY TO CTRL PNL TO WATER SENSOR TO CTRL PNL TO COOLING FAN TO COOLING FAN RELAY TO PRE-HEAT
M224673AF-3

79
3.20 Interface Harness - Kubota
A B C D E F G H
TO BASE BOX TO ENGINE

ENCLOSURE HARNESS
1
V
2
34
5
6
1
68
2
7
57A
3
8
11
4
76
5
6
W
7
8
1
9
76
2
00A
10
3
CANH
11
00A(ENGINE RUN= GND)
CANL
12
68
5
11
6
CANH
7
CANL
CONNECTOR J1
8
CONNECTOR J3
PIN 1 - PLUGGED
SOCKET 1 - PLUGGED
PIN 2 - PLUGGED
PIN 3 - PLUGGED
SOCKET 2 - 68 X
SOCKET 3 - 57A
PIN 4 - PLUGGED
SOCKET 4 - 11
PIN 5 - PLUGGED
SOCKET 5 - 76
PIN 6 - PLUGGED
SOCKET 6 - PLUGGED
PIN 7 - PLUGGED
SOCKET 7 - PLUGGED
PIN 8 - 57A
SOCKET 8 - PLUGGED
PIN 9 - PLUGGED
SOCKET 9 - PLUGGED
PIN 10 -PLUGGED
SOCKET 10- 00A
PIN 11 -PLUGGED
SOCKET 11- CANH
PIN 12 -PLUGGED
SOCKET 12 - CANL
J1
Y
J3
J2
CONNECTOR J2
SOCKET 1 - PLUGGED
SOCKET 2 - 76
SOCKET 3 - PLUGGED
SOCKET 4 -00A(Engine run=GND)
SOCKET 5 - 68
SOCKET 6 - 11
SOCKET 7 - CANH
Z
SOCKET 8 - CANL
SOCKET 9 - PLUGGED
SOCKET 10 -PLUGGED
SOCKET 11 -PLUGGED
SOCKET 12 -PLUGGED
M218377AA

80
3.21 ECU Engine Wiring Diagram - Deutz D2011
A B C D E F G H
00A
02
02
1 1 1 1 1
PIN 1 - 02 - WHITE 11
PIN 2 - 106 - GREEN/PINK 54A
PIN 3 - 96 - WHITE/GREY 54A
PIN 4 - 76 - BROWN/BLUE
PIN 5 - 74 - GREEN/GREY
57C W
PIN 6 - PLUGGED 74
PIN 7 - PLUGGED 76
PIN 8 - PLUGGED 77
PIN 9 - PLUGGED 84
PIN 10 - 105 - GREEN/BROWN
PIN 11 - 104 - GREEN/ORANGE
PIN 12 - CAN H PIN 1 - 77 - BROWN/GREY 90
PIN 13 - CAN L PIN 4 - 57C - BROWN/GREEN 96 X
PIN 14 - 54A - PURPLE/RED PIN 6 - 02 - WHITE
PIN 15 - 84 - WHITE/BLACK/PURPLE PIN 10 - 11 - WHITE/ORANGE
PIN 16 - PLUGGED PIN 11 - 00A - WHITE 99
PIN 17 - 103 - BLACK/PURPLE PIN 12 - 54A - PURPLE/RED
103
PIN 18 - 99 - BLACK/GREY
PIN 19 - PLUGGED 104
PIN 20 - PLUGGED
105
PIN 21 - 90 - RED/GREY
PIN 22 - PLUGGED 106
PIN 23 - JUMPER TO PIN 24 Y
PIN 24 - JUMPER TO PIN 23 CAN H TWIST WITH CAN L
PIN 25 - PLUGGED CAN L TWIST WITH CAN H
M138708AE

81
3.22 Glow Plug Harnesses - Deutz D2.9L
A B C D E F G H
CONNECTOR J5
PIN 1 - 11C
PIN 2 - 11A
V
PIN 3 - AA
PIN 4 - PLUGGED
8 AWG
100
03 03 11B
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

82
3.23 Glow Plug Harnesses - Deutz D2011
A B C D E F G H
TO AIR BOX
V
LEFT CYLINDER
RELAY
SOCKET
DETAIL
W
CENTER CYLINDER RIGHT CYLINDER
SOCKET #87
54A
11
X
BASE CONTROL
BOX TERMINAL
BLACK - 54A
WHITE - 11
STRIP
03
6 AWG
TO ENGINE STARTER
Z
M148653AA1

83
3.24 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

84
3.25 Platform Control Cables - CE & AS
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

85
3.26 Limit Switch Connections - ANSI/CSA
A B C D E F G H
121
122
29A
09
09
09
09
09
17
29
59
Base Control Box
Terminal Strip
Black (09) Black/White (17) Black (09) Black/White (29A) Black (09) Black/White (59) Black (29) Black/White (29A)
LS1 - Direction Sensing LS2 - Fly Stowed Limit LS3 - Main Boom LS6 - Riser Stowed
Limit Switch Switch Limit Switch Limit Switch
M68651AA

86
3.27 Limit Switch Connections - CE & AS
A B C D E F G H
W
29A
29A
29
29
59
09
09
09
17
BLK/WHT
BLACK
WHITE
BLACK
BLACK WHITE BLACK WHITE
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

87
3.28 Load Sensing Cable Connections - CE & AS
A B C D E F G H
3
2
24
23
22
21
20
19
18
17
16
15
14
13
24P-MALE
'B' PLUG
8
D11
W
12
11
10
3
4
5
9
2
6
8
7
1
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
X
GREEN/YELLOW
4P-MALE 4P-FEMALE 3P-FEMALE

PLATFORM CONTOL BOX WIRING 4" PIGTAIL
TYP.
Z
M152502AA

88
3.29 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
M152361AA_S3

89
3.30 Flashing Amber Light Connections
A B C D E F G H
20
02
BLACK - 20 WHITE-02
CONTROL COMPARTMENT BASE CONTROL BOX LAYOUT Y
TO LAMP
1
CONNECTOR
M148528AA_S3

90
3.31 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 Siren W
07C
MIL
60 60A NEW DIODE D09-1
07B 07D
7DCR - Kill Engine
07C
Delay on Timer
D07D BASE CONTROLS MODIFICATION -
07C 07D
PLATFORM CONTROLS MODIFICATION - All Models Models with Deutz D2.9 or TD2.9 Engines X
AT1
12A @ START/E-pump 12A 12A ANGLE TRANSDUCER
BASE TOGGLE SW. (WAS 09) & TILT SWITCH
TO 24 POLE PLUG "B"

Y
12A @ START/E-pump 12A 12A 161 (PINK/WH)
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

91
3.32 SGE Connections - ANSI/CSA
A B C D E F G H
LEGEND VIEW V
04- BLACK SECTION A
61- WHITE
04- BLACK
W
61- WHITE
A
X
PLATFORM
Y
M231422AA_SGE

92
3.33 Moba Load Cell Connections - ANSI/CSA
A B C D E F G H
LEGEND
02- BLACK & BLUE V
04- RED & YELLOW VIEW
CANH- PUR & WHITE SECTION A
CANL- BROWN & GREEN
BLACK
W
BLUE
RED
YELLOW
PURPLE A
WHITE BROWN
GREEN
PLATFORM
M231422AA_Moba

93
3.34 Footswitch Connections - ANSI/CSA
A B C D E F G H
VIEW V
SECTION A
LEGEND
04- BLACK
08A- WHITE
04- BLACK
08A- WHITE
X
A
PLATFORM Y
M231422AA_FS

94
3.35 CANbus Cable Connections - ANSI/CSA
A B C D E F G H
VIEW
SECTION B
CANL - WHITE WIRE

W
A
CANH - BROWN WIRE
PLATFORM
VIEW
SECTION A X
BASE
B
Y
Z
CAN2H - BROWN WIRE
CAN2L - WHITE WIRE
M231421AA_CAN

95
3.36 Power Cable Connections - ANSI/CSA
A B C D E F G H
V
02- WHITE
04- RED
07A- BLK
VIEW
SECTION B
49- GREEN
A
PLATFORM
BASE
B
VIEW Y
SECTION A
Z
07A- BLK
49- GRN
04- RED
02- WHITE
M231421AA_PWR

96
3.37 Oil Cooler and 3.5 kW Generator Base Control Box 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-
12 24
PLUG B
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
1
CONNECTOR
TO GENERATOR
1
TO COOLER FAN
SOLENOID VALVE
1
CONNECTOR
00 INSTALL UNDER COOLER MOUNTING BOLT
M152418AB_148596AB

97
3.38 Generator (3.5 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
04A
85 57A
02
57A
85
12 24
11 23
10 22
9 21
8 20
7 19
6 18
5 17
4 16
3 15
2 14
1 13
CBL
'D'
Y
04A
02
13 1
14
15
16
17
18
19
20 8
21 9
22 10
23 11
24 12
CBL
'C'
7
2
6
3
4
5
Z
M152583AA

98
3.39 Oil Cooler and 12 kW Generator Base Control Box Wiring
A B C D E F G H
Oil Cooler Wiring 12 kW Generator Wiring V

A
CONNECT
21B TO PIN 21,
CONNECTOR B
01CR 49CR
03
20A 03B
86CR
W
57ACR 79CR
03B
86A
86
TO TERMINAL SECTION A-A
BLOCK 85
A
SEE TOP VIEW
RELAY SOCKET
09
09
TO TERMINAL TO TERMINAL
X
BLOCK ‘09’ BLOCK 85
TO TERMINAL
BLOCK 02
TO EMERG. PUMP
POWER STUD 03 TO GENERATOR
SOLENOID
VALVES
Y
TO TEMPERATURE SWITCH
1
CONNECTOR
86A
1
TO COOLER FAN
02 (existing)
CONNECTOR
86
00
03B
INSTALL UNDER COOLER MOUNTING BOLT
TOP VIEW
RELAY SOCKET
M152418AC_M169999AB

99
3.40 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
04A
85 57A
02
57A
85
12 24
11 23
10 22
9 21
8 20
7 19
6 18
5 17
4 16
3 15
2 14
1 13
CBL
'D'
Y
04A
02
13 1
14
15
16
17
18
19
20 8
21 9
22 10
23 11
24 12
CBL
'C'
7
2
6
3
4
5
Z
M169581AC

100
3.41 12kW Generator Electrical Connections
A B C D E F G H
GENERATOR WIRING DIAGRAM (REF)
V
LOCATED ON PLATFORM
Z G
GREEN 8 GA WHITE 8 GA W
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

101
3.42 Load Circuit Wiring - SJ46 AJ+
A B C D E F G H
11 (BLACK)
02 (WHT)
CAN2H
CAN2L
07A
CANH
CANH
121
CANL
CANL
122
165
09
09
09
54A
02
02
02
02
09
11
04
09
17
20
29
49
55
68
59 Y
11 (BLACK)
02 (WHT)
CONNECT TO LOAD
CIRCUIT SOLENOID Z
1
M218991AA

102
3.43 Hydraulic Schematic - ANSI/CSA
A B C D E F G H I J K L M N O
C7 C6
RISER RISER
CYLINDER CYLINDER
SAE 04
C5 C1
PLATFORM LEVELING JIB LIFT
SLAVE CYLINDER CYLINDER
RA2
BOOM ROTATE
SWING DRIVE 2.5 2.5 C4 C3
C2/C11
R
1.75 1.75 MASTER MAIN BOOM LIFT
CYLINDER CYLINDER FLY BOOM EXTENSION
36.2 36.2 CYLINDER
RA1
CV1 M2 PLATFORM ROTARY
ACTUATOR
RV9
RELIEF VALVE 3.25 2.5
2500 PSI 1.5 1.6
11.63 29.5
CB4 CB3 4.0 2.5 CB14
500 PSI 500 PSI 3.75 3 1.5 CB15
1.5 60 175 3300 PSI 3300 PSI
12.06 CB8 CB7 3:1 3:1 CB13 CB12
CB5 3000 PSI 3000 PSI 3000 PSI 3000 PSI
CB6 3500 PSI 4.5:1 4.5:1 1.5:1 1.5:1
EPU 3500 PSI 1.5:1
1.5:1 SAE 06 CB11 CB10
EMERGENCY 1000 PSI 3000 PSI
POWER UNIT 3:1 4.5:1
SAE 06
SAE 06
12VDC
MOTOR M SV3
SAE 04
SAE 04
CB9
SAE 04
SAE 04
SAE 04
SAE 04
4000 PSI
OR6 3:1 S
SAE 08
CV5
BULKHEAD #1 TOP OF FLYBOOM - AT TIP
CV6
SAE 06
1A 1B 2A 2B
T3 4H-37 4H-36 4H-35 4H-34
RIGHT LEFT UP DOWN
SAE 04
SAE 04
SAE 06
SAE 06
SAE 04
SAE 04
SAE 04
SAE 04
SAE 04
SAE 06
SA SB RA RB RSA RSB PLA PLB LA LB EA EB P T
P1
SV8
PROVISIOIN T
PROVISIOIN FOR
FOR ORIFICE MB3 JIB LIFT & PLATFORM ROTATE
ORIFICE PLUG MANIFOLD
RV8 RV9 PLUG 1/16-27
POWER TRACK CARRIER ASSEMBLY

SV4 2750 SV5 2750 SV6 1/16-27 NPTF
MB2 BRAKE MANIFOLD NPTF
PSI PSI
CV4 3H-38
BOOM
RET
T
SV2 CP1
M1 M2
SV7
V2
LOOP FLUSH
3H-39
BOOM 2H-42
VALVE 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
SAE 04
SAE 04
SAE 04
SAE 04
PR1 PFC1 4H-41 4H-40
UP DOWN
n 0.073"
PRESS.
OR3
OR5 REDUCING DSV2 DSV3 DSV4 DSV5
VALVE AUX
500 PSI OR4
RV7
1750
CV2
GP1
QD1
PSI
U
CE ONLY
P
CV3
TEST4 CV7 CV8
CV9 CV10
CV11 CV12
DSV1
2H-21A RV6
DUMP 3100
T1 PSI
3H-165 3H-65
D AXLE AL
DIFF LOCK SV1
VALVE LOCKOUT
VALVE LS T2
T3 TEST3 GP2 LS MB1 MAIN MANIFOLD
3H-26 SAE 12 SAE 04

3H-45A
BRAKE
2 SPEED ?
2SPD
VALVE
VALVE
?
4.7
V
C8
FRONT AXLE
V1 STEERING CYLINDER
BRAKE SAE 08 SAE 04
RELEASE
V3 OVERRIDE
BRAKE BRG
HAND
PUMP SAE 04
?
?
?
BR
C13
REAR AXLE
DIFF. LOCK
T
SAE 04
2
1.25
2.75
C12
SAE 06
REAR AXLE SAHR

BRAKE CYLINDER
CB1
SAE 04 4800PSI
12:1
SAE 04
W
SAE 06
4.25
3.5
T4
SAE 04
C9/C10
AXLE LOCK-OUT
CYLINDERS
SAE 06
4.25
3.5
CB2
SAE 08 SAE 04 4800 PSI
12:1
M1
DRIVE MOTOR
(17.5 CC/1.07 CIR) A
(40.6 CC/2.48 CIR)
SAE 04
T6
S1 D2
B X
SAE 12
SAE 12
PUMP DISPL FILTER F1

CONTROL
SAE 04
4H-15 = REVERSE
4H-16 = FORWARD
a b
SAE 10
TP TP
Mb C2 C1 B
V4
DIESEL OR
BYPASS
VALVE Y
DUAL FUEL RV2
ENGINE 5000 PSI
T6
P1A P2
CHARGE T5
PUMP SYSTEM PUMP
SAE 12
(13.8 CC/
0.84 CIR) (10.8 CC/0.66CIR)
P1
DRIVE PUMP RV3 RV1 (7.43 GPM @ 2600 RPM) T4
(40.6 CC/ 2.48 CIR) 313 PSI 5000 PSI
(27.91 GPM @ 2600 RPM) (8.57 GPM @ 3000 RPM)
(32.21 GPM @ 3000 RPM)
T3
D1 D2 Ma S A T1
TP
T2
F2
VIEW OF TANK PORT PHYSICAL LOCATION
SAE 04 RETURN FILTER
Z
SAE 16
SAE 12
SAE 16
T5 T2 T1
M218470AD 3.43 Hydraulic Schematic - ANSI/CSA

103
3.44 Hydraulic Schematic - CE & AS
C7 C6
RISER RISER
CYLINDER CYLINDER
SAE 04
C5 C1
PLATFORM LEVELING JIB LIFT
RA2 SLAVE CYLINDER CYLINDER
BOOM ROTATE C4 C3
SWING DRIVE 2.5
1.75
36.2
2.5
1.75
36.2
MASTER
CYLINDER
MAIN BOOM LIFT
CYLINDER
C2/C11
FLY BOOM EXTENSION
CYLINDER
R
RA1
CV1 M2 PLATFORM ROTARY
ACTUATOR
RV9
RELIEF VALVE 3.25 2.5
2500 PSI 1.5 1.6
11.63 29.5
CB4 CB3 4.0 2.5 CB14
500 PSI 500 PSI 3.75 3 1.5 CB15
1.5 60 175 3300 PSI 3300 PSI
12.06 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
EPU 3500 PSI 1.5:1
1.5:1 SAE 06 CB11 CB10
EMERGENCY 1000 PSI 3000 PSI
POWER UNIT 3:1 4.5:1
SAE 06
SAE 06
12VDC
M SV3
SAE 04
MOTOR
SAE 04
CB9
SAE 04
SAE 04
SAE 04
SAE 04
4000 PSI
OR6 3:1
SAE 08
CV5
BULKHEAD #1 TOP OF FLYBOOM - AT TIP S
CV6
SAE 06
2B 1B 2A 1A
T3 4H-35 4H-35
SAE 04
SAE 04
UP DOWN
SAE 04
SAE 04
SAE 04
SAE 06
SAE 06
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
SV8
4A
MB3 JIB LIFT & PLATFORM ROTATE

OR1 OR2 MANIFOLD
RV8 RV9 0.035" 0.052"
POWER TRACK CARRIER ASSEMBLY

MB2 BRAKE MANIFOLD SV4 2750 SV5 2750 SV6
PSI PSI 3H-38
CV4
BOOM 2H-34A
RET JIB
SV2
M1 M2
T
SV7
V2
3H-39
LOOP FLUSH BOOM
VALVE
2H-36A
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
SAE 04
SAE 04
SAE 04
SAE 04
PFC1 4H-41 4H-40
PR1 UP DOWN
n 0.073"
PRESS.
OR3
OR5 REDUCING DSV2 DSV3 DSV4 DSV5
VALVE AUX
500 PSI OR4
RV7
1750
CV2
TEST1 PSI
QD1
CE ONLY
P
CV3
TEST4 CV7 CV8
CV9 CV10
CV11 CV12
DSV1 U
2H-21A RV6
DUMP 3100
T1 PSI
3H-165 3H-65
D AXLE AL
DIFF LOCK SV1
VALVE LOCKOUT
VALVE LS
T2
T3 TEST3 TEST5 TEST2 MB1 MAIN MANIFOLD
3H-26 SAE 12 SAE 04

3H-45A
BRAKE
2 SPEED ?
VALVE
VALVE ?
2SPD 4.7
WITH GENERATOR SAE 08
C8
FRONT AXLE
V1 STEERING CYLINDER
BRAKE WITHOUT GENERATOR SAE 08 SAE 04
RELEASE
V3 OVERRIDE
BRAKE
HAND
PUMP
BRG
SAE 04
V
?
?
?
BR
C13
REAR AXLE
DIFF. LOCK
T
SAE 04
2
1.25
2.75
C12
SAE 06
REAR AXLE SAHR

BRAKE CYLINDER
CB1
SAE 04 5000 PSI
10:1
SAE 04
SAE 06
4.25
3.5
T4
SAE 04
C9/C10
AXLE LOCK-OUT
CYLINDERS
W
SAE 06
4.25
3.5
CB2
SAE 08 SAE 04 5000 PSI
10:1
3H-21 M1
OR7 DRIVE MOTOR
(17.5 CC/1.07 CIR) A
F1 (40.6 CC/2.48 CIR)
PRESSURE FILTER SAE 04
T6
S1 D2
SAE 10 WITH GENERATOR B T6
P A
SAE 12
T5
T SAE 12
RV 13 P3
3250 PSI T4
10
3H-85
MB7 LOAD CIRCUIT MANIFOLD
SAE
GENERATOR
PUMP DISPL LOAD CIRCUIT OPTION
CONTROL SELECT T3
X
SAE 04
4H-15 = REVERSE
WITHOUT GENERATOR
4H-16 = FORWARD SAE 08 P2
WITH GENERATOR
SAE 10 P4
PFC2 T1
T
M3
CI UT
UI
RC
AD THO
a b
TP TP P5 CV13
LO
GEN T2
LO WI
AD
W IRC
Mb C2 C1 B
SAE 08
IT
VIEW OF TANK PORT PHYSICAL LOCATION

C
H UIT
RV10 RV12
V4 3250 PSI 400 PSI
WITH GENERATOR
RV2 BYPASS P1
5000 PSI VALVE
DIESEL OR
DUAL FUEL (4500 PSI MB5 GENERATOR CONTROL MANIFOLD
ENGINE FOR CE
D2.2 T4
ENGINE)
10
10
3.5KW GENERATOR OPTION

SAE
SAE
P1A OC1
CHARGE
P2 OIL COOLER
PUMP SYSTEM PUMP WITH GENERATOR
WITH GENERATOR
SAE 12
(13.8 CC/
RV1 0.84 CIR) (11 CC/0.66CIR)
P1 5000 PSI
DRIVE PUMP RV3 (4500 PSI (5.7 GPM @ 2000RPM)
313 PSI FOR CE P3
(40.6 CC/ 2.48 CIR) w/o 12kW GENERATOR
(20.4 GPM @ 2000 RPM) D2.2
ENGINE) DUAL SYSTEM PUMP Y
(11 CC/0.66CIR) MAIN
(14 CC/0.84CIR) 3H-85-2
(13 GPM @ 2000RPM) GENERATOR
G1 SELECT PFC3
D1 D2 Ma S A
SAE 12
TP
P1
M1 SAE 10
F2
SAE 04 G4 RETURN FILTER
WITH GENERATOR
SAE 16
SAE 12
SAE 16
M4
P2
CV14
GEN
G2
RV11 RV15 RV16
3250 PSI 400 PSI 3250 PSI SAE 08
T5 T2 T1
3H-85-1
GENERATOR
SELECT
T1
CV15
T4
Z
TM
MB4 GENERATOR CONTROL MANIFOLD
12KW GENERATOR OPTION
M220532AC 3.44 Hydraulic Schematic - CE & AS

104
3.45 Platform Control Box Wiring - ANSI/CSA
Wire Number and Colour Chart

A3 JOYSTICK A2 JOYSTICK
R
A1 P11
GLAZIER
JOYSTICK ACTIVE
04(RED) 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 24A (BLUE/BLACK) LEFT WHT/RED
233A
02
23A (BLACK/WHITE) RIGHT WHT/YEL
NOTE: ZIP TIE

DUAL FUEL READY
S20-PLTF S19-LEVEL S18-TELE S21-JIB
LOOSE END
NEAR DUAL FUEL ROTATE S
RED (+)
WHT (X)
BLU (Y)
BLK (-)
SWITCH LOCATION
04
11
HEAT SHRINK ON RING
165A
04 S28-DIFF.
41A 38A 35A
Y-SIGNAL
GROUND
POWER
X-SIGNAL
165A
04 04 04
37A
36A
04
40A 39A 34A
04 (RED/YELLOW)
PL6
BLUE
02 (WHITE)
RED
02 165B TO J13 ON CONTROLLER PIN 18 - N/U
GRN PIN 1 N/U PIN 19 - R SIG RED/GRN
PIN 2 - 55 YLW/PUR PIN 20 - N/U
GENERATOR READY PIN 3 - 577 PIN 21 - N/U
NOTE:
PIN 4 - 27A RED/BLK/WHT PIN 22 - N/U
ZIP TIE
LOOSE END
PIN 5 - N/U
T
04
85
NEAR GENERATOR
SWITCH LOCATION ECO START NOTE:
PIN 23 - 76 BRN/BLU
HEAT SHRINK ON RING
PL23 LED SHOWN FOR
REFERENCE
GLOW
S48- S10- PIN 6 - 63 GRAY/YEL PIN 24 - N/U
02
FOOTSWITCH TILT OVERLOAD MIL FUEL PIN 7 - 82 BRN/WHT PIN 25 - 08 PUR/WHT
S30-SGE 577
NOTE:
ZIP TIE LOOSE ENDS
PL9 PL8 PL10 PL7 PL6
PLUG
PL5 S6-EPUMP TORQ THROT PIN 8 - 118 PUR/PINK PIN 26 - 40A BLU/RED
S4-E STOP PIN 9 - 74A GRN/GRY PIN 27 - N/U
01 78
S23-HORN PIN 10 - 119 PIN 28 - 37A WHT/RED/BLK
04 04 04 PIN 11 - 120A
63
62 04A 57B 49 07A
PIN 29 - 36A RED/PUR
07A 04
01 45 PIN 12 - 120
04 04 PIN 30 - 165A PINK/BLK
02
02
02
27
82
02
08
02
02
76
55
74
PIN 13 - 27 RED/BLK/WHT
02
04 PIN 31 - 85A GRAY/BLU
04
02
PIN 14 - D BLK
12
10 PIN 15 - Y BLU PIN 32 - 61 GRAY/BRN
PIN 16 - X RED PIN 33 - 62 GRAY/RED
PIN 34 - N/U
S9-IGN PIN 17 - N/U
PIN 35 - 165B PINK/BLK
U
TO J11 ON CONTROLLER
PIN 1 - 04 RED/YEL
PIN 2 - 04 RED/YEL
PIN 3 - 04 RED/YEL
PIN 4 - 04 RED/YEL
PIN 5 - N/U
PIN 6 - SPARE
PIN 7 - SPARE V
PIN 8 - CANH BLK
PIN 9 - CANL WHT
PIN 10 - 02 WHT
PIN 11 - 02 WHT
PIN 12 - 02 WHT
PIN 13 - 02 WHT
PIN 14 - SPARE
J13
12 35
23
11 34
22
10 33
9
21
20
32
02 W
8 31
02
19
7 30
18
6 29
5
17
16
28
02 PIN 18 - 01A PUR/BLK
4 27 TO J12 ON CONTROLLER
3
15
14
26 02 PIN 1 - 37 WHT/RED/BLOK PIN 19 - 04A
2 25
J11 1
13
24 04 PIN 2 - 36 RED/PUR PIN 20 - N/U
04 PIN 3 - N/U PIN 21 - 38A ORG/RED
5 14
PIN 4 - N/U PIN 22 - 41A BLU/PUR
04
9
4 13
3
8
12 PIN 5 - N/U PIN 23 - N/U
2
7
6
11 63(La) La 04 PIN 6 - N/U PIN 24 - 34 ORG/BLK
1 10
02(N)
N
07A PIN 7 - N/U PIN 25 - 233 BLU/BRN
BP4 PIN 26 - 34A ORG/BLK
Lb
08A PIN 8 - N/U
X
J12 PIN 9 - N/U PIN 27 - N/U
12 35
34 PIN 10 -N/U PIN 28 - 35A ORG/WHT
11
10
23
22
34
33
35 PIN 11 -N/U PIN 29 - 78 RED/BLU
9
21
20
32 36 PIN 12 - N/U PIN 30 - 57B BRN/GRN
8 31
PIN 31 - N/U
7
19
18
30 37 PIN 13 - 35 ORG/WHT
PIN 32 - 11 WHT/ORG
PIN 14 - 08A PUR/WHT
6
5
17
29
28
61 PIN 15 - 24A BLU/BLK PIN 33 - 39A BLK/RED
16
4
15
27
CANH PIN 16 - 23A BLK/WHT PIN 34 - N/U
3 26
14
2 25
CANH PIN 17 - 45 YEL/ORG PIN 35 - N/U
120ohm
13
1 24
CANL
CANL
Y
233
233A
04
TOP
27A
118
02
02
SCREW
Z
S30
GLAZIER
BP1 TILT ALARM SWITCH BP3 OVERLOAD ALARM
3.45 Platform Control Box Wiring - ANSI/

M218376AG CSA

105
3.46 Platform Control Box Wiring - CE
A3 JOYSTICK A2 JOYSTICK R
A1
JOYSTICK 162A (YELLOW) POWER RED
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

S20-BASKET
BLU (Y) Y-SIGNAL BLUE
ROTATE S28-DIFF.
S19-LEVEL S18-TELE S21-JIB S
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
D27
D76
D74
T
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 04A 01 04
04A 04A 45 79
49 04A
02 04
U
12 10
02
S9-IGN 04
76
55
74
49
02
04
08 08B 08
D08
04
D04
60
59
60
V
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)
04
8
D11
PLUG B
04C
02
04A
08A
118
02
02
02
02
04
04
35
34
37
36
59
82
20
60
08
12
11
10
W
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
165
08A
07A
07A
23A
24A
01
10
12
13
14
20
26
30
26
35
04
36
D20B
37
165CR
04C
04C
20B
02A
20 45
X
82CR
82
02 04C
24 1
02B
04C
02
02 59 02
13 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
27A
29 6 23
R-SIG
18 65
30 7 26A
59
19 13
31 8
02
32
28
20 31
32 9
02
23A
20A
21 26
33 10 14
16
34
22
11
27 Y
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 3.46 Platform Control Box Wiring - CE

106
3.47 Platform Control Box Wiring - AS
A3 JOYSTICK A2 JOYSTICK R
A1
JOYSTICK 162A (YELLOW) POWER RED
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

S20-BASKET
BLU (Y) Y-SIGNAL BLUE
ROTATE
JUMPER(26A) JUMPER(20A)
S28-DIFF.
S19-LEVEL S18-TELE S21-JIB S
85A
02 165
26C
20A
20A
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
37
36
26C
02 165
- +
PL6
AMB
D27
D76
D74
T
02B
27A
08
02
76
55
74
60
S48- S10-
S6-EPUMP TORQ THROT
PL17
BLUE 78
S4-E STOP 01 04
02
- +
04K
04 57 S23-HORN 07A 04B
20
01
04B
04
59 08
04B 04B
04B 45 79
49
BLACK RED 02 04 U
12 10
02
S9-IGN 04
04K
02
76
55
74
49
02
04KCR
26C 20
04K
04
08
D08
V
60
59
04D
D04K
60
04 04D 59
D04
02
28
02
04HCR
04J
04G
04H
128A
128A
57A
162A
79
78
76
74
60
59
55
102
R17=22
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)
8
D11
PLUG B
26A
26A
04A
08A
118
04D
08
04
02
02
02
02
04
04
35
37
34
36
59
82
20
60
08
26C
12
11
10
3
4
9
2
6
8
7
1
26ACR
08
13
14
15
16
17
18
19
20
21
22
23
24
24P-FEMALE (A)
02
02
PLUG A
165
165
165
26B
D08-1
04G
10
11
12
1
7
8
2
9
4
5
3
34
165
165CR
31
32
33
34
35
36
37
45
65
D26A
08A
07A
07A
23A
24A
85A
102
12
01
10
12
13
14
20
26
30
26A
02A
35
D102
D85A-2
D12-1
36
D20B
82CR
82
37
04
04
02B
20B
08A
02
20
D08A
57
57
X
D57-1
02 04
24 1
02
04J
04 D04J
02 59 02
13 04
D59
25 2
27
128A
14
27CR
02
27A
26 3 17
D-SIG
15 24A
27 4 08A
X-SIG
16 20B 04G
08R
28 5 C 6
02
24
Y-SIG
17 08F
29 6 NC 04K
02
23
TIME 1
R-SIG
18 65
DELAY-ON-BREAK
RELAY
30 7 26A
NO
2
02
19
59
31 8
13
TT2
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
08
08FCR
118
02 _
02
BP1
Z
+ 60
27A
_
M232592AA 3.47 Platform Control Box Wiring - AS

107
3.48 Base Control Box Wiring - ANSI/CSA
R
CONNECTOR J4
CB's & PIN 1 - 56(fromCB3)
PIN 2 - 103
SWITCH S8 PIN 3 - 103A
PIN 4 - 84
ON LEFT PIN 5 - 74
PIN 6 - 09
SIDE OF 20 RED PIN 7 - 02
PIN 8 - 57A
BOX PIN 9 - 54A
BP2
02 BLACK PIN 10 - N/A
PIN 11 - N/A
PIN 12 - N/A
NOTE: ZIP TIE
LOOSE END
S8 NOTE:
FOR D2011 ENGINE
REPLACE 103A ON POSITION 3
S
DIAGNOSE
WITN 76 ON S8 SWITCH
76 J4
103A
CONNECTOR J5
103 SOCKET 1 - 96
103A
TT1 D57D SOCKET 2 - 76
FOR
J3 SOCKET 3 - 81 BATTERY (B+)
05-14ga S13-TUR S16-ROT J1,J2&J3
SOCKET 4 - 77(EngineRun= GND)
03 - BLACK 12 GAUGE Ă5/16"
57D
57DCR
57C
12 35 SOCKET 5 - 68
23
CONNECT TO E-PUMP POWER STUD
57A
11
10
22
34
33
SOCKET 6 - 11
9
21
32
J5 SOCKET 7 - CANH
09
09 BATTERY (B-)
10A
77 20
SOCKET 8 - CANL
10A
8 31
36B
37B
32B
33B
05 19
SOCKET 9 - PLUGGED
02
00 - WHITE12 GAUGE Ă5/16"
7 30
18
CB1
04ACR
6 29
17 SOCKET 10 -PLUGGED
5 28
CONNECT TO E-PUMP HOUSING (REAR)
07
16
SOCKET 11 -PLUGGED T
09
15A
D10 4 27
15
04A
NOTE: SOLDER RESISTOR
3
14
26
SOCKET 12 -PLUGGED
+ _
AND HEAT SHRINK
25
J1
RESISTOR D04 2
R1 13
22kµF
13Mohms
02
1 24
03
49CR
09
5 14
9
4 13
49A
03
49
8
3 12
7
2 11
6
02
1 10
01ACR
85B
00
108
03-12ga
J2
09
01
S17 S15-
00A
12 35
23
00ACR
11 34
02-14ga
-JIB LEVEL 10
9
22
21
33
32
09B
09
09B
20
34B 40B 8 31
09
19
7
18
30
D12
KEY U
10A 10A 6
5
17
29
28
16 D10B
02
41B
4 27
02 35B 3
15
26
CB2 2
1
14
13
25
24
CANH
D09
-1
15A CANL
1 13 38
13
2 14 39
HARNESS
14
3 15 40
21A
4 16 41
23
00 5 17
24
45A
49A
PLUG
MAIN 6 18
26
7 19 65
30
8 20 108
31
00-12ga 9 21 165
32
02-14GA
V
10 22
33
11 23 02-14GA
56- 14ga
S14-TELE S12-BOOM S25-RISER
1
2
12 24 02-14GA
42
38B 13B 30B Note: Use 12GA DEUTSCH
DRIVE PUMP VALVE

before splice
10A 10A 10A 24P-FEMALE

PIN 1 - 15 BLUE
3
4
56 39B 14B 31B BACK VIEW PIN 2 - 02 WHITE
CB3 PIN 3 - 02 GREEN
20A 10A
D10A
04
ADD WIRE LABEL
85 PIN 4 - 16 WHT/BLK
CONNECTOR J6
SOCKET 1 - 09B
B+
SOCKET 2 - KEY
03 SOCKET 3 - B+
OVERLOAD SOCKET 4 - 00 W
SOCKET 5 - PLUG
10A
PL20
57
10
SOCKET 6 - PLUG
03-12ga
09B SOCKET 7 - CANH
118A
02
KEY SOCKET 8 - CANL

CB4 00
J6 SOCKET 9 - 57D
SOCKET 10 - PLUG
S5-IGN CANH
CANL
SOCKET 11 - PLUG
CAN2H
CAN2L
CANH
CANH
120ohm
57D
07A
CANL
120ohm
CANL
SOCKET 12 - PLUG
121
09
09
165
09
17
59
09
09
29A
02
02
02
04
02
54A
122
68
21A
29
20
55
11
49
26
S3
E STOP
05 09 PL22 PL16 PL3 PL18 RESERVED FOR
X
10
10
LIMIT SWITCH WIRING

07
12
FUEL WIF MIL GLOW

NOEM 3 NCLB 1 NC 5
4 2 6
74
81
09
09
09
76
55
02
NOTE:
SUPP
29A NOT
07 02
CAN2H
CAN2L
CANH
CANH
07A
SHOWN
07A
07A
120ohm
CANL
120ohm
CANL
ON TERMINAL
RESERVED FOR RESISITOR
S2-KSW MISC. WIRING
PLACEMENT
(FUEL LEVEL)
Y
TILT SWITCH CONNECTION
PIN 1 - 09 YELLOW
02
BP4 PIN 2 - 28 GREEN
PIN 3 - 02 WHITE
PIN 4 - 128 BLACK/YELLOW
118A
AT1
ANGLE
TRANS.
DETAIL A
Z
M218378AH 3.48 Base Control Box Wiring - ANSI/CSA

108
3.49 Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option
R
CB's &
SWITCH S8
ON LEFT
SIDE OF 20 RED
BOX
BP2
02 BLACK
CONNECTOR J4
NOTE: ZIP TIE
LOOSE END PIN 1 - 56C
S8 NOTE:
FOR D2011 ENGINE
PIN 2 - 103 S
REPLACE 103A ON POSITION 3
PIN 3 - 103A
DIAGNOSE
WITN 76 ON S8 SWITCH
76 CB40 J4 PIN 4 - 84
PIN 5 - 74
103A
403ACR
PIN 6 - 09
03
CONNECTOR J5
02
PIN 7 - 02
56
103 SOCKET 1 - 96
TT1 PIN 8 - 57A
56C
403
SOCKET 2 - 76
103A PIN 9 - 54A
403A
FOR
J3 SOCKET 3 - 81
PIN 10 - N/A
S13-TUR S16-ROT
D57D
J1,J2&J3 NOTE:
05-14ga
BREAKER SHOWN FOR REF
SOCKET 4 - 77(EngineRun= GND)
BRING WIRE LEADS TO UPPER
PIN 11 - N/A
57D
57DCR
RIGHT CORNER OF BOX
SOCKET 5 - 68
57C
12 35
23 PIN 12 - N/A
SOCKET 6 - 11
57A
11 34
22
10 33
SOCKET 7 - CANH
9
21
32
J5
09
09 SOCKET 8 - CANL
10A
77 20
10A
8 31
36B
37B
32B
33B
05 19
SOCKET 9 - PLUGGED
02
7 30
18
CB1
04ACR
6 29
SOCKET 10 -PLUGGED
09
17
07
T
5 28
16
SOCKET 11 -PLUGGED BATTERY (B+)
15A
D10 4 27
15
SOCKET 12 -PLUGGED
04A
NOTE: SOLDER RESISTOR
AND HEAT SHRINK
3
14
26 03 - BLACK 12 GAUGE Ă5/16"
RESISTOR + _ 25
J1
D04 2
13Mohms R1 13
02
22kµF
1 24
03
49CR
09
5 14
9
4 13
49A
03 BATTERY (B-)
49
8
3 12
7
2 11 00 - WHITE12 GAUGE Ă5/16"
6
02
1 10 CONNECT TO EPUMP HOUSING (REAR)
01ACR
85B
00
0"
108
03-12ga
J2
09
01
S17 S15-
00A
12 35
23
00ACR
11 34
02-14ga
-JIB LEVEL 10
9
22
21
33
32
09
09B
09B
20
34B 40B 8 31
09
7
19
18
30
D12
KEY U
10A 10A 6
5
17
29
28
16 D10B
02
41B
4 27
02 35B 3
15
26
CB2 2
14
13
25
CANH
D09
1 24
-1
15A CANL
1 13 38
13
2 14 39
HARNESS
14
3 15 40
21A
4 16 41
23
00 5 17
24
45A
49A
PLUG
6 18
MAIN
26
7 19 65
30
8 20 108
31
00-12ga 9 21 165
32
02-14GA
V
10 22
11 23
33
02-14GA DRIVE PUMP VALVE
56- 14ga
S14-TELE S12-BOOM S25-RISER
1
2
12 24
42
02-14GA
PIN 1 - 15 BLUE
38B 13B 30B Note: Use 12GA
before splice
PIN 2 - 02 WHITE DEUTSCH
10A 10A
PIN 3 - 02 GREEN
10A 24P-FEMALE
3
4
PIN 4 - 16 WHITE/BLK
56 39B 14B 31B BACK VIEW
CB3
20A 10A
D10A
04 ADD WIRE LABEL
NOTE: ZIP TIE
WIRE CLOSE TO
85
TERMINAL STRIP
TO SOLENOID
PIN A-WHITE (408) CONNECTOR J6
PIN B-RED (403A) SOCKET 1 - 09B
B+
PIN C-BLACK (401) SOCKET 2 - KEY
03 SOCKET 3 - B+
OVERLOAD SOCKET 4 - 00 W
SOCKET 5 - PLUG
10A
PL20
57
10
SOCKET 6 - PLUG
03-12ga 09B SOCKET 7 - CANH
118A
02
KEY SOCKET 8 - CANL

00
J6 SOCKET 9 - 57D
SOCKET 10 - PLUG
S5-IGN CANH
CANL
SOCKET 11 - PLUG
CAN2H
CAN2L
CANH
CANH
120ohm
57D
07A
CANL
120ohm
CANL
SOCKET 12 - PLUG
121
09
09
165
09
17
59
09
09
02
02
02
04
02
54A
122
68
21A
29
55
11
20
49
26
S3
E STOP
05 09 S40 PL40 PL22 PL16 PL3 PL18 RESERVED FOR
LIMIT SWITCH WIRING
10
10
X
07
12
POSI POSI FUEL WIF MIL GLOW

NOEM 3 NCLB 1 NC 5
4 2 6
402
74
403A
81
09
09
09
76
02
55
02
NOTE:
07 02 02 29A NOT
07A
07A
07A
SHOWN
CAN2H
CAN2L
CANH
CANH
120ohm
ON TERMINAL
RESERVED FOR
SUPP
CANL
120ohm
CANL
MISC. WIRING RESISITOR
S2-KSW
(FUEL LEVEL) PLACEMENT
Y
403A
TILT SWITCH CONNECTION
402
403 PIN 1 - 09 YELLOW
02
02
BP4 PIN 2 - 28 GREEN
PIN 3 - 02 WHITE
118A
POSITIVE AIR SHUT OFF MODULE 10 PIN CONNECTOR PLUG

AT1
DETAIL A
PIN 1 -BLACK (401) PIN 6 -BLUE (403)
PIN 2 -EMPTY PIN 7 -WHITE (02) TO ALTERNATOR ANGLE
PIN 3 -RED (403A) PIN 8 -WHITE (408) TRANS.
PIN 4 -GREEN (402) PIN 9 -EMPTY R1=330K W
PIN 5 -EMPTY PIN 10 -YELLOW (410)
3.49 Base Control Box Wiring - ANSI/CSA

M218491AH with Positive Air Shut-Off Option

109
3.50 Base Control Box Wiring - CE Deutz D2.2
Wire Number and Colour Chart CONNECTOR (FEMALE)

DETAIL C PIN1 - 05 PURPLE
PIN2 - 77 BROWN
1 2 3
PIN3 - 01B PURPLE/BLACK
4 5 6
PIN4 - n/a CONNECTOR J1 R
PIN5 - 09F YELLOW PIN 1 - 103
PIN6 - 02 WHITE PIN 2 - 103A
PIN 3 - 56B
PIN 4 - 56A
05-14ga PIN 5 - PLUGGED
D57D 56A
PIN 6 - CAN H
56B
PIN 7 - PLUGGED
57B
PIN 8 - 57B
103A J1
00-12ga
77CR 76ACR 01ACR 21CR 45CR1 45CR2 49CR 57DCR
03-12ga
02-14ga
PIN 9 - CAN L
103
PIN 10 - 74
56 02 05
S8 09
01A
77 76A
02
76B 01A
108
02 21
21A
02 45
45A
02 45
128B
128A
02 49
49A
02 09
57A
57D
105
PIN 11 - 105
CB3 CB2 CB1 DIAGNOSE 01 76 09 162A 09 128 07 57B 104

74
PIN 12 - 104
R2=250
103A CAN H
CONNECTOR J2
SOCKET 1 - 76B
103 CAN L SOCKET 2 - PLUGGED
54 SOCKET 3 - 76A
S
103A SOCKET 4 - 99
77
J2 SOCKET 5 - 90
03 00 03 76B SOCKET 6 - JUMPER WITH SOCKET 7
99 SOCKET 7 - JUMPER WITH SOCKET 6
90 SOCKET 8 - 09
00-16ga
76A SOCKET 9 - 54 BATTERY (B+)
09A SOCKET 10 - PLUGGED
09 SOCKET 11 - 77 03 - BLACK 12 GAUGE Ă5/16"
59CR 60CR 78CR 79CR SOCKET 12 - 09A CONNECT TO E-PUMP POWER STUD
S3-E STOP S2-KSW TT1 77ACR 56ACR 162BCR OPTION SPARE
77A 56B 09 09 99A 99B
03
05 10
12
09 77 54 56A 162B 01B 02 59 02 60 02 78 02 79 02
12
07A
09 56 01A 162A 07 90 90
77A
05
01B 00
NOEM 3 NCLB 1
T
02
4 2
09F
07 02
BATTERY (B-)
07
07
00 - WHITE 12 GAUGE Ă5/16"
B+
CONNECT TO E-PUMP HOUSING
09
CONNECTOR J3
D12
SOCKET 1 - 77
SOCKET 2 - KEY
SOCKET 3 - B+
07A
D07A
12A KEY J3 SOCKET 4 - 00
SOCKET 5 - PLUG
SOCKET 6 - PLUG U
SOCKET 7 - CAN H
24P-MALE 'B'
SOCKET 8 - CAN L
SOCKET 9 - 57D
SOCKET 10 - PLUG
D59
SOCKET 11 - 20
SOCKET 12 - 26
162A
49
12 24
1
2
128A
41
128A 11 23
D162
PL2 PL1 -2 40
10 22 DEUTSCH
REFER TO 39
9 21
79
DETAIL C 38
DRIVE PUMP VALVE
GLOW FAULT 78 8 20
PLUG B
3
4
1 13 38 28
7 19
13 76
PIN 1 - 15 RED
2 14
14
39 17
74 6 18 BACK VIEW
+ - + -
3 15
21A
40 16
60 5 17 PIN 2 - 02 WHITE
41 15
V
4 16
5 17
23A
45A
59 4 16
PIN 3 - 02 GREEN
24A 3 15
09 74 09 76 6 18
26
49A 02
57A
55 2 14 PIN 4 - 16 BLACK
7 19 65 02
30 1 13
8 20 108
31
9 21 165
32
10 22 02-14GA
33
11 23 02-14GA 30
34A 165
12 24 02-14GA 26 24 12
36A 162
24A 23 11
161
23A 22 10
65
20 21 9
45
24P-FEMALE 20 14 20 8
37
36
13
12
19
18
7
6 PLUG A
35
10 17 5
34
07A-14ga 16 4
33
15 3
32
07A-14ga
01 14 2
W
31
13 1
D10A
-1
24P-FEMALE 'A'
36A
S17 S15-
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
2.1k
120
120
36
37
34A
R8=
R7=
R5=
34 34 D34 40 38
R3=680
10A 10A 10A

29A
162A
01A
10A
99B
CAN H
99A
09/161
CAN L
09
09
60/01
21
103
104
105
X
20
13
14
31
17
01
162
128
29
59
55
74
76
40
41
30
32
11
33
38
39
90
99
02
77
02
02
02
02
35 35 41 39
10A
D35
36
37
R6=3.9k
R4=2.2k
S25-RISER S12-BOOM
10
10A
57A
S13-TUR D01A
-2
09F
30 13
S5-
D09
D01A
10A 10C 10A 10C

D10A
31 14 IGN.
10C
32
33
01
12A
Y
162A
X22 CONN.
A - 09
D162
G
H
A B - 02
G - 105
162
10A 10C B
R1=5 H - 104
YEL
R9=680
AT1 WHITE
DEUTSCH
ANGLE BLACK
4
3
1
2
R10=680
TRANS. GREEN
BACK VIEW
TILT SWITCH TILT SWITCH CONNECTION Z

PIN 1 - YELLOW PIN 1 - 09 YELLOW
PIN 2 - GREEN PIN 2 - 28 GREEN
PIN 3 - WHITE PIN 3 - 02 WHITE
PIN 4 - BLACK PIN 4 - 128 BLACK/YELLOW
3.50 Base Control Box Wiring - CE Deutz
M224657AE D2.2

110
3.51 Base Control Box Wiring - CE Deutz D2011
Wire Number and Colour Chart 05-14ga

D57D
03A-14ga
00-12ga
01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR 57DCR
03-12ga
02-14ga
03
S8 01A
108
02 01
01A
00B 09
54A
02 21
21A
02 45
45A
02 45
128B
02 49
49A
02 09
57C
57D
03A 02 05
DIAGNOSE
128A
CB3 CB2 CB1 09 01 03A 162A 09 128 07 57B
76
R2=250
103
76
03 00 03
00-16ga
DEUTZ EDC
S3 HARNESS
S
BATTERY (B+)
E STOP TT1 57ACR 162BCR 59CR 60CR 78CR 79CR 03 - BLACK 12 GAUGE Ă5/16"
S2-KSW 57B 09 09 103 103
03 CONNECT TO E-PUMP POWER STUD
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 BATTERY (B-)
07
07A 12 00 - WHITE 12 GAUGE Ă5/16"
02
09F CONNECT TO E-PUMP HOUSING
07 02
B+
09
CONNECTOR J3
D12
SOCKET 1 - 77
SOCKET 2 - KEY
SOCKET 3 - B+
07A
D07A
12A KEY J3 SOCKET 4 - 00
SOCKET 5 - PLUG
SOCKET 6 - PLUG
SOCKET 7 - CAN H
SOCKET 8 - CAN L
SOCKET 9 - 57D
24P-MALE 'B' SOCKET 10 - PLUG
D59
SOCKET 11 - 20 U
SOCKET 12 - 26
162A
49
12 24
1
2
128A
41
128A 11 23
D162
PL2 -2 40
10 22 DEUTSCH
REFER TO 39
PL1 DETAIL C 38
79 9 21
DRIVE PUMP VALVE
GLOW 78 8 20
PLUG B
3
4
1 13 38 28
FAULT 2 14
13
14
39 17
76
74
7
6
19
18 BACK VIEW
PIN 1 - 15 RED
+ - + -
3 15
21A
40 16
60 5 17 PIN 2 - 02 WHITE
4 16 41 15
5 17
23A
45A
59 4 16
PIN 3 - 02 GREEN
24A 3 15
54A 74 54A 76 6 18
26
49A 02
57A
55 2 14 PIN 4 - 16 BLACK
7 19 65 02
30 1 13
8 20 108
9 21
31
32
165 V
10 22 02-14GA
33
11 23 02-14GA 30
34A 165
12 24 02-14GA 26 24 12
36A 162
24A 23 11
161
23A 22 10
65
20 21 9
20 45
24P-FEMALE 14 20 8
37
36
13
12
19
18
7
6 PLUG A
35
10 17 5
34
07A-14ga 16 4
33
07A-14ga 15 3
32
01 14 2
31
13 1
D10A
-1
24P-FEMALE 'A'
36A DETAIL C
S15-
1 2 3
S17 4 5 6
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
CONNECTOR (FEMALE)
36
37
34A
R8=
68
34 34 D34 40 38 PIN1 - 05 PURPLE
PIN2 - 77 BROWN
10A 10A 10A R5=51
CAN H
R6=680
CAN L
PIN3 - 01B PURPLE/BLACK
PIN4 - n/a
35 35 41 39
10A
D35
36
37
PIN5 - 09F YELLOW

PIN6 - 02 WHITE X
R7=680
S25-RISER S12-BOOM
10
10A
57A
S13-TUR D01A
-2
09F
30 13
S5-
D01A
10A 10C 10A 10C

D10A
31 14 IGN.
10C
32
33
01
12A
Y
162A
54A
X22
106
A
104 B
D162
K
105
L
162
10A 10C
R1=5
YEL
AT1 WHITE
DEUTSCH
ANGLE BLACK
4
3
1
2
TRANS. GREEN
BACK VIEW
TILT SWITCH TILT SWITCH CONNECTION Z

PIN 1 - YELLOW PIN 1 - 09 YELLOW
PIN 2 - GREEN PIN 2 - 28 GREEN
PIN 3 - WHITE PIN 3 - 02 WHITE
PIN 4 - BLACK PIN 4 - 128 BLACK/YELLOW 3.51 Base Control Box Wiring - CE Deutz
M170773AF D2011

111
3.52 Base Control Box Wiring - AS
Wire Number and Colour Chart 05-14ga

D57D
03A-14ga
BP2
R
00-12ga
01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR 57DCR
03-12ga
02-14ga
S8 01A
108
02 01
01A
00B 09
54A
02 21
21A
02 45
45A
02 45
128B
02 49
49A
02 09
57C
57D
03A 02 05
DIAGNOSE
128A
SPARE SPARE CB3 CB2 CB1 09 01 03A 162A 09 128 07 57B

20
RED
02
BLACK
76
R2=250
103
76
03 00 03
BATTERY (B+)
DEUTZ EDC
S3 03 - BLACK 12 GAUGE Ă5/16" S
HARNESS
E STOP 57ACR 59CR 60CR 78CR 79CR
S2-KSW 03
TT1
57B 09 09 103 103
05 10 57A 00A 59 02 60 02 78 02 79 02
54A 02 162A 07 90 99
07 00
07A 12
77 02
07 02 BATTERY (B-)
00 - WHITE 12 GAUGE Ă5/16"
B+
J6 CONNECT TO E-PUMP HOUSING T
D12
07A 12A KEY
D07A
ENGINE TEMPERATURE SENSOR

J3 CONNECTOR J6-BLACK
20
PIN 1 - BLACK - 102
24P-MALE 'B'
PIN 2 - WHITE - 09
162A
CONNECTOR J3 U
49
12 24 SOCKET 1 - 77
128A
41
11 23 SOCKET 2 - KEY
128A
1
2
SOCKET 3 - B+
PL2
40
10 22
39 SOCKET 4 - 00
PL1 38
79 9 21
SOCKET 5 - PLUG DEUTSCH
GLOW 1 13 38 28
78 8 20
SOCKET 6 - PLUG
FAULT 13 76 7 19
SOCKET 7 - CAN H
3
4
2 14 39 17
14 74 6 18
SOCKET 8 - CAN L BACK VIEW
HARNESS
3 15 40 16
+ - + - 21A 60 5 17
4 16 41 15
4 16 SOCKET 9 - 57D
23A 59
5 17 45A 102
3 15 SOCKET 10 - PLUG
24A 57A
54A 74 54A 76 6 18
26C
49A 02
55 2 14
PLUG B SOCKET 11 - 20
DRIVE PUMP VALVE
PLUG
SOCKET 12 - 26
MAIN
7 19 65 02
1 13
8 20
30
31
108 PIN 1 - 15 RED
9
10
21
22
32
165
02-14GA
PIN 2 - 02 WHITE
11 23
33
02-14GA 30 PIN 3 - 02 GREEN V
34A 165
24 12
12 24
36A
02-14GA
162
26
23 11
PIN 4 - 16 BLACK
24A
09
23A 22 10
65
20 21 9
45
24P-FEMALE 14 20 8
37
19 7
36
35
13
12 18 6 PLUG A
10 17 5
34
07A-14ga 16 4
33
07A-14ga 15 3
32
01 14 2
31
13 1
24P-FEMALE 'A'
D10A
W
-1
36A
S17 S15-
D37
D36
-JIB LEVEL S14-TELE

S16-ROT
36
37
34A
R8=
34 34 D34 40 38
68
10A 10A 10A
10
35 35 41 39
10A
D35
36
37
CAN H
R5=51 R6=680
CAN L
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 X
S25-RISER S12-BOOM
10
10A
57A
S13-TUR D01A
-2
30 13
S5-
D01A
10A 10C 10A 10C

D10A
31 14 IGN.
10C
32
33
01
12A
162A
AT1
Y
54A
X22
106
D162
ANGLE
BLACK
GREEN
A
WHITE
YEL
TRANS. 104
K
B
10A 10C
162
105
L
R1=5
TILT SWITCH
DEUTSCH
4 1
3 2
PIN 1 - YELLOW
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
M228195AA 3.52 Base Control Box Wiring - AS

112
M231435AG
A
OPTION - TELEMATICS
FU1

B+ 1 AMP
CAN L 8 3 IEC 9.1
CAN H 7 TRACK UNIT 00

4
07A(KEY) 2
9
JMPR IS J6
S2 REMOVE WHEN
S4 KEY SWITCH
EMERGENCY BOOM S3 OPTION
57D
CABLE OFF/BASE/PLATFORM EMERGENCY INSTALLED
STOP (IN OFF POSITION) S1
TRACK STOP DISCONNECT 1
CB1 15 AMP SWITCH
04 07A 07A BLACK 07A 07 05 05 03 + - 00 2 BATTERY
PL12 02 NCHO CB2 15 AMP
PL21 09 C1=22kuF 00 00 3
04ACR 108CR 4
B
D04 04A 02 CB3

04 RED 04 20AMP 03
M1 5
56 108 EMERGENCY PUMP
D10A D10
02 02 WHITE 02 02 6
S23
HORN SWITCH 7
49CR
49 49 GREEN 49 49 02 02
8
H1
HORN 9
CB4 86CR
02 03B 86A OPTIONAL OIL COOLER
07 09 49A
3.53 Electrical Schematic - ANSI/CSA
03 M
PLATFORM LOAD SENSOR-CAN 10
CB40 20A
S40 20A
POSITIVE AIR
SHUT OFF 403 11
04 YL BU 02 02 SWITCH 02
TSW1
09 86
SMB1-105 402 REV 12
04 RD AF BK 02 02 CONTROLLER
401
408 13
J1.1 09 SHUT OFF 410
C
SOLENOID 403A 14
VIO CAN1+ 403A
J1.2 09
BN CAN1- B+ 03 00 15
R4=330K ohm
J1.3 09 AIR S.O.

WH CAN2+ 07A BASE 10 J2.31 TO TO ENGINE TO ENGINE
PL40 A ECU STARTER POST GROUND 16
J1.4 09 02 403A
NC
+
GN CAN2- - ALT.
17
07A
PLATFORM 12 J2.20
BP4 18
NO
JMPR4
OVERLOAD ALARM 56 56C ENGINE DETAIL ON SHEET 2, 3 & 4

118A 19
403ACR
SMB1-106
S5 J3.4 118A
OVERLOAD 02 403A S8 20
IGNITION/ENABLE
S30 SWITCH 118A PL20 02 WITH OPTIONAL POSITIVE AIR DIAGNOSE
GLAZIER SHUT OFF REMOVE JMPR4 SWITCH 56 21
ENGINE START
1
SWITCH J12.25 57 57 J2.30

233 GLAZIER ON 10 01ACR 103
10A 10A J2.18 J3.2 22
2
04 PL11
01A 02
233A 233A 02
ENABLE or 103A
3
E-PUMP 23
D
04 J11.1 J11.10 02 108

24
04
4
J11.2 J11.11 02
FS1 LOW 25
04 J11.3 J11.12 02 FUEL SWITCH
09 55 PL18 PREHEAT 74 J4 26
5
PREHEAT/GLOW PLUG INDICATOR

+
04 J11.4 J11.13 02 - 09
6
PL22 27
S49 J2.14 55 LOW FUEL 02 02
7
04 DUAL FUEL + - 28 FUEL INDICATOR

LPG 11A J12.32 57A
8
ENGINE START
S6 29
54A
9
E-PUMP J3.9 57C 57C 57A TO TERMINAL

04 01 J12.18 R1= 120 R2= 120 STRIP 54A 30
10
ohm ohm
S9 09 57D
IGNITION 31
4 START 57B J12.30 J11.8 CAN 2H CAN 2H J1.8 57DCR
BROWN
11 12
04 5 32
6 J11.9 CAN 2L CAN 2L J1.9 D57D N/A FOR DUAL FUEL ENGINES
WHITE
1 RUN 04A J12.19 OPTION-LOAD CIRCUIT 33
E
04 2
CAN SHLD J3.23
1
S48 11 11 2H-11 34
3
DRIVE TORQUE 09 PL3 76
2
SUPPR. MIL
+
SWITCH -
09 MIL PL16 W.I.F. 81 35
3
04 J3.8 68 WATER IN FUEL INDICATOR

+
LOW TORQUE 45 J12.17 R3=13Mohm 09C - 77

09 36 HOURMETER
4
TT
R3= 120 68
BP3 ohm
5
S10 J5 37 RUN ENABLE

OVERLOAD ALARM
THROTTLE 11
6
SWITCH J13.8 118 38 FUEL SELECTION

04 J1.6 CAN H
7
2675 RPM 78 J12.29 OVERLOAD J1939 COMMUNICATION

J1.7 39
CAN L
8
J13.7 82 PL10 02
S11 CAN SHLD 40
9
FOOT BP1
10
SWITCH J13.4 TILT ALARM 41

04 08A J12.14 27A
LS6 LS2 42
FOOTSWITCH
11 12
RISER STOWED FLY STOWED

F
J13.25 08 PL9 02 43
NORMALLY NORMALLY
S22 CLOSED CLOSED
ELECTRICAL 44
TILT J2.19 29 29A 09
GENERATOR
J13.13 27 PL8 02 S12 45
04 LS3
85 J13.31 MAIN LIFT MAIN BOOM
UP/DOWN LS3 NORMALLY 46
S28 UP 14B J2.15
DIFF LOCK CLOSED
10A 47
SWITCH DN 13B J2.16 J2.29 59 09
BOOM TURRET LIMIT SWITCHES
ENGINE FAULT (MIL) S14 48
04 165A J13.30 TELESCOPE 02 02
J13.23 76P PL7 02
RET/EXT 49
IN 38B J2.21 SUPPR.
10A J3.25 45A 45A 3H-45A 50
J12.21 LOW FUEL
IN 38A OUT 39B J2.33 MOTOR 2-SPEED VALVE
S18 J13.2 55 PL6 02 SUPPR.
04 S13 51 (COIL ON = HIGH SPEED)
TELESCOPE
39A J12.33 TURRET
IN/OUT OUT ROTATE SUPPR. 52
GLOW PLUG 02
LT 32B J2.17
G
J13.9 74 PL5 02 10B

10A 2H-21A 53
RT 33B J2.32 J3.24 21A 21A 02 DUMP VALVE
41A J12.22
UP LOW CAPACITY 54
S19 04
PLATFORM 40A J13.26 J13.12 120 PL4 02 S15 55
LEVEL DN PLATFORM OPTION - GENERATOR 2H-85
LEVELING J3.7 85 85 02 OPTIONAL GENERATOR VALVE
HI CAPACITY 63AJ UP 41B J2.22 56
PL3 ONLY 10A
J13.11 120A 02 40B J3.26
DN OPTION - 12KW GENERATOR(46AJ ONLY) 2H-85B 57 OPTIONAL 12KW GENERATOR VALVE(46AJ)
LT 36A J13.29 J2.8 85B 85B 02
S20 S16
04 58
PLATFORM 37A J13.28 LOAD ZONE BORD. PLATFORM
ROTATE RT PL2
ROTATE
J13.10 119 02 36B
LT J3.29 59
10A
DIFF LOCK ON RT 37B J3.28 60
S21 J12.28 J13.35 165B PL11 OPTION - BEACON
UP 35A 02
JIB 61
04 20 02
UP/DOWN OPTIONAL STROBE LIGHT
34A J12.26
DN 62
H
S17 LB2
JIB UP/DOWN J3.10 20 20 02 ALL MOTION ALARM
63
UP 35B J2.28
BOOM/TUR 10A BP2
04 X J13.16 64
Vbat Xaxis DN 34B J2.26
J3.35 165 165 3H-165 DIFFERENTIAL LOCK
A1 Y 65
J13.15
BOOM/TURRET Yaxis SUPPR.
JOYSTICK S25 66
02 RISER UP/DOWN AT1 - CHASSIS
Gnd N.C. HELD OPEN LS1
UP 31B J3.31 WITH ENGINE OVER DIRECTION ANGLE TRANSDUCER 67
10A J2.25 STEERING AXLE SENSING 09 & TILT SWITCH
17
DN 30B J3.30 68
A2 04 DRIVE 24A J12.15
DRIVE/STEER Vbat Left J3.20
128
128 02
JOYSTICK 23A 4H-36 69
J12.16 J12.2 36
Right PLATFORM LEFT J2.27 28
28 70
D J13.14 J12.1 37 4H-37
Output PLATFORM RIGHT LS4
J3.32 121 LS4 09 NC HELD OPEN 71
02
Gnd BOOM DOWN
I
72
J3.33 122 LS5 09
J12.13 35 4H-35 63AJ
JIB UP LS5 (FLY OUT) 73
RISER NC ONLY 3H-16
A3 04 R J13.19 J12.24 4H-34 J2.1 16 16
34 JIB DOWN 74
RISER Vbat Output
JOYSTICK 3H-15 FORWARD DRIVE VALVE
02 J2.2 15 15
R 75
3H-26 REVERSE DRIVE VALVE
J3.34 26 26 02 76
BRAKE VALVE
SUPPR. 02 77
3H-65
J3.5 65 65 02 78
SUPPR. 02
79 AXLE LOCK VALVE
J3.13 24 4H-24 (COIL ON = FLOATING AXLE)
24 02
80
SENSOR BAR SUPPR. 02
J13.32 81
61 LEFT STEER VALVE
J
04 J3.3 23 4H-23
23 02
82
BP6 SUPPR. 02
S30 83
J13.33 RIGHT STEER VALVE
J13.6 SIREN J2.5 14 14 4H-14
62 63 84
4H-13 BOOM UP VALVE
J2.6 13 13
63 BEACON 85
BOOM DOWN VALVE
SGE 86
RESET J2.9 38 38 4H-38
87
4H-39 TELESCOPE IN VALVE
J2.10 39 39
88
TELESCOPE OUT VALVE
89
J2.13 32 32 4H-32
90
4H-33 TURRET ROTATE LEFT VALVE
J2.24 33 33 91
K
TURRET ROTATE RIGHT VALVE

92
J2.7 41 4H-41
41
93
J2.35 4H-40 PLATFORM LEVEL UP
40 40
94
PLATFORM LEVEL DOWN
2H-42 95
J2.12 42 42
96
J2.3 4H-31 PROPORTIONAL FLOW ENABLE
31 31
97
4H-30 RISER UP VALVE
J2.4 30 30
98
RISER DOWN VALVE
2H-13A 99
J2.8 13A 13A
100 BOOM DOWN THROTTLE VALVE
LOW CAP 63AJ
120
L
J3.6 PL15 02 ONLY

120 101
LOW CAP INDICATOR
HIGH CAP 102
J3.11 120A PL14 02
120A
103 HIGH CAP INDICATOR
LOAD ZONE BORDER
J3.1 119 119 PL13 02 104
J1.10 02 02 105 BORDER ZONE INDICATOR
J1.11 02 02 106
J1.12 02 02 107
J1.13 02 02 108
109
110
M
110A 110A 110A

WHITE HYDRAULIC
110A
110V PLATFORM POWER
110B BLACK 110B 110B CB6 15 AMP 3.5KW GENERATOR
M 110B 110C
F
GND GND
OPTION
GREEN NOTE: WITH HYDRAULIC GENERATOR OPTION
OPTIONAL 3.5KW GENERATOR
MALE AND FEMALE PLUGS ARE CONNECTED
CB5 50 AMP WELDER

WHITE WHITE
GENERATOR
RED RED 3Ø
N
F OPTION
BLACK BLACK
GREEN GREEN
110A
CB6 15 AMP
110B 110C
F
NOTE: WITH WELDER GENERATOR OPTION

MALE AND FEMALE PLUGS ARE CONNECTED
O
3.53 Electrical Schematic - ANSI/CSA

Z
T
Y
X
S
R
229042AFA
113
FU2
S9 1 AMP CI
IGNITION IEC 9.1
03 00 1
M224639AF
57 START S4 S2 V CHARGE INDICATOR
EMERGENCY KEY SWITCH S3 2
07A WIRE 2 07A EMERGENCY S1
STOP BASE/OFF/PLATFORM
POSITION 2-A STOP DISCONNECT
3
04 RUN SWITCH B1
04A 07A 07A WIRE 3 07A 07A RT CB1 15 AMP
07 05 05 03 00 4 BATTERY
POSITION 3-A CTR
A
ENGINE OFF
12 12 WIRE 5 LEFT PL3 CB2 15 AMP
10 12 12 10 02 00 00 5
POSITION 5-A
10 WIRE 4 CB3 25 AMP 108CR 6
10 56 03

POSITION 4-A 03
PL4 M1 7
01ACR 108 EMERGENCY PUMP
01 WIRE 1 01 01 01A 02 8
POSITION 1-A
D07A
09 108 CB4 86CR 9 ECO START OPTION
S6 03B 86A
E-PUMP D12 M OPTIONAL OIL COOLER
SWITCH TSW1 20A 10
S5 09 86
IGNITION/E-PUMP
162A 01 SWITCH 11
02
E-PUMP 01
D57D 12
12A
04A 04 D01A 00
ENABLE B+ 03 13
10A STARTER
10 57DCR
09 57D 14
START 54 77 TO TO ENGINE TO ENGINE
JMPR1
NOTE D ECU STARTER POST GROUND 15
B
04
77CR
57 57A WIRE 14 57A 57A 16
ENGINE DETAIL HERE
GEN. POSITION 14-B
02 OPTION 17
57A 57B
08CR 02 57ACR1 103 18
DIAGNOSE
1
SWITCH 103A
2
07 09 S8 19
D04-1 D10 56 56B
3
04 60A
56ACR 20
S23 60 WIRE 16 60 60 02 02 54 56A
4
HORN SWITCH POSITION 16-B 21

60CR 49CR X22
04B 49 49 WIRE 12 49 49 02 DIAGNOSTIC 22 COLD START RELAY
PORT
5
POSITION 12-B 09
H1 A G 105 CAN H 23 DIAGNOSTIC CONNECTOR
6
HORN
02 B H 104
7
07 49A 02 24
R8= 120 57B HORN
8
02 02 WIRE 1 ohm
02 25
CAN L
9
POSITION 1-B
09 77ACR 74
77 54 26
10
PL5
C
08
3.54 Electrical Schematic - CE with Deutz D2.2
105
08
27
104
11 12
02 02 02 WIRE 2 02 09 77A HOURMETER

FOOTSWITCH 28
POSITION 2-B
D27 27A 76ACR
TILT 76A 76B 76B 29
1
02B
2
OVERLOAD 76 02 30 ANTI-RESTART
D76 76A
3
76 76 WIRE 18 76 FS1 LOW

ENGINE FAULT 31
POSITION 18-B FUEL SWITCH 99
4
55 55 WIRE 13 55 55 02
LOW FUEL 90 32
5
POSITION 13-B
D74 74 74 WIRE 17 74
6
GLOW PLUG 33
POSITION 17-B JUMPER
7
04 BP1
09J 34
8
TILT
60A ALARM 27A 54 35
9
04
R7=
02 27A 120 36
10
ohm R10=680 ohm

77 37
D
D09
PL1 09A
11 12
02 27 38
CAN L
CAN H
57D
ENGINE FAULT 09 76
B+ 7 8 9
82 02 3 TRACK UNIT TELEMATICS OPTION
27CR 1
77 39
00 4 TRACK UNIT PL2
BP3 82CR TELEMATICS 2
KEY GLOW PLUG 09 74
20 40
OVERLOAD 11
D118 12
118 ALARM 02 41
26
R9=680 ohm
PLATFORM LOAD SENSOR 42
09
43
118 4 1 60A
44
82 5 7 02 02
45
162 3 2 161 161 WIRE 22 161 09 46
POSITION 22-A JMPR4
NOTE D 79CR 47
1700RPM
162 WIRE 23 162 79 79
R6=
E
48
POSITION 23-A 3.9k
90 99B ohm R4=
2.2k 49 MID IDLE RELAY N=1700 RPM
S10 78CR ohm
THROTTLE D10A-1 2000RPM 50 HIGH IDLE RELAY N=2000 RPM
SWITCH 78 2000 RPM 78 WIRE 19 78 78 78
R5=
08 D08-1 POSITION 19-B 2.1k 51
79 1650 RPM 79 WIRE 20 79 ohm
90 99A
POSITION 20-B 52
162
53 LOAD SENSOR RESISTOR
LS3 LS2 LS2 R3=680 ohm
SUPPR FLY IN LS BOOM DN LS RISER DN LS 54
59 WIRE 15 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 WIRE 20 45 45 02
59 POSITION 20-A 3H-45 57
45 LOW TORQUE 09 09 45A 45A
MOTOR 2-SPEED VALVE
SUPPR. 58 (COIL ON = HIGH SPEED)
F
59
D85A-1 S11
59 59CR
FOOT 59 60
08A SWITCH
09 09 162A 61
D162B SUPPR.
D162 D01A-2 62
04 JMPR2 04D D10A 21A 2H-21A
162A 162A 162A 02 63 DUMP VALVE
NOTE B
20 WIRE 8 20 20 JMPR3 21 21CR 02 DUMP VALVE RELAY
64
POSITION 8-A NOTE C
S22 65
ELECTRICAL SUPPR.
GENERATOR D59 D162-2 66
04 04D 2H-85
85A 85 WIRE 21 85 85 02 OPTIONAL GENERATOR VALVE
67
POSITION 21-B
68
20 02
69 OPTIONAL STROBE LIGHT
S28 LB2
DIFF LOCK
G
04 165 SWITCH 20 02 70
OPTIONAL ALL MOTION ALARM
02
165 02A BP2 71
LOCK OFF
165CR 72
165 LOCK ON 165 WIRE 24 165 165 3H-165
26C POSITION 24-A DIFFERENTIAL LOCK
SUPPR. 73 (COIL ON = LOCKED)
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 WIRE 21 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
AT1
H
128A WIRE 23 128A 81

04C 2 31 59 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
14 WIRE 22 128A 128 02 82
128A 128A 128A
POSITION 22-B 3H-16
04C 13 34 WIRE 5 16 16 83
16 16 FORWARD DRIVE VALVE
162A 02 POSITION 5-B 3H-15
23 15 15 WIRE4 15 15 84
REVERSE DRIVE VALVE
162ACR POSITION 4-B 3H-26 85
26 WIRE11 26 26 02 BRAKE VALVE
BOOM/TUR POSITION 11-A
04 X 28 5 N.C. HELD OPEN LS1 SUPPR. 86
20D D20D
Vbat Xaxis WITH ENGINE OVER DIRECTION 05
A1 Y 29 15 17 WIRE 6 17 STEERING AXLE SENSING 09 09 TT1 87
17 H-1
BOOM/TURRET Yaxis 77A TT HOURMETER
POSITION 6-B
JOYSTICK 02 25 01B C1 88
C-1
D20C
Gnd C COUNTER
09F RC-1 89
32 28 28 WIRE 7 28 28
02
POSITION 7-B
4 24A 4H-24A 90
24A 24A WIRE 10 24A 02 LEFT STEER VALVE
RISER POSITION 10-A
04 02 24 SUPPR. 91
I
Vbat Gnd
A3
R 30 21 23A WIRE 9 23A 23A 4H-23A 92
RISER 23A 02 RIGHT STEER VALVE
Output
JOYSTICK POSITION 9-A
SUPPR. 93
162A WIRE 24 162A 94

POSITION 24-B
02 UP 31 95
10A
DRIVE S25
162C 02 96
Vbat Gnd RISER
D 27 20C
DN 30 97
A2 Output
DRIVE/STEER 24 9 31 31 WIRE 13 31 31 4H-31
17 31 98
JOYSTICK Left RISER UP VALVE
POSITION 13-A
23 18 12 30 30 WIRE12 30 30 30 4H-30 99
Right POSITION 12-A RISER DOWN VALVE
100
LT
S13 101
10A 20C
TURRET
RT ROTATE 102
R1=6 ohm
J
20 32 32 WIRE14 32 32 32 4H-32
103 TURRET ROTATE LEFT VALVE
POSITION 14-A
35 33 33 WIRE15 33 33 33 4H-33
104 TURRET ROTATE RIGHT VALVE
POSITION 15-A
105
UP 106
10A
107
S12
20C BOOM LIFT 108
DN
109
22 14 14 WIRE 7 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 WIRE 6 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 6-A 111
26A 19 33 20A
112
IN
10A S14
TELESCOPE 113
OUT SUPPR.
K
114
38 38 WIRE8 38 38 38 3H-38
S18 IN TELESCOPE IN VALVE
26C POSITION 8-B 115
TELESCOPE 39 3H-39
39 39 WIRE 9 39 39 TELESCOPE OUT VALVE
RET/EXT OUT POSITION 9-B 116
SUPPR.
26C 20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
119
41 41 WIRE 11 41 41 41 4H-41
S19 UP PLATFORM LEVEL UP VALVE
26A POSITION 11-B 120
PLATFORM 40 4H-40
40 40 WIRE 10 40 40
LEVELING DN PLATFORM LEVEL DN VALVE
POSITION 10-B 121
26A SUPPR.
20C
122
123
LT 36 WIRE 18 36 36 D36 36A 36A 2H-36A
S20 36 PLATFORM ROT. ENABLE VALVE
26C POSITION 18-A 124
PLATFORM 37 SUPPR.
L
ROTATE 02 02 4H-36 LT
RT 10A PLATFORM ROT. LEFT VALVE
125
SUPPR.
126
02 02 4H-37 RT S16
26C 20A PLATFORM ROT. RIGHT VALVE
PLATFORM
D37 127
37 WIRE 19 37 37 36A ROTATE
POSITION 19-A 128
SUPPR.
129
UP 35 35 WIRE 17 35 35 D35 34A 34A 2H-34A
S21 26C 130
JIB 34 POSITION 17-A
02 02 4H-35 UP
UP/DOWN DN 10A 131 JIB ENABLE VALVE
SUPPR. DN 132
02 02 4H-34 S17
26C 20A JIB UP/DOWN 133 JIB UP VALVE
D34
34 WIRE 16 34 34 34A
POSITION 16-A 134 JIB DOWN VALVE
135
M
SENSOR BAR 162A 162C

136
07A 07B 07C 07C 02 137
7CCR1 - KILL DRIVE HYDRAULIC 138
20B 20
GENERATOR 139
07C 02 OPTIONAL GENERATOR
04E 02 OPTION 140
4ECR 7CCR2 - KILL DUMP
RESET 110A 110A 110A 141
DELATCH 07C 02 WHITE 110A
110B CB6 15 AMP 142 110V PLATFORM POWER

BEACON BLACK 110B 110B 110B 110C
07A 04E M F
02 GND GND 143
GREEN
Amber NOTE: WITH HYDRAULIC GENERATOR OPTION
02 07C SIREN
MALE AND FEMALE PLUGS ARE CONNECTED 144
60A 60
4ECR1 07B 07D 02 145

02 04E
7DCR 146
N
04A 04B KILL ENGINE

147
07C 02 02
DELAY ON TIMER 148
D07D 149
07C 07D
02 150
151
152
153 OPTIONAL SGE
154
NOTE A: JMPR1 REMOVED WITH TRACK UNIT
TELEMATICS 155
NOTE B: JMPR 2 REMOVED WITH GENERATOR 156
OPTION 157
O
NOTE C: JMPR3 NEEDED FOR D2.2 158
NOTE D: JMPR4 IN STANDARD SGE FIELD KIT

D2.2
3.54 Electrical Schematic - CE with Deutz
Z
T
Y
X
S
R
229042AFA
114
ENGINE
12 12 J6 TEMPERATURE
102 102 WIRE 3 102 102 SWITCH
M222992AE
102
POSITION 3-B TSW2 FU2
S9 09
09 1 AMP CI
D12-1 D102 IGNITION IEC 9.1
03 00 1
08R D57-1 S2 V
08R 57 START S4 CHARGE INDICATOR
EMERGENCY KEY SWITCH S3 2
07A WIRE 2 07A S1
A
STOP BASE/OFF/PLATFORM EMERGENCY

POSITION 2-A DISCONNECT
FU3 5A STOP 3
04G 04G 04 RUN SWITCH B1
07 05 05 03 00 4 BATTERY
ECOSTART POSITION 3-A CTR
ENGINE OFF

10 12 12 WIRE 5 12 LEFT PL3 CB2 15 AMP
12 10 02 00 00 5
OPTION POSITION 5-A
10 WIRE 4 108CR 6
R17=22 OHM 10
03A CB3 15 AMP 03 03
PL4 POSITION 4-A
04H M1 7
04HCR 01ACR 108 EMERGENCY PUMP
S6 01 01 01A 02
E-PUMP WIRE 1 01 8
04J
SWITCH POSITION 1-A
D04J D07A
09 108 CB4 86CR 9
08R 162A 01 03B 86A
D12 M OPTIONAL OIL COOLER
TSW1 20A 10
S5 09 86
D04K
TT2
IGNITION/E-PUMP
04 SWITCH 102R 11
04A 02
04KCR
E-PUMP 01
C 6 D57D 12
04K 04K 12A
03A 54A 57BCR
NC 04G D01A
1 03 13 STARTER
PL17 ENABLE 10A M
B
NO 10 57DCR X23-ENGINE
02 02 09 09 57D 57B 14 ECOSTART
2 CONNECTOR
START 01 00B NOTE D
15
TIME 04 57ACR PS1
DELAY-ON-BREAK 07CR 11 ENGINE OIL PR.
57 57A WIRE 14 57A 57A 57A 00A 00B 00B 16
RELAY
GEN. POSITION 14-B
OPTION 4 17
54A 57C 57B
08R D08A 02 57ACR1 03 18
08 A ALTERNATOR
77 1 77
D85A-2 08CR 07 09 19
04 D04-1 D10 10
04D 60 NOTE A 11 FU1 20
S23 60 WIRE 16 60 60 02 02 50A
NOTE A HORN SWITCH POSITION 16-B 21
49CR 11A
60CR
54ACR 22
3.55 Electrical Schematic - CE with D2011
04A 49 WIRE 12 49 49 02 COLD START RELAY

POSITION 12-B 11B
H1 54A 23 GLOW PLUGS (3)
HORN
07 49A 02 TO ECU 24
C
D5.1, PIN 3 HORN

25
08 PL5 02 02 02 02 26
WIRE 1
08 POSITION 1-B
27
R5=51 ohm ECU
02 02 02 WIRE 2 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
OVERLOAD 30 ANTI-RESTART
D76 76 76 WIRE 18 76 FS1 LOW
ENGINE FAULT 31
POSITION 18-B FUEL SWITCH
55 55 WIRE 13 55 55 02 02 1
LOW FUEL 32
POSITION 13-B
D74 74 74 WIRE 17 74
GLOW PLUG B 106 2 33 DIAGNOSTIC CONNECTOR
POSITION 17-B
04(60) 60 BP1 L 105 10 34
TILT
ECOSTART 104
04 OPTION 60 ALARM 27A K 11 35
D
NOTE E R7=680 ohm 54A

02 27A R8=68 ohm 54A 76 A 36
54A X22 DIAG PORT 54A 14 37
02 PL1 CAN H 6
27 38
CAN L
CAN H
57D
54A 76
ENGINE FAULT
B+ 7 8 9
82 02 3 CAN L 9 39 TRACK UNIT TELEMATICS OPTION
27CR 77
ONLY WITH SGE OPTION

1
00 4 TRACK UNIT PL2
BP3 82CR TELEMATICS 2
KEY 74 74 5
20 GLOW PLUG 40
D118 OVERLOAD 11
12
118 ALARM 02 DIAGNOSE 41
26
SWITCH
PLATFORM LOAD SENSOR S8 42
76 4
43
118 4 1 60
103 103 17 44
82 5 7 02 02
NOTE C 45
162 3 2 161 161 WIRE 22 161 JMPR4 09 79
46 MID IDLE RELAY N=1650 RPM
E
POSITION 22-A 79CR

JMPR5 78 1650RPM
99 18 47 HIGH IDLE RELAY N=2000 RPM
78CR
162 WIRE 23 162 2000RPM
90 21 48
POSITION 23-A
JMPR 23 49
S10
THROTTLE D10A-1 24 50
SWITCH 78 2000 RPM 78 WIRE 19 78
08 D08-1 POSITION 19-B 51
79 1650 RPM 79 WIRE 20 79 02 02
POSITION 20-B 52
162
SUPPR FLY IN LS BOOM DN LS RISER DN LS 54
59 WIRE 15 59 59 N/C 29A N/C 29 N/C 09
POSITION 15-B
S48
SWITCH 45 WIRE 20 45 45 02
45A
F
45 LOW TORQUE 09 09 45A

MOTOR 2-SPEED VALVE
59
D85A-1 S11
59 59CR
FOOT 59 60
08A SWITCH
09 09 162A 61
D162B SUPPR.
D162 D01A-2 62
04 JMPR2 04A D10A 21A 2H-21A
162A 162A 162A 02 63 DUMP VALVE
WITH OPTIONAL GENERATOR
REMOVE JMPR2 20 20 WIRE 8 20 20 JMPR3 21 21CR 02 DUMP VALVE RELAY
64
POSITION 8-A
NOTE A
S22 65
ELECTRICAL SUPPR.
GENERATOR D59 D162-2 66
04 04A 2H-85
85A 85 WIRE 21 85 85 02 OPTIONAL GENERATOR VALVE
67
POSITION 21-B
68
G
20 02
S28 LB2
DIFF LOCK
04 165 SWITCH 20 02 70
02
165 02A BP2 71
LOCK OFF
165CR 72
165 LOCK ON 165 WIRE 24 165 165 3H-165
26C POSITION 24-A DIFFERENTIAL LOCK
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 WIRE 21 65 65 02 AXLE LOCK VALVE
26C 08 08A 16 11 SUPPR. 78
27
driving=open
stopped=closed 08F 6 79
H
02 08F 45CR2
45
08FCR 04C 1 26 80
02
128A WIRE 23 AT1
128A 09 81
04C 2 31 59 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
14 128A 128 02 82
128A 128A WIRE 22 128A
POSITION 22-B 3H-16
04C 13 34 16 16 83
16 16 WIRE 5 FORWARD DRIVE VALVE
162A 02 POSITION 5-B 3H-15
23 15 15 15 15 84
WIRE4 REVERSE DRIVE VALVE
162ACR POSITION 4-B 3H-26 85
26 WIRE11 26 26 02 BRAKE VALVE
04 X 28 5 D20B N.C. HELD OPEN LS1 SUPPR. 86
20B
Vbat Xaxis WITH ENGINE OVER DIRECTION 05
A1 Y 29 15 17 17 STEERING AXLE SENSING 09 09 TT1 87
17 WIRE 6 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 WIRE 7 28 28
02
POSITION 7-B
90
I
4 24A 24A 24A 24A 4H-24A

WIRE 10 02 LEFT STEER VALVE
RISER POSITION 10-A
04 02 24 SUPPR. 91
Vbat Gnd
A3
R 30 21 23A 23A 23A 4H-23A 92
RISER 23A WIRE 9 02 RIGHT STEER VALVE
Output
SUPPR. 93
162A WIRE 24 162A 94

POSITION 24-B
02 UP 31 95
NOTE A 10A
DRIVE S25
162A 02 96
Vbat Gnd RISER
D 27 20C
DN 30 97
A2 Output
DRIVE/STEER 24 9 31 31 31 31 4H-31
17 WIRE 13 31 98
POSITION 13-A
23 18 12 30 30 WIRE12 30 30 30 4H-30 99
100
LT
S13 101
J
10A 20C
TURRET
RT ROTATE 102
R1=6 ohm
20 32 32 32 32 32 4H-32
WIRE14 103 TURRET ROTATE LEFT VALVE
POSITION 14-A
35 33 33 WIRE15 33 33 33 4H-33
POSITION 15-A
105
UP 106
10A
107
S12
20C BOOM LIFT 108
DN
109
22 14 14 WIRE 7 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 WIRE 6 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 6-A 111
26A 19 33 20A
112
K
IN
10A S14
S18 TELESCOPE 113
TELESCOPE OUT SUPPR.
RET/EXT 114
38 38 WIRE8 38 38 38 3H-38
IN TELESCOPE IN VALVE
39 39 WIRE 9 39 39 39 3H-39
TELESCOPE OUT VALVE
OUT POSITION 9-B 116
SUPPR.
26C 20A
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 WIRE 11 41 41 41 4H-41
PLATFORM UP PLATFORM LEVEL UP VALVE
26A POSITION 11-B 120
LEVELING 40 4H-40
40 40 WIRE 10 40 40
DN POSITION 10-B PLATFORM LEVEL DN VALVE
121
26A SUPPR.
20C
122
123
L
LT 36 36 36 D36 36A 36A 2H-36A

36 WIRE 18 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
PLATFORM
D37 127
POSITION 19-A 128
SUPPR.
129
UP 35 35 WIRE 17 35 35 D35 34A 34A 2H-34A
S21 26C 130
02 02 4H-35 UP
UP/DOWN DN 10A 131 JIB ENABLE VALVE
SUPPR. DN 132
02 02 4H-34 S17
D34
34 WIRE 16 34 34 34A
134 JIB DOWN VALVE
M
POSITION 16-A
135
SENSOR BAR 136

(09A/162A) (09B/162B)
07A 07B 07C 07C 02 137
7CCR1 - KILL DRIVE HYDRAULIC 138
20 20E
GENERATOR 139
07C 02 OPTIONAL GENERATOR
04E 02 OPTION 140
4ECR 7CCR2 - KILL DUMP
RESET 110A 110A 110A 110A 141
DELATCH 07C 02 WHITE
BEACON BLACK 110B 110B 110B 110C
07A 04E M F
02 GND GND 143
GREEN
Amber NOTE: WITH HYDRAULIC GENERATOR OPTION
02 07C SIREN
MALE AND FEMALE PLUGS ARE CONNECTED 144
60 60A
N
4ECR1 02 145
02 04E 07B 07D
7DCR 146
04B 04F KILL ENGINE
02 147
07C 02
DELAY ON TIMER 148
D07D 149
07C 07D
02 150
151
152
SGE OPTION 153 OPTIONAL SGE
154
NOTE A: JMPR REMOVED WITH SGE OPTION NOTE D: REMOVE JUMPER WITH TRACK
UNIT TELEMATICS 155
O
156
NOTE E: WITH ECOSTART OPTION
CHANGE 04 TO 60 157
NOTE C: 1- JMPR4 REMOVED WITH SGE OPTION
158
2- JMPR5 REMOVED WITHOUT SGE OPTION
3.55 Electrical Schematic - CE with D2011
Z
T
Y
X
S
R
229042AFA
115
M222993AE
ECOSTART 102 WIRE 3 102
POSITION 3-B ENGINE
OPTION J6 TEMPERATURE 1 AMP
102 SWITCH
IEC 9.1
S9 102 CI
D102 D12-1 IGNITION 1
TSW2 03 00
D57-1 S2 09 V
08R 08R 57 START S4 CHARGE INDICATOR
A
S3 09 2
EMERGENCY KEY SWITCH
07A WIRE 2 07A EMERGENCY S1
STOP BASE/OFF/PLATFORM
FU3-5A POSITION 2-A STOP DISCONNECT
3
04G 04G 04 04 RUN SWITCH B1
07 05 05 03 00 4 BATTERY

POSITION 3-A CTR
ENGINE OFF
10 12 12 WIRE 5 12 LEFT PL3 CB2 15 AMP
12 10 02 00 00 5
R17=22 OHM POSITION 5-A
04H 10 WIRE 4 108CR 6
10
03A CB3 15 AMP 03 03
04HCR PL4 POSITION 4-A
04 M1 7
04J D07A 108 EMERGENCY PUMP
01 01ACR
WIRE 1 01 01 01A 02 8
D04J POSITION 1-A
08R 09 108 CB4 86CR 9
S6 03B 86A
E-PUMP D12 M
TSW1 10 OPTIONAL OIL COOLER
SWITCH S5 09 86 20A
TT2
IGNITION/E-PUMP
20 01 01 SWITCH 102R 11
09 02
C 6 E-PUMP 01
12
12A D57D
04G 03A 54A 57BCR
NC 1 04A 04 D01A
NOTE D 03 13
ENACLE 10A
B
NO 57DCR M STARTER
02 02 10 X23-ENGINE
2 09 09 57D 57B 14 ECOSTART
CONNECTOR
04 START 01 00B
3.56 Electrical Schematic - AS
TIME 15
57ACR PS1
DELAY-ON-BREAK PL17 07CR ENGINE OIL PR.
57 57A 57A 57A 00A 00B 11 00B
04K 02 WIRE 14 57A 16
RELAY
08R D08A D04K GEN. POSITION 14-B
08 02 07 17
OPTION 4
54A 57C 57B
04KCR 08CR 57ACR1 03
04K 04K 02 02 18
D85A-2 1 A ALTERNATOR
77 77
07 09 19
D10 10
D04 NOTE A 11 FU1 20
04D 60 60 WIRE 16 60 60 02 02
50A
S23 POSITION 16-B 21
HORN SWITCH 49CR 11A
60CR
04A 49 WIRE 12 49 49 02 22 COLD START RELAY
POSITION 12-B 54ACR 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 02 02 26
WIRE 1
08 POSITION 1-B
27
R5=51 ohm ECU
02 02 02 WIRE 2 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
OVERLOAD 30 ANTI-RESTART
D76 76 76 WIRE 18 76 FS1 LOW
ENGINE FAULT 31
POSITION 18-B FUEL SWITCH
55 55 WIRE 13 55 55 02 02 1
LOW FUEL 32
POSITION 13-B
D74 74 74 WIRE 17 74
GLOW PLUG B 106 2 33 DIAGNOSTIC CONNECTOR
POSITION 17-B
60 60 BP1 L 105 10
X22 34
TILT
DIAG PORT
60 ALARM 27A K 104 11 35
R7=680 ohm 54A
02 27A 54A 76 A 36
R8=68 ohm
D
54A 54A 14 37

02 PL1
27 CAN H 6 38
54A 76
ENGINE FAULT
82 02 27CR CAN L 9 39
PL2
BP3 74
CAN L
74 5
CAN H
57D
82CR GLOW PLUG 40
D118 OVERLOAD
B+ 7 8 9
ALARM 3
118 02 1
77 DIAGNOSE 41
00 4 TRACK UNIT
TRACKUNIT TELEMATICS OPTION
KEY
SWITCH
TELEMATICS 2
PLATFORM LOAD SENSOR 20 S8 42
11
12
76 4
43
26
118 4 1 60
103 103 17 44
82 5 7 02 02
NOTE C 45
162 3 2 161 161 WIRE 22 161 JMPR4 09 79
46 MID IDLE RELAY N=1650 RPM
POSITION 22-A 79CR
JMPR5 78 1650RPM
99 18 47 HIGH IDLE RELAY N=2000 RPM
78CR
E
162 WIRE 23 162 2000RPM

90 21 48
POSITION 23-A
JMPR 23 49
S10
THROTTLE D10A-1 24 50
SWITCH 78 2000 RPM 78 WIRE 19 78
08 D08 POSITION 19-B 51
79 1650 RPM 79 WIRE 20 79 02 02
POSITION 20-B 52
162
02 D59 FLY IN LS BOOM DN LS RISER DN LS 54
59 WIRE 15 59 59 N/C 29A N/C 29 N/C 09
POSITION 15-B
S48
SWITCH 45 WIRE 20 45 45 02
45 LOW TORQUE 09 09 45A 45A
MOTOR 2-SPEED VALVE
ONLY WITH SGE OPTION 59
F
D85A-1 S11
59CR
FOOT 59 60
08A SWITCH D162B
09 09 162A 61
SUPPR.
D162 D01A-2 62
04 JMPR2 04A D10A 21A 2H-21A
162A 162A 162A 02 63 DUMP VALVE
WITH OPTIONAL GENERATOR NOTE A
REMOVE JMPR2 20 20 WIRE 8 20 20 JMPR3 21 21CR 02 DUMP VALVE RELAY
64
POSITION 8-A
S22 65
ELECTRICAL
GENERATOR 66 OPTIONAL GENERATOR VALVE
04 04A
85A 85 WIRE 21 85
67
POSITION 21-B
68
20 02
S28 LB2
D08-1 DIFF LOCK
26B 165 SWITCH 20 02 70
02 02
G
D26A 165 02A BP2 71

LOCK OFF
165CR 72
165 LOCK ON 165 WIRE 24 165 165 3H-165
26A POSITION 24-A DIFFERENTIAL LOCK
PL6 74
02
02 75
26ACR SCM-VALVE DRIVER 76
26A 02
26A 3H-65 77
26C 08 08 04 04 19 7 65 65 WIRE 21 65 65 02 AXLE LOCK VALVE
08A 16 11 SUPPR. 78
27
08F 6 79
02 08F 45CR2
45
08FCR 26 02 80
02
128A WIRE 23 AT1
128A 09 81
04 04 1 31 59 59 ANGLE TRANSDUCER
POSITION 23-B
& TILT SWITCH
04 2 14 128A 128 02 82
H
128A 128A WIRE 22 128A

POSITION 22-B 3H-16
34 16 16 83
16 16 WIRE 5 FORWARD DRIVE VALVE
POSITION 5-B 3H-15
04 13 23 15 15 15 15 84
WIRE 4 REVERSE DRIVE VALVE
POSITION 4-B 3H-26
10 26 85
26 26 WIRE 11 26 02 BRAKE VALVE
04 X 28 5 D20B N.C. HELD OPEN LS1 SUPPR. 86
20B
Vbat Xaxis WITH ENGINE OVER DIRECTION
A1 Y 29 15 17 17 STEERING AXLE SENSING 09 87
17 WIRE 6
BOOM/TURRET Yaxis
POSITION 6-B
JOYSTICK 02 25 88
Gnd
32 28 28 28 89
28 WIRE 7
POSITION 7-B
4 24A 4H-24A 90
24A 24A WIRE 10 24A 02 LEFT STEER VALVE
RISER POSITION 10-A
04 02 24 SUPPR. 91
Vbat Gnd
A3
R 30 21 23A 23A 23A 4H-23A 92
RISER 23A WIRE 9 02 RIGHT STEER VALVE
Output
SUPPR. 93
NOTE A
I
162A WIRE 24 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 31 31 4H-31
17 WIRE 13 31 98
POSITION 13-A
23 18 12 30 30 WIRE 12 30 30 30 4H-30 99
100
LT
S13 101
10A 20C
TURRET
RT ROTATE 102
R1=6 ohm
20 32 32 32 32 32 4H-32
WIRE 14 103 TURRET ROTATE LEFT VALVE
POSITION 14-A
35 33 33 WIRE 15 33 33 33 4H-33
POSITION 15-A
105
J
UP 106
10A
107
S12
20C BOOM LIFT 108
DN
109
22 14 14 WIRE 7 14 14 14 4H-14
BOOM UP VALVE
POSITION 7-A 110
8 13 13 WIRE 6 13 13 13 4H-13
BOOM DOWN VALVE
POSITION 6-A 111
33 20A
112
IN
10A S14
S18 TELESCOPE 113
TELESCOPE OUT SUPPR.
RET/EXT 114
38 38 WIRE 8 38 38 38 3H-38
IN TELESCOPE IN VALVE
39 39 WIRE 9 39 39 39 3H-39
TELESCOPE OUT VALVE
OUT POSITION 9-B 116
SUPPR.
26C 20A
K
117
10A UP 41 S15
PLATFORM 118
DN 40 SUPPR.
LEVELING
S19 119
41 41 WIRE 11 41 41 41 4H-41
PLATFORM UP PLATFORM LEVEL UP VALVE
LEVELING 40 4H-40
40 40 WIRE 10 40 40
DN POSITION 10-B PLATFORM LEVEL DN VALVE
121
26C SUPPR.
20A
122
123
LT 36 36 36 D36 36A 36A 2H-36A
36 WIRE 18 PLATFORM ROT. ENACLE 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
PLATFORM
D37 127
POSITION 19-A 128
L
SUPPR.
129
UP 35 35 WIRE 17 35 35 D35 34A 34A 2H-34A
S21 26C 130
02 02 4H-35
UP/DOWN DN 10A UP 131 JIB ENACLE VALVE
SUPPR. DN 132
02 02 4H-34 S17
D34
34 WIRE 16 34 34 34A
POSITION 16-A 134 JIB DOWN VALVE
135
136
SENSOR BAR (09A/162A) (09B/162B)
137
07A 07B 07C 07C 02
138
7CCR1 - KILL DRIVE
2H-85-1
85 02 139
20 20E 7.5 kW OPTIONAL GENERATOR
M
D04D 04E 02 07C 02 140
4ECR 7CCR2 - KILL DUMP 2H-85-2

110A 110A 110A 110A 85 02 141
RESET DELATCH 07C WHITE
02
BLACK 110B 110B 110B 110C
BEACON M F
07A 04E D85
02 GND GREEN GND 143
NOTE: WITH HYDRAULIC GENERATOR OPTION
Amber SIREN MALE AND FEMALE PLUGS ARE CONNECTED
02 07C 144
60 60A
145
07B 07D 02
7.5 kW HYDRAULIC
7DCR 146
KILL ENGINE
GENERATOR
OPTION 147
07C 02 02
DELAY ON TIMER 148
D07D 149
07C 07D
150
02
N
151
152
153
SGE OPTION 154
NOTE A: JMPR REMOVED WITH SGE OPTION 155
156
157
NOTE C: 1- JMPR4 REMOVED WITH SGE 158 OPTIONAL SGE

2- JMPR5 REMOVED WITHOUT SGE 159
NOTE D: REMOVE JUMPER WITH TRACKUNIT 160
TELEMATICS INSTALLED 161
162
O
163
164
165
3.56 Electrical Schematic - AS
Z
T
Y
X
S
R
229042AFA
116
3.57 Interface & Engine Electrical Schematic - Deutz D2.9L
TO BATTERY TO BATTERY
MAIN PANEL INTERFACE ENGINE HARNESS B+ POST B- POST

ENGINE D2.9/D2.2/TD2.9 R
B+-12 RD
00-14 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
33
A18-16 WH
18
A48-16 BK
48
A37-18 WH S
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
A07-18 BK TO ECU
7
A19-16 BK
19
A20-16 WH
20
A23-18 BK
23
(-) 00-14 WH
A24-18 BK
24
FUEL
PUMP FP A25-18 BK
25
(+) 56B-14 RD
A26-18 BK
26
A27-18 BK
27
A28-18 BK
T
28
A29-18 BK
29
L L1
A35-18 BK
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
K01-12 RD K01-14 RD
3
SPLK01
K01-14 RD
5
00-14 WH
2
TO ENGINE 00-12 WH 00-14 WH U
4
TO BASE BOX 56ACR
SPL00
00-14 WH
HARNESS
6
56A 54
ENCLOSURE 204-18 RD
13 15
103 SPL103
1
103-18 BK 103-18 BK
1
56 56 56B 103A 103A-18 WH 103A-18 WH
19
1
2
103 56B-14 RD K22-18 BK
22
2
3
103A 56B 56A-18 WH 56A-18 WH
26
4
3
3
84-18 WH (T-ONLY) 84-18 WH
27
84 56A
5
4
CONNECTOR P3
4
CAN H-18 BK K28-18 BK
28
74
6
84
5
5
203-18 BK SPL203 203-18 BK
29
7
09 CANH
6
6
57A-16 BK 57A-16 BK
35
8
02 CAN L-18 WH K44-18 BK
7
7
R= 120 ohm
44
9
57A 57A 74-18 WH 74-18 WH
8
10
48
CANL 105-18 WH 105-18 WH
11 12
53
9
9
74 104-18 BK
10
10
D2.2 - 94 PIN
76ACR 105 201-18 WH
V
57
11
11
76 02 K61-18 BK TO ECU
104
61 64
12
12
200-18 BK
76A 76B 76A-18 WH
65
76B
1
103-18 BK
68
96 96
2
1
96-18 WH
69
76 76A
3
2
76A-18 WH 76-18 BK
70
1
81
3
4
96-18 WH (T-ONLY) K73-18 BK
73
2
77(ENGINE RUN= GND) 99-18 WH
5
76-18 BK
4
74
3
68 99-18 WH 104-18 BK
75
5
4
90-18 BK 90-18 BK
80
6
5
7
CONNECTOR P4
CANH K22-18 BK (46AJ ONLY) K82-18 BK
68
82 85
6
8
7
CANL K85-18 BK
54 9
8
202-18 WH (46AJ ONLY) SPL202 202-18 WH
87
81
7
10
9
09-16 BK 09-16 BK
88
8
77
11
10
54-18 BK 54-18 BK
W
90
D09
9
09A
12
11
81-18 WH 81-18 WH
10
92
77-18 WH 77-18 WH
12
11 12
71 54
09A-18 BK CAN H-18 BK
CAN L-18 WH
76
X22
DIAG. PORT
09
A
02
B
105 G
104
H
R= 120 ohm
K82-18 BK
A02-16 WH
A32-16 BK
A03-16 WH
A46-16 BK
A04-16 WH
A05-16 BK
A16-16 WH
A33-16 BK
A18-16 WH
A48-16 BK
A37-18 WH
A52-18 BK
A53-18 RD
A38-18 RD
A39-18 WH
A54-18 BK
K28-18 BK
A28-18 BK
K61-18 BK
A25-18 BK
A26-18 BK
A40-18 BK
A27-18 BK
A24-18 BK
A43-18 BK
A44-18 BK
A29-18 BK
K44-18 BK
K85-18 BK
A19-16 BK
A20-16 WH
204-18 RD
202-18 WH
203-18 BK
A07-18 BK
K73-18 BK
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
Y
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
ENGINE ENGINE COOLING FUEL LOW FUEL BOOST OIL 100A 11C GP2
INJ. INJ. MPROP INJ. INJ.
CYL.3 CYL.2 CYL.1 CYL.4 SPEED SPEED TEMPERATURE PRESSURE RAIL PRESSURE & PRESSURE 03
EXHAUST GAS
SENSOR SENSOR SENSOR SENSOR PRESS. TEMPERATURE SENSOR
RECIRCULATION
CAMSHAFT CRANKSHAFT SENSOR SENSOR GP3
VALVE (EGR) 11C
11C GP4
START STARTER
RELAY
STARTER
SOLENOID
TO S1 BATTERY TO BATTERY
03 00
DISCONNECT SW. B- POST
Z
M
B+ G
3
D+
09A
3.57 Interface & Engine Electrical

M231435AB-2 Schematic - Deutz D2.9L

117
3.58 Interface & Engine Electrical Schematic - Deutz D2011
TO BASE BOX INTERFACE HARNESS TO ENGINE TO ENGINE ENGINE D2011

ENCLOSURE 00ACR HARNESS
09 00A
56ACR
09 02
77 02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
57BCR
A Hinweise: (N ...) A
56 56 54A 54A 54A 54A 12 57B

M 5 8 9 13 12 11 10 23 4 25 24 22 21 20 2 14 15 17 19 18 16 6 1 3 7 1. Ger ätebezeichnung nach H829908 Teil 1, z.B. D5
1
1
02 6
MOTOR D5/xx.1
Steuerger ät
2. max. Spulenstrom 400mA
z.B. TYCO Siemens Nr.V23132-B2002-A200
oder Bosch Nr. 0 332 002 250
103 02 02 PS1 Kodierung 1
GND
3. Kein DEUTZ Lieferanteil
DigIn5
2
DigOut4
DigOut3
EMR
Speed1In
GND(Speed1)
Chassis
ActorOut+
GND(ADC4)
13 13
GND(ADC2)
GND(Speed2)
ActorOut-
GND(TempAll)
ENGINE OIL PR.
RackMeasCom
RackMeasRef
ADC5(Temp1)
RackMeasSignal
ADC6(Temp2)
ADC7(Temp3)
25 25
+5Vref(ADC2)
11
+5Vref(ADC4)
PWM2 or DigOut6
ADC4 or DigIn9
ADC2 or DigIn7
12 12
Speed2 or DigIn2
24 24
00A 00C engine code 1

23
22
11
10
23
22
11
10
4. Leitungsquerschnitte nach TPI 0199-63-0206
B B
9 9
21 21
8
control unit 8
76 00A U
20 20
00A(ENGINE RUN= GND)

7 7
19 19
X23 18
6
EMR 18
6
3
3
57B 4 D5/xx.1 17
5
4
17
5
Anschlu ß Kunde
16
15
3
2
16
15
3
2
Notes: (N ...)
03
14 14
1 1
A female connector
D5 1. equipment declaration according
57B
1,5mm 2
1,5mm 2
2
1,5mm 2
1,5mm 2
1
1,5mm
84 57B 77 77 with female terminals
D5/xx.2
to H829908, part 1, e.g. D5
4
4
2. max. coil current 400mA
D54A 11 10
FU1
1 2 3
4
Ger ät
for example
TYCO Siemens Nr.V23132-B2002-A200'
74 77 77 50A
C 5 6
Bosch Nr. 0 332 002 250
C
5
5
7 8
AnschluB Motorstecker Anschlu ß Gerätestecker Kodierung 2

9 10 11 12 3. not supplied by DEUTZ
11A connection engine plug connection equipment plug equipment code 2
09 54ACR 7 4. cross-sections according TPI 0199-63-0206

103 103 K2 10
6
6
GND 5
11B 1,5mm 2
CONNECTOR P3 6
3
Anschlu ß Druckschalter Wartung Luftfilter
02 76 76 TO ECU D
2
9
Anschlu ß Druckschalter Wartung Luftfilter D
7
7
Anschlu ß Generator W
D5.1, PIN 3 1
Anschlu ß Generator D+
4
Anschlu ß Starter Kl. 50
57A 74 74
11
12
Anschlu ß Druckschalter Motoröl
Anschlussplan-Ger äteseite
8
8
8
N2 K2 Hochstromrelais wiring diagram-equipment
X23
54A 84 high-current relay
9
84 X17.3.2 X17.3.1
1 2 5 3
9
E E
57ACR
male connector female connector
ECU with female terminals with female terminals
104 104 CONNECTOR D5.2

N4
10
10
10
57A 02
1 2
(LOCATED ON ECU R.H.S.) 1 2 3 4 2 3
6,0mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1,2mm 2
1,2mm 2
1,2mm 2
1,5mm 2
2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
1 4 (30) + U_Batt
1,5mm
2,5mm
2,5mm
5 8 5 6
105 105 9 12 7 8 (15) + U_Batt

11
11
11
16
V
13 14 15 16 9 10 11 12
Kunde X17.3.2 X17.3.1
F 15 9 5 14 13 6 2 10 11 12 16 3 7 8 4 1 1 9 2 5 7 10 6 3 11 8 4 12 F
84 15
106 106 Motor
12
12
12
4 3 2 1 3 2
1,5mm 2
1,5mm 2
1,5mm 2
2
1,5mm 2
1,5mm 2
1,5mm 2
1,5mm 2
4 1
1,0mm2
1,0mm2
1,0mm2
1,0mm2
1,0mm2
1,0mm2
1,0mm2
1,0mm2
1,0mm2
1,5mm
54A 57B 8
12
5
9
6
8
5
7
Der weitere Schaltplanverlauf
ist auf Blatt2 dargestellt.
2
16 15 14 13 12 11 10 9 The following schematic
106 2 diagram is pictured on page2.
96 68A 68A 105 10 G

female connector
with male terminals
male connector
with male terminals G
1
1
104 11
76 96 96
68CR
2
DIMENSIONS AND INDICATIONS IN PARENTHESES ( )

68 02 CANH 68A 14
Masszahlen und Angaben in Klammern ( ) gelten

CANH
3
3
CAN H 12 H H
ARE NOT FOR INSPECTION.

nicht fuer die Pruefung.
...
77(ENGINE RUN=GND) CANL CANL CAN L 13
1 2 3 4 5
4
4
2 1 2 1 1 2 3 4 1 2 3
68 54A 68A 11 11
74 5
5
5
J J
11
MENT OF DAMAGES. ALL RIGHTS ARE RESERVED IN THE EVENT OF THE

USE OR COMMUNICATION OF THE CONTENTS THEREOF, ARE FORBIDDEN
3-4 1-2
WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAY-

COPYING OF THIS DOCUMENT, AND GIVING IT TO OTHERS AND THE
(+) (-) (+) Out (-)
6
6
2 3
CONNECTOR P4
1 4
2 1 1 2 3
1 Gl ühstiftkerzen Gl ühwendelkerzen
CANH 76 4
oder
R1 R2
W
7
7
7
103 17 3-4 glow plug 1-2 glow plug
CANL K
OPTION
K
8
8
8
96 3 Wenn nicht anders angegeben Werkstoff Darstellungs-

UNLESS OTHERWISE SPECIFIED MATERIAL Methode
--
Masse in mm Werkstueckkanten Form- und Oberflaechen PROJECTION
-
DIMENSIONS ARE IN nach DIN ISO 13715 Lagetoleranzen Angaben nach METHOD
9
ür den Fall der

MILLIMETERS nach ISO1101 u. DIN7167 ISO 1302
Temperatur Drehzahl Druck Druck Druckschalter EMR
ältigung dieser Unterlage, Verwer-

99 18 Bauart CORNERS PER GEOMETRIC TOLERANCES Massstab Gewicht
R= 120 Nockenwelle Ladeluft Motor öl Motor öl Stellglied o.M. -
Patenterteilung oder Gebrauchsmuster-Eintragung vorbehalten.

K ühlmittel
ücklich zugestanden. Zuwiderhandlungen ver-

TYPE DIN ISO 13715 PER ISO1101 AND DIN7167 SURFACE SCALE WEIGHT
tung und Mitteilung ihres Inhalts nicht gestattet, soweit

(B)FM-L 2011 Allgemeintoleranzen TEXTURE PER Rohteil-Nr.
90 21 L -0,3 +0,6 - L
10
10
10
GENERAL TOLERANCES ISO 1302 BLANK NO. ISO 128
B43 B40 B48 B6 F1 Y3 - IN MICROMETERS
pflichten zu Schadenersatz. Alle Rechte f

UG Datum/DATE Name/NAME Benennung 00131
coolant engine oil
Bearb.
20.08.03 Sachser TITLE Anschlussplan
Weitergabe sowie Vervielf

engine speed charge air engine oil EMR actuator DRAWN
02 1
11
11
11
Norm
pressure STANDARDS 23.09.03 Odermatt EMR2
temperature camshaft pressure pressure switch Freigegeb.
Motorseite
nicht ausdr
RELEASED 22.09.03 TH
OE
DEPT. TE-EM
2 M0138-48-0093 06.01.05 Sachser
Teilenummer (Sach-, Identnummer) Cha. For. Techn. Ordnungsnummer Blatt
PART-NUMBER CHA. FOR. TECH.-ORDER-NUMBER
12
12
12
SHEET
M OPTION OPTION 2 Blatt 2 hinzu 1 M
1 M0138-48-0085
06.01.05
12.03.04
Sachser
Sachser
R
2005
DEUTZ AG 0421 3231 U B 0138-48 von
OF 2
Bl.
SH.
Zust. Datum/Name
INDEX
Aenderung
REVISION DATE/NAME
Ursprung
ORIGIN. M0138-48-0085 Ers. fuer
REPLACES
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0109 9910 DIN A1
.
X22
DIAG. PORT
X
09
A
106
B
105 L
104
K

M231435AH-3 Schematic - Deutz D2011

118
M224639AD-2
A

TO BATTERY TO BATTERY TO BATTERY
B+ POST B+ POST B- POST
B
B+-10 RD
B+-12 RD
00-18 WH
00-12 WH
00-10 WH
FU2 FU1
30A 30A A02-16 WH
2
A32-16 BK
32
K01-12 RD
86B-10 RD
A04-16 WH
4
A05-16 BK
5
3.59 Engine Electrical Schematic - Deutz D2.2
C
A16-16 WH
16
09A-18 BK
A33-16 BK
33
09CR
A18-16 WH
18
A48-16 BK
48
A37-18 WH
00-18 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
D
A07-18 BK
7
TO ECU
A19-16 BK
19
A20-16 WH
20
A23-18 BK
23
(-) 00-14 WH
SPL00 A24-18 BK
24
FUEL
PUMP FP A25-18 BK
25
(+) 56B-14 RD
A26-18 BK
26
A27-18 BK
27
A28-18 BK
28
A29-18 BK
29
E
L L1
A35-18 BK
35
201-18 WH
WATER IN A40-18 BK
40
FUEL SWITCH 200-18 BK

A43-18 BK
43
A44-18 BK
44
A45-18 BK
45
A15-18 BK
15
K01-14 RD
1
F
K01-12 RD K01-14 RD
3
K01-14 RD
5
00-14 WH
SPLK01
2
00-12 WH 00-14 WH
4
00-14 WH
6
SPL00
204-18 RD
103-18 WH SPL202 103-18 BK
1
103A-18 WH 103A-18 WH
2
13 15 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
CAN H-18 BK K28-18 BK
6
26 27 28
203-18 BK
7
TO CONTROL PANEL.
57B-16 BK 57B-16 BK
8
SEE MACHINE
CAN L-18 WH K44-18 BK
9
ELEC. SCHEMATIC.
74-18 WH 74-18 WH
10
29 35 44 48
105-18 WH 105-18 WH
53
104-18 BK
11 12
D2.2 - 94 PIN
201-18 WH
K61-18 BK TO ECU
57 61
200-18 BK
H
76B-18 WH
103-18 BK
64 65 68
76B-18 WH 76A-18 BK
1
K73-18 BK
2
76A-18 BK 99-18 WH
3
70 73 74
99-18 WH 104-18 BK
4
75
90-18 BK 90-18 BK
5
80
CONNECTOR P2
K22-18 BK (46AJ ONLY) K82-18 BK
6 K85-18 BK
I
TO CONTROL PANEL.
202-18 WH (46AJ ONLY) SPL203 202-18 WH
7
SEE MACHINE
09J-16 BK 09J-16 BK
8
ELEC. SCHEMATIC.
54-18 BK 54-18 BK
9
82 85 87 88 90
81-18 WH 81-18 WH
10
77-18 WH 77-18 WH
09A-18 BK SPL204 CAN H-18 BK

11 12
CAN L-18 WH
92 71 54 76
R=
120
ohm
J
K
K82-18 BK
203-18 BK
204-18 RD
A40-18 BK
A27-18 BK
A24-18 BK
A32-16 BK
A05-16 BK
A33-16 BK
A48-16 BK
A52-18 BK
A54-18 BK
K28-18 BK
A28-18 BK
K61-18 BK
A25-18 BK
A26-18 BK
A43-18 BK
A44-18 BK
A29-18 BK
K44-18 BK
K85-18 BK
A19-16 BK
A53-18 RD
A38-18 RD
A07-18 BK
K73-18 BK
00-10 WH
202-18 WH
A23-18 BK
A02-16 WH
A04-16 WH
A16-16 WH
A18-16 WH
A37-18 WH
A39-18 WH
A20-16 WH
A45-18 BK
A35-18 BK
86C-10 RD
A15-18 BK
X17.1-62 PIN
L
61 38 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 1 2 3 4
AT ENGINE
COOLANT
LEVEL
SENSOR
L L2
11 11A 1 2 3
11CR
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 COOLING

U U U U U U U FAN
n n n P P p&t° P M
FUEL ACTUATOR FUEL FUEL FU2
100A 11C GP2
INJ. MPROP INJ. INJ. ENGINE ENGINE COOLING FUEL LOW FUEL BOOST OIL
CYL.3 CYL.1 CYL.2 SPEED SPEED TEMPERATURE PRESSURE RAIL PRESSURE & PRESSURE 03
EXHAUST GAS
SENSOR SENSOR SENSOR SENSOR PRESS. TEMPERATURE SENSOR
M
RECIRCULATION
CAMSHAFT CRANKSHAFT SENSOR SENSOR 11C GP3
VALVE (EGR)
START STARTER
RELAY
STARTER
SOLENOID
TO S1 BATTERY TO BATTERY
03 00
DISCONNECT SW. B- POST
B+ G
3
N
D+
09A
O
D2.2
3.59 Engine Electrical Schematic - Deutz
Z
T
Y
X
S
R
229042AFA
119
3.60 Interface & Engine Electrical Schematic - Kubota WG2503
MAIN PANEL INTERFACE ENGINE HARNESS ENGINE Kubota WG2503 KUBOTA EFI DUAL FUEL ENGINE
ECU1
R
CONNECTOR VIC2
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
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)
43 (GRAY) TACH 9
B (WHITE/BROWN)
83 (WHITE/BROWN) AUX PWM5 RECIRC 10
S
J (GRAY/RED) 1700 RPM
42 (GRAY/RED) (GOV 2) AUX DIG 4 11
K (GRAY/DK BLUE) 2675 RPM

34 (GRAY/DK BLUE) GOV 1 12
00A C (BROWN/WHITE)
84 (BROWN/WHITE) AUX PWM5 13 ENGINE RUNNING
3000 E (BLACK)
69 (BLACK) GROUND 14
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 T
KS
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
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
U
4 (BLACK) SPARK GND 29
SC2
1 2 5 (YELLOW/WHITE) SPK COIL 2B 30 SPARK COIL
CYLINDER #2
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
F4 A
C D 61 (BLACK/YELLOW) EGOH 2 34 POWER RELAY
FUSE 15A
IGNITION
73 (WHITE/LT BLUE) RELAY 35
2002CR
F2
79 (RED/TAN) VBAT 36
1
FUSE 10A
ECM TPS1
(BLACK) A (BLACK/LT GREEN) D
1 2 37 (TAN/WHITE) ECT 37 ENGINE COOLANT
V
2
TEMPERATURE SENSOR
GPS1
(GREEN/WHITE) B (LT GREEN/WHITE)
GASOLINE
3
1 2 38 (LT GREEN/WHITE) (FRT) AUX ANA PU1 38

PRESSURE SENSOR
(WHITE) D (WHITE/LT GREEN)
4
3 4 13 (WHITE/LT GREEN) (FRP) AUX ANA PD2 39
TA1
5
(GREEN/RED) C (LT GREEN/RED)

2 1 82 (TAN/ORANGE) DBW - 40 THROTTLE
ACTUATOR
6
1
C
3 4 80 (PINK/WHITE) DBW + 41
68
2
7
57A 57A 5 48 (LT BLUE/DK BLUE) TPS 2 42
3
8
11 6 47 (PURPLE/LT BLUE) TPS 1 43

9
4
76
10
5
44
(PINK/DK GREEN) MS1
11
6
C A 36 (YELLOW/GRAY) IAT 45 M.A.P. SENSOR
DIAGNOSTIC
12
DEPR1 F3
7
8 (BLUE/WHITE)
5 3
FUSE 10A
B D 23 (LT GREEN) MAP 46
W
8
7 (DK BLUE/PINK) DEPR
2 6 47 PROPANE DIRECT
1
ELECTRONIC PRESSURE
9
REGULATOR
76
2
77 DIAGNOSTIC DISPLAY
1 4 48
10
(WHITE)
3
CANH 54A
2 4
CAN L P (BLUE/WHITE)
14 (DK BLUE/PINK) CAN 1 + 49
11
77
CANL
4
3000 CAN H N (DK BLUE/PINK)

12
1 3 15 (BLUE/WHITE) CAN 1 - 50
68
5
CONNECTOR VIC1
L (BLACK/LT GREEN)
20 (BLACK/LT GREEN) 5V RTN 1 51
11
6
M (LT GREEN/RED)
CANH 19 (LT GREEN/RED) 5V EXT 1 52
7
CANL S (LT GREEN/PURPLE)

31 (LT GREEN/PURPLE) 5V EXT 2 53
8
R (LT GREEN/BLACK)
9
32 (LT GREEN/BLACK) 5V RTN 2 54

10
K (DK BLUE/ORANGE)
53 (DK BLUE/ORANGE) FPP1 55
X
11
J (PURPLE/YELLOW)
54 (PURPLE/YELLOW) FPP2 IVS 56
12
E (DK BLUE) MAIN ENGINE
INTERFACE HARNESS
87 (DK BLUE) AUX PWM 2 57
SWITCH
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
68 3056 F5
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
CONNECTOR P1 56CR 2P-56
57A
77 (WHITE/BLACK) LOCK OFF 62 PROPANE LOCKOFF
SOLENOID
11 11 H (DK GREEN/PURPLE)
49 (DK GREEN/PURPLE) (FUEL SEL) AUX DIG 1 63 GAS/PROPANE
SELECTOR SWITCH
76 76 G (GREEN/YELLOW) CHECK ENGINE
74 (GREEN/YELLOW) MIL 64
57A F (LT BLUE/PINK)

57ACR
LIGHT
Y
00A 72 (PINK/BLACK) (STARTER) AUX PWM4 65 STARTER RELAY
F1 (WHITE)
68 A (PINK)
CAN H 44 (PINK/TAN) VSW 66
FUSE 5A
F6 32BCR
CAN L VSW
67 ENGINE STARTER
FUSE 30A SOLENOID
STARTER
M 68 ENGINE STARTER
EL. MOTOR
(RED/TAN)
B (PURPLE) 69
(RED)
70
F7 2 3
71 ALTERNATOR
G
FUSE 60A
ALTERNATOR
72
TO MAIN TO BATTERY
DISCONNECT GROUND

M231435AE-4 Schematic - Kubota WG2503

120
Section 4 – Troubleshooting Information
4.1 Introduction
The following pages contain a table of
Troubleshooting for locating and correcting most
service trouble which can develop. Careful and
accurate analysis of the systems listed in the table
of Troubleshooting 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 in the left-
hand column, preceded by a number, represents the
“probable cause.” The information in the right-hand
column, in bold text, represents the “remedy” to the
“probable cause” directly beside it. See the example
below for clarification.
1. Probable cause Remedy

121
Section 4 – Troubleshooting Information Electrical System - ANSI/CSA
4.2 Electrical System - ANSI/CSA
4.2-1 All Controls are Inoperative from the Base or Platform Console
NOTE
Functions may be disabled by the dual load zone system or the overload system. Please first
make sure the boom is at or below level and fully retracted, the platform is level and free of added
weight, and there are no faults in the dual load or overload systems.
1. Battery cables loose/disconnected Tighten or connect battery cables

2. Battery Discharged or Defective Charge battery or replace if defective
3. Loose or broken B+ cable from batteries to Check continuity. Replace if defective.
battery disconnect switch S1
4. Open or defective battery disconnect switch S1 Close switch. Replace if defective
5. Loose or broken wire #03 from battery Check continuity. Replace if defective
disconnect switch S1 to circuit breaker CB1
6. Circuit breaker CB1 tripped or defective. Reset breaker, check for defective wiring. Replace
if defective.
7. Loose or broken wire #05 from circuit breaker Check continuity. Replace if defective.
CB1 to base emergency stop switch S3.
8. Open or defective base emergency stop switch Close switch. Replace if defective.
S3.
9. Loose or broken wire #07 from base emergency Check continuity. Replace if defective.
stop switch S3 to base key switch S2.
10. Loose or broken #07A wires between base key Check continuity. Replace if defective.
switch S2 terminals
11. Open or defective key select switch S2 Close switch. Replace if defective
12. Loose or broken wire #04A from base terminal Check continuity. Replace if defective.
block to relay 04ACR.
stop switch S3 to relay 04ACR.
14. Loose or broken wire #02 from relay 04ACR to Check continuity. Replace if defective.
base terminal block.
15. Defective relay 04ACR. Check relay. Replace if defective.
16. Loose or broken wire #09 from relay 04ACR to Check continuity. Replace if defective.

122
Electrical System - ANSI/CSA Section 4 – Troubleshooting Information
17. Loose or broken wire #09 from base terminal Check continuity. Replace if defective.
block to base control module connector J1 pins
1, 2, 3, and/or 4.
18. Loose or broken wire #02 from base control Check continuity. Replace if defective.
module connector J1 pins 10, 11, 12, and/or 13
to base terminal block.
block to circuit breaker CB2.
if defective.
CB2 to battery negative.
22. Loose or broken wire #07A from base key Check continuity. Replace if defective.
switch S2 to base terminal block.
block to platform terminal block.
24. Loose or broken wire #07A from platform Check continuity. Replace if defective.
terminal block to platform emergency stop switch
S4.
25. Open or defective platform emergency stop Close switch. Replace if defective.
switch S4.
26. Loose or broken wire #04 from platform Check continuity. Replace if defective.
emergency stop switch S4 to platform terminal
block.
27. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block platform control module connector J11
pins 1, 2, 3, and/or 4.
28. Loose or broken CAN H wire from platform Check continuity. Replace if defective.
control module connector J11 pin 8 to platform
terminal block
29. Loose or broken CAN H wire from platform Check continuity. Replace if defective.
terminal block to base terminal block.
30. Loose or broken CAN H wire from base terminal Check continuity. Replace if defective.
block to base control module connector J1 pin 8.
31. Loose or broken CAN L wire from platform Check continuity. Replace if defective.
control module connector J11 pin 9 to platform
terminal block
32. Loose or broken CAN L wire from platform Check continuity. Replace if defective.
terminal block to base terminal block.
33. Loose or broken CAN L wire from base terminal Check continuity. Replace if defective.
block to base control module connector J1 pin 9.

123
34. Loose, broken, or defective 120 ohm CAN Check that resistance between CAN H and CAN L
termination resistor(s) between CAN H and is appoximately 60 ohms (2 x 120 ohm in parallel).
CAN L teminals in platform and/or base terminal Check connections. Repair connections or replace
block(s). if defective.
35. Loose or broken wire #02 from platform control Check continuity. Replace if defective.
module connector J11 pins 10, 11, 12, and/or 13
to platform terminal block.
block to base terminal block.
37. Defective base (master) control module SMB1- Replace if Defective
105
38. Defective platform (slave) control module SMB1- Replace if Defective
106
4.2-2 All Controls are Inoperative from the Base Console
1. loose or defective wire #10 from keyswitch S2 to Check continuity. Replace if defective
ignition/enable switch S5
2. Defective ignition/enable switch S5 Check continuity through switch when activated.
Replace if defective
3. Loose or broken wire #10A from ignition/enable Check continuity. Replace if defective
switch S5 to base control module connector J2
pin 18.
4. Loose or broken wire #10A from ignition/enable Check continuity. Replace if defective
switch S5 to base boom control toggle switches.
4.2-3 The Engine will not Crank from the Base or Platform
1. Loose or broken wire #57C from base control Check continuity. Replace if defective
module connector J3 pin 9 to 57DCR relay pin
30.
2. Loose or broken wire #09 from base terminal Check continuity. Replace if defective
block to 57DCR relay pin 85
3. Loose or broken wire #57D from 57DCR relay Check continuity. Replace if defective
pin 86 to telematics connector J6 pin 9
4. Loose or broken junper wire from J6 pin 9 to J6 Check continuity of jumper. Check telematics if
pin 4, or if equipped with telematics then either equipped. Repair or replace as required.
start interlock is engaged or telematics are
inoperative
5. Loose or broken wire#00 from J6 pin 4 to Check continuity. Replace if defective
ground.
6. Loose or broken wire #57A from relay 57DCR pin Check continuity. Replace if defective
87 to connector J4 pin 8.

124
7. Defective relay 57DCR. Check relay. Replace if defective.

8. Loose or broken 57A wire from connector P4 Check schematic applicable to the engine equipped
pin 8 to start input on ECU or 57ACR relay if on the machine to determine ECU pin # or relay if
equipped. equipped.
NOTE
For other engine-related problems, consult the engine manufacturer’s manual.
4.2-4 The Engine will not Crank from the Base
1. Loose or broken wire #10 from base keyswitch Check continuity. Replace if defective
S2 to base start switch S5
2. Loose or broken wire #57 from base start switch Check continuity. Replace if defective
S5 to base control module connector J2 pin 30.
3. Defective start/enable switch S5 Check continuity through switch. Replace if
defective
4.2-5 The Engine will not Crank from the Platform
NOTE
The engine will not crank from the platform with the footswitch pressed.
1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective
block to start switch S9.
2. Loose or broken wire #57B from start switch S9 Check continuity. Replace if defective
to platform control module connector J12 pin 30
3. Defective start switch S9 Check continuity through switch. Replace if
defective
4.2-6 The Boom Controls are Inoperative (Drive Operates)
1. Loose or broken wire #21A from base control Check continuity. Replace if defective
module connector J3 pin 24 to main harness 24
pin connector pin 3
2. Loose or broken wire #21A from main harness Check continuity. Replace if defective
plug pin #3 to dump valve 2H-21A
3. Loose or broken wire #02 from dump valve Check continuity. Replace if defective
2H-21A to main harness plug
4. Defective dump valve coil 2H-21A Check continuity and resistance through coil.

125
4.2-7 No Boom Up from the Base or Platform Controls
1. Loose or broken wire #14 from base control Check continuity. Replace if defective
module connector J2 pin 5 base terminal block to
turret harness plug pin #2
2. Loose or broken wire #14 from turret harness Check continuity. Replace if defective
plug pin #2 to boom up valve 4H-14
plug to boom up valve 4H-14
4. Defective boom up coil 4H-14 Check continuity and resistance through coil.
4.2-8 No Boom Up from the Base Console
1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective
to boom switch S12
2. Defective boom switch S12 Check continuity through switch while activating
boom up function between wires #10A and #14B.
Replace switch if no continuity
3. Loose or broken wire #14B from boom switch Check continuity. Replace if defective
S12 to base control module connector J2 pin 15
4.2-9 No Boom Up from the Platform Console
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 Check continuity. Replace if defective
to J13 pin #16 of platform control module
4.2-10 No Boom Down from the Base or Platform Consoles
module connector J2 pin 6 base terminal block to
turret harness plug pin #1
plug pin #1 to boom down valve 4H-13
plug to boom down valve 4H-13
4. Defective boom down coil 4H-13 Check continuity and resistance through coil.

126
4.2-11 No Boom Down from the Base Console
to boom switch S12
boom down function between wires #10A and
#13B. Replace switch if no continuity
4.2-12 No Boom Down from the Platform Console
4.2-13 No Turret Rotate Right from the Base or Platform Consoles
module connector J2 pin 24 base terminal block
to turret harness plug pin #10
plug pin #10 to boom up valve 4H-33
4. Defective boom up coil 4H-33 Check continuity and resistance through coil.
4.2-14 No Turret Rotate Right from the Base Console
to turret rotate switch S13
2. Defective turret rotate switch S13 Check continuity through switch while activating
turret rotate right function between wires #10A and

127
4.2-15 No Turret Rotate Right from the Platform Console
3. No output on X-axis of joystick controller A1 Refer to joystick test procedure in section 5
4. Loose or broken wire “x” from joystick controller Check continuity. Replace if defective
4.2-16 No Turret Rotate Left from the Base or Platform Consoles
module connector J2 pin 13 to turret harness
plug pin #9
plug pin #9 to turret rotate left valve 4H-32
plug to turret rotate left valve 4H-32
4. Defective turret rotate left coil 4H-32 Check continuity and resistance through coil.
4.2-17 No Turret Rotate Left from the Base Console
to turret rotate switch S13
2. Defective turret rotate switch S13 Check continuity through switch while activating
down function between wires #10A and #32B.
3. Loose or broken wire #32B from turret rotate Check continuity. Replace if defective
pin 17
4.2-18 No Turret Rotate Left from the Platform Console

128
4.2-19 No Riser Up from the Base or Platform Consoles
module connector J2 pin 3 to turret harness plug
pin #8
plug pin #8 to riser up valve 4H-31
plug to riser up valve 4H-31
4. Defective rise up coil 4H-31 Check continuity and resistance through coil.
4.2-20 No Riser Up from the Base Console
to boom switch S25
2. Defective riser switch S25 Check continuity through switch while activating
riser up function between wires #10A and #31B.
3. Loose or broken wire #31B from riser switch S25 Check continuity. Replace if defective
to base control module connector J3 pin 31
4.2-21 No Riser Up from the Platform Console
3. No output on "R" of joystick controller A3 Refer to joystick test procedure in section 5
4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective
4.2-22 No Riser Down from the Base or Platform Consoles
pin #7
plug pin #7 to riser down valve 4H-30
plug to riser down valve 4H-30
4. Defective rise down coil 4H-30 Check continuity and resistance through coil.

129
4.2-23 No Riser Down from the Base Console
to boom switch S25
2. Defective riser switch S25 Check continuity through switch while activating
riser down function between wires #10A and #30B.
3. Loose or broken wire #30B from riser switch S25 Check continuity. Replace if defective
to base control module connector J3 pin 30
4.2-24 No Riser Down from the Platform Console
3. No output on "R" of joystick controller A3 Refer to joystick test procedure in section 5
4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective
4.2-25 No Telescope Out from the Base or Platform Consoles
plug pin #14
plug pin #14 to telescope out valve 4H-39
4. Defective telescope out coil 4H-39 Check continuity and resistance through coil.
4.2-26 No Telescope Out from the Base Console
to telescope switch S13
telescope out function between wires #10A and
3. Loose or broken wire #39B from telescope Check continuity. Replace if defective
pin 33

130
4.2-27 No Telescope Out from the Platform Console
block totelescope switch S18
telescope out function between wires #04 and
#39A. Replace switch if no continuity
3. Loose or broken wire #39A from telescope Check continuity. Replace if defective
switch S18 to platform control module connector
J12 pin 33
4.2-28 No Telescope In from the Base or Platform Consoles
pin #13
plug pin #13 to telescope in valve 4H-38
plug to telescope in valve 4H-38
4. Defective telescope in coil 4H-38 Check continuity and resistance through coil.
4.2-29 No Telescope In from the Base Console
to telescope switch S14
2. Defective telescope switch S14 Check continuity through switch while activating
telescope in function between wires #10A and
4.2-30 No Telescope In from the Platform Console
block to telescope switch S18
2. Defective telescope switch S18 Check continuity through switch while activating
down function between wires #04 and #38A.
3. Loose or broken wire #38A from boom switch Check continuity. Replace if defective
S18 to platform control module connector J12
pin 21

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4.2-31 No Platform Level Up from the Base or Platform Consoles
module connector J2 pin #7 to turret harness
plug pin #16
plug pin #16 to platform level up valve 4H-41
plug to platform level up valve 4H-41
4. Defective platform level up coil 4H-41 Check continuity and resistance through coil.
4.2-32 No Platform Level Up from the Base Console
to platform level switch S15
2. Defective platform level switch S15 Check continuity through switch while activating up
function between wires #10A and #41B. Replace
switch if no continuity
3. Loose or broken wire #41B from platform level Check continuity. Replace if defective
pin 22
4.2-33 No Platform Level Up from the Platform Console
block to platform level switch S19
2. Defective platform level switch S19 Check continuity through switch while activating
platform level up function between wires #04 and
3. Loose or broken wire #41A from platform level Check continuity. Replace if defective
switch S19 to platfrom control module connector
J12 pin 22
4.2-34 No Platform Level Down from the Base or Platform Consoles
plug pin #15
plug pin #15 to platform level down valve 4H-40
plug to platform level down valve 4H-40
4. Defective platform level down coil 4H-40 Check continuity and resistance through coil.
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4.2-35 No Platform Level Down from the Base Console
2. Defective platfrom level switch S16 Check continuity through switch while activating
platfrom level down function between wires #10A
and #40B. Replace switch if no continuity
pin 26
4.2-36 No Platform Level Down from the Platform Console
block to platform level switch S19
platfrom level down function between wires #04
and #40A. Replace switch if no continuity
3. Loose or broken wire #40A from platform level Check continuity. Replace if defective
switch S19 to platform control module connector
J13 pin 26
4.2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles
plug pin #20
plug pin #20 to platform flow enable valve 2H-
42
plug to platform flow enable valve 2H-42
4. Defective platform flow enable coil 2H-42 Check continuity and resistance through coil.

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4.2-38 No Platform Rotate Right from the Base or Platform Consoles
1. Loose or broken wire #37 from platform control Check continuity. Replace if defective
module connector J12 pin #1 to platform
terminal strip
strip to platform platform rotate right valve 4H-37
strip to platform rotate right valve 4H-37
4. Defective platform rotate right coil 4H-37 Check continuity and resistance through coil.
4.2-39 No Platform Rotate Right from the Base Console
to platform rotate switch S16
2. Defective platform rotate switch S16 Check continuity through switch while activating
platform rotate right function between wires #10A
3. Loose or broken wire #37B from platform rotate Check continuity. Replace if defective
pin 28
4.2-40 No Platform Rotate Right from the Platform Console
block to platform rotate switch S20
platform rotate right function between wires #04
and #37A. Replace switch if no continuity
3. Loose or broken wire #37A from platform rotate Check continuity. Replace if defective
J13 pin 28

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4.2-41 No Platform Rotate Left from the Base or Platform Consoles
terminal strip
strip to platform platform rotate left valve 4H-36
strip to platform rotate left valve 4H-36
4. Defective platform rotate left coil 4H-36 Check continuity and resistance through coil.
4.2-42 No Platform Rotate Left from the Base Console
platfrom level down function between wires #10A
pin 29
4.2-43 No Platform Rotate Left from the Platform Console
block to platform rotate switch S20
platform rotate left function between wires #04 and
3. Loose or broken wire #37A from platform rotate Check continuity. Replace if defective
J13 pin 28
4.2-44 No Jib Up from the Base or Platform Consoles
terminal strip
strip to jib up valve 4H-35
strip to jib up valve 4H-35
4. Defective jib up coil 4H-35 Check continuity and resistance through coil.
135
4.2-45 No Jib Up from the Base Console
to jib switch S17
2. Defective jib switch S17 Check continuity through switch while activating
jib up function between wires #10A and #35B.
3. Loose or broken wire #35B from jib switch S17 to Check continuity. Replace if defective
base control module connector J2 pin 28
4.2-46 No Jib Up from the Platform Console
block to jib switch S21
2. Defective jib switch S21 Check continuity through switch while activating jib
up function between wires #04 and #35A. Replace
switch if no continuity
3. Loose or broken wire #35A from jib switch S21 to Check continuity. Replace if defective
platfrom control module connector J12 pin 28
4.2-47 No Jib Down from the Base or Platform Consoles
terminal strip
strip to jib down valve 4H-34
strip to jib down valve 4H-34
4. Defective jib down coil 4H-34 Check continuity and resistance through coil.
4.2-48 No Jib Down from the Base Console
to jib switch S17
jib down function between wires #10A and #34B.
3. Loose or broken wire #34B from jib switch S17 to Check continuity. Replace if defective
base control module connector J2 pin 26

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4.2-49 No Jib Down from the Platform Console
block to jib switch S21
jib down function between wires #04 and #34A.
3. Loose or broken wire #34A from jib switch S21 to Check continuity. Replace if defective
platfrom control module connector J12 pin 26
4.2-50 No Drive or Steer Functions
block to drive joystick A2
block to drive joystick A2
3. Defective drive joystickA2 See drive joystick test procedure in section 5
4.2-51 No Forward or Reverse Drive
1. No output on “D” when forward is selected on See drive joystick test procedure in section 5
drive joystick A2
2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective
joystick A2 to platform control module connector
J13 pin #14
4.2-52 No Forward Drive
1. No output from base control module at connector Check for correct output voltage.
J2 pin #1 to wire #16
2. Loose or broken wire 16 from base control Check continuity. Replace if defective
module connector J2 pin #1 to turret connector
pin 21
3. Loose or broken wire #16 from turret plug pin 21 Check continuity. Replace if defective
to drive pump valve connector pin #4
4. Loose or broken wire #16 from drive pump valve Check continuity. Replace if defective
connector pin #4 to 3H-16 Forward coil
5. Loose or broken wire #02 wire from 3H-16 Check continuity. Replace if defective
Forward coil to ground
6. Defective forward coil 3H-16 Check continuity and resistance through coil.

137
4.2-53 No Reverse Drive
1. No output from base control module at connector Check for correct output voltage.
module connector J2 pin #2 to turret connector
pin 20
3. Loose or broken wire #15 from turret plug pin 20 Check continuity. Replace if defective
to drive pump valve connector pin #1
4. Loose or broken wire #15 from drive pump valve Check continuity. Replace if defective
connector pin #1 to 3H-15 Forward coil
5. Loose or broken wire #02 wire from 3H-15 Check continuity. Replace if defective
Reverse coil to ground
6. Defective reverse coil 3H-15 Check continuity and resistance through coil.
4.2-54 The Brake will not Release
1. No output from base control module coneector Check for correct output voltage
connector pin #8
connector pin #8 to 3H-26 Brake coil
4. Loose or broken wire #02 wire from 3H-26 Brake Check continuity. Replace if defective
coil to ground
5. Defective brake coil 3H-26 Check continuity and resistance through coil.
4.2-55 No Left Steer
1. Loose or broken wire #24P from drive joystick Check continuity. Replace if defective
A2 to platform control module connector J12 pin
#15
2. No output from base control module on Check pin #13 for 12 volts. If no voltage present
connector J3 pin #13 with foot on footswitch and activating steer function
check section 5 for OCM pin voltage reference
connector pin #7
plug pin #7 to left steer valve 4H-24

138
plug to left steer valve 4H-24
6. Defective left steer valve coil 4H-24 Check continuity and resistance through coil.
4.2-56 No Right Steer
1. Loose or broken wire #23P from drive joystick Check continuity. Replace if defective
A2 to platform control module connector J12 pin
#16
2. No output from base control module on Check pin #13 for 12 volts. If no voltage present
connector J3 pin #3 with foot on footswitch and activating steer function
check section 5 for OCM pin voltage reference
connector pin #6
plug pin #6 to right steer valve 4H-23
plug to right steer valve 4H-23
6. Defective right steer valve coil 4H-23 Check continuity and resistance through coil.
4.2-57 The Directon Sensing is Inoperative
block to limit switch LS1
2. Open or defective limit switch LS1 Adjust limit switch if required. Check continuity
through switch. Replace if defective
3. Loose or broken wire #17 from limit switch LS1 Check continuity. Replace if defective
to base terminal block
block to base control module connector J2 pin
#25
5. Defective base control module channel input for Replace if Defective
direction sense enable

139
4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform
Empty or Below Weight
1. Load sense mis-calibration Refer to calibration procedure for recalibration of

load cell
2. Load cell circuit not operating Check wiring from load cell to platform control
module. Check CAN termination resistors. Check
load cell. Repair or replace as required
4.2-59 The Overload Indicator Light does not Turn On when the Platform is Overloaded
1. Defective lamp Check lamp. Replace if defective

2. Load cell circuit not operating Check wiring from load cell to platform control
module. Check CAN termination resistors. Check
load cell. Repair or replace as required
3. Load sense out of calibration Refer to calibration procedure for recalibration of
load cell
4. No output control module Check Voltage at platform control module
connectpr J3 pin #7 for 12V when platform is
loaded with 110% of rated capacity. (Boom fully
retracted and 12” (30cm) off the ground.)
5. Loose or broken wire #82 from the platform Check continuity. Replace if defective
control module connector J13 pin 7 to overload
lamp PL10.
6. Loose or broken wire #02 from overload lamp to Check continuity. Replace if defective
platform terminal strip
4.2-60 The Audible Alarm does not Turn On with the Platform Overloaded
1. Defective alarm BP3 Check alarm. Replace if defective

module connector J13 pin 8 to alarm BP3
3. Loose or broken wire #02 from alarm BP3 to Check continuity. Replace if defective
platform terminal block

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Electrical System - CE & AS Section 4 – Troubleshooting Information
4.3 Electrical System - CE & AS
4.3-1 All Controls are Inoperative
1. Battery disconnected or discharged. Connect battery or recharge.

2. Loose or broken B+ cable from battery to battery Check continuity. Replace if defective.
disconnect switch S1.
3. Open or defective battery disconnect switch S1. Close switch. Replace if defective.
4. Loose or broken wire #03 from battery Check continuity. Replace if defective.
disconnect switch S1 to circuit breaker CB1.
if defective.
CB1 to base emergency stop switch S3.
7. Open or defective base emergency stop switch Close switch. Replace if defective.
S3.
stop switch S3 to base key S2.
9. Open or defective key select switch S2. Close switch. Replace if defective.
block to relay 60CR.
stop switch S3 to relay 60CR.
12. Loose or broken wire #02 from relay 60CR to Check continuity. Replace if defective.
13. Defective relay 60CR. Check relay. Replace if defective.
14. Loose or broken wire #9 from relay 60CR to base Check continuity. Replace if defective.
terminal block.
block to circuit breaker CB2.
if defective.
CB2 to battery negative.

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Section 4 – Troubleshooting Information Electrical System - CE & AS
4.3-2 No Power
To Platform
1. Open or defective key select switch S2. Close switch. Replace if defective.
2. Loose or broken wire #07A from key select Check continuity. Replace if defective.
switch S2 to plug A pins # 2 & 3 in base control
console.
3. Loose or broken wire #07A from plug A pins Check continuity. Replace if defective.
# 2 & 3 in platform control console to platform
emergency stop switch S4.
4. Open or defective platform emergency stop Check switch. Replace if defective.
switch S4.
5. Loose or broken wire #04 from platform Check continuity. Replace if defective.
emergency stop switch S4 to Ignition/E-pump
switch S6
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 Check continuity. Replace if defective
S2 to Ignition/E-pump switch S5.
3. Loose or broken wire #12 from base key switch Check continuity. Replace if defective
S2 to base connector plug A pin #5.
4. Loose or broken wire #12 in boom cable A or its Check for continuity between pins #5 on cable A.
connectors. 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 Check continuity. Replace if defective
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 Check continuity. Replace if defective
switch S4 to plug A pin #4.
9. Loose or broken wire #10 from plug A pin #4 to Check continuity. Replace if defective
10. Open or defective diode D10. Check diode. Replace if defective.

142
block to Ignition/E-pump (enable) switch S5.
12. Open or defective Ignition/E-pump (enable) Check switch. Replace if defective
switch S5.
4.3-3 Engine Will Not Crank
From Base
1. Loose or broken wire #57A from base start Check continuity. Replace if defective.
switch S5 to relay 57ACR (Deutz D2011 and GM
3.0l engines).
2. Defective base start switch S5. Check start switch. Replace if defective.
From Platform
NOTE
Engine will not crank from platform with footswitch depressed.
1. Loose or broken wire #4 from emergency stop Check continuity. Replace if defective.
switch S4 to start switch S6.
2. Defective start switch S6. Check continuity through contacts of relay. Replace
if defective.
3. Loose or broken wire #57 from start switch S6 to Check continuity. Replace if defective.
relay 08CR.
4. Defective relay 08CR. Check continuity through contacts of relay. Replace
if defective.
5. Loose or broken wire #57A from relay 08CR to Check continuity. Replace if defective.
plug B pin #14.
6. Loose or broken wire #57A in boom cable B or Check for continuity between pin #14 on cable B.
its connectors. Check for loose or corroded connections on cable
7. Loose or broken wire #57A from plug B pin #14 Check continuity. Replace if defective.
to relay 57ACR in base control console (Deutz
D2011, GM 3.0L) or to base start switch S5
(Deutz TD2.9L).
From Platform or Base
With the following conditions:
▪ Deutz Diesel D2.9L
1. Loose or broken wire #57A from base start Check continuity. Replace if defective.
switch S5 to 12 pin connector (J1) pin 8.

143
2. Loose or broken wire #57A from 12 pin Check continuity. Replace if defective.
connector (P1) pin 8 to 94 pin ECU connector,
pin 35.
3. Loose or broken B+ wire from battery B+ to ECU Check continuity. Replace if defective.
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 Check continuity. Replace if defective.
connector P6 pin B to 94 pin ECU connector 3
places pins 1, 3, and 5.
6. Loose or broken ground wire #00 from battery Check continuity. Replace if defective.
B- to 94 pin ECU connector 3 places pins 2, 4,
and 6.
NOTE
For other engine related problems, consult engine manufacturer’s manual.

▪ Deutz Diesel D2011
1. Loose or broken wire #57A at relay 57ACR (2 Check for connections at relay. Check for voltage
places). on relay (2 places).
2. Loose or broken wire #57A from relay 57ACR to Check continuity. Replace if defective.
relay 57BCR.
3. Loose or broken wire #00A from X23 engine Check continuity. Replace if defective.
connector pin #11 to relay 57ACR.
4. Loose or broken wire #00A from X23 engine Check continuity. Replace if defective.
connector pin #11 to engine oil pressure switch.
7. Loose or broken wire #03A from circuit breaker Check continuity. Replace if defective.
CB3 to relay 09CR.
8. Tripped or defective circuit breaker CB3. Reset circuit breaker. Check continuity through
circuit breaker. Replace if defective.
CB3 to turret harness plug pin #2.

144
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 Check continuity. Replace if defective.
X23 engine connector pin #4.
16. Loose or broken wire #57C from X23 engine plug Check continuity. Replace if defective.
to start solenoid 57CCR.
17. Loose or broken starter cable #03 from Check continuity. Replace if defective.
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.
▪ Kubota Dual Fuel
block TB1 to engine harness plug.
2. Loose or broken wire #54A from engine harness Check continuity. Replace if defective.
plug to GM engine connector 1.
3. Loose or broken pink wire from GM engine Check continuity. Replace if defective.
connector 1 to fuse F7.
4. Defective fuse F7. Check fuse. Replace if defective
5. Loose or broken pink/tan wire from fuse F7 to Check continuity. Replace if defective.
ECU connector pin #45.
6. Loose or broken red wire from battery positive to Check continuity. Replace if defective.
ECU fuse F8.
7. Defective fuse F8. Check fuse. Replace if defective.
8. Loose or broken red/tan wire from fuse F8 to Check continuity. Replace if defective.
ECU connector pin #60 and pin #79.
9. Loose or broken black wire from engine ground Check continuity. Replace if defective.
to ECU connector pin #69 and #81.
10. Loose or broken light blue/pink wire from GM Check continuity. Replace if defective.
engine connector 1 to relay 57ACR.
11. Loose or broken pink/black wire from ECU Check continuity. Replace if defective.
connector pin #89 to relay 57ACR.
starter fuse F12.

145
15. Loose or broken red/tan wire from fuse F12 to Check continuity. Replace if defective.
relay 57ACR.
16. Loose or broken white wire from relay 57ACR to Check continuity. Replace if defective.
start solenoid 32BCR.
17. Defective starter solenoid 32BCR. Check solenoid. Replace if defective.
18. Loose or broken battery cable from starter Check continuity. Replace if defective.
solenoid 32BCR to starter motor.
19. Defective starter motor. Check motor. Repair or replace if defective.
▪ If equipped with Elevate/Trackunit Telematics Ready
NOTE
If the unit is equipped with an Access keypad, a passcode is required from the machine owner.
1. Loose or broken B+ wire from battery + to Check continuity. Replace if defective.

telematics pin 3.
2. Loose or broken B- wire 00 from battery - to Check continuity. Replace if defective.
telematics pin 4.
3. Loose or broken wire 07 from S3 base Check continuity. Replace if defective.
Emergency stop switch to 57DCR pin 86.
4. Loose or broken wire 57A from S5 ignition switch Check continuity. Replace if defective.
to 57DCR pin 30.
5. If telematics device is not installed: loose, broken Check continuity. Replace if defective or missing.
or missing Jumper JMPR1 from 57DCR pin 85 to
ground 00.
6. Loose or broken wire 57D from telematics pin 9 Check continuity. Replace if defective.
to 57DCR pin 85.
7. Missing output from telematics pin 9. Check for ground on pin 9. If no ground, contact
the machine owner.
8. Defective relay 57DCR. Check relay. Replace if defective.
9. Loose or broken wire 57B from 57DCR pin 87 to Check continuity. Replace if defective.
engine starter contactor coil.
10. Defective telematics module. Check telematics assembly; repair or replace as
required.

146
4.3-4 Engine Cranks but Will Not Start
Deutz Diesel D2.9L

1. Loose or broken wire #54 from 94 pin ECU Check continuity. Replace if defective.
connector, pin90 to 12 pin connector (P2), pin 9.
2. Loose or broken wire #54 from 12 pin connector Check continuity. Replace if defective.
(J2) pin 9 to relay 56ACR.
3. Loose or broken wire #03 to circuit breaker CB3. Check continuity. Replace if defective.
if defective
5. Loose or broken wire #56 from CB3 to relay Check continuity. Replace if defective.
56ACR.
12 pin connector (J1) pin 4.
7. Loose or broken wire #56A from 12 pin Check continuity. Replace if defective.
connector (P1) pin 4 to 94 pin ECU connector,
pin 26.
8. Loose or broken wire #56B from relay 56ACR to Check continuity. Replace if defective.
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 Check continuity. Replace if defective.
connector (P1) pin 3 to fuel pump.
11. Loose or broken ground wire #00 from fuel Check continuity. Replace if defective.
pump to battery B-.
12. Engine pre-heat circuit inoperative. Refer to Engine manufacturer’s manual to
diagnose.
NOTE
Deutz Diesel D2011

1. Loose or broken wire #57B from relay 57ACR to 57BCR maintains power for start circuit before
relay 57BCR (2 places). engine starts and after oil pressure switch opens
to relay 57BCR1. Check wire #57B for continuity.
Replace if defective.
relay 57BCR.
block to relay 57BCR.

147
4. Defective relay 57BCR. Check relay. Replace if defective.

5. Glow plug circuit not operating. See “Glow Plug Circuit Inoperative” in this section.
6. No fuel in fuel tank or fuel line obstructions. Check fuel level and flow through lines. Fill or
repair if necessary.
NOTE
Kubota Dual Fuel
NOTE
For additional engine troubleshooting refer to diagnostic trouble codes for use with the check engine light.
relay 2002CR.
2. Loose or broken red/tan wire from ECU fuse F8 Check continuity. Replace if defective.
to relay 2002CR.
3. Loose or broken white/ light blue wire from ECU Check continuity. Replace if defective.
connector pin #71 to relay 2002CR.
5. Loose or broken pink/dark green wire from relay Check continuity. Replace if defective.
2002CR to ignition fuse F10.
7. Loose or broken pink/dark green wire from fuse Check continuity. Replace if defective.
F10 to ignition coil IGC1 pin #A.
8. Loose or broken yellow wire from ignition coil Check continuity. Replace if defective.
IGC1 pin #B to ignition module IGM1.
9. Defective ignition coil IGC1. Check coil for spark. Replace if defective.
F10 to ignition module IGM1 pin #A.
11. Loose or broken black wire from ignition module Check continuity. Replace if defective.
IGM1 pin #C to engine ground.
12. Loose or broken yellow wire from ignition module Check continuity. Replace if defective.
IGM1 pin #B to ECU connector pin #31.
13. Defective ignition module IGM1. Check module for operation. Replace if defective.
F10 to gas injectors GI-1, GI-2, GI-3 and GI-4.
15. Loose or broken pink/white wire from ECU Check continuity. Replace if defective.
connector pin #82 to throttle actuator RA1.

148
16. Loose or broken tan/orange wire from ECU Check continuity. Replace if defective.
17. Loose or broken light green/red wire from ECU Check continuity. Replace if defective.
18. Loose or broken black/light green wire from ECU Check continuity. Replace if defective.
19. Loose or broken light blue/dark blue wire from Check continuity. Replace if defective.
ECU connector pin #6 to throttle actuator RA1.
20. Loose or broken purple/light blue wire from ECU Check continuity. Replace if defective.
Fuel Related Problems
▪ Gasoline Only
fuel pump relay 56CR.
fuel pump relay 56CR.
23. Loose or broken tan/black wire from ECU Check continuity. Replace if defective.
connector pin #84 to fuel pump relay 56CR.
24. Defective fuel pump relay 56CR. Check relay. Replace if defective.
25. Loose or broken pink/yellow wire from fuel pump Check continuity. Replace if defective.
relay 56CR to fuse F11.
27. Loose or broken pink/yellow wire from fuse F11 Check continuity. Replace if defective.
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 Check continuity. Replace if defective.
to GM engine connector 1.
30. Loose or broken black/red wire from GM engine Check continuity. Replace if defective.
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.

149
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 Check continuity. Replace if defective.
switch S26 to plug B pin #15 in platform control
console.
34. Loose or broken wire #11 in boom cable B or its Check continuity between pins #15 on cable B.
35. Loose or broken wire #11 from plug B pin #15 to Check continuity. Replace if defective.
engine harness plug.
36. Loose or broken wire #11 from engine harness Check continuity. Replace if defective.
37. Loose or broken tan/brown wire from GM engine Check continuity. Replace if defective.
connector 1 to ECU connector pin #42.
propane lock off 2P-56.
39. Loose or broken white/black wire from ECU Check continuity. Replace if defective.
connector pin #75 to propane lock off 2P-56.
40. Defective propane lock off 2P-56. Check lock off. Replace if defective.
F10 to fuse F9.
43. Loose or broken red/light blue wire from fuse F9 Check continuity. Replace if defective.
to propane regulator PRV1.
44. Loose or broken black wire from engine ground Check continuity. Replace if defective.
to propane regulator PRV1.
4.3-5 Glow Plug Circuit Inoperative - Deutz D2011 diesel engine

1. Defective glow plug fuse FU1 50 amp. Check fuse. Replace if defective.
2. Loose or broken wire #03 from start solenoid Check continuity. Replace if defective.
57CCR to fuse holder FU1.
3. Loose or broken wire #11A from fuse holder FU1 Check continuity. Replace if defective.
to relay 54ACR.
4. Loose or broken wire #11B from relay 54ACR to Check continuity. Replace if defective.
glow plugs.

150
strip to relay 54ACR.
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.
4.3-6 All Base Control Console Inoperative
stop switch S3 to ignition/ pump switch S5.
2. Defective ignition/ pump switch S5. Check continuity through switch when activated.
3. Loose or broken wire #10A from ignition/pump Check continuity. Replace if defective.
block to diode D10A.
5. Open or defective diode D10A. Check diode. Replace if defective.
6. Loose or broken wire #20 from diode D10A to Check continuity. Replace if defective.
7. Missing or broken jumper JMPR3 on base Check for jumper. Replace if missing or broken.
terminal block between wires #20 and #21.
NOTE
Jumper is removed if equipped with generator option.
block to relay 21CR. (ANSI/CSA)
block to relay 59CR. (CE)
base terminal block. (CE)
block to relay 21CR. (CE)

151
NOTE
For further CE troubleshooting refer to Load Sensing System.

main harness plug pin #3.
16. Loose or broken wire #21A from main harness Check continuity. Replace if defective.
plug pin #3 to dump valve 2H-21A.
17. Loose or broken wire #02 from dump valve Check continuity. Replace if defective.
2H-21A to main harness plug.
18. Defective dump valve coil 2H-21A. Check continuity and resistance through coil.
4.3-7 No Movement from Base Control Console
No Main Boom Down, Riser Down or Turret Rotate

1. Loose or broken wire #10A from ignition/ pump Check continuity. Replace if defective.
switch S5 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 Check continuity. Replace if defective.
turret rotate switch S13 and boom down switch
S12.
No Boom Up
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 Check continuity. Replace if defective.
block to turret harness plug pin #4.
5. Loose or broken wire #14 from turret harness Check continuity. Replace if defective.
plug pin #4 to boom up valve 4H-14.
plug to boom up valve 4H-14.
7. Defective boom up coil 4H-14. Check continuity and resistance through coil.

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No Boom Down
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 Check continuity. Replace if defective.
plug pin #3 to boom down valve 4H-13.
plug to boom down valve 4H-13.
7. Defective boom down coil 4H-13. Check continuity and resistance through coil.
No Riser Up from Base Control Console

1. Loose or broken wire #10A from ignition/pump Check continuity. Replace if defective.
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
3. Loose or broken wire #31 from riser switch S25 Check continuity. Replace if defective.
block to main harness plug pin #8.
5. Loose or broken wire #31 from main harness Check continuity. Replace if defective.
plug pin #8 to riser up valve 4H-31.
plug to riser up valve 4H-31.
7. Defective boom up coil 4H-31. Check continuity and resistance through coil.
No Riser Down from Base Control Console

1. Loose or broken wire #10B from ignition/pump Check continuity. Replace if defective.
switch S5 to riser switch S25.
2. Defective riser switch S25. Check continuity through switch while activating
up function between wires #10B and #30.Replace
3. Loose or broken wire #30 from riser switch S25 Check continuity. Replace if defective.

153
plug pin #87to riser up valve 4H-30.
7. Defective boom down coil 4H-30. Check continuity and resistance through coil.
No Turret Rotate Left
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 Check continuity. Replace if defective.
plug pin #9 to turret rotate left valve 4H-32.
plug to turret rotate left valve 4H-32.
7. Defective turret rotate left valve coil 4H-32. Check continuity and resistance through coil.
No Turret Rotate Right
turret rotate switch S13.
2. Defective turret rotate switch S13. Check continuity through switch while activating
rotate left function between wires #10B and #33. If
3. Loose or broken wire #33 from turret rotate Check continuity. Replace if defective.
plug pin #10 to turret rotate left valve 4H-33.
plug to turret rotate left valve 4H-33.
7. Defective turret rotate right valve coil 4H-33. Check continuity and resistance through coil.

154
No Telescope Retract From Base Control Console

switch S5 to telescope switch S14.
2. Defective telescope switch S14. Check continuity through switch while activating
retract function between wires #10A and #38. If no
3. Loose or broken wire #38 from telescope switch Check continuity. Replace if defective.
S14 to base terminal block.
plug pin #12 to telescope retract valve 3H-38.
plug to telescope retract valve 3H-38.
7. Defective telescope retract valve coil 3H-38. Check continuity and resistance through coil.
No Telescope Extend
switch S5 to telescope switch S14.
extend function between wires #10A and #39. If no
S14 to base terminal block.
plug pin #13 to telescope extend valve 3H-39.
plug to telescope extend valve 3H-39.
7. Defective telescope extend valve coil 3H-39. Check continuity and resistance through coil.
No Platform Rotate Left
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 #36. If

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4. Loose or broken wire #36A from diode D36 to Check continuity. Replace if defective.
plug pin #12 to platform rotate enable valve
2H-36A.
plug to platform rotate enable valve 2H-36A.
7. Defective platform rotate enable valve 2H-36A. Check continuity and resistance through coil.
8. Loose or broken wire #36 from platform rotate Check continuity. Replace if defective.
switch S16 to base connector plug A pin #18.
10. Loose or broken wire #36 plug A pin #18 to Check continuity. Replace if defective.
platform terminal block.
block to platform rotate left valve 4H-36.
block to platform rotate left valve 4H-36.
13. Defective platform rotate left valve coil 4H-36. Check continuity and resistance through coil.
No Platform Rotate Right
switch S5 to platform rotate switch S16.
rotate right function between wires #10A and #37.
If no continuity found, replace switch.
2H-36A.
switch S16 to base connector plug A pin #19.

156
10. Loose or broken wire #37 plug A pin #19 to Check continuity and resistance through coil.
platform terminal block. Replace if defective.
block to platform rotate right valve 4H-37.
block to platform rotate right valve 4H-37.
13. Defective platform rotate right valve coil 4H-37. Check continuity and resistance through coil.
No Jib Up
1. Loose or broken wire #10A from ignition/ pump Check continuity. Replace if defective
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.If no
plug pin #11 to jib enable valve 2H-34A.
6. Loose or broken wire #02 from main harness Check continuity. Replace if defective
plug to jib enable valve 2H-34A.
7. Defective jib enable valve 2H-34A. Check continuity. Replace if defective
8. Loose or broken wire #35 from jib up switch S17 Check continuity. Replace if defective
to base connector plug A pin #17.
block to jib up valve 4H-35.
block to jib up valve 4H-35.
13. Defective jib up valve coil 4H-35. Check continuity and resistance through coil.

157
No Jib Down
switch S5 to jib switch S17.
2. Defective jib down switch S17. Check continuity through switch while activating jib
down function between wires #10A and #34. If no
4. Loose or broken wire #34A from diode D34 to Check continuity. Replace if defective
6. Loose or broken wire #02 from main harness Check continuity. Replace if defective
7. Defective jib enable valve 2H-34A. Check continuity and resistance through coil.
8. Loose or broken wire #34 from jib down switch Check continuity. Replace if defective
S17 to base connector plug A pin #16.
block to jib down valve 4H-34.
block to jib down valve 4H-34.
13. Defective jib down valve coil 4H-34. Check continuity and resistance through coil.
No Manual Platform Level Up
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 Check continuity. Replace if defective
block to main harness pin plug pin#16.
5. Loose or broken wire #41 from main harness pin Check continuity. Replace if defective
plug pin#16 platform level up valve 4H-41.

158
6. Loose or broken wire #02 from turret harness pin Check continuity. Replace if defective
plug platform level up valve 4H-41.
7. Defective platform level up valve coil 4H-41. Check continuity and resistance through coil.
No Manual Platform Level Down
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 Check continuity. Replace if defective
block to main harness pin plug pin#15.
5. Loose or broken wire #40 from main harness pin Check continuity. Replace if defective
plug pin#16 platform level down valve 4H-40.
6. Loose or broken wire #02 from turret harness pin Check continuity. Replace if defective
plug platform level down valve 4H-40.
7. Defective platform level down valve coil 4H-40. Check continuity and resistance through coil.
4.3-8 All Controls Inoperative From Platform Control Console
1. Open or defective emergency stop switch S4. Pull emergency switch out. Check continuity
2. Loose or broken wire #4A from emergency stop Check continuity. Replace if defective.
switch S4 to platform start switch S9.
3. Loose or broken wire #4 platform start switch S9 Check continuity. Replace if defective.
to platform terminal block.
4. Loose or broken pin jumper between #04 Check continuity. Replace if defective.
and #04A on platform terminal block (without
generator option only).
block to generator switch S22 (generator option
only).
6. Generator switch S22 in generator mode or is Select OFF mode on generator switch. Check
open or defective (generator option only). continuity through switch from #04 to #04A.
7. Loose or broken wire #04A from generator Check continuity. Replace if defective.
switch S22 to platform terminal block (generator
option only).

159
8. Loose or broken wire #04A from platform Check continuity. Replace if defective.
terminal block to footswitch S11.
9. Open or defective footswitch S11. Check continuity through switch while activating
footswitch function between wires #04A and #08A.
10. Loose or broken wire #08A from footswitch S11 Check continuity. Replace if defective.
to valve driver pin #16.
block to valve driver pin #1, 2 & 13.
block to valve driver pin #24, 25 & 26.
13. No output on pin #6 of the valve driver to wire Check pin #6 for 12 volts. If no voltage present with
#08. foot on footswitch check section 5 for OCM pin
voltage reference.
block to diode D04.
16. Loose or broken wire #60 from diode D04 to Check continuity. Replace if defective.
block to plug B pin #16 in platform control
console.
18. Loose or broken wire #60 in boom cable B or its Check for continuity between pins #16 on cable B.
No Boom Up From Platform Control Console
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 Check continuity. Replace if defective.
A1 to valve driver pin #29.
#20B. foot on footswitch check section 5 for OCM pin
voltage reference.
6. No output on pin #22 of the valve driver to wire Check pin #22 for minimum 3.5 volts. If no voltage
#14. present with foot on footswitch check section 5 for
OCM pin voltage reference.

160
7. Loose or broken wire #14 from valve driver pin Check continuity. Replace if defective.
#22 to plug A pin #7 in platform control console.
9. Loose or broken wire #14 from base connector Check continuity. Replace if defective.
plug A pin #7 to base terminal block.
plug pin #4 to boom up valve 4H-14.
plug to boom up valve 4H-14.
13. Defective boom up valve coil 4H-14. Check continuity and resistance through coil.
No Boom Down
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 Check continuity. Replace if defective.
#20B. foot on footswitch check section 5 for OCM pin
voltage reference.
plug pin #3 to boom down valve 4H-13.

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plug to boom down valve 4H-13.
13. Defective boom down valve coil 4H-13. Check continuity and resistance through coil.
No Riser Up from Platform Control Console

3. No output on R signal from joystick controller A3. Refer to joystick test procedure in section 5.
4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective.
voltage reference.
6. No output on pin #9 of the valve driver to wire Check pin #9 for minimum 3 volts. If no voltage
plug pin #8 to riser up valve 4H-31.
13. Defective riser up valve coil 4H-31. Check continuity and resistance through coil.
No Riser Down from Platform Control Console

3. No output on R signal from joystick controller A3. Refer to joystick test procedure in section 5.

162
4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective.
voltage reference.
6. No output on pin #12 of the valve driver to wire Check pin #12 for minimum 3 volts. If no voltage
7. Loose or broken wire #30 from valve driver Check continuity. Replace if defective.
pin #12 to plug A pin #12 in platform control
console.
plug pin #7 to riser down valve 4H-30.
plug to riser down valve 4H-30.
13. Defective riser down valve coil 4H-30. Check continuity and resistance through coil.
No Turret Left
3. No output on x-axis of joystick controller A1. Refer to joystick test procedure in section 5.
4. Loose or broken wire “X” from joystick controller Check continuity. Replace if defective.
voltage reference.
console.

163
plug pin #10 to turret left valve 4H-32.
plug to turret left valve 4H-32.
13. Defective turret left valve coil 4H-32. Check continuity and resistance through coil.
No Turret Right
3. No output on x-axis of joystick controller A1. Refer to joystick test procedure in section 5.
4. Loose or broken wire “X” from joystick controller Check continuity. Replace if defective.
voltage reference.
console.
plug pin #11 to turret right valve 4H-33.
plug to turret right valve 4H-33.

164
13. Defective turret right valve coil 4H-33. Check continuity and resistance through coil.
No Toggle Switch Functions from Platform Control Console

block to toggle switches.
2. Loose or broken wire #20A from toggle switches Check continuity. Replace if defective.
voltage reference.
No Telescope In
block to telescope switch S18.
2. Defective telescope switch S18. Check continuity through switch while activating in
function between wires #08 and #38.
3. Loose or broken wire #20A from telescope Check continuity. Replace if defective.
switch S18 to valve driver pin #33.
voltage reference.
S18 to plug B pin #8 in platform control console.
plug B pin #8 to base terminal block.
plug pin #13 to telescope in valve 4H-38.
plug to telescope in valve 4H-38.
11. Defective telescope in valve coil 4H-38. Check continuity and resistance through coil.
No Telescope Out
block to telescope switch S18.
out function between wires #08 and #39.

165
3. Loose or broken wire #20A from telescope Check continuity. Replace if defective.
voltage reference.
S18 to plug B pin #9 in platform control console.
plug pin #14 to telescope out valve 4H-39.
plug to telescope out valve 4H-39.
11. Defective telescope out valve coil 4H-39. Check continuity and resistance through coil.
No Platform Rotate Left
block to platform rotate switch S20.
rotate left function between wires #08 and #36.
3. Loose or broken wire #20A from platform rotate Check continuity. Replace if defective.
voltage reference.
switch S20 to platform terminal block.
6. Loose or broken wire #36 or #02 from platform Check continuity. Replace if defective.
terminal block to rotate left valve 4H-36.
7. Defective rotate left valve coil 4H-36. Check continuity and resistance through coil.
block to plug A pin#18 in platform control
console.

166
plug A pin #18 to base platform rotate switch
S16.
11. Defective base platform rotate switch S16. Check continuity through switch while activating
2H-36A.
No Platform Rotate Right
block to platform rotate switch S20.
rotate right function between wires #08 and #37.
3. Loose or broken wire #20A from platform rotate Check continuity. Replace if defective.
voltage reference.
switch S20 to platform terminal block.
terminal block to rotate right valve 4H-37.
7. Defective rotate right valve coil 4H-37. Check continuity and resistance through coil.
console.

167
plug A pin #19 to base platform rotate switch
S16.
11. Defective base platform rotate switch S16. Check continuity through switch while activating
2H-36A.
No Jib Up
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 Check continuity. Replace if defective.
valve driver pin #33.
voltage reference.
5. Loose or broken wire #35 from jib switch S20 to Check continuity. Replace if defective.
terminal block to jib up valve 4H-35.
console.
plug A pin #17 to base jib up switch S17.

168
11. Defective base jib up switch S17. Check continuity through switch while activating
jib up function between wires #10A and #35. If no
12. Open or defective diode D35. Check continuity. Replace if defective.
No Jib Down
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.
3. Loose or broken wire #20A from jib switch S21 to Check continuity. Replace if defective.
valve driver pin #33.
voltage reference.
5. Loose or broken wire #34 from jib switch S20 to Check continuity. Replace if defective.
terminal block to jib down valve 4H-34.
console.
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 #34. If no
12. Open or defective diode D34. Check continuity. Replace if defective.

169
No Manual Platform Level Up from Platform Control Console

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 Check continuity. Replace if defective.
voltage reference.
5. Loose or broken wire #41 from platform leveling Check continuity. Replace if defective.
console.
plug pin #16 to level up valve 4H-41.
plug to level up valve 4H-41.
11. Defective level up valve coil 4H-41. Check continuity and resistance through coil.
No Manual Platform Level Down from Platform Control Console

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.

170
3. Loose or broken wire #20A from platform leveling Check continuity. Replace if defective.
voltage reference.
5. Loose or broken wire #40 from platform leveling Check continuity. Replace if defective.
console.
plug pin #15 to level down valve 4H-40.
plug to level down valve 4H-40.
11. Defective level down valve coil 4H-40. Check continuity and resistance through coil.
4.3-9 Throttle Inoperative, Mid and High - Deutz D2.9L
block to connector J2 pin #5.
2. Loose or broken wire #90 from connector P2 pin Check continuity. Replace if defective.
#5 94 pin ECU connector pin 80.
block to connector J2 pin 4
4. Loose or broken wire #99 from connector P2 pin Check continuity. Replace if defective.
4 to 94 pin ECU connector pin 74
5. Resistor R4 open or poor connection at base Measure resistance (1KΩ) between 99 and 99A.
terminal block. Check connections. Replace if defective.
6. Resistor R5 open or poor connection at base Measure resistance (3.3KΩ) between 99A and 99B.
7. Resistor R6 open or poor connection at base Measure resistance (3.9KΩ) between 99B and 90.

171
4.3-10 Mid Throttle Inoperative
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
3. Loose or broken wire #79 from throttle switch Check continuity. Replace if defective.
S10 to plug B pin #20 in platform control
console.
4. Loose or broken wire #79 in Cable B or its Check for continuity between pins #20 on cable B.
▪ Deutz D2.9L Diesel
5. Loose or broken wire #79 from base plug B pin Check continuity. Replace if defective.
#20 to relay 79CR.
8. Loose or broken wire #99B from relay 79CR to Check continuity. Replace if defective.
▪ Deutz D2011 Diesel
#20 to relay 79CR.
block to ECU connector pin #17.

172

▪ Kubota Dual Fuel
#20 to engine harness plug.
17. Loose or broken wire #79 from engine harness Check continuity. Replace if defective.
18. Loose or broken gray/dark blue wire from Kubota Check continuity. Replace if defective.
Dual Fuel engine connector to ECU connector
pin #51.
19. Loose or broken purple/light blue wire from ECU Check continuity. Replace if defective.
20. Defective throttle actuator RA1. Check actuator. Replace if defective.
4.3-11 High Throttle Inoperative
block to throttle switch S10.
2. Defective throttle switch S10. Check continuity through switch while activating
high throttle function between wires #08 and #78.
3. Loose or broken wire #78 from throttle switch Check continuity. Replace if defective.
S10 to plug B pin #19 in platform control
console.
4. Loose or broken wire #78 in Cable B or its Check for continuity between pins #19 on cable B.
▪ Deutz D2.9L Diesel
#19 to relay 78CR.

173

▪ Deutz D2011 Diesel
#17 to relay 78CR.
block to ECU connector pin #17.
4.3-12 Brake will not Release
1. No output on pin #10 from valve driver to wire Check pin #10 for 12 volts. If no voltage present
#26 when operating a drive function. with foot on footswitch check section 5 for OCM pin
voltage reference.
2. Loose or broken wire #26 from valve drive Check continuity. Replace if defective.
console.
3. Loose or broken wire #26 in Cable A or its Check for continuity between pins #11 on cable A.
4. Loose or broken wire #26 from base plug A pin Check continuity. Replace if defective.
#11 to turret harness plug pin #8.
5. Loose or broken wire #26 or #02 from turret Check continuity. Replace if defective.
harness plug to brake valve 3H-26.
6. Defective brake valve coil 3H-26. Check continuity and resistance through coil.

174
4.3-13 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 Check pin #19 for 12 volts when drive in neutral
#26A. 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 Check continuity. Replace if defective.
#19 to differential lock switch S28.
3. Loose or broken wire #165 from differential lock Check continuity. Replace if defective.
switch S28 to plug A pin #24 in platform control
console.
4. Loose or broken wire #165 in Cable A or its Check for continuity between pins #24 on cable A.
5. Loose or broken wire #165 from base plug A pin Check continuity. Replace if defective.
#24 to base terminal block.
6. Loose or broken wire #165 or #02 from base Check continuity. Replace if defective.
terminal block to differential lock valve 3H-165.
7. Defective differential lock valve coil 3H-165. Check continuity and resistance through coil.
4.3-14 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. Check continuity. Replace if defective.
2. Open or defective diode D26A. Check diode. Replace if defective.
3. Loose or broken wire #26B from diode D26A to Check continuity. Replace if defective.
relay 165CR.
4. Loose or broken wire #165 from differential lock Check for 12 volts on wire #165 (2 places) while
switch S28 to relay 165CR. (2 places) activating differential lock at relay 165CR.
Check continuity. Replace if defective.
block to differential lock switch S28.
7. Loose or broken wire #02A from differential lock Check continuity. Replace if defective.
switch S28 to relay 165CR.

175
block to diode D08-1.
9. Open or defective diode D08-1. Check diode. Replace if defective.
10. Loose or broken wire #26B from diode D08-1 to Check continuity. Replace if defective.
relay 165CR.
4.3-15 No Drive and Steer
NOTE
MEWP will not drive or steer if it is tilted and off limit switches.
block to base plug B pin #24. (CE only)
2. Loose or broken wire #162A in Cable B or its Check for continuity between pins #24 on cable B.
connectors. (CE only) Check for loose or corroded connections on cable
3. Loose or broken wire #162A from plug B pin #24 Check continuity. Replace if defective.
in platform control console to drive joystick A2.
(CE only)
NOTE
For further CE troubleshooting refer to Load Sensing System.
block to drive joystick A2.
block to drive joystick A2.
No Forward Drive
1. No output on “D” when forward is selected on See drive joystick test procedure in section 5.
drive joystick A2.
2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective.
joystick A2 to valve driver pin #27.
3. No output from valve driver pin #34 to wire #16. Check pin #34 for minimum 2 volts. If no voltage
present with foot on footswitch check section 5 for
#34 to plug B pin #5 in platform control console.
5. Loose or broken wire #5 in cable B or its Check for continuity between pins #5 on cable B.

176
harness plug to forward drive valve 3H-16.
8. Defective forward drive valve coil 3H-16. Check continuity and resistance through coil.
No Reverse Drive
1. No output on “D” when forward is selected on See drive joystick test procedure in section 5.
drive joystick A2.
2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective.
joystick A2 to valve driver pin #27.
3. No output from valve driver pin #23 to wire #15. Check pin #23 for minimum 2 volts. If no voltage
present with foot on footswitch check section 5 for
#23 to plug B pin #4 in platform control console.
harness plug to reverse drive valve 3H-15.
8. Defective reverse drive valve coil 3H-15. Check continuity and resistance through coil.
No Left Steer
NOTE
This function times out after 15 seconds when operating this function only.
1. Loose or broken wire #24 from drive joystick A2 Check continuity. Replace if defective.
2. No output from valve driver pin #4 to wire #24A. Check pin #4 for 12 volts. If no voltage present
with foot on footswitch check section 5 for OCM
pin voltage reference.
3. Loose or broken wire #24A from valve driver pin Check continuity. Replace if defective.
4. Loose or broken wire #24A in boom cable A or Check for continuity between pins #10 on cable A.

177
5. Loose or broken wire #24A from base plug A pin Check continuity. Replace if defective.
#10 to main harness plug pin #5.
6. Loose or broken wire #24A or #02 from main Check continuity. Replace if defective.
harness plug to left steer valve 4H-24A.
7. Defective left steer valve coil 4H-24A. Check continuity and resistance through coil.
No Right Steer
NOTE
This function times out after 15 seconds when operating this function only.
1. Loose or broken wire #23 from drive joystick A2 Check continuity. Replace if defective.
2. No output from valve driver pin #21 to wire Check pin #21 for 12 volts. If no voltage present
#23A. with foot on footswitch check section 5 for OCM
pin voltage reference.
3. Loose or broken wire #23A from valve driver pin Check continuity. Replace if defective.
4. Loose or broken wire #23A in boom cable A or Check for continuity between pins #9 on cable A.
5. Loose or broken wire #23A from base plug A pin Check continuity. Replace if defective.
#9 to main harness plug pin #4.
harness plug to right steer valve 4H-23A.
7. Defective right steer valve coil 4H-23A. Check continuity and resistance through coil.
4.3-16 No High Speed Drive
NOTE
Aerial platform must be level and boom must be below 15 degrees and fully retracted for high speed drive.
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 Check continuity. Replace if defective.

178
5. Open or defective limit switch LS3. Ensure boom is fully retracted and horizontal or
below. Adjust switch if required. Check continuity
6. Loose or broken wire #29A from limit switch LS3 Check continuity. Replace if defective.
8. Open or defective limit switch LS4. Ensure boom is fully retracted and horizontal or
below. Adjust switch if required. Check continuity
block to plug B pin #15.
block to valve driver pin #31.
14. Defective valve driver channel input for high drive See section 5 for OCM pin voltage reference.
enable.
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 #45. If
17. Loose or broken wire #45 from torque switch S48 Check continuity. Replace if defective.
to plug A pin #20 in platform control console.
18. Loose or broken wire #45 in cable A or its Check for continuity between pins #20 on cable A.
19. Loose or broken wire #45 from plug A pin #20 to Check continuity. Replace if defective.
relay 45CR1.
block to relay 45CR1.
21. Loose or broken wire #02 from relay 45CR1 to Check continuity. Replace if defective.

179
22. Defective relay 45CR1. Check relay. Replace if defective.

23. Loose or broken wire #45A from relay 45CR1 to Check continuity. Replace if defective.
harness plug to 2 speed valve 3H-45A.
25. Defective 2 speed valve 3H-45A. Check continuity and resistance through coil.
4.3-17 No Elevated Drive
NOTE
MEWP must be level to drive elevated.
1. Loose or broken wire #09 or #02 from base Check continuity. Replace if defective.
terminal block to level sensor TS1.
2. Misadjusted, no output or defective level sensor Adjust level sensor if required. Check for 12 volts
TS1. 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 Check continuity. Replace if defective.
to plug B pin #7.
block to valve driver pin #32.
4.3-18 Direction Sensing Inoperative
2. Open or defective limit switch LS1. Adjust limit switch if required. Check continuity
block to base plug B pin #6.

180
#6 to valve driver pin #15 in platform control
console.
7. Defective valve driver channel input for direction See section 5 for OCM pin voltage reference.
sense enable.

181
Section 4 – Troubleshooting Information Load Sensing System - CE & AS
4.4 Load Sensing System - CE & AS
4.4-1 Green Power LED is not Flashing
1. Loose or broken wires #60 and #02 at platform Check for connections. Check for voltage (12V).
terminal block.
2. Load cell has lost its calibration. Refer to calibration procedure for recalibration of
load cell.
4.4-2 Load Cell red Alarm LED is ON (with platform empty)
load cell.
4.4-3 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.
4.4-4 Load Cell red Alarm LED is OFF (with platform overloaded)
load cell.
4.4-5 Platform Indicator Light does not turn ON
1. Defective lamp. Check relay. Replace if defective.

3. Load cell circuit not operating. Check for connections with wire #02A 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.
4.4-6 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 #02A and #118
at platform terminal block.
4. Defective load cell. Defective if 0V is measured between wire #118 and
#02 from platform terminal block.

182
Load Sensing System - CE & AS Section 4 – Troubleshooting Information
4.4-7 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 Check for voltage (0V) between wires #162A and
closed. #02 from base terminal block. Defective if 12V is
measured.

183
Section 4 – Troubleshooting Information Hydraulic System
4.5 Hydraulic System
4.5-1 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.
4.5-2 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 Check O-rings and clean valve. Check operation of
sensing valve DSV1. 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.
4.5-3 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. Clean valve. Check O-rings on valve. Check
required.
3. Stuck or defective check valve CV10. Clean valve. Check operation of valve. Repair or
4. Stuck or defective differential sensing valve Clean valve. Check O-rings on valve. Check
DSV4. operation of valve. Repair or replace valve as
required.
5. Stuck or defective counterbalance valve CB9. Clean valve. Check O-rings on valve. Repair or
6. Defective lift cylinder C3. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

184
Hydraulic System Section 4 – Troubleshooting Information
4.5-4 No Main Boom Down
1. Stuck or defective lift down valve 4H-13. Clean valve. Check operation of valve. Repair or
required.
4. Stuck or defective differential sensing valve Clean valve. Check O-rings on valve. Check
DSV4. operation of valve. Repair or replace valve as
required.
6. Defective lift cylinder C3. Check seals on cylinder. Replace as necessary.
4.5-5 No Riser Boom Up

1. Stuck or defective riser up valve 4H-31. Clean valve. Check operation of valve. Repair or
required.
3. Stuck or defective check valve CV5. Clean valve. Check O-rings on valve. Check
required.
5. Stuck or defective differential pressure sensing Clean valve. Check O-rings on valve. Check
valve DSV3. operation of valve. Repair or replace valve as
required.
6. Stuck or defective counterbalance valve CB5 or Clean valve. Check O-rings on valve. Repair or
CB6. replace valve as required.
7. Defective riser cylinder C6 or C7. Check seals on cylinder. Replace as necessary.

185
4.5-6 No Riser Boom Down

1. Stuck or defective riser down valve 4H-30. Clean valve. Check operation of valve. Repair or
required.
3. Plugged or defective orifice OR6. Check orifice. Replace if plugged or defective.
required.
required.
8. Stuck or defective counterbalance valve CB5 or Clean valve. Check O-rings on valve. Repair or
CB6. replace valve as required.
9. Defective riser cylinder C6 or C7. Check seals on cylinder. Replace as necessary.
4.5-7 Riser Boom Down Jerky

1. Stuck open or defective check valve CV5. Clean valve. Check operation of valve. Repair or
2. Stuck or incorrectly set counterbalance valve CB5 Clean valve. Check O-rings on valve. Check
or CB6. operation of valve. Repair or replace valve as
required.
4.5-8 No Turret Rotate Left

1. Stuck or defective rotate left valve 4H-32. Clean valve. Check operation of valve. Repair or
required.
3. Stuck or defective relief valve RV7. Set valve to specifications. Check o-rings and

186
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. Check motor. Repair or replace if defective.
4.5-9 No Turret Rotate Right

1. Stuck or defective rotate right valve 4H-33. Clean valve. Check operation of valve. Repair or
required.
3. Stuck or defective relief valve RV7. Set valve to specifications. Check o-rings and
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. Check motor. Repair or replace if defective.

187
4.5-10 No Boom Extend

1. Stuck or defective boom extend valve 3H-39. Clean valve. Check operation of valve. Repair or
2. Plugged, incorrectly adjusted or defective orifice Check orifice. Replace if plugged or defective.
OR3.
3. Stuck in the shifted position or defective boom Clean valve. Check operation of valve. Repair or
retract valve 3H-38. replace valve as required.
6. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary.
4.5-11 No Boom Retract

1. Stuck or defective boom retract valve 3H-38. Clean valve. Check operation of valve. Repair or
OR3.
5. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective
4.5-12 No Jib Up - ANSI/CSA

1. Stuck or defective jib enable valve 2H-42. Clean valve. Check O-rings on valve. Check
required.
required.
4. Stuck or defective jib up valve 4H-35. Clean valve. Check operation of valve. Repair or
6. Defective jib cylinder C1. Check seals on cylinder. Replace as necessary.

188
4.5-13 No Jib Up - CE & AS

1. Stuck or defective jib enable valve 2H-34A. Clean valve. Check O-rings on valve. Check
required.
required.
5. Stuck or defective jib up valve 4H-35. Clean valve. Check operation of valve. Repair or
4.5-14 No Jib Down - ANSI/CSA

1. Stuck or defective jib enable valve 2H-42. Clean valve. Check O-rings on valve. Check
required.
required.
4. Stuck or defective jib down valve 4H-34. Clean valve. Check operation of valve. Repair or

189
4.5-15 No Jib Down - CE & AS

1. Stuck or defective jib enable valve 2H-34A. Clean valve. Check O-rings on valve. Check
required.
required.
5. Stuck or defective jib down valve 4H-34. Clean valve. Check operation of valve. Repair or
4.5-16 No Platform Rotation Right - ANSI/CSA

1. Stuck or defective platform rotate enable valve Clean valve. Check O-rings on valve. Check
2H-42. operation of valve. Repair or replace valve as
required.
required.
4. Stuck or defective platform rotate right valve 4H- Clean valve. Check operation of valve. Repair or
37. replace valve as required.
6. Defective rotary actuator RA1. Check actuator. Repair or replace as necessary.

190
4.5-17 No Platform Rotation Right - CE & AS

2H-36A. operation of valve. Repair or replace valve as
required.
required.
4.5-18 No Platform Rotation Left - ANSI/CSA

2H-42. operation of valve. Repair or replace valve as
required.
required.

191
4.5-19 No Platform Rotation Left - CE & AS

2H-36A. operation of valve. Repair or replace valve as
required.
required.
4.5-20 Platform will not Level Down Manually

OR4.
2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or
required.
required.
required.
9. Defective leveling cylinder C4 or slave cylinder Check seals on cylinder. Replace as necessary.
C5. Replace cylinder if defective.

192
4.5-21 Platform will not Level Up Manually

OR4.
2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or
required.
required.
required.
9. Defective leveling cylinder C4 or slave cylinder Check seals on cylinder. Replace as necessary.
4.5-22 Brake will not Release

required.
2. Defective or misadjusted pressure reducing valve Set valve to specifications. Check O-rings and
PR1. clean valve. Repair or replace valve as required.
3. Stuck or defective brake valve 3H-26. Clean valve. Check O-rings on valve. Check
required.
required.
5. Defective or misadjusted relief valve RV4. Set valve to specifications. Check O-rings and
6. Stuck or defective brake release override valve Clean valve. Check O-rings on valve. Repair or
V1. replace valve as required.
7. Bypassing or defective brake hand pump V3. Clean valve. Check O-rings on valve. Repair or
8. Bypassing or defective brake cylinder C12. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective
193
4.5-23 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.
4.5-24 Differential Lock will not Engage

required.
2. Defective or misadjusted pressure reducing valve Set valve to specifications. Check O-rings and
PR1. clean valve. Repair or replace valve as required.
3. Stuck or defective differential lock valve 3H-165. Clean valve. Check O-rings on valve. Check
required.
4. Bypassing or defective differential lock cylinder Check seals on cylinder. Replace as necessary.
C13. Replace cylinder if defective
4.5-25 No Drive Forward or Reverse

1. Brake not releasing. See “brake will not release” in this section.
2. Defective or misadjusted charge pump relief Set valve to specifications. Check O-rings and
valve RV3. clean valve. Repair or replace valve as required.
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 Check control. Replace if defective.
4H-16.
6. Open bypass valve V4. Close bypass valve.
7. Worn drive pump P1. Check pump. Replace if defective.
8. Worn or defective drive motor M1. Check motor. Replace if defective.
4.5-26 No Forward Drive

1. Defective pump displacement control 4H-16. Check control. Replace if defective.
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. Check pump. Replace if defective.

194
4.5-27 No Reverse Drive

1. Defective pump displacement control 4H-15. Check control. Replace if defective.
2. Defective or misadjusted drive relief valve RV2. See section 5 for drive pump set up procedures.
3. Drive pump servo stuck or not shifting. Check pump. Replace if defective.
4.5-28 No High Speed Drive

1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check
required.
2. Defective shift spool in drive motor M1. Check motor. Repair or replace if necessary.
4.5-29 No Right Steer

1. Plugged, incorrectly adjusted or defective priority Check operation. Set flow rate to 1.25 GPM @ 2000
flow control PFC1. psi. Replace if plugged or defective.
2. Stuck or defective right steer valve 4H-23A. Clean valve. Check operation of valve. Repair or
3. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary.
4.5-30 No Left Steer
1. Plugged, incorrectly adjusted or defective priority Check operation. Set flow rate to 1.25 GPM @ 2000
flow control PFC1. psi. Replace if plugged or defective.
2. Stuck or defective left steer valve 4H-24A. Clean valve. Check operation of valve. Repair or
3. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary.
4.5-31 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. Check O-rings on valve. Repair or
2. One or more counterbalance valves (CB1 or CB2) Clean valve. Check O-rings on valve. Repair or
failed to shift or is defective. replace valve as required.

195
4.5-32 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 Clean valve. Check O-rings on valve. Check
position or is defective. operation of valve. Repair or replace valve as
required.
2. Bypassing or defective axle lock cylinders C9 and Check seals on cylinder. Replace as necessary.
3. Counterbalance valves (CB1 or CB2) out of Clean valve. Check O-rings on valve. Repair or
adjustment or are defective. replace valve as required.

196
Section 5 – Procedures
5.1 General
The following information is provided to assist you in WARNING
the use and application of servicing and maintenance
procedures contained in this chapter. Make sure you maintain three points of contact
when mounting and dismounting the platform.
NOTE
The illustrations shown in this manual are for WARNING
instructional purposes only. The models and
components shown may appear somewhat Do not operate any platform controls without the
different from those on your actual MEWP. proper fall protection secured to the designated
location in the platform. Failure to do so could
result in death or serious injury!
5.1-1 Safety and Workmanship

WARNING
Your safety, and that of others, is the first
consideration when engaging in the maintenance of Make sure there are no people or obstructions in
equipment. Always be conscious of weight. Never the test area, and there is sufficient space for the
attempt to move heavy parts without the aid of a boom and drive functions required for the given
mechanical device. Do not allow heavy objects to rest procedures.
in an unstable position. When raising a portion of the
equipment, ensure that adequate support is provided.
Before performing routine maintenance underneath
the riser, support it using a suitably rated lifting device
(refer to Figure 01), or cylinder chocks on both riser
cylinders. Contact Skyjack Parts to order chocks.
WARNING
Remove all material and personnel from the
platform while using the maintenance support(s).
1. Park the MEWP on a firm, level surface.

2. Retract and lower the boom, riser, and platform 13 345 N
3,000 lbf
until the MEWP is in the stowed position.
3. Turn the engine off.
4. Pull out the emergency stop buttons on the Figure 01 Support location
base controls and on the platform controls.
5. Turn the battery disconnect switch to the off
position .
After completing any procedure which involves
modifying, adjusting, or replacing any hydraulic or
electrical components, perform all of the function tests
given in your unit’s Operating Manual.

197
Section 5 – Procedures System Control Modules (OCM/SCM)
5.2 System Control Modules

(OCM/SCM) C O N T R O L S
Maintaining proper calibration is essential for good

performance of the MEWP.
To access the OCM console, open the platform
control cover.
The OCM 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
5.2-1 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.
+
SAVE 1.3-1 <SAVE> saves the new data to EEPROM (permanent

1.3
memory storage).
---- Simultaneously pressing <UP> and <DOWN> resets the HMI to

1.4
menu screen 0.
+

198
System Control Modules (OCM/SCM) Section 5 – Procedures
5.2-2 OCM Character Functions Charts
SCM 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
1345AA
5.2-3 OCM Function Channel Names
SCM Function (Channel) Names

DRIVE REV Fn01A Drive Reverse (Flat)
DRIVE FWD Fn01B Drive Forward (Flat)
CHAN 2A Fn02A Drive Off Confirmation
CHAN 2B Fn02B Drive On Confirmation
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
LR REV Fn06A Drive Reverse (Hill)
LR FWD Fn06B Drive Forward (Hill)
1346AB

199
5.2-4 OCM Operating Values Chart - CE & AS
Input Description
AI 1 Drive Controller
AI 2 Turret Rotation Controller
AI 3 Boom Elevation Controller
AI 4 Flow Enable Rotary Potentiometer
AI 6 Fly Control
DI 1 Drive Direction Reverse (Limit Switch)
DI 2 Footswitch Actuated
DI 3 Platform Rotation Enables
DI 4 Tilt Switch Active
DI 5 Jib Elevation
DI 11 High Speed Drive Enable (Limit Switch)
Output Description
PWM 1 Drive Reverse
PWM 2 Drive Forward
PWM 3 Brakes Applied
PWM 4 Holding Brake Off
PWM 5 Main Boom Down
PWM 6 Main Boom Up
PWM 7 Rotate Left
PWM 8 Rotate Right
PWM 9 Fly Out
PWM 10 Fly In
Output Description
DOUT 1 Steering Reverse Relay
DOUT 2 Load Sense Valve Enable
DOUT 3 Footswitch Actuated Indicator
DOUT 4 Axle Lock
DOUT 7 Tilt Alarm Indicator
1371AD

200
5.2-5 How to Select OCM Functionality - CE & AS
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 #
FUNCTIONS OFF  PRESS SELECT
– 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.

201
5.2-6 How to View OCM Operation - CE & AS

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
▲ ▲ ▲
PWM1 to PWM2 PWM3 to PWM4 PWM5 to PWM6
▬▬▬ ▬▬▬ ▬▬▬
┼ ┼ ┼
▲ ▲
PWM11 to PWM12 PWM9 to PWM10 PWM7 to PWM8
▬▬▬ ▬▬▬
┼ ┼
MENU
▬▬▬▬
SELECT MENU
VDD POWER SUPPLY 8V SENSOR SUPPLY
▬▬▬▬
VALUE = VOLTAGE VALUE = VOLTS
SELECT
See 5.2-4 OCM Operating Values Chart - CE & AS for operating values for the previous observations.

202
5.2-7 How to Unlock and Modify OCM Settings - CE & AS
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 FLAT) THRESH Fn01A VALUE= %
ADJUST MENU +(DRIVE FWD FLAT) THRESH Fn01B VALUE= %
(FLASHING) ▬▬▬▬ +(DRIVE OFF) THRESH Fn02A VALUE= %
SELECT +(DRIVE ON) THRESH Fn02B VALUE= %
MENU +(BOOM DOWN) THRESH Fn03A VALUE= %
▬▬▬▬ +(BOOM UP) THRESH Fn03B VALUE= %
SELECT +(ROTATE LEFT) THRESH Fn04A VALUE= %
TOGGLE
+(ROTATE RIGHT) 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) ┼ +(DRIVE REV HILL) THRESH Fn06A VALUE= %
+(DRIVE FWD HILL) 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.

203
5.2-8 OCM Pin Voltage Reference - CE & AS
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 5H-24A

Pin 5 - 12 volt output on wire 20B 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 5H-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 5H-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.

204
Pin 10 - 12 volt output on wire 26 brake valve 3H-26. 12V=Drive selected

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 5H-30.

Pin 14 - Variable input from wire 128A.

1 Volt to 5 volts depending on angle of machine
1 volt = Level
Test between pin 14 and 02 wire
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. 12V= Footswitch activated.
Pin 20 - Turret rotate left selected. Proportional output on wire 32 to turret rotate left valve 5H-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 5H-23A

Pin 22 - Boom up selected. Proportional output on wire 14 to boom up valve 5H-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 4H-15.
Test between pin 23 and 02 wire while operating reverse drive.

205
Pin 24 - Battery negative. Wire 02.
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, LS3 and LS4 limit switches 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 4H-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 5H-33.
Test between pin 10 and 02 wire while operating turret rotate right.

206
5.2-9 SCM Pin Reference - ANSI/CSA
P3/P13
WHITE
12 35
23
11 34
22
10 33
21
9 32
20
8 31
19
7 30
18
6 29
17
5 28
16
4 27
15
3 26
14
P1/P11 2
1
13
25
24
BLACK
5 14
9
4 13
8
3 12
7
2
1
6
11
10 P2/P12
GREY
12 35
23
11 34
22
10 33
21
9 32
20
8 31
19
7 30
18
6 29
17
5 28
16
4 27
15
3 26
14
2 25
13
1 24
P1 (Black) Lower Main Controller: SMB1-105

Pin Wire Function Input/Output Type I/O Test I/O Error
1 09 Power VS1
2 09 Power VS2
3 09 Power VS3
4 09 Power VS4
5 Not used Vreg 5v
6 CAN H CANH to Engine ECU & Telematics J1939 CAN
7 CAN L CANL to Engine ECU & Telematics J1939 CAN
8 CAN 2H CANH to PLTF SMB1-106 CANopen
9 CAN 2L CANL to PLTF SMB1-106 CANopen
10 02 Ground GND1
11 02 Ground GND2
12 02 Ground GND3
13 02 Ground GND4
14 Not used --
2056AC

207
P2 (Grey) Lower Main Controller: SMB1-105

1 16 Drive Forward Analog Output PWM02 PE2
2 15 Drive Reverse Analog Output PWM01 PE1
3 31 Riser Up Analog Output PWM08 PE8
4 30 Riser Down Analog Output PWM07 PE7
5 14 Boom Up Analog Output PWM06 PE6
6 13 Boom Down Analog Output PWM05 PE5
7 41 Platform Level Up Analog Output PWM12 PE12
13A SJ63 AJ Boom Down Throttle
8 Analog Output PWM11 PE11
85B SJ46 AJ 2nd Generator O/P
9 38 Fly Boom In Analog Output PWM10 PE10
10 39 Fly Boom Out Analog Output PWM09 PE9
11 Not Used -- --
12 42 Proportional Flow Analog Output PWM15 PE15
13 32 Turret Rotate Left Analog Output PWM03 PE3
14 55 Fuel level float sw Digital Input DI2 IE2
15 14B Main Boom Up Digital Input DI4 IE4
16 13B Main Boom Dn Digital Input DI6 IE6
17 32B Turret Rotate L Digital Input DI8 IE8
18 10A Emergency Pump / Enable Digital Input DI10 IE10
19 29 Fly Boom In LS (Hi Speed Drive) Digital Input DI12 IE12
20 12 Platform key position Digital Input DI14 IE14
21 38B Telescope Retract Digital Input DI16 IE16
22 41B Platform Level Up Digital Input DI18 IE18
23 Not Used -- --
24 33 Turret Rotate Right Analog Output PWM04 PE4
25 17 Direction Sensing Digital Input DI1 IE1
26 34B Jib Down Digital Input DI3 IE3
27 28 Tilt Switch Active Digital Input DI5 IE5
28 35B Jib Up Digital Input DI7 IE7
29 59 Main Boom Cradled LS (Hi Speed Drive) Digital Input DI9 IE9
30 57 Engine Start Request Digital Input DI11 IE11
31 10 Base key position Digital Input DI13 IE13
32 33B Turret Rotate R Digital Input DI15 IE15
33 39B Telescope Extend Digital Input DI17 IE17
34 Not Used -- --
35 40 Platform Level Down Analog Output PWM13 PE13
2057AC

208
P3 (White) Lower Main Controller: SMB1-105

1 119 Load Zone Border Lamp Digital Output DO1 OE1
2 01A Emergency Pump Relay Digital Output DO8 OE8
3 23 Steer Right Digital Output DO7 OE7
4 118A Overload Alarm/lamp Digital Output DO6 OE6
5 65 Axle Lock Digital Output DO5 OE5
6 120 Low capacity zone lamp Digital Output DO12 OE12
7 85 Generator Solenoid Digital Output DO11 OE11
8 68 Engine Run Enable Digital Output DO10 OE10
9 57A Engine Start Digital Output DO9 OE9
10 20 All-Motion Alarm Digital Output DO16 OE16
11 120A High capacity zone lamp Digital Output DO15 OE15
12 Not Used Digital Output DO14 OE14
13 24 Steer Left Digital Output DO2 OE2
14 Not Used Analog Input AI1 AE1
20 128 Angle Sensor - Chassis Analog Input AI7 AE7
Propane Run (Dual Fuel)
23 11 Digital Output DO13 OE13
Load Kit Option (ANSI/CSA D2.9L)
24 21A Dump Valve Digital Output DO3 OE3
25 45A Motor 2 Speed Digital Output DO4 OE4
26 40B Platform Level Down Digital Input DI19 IE19
27 Main Boom Creep (used on 86) Digital Input DI20 IE20
28 37B Platform Rotate Right Digital Input DI21 IE21
29 36B Platform Rotate Left Digital Input DI22 IE22
30 Riser Down Digital Input DI23 IE23
31 Riser Up Digital Input DI24 IE24
32 121 load zone safety limit (Main) Digital Input DI25 IE25
33 122 load zone safety limit (Fly) Digital Output DI26 IE26
34 26 Holding Brake Off Digital Output DO17 OE17
35 165 Diff Lock Digital Output DO18 OE18
2058AD

209
P11 (Black) Upper Secondary Controller: SMB1-106

1 04 Power VS1
2 04 Power VS2
3 04 Power VS3
4 04 Power VS4
5 L Speed control supply (T Booms) Vreg 5v
6 Not Used J1939 CAN
7 Not Used J1939 CAN
8 CAN 2H CANH To PLTF SMB1-106 CANopen
9 CAN 2L CANL To PLTF SMB1-106 CANopen
10 02 Ground GND1
11 02 Ground GND2
12 02 Ground GND3
13 02 Ground GND4
14 Not used --
2059AC

210
P12 (Grey) Upper Secondary Controller: SMB1-106

1 37 Platform Rotation Right PWM17 PE17
2 36 Platform Rotation Left PWM16 PE16
3 Not Used PWM18 PE18
4 Not Used -- --
7 Not Used -- --
8 Not Used -- --
9 Not Used -- --
10 Not Used -- --
11 Not Used -- --
12 Not Used -- --
13 35 Jib Up PWM18 PE18
14 08A Footswitch Actuated Y DI28 IE28
15 24P Steer Left Y DI30 IE30
16 23P Steer Right Y DI32 IE32
17 45 High Torque Drive Mode Selected Y DI34 IE34
18 01 Emergency Pump Request Y DI36 IE36
19 04A Engine Run/Enable DI38 IE38
20 MPS2 = KC O/H (Korea) Y DI40 IE40
21 38A Fly Boom In Y DI42 IE42
22 41A Platform Level Up Y DI44 IE44
23 Not Used -- --
24 34 Jib Down PWM19 PE19
25 233 Glazier Load Restrict DI27 IE27
26 34A Jib Down Y DI29 IE29
27 Not Used Y DI31 IE31
28 35A Jib Up Y DI33 IE33
29 78 High Throttle Selected Y DI35 IE35
30 57B Engine Start Request Y DI37 IE37
31 MPS1 = KC O/H (Korea) Y DI39 IE39
Propane Fuel Select (Dual Fuel)
32 11A DI41 IE41
Load Kit Option (ANSI/CSA TD2.9L)
33 39A Fly Boom Out Y DI43 IE43
34 Not Used -- --
35 Not Used -- --
2060AC

211
P13 (White) Upper Secondary Controller: SMB1-106

1 Not Used Y DO19 OE19
2 55 Low Fuel Indicator Lamp Y DO26 OE26
3 577 EcoStart Indicator Light DO25 OE25
4 27A Tilt Audible Indicator Y DO24 OE24
5 231 Regen Lamp (EU Stage 5 engine) DO23 OE23
6 63 SGE Alarm DO30 OE30
7 82 O/L Lamp DO29 OE29
8 118 O/L Alarm DO28 OE28
9 74 Glow Plug Indicator Lamp Y DO27 OE27
10 119 Load Zone Border Lamp DO34 OE34
11 120A High capacity zone lamp DO33 OE33
12 120 Low capacity zone lamp DO32 OE32
13 27 5 Degree Tilt LED Indicator DO20 OE20
14 D Drive Controller Y AI10 AE10
15 Y Main Boom Elevation Controller Y AI11 AE11
16 X Turret controller Y AI12 AE12
17 Not Used Y AI13 AE13
19 R Riser Controller (AJ Booms) AI15 AE15
22 C Speed control knob (T booms) Y AI18 AE18
23 76P MIL DO31 OE31
24 Not Used DO21 OE21
25 08 Footswitch Indicator Y DO22 OE22
26 40A Platform Level Down Y DI45 IE45
27 232 Regen Temp. Override (EU Stage 5 engine) DI46 IE46
28 35A Platform Rotate Right Y DI47 IE47
29 36A Platform Rotate Left Y DI48 IE48
30 165A Diff Lock Y DI49 IE49
31 85 Generator On/Off Y DI50 IE50
32 61 SGE - Bar In Y DI51 IE51
33 62 Reset SGE Y DI52 IE52
34 Not Used -- --
35 165B Diff Lock Indicator DO36 OE36
2061AC

212
5.2-10 Check I/O Error - ANSI/CSA
If a fault is detected, the engine shuts off and the SCM displays “Check I/O Err? Press select”.
Press Menu/Select.
This check helps to determine which channel has the fault.
PE=PWM error
OE=Digital output error
IE=Digital input error
AE=Analog error
Scroll through to the end of the first set of channels, then use Menu/Select to enter into the next channel menu.
Make sure to repeat through all four channel menus.
Use the 5.2-9 SCM Pin Reference - ANSI/CSA chart to determine which function each channel is related to. A
properly working channel is indicated by a “0”. A fault is indicated by a “1”.
Check IO Err? MENU

PRESS SELECT SELECT
PE 1 2 3 4 5
0 0 0 0 0
PE 6 7 8 9 10
0 0 0 0 0 
+
PE 11 12 13 14 15
0 0 0 0 0
This is an example. The

MEWP may have more
channels than shown here.
Make sure to scroll
through all of the channels
in each menu using the
+ key.
OE 1 2 3 4 5
Example:
0 0 0 0 0
MENU
SELECT PE 6 7 8 9 10
IE 1 2 3 4 5 0 1 0 0 0
0 0 0 0 0
This example indicates a
SAVE PWM (PE) error (1) in
AE 1 2 3 4 5
channel 7.
0 0 0 0 0 EXIT

213
5.2-11 How to Unlock and Modify the SCM - ANSI/CSA
START SCREEN BASE SMB1-105** (SOFTWARE

REV)
MODEL: XXXX****
FUNCTIONS OFF SMB1-106** (SOFTWARE
REV)
PLATFORM
5X
MENU
UNLOCK SETUP? ENTER PASSWORD
PRESS SELECT SELECT 0**
1X
MENU
ENTER PASSWORD ENTER PASSWORD
5** SELECT 50*
9X
MENU ENTER PASSWORD

ENTER PASSWORD
SELECT 510
51*
ENTER PASSWORD MENU SETUP UNLOCKED
519 SELECT PRESS - OR +
SET DRIVE TIMER SAVE MODEL: XXXX**** MENU
PRESS SELECT EXIT FUNCTIONS OFF SELECT
ADJUST CANBUS MENU

Continued on the next page
IO TEST MAIN SELECT

214
Continued from the previous page
DRIVE REV THRESH DRIVE FWD THRESH

DRIVE REV THRESH
Fn 1 xxxmA Fn 1 ##mA Fn 1 200mA
DRIVE FWD THRESH
Fn 2 200mA
ROTATE L THRESH
MENU
Fn 3 400mA
ROTATE R THRESH
SELECT Fn 4 400mA
BOOM DOWN THRESH
Fn 5 650mA
BOOM UP THRESH
Fn 6 500mA
FLY OUT THRESH
DRIVE REV THRESH Fn 7 200mA
*func. name* THRESH
Fn 1 xxxmA Fn # ##mA FLY IN THRESH
Fn 8 200mA
*func. name* MAXOUT
Fn # ##mA RISER DN THRESH*
Fn 9 450mA
*func. name* LOWRNG
Fn # ##mA RISER UP THRESH*
Fn 10 450mA
*func. name* RAMPUP
Fn # ##SEC JIB DOWN THRESH
Fn 1 350mA
*func. name* RAMPDN
Fn # ##SEC JIB UP THRESH
Fn 12 350mA
PLATF LFT THRESH
Fn 13 430mA
PLATF RGT THRESH
Fn 14 430mA
PROP FLOW THRESH
MENU
Fn 15 200mA
SAVE
SELECT EXIT * AJ models only
Adust value

215
5.2-12 SCM Select Model - ANSI/CSA

REV)
MODE: NO CONFIG
REV)
PLATFORM
5X
MENU
1X
MENU
5** SELECT 50*
9X
MENU ENTER PASSWORD

ENTER PASSWORD
SELECT 510
51*
SET DRIVE TIMER SET LRNG B&C&THR

PRESS SELECT PRESS SELECT
WEIGHT CALIB? SET A-STALL PID?

PRESS SELECT PRESS SELECT

216
Continued from the previous page
ANTI-STALL CHG? AE=XXX=5 W=X
PRESS SELECT P1=XXX P2=XXXX
MENU (T)D2.9 DEUTZ MENU

CURRENT ENGINE
D2011 DEUTZ
PRESS SELECT SELECT WG2503 KUBOTA SELECT
D2.2 DEUTZ
TCD2.2 DEUTZ
ARTIC LOAD KIT* MODEL SELECT MENU
PRESS SELECT PRESS SELECT SELECT
*Deutz (T)D2.9 only
46AJ
63AJ
40T SAVE SELECT MULTIFNCT
61T ANSI CE AS
EXIT
66T
45T
SAVE MODEL:XXXX
EXIT FUNCTIONS OFF

217
5.2-13 SCM Weight Calibration - ANSI/ 4. Do the calibration procedure from the SCM 3
CSA in the base control box. Follow the flowchart on
the next two pages.
Tare weight calibration sets the unladen weight of the 3
platform. It is the weight of an empty platform that the
SCM subtracts from the gross weight reading of the
load cell, giving a new zero (net) weight to start from
when measuring the contents of the platform.
Net weight = Gross weight - Tare weight CONTROLS INC.
Net weight: the weight of the platform.

Gross weight: the total weight as measured by the
load cell.
Tare weight: the weight of the empty platform as set
by the tare weight calibration.
1. Make sure the platform is level.

2. Remove all items from the platform, including
optional attachments.
3. Make sure the capacity derate switch 1 is
in the full capacity position, and the capacity
derate light 2 is not on.
TM
TM
1
+ +

218
5.2-14 SCM Weight Calibration Flowchart - ANSI/CSA

REV)
MODEL: XXXX****
REV)
PLATFORM
5X
MENU
1X
MENU
5** SELECT 50*
9X
MENU ENTER PASSWORD

ENTER PASSWORD
SELECT 510
51*
SET DRIVE TIMER Press the + or - button until

you see the weight calibration
PRESS SELECT screen.
WEIGHT CALIB?
PRESS SELECT

219
SCM Weight Calibration Flowchart (continued)
328 lb used as an example.

Continued from the previous page Value = the platform weight
SAVE
WEIGHT CALIB? MENU TARE CAL= 0 lb
EXIT
PRESS SELECT SELECT VALUE= 328 lb
TARE CAL= 328 lb

VALUE= 328 lb
CALIB: ABORTED!
USE +/- OR EXIT
Press the Save/Exit button

to save the calibration and
exit, or press up/+ to return
to calibration.
SAVE
EXIT
Weight Calibration Complete

220
5.2-15 CAN Bus Communication Check - ANSI/CSA
MODEL: XXXX MENU ADJUST CAN BUS  ADJUST CAN BUS MENU
FUNCTIONS OFF SELECT IO TEST MAIN + IO TEST MAIN SELECT
SCMB1-105 Brain  SCMB1-106 Slave 1  MRW-1 Slave 4 

ID 1 OPERATING + ID 8 OPERATING + ID 11 OPERATING +
MRW-2 Slave 5  ENGINE J1939

ID 12 OPERATING + ID 0 OPERATING
All channels must be “OPERATING”.

If a channel is not reading correctly (OPERATING), “NO DATA” is shown.
Look at each channel for several seconds to confirm that it is not switching
from “OPERATING” to “NO DATA”.
SCMB1-105 Brain is the lower controller

SCMB1-106 Slave is the upper controller
MRW-1 Slave 4 ID 11 is CAN from the load cell. If it is not operating,
“LOAD CELL 1 LOST” appears on the screen when powered on.
MRW-2 Slave 5 ID 12 is CAN from the load cell. If it is not operating,
“LOAD CELL 2 LOST” appears on the screen when powered on.
ENGINE J1939 is CAN from the engine.

221
Section 5 – Procedures Platform
5.3 Platform
5.3-1 Fly Boom Switch Voltage References
TELESCOPE SWITCH WORKSHEET

VOLTAGE DIVIDER CIRCUIT
R9
250 OHMS
250 OHMS R10

TELESCOPE IN
WIRE
L
PIN WIRE#38A +
32
4.83V
> >> P1-32 FLY TOGGLE SWITCH
7.25V
-
GND
TELESCOPE OUT O2
250 OHMS
R11
R8
250 OHMS
R9
250 OHMS
250 OHMS R10

TELESCOPE IN
WIRE
L
PIN WIRE#38A +
32
2.41V
> >> P1-32
FLY TOGGLE SWITCH 7.25V
-
GND
TELESCOPE OUT O2
250 OHMS
R11
R8
250 OHMS

222
Platform Section 5 – Procedures
5.3-2 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
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

223
5.3-3 Replace the load cell Remove the old load cell
1. Remove the four outer bolts, washers, and
spacers that secure the rotary actuator bracket
Disconnect the old load cell to the platform. Set aside the hardware.
1. Lower the jib and boom until the platform rests
in a stable position at a comfortable working
height on support stands or a similar device.
Make sure you have easy access to the load cell
hardware under the platform.
2. Remove the platform control box from its
brackets and set it on the floor of the platform.
3. If needed, cut the cable ties which secure the
cables to the upright platform railing.
both sides
2. Remove the four bolts and washers from the

load cell on the underside of the platform.
4. Find the load cell cable and follow it into the

platform control box. Make note of the wire
connections, then disconnect it. Note: wire
colours can vary and may not be the same as
the legend below.
5. Loosen the strain relief connector and pull the
load cell cable out of the platform control box.
Cut cable ties as needed to free it.
black
blue
red
yellow
purple
white brown
green
Legend
02 - black
02 - blue
04 - red
04 - yellow
CANH - purple
CANH - white
CANL - brown
CANL - green

224
3. Separate the platform from the jib/boom until the Install the new load cell
load cell is fully visible. 1. Take the new load cell and use a small flat
4. Remove the remaining four sets of hardware screwdriver to turn both dials on the side from 0
from the load cell. Set the hardware aside. to 2.
5
34 6
789A
F012
BC E
D
5
34 6
789A
F012
BC E
D
3456
F0 1 2
789A
5. Pull the load cell cable out of the rotary actuator
bracket.
6. Remove the load cell.
E
BCD
2. Feed the load cell cable through the hole in the

rotary actuator bracket.

225
3. With the side marked “TOP” facing up, secure 8. Install the four outer bolts, washers, spacers,
the load cell to the rotary actuator bracket with safety washers, and nuts.
the hardware removed earlier. Hand-tighten the 9. Torque the bolts to 108 Nm (80 ft-lb).
bolts.
4. Then use the sequence below to torque the
bolts to 271 Nm (200 ft-lb).
1 4
both sides
3 2
5. Move the platform and the rotary actuator

bracket together and line up the holes.
6. Install the four bolts and washers on the load
cell, under the platform. Hand-tighten the bolts.
7. Torque the bolts to 271 Nm (200 ft-lb). 10. Mount the platform control box on its brackets.
1 4
3 2

226
11. Feed the load cell cable into the platform control
box.
12. Connect the load cell wires to the terminal
blocks.
13. Tighten the strain relief connector.
black
blue
red
yellow
purple
white brown
green
Legend
02 - black
02 - blue
04 - red
04 - yellow
CANH - purple
CANH - white
CANL - brown
CANL - green
14. Replace any cable ties that were cut inside and
outside of the control box.
15. Follow 5.2-13 SCM Weight Calibration - ANSI/

CSA and 5.2-14 SCM Weight Calibration
Flowchart - ANSI/CSA or 5.4-3 Calibration of
Load Sensing System (with “Teach In” Handset)
to calibrate the load cell.

227
Section 5 – Procedures Load Sensing System - CE & AS
5.4 Load Sensing System - CE & AS

5.4-1 Load Sensing System
The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The
deck steel structure is isolated from the MEWP. 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.
MEWP
(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 ± 15 kg
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.

228
Load Sensing System - CE & AS Section 5 – Procedures
5.4-2 Verify Proper Operation of the Load Sensing System
Overload Status Chart
Indicator Load Cell Audible MEWP

Weight
Light LED Display Alarm Functions
Error - OFF
Alarm - OFF
Zero/Tare - ON (orange)
Power - FLASHING (green)
(Zero) OFF OFF ENABLED
Error - OFF
Alarm - FLASHING (red)
Zero/Tare - OFF
(Work Mode Power - FLASHING (green)
@ 244+) FLASHING PULSING
DISABLED
Error - OFF
Alarm - FLASHING (red)
Zero/Tare - OFF
(Travel Mode Power - FLASHING (green)
FLASHING PULSING ENABLED
@ 244+)
1. Ensure MEWP 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 244 kg 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 > 30 cm.
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.

229
Section 5 – Procedures Load Sensing System - CE & AS
5.4-3 Calibration of Load Sensing System (with “Teach In” Handset)
WARNING
Do not interrupt system power during this procedure.
Do not rest your hand or foot on the platform during this procedure.
1. Ensure MEWP 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 the handset at any point during 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 1.25 Hz.
9. Add a test load of 244 kg 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 244 kg 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.

230
Boom Section 5 – Procedures
5.5 Boom 5.5-3 Cable Carrier Repair

To repair the cable carrier, simply use a screwdriver.
5.5-1 Check Wear Pads Snap each crossbar off from either side of the chain,
either by hand or by using the screwdriver as a lever.
1. Ensure the MEWP is on a firm level surface and Install new crossbars by snapping the links together.
is in the stowed position.
2. Start the engine from the base control console.
3. Raise the main boom to a comfortable working
Female Side
height (chest high), and then extend fly boom
approximately 30 cm (1 ft).
4. Measure the thickness of each wear pad, and
replace wear pad if it is less than 11 mm (7/16").
5. If the wear pad is within the specified thickness,
shim it as necessary.
Male Side
5.5-2 Shim Wear Pads Crossbar
1. Ensure the MEWP is on a firm level surface and

is in the stowed position.
2. Raise the main boom to a comfortable working
height (chest high) and extend the fly boom until 5.5-4 Rotary Actuator Bolt Torque
the wear pads are accessible. Procedure
3. Loosen the wear pad fasteners.
4. Shim the wear pads as necessary to obtain zero WARNING
to 1/32”(0.8 mm) clearance and zero drag. Maintaining proper torque is essential to safe
MEWP operation. Improper bolt torque could result
Fly Boom in an unsafe operating condition and component
damage.
1. Set the torque wrench to 25 Nm (17 ft-Ib) and

tighten the mounting bolts in a cross pattern
sequence.
1/32” Feeler
Gauge 1
8 5
Shim
Wear Pad
4 3
5. Extend and retract the fly boom through the
entire range of motion and observe for loose
points.
6 7
NOTE
Always maintain squareness between the boom’s
2
outer and inner tubes. 2. Set the torque wrench to 47 Nm (35 ft-Ib) and
tighten mounting bolts with the same sequence.
3. Torque the center bolt to 650 Nm (480 ft-lb).
231
Section 5 – Procedures Boom
5.5-5 Master Cylinder Replacement 5. Secure the master cylinder with straps. See below
for an example.
1. Ensure the MEWP is parked on a firm and level
surface.
WARNING
Ensure that there is sufficient room for boom to
swing and elevate.
WARNING
Be aware of overhead obstructions or other
possible hazards around the machine when lifting.
2. By using the base controls, position the machine

as below to allow for easy work access to the CAUTION
basket/jib boom and the master cylinder.
Label all electrical cables and hydraulic hoses
before removal
CAUTION
To prevent hydraulic system contaminations, cap
all hydraulic hoses and fittings after removal.
6. Remove the hydraulic hoses and fittings on the

master cylinder. Replace any worn or damaged
components.
7. Disconnect the master cylinder from the main
boom by removing the connecting pin, see
below. Set all parts aside for reuse.
3. Turn the main disconnect switch to the off position

. Lock the switch to prevent unauthorized
use during this procedure.
NOTE
Ensure all components are secured before lifting
or removing them.
4. Using straps, secure the main boom on suitable

lifting equipment such as a crane.
8. Install the new master by installing the cylinder

pins as shown above. Secure the keeper pin and
the bolt with Loctile 242 (Blue) or equivalent.
9. Install the hydraulic hoses and fittings on the
master cylinder.

232
Boom Section 5 – Procedures
5.5-6 Limit Switch Locations - SJ46 AJ+ ANSI/CSA
4 2 3
1 Limit Switch LS1 - Direction Sensing

2 Limit Switch LS2 - Fly Stowed (high speed cut-out)
3 Limit Switch LS3 - Main Boom (high speed cut-out)
4 Limit Switch LS6 - Riser Stowed

233
Section 5 – Procedures Boom
5.5-7 Limit Switch Locations - SJ46 AJ & SJ51 AJ CE & AS
2 4 3
1 Limit Switch LS1 - Direction Sensing

2 Limit Switch LS2 - Riser Down
3 Limit Switch LS3 - Boom Down (high speed cut-out)
4 Limit Switch LS4 - Fly In (high speed cut-out)

234
Turret Section 5 – Procedures
5.6 Turret 5.6-2 Turret Rotation Gear Bolt Torque

Sequence
5.6-1 Check and Replace the High WARNING

Pressure Filter Maintaining proper torque is essential to safe
MEWP operation. Improper bolt torque could result
1. Start the engine from the base control console. in an unsafe operating condition and component
damage.
2. Inspect the filter restriction indicator gauge 1 .
The filter should operate with the gauge pointing
to the green area. If it is in the red area, the filter
1. Set the torque wrench to 115 Nm (85 ft-lb)
needs to be replaced.
and tighten the mounting bolts in a criss-cross
3. To replace the filter, turn the engine off. pattern sequence.
4. Place a suitable container under the filter.
1 5
16
12 9
5
8 11 12 17
4 18 10 22
17 23
16
4 6 1 13
5 2
4 3 3
18
21 13
3 20 14
19 9 15
14 8 7 7
10 11
6 15
2
2
2. Set the torque wrench to 230 Nm (170 ft-Ib)
and tighten the mounting bolts with the same
5. Using a 30 mm box wrench on the filter housing
sequence.
nut 2 , loosen the filter housing 3 and remove
it from the filter head 4 .
6. Remove the filter element 5 from the filter head
and install a new high pressure filter element.
7. Apply hydraulic oil to the o-ring on the high
pressure filter housing.
8. Reinstall the housing, screwing it in fully, then
backing it off by one quarter turn.

235
Section 5 – Procedures Turret
5.6-3 Electronic Tilt Switch Setup 7. Pull out both emergency stop buttons.
Procedure 8. Verify the switch is powered (the red or green
LED will be solid).
Tilt Switch Replacement
Red LED Red LED

Y AXIS Green LED Green LED
X AXIS
9. Program the tilt switch:

a. Press and release the set to zero button 3
times. Observe LED flash codes as shown
below.
b. Only the red LED will
blink for 4 seconds.
Red LED
Green LED
c. Both LEDs will flash for

1 second.
1. Park the MEWP on a firm level surface. Results: The switch is Red LED
2. Disconnect the tilt switch from the 4 pin learning the new zero Green LED
connector. position.
NOTE d. Both LEDs will turn on

solid for 1 second.
Make sure the part number of the old tilt switch
Results: The new zero Red LED
and new tilt switch are the same.
position has been Green LED
3. Remove the old tilt switch from the mount. learned.
e. The green LED will flash and then the

red LED will turn on solid for 2 seconds.
Results: The switch is verifying the new zero
position.
Red LED Red LED

Green LED Green LED
4. Install the new switch on the mount and connect

the switch plug to the 4 pin connector.
f. Only the red LED will
NOTE blink for 4 seconds.
The tilt circuit is only powered when the controls Red LED
are powered up. Green LED
5. Turn the main disconnect switch to the ON

position. 10. Turn the main power disconnect switch to the off
position.
6. Turn te base/off/platform key switch to the base
position. 11. Push in the emergency stop buttons.

236
Turret Section 5 – Procedures
Reprogramming the Existing Tilt Switch

IMPORTANT
Step “c” must be completed within a 5 second
The set to zero button is located period, or the switch will automatically exit
Light Indicators on this face next to the harness
program mode and return to normal operation
using the previously stored data.
c. Press and release the set to zero button 3

times.
R
Gre ed LE
en
LE
D
D d. If the 5 second period has expired prior to
completion, repeat steps “a”, “b” and “c”.
e. Observe program
delay / stabilization
time (only the red Red LED
LED will blink for 4 Green LED
seconds).
NOTE f. Both LEDs will flash for
The tilt circuit is only powered when the controls 1 second.
are powered up. Results: The switch is Red LED
1. Turn the main disconnect switch to the ON learning the new zero Green LED
position. position.
2. Turn the base/off/platform key switch to the base g. Both LEDs will turn on
position. solid for 1 second.
3. Pull out both emergency stop buttons. Results: The new Red LED
zero position has been Green LED
4. Verify switch is powered (the red or green LED
learned.
will be solid).
h. The green LED will flash and then the red
LED will turn on solid for 2 seconds.
Red LED Red LED
Results: The switch is verifying the new zero
Green LED Green LED position.
Red LED Red LED

Green LED Green LED
5. Reprogram the Tilt Switch
i. The green LED will turn

a. Press and hold the on solid.
set to zero button for Results: The switch Red LED
5 seconds. Red LED
is ready for normal Green LED
Results: Both LEDs Green LED
operation.
will be OFF.
6. Turn the main power disconnect switch to the off
position.
b. Both LEDs will flash. 7. Push in the emergency stop buttons.
Red LED
Green LED 8. Proceed to Verify Tilt Circuit.

237
Section 5 – Procedures Turret
Verify Tilt Circuit 5.6-4 Battery Replacement
Light Indicators 1. Turn the main power disconnect switch to the off
position.
R
Gre ed LE
2
en D
LE
D
4
Operations of the Tilt Switch
The following describes the LED’s and what they
indicate.
Illuminated whenever both tilt

axes are within the specified
degrees of the zero/ home 2. Remove the positive and negative connectors
learned position. from the batteries.
Green LED
Flashes when transitioning in 3. Remove the battery retainer bracket nuts,
or out of tilt angle limits, but washers, and j-hooks 1 .
built in time delay has not fully
occurred. 4. Remove the bracket 2 .
Illuminated whenever tilt on 5. Remove the batteries 3 .
one or more axes is more than 6. Replace the battery pad 4 if needed.
Red LED
the specified degrees out from 7. Replace the batteries and secure them with the
the zero/ home position.
bracket, j-hooks, washers and nuts.
On together, no blinking when
Green & Red LED 8. Clean the terminal posts and clamps of the
fault detected.
batteries, and apply acid-free and acid-resistant
grease.
9. Re-connect the batteries with the positive and
negative connector cables (ensure the clamps
make good contact).

238
Deutz Diesel Engines Section 5 – Procedures
5.7 Deutz Diesel Engines 5. Remove the oil drain plug and allow all engine
oil to drain into the container.
Maintaining the engine components is essential to WARNING

good performance and service life of the MEWP. Dispose of oil in accordance with local and federal
regulations.
5.7-1 Replace Engine Oil and Filter 6. Install the oil drain plug with a new seal ring and
tighten it firmly.
7. Remove the oil filter and catch any escaping oil.
Periodic replacement of the engine oil and filter is
8. Clean inside the filter head.
essential to good engine performance.
9. Add clean engine oil to the oil filter.
NOTE 10. Apply a thin layer of engine oil to the new oil
filter gasket.
Warm the engine to normal operating temperature
before starting this procedure. 11. Install the filter and tighten it by hand.
12. Clean up any oil that may have spilled during
this procedure.
CAUTION
13. Refill the engine with new oil. Refer to 2.14
Beware of hot engine components and hot oil. Engine Specifications.
Contact with hot components may cause severe
14. Swing the engine tray back to its original
burns.
position.
15. Reinstall the engine tray bolt.
1. Turn the engine off. 16. Start the engine from the base control console
and allow the engine to run for 30 seconds, then
2. Remove the bolt securing the engine tray to the
shut off the engine.
turret.
17. Check for oil leakage.
18. Check the engine oil level on the dipstick and
add oil if needed.
3. Swing the engine tray away from the turret.

4. Place a suitable container under the engine oil
drain.

239
Section 5 – Procedures Deutz Diesel Engines
5.7-2 Replace the Fuel Filter 5.7-4 Check the Engine Belt
1. Remove the bolt securing the engine tray to the
turret. The MEWP will not operate properly with a loose
2. Pull the locking pin down and swing the engine or defective belt. Continuous usage may cause
tray away from the turret. component damage.
3. Close the fuel shut-off valve.
4. Place a suitable container under the fuel filter. WARNING
5. Remove the fuel filter and catch any escaping Do not inspect the fan belt while the engine is
fuel. running. Remove the key to prevent accidental
operation.
WARNING
1. Inspect the engine belt for:
Dispose of fuel in accordance with local and
federal regulations. ▪ cracking
▪ glazing
▪ separation
6. Clean any dirt from the filter carrier sealing breaks
surface.
▪
2. For correct tension of the engine belt, refer to
7. Apply a thin layer of oil or diesel fuel to the the engine manual.
rubber gasket of the new fuel filter.
8. Install the fuel filter and tighten it by hand, then
tighten the filter cartridge with a final half-turn.
9. Clean up any fuel that may have spilled during 5.7-5 Check the Oil Cooler (Deutz D2011
this procedure. only)
10. Open the fuel shut-off valve. 1. Remove the cover from the side of the engine.
11. Check for fuel leakage. 2. Inspect the oil cooler for leaks and physical
12. Swing the engine tray back to its original damage.
position. 3. Clean the oil cooler of any kind of debris.
13. Reinstall the engine tray bolt. 4. Reinstall the cover.
5.7-3 Replace the Air Filter

Engine specifications require that this procedure be
performed more often if dusty conditions exist. Refer
to the engine manual.
CAUTION
Perform this procedure with the engine off.
1. Remove the mounting fasteners from the air filter

canister, and remove the end cap.
2. Remove the filter from inside of the canister.
3. Clean the inside of the canister and gasket with
a dry cloth.
4. Insert a new filter into the canister.
5. Reinstall the end cap.

240
5.7-6 Retrieve Engine Fault Codes -

Deutz D2.9L
1. Turn the engine on. Keep the e-stop pulled
out.
2. Hold the diagnostic switch 1 down for
about 3 seconds, then let it go. The switch
is located on the left side of the base control
box.
3. The diagnostic indicator light 2 flashes in
this sequence:
▪ fast flash, pause, slow flash, pause, fast flash
4. The flashes represent a 3-digit engine code.
Example: 2 fast flashes, 1 slow flash, 6 fast
flashes represents engine code 216.
5. Repeat steps 2 and 3 to read any additional
engine codes.
TM

241
5.7-7 Deutz D2.9L Fault Codes
Code SPN FMI Blink Code Error Identification

The air mass flow AFS_dm is greater than or equal to AFS_PhysRng.Min_C.
8 132 1 2-2-6
Physical range check is low for air mass flow sensor.
9 172 2 2-2-6 Air inlet filter temperature, plausibility error.
When AirHt_ctDefSRCLoOn_mp is lower than AirHt_ctMaxDef_C.
26 523891 14 2-6-3
DFC to SRC Low error when heater is on.
Healing takes place if the condition for error detection is not present.
28 523953 2 7-2-8
Air temperature monitoring plausibility check array.
Healing takes place if the condition for error detection is not present.
30 523955 2 7-2-8
Air temperature monitoring plausibility check array.
36 523923 3 7-2-9
37 523924 3 1-6-7 Short circuit to battery error of actuator relay 2.
38 523925 3 7-3-1 Short circuit to battery of actuator relay 3.
40 523927 3 7-3-3 Short circuit to battery of actuator relay 6.
Short circuit to ground error.
41 523923 4 7-2-9
Detailed information not available.
42 523924 4 1-6-7 Short circuit to ground of actuator relay 2.
45 168 3 3-1-8 Sensor battery voltage error; signal range check is high.
46 168 4 3-1-8 Sensor battery voltage error; signal range check is low.
47 168 2 3-1-8 High battery voltage; warning threshold is exceeded.
48 168 2 3-1-8 High battery voltage; Shot off threshold exceeded.
Air pump doesn’t achieve air mass flow setpoint. Burner Control - burner air
55 523910 14 6-9-5
pump.
Burner Control. Burner does not start after several trials (burner flame lost
56 524013 7 8-5-6 detection).
Burner flame unintentional deleted.
Burner Control: Power reduction due to low lambda. Engine power: Not
57 524020 14 8-6-3
enough oxygen for regeneration.
58 523911 0 7-2-3 Burner dosing valve (DV2); Overcurrent at the end of the injection phase.
59 523911 12 7-2-3 Burner dosing valve (DV2); Powerstage over temperature.
60 523911 3 7-2-3 Burner dosing valve (DV2); Short circuit to battery.
62 523911 4 7-2-3 Burner dosing valve (DV2); Short circuit to ground.
63 523911 11 7-2-3 Burner dosing valve (DV2); Short circuit high side powerstage.
64 523912 2 7-2-2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error.
Physical range check high for burner dosing valve (DV2) downstream
66 523912 0 7-2-2
pressure; Shut off regeneration.
1513AA-1

242

Physical range check low for burner dosing valve (DV2) downstream
pressure; Shut off regeneration.
69 523912 1 7-2-2
When burner injector is actuated, the measured pressure does not rise
above 1250mbar abs (expected: about 2400mbar).
Sensor error burner dosing valve (DV2) downstream pressure sensor; Signal
72 523912 3 7-2-2
range check high.
For engines < 4l:
Throttle valve error, Open load or short cut to battery, blocked valve or wrong
73 523912 4 7-2-2 control signal for valve.
For engines with Burner T4i:
Pressure Sensor error after valve (DV2), lower limit reached.
Sensor error glow plug control diagnostic line voltage; Signal range check
74 523913 3 7-2-1
high.
Sensor error glow plug control diagnostic line voltage; Signal range check
75 523913 4 7-2-1
low.
Glow plug control; Open load.
76 523914 5 7-2-1
Water pump control (PWM) only TTCD 6.1/7.8.
77 523914 12 7-2-1 Glow plug control; Powerstage over temperature.
78 523914 3 7-2-1 Glow plug control; Short circuit to battery. Water pump control (PWM).
79 523914 4 7-2-1 Glow plug control; Short circuit to ground. Water pump control (PWM).
CAN-Bus 2 = CAN_C reports Bus-error (for engines <8L and CV52 it is the
82 1235 14 2-7-1 engine-CAN@250kbaud)
CAN Bus error passive; warning CAN C - engine CAN.
83 16 0 2-7-1 No detail information.
84 639 14 2-7-1 CAN-Bus 0: "BusOff-Status"
85 1231 14 2-7-1 CAN-Bus 1: "BusOff-Status"
86 1235 14 2-7-1 CAN-Bus 2 = engine bus "BusOff-Status"
87 16 0 2-7-1 BusOff error CAN.
88 102 2 2-2-3 Charged air pressure above warning threshold.
89 102 2 2-2-3 Charged air pressure above shut off threshold.
90 110 2 2-2-5 Defect fault check for absolute plausibility test.
92 110 0 2-2-5 Physical range check high for coolant temperature.
93 110 1 2-2-5 Physical range check low for coolant temperature.
96 110 3 2-2-5 Sensor error coolant temperature; Signal range check high.
97 110 4 2-2-5 Sensor error coolant temperature; Signal range check low.
98 110 0 2-3-2 High coolant temperature; Warning threshold exceeded.
99 110 0 2-3-2 Coolant temperature; System reaction initiated.
101 111 1 2-3-5 Coolant level too low.
106 598 2 3-2-5 Plausibility check for clutch.
121 1109 2 3-4-1 Engine shut off demand ignored.
1513AA-2

243

122 523698 11 5-9-1 Shut off request from supervisory monitoring function.
124 523969 11 7-7-4 Fault entry for override control mode.
125 523717 12 5-9-5 Timeout error of CAN-transmit-frame AmbCon; Weather environments.
126 523603 9 3-3-8 Timeout Error of CAN-receive-frame AMB; Ambient temperature sensor.
128 3224 9 5-9-7 Timeout error of CAN-receive-frame AT1IG1; NOX sensor upstream.
129 3224 2 5-9-6 DLC error of CAN-receive-frame AT1IG1Vol NOX sensor.
130 3224 9 5-9-7 Timeout error of CAN-receive-frame AT1IG1Vol; NOX sensor.
133 523938 9 7-6-6 Timeout error (BAM to packet) for CAN-receive-frame AT1IGCVol1.
Broadcast announce message of the calibration message of the upstream
134 523939 9 7-6-6
catalytic NOx sensor has failed.
135 523940 9 7-6-6 Timeout error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1.
136 3234 2 1-1-4 DLC error of CAN-Receive-Frame AT1O1.
Timeout error of CAN-Receive-Frame AT1OG1. NOX sensor (SCR-system
137 3234 9 1-1-7
downstream cat; DPF-system downstream cat).
138 3234 2 1-1-4 DLC error of CAN-Receive-Frame AT1O1Vol.
139 3234 9 1-1-7 Timeout error of CAN-Receive-Frame AT1OG1Vol.
140 523941 9 7-6-7 Timeout error (BAM to packet) for CAN-Receive-Frame AT1OGCVol2.
141 523942 9 7-6-7 Calibration message 1 of the after catalyst Nox sensor has failed.
142 523943 9 7-6-7 Timeout error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2.
153 523992 9 7-9-3 Not used.
155 0 0 - Not used.
164 523211 9 3-3-1 Timeout error of CAN-Receive-Frame EBC1.
167 523704 12 6-1-5 Timeout error of CAN-Transmit-Frame EEC3.
168 523935 12 7-6-3 Timeout error of CAN-Transmit-Frame EEC3VOL1. Engine send messages.
169 523936 12 7-6-4 Timeout error of CAN-Transmit-Frame EEC3VOL2. Engine send messages.
171 523212 9 3-3-3 Timeout error of CAN-Receive-Frame ComEngPrt. Engine Protection.
172 523741 14 6-1-8 Engine shut off request through CAN.
174 523213 12 3-3-4 Timeout error of CAN-Transmit-Frame ERC1.
178 523706 12 6-2-3 Timeout error of CAN-Transmit-Frame FlEco.
179 523240 9 5-2-7 Timeout CAN-message FunModCtl. Function Mode Control.
193 523937 9 7-6-5 Timeout DFC for NOxSensGlbReqTx.
196 3227 2 6-3-8 DFC SAE J1939 error.
Timeout error of CAN-Receive-Frame PrHtEnCmd. Pre-heat command, en-
198 523216 9 3-3-7
gine command.
202 523793 9 6-7-8 Timeout error of CAN-Receive-Frame UAA10. AGS sensor service message.
203 523794 9 6-7-8 Timeout error of CAN-Receive-Frame UAA11. AGS sensor data.
212 523803 9 6-7-8 Timeout error of CAN-Receive-Message RxEngPres. Status Burner Air Pump.
1513AA-3

244

273 3219 2 6-4-9 DFC SAE J1939 error.
281 523766 9 1-1-8 Timeout error of CAN-Receive-Frame Active TSC1AE.
282 523767 9 1-1-8 Timeout error of CAN-Receive-Frame Passive TSC1AE.
283 523768 9 1-1-9 Timeout error of CAN-Receive-Frame Active TSC1AR.
284 523769 9 1-1-9 Timeout error of CAN-Receive-Frame Passive TSC1AR.
291 523776 9 1-1-9 Timeout error of CAN-Receive-Frame TSC1TE - active.
292 523777 9 1-1-9 Passive timeout error of CAN-Receive-Frame TSC1TE. Setpoint.
293 523778 9 1-1-8 Timeout error of CAN-Receive-Frame TSC1TR.
294 523779 9 1-1-8 Passive timeout error of CAN-Receive-Frame TSC1TR.
299 523788 12 6-5-5 Timeout error of CAN-Transmit-Frame TrbCH. Status Wastegate.
300 523605 9 1-1-8 Timeout error of CAN-Receive-Frame TSC1AE. Traction Control.
301 523606 9 1-1-9 Timeout error of CAN-Receive-Frame TSC1AR. Retarder.
305 898 9 1-1-8 Timeout error of CAN-Receive-Frame TSC1TE. Setpoint.
306 520 9 1-1-9 Timeout Error of CAN-Receive-Frame TSC1TR; control signal
313 523858 12 6-7-9 Timeout error of CAN-Transmit-Frame UAA11.
Timeout error of CAN-Transmit-Frame UAA1 on CAN 2. Control burner air
322 523867 12 6-7-9
pump.
360 523982 0 7-3-7 Powerstage diagnosis disabled. High battery voltage.
361 523982 1 7-3-7 Powerstage diagnosis disabled. Low battery voltage.
362 523090 2 3-2-9 Engine brake Pre-Selection switch. Plausibility error.
376 630 12 2-8-1 Access error EEPROM memory (delete).
377 630 12 2-8-1 Access error EEPROM memory (read).
378 630 12 2-8-1 Access error EEPROM memory (write).
381 411 4 6-9-3 Physical range check low for EGR differential pressure.
384 2791 12 4-1-5 Actuator EGR valve. Powerstage over temperature.
387 523612 12 5-5-5 Internal software error ECU. Injection cut off.
Engine speed above warning threshold.
388 190 0 2-1-4
Overspeed detection in component engine protection.
389 190 0 2-1-4 Engine speed above warning threshold (FOC-Level 1).
390 190 11 2-1-4 Engine speed above warning threshold (FOC-Level 2).
391 190 14 2-1-4 Engine speed above warning threshold (Overrun Mode).
411 108 11 2-9-2 Ambient air pressure received from a CAN-bus is reported as defective.
412 108 3 2-9-2 Sensor error ambient air pressure. Signal range check high.
413 108 4 2-9-2 Sensor error ambient air pressure. Signal range check low.
Environment temperature sensor, temperature above upper physical thresh-
415 171 0 3-1-2
old.
416 171 1 3-1-2 Environment temperature physical range check low.
1513AA-4

245

Sensor error SCR-System environment temperature.
417 171 3 3-1-2
DPF-System air inlet temperature, signal range check high.
Sensor error SCR-System environment temperature.
418 171 4 3-1-2
DPF-System air inlet temperature, signal range check low.
419 190 8 2-1-2 Sensor camshaft speed, disturbed signal.
Sensor camshaft detection.
420 190 12 2-1-2
Out of range, signal disrupted, no signal.
421 190 2 2-1-3 Offset angle between crank- and camshaft-sensor is too large.
Sensor crankshaft detection.
422 190 8 2-1-2
Out of range, signal disrupted or no signal.
423 190 12 2-1-2 Speed detection, out of range, signal disrupted or no signal.
455 975 5 2-3-8 PWM-Signal fan, open load or short-circuit ground.
457 975 3 2-3-8 PWM-Signal fan, short-circuit to battery.
458 975 4 2-3-8 PWM-Signal fan, open load or short circuit to ground
459 1639 12 2-3-8 Fan speed sensor, electrical error, signal disturbed or very low fan speed.
Sensor error fan speed.
460 1639 0 2-3-8
Signal range check high or engine speed resp. Fan speed too big.
461 1639 1 2-3-8 Sensor error fan speed, signal range check low or fan speed too low.
462 523602 0 2-3-8 High fan speed, warning threshold exceeded.
463 523602 0 2-3-8 High fan speed, shut off threshold exceeded.
464 97 3 2-2-8 Sensor error water in fuel, signal range check high.
465 97 4 2-2-8 Sensor error water in fuel, signal range check low.
472 94 3 2-1-6 Sensor error low fuel pressure, signal range check high.
473 94 4 2-1-6 Sensor error low fuel pressure, signal range check low.
474 94 1 2-1-6 Low fuel pressure, warning threshold exceeded.
475 94 1 2-1-6 Low fuel pressure, shut off threshold exceeded.
483 174 11 2-2-7 Fuel temperature not plausible.
486 523618 3 1-3-3 Sensor error gearbox oil temperature, signal range check high.
487 523618 4 1-3-3 Sensor error gearbox oil temperature, signal range check low.
Physical range check high for exhaust gas temperature upstream (SCR-
488 523619 2 1-3-3
CAT).
Shutoff condition.
489 523619 2 1-3-3
No detailed information!
500 523915 0 1-6-5 HCI dosing valve (DV1); overcurrent at the end of the injection phase
501 523915 12 1-6-6 HCI dosing valve (DV1): Powerstage over temperature.
502 523915 3 1-5-9 HCI dosing valve (DV1): Short circuit to battery.
503 523915 3 1-6-4 Short circuit to battery high side, HCI dosing valve (DV1).
504 523915 4 1-5-9 HCI dosing valve (DV1): Short circuit to ground.
505 523915 11 1-6-4 HCI dosing valve (DV1): Short circuit high side powerstage.
1513AA-5

246

506 523916 2 7-1-9 Sensor HCI dosing valve (DV1) downstream pressure: Plausibility error.
HCI dosing valve (DV1) downstream pressure: Physical range check high.
508 523916 0 7-1-9
Shut off regeneration.
HCI dosing valve (DV1) downstream pressure: Physical range check low.
511 523916 1 7-1-9
Shut off regeneration.
Sensor error HCI dosing valve (DV1) downstream pressure: Signal range
514 523916 3 7-1-9
check high.
Sensor error HCI dosing valve (DV1) downstream pressure: Signal range
515 523916 4 7-1-9
check low.
525 523917 4 7-1-8 Sensor error DV1 & DV2 upstream pressure: Signal range check low.
534 523918 3 7-1-7 Sensor error DV1 & DV2 upstream temperature: Signal range check high.
535 523918 4 7-1-7 Sensor error DV1 & DV2 upstream temperature: Signal range check low.
542 1638 2 3-1-4 Hydraulic oil temperature check for Shut off condition.
543 676 11 263 Cold start aid relay error.
544 676 11 263 Cold start aid relay: Open load.
545 729 5 263 Cold start aid relay open load.
547 729 12 263 Cold start aid relay: Over temperature error.
549 729 3 263 Intake Air Heater Device: Short circuit to battery.
551 729 4 263
559 523895 13 1-5-8 Check of missing injector adjustment value programming (IMA) injector 1.
565 523350 4 151 Injector cylinder-bank 1: Short circuit.
566 523352 4 152 Injector cylinder-bank 2: Short circuit.
567 523354 12 153 Injector powerstage output defect.
568 651 5 154 Injector 1 (in firing order): Interruption of electric connection.
575 523756 14 1-5-5 Special pattern for special cases. No detailed information!
1513AA-6

247

578 523759 14 1-6-2 Special pattern for special cases No detailed information!
579 523760 14 1-6-3 Special pattern for special cases No detailed information!
580 651 3 154 Injector 1 (in firing order): Short circuit.
590 655 4 1-6-2 High side to low side short circuit in the injector 5 (in firing order).
591 656 4 1-6-3 High side to low side short circuit in the injector 6 (in firing order).
592 523615 5 135 Metering unit (Fuel-System): Open load.
593 523615 12 135 Metering unit (Fuel-System): Powerstage over temperature.
594 523615 3 135 Metering unit (Fuel-System): Short circuit to battery, highside.
595 523615 4 135 Metering unit (Fuel-System): Short circuit to ground, high side.
596 523615 3 135 Metering unit (Fuel-System): Short circuit to battery, low side.
597 523615 4 135 Metering Unit (Fuel-System): Short circuit to ground, low side
598 523615 3 1-3-5 Metering unit, short circuit to battery.
599 523615 4 1-3-5 Metering unit, short circuit to ground.
605 1323 12 2-4-1 Too many recognized misfires in cylinder 2 (in firing order).
610 1322 12 2-4-1
611 1346 0 2-4-1 Misfire detection monitoring No detailed information!
612 523612 12 555 Internal ECU monitoring detection reported error.
ECU reported internal software error.
613 523612 12 555
Internal ECU monitoring detection reported error.
614 523612 12 555 ECU reported internal software error.
619 523612 12 555 Injection system,electrical error injectors.
1513AA-7

248

629 523612 12 555 Diagnostic fault check to report the accelerator pedal position error.
630 523612 12 555 Diagnostic fault check to report the engine speed error.
631 523612 12 555 Error in the plausibility of the injection energizing time.
632 523612 12 555 Error in the plausibility of the start of energising angles.
633 523612 12 555 Diagnostic fault check to report the error due to non plausibility in ZFC.
Diagnosis fault check to report the demand for normal mode due to an error
634 523612 12 555
in the PoI2 quantity.
Diagnosis fault check to report the error to demand for an ICO due to an
635 523612 12 555
error in the PoI2 shut-off.
Diagnosis fault check to report the error to demand for an ICO due to an
636 523612 12 555
error in the PoI3 efficiency factor.
637 523612 12 555 Internal ECU monitoring detection reported error.
638 523612 12 555 Monitoring of Fuel Quantity Correction.
Diagnostic fault check to report the plausibility error in rail pressure
639 523612 12 555
monitoring.
640 523612 12 555 Diagnostic fault check to report the error due to torque comparison.
641 523612 12 555 Diagnosis of curr path limitation forced by ECU monitoring level 2.
642 523612 12 555 Diagnosis of lead path limitation forced by ECU monitoring level 2.
643 523612 12 5-5-5 Diagnosis of set path limitation forced by ECU monitoring level 2.
644 523612 3 5-5-5 Reported Over Voltage of Supply.
646 523612 4 5-5-5 Reported UnderVoltage of Supply.
648 523008 1 4-2-4 Manipulation control was triggered.
649 523008 2 4-2-4 Timeout error in Manipulation control.
654 2634 12 7-5-7 Early opening defect of main relay No detailed information!
656 2634 12 7-5-7 DFC for stuck main relay error No detailed information!
659 3226 2 8-1-3 Nox feed back fault detection No detailed information!
692 523752 0 7-5-8 Plausibiliti error during Rich to Lean switch over No detail informationen!
693 523752 0 7-5-8 Monitoring of Nox signal readyness No detail informationen!
Diagnostic fault check to report WDA active due to errors in query-/response
714 523612 12 5-5-5
communication.
715 523612 12 5-5-5 Diagnostic fault check to report ABE active due to undervoltage detection.
716 523612 12 5-5-5 Diagnostic fault check to report ABE active due to overvoltage detection.
717 523612 12 5-5-5 Diagnostic fault check to report WDA/ABE active due to unknown reason.
1513AA-8

249

Plausibility Check.
720 98 2 2-1-1
732 100 3 2-2-4 Sensor error oil pressure; signal range check high.
733 100 4 2-2-4 Sensor error oil pressure sensor; signal range check low.
734 100 0 2-3-1 High oil pressure; warning threshold exceeded.
735 100 0 2-3-1 High oil pressure; shut off threshold exceeded.
736 100 1 2-3-1 Low oil pressure; warning threshold exceeded.
737 100 1 2-3-1 Low oil pressure; shut off threshold exceeded.
743 175 3 1-4-4 Sensor error oil temperature; signal range check high.
744 175 4 1-4-4 Sensor error oil temperature; signal range check low.
745 175 0 1-4-4 High oil temperature; warning threshold exceeded.
746 175 0 1-4-4 High oil temperature; shut off threshold exceeded.
747 1237 2 1-4-5 Override switch; plausibility error.
750 107 3 1-3-6 Sensor error airfilter differential pressure; short circuit to battery.
751 107 0 1-3-6 Sensor error airfilter differential pressure; short circuit to ground.
752 107 0 1-3-6 Air filter differential pressure; air filter cologged.
753 523919 2 6-9-4 DPF burner air pump pressure sensor, plausibility error.
DPF burner air pump pressure sensor, pressure above upper shutoff
755 523919 0 6-9-4
threshold.
DPF burner air pump pressure sensor, pressure below lower shutoff
758 523919 1 6-9-4
threshold.
761 523919 3 6-9-4 DPF burner air pump pressure sensor, short circuit to battery or open load.
762 523919 4 6-9-4 DPF burner air pump pressure sensor, short circuit to ground.
763 523920 2 7-1-6 Exhaustgaspressure upstream burner, plausibility error.
Exhaust gas pressure upstream burner, pressure above upper shutoff
765 523920 0 7-1-6
threshold.
770 523920 3 7-1-6 Exhaust gas pressure upstream burner, short circuit to battery or open load.
771 523920 4 7-1-6 Exhaust gas pressure upstream burner, short circuit to ground.
772 102 2 2-2-3 Pressure downstream charge air cooler, plausibility error.
Pressure downstream charge air cooler, pressure below lower physical
774 102 1 2-2-3
threshold.
776 102 3 2-2-3 Pressure downstream charge air cooler, short circuit to battery or open load.
777 102 4 2-2-3 Pressure downstream charge air cooler, short circuit to ground.
780 523699 3 1-1-3 Boost pressure control; negative governor deviation below limit.
781 523699 4 1-1-3 Learning value too high. No detailed information!
Over temperature of device driver of pressure control valve. No detailed
785 523889 3 1-1-3
information!
1513AA-9

250

791 411 0 6-9-3 Delta pressure across venturi in EGR line above physical high limit.
Plausibility Check fault for deviation of desired and actual EGR-mass flow,
793 411 0 6-9-3
where the latter is calculated out of EGR Delta Pressure Sensor.
795 411 3 6-9-3 Sensor error differential pressure Venturiunit (EGR), signal range check low.
796 411 4 6-9-3 Sensor error differential pressure Venturiunit (EGR), signal range check high.
Particulate filter regeneration.
(3x) over the max. has been aborted allowed recovery time.
805 524025 14 8-4-5
Regeneration after time X is not successful (the error occurs when the
regeneration times).
806 524058 2 8-4-4 Particulate filter; regeneration not succesful.
807 3253 2 6-9-2 Differential pressure DPF, plausibility error.
809 3251 0 6-9-2 Differential pressure DPF maximum value is exceeded.
810 3251 0 6-9-2 Differential pressure sensor across DPF exceeds warning high limit.
812 3251 1 6-9-2 Differential pressure DPF, pressure below lower shutoff threshold.
813 3251 1 6-9-2 Differential pressure DPF, pressure below lower warning threshold.
814 3253 3 6-9-2 Electrical error differential pressure B58 (DPF). (Signal range check high).
815 3253 4 6-9-2 Electrical error differential pressure (DPF). signal range check low.
The pressure relief valve (PRV) has reached the number of allowed
825 523009 9 2-5-3
activations.
826 523470 2 1-4-6 Pressure relief valve is forced to open, perform pressure increase.
827 523470 2 1-4-6 Pressure Relief Valve (PRV) forced to open. Performed by pressure increase.
828 523470 12 1-4-6 Pressure Relief Valve (PRV) forced to open. Shutoff conditions.
829 523470 12 1-4-6 Pressure Relief Valve (PRV) forced to open. Warning conditions.
830 523470 14 1-4-6 Open Pressure Relief Valve (PRV).
831 523470 11 1-4-6 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range.
Rail pressure out of tolerance range.
832 523470 11 1-4-6
The PRV can not be opened at this operating point with a pressure shock.
Open time of Pressure Relief Valve (PRV) for wear out monitoring had
833 523009 10 2-5-3
exceeded.
834 523906 5 7-6-1 Electrical fuel pre - supply pump; open load.
835 523906 12 7-6-1 Electrical fuel pre - supply pump. ECU powerstage over temperature.
836 523906 3 7-6-1 Electrical fuel pre - supply pump; short circuit to battery.
837 523906 4 7-6-1 Electrical fuel pre - supply pump. Short circuit to ground.
847 1176 0 1-3-9 Pressure sensor upstream turbine, Physical Range Check high.
848 1176 1 1-3-9 Pressure sensor upstream turbine, Physical Range Check low.
849 1176 3 1-4-1 Pressure sensor upstream turbine, signal range check (SRC) high.
850 1176 4 1-4-1 Pressure sensor upstream turbine, signal range check (SRC) low.
856 523613 0 1-3-4 Rail pressure metering unit, Positive governor deviation.
1513AA-10

251

Rail pressure metering unit, Rail pressure disrupted. Maximum positive
857 523613 0 1-3-4
deviation of rail pressure exceeded.
Rail pressure metering unit, Rail pressure disrupted. Maximum positive
858 523613 0 1-3-4
deviation of rail pressure in metering unit exceeded (RailMeUn1).
Rail pressure metering unit, Rail pressure below the target range.
859 523613 0 1-3-4 (RailMeUn2)
Railsystem leakage detected.(RailMeUn10)
Rail pressure metering unit, Minimum rail pressure exceeded (RailMeUn3).
861 523613 1 1-3-4
Negative deviation of rail pressure second stage (RailMeUn22).
862 523613 0 1-3-4 Rail pressure metering unit, Maximum rail pressure exceeded.
Rail pressure metering unit, Setpoint of metering unit in overrun mode not
864 523613 2 1-3-4
plausible.
865 523613 0 1-3-4 Setpoint of metering unit in overrun mode not plausible.
874 157 0 1-4-7 Rail pressure raw value is intermittent. No detailed information!
875 157 1 1-4-7 rail pressure raw value is above maximum offset. No detailed information!
876 523470 7 1-4-6 Maximum rail pressure exceeded (PRV).
877 157 3 1-4-7 Sensor error rail pressure. Sensor voltage above upper limit.
878 157 4 1-4-7 Sensor error rail pressure. Sensor voltage below lower limit.
881 523633 11 1-4-9 Longterm adaption factor below threshold.
882 523633 11 1-4-9 Nox conversion rate insufficient (SCR-Cat defect, bad DEF quality).
Nox conversion rate insufficient (SCR-Cat defect, bad DEF quality);
883 523633 11 1-4-9
temperature range 1
887 3234 11 1-8-4 DFC for plausibility error Min for NOx sensor downstream of SCR Cat.
889 3224 1 1-8-5 DFC for plausibility error Max for NOx sensor upstream of SCR Cat.
892 4345 11 2-3-6 Sensor backflow line pressure (SCR); plausibility error.
SCR Monitoring; Pressure stabilisation error, general pressure check error
893 4343 11 8-7-1
(SCR).
894 4374 13 8-7-2 Pressure stabilisation error dosing valve (SCR).
897 523632 16 8-7-5 Pump pressure SCR metering unit too high.
898 523632 18 8-7-6 Pump pressure SCR metering unit too low.
899 523632 0 8-7-7 Pressure overload of SCR-System.
900 523632 1 8-7-8 Pressure build-up error SCR-System.
903 4365 0 8-8-1 DEF tank temperature too high.
905 3241 0 8-8-3 Sensor SCR catalyst upstream temperature too high; plausibility error.
908 3361 7 8-8-6 DEF dosing valve blocked (SCR).
914 523720 2 1-4-8 DEF supply module heater temperature; plausibility error (normal condition).
Sensor DEF supply module heater temperature; plausibility error (cold start
915 523720 2 1-4-8
condition).
1513AA-11

252

916 523721 2 6-8-9 Sensor DEF supply module temperature; plausibility error (normal condition).
Sensor DEF supply module temperature; plausibility error (cold start
917 523721 2 6-8-9
condition).
SCR plausibility, OBD and diagnosis; Stuck in range check of DEF tank
918 523981 11 2-4-3 temperature sensor.
DEF-tank without heating function (heating phase).
919 523330 14 1-3-1 Immobilizer status; fuel blocked.
920 523330 14 1-3-1 DFC to block the fuel by Sia. No detailed information!
DFC to indicate that TEN-code or UC-code received if ECU is learned.
921 523330 14 1-3-1
922 523330 14 1-3-1 DFC to indicate that no code is received via CAN. No detailed information!
923 523330 14 1-3-1 DFC to indicate that wrong code is received. No detailed information!
925 523720 8 1-4-8 DEF supply module heater temperature; duty cycle in failure range.
926 523720 8 1-4-8 DEF supply module heater temperature; duty cycle in invalid range.
927 523721 11 6-8-9 Urea supply module temperature measurement not available.
928 523722 8 6-9-1 DEF supply module PWM signal; period outside valid range.
929 523722 8 6-9-1 Detect faulty PWM signal from Supply Modul.
930 523721 8 6-8-9 DEF supply module temperature; duty cycle in failure range.
931 523721 8 6-8-9 Urea supply module temperature; duty cycle in invalid range.
932 29 3 1-2-6 Handthrottle idle validation switch; short circuit to battery
935 91 3 2-2-6 Sensor error accelerator pedal. signal range check high.
937 29 4 1-2-6 Handthrottle; short circuit to ground.
940 91 4 2-2-6 Sensor error accelerator pedal. Signal is below the range.
942 523921 3 7-1-4 Sensor error burner temperature; signal range check high.
943 3532 3 1-2-7 Sensor error DEF tank level; signal range check high.
944 523921 4 7-1-4 Sensor error burner temperature; signal range check low.
946 1079 13 2-8-2 Failure of sensor supply voltage 1.
956 677 3 5-1-2 Starter relay high side. Short circuit to battery.
957 677 4 5-1-2 Starter relay high side short circuit to ground.
958 677 5 5-1-2 Starter relay low side no load error.
959 677 12 5-1-2 Starter relay powerstage over temperature.
960 677 3 5-1-2 Starter relay low side short circuit to battery.
961 677 4 5-1-2 Starter relay low side short circuit to ground.
965 523922 3 7-1-5 Burner shut of valve; short circuit to battery.
969 624 5 5-1-3 SVS lamp; open load.
1513AA-12

253

970 624 12 5-1-3 SVS lamp: powerstage over temperature
971 624 3 5-1-3 SVS lamp; short circuit to battery
972 624 4 5-1-3 SVS lamp; short circuit to ground
973 523612 14 5-5-5 Softwarereset CPU SWReset_0
976 91 11 2-2-6 Plausibility error between APP1 and APP2 or APP1 and idle switch.
Plausibility error between sensor and idle switch, Acceleratio Pedal
Detection.
978 29 2 1-2-6
In case of Hand Throttle with Low Idle Switch, it is the plausibility check
between hand throttle and idle switch.
980 523550 12 5-1-5 Terminal 50 was operated too long.
981 172 3 2-2-6 Air flow temperature sensor; short circuit to battery or open load.
982 172 4 2-2-6 Air flow temperature sensor; short circuit to ground.
986 523921 0 7-1-4 Burner temperature, temperature above upper shutoff threshold.
989 523921 1 7-1-4 Burner temperature, temperature below lower shutoff threshold.
Charged Air cooler down stream temperature. Temperature below lower
992 105 1 1-2-8
physical threshold.
994 105 3 1-2-8 Electrical error charged air temperature. Signal range check high.(SRC)
995 105 4 1-2-8 Electrical error charged air temperature. Signal range check low.
Charged air cooler temperature. System reaction initiated. High charged air
996 105 0 2-3-3
cooler temperature. Warning threshold exceeded.
997 105 0 2-3-3 High charged air cooler temperature. Shut off threshold exceeded.
Diagnostic fault check for charged air cooler downstream temperature
998 105 11 1-2-8 sensor
Electrical error EGR cooler downstream temperature. Signal range check
1007 412 3 6-8-2
high.
1008 412 4 6-8-2 electrical error EGR cooler downstream temperature. Signal range check low.
1011 523960 0 7-7-1 Physical range check high for EGR cooler downstream temperature.
1012 523960 1 7-7-1 Physical range check low for EGR cooler downstream temperature.
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8).
1014 51 6 5-9-4
Signal range check high.
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range
1015 520521 5 5-9-4
check low.
Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8) not
1016 51 7 5-9-4
plausible.
1022 51 6 5-9-4
check high
1513AA-13

254

1023 51 5 5-9-4
check low.
Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve
1024 51 3 5-9-4 (4.1;6.1;7.8).
Signal range check high.
Position sensor error actuator EGR-Valve (2.9;3.6) or Throttle-Valve
1025 51 4 5-9-4 (4.1;6.1;7.8).
Signal range check low.
1026 4769 2 6-8-4 Temperature downstream DOC, plausibility error.
1029 4766 0 6-8-4 Temperature downstream DOC, temperature above upper shutoff threshold.
1030 4766 0 6-8-4 Temperature downstream DOC, temperature above upper warning threshold.
Sensor error exhaust gas temperature downstream (DOC); signal range
1034 4769 3 6-8-4
check high.
Sensor error exhaust gas temperature downstream (DOC); signal range
1035 4769 4 6-8-4
check low.
1036 4768 2 6-8-3 Temperature upstream DOC, plausibility error.
1039 4765 0 6-8-3 Temperature upstream DOC, temperature above upper shutoff threshold.
1040 4765 0 6-8-3 Temperature upstream DOC, temperature above upper warning threshold.
Electrical error exhaust gas temperature upstream (DOC); signal range
1044 4768 3 6-8-3
check high.
Electrical error exhaust gas temperature upstream (DOC); signal range
1045 4768 4 6-8-3
check low.
1047 3248 4 6-8-5 Sensor error particle filter downstream temperature; signal range check low.
Sensor error exhaust gas temperature upstream turbine; signal range check
1067 1180 3 5-5-6
high.
Exhaust temperature upstream SCR-Cat, temperature above upper physical
1069 4360 0 6-6-8
threshold.
1070 4360 1 6-6-8 Sensed exhaust temperature before SCR-Cat is < physical low limit.
1071 4361 2 6-6-8 Signal error for CAN message No detail informationen!
1166 523948 1 7-7-2 Zerofuel calibration injector 3 (in firing order); minimum value exceeded.
1170 523612 12 5-5-5 Internal software error ECU.
1180 168 0 3-1-8 Physical range check high for battery voltage.
1181 168 1 3-1-8 Physical range check low for battery voltage.
1183 172 1 2-2-6 Air inlet filter sensor out of physical range check.
1187 523980 14 7-8-4 Bad quality of reduction agent detected.
1193 1180 0 5-5-6 Physical range check high for exhaust gas temperature upstream turbine.
1194 1180 1 5-5-6 Physical range check low for exhaust gas temperature upstream turbine.
1513AA-14

255

HMI engine derate service state.
1219 524018 14 7-8-6 DPF wasn’t regenerated, power reduction phase 1 (manuell regeneration
request).
HMI engine derate stop state.
1220 524022 14 7-8-6 DPF wasn’t regenerated, power reduction phase 2 (manuell regeneration
request).
1222 190 14 2-1-2 Camshaft- and Crankshaft speed sensor signal not available on CAN.
1223 51 5 5-9-4 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); open load.
1224 51 6 5-9-4 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over current.
1226 51 3 5-9-4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to battery.
1227 51 3 5-9-4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to battery.
1228 51 4 5-9-4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to ground.
1229 51 4 5-9-4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to ground.
Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); Overload by
1230 51 6 5-9-4
short-circuit.
1231 51 11 5-9-4 Power stage overtemperature due to high current.
actuator AGR valve (2.9;3.6) throttle valve (4.1;6.1;7.8); Voltage below thresh-
1232 51 4 5-9-4
old.
1239 523984 3 7-8-8 UB7; Short circuit to battery error of actuator relay 7.
1241 523986 4 1-7-6 UB6; Short circuit to ground actuator relais 6.
1242 523987 4 7-9-1 UB7; Short circuit to ground actuator relay 7.
1247 524019 11 8-6-2 Burner Control; Air Line - Blocked Air Pump; air lines blocked.
1248 523910 9 6-9-5 Burner Control; Air Pump - CAN Lost Air Pump; CAN communication lost.
1249 523910 7 6-9-5 Air pump; CAN communication interrupted no purge function available.
1250 523910 12 6-9-5 Air Pump; internal error.
1252 523910 0 6-9-5 Air Pump; operating voltage error.
Air inlet EPV - pressure too low.
1254 524014 1 8-5-8
Air pressure glow plug flush line; below limit.
Burner Control; Flame lost max.
1255 524013 7 8-5-7
Burner operation is interrupted too often.
1257 523915 7 8-5-3 HCI dosing valve (DV1); blocked open.
1258 524016 11 8-5-9 Burner Control; HFM - Electrical Fault HFM sensor; electrical fault.
Burner Control; HFM - Plausibilitätsfehler 1 Amount of air is not plausible to
1259 524016 2 8-5-9
pump speed.
1261 523910 6 6-9-5 Burner Control Air Pump; over current Air pump electrically overloaded.
Burner Control; Shut-off Valve - Blocked closed Burner Shut Off Valve;
1262 523922 7 8-5-4
blocked closed.
Burner Control; Fuel line ShutOff downstream - broken Burner fuel line pipe
1263 524021 11 8-6-4
leak behind Shut Off Valve.
1513AA-15

256

1264 523922 7 8-5-5 Burner Shut Off Valve; blocked open.
Timeout error of CAN-Receive-Frame ComMS_Sys1TO (error memory Slave);
1285 524038 9 8-2-4
Master-Slave internal CAN message.
1286 524039 9 8-2-5
1287 524040 9 8-2-6
1288 524041 9 8-2-7
1289 524042 9 8-2-8
1290 524043 9 8-2-9
Master Slave, Error of message counter CAN receive message
1291 524045 9 8-3-1
ComMSMoFOvR; ComMSMoFOvR1CNT.
1292 524046 9 8-3-2 Master-Slave CAN; Error Checksum of CAN-Receive Message.
Master-Slave CAN; Error of message length of CAN receive message
1293 524047 9 8-3-3
ComMSMoFOvR;_ComMSMoFOvR1DLC.
1294 524048 9 8-3-4 Timeout error CAN message ComMSMoFOvR1TO error memory Slave.
1299 523788 0 6-5-5 Wastegate plauisibility error off CAN transmit message.
1300 523788 0 6-5-5 Timeout Error of CAN-Receive-Frame ComTrbChActr; Wastegate.
Deviation of the exhaust gas temperature setpoint to actual value
1302 524024 11 8-6-6
downstream (DOC) too high.
Check of missing injector adjustment value programming (IMA) injector 7 (in
1324 523995 13 7-9-5
firing order).
check of missing injector adjustment value programming (IMA) injector 8 (in
1325 523996 13 7-9-6
firing order).
1326 523997 4 7-9-7 Injector cylinder bank 1 slave; short circuit.
1327 523998 4 7-9-8 Injector cylinder bank 2 slave; short circuit.
1328 523999 12 7-9-9 Injector powerstage output Slave defect.
1329 524000 5 1-7-7 Injector 7 (in firing order); interruption of electric connection.
1330 524001 5 1-7-8 Injector 8 (in firing order); interruption of electric connection.
1333 524000 3 1-7-7 Injector 7 (in firing order); short circuit.
1334 524001 3 1-7-8 Injector 8 (in firing order); short circuit.
Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 0;_
1337 2797 4 5-6-5
IVDiaShCirGndToutBnk_0.
Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 1;_
1338 2798 4 5-6-6
IVDiaShCirGndToutBnk_1.
1339 2797 4 5-6-5 Injector diagnostic; Short circuit to ground cylinder bank 0.
1340 2798 4 5-6-6 Injector diagnostic; Short circuit to ground cylinder bank 1.
1513AA-16

257

1341 524035 12 5-5-5 Injector diagnostics; time out error in the SPI communication.
1342 524036 12 5-5-5 Injector diagnostics Slave; time out error in the SPI communication.
Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN
1345 524069 9 8-9-6
communication faulty.
1357 524052 11 8-3-6 Error memory Slave reports FID MSMonFC2 (collective error).
1368 524052 11 8-3-6 Error memory Slave reports FID MSMonFC3 (collective error).
1378 523919 2 6-9-4 Sensor air pump airpressure; plausibility error.
1379 523920 2 7-1-6 Sensor exhaust gas back pressure burner; plausibility error.
1380 3253 2 6-9-2 Sensor differential pressure (DPF); plausibility error.
1381 164 2 8-3-9 Rail pressure safety function is not executed correctly ().
1389 523922 5 7-1-5 Burner Shut Off Valve; open load.
1390 523922 12 7-1-5 Burner Shut Off Valve; powerstage over temperature.
1392 523922 4 7-1-5 Burner Shut Off Valve; short circuit to ground.
Burner temperature sensor; Plausibility Check for burner temperature sensor
1395 523921 2 7-1-4
Sensor burner temperature; plausibility error.
1398 1136 0 6-8-1 Physical range check high for ECU temperature.
Sensor exhaust gas temperature OxiCat downstream (normal operation);
1402 4769 2 6-8-4
plausibility error.
Sensor exhaust gas temperature OxiCat downstream (regeneration);
1403 4769 2 6-8-4
plausibility error.
1411 1188 11 8-1-4 Wastegate actuator; internal error.
1412 1188 11 8-1-4 Wastegate actuator; EOL calibration not performed correctly.
1413 1188 13 8-1-4 Wastegate actuator calibration deviation too large, recalibration required.
1414 1188 2 8-1-4 Wastegate; status message from ECU missing.
1415 1188 7 8-1-4 Wastegate actuator; blocked.
1417 1188 11 8-1-4 Wastegate actuator; over temperature (> 135°C).
1418 1188 11 8-1-4 Wastegate actuator; operating voltage error.
Warning threshold for an internal actuator error exceeded, < 4L EGR.
1423 51 0 5-9-4
actuator und >4L Air Intake Flap.
Shut off threshold for an internal actuator error exceeded, < 4L EGR.actuator
1424 51 1 5-9-4
und >4L Air Intake Flap.
1425 172 0 2-2-6 air temperature within air filter box above maximum physical value.
1431 524028 2 8-1-5 CAN message PROEGRActr; plausibility error.
Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas
1432 524029 2 8-1-5
recirculation positioner.
1436 524034 5 8-1-6 Disc separator; open load.
1437 524034 12 8-1-6 Disc separator; powerstage over temperature.
1438 524034 3 8-1-6 Disc separator; short circuit to battery.
1513AA-17

258

1439 524034 4 8-1-6 Disc separator; short circuit to ground.
1440 524030 7 8-1-5 EGR actuator; internal error.
1441 524031 13 8-1-5 EGR actuator, calibration error.
1442 524032 2 8-1-5 EGR actuator; status message "EGRCust" is missing.
1443 524033 7 8-1-5 EGR actuator; due to overload in Save Mode.
1455 3711 12 7-1-1 Temperature during stand-still main phase too low or too high.
High exhaust gas temperature EGR cooler downstream; warning threshold
1458 523960 0 7-7-1
exceeded.
1464 0 0 -
1466 0 0 -
1467 0 0 -
1469 0 0 -
1470 0 0 -
1471 0 0 -
1472 0 0 -
1481 524025 5 8-4-5 DPF system; operating voltage error.
1482 524044 9 1-8-8 CAN message ComMS_Sys7 not received from slave.
1484 524068 2 8-9-5 Master ECU and Slave ECU have been identified as the same types.
1485 524052 11 8-3-6 Master ECU and Slave ECU data sets or software are not identical.
1486 523718 5 6-7-6 SCR mainrelay; open load (only CV56B).
1488 523718 3 6-7-6 SCR mainrelay; short circuit to battery (only CV56B).
1489 523718 4 6-7-6 SCR mainrelay; short circuit to ground (only CV56B).
1661 524116 9 1-9-4 Timeout error of CAN-Transmit-Frame SCR2.
1662 524117 9 9-4-1 Timeout error of CAN-Transmit-Frame SCR3.
1663 524097 9 9-2-1 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl.
1664 524098 9 9-2-2 Timeout error of CAN-Transmit-Frame ComDPFBrnPT.
1665 524099 9 9-2-3 Timeout error of CAN-Transmit-Frame ComDPFC1.
1666 524100 9 9-2-4 Timeout error of CAN-Transmit-Frame ComDPFHisDat.
1667 524101 9 9-2-5 Timeout error of CAN-Transmit-Frame ComDPFTstMon.
1668 524105 9 9-2-9 Timeout error of CAN-Transmit-Frame ComEGRMsFlw (EGR Steller).
1669 524108 9 9-3-2 Timeout error of CAN-Transmit-Frame ComEGRTVActr (EGR actuator).
1670 524110 9 9-3-4 Timeout error of CAN-Transmit-Frame ComETVActrTO.
1671 524112 9 9-3-6 Timeout ComIntake Throttle Valve Actr.
1672 524118 9 9-4-2 Timeout error of CAN-Receive-Frame ComRxCM1.
1675 524103 9 9-2-7 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp.
1676 524104 9 9-2-8 Timeout error of CAN-Receive-Frame ComRxDPFCtl.
1513AA-18

259

1677 524106 9 1-9-5 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1 (EGR actuator)
1678 524107 9 9-3-1 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2 (EGR actuator).
1679 524109 9 9-3-3 Timeout error of CAN-Receive-Frame ComRxEGRTVActr (EGR actuator).
1680 524111 9 9-3-5 Timeout error of CAN-Receive-Frame ComRxETVActr.
1681 524113 9 9-3-7 Timeout error of CAN-Receive-Frame ComRxITVActr.
1682 524120 9 9-4-4 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag.
1683 524121 9 9-4-5 Timeout error of CAN-Receive-Frame ComRxTrbChActr (wastegate actuator).
1684 524122 9 9-4-6 Timeout error of CAN-Receive-Frame ComRxUQSens (Urea quality).
1685 524123 9 9-4-7 Timeout error of CAN-Receive-Frame ComSCRHtCtl.
1686 524124 9 9-4-8 Timeout error of CAN-Receive-Frame ComTxAT1IMG.
1687 524125 9 9-4-9 Timeout error of CAN-Receive-Frame ComTxTrbChActr (Wastegate actuator).
1698 524133 2 9-5-6 HMI system; set if restore button blocked.
1699 524134 0 9-5-7 DPF, ash load exceeds the shutoff threshold.
1700 524134 0 9-5-7 DPF, ash load exceeds the warning threshold.
1701 524135 0 9-5-8 DPF, soot load exceeds the shutoff threshold.
1702 524135 14 9-5-8 DPF, soot load exceeds the service request threshold.
1703 524135 0 9-5-8 DPF, soot load exceeds the warning threshold.
1705 524156 9 9-7-2 Timeout error of CAN-Receive-Frame ComRxEBC2.
1706 524157 9 9-7-3 Fan control; time out for fan governing.
1708 524159 0 9-7-5 Fan; short circuit battery or open load.
1709 524159 1 9-7-5 Fan; short circuit ground.
1710 524160 5 9-7-6 Fan; in/outlet valve 1; open load.
1712 524160 3 9-7-6 Fan; in/outlet valve 1; short circuit battery.
1713 524160 4 9-7-6 Fan; in/outlet valve 1; open load ground.
1714 524161 5 9-7-7 Fan; in/outlet valve 2; open load.
1716 524161 3 9-7-7 Fan; in/outlet valve 2; short circuit battery.
1717 524161 4 9-7-7 Fan; in/outlet valve 2; open load ground.
1718 524162 12 9-7-8 Fan; fancontrol; angle sensor defect.
1719 524163 12 9-7-9 Fan; fancontrol; fan or valve defect.
1752 2791 7 4-1-5 EGR actuator, actuator blocked.
1753 2791 2 4-1-5 EGR actuator, CAN error.
1754 2791 13 4-1-5 EGR actuator, EOL calibration error.
1755 2791 12 4-1-5 EGR Actuator, internal electrical fault.
1756 2791 13 4-1-5 EGR actuator, learning process aborted.
1757 2791 6 4-1-5 EGR actuator current is above maximum threshold.
1758 2791 3 4-1-5 EGR actuator supply voltage is above the maximum threshold.
1513AA-19

260

1759 2791 4 4-1-5 EGR actuator supply voltage is below minimum threshold.
1760 2791 13 4-1-5 EGR actuator, learning process out of range.
1761 2791 7 4-1-5 EGR actuator, broken spring detected.
1762 2791 16 4-1-5 EGR actuator, temperature high.
1763 2791 0 4-1-5 EGR actuator, temperature critical high.
1788 1188 7 8-1-4 Turbocharger wastegate, mechanical blocking detected.
1789 1188 2 8-1-4 Turbocharger wastegate, CAN Error.
1790 1188 13 8-1-4 Turbocharger wastegate, EOL calibration error.
1791 1188 12 8-1-4 Turbocharger wastegate, internal electrical error.
1792 1188 13 8-1-4 Turbocharger wastegate, learning process aborted.
1793 1188 6 8-1-4 Turbocharger wastegate, current above maximum threshold.
1794 1188 3 8-1-4 Turbocharger wastegate, supply voltage above maximum threshold.
1795 1188 4 8-1-4 Turbocharger wastegate, supply voltage below minimum threshold.
1796 1188 13 8-1-4 Turbocharger wastegate, learning process out of range.
1797 1188 7 8-1-4 Turbocharger wastegate, broken spring detected.
1799 1188 0 8-1-4 Turbocharger wastegate, temperature critical high.
1827 524141 7 1-9-2 DEF dosing valve, dosing valve blocked.
1857 523612 12 5-5-5 Engine starter, plausibility error of starter release condition.
1858 524147 7 9-6-6 SCR-System, reverting valve blocked.
1513AA-20

261
Section 5 – Procedures Hydraulic Tank
5.8 Hydraulic Tank 5.8-2 Hydraulic Filter Replacement
1. Turn the MEWP off.

Maintaining the hydraulic components and hydraulic
oil at the proper level are essential to the good 2. Place a suitable container under the filter.
performance and service life of the MEWP.
5.8-1 Hydraulic Oil Replacement
1. Turn the engine on and allow the hydraulic oil to

warm up.
2. Shut the engine off.
3. Place a suitable container under the hydraulic
tank.
4. Remove the oil drain plug and allow all of the
hydraulic oil to drain into the container.
5. Reinstall the drain plug with a new seal ring and
tighten the plug firmly.
6. Refill the hydraulic tank with new oil. Refer to 3. Use a filter wrench to remove the filter from the
2.12 Hydraulic & Gear Oils. head. Throw out the filter.
7. Check for leakage. 4. Apply hydraulic oil to the o-ring on the new filter,
8. Clean up any oil that may have spilled during and screw the filter into place.
this procedure. 5. Tighten the filter with the filter wrench.
9. Check the hydraulic oil level. The hydraulic oil
level should be at or slightly above the fill line on
the tank. NOTE
Refer to your national/local regulations on how to
dispose of used filters and oil.
NOTE
Refer to your national/local regulations on how to
dispose of the 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 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 specifications, refer to 2.12
Hydraulic & Gear Oils.

262
Kubota WG2503 Dual Fuel Engine Section 5 – Procedures
5.9 Kubota WG2503 Dual Fuel the units and a bar graph.
2. Dual Screen. This mode is used to monitor two
Engine parameters at a time. The screen also displays
Maintaining the engine components is essential to the associated parameter icon and units.
good performance and service life of the MEWP. 3. Multi Screen. This mode is used to monitor a list
of four(4) parameters selected by the user. Every
5.9-1 Engine Parameter Display (KAntrak item is listed with its associated icon and units.
1700) 4. DTC Screen. This mode is used to display Data
Trouble Codes
KAntrak 1700 display allows users to easily monitor
diagnostic trouble codes or critical engine faults such Diagnostic Trouble Codes (DTC)
as oil pressure and water temperature as well as Diagnostic Trouble Codes (DTCs) are manufacturer’s
providing an alarm system to alert the user when the codes to indicate specific engine malfunction. These
ECU (Engine Control Unit) detects an engine fault. codes will appear on the KAntrak screen whenever
an engine malfunction occurs. For DTCs, see 5.9-2
Kubota WG2503 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.
2. On the Display Mode option, select Dtc.
3. To display the DTC detailed info, select the “?”
function. A detailed screen of the selected DTC
including the SPN description (Header), the FMI
Menu Browsing Description (Header), the fault status (Status),
The KAntrak 1700 unit has only three (3) buttons for the SPN Number (SPN), the FMI Number (FMI),
different features selection on its dynamic style menu the total number of occurrences (OCC) and the
system. These buttons, located at the bottom of the related node source address (SRC) will then
unit, are used to navigate on the menu. appear.
During normal operation, the buttons have no specific 4. Note the SPN Number on the display and check
functions. When pressing any button once, a dynamic it against the list found in 5.9-2 Kubota WG2503
pop-up menu appears which contains some function Diagnostic Trouble Codes Look for the Detected
icons aligned above the associated buttons. The Item/Hardware information and correct the
user selects the required function from the displayed error. Once the fault is fixed, the amber lights on
menu. When a fault occurs, the amber light on top of KAntrak unit and on Engine Control Console will
the KAntrak unit and the Check Engine Indicator Light turn off.
on the Engine Control Console illuminate and will stay 5. To exit from DTC Screen, select tool to
on until the fault is corrected. continue browsing for other parameters. The
menu will be hidden after a few seconds.
Display Modes
KAntrak 1700 unit has four display modes and can be
accessed through the Setting Menu by selecting the
tool.
1. Single Screen. This mode is used to monitor one
parameter at a time. The screen also displays
the associated parameter icon, the description,

263
Section 5 – Procedures Kubota WG2503 Dual Fuel Engine
5.9-2 Kubota WG2503 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

264
Kubota WG2503 Diagnostic Trouble Codes

(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

265

(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

266

(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

267

(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

268
5.9-3 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

269
5.9-4 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

270
5.9-5 MAP Sensor (Kubota WG2503)

ECM
TAMP Sensor
V
B 19 5v
5V ext 1
V
D 23
MAP Signal
C 20
5V rtn 1
5.9-6 IAT Sensor (Kubota WG2503)

ECM
TAMP Sensor V
IAT
A 36 5v
Thermistor
D 20 5V rtn 1

271
5.9-7 ECT (Kubota WG2503)

ECM
ECT Sensor V
A ECT 5v
37
B 20 5V rtn 1
Thermistor
5.9-8 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

272
5.9-9 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
5.9-10 Oil Pressure Sensor (Kubota WG2503)

Oil Pressure Switch ECM
+5V
35 Pressure Voltage

273
Section 5 – Procedures Manifold and Hydraulic Pumps
5.10 Manifold and Hydraulic

WARNING
Pumps Ensure there are no personnel or obstructions in
test area and there is sufficient room for forward or
5.10-1 Hydraulic Brake Pressure reverse travel.
Adjustment
6. Start the engine from the platform control
Maintaining accurate hydraulic brake pressure is console and extend the boom slightly to achieve
low speed drive.
important when it comes to safe MEWP operation.
7. Drive the MEWP forward or reverse. The
1. Ensure the MEWP is on a firm level surface and pressure gauge reading should be 38 bar (550
is in the stowed position. psi). Stop the MEWP. Follow the next steps for
2. Locate the pressure gauge on the brake valve adjusting the relief valve pressure, if needed. If
assembly. no adjustment is required continue to step 10.
8. Locate brake pressure relief valve RV4 3 and
loosen the lock nut.
1 9. Turn the adjusting stem on the pressure
relief valve RV4 one-quarter of a revolution
2 at a time clockwise to increase pressure, or
counterclockwise to decrease pressure. Drive
the MEWP forward or reverse, note the pressure,
and stop the MEWP.
10. Repeat step 9 until brake pressure is achieved
(38 bar / 550 psi) then tighten the lock nut on
brake system pressure relief valve RV4 3 .
3
11. Locate brake system pressure reducing
valve PR1 2 and turn the valve gently
counterclockwise to the initial position.
3. Connect a pressure gauge (69 bar / 1000 psi) to
port BR 1 . 12. Drive the MEWP forward or reverse. The
pressure gauge reading should be 34.5 bar (500
4. Remove the wiring from three valves: differential
psi).
lock valve wire numbers 165 and 02, axle
lockout valve wires 65 and 02, as well as two 13. Stop the MEWP and adjust pressure reducing
speed valve wires 45A and 02. Mark the valves valve PR1 2 one-quarter of a turn at a time
to ensure you put the wiring back in the correct by turning either clockwise to increase the
positions later. pressure, or counterclockwise to decrease the
pressure.
CAUTION 14. Repeat step 11 and 12 until the brake pressure
is achieved 34.5 bar (500 psi), then tighten the
Failure to remove the wiring may cause damage to lock nut on brake system pressure reducing
components downstream. valve PR1 2 .
5. Locate brake system pressure reducing valve 15. Reinstall the wiring in the same position it was
PR1 2 . Loosen the lock nut and turn the removed from in step 4.
adjustment stem gently clockwise 2 full turns. 16. Test the brake and two-speed functions.
WARNING
Valve damage will occur if tightened too much.

274
Manifold and Hydraulic Pumps Section 5 – Procedures
5.10-2 Hydraulic System Relief Valve 5.10-3 Riser Down Relief Valve Adjustment
Adjustment
1. Locate Test Port 5 3 on the main manifold.
1. Locate Test Port 1 1 on the main manifold. 2. Connect a pressure gauge (345 bar 5000 psi) to
Remove the cap. Test Port 5 3 .
2. Connect a pressure gauge (345 bar / 5000 psi)
to Test Port 1 1 .
4
2
3
1
3. Start the engine from the base control console

and let it run for 2-5 minutes.
4. Raise the main boom to ensure the platform will
3. Start the engine from the base control console not contact the ground.
5. Fully lower the riser and check the reading on
4. Steer fully to one direction and then check the the gauge. The pressure should be 189.5 bar
reading on the gauge. The pressure should be (2750 psi). Follow the next steps for adjusting
214 bar (3100 psi). Follow the next steps for the pressure, if needed.
adjusting the pressure, if needed.
6. Locate riser down relief valve RV8 4 .
5. Locate system relief valve RV6 2 .
7. Loosen the lock nut on system relief valve
6. Loosen the lock nut on system relief valve RV8 4 . Turn the adjusting stem clockwise to
RV6 2 . Turn the adjusting stem clockwise to increase the pressure, and counterclockwise to
increase the pressure, and counterclockwise to decrease the pressure.
decrease the pressure.
8. Tighten the lock nut on system relief valve RV8
7. Tighten the lock nut on system relief valve RV6 2 once 189.5 bar (2750 psi) is observed on the
2 once 214 bar (3100 psi) is observed on
gauge. Note: You must fully lower the riser to
the gauge. Note: You must steer fully in one activate the pressure reading on the gauge.
direction to activate the pressure reading on the
gauge.

275
5.10-4 Turret Rotate Relief Valve 5.10-5 Platform Level Relief Valve
Adjustment Adjustment
1. Locate Test Port 5 1 on the main manifold. 1. Locate the Test 5 Port 1 on the main manifold.
2. Connect a pressure gauge (345 bar / 5000 psi) 2. Connect a pressure gauge (345 bar / 5000 psi)
to Test Port 5 1 . to Test Port 5 1 .
3
1
1
2
3. Start the engine from the base control console

3. Start the engine from the base control console 4. Raise the main boom to ensure the platform will
and let it run for 2-5 minutes. not contact the ground.
4. Raise the main boom to ensure the platform will 5. Fully raise or lower the platform level and check
not contact the ground. the reading on the gauge. The pressure should
be 207 bar (3000 psi). Follow the next steps for
5. Engage the turret transport lock.
adjusting the pressure, if needed.
6. Attempt to rotate the turret. The pressure should
6. Locate the platform leveling relief valve RV9 3 .
be 124-131 bar (1800-1900 psi). Follow the next
steps for adjusting the pressure, if needed. 7. Loosen the lock nut on the platform level relief
valve RV9 3 . Turn the adjusting stem clockwise
7. Locate the turret rotate relief valve RV7 2 .
to increase the pressure, and counterclockwise
8. Loosen the lock nut on the turret rotate relief to decrease the pressure.
valve RV7 2 . Turn the adjusting stem clockwise
8. Tighten the lock nut on the platform level
to increase the pressure, and counterclockwise
relief valve RV9 3 once 207 bar (3000 psi) is
to decrease the pressure.
observed on the gauge. You must fully raise or
9. Tighten the lock nut on the turret rotate relief lower the platform level to activate a pressure
valve RV7 2 once 86 bar 124-131 bar (1800- reading on the gauge.
1900 psi) is observed on the gauge. You must
activate the turret rotate to obtain a pressure
reading on the gauge.
10. Disengage the turret transport lock.

276
Manifold and Hydraulic Pumps Section 5 – Procedures
5.10-6 Test Charge Pump Pressure on 5.10-7 Test Forward Drive Pressure on
Drive Pump Drive Pump
1. Locate test port TP3 1 on the drive pump. NOTE

2. Connect a pressure gauge 41.5 bar (600 psi) to Make sure the charge pump pressure test is
the test port. completed first.
1. Locate test port TP1 2 on the drive pump.

2. Connect a pressure gauge (690 bar / 10 000 psi)
2 to test port TP1.
2
3. Start the engine from the base control console.
WARNING
To protect the gauge, do not activate any controls
during this procedure.
4. Check the reading on the gauge. Standard console.
pressure should be 21.5 ±2 bar (313 ±31 psi).
4. Unplug the brake solenoid power cable (26) on
5. Replace the charge pump relief valve RV3 2 if the brake valve.
the standard pressure is not achieved.
5. Activate the drive function slowly forward with
6. Repeat steps 2, 3, and 4 after the charge pump the engine at high speed. The wheels should not
relief valve is replaced. turn.
7. If the pressure is still not in range, repair or
replace the pump as necessary. NOTE
Activating the drive function too quickly will stall
the engine.
6. Check the reading on the gauge. The standard

pressure should be 345 bar (5000 psi).
7. Replace the pump if the pressure is not
achieved.
9. Remove the pressure gauge from the port, cap
the port, and re-plug the brake solenoid power
cable.

277
5.10-8 Test Reverse Drive Pressure on

Drive Pump
NOTE
Make sure the charge pump pressure test is
completed first.
1. Locate test port TP2 1 on the drive pump.
2. Connect a pressure gauge (690 bar / 10 000 psi)

to test port TP2.
WARNING
To protect the gauge, do not activate any controls
during this procedure.

console.
4. Unplug the brake solenoid power cable (26) on
the brake valve.
5. Activate the drive function slowly in reverse with
the engine at high speed. The wheels should not
turn.
NOTE
Activating the drive function too quickly will stall
the engine.
6. Check the reading on the gauge. The standard

pressure should be 345 bar (5000 psi).
7. Replace the pump if the pressure is not
achieved.

278
Axles Section 5 – Procedures
5.11 Axles 5.11-2 Check the Oil Level in the Torque

Hubs
5.11-1 Change the Oil in the Axles
1. Drive the MEWP to rotate the hub until the plug
1. Place a suitable container under the axle. is in the 3 or 9 o’clock position. Shut off the
engine.
2. Remove the fill plug.
2. Remove the plug and check the oil level. The oil
3. Remove all three drain plugs to allow the oil to level should be even with the bottom of the plug
drain into the container. hole. Add oil if needed. Refer to 2.12 Hydraulic &
Gear Oils. for oil specifications.
Fill Level Check
Drain Fill
Drain
Front Axle
Fill Level Check 5.11-3 Change the Oil in the Torque Hubs
1. Start the engine and drive the boom until the fill/
drain port of one of the hubs is in the 6 o’clock
position. Shut off the engine. Place a container
under the fill/drain port.
2. Remove the plug and allow all of the oil to drain,
watching carefully to avoid spills.
Drain 3. Restart the engine and drive the boom until the
Rear Axle drain plug is in the 3 or 9 o’clock position. Shut
off the engine.
4. Refill the hub with new oil as per specifications.
4. Reinstall all of the drain plugs. Refer to 2.12 Hydraulic & Gear Oils.
5. Remove the check plug. 5. Repeat the above steps with the other three
wheel hubs.
NOTE
The axle is full when oil is leaking from the check
port.
6. Refill the axle with new oil as per specifications

Refer to 2.12 Hydraulic & Gear Oils.
7. Reinstall both of the fill and check plugs.
Drain Fill

279
Section 5 – Procedures Axles
5.11-4 Check the Oil Level in the Axle 5.11-5 Change the Oil in the Axle Gearbox
Gearbox
1. Place a suitable container under the gearbox.
1. Remove the fill plug 1 from the gear box. 2. Remove the fill plug.
2. Check the oil level. It should be even with the 3. Remove the drain plug to allow oil to drain into
bottom of the fill plug hole. Add oil if needed. the container.
Refer to 2.12 Hydraulic & Gear Oils. for oil
specifications.
Fill/Check Port Drain Port

1
4. Reinstall the drain plug.
NOTE
The gearbox is full when oil is leaking from the
check port.
5. Refill the gearbox with new oil as per
specifications. Refer to 2.12 Hydraulic & Gear
Oils.
6. Reinstall the fill plug.

280
5.11-6 Oscillating Cylinder Bolt 5.11-7 Oscillating Cylinder Replacement

Replacement
CAUTION
If upon inspection it is determined that the oscillating The oscillating axle cylinder weighs approximately
cylinder bolts have missing or damaged torque seal, 19.5 kg (43 lb), so a second person to assist with
the affected bolts must be replaced. If replacing the 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
1. Remove the affected bolt. oscillating during the procedure.
2. Clean the cylinder’s corresponding internal
threaded hole thoroughly.
3. Replace the removed bolt with a new 01/2”-13 x
1-3/4” 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 108 Nm (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.
3. With a rag in hand to catch any leaking oil,

slowly loosen the bleeder screw to release any
trapped air within the cylinder, then tighten it
again. Slowly loosen the oscillating axle cylinder
hoses to release the pressure, then disconnect
them fully, being sure to plug the hose ends.

281
4. Remove and set aside the cylinder fittings, 7. Adjust the oscillating cylinder position until
ensuring they stay clean. there is continuous contact between the cylinder
mounting surface and the mounting plate, and
between the mounting plate and the cylinder
shoulder, with no gaps. Torque the bolts to 108
Nm (80 ft-lbs).
No gaps
5. Remove and throw away the bolts and washers

securing the cylinder to the chassis. Lift the
cylinder away.
6. Lift a new cylinder into place and install new
bolts (1/2"-13 x 1-3/4" grade 8) and 1/2”
hardened washers, applying liquid blue Loctite
242 or 243 to the lower half of the bolts before
installing them. Hand tighten the bolts. 8. Apply a line of torque seal to each bolt extending
from the bolt head over the washer and to the
chassis wall.

282
9. Reinstall the cylinder fittings, torquing the larger 5.11-9 Test the Oscillating Axle Cylinders
one to 33 Nm (24 ft-lb) and the smaller one to 20
Nm (15 ft-lb).
10. Remove the plugs and reconnect the hoses to 1. Extend the fly boom 30 cm (1 ft) while on
the cylinder fittings, torquing the larger hose end a firm, level surface.
to 28 Nm (21 ft-lb) and the smaller hose end to
16 Nm (12 ft-lb).
▪ Result: The steer axle should be locked.
2. Drive one of the steer tires up onto a 15 cm (6")
11. Reinstall the base cover and remove the block of block or curb.
wood.
12. Turn the engine on and let it run for a few
▪ Result: An appropriate tilt of the MEWP
chassis should occur.
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).
5.11-8 Bleed the Oscillating Axle Cylinders
If the axle oscillation system is not operating properly,

the stability of the MEWP is compromised and it may
tip over.
Items you will need before starting:

▪ oil container
3. Retract the fly boom while in tilt position.
▪ hose (to reach from bleeders to bucket)
▪ Result: The steer axles should unlock and
the MEWP chassis should level itself to the
1. Locate a bleeder on either side of the oscillating ground.
axle cylinder.
2. Connect a hose to the bleeder nipple.
3. Start the engine and slowly open the bleeder to
allow the oil to flow in a continuous stream.
4. Close the bleeder.
5. Repeat the procedure with the other oscillating
axle cylinder.

283
5.11-10 Pin Brake Adjustments 4. Tighten the Jam nut. Repeat this procedure for
the other side.
1. To manually release the brake give a light blow

to the external ring of the check unit.
2. To adjust the idle elimination loosen jam nut and

back out adjustment stem a few turns. 5. On the Cylinder side ensure that there is some
clearance between the cylinder and the lever “A”
with the lever against the stop.
3. Apply a 2lb. force (1Kg) in the direction of brake

application and turn adjusting stem so that it
touches the stop. 6. Introduce pressure into the cylinder and ensure
that the check unit engages.

284
7. Release the pressure from the cylinder and 5.11-11 Brake Inspection
check that the rod returns and stops in a
position where it projects out from the cylinder
head by 5 mm (3/16"). 1. Remove the oil level plug from one of the
braking axle arms, as shown below.
2. Insert a 4.5 mm feeler gauge into the drain port.
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.
3. Use the gauge to check the gap between the

disks (A). The minimum distance allowed is
4.5 mm. Reinstall the oil level plug.
9.
4. Repeat the inspection on the other axle arm. If

the gap is smaller than 4.5 mm between the
disks of either arm (i.e. the gauge doesn’t fit),
the brake disks must be replaced on both arms.

285
Section 5 – Procedures Grease Points
5.12 Grease Points
Maintaining proper lubrication is essential for good performance and service life of the MEWP. If the
bearing and gear of the MEWP are improperly greased, it could result in component damage.
5.12-1 Grease the Turret Ring Gear

1. Open the control side cowling, and locate the turret ring gear grease fitting 1 under the bottom right corner
of the base control box.
2. Pump grease into the fitting, and continue pumping until new lube appears continuously around the grease
seal lip of the ring gear.
3. Rotate the turret in increments of 10 to 13 cm (4 to 5 inches) at a time, and repeat step 2 until the entire
bearing has been greased.
5.12-2 Grease the Turret Swing Drive

1. Apply open gear lube to each tooth of the swing drive gear 2 , located under the turret.
2 1

286
Grease Points Section 5 – Procedures
5.12-3 Grease the Axles

1. Open the axle cover plates and locate the grease fittings.
2. Pump grease into the grease fittings.
5.12-4 Grease the Drive Shaft

1. Locate the grease fittings on the drive shaft u-joints, and pump grease into the fittings.

287
Section 5 – Procedures Options
5.13 Options
5.13-1 Generator Troubleshooting
Problem Cause Remedy

Generator not rotating - Motor not turning - Check for proper hydraulic flow
- Directional valve not working - Check voltage to coil
- Bad coil or valve
- Broken drive key - Check and replace
Frequency falls under load - Hydraulic flow to motor falling - Check flow to motor is constant
- Bad motor - Replace motor
Generator does not excite - Low speed - Check and adjust speed
- Faulty capacitor - Check and replace
- Breakdown in windings - Check winding resistance
High no-load voltage - Excessive speed - Check and adjust speed
- High capacity of capacitor - Check and replace
Low no-load voltage - Low speed - Check and adjust RPM
- Faulty rotary diodes - Check and replace
- Worn windings - Check winding resistance
- Low capacity of capacitor - Check and replace
Proper no-load but low loaded - Low speed when loaded - Check and adjust RPM
voltage - Excessive load - Check and repair
- Short-circuited diodes - Check and replace
Proper voltage in no-load - High speed in loaded - Check and adjust speed
conditions but high voltage at load condition
Unstable voltage - Poor contacts - Check connections

- Uneven rotation - Check for uniform rotation speed
Noisy generator - Broken bearings - Replace bearings
- Poor coupling - Check and repair
1177AA

288
Options Section 5 – Procedures
5.13-2 Generator Frequency/Voltage Check & Adjustment
Check the Frequency and Voltage

1. On the base control box, turn the base/off/platform key switch to the platform position.
2. On the platform control box, ensure the generator switch is in the off position .
3. Select the start position on the start/emergency power switch until the engine starts .
4. Turn the generator on/off switch to the on position .
5. Connect a multimeter to the platform power outlet.
6. Note the voltage and frequency.
Adjust the Frequency and Voltage

1. Loosen the generator control valve jam nut.
2. Turn the control valve screw with an allen head wrench. Turning it counterclockwise (out) increases voltage
and frequency, turning it clockwise (in) decreases voltage and frequency.
3. The output must be:
ANSI/CSA
▪ Voltage: 104.4 VAC to 127.2 VAC
▪ Frequency: 57 Hz to 63 Hz
CE & AS
▪ Voltage: 207.0 VAC to 243.8 VAC
▪ Frequency: 47.5 Hz to 52.5 Hz
4. Tighten the jam nut when the correct output is achieved.
Screw Nut

289
Notes

290
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SERVICE

Please refer to the website (www.skyjack.com) for contact

The original instructions are in English.

BECOME ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042AFA

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Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 53

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Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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229042AFA SJ46 AJ+, SJ46 AJ, SJ51 AJ

SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042AFA

Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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1.2 Maintenance and Service 1.2-4 Maintenance and Service Safety

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1.2-7 Railing Maintenance and Repair

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1.3 Scheduled Maintenance 1.3-3 Maintenance Instructions

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Table 1.4 Owner’s Annual Inspection Record

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1.5 Pre-Delivery/Maintenance Inspection Checklist

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

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1.6 Scheduled Maintenance 1.6-2 Hydraulic

1.6-1 Electrical 1.6-4 Limit switches

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1.6-5 Engine Compartment B - Frequent Inspection

Make sure all compartment latches are latched tightly

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3 Hydraulic pump and motor (B) 6 Muffler and exhaust (B)

Engine and Components

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7 Radiator (B, C) 9 Air filter (B,C)

▪ Use the dipstick to check the oil level.

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1.6-6 Control Compartment C - Annual Inspection

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7 Emergency Power Unit (B)

▪ Make sure that the fuel filler cap closes tightly.

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1.6-7 Base 4 Brake Cylinder (B)

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7 Oscillating cylinders (B,C) 8 Wheel/tires (B,C)

Refer to 2.9 Tire Specifications.

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1.6-8 Platform 7 Platform control console (B)

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1.6-9 Boom Assembly 5 Wear Pads (B)

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1.6-10 Optional equipment 4 Cold or arctic weather package

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1.7 Function Tests

▪ After repairs are completed, the operator must

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