SKyYJacKk. OPERATING MAINTENANCE & PARTS MANUAL For Service please call. 800 275-9522 ‘Skyjackinc. Service Center 2451 Swenson Ave., St. Charles, IL, 60174... FAX690 262-0006 For Parts in North America and Asia please call ‘Skyjack ine, Parts Center 990 Vernon Rd., Wathena, KS, 66090 For Parts & Service in Europe please call. ‘Skyjack Europe Communioatieweg 28, 9641 SG Mijdrecht Netherlands ... FAX 31 297 256 948 ts22088 Printedin Canada ‘et. 2000 295 I'S Zee puy ‘9ze9 ‘ZEEP ‘OEEP ‘9z9r ‘OzZEP SJEPOW uondo YIed JamMed /ENd FULCALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.Table Of Contents Section - Paragraph Page No. 1 1 1 1 1 1 1 2 3 Section 1 - Introduction Purpose Of Equipment. Use Of Equipment Warnings . Description .. The Engine Enclosure « The Control Box.. Sorial Number Nameplate .... Spocitications . Dual Power Pack Major Component identitication. Section 2 - Operation Operating Controls Identification ...... Platform Controls... Electrical Panel. Operating Procedures... . - a Sot-Up Procedure ..... installation Of The Oual Power Pack. Operating Procedures (Prestart Checks) Starting and Operation Operating The Power Pack. Shutdown Procadue Battery Sorvice And Charging Procedures: a4 0 moO Section 3- Systems ponbetons Identification And Schematics Table of contents... Section 4 - Troubleshooting Information Troubleshooting Information Section 5 - Maintenance And Service Table of contents... Section 6 - Parts Lists N List OF lustrtions. List Of Tables D Section 1, Page 2 Sevtion 2, Pago 18 ge Section 5, Page 4 Section 5, Page 4 Table 1-1. Specifications... Table 2-3. Maintenance And inspection Schedule Table 5-1. General Spocitications Table 5-2, Torque Specifications... Sulll Serles - Dual Power Pack Option Page! jerles - Dual Power Pack Op! ea can ageAX WARNING ANSUSIA (United States) You are required by the current ANSI/SIA standards to read and understand YOUR RESPONSIBILITIES in the Manual Of Responsibilities before you use or operate this work platform. CSA (Canada) and CE (Europe) ‘You are required to conform to national health and safety regulations applicable to the operation of this work platform. FAILURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the work Platform could result in death or serious injury. ‘OPERATOR SAFETY REMINDERS The National Safety Council reminds us that most accidents are caused by the fallure of some Individuals to follow simple and fundamental safety rules and precautions. Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety devices to protect your eyes, ears, hands, feet and body. You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this work platform is mandatory. The following pages of this manual should be read and understood completely before operating the work platform. Any modifications from the original design are strictly forbidden without written permission from SKYJACK, Inc. Safety Precautions To insure safe operations please read the following statements and understand their meaning. Also refer to your owner's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. Z\warnine ‘Warning is used to indicate the presence of a hazard that can cause sever personal injury, death, or substantial property damage if the waming is ignored. ZN caution Caution is used to indicate the presence of a hazard that willor can cause minor personal injury or property damage if the warning is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but hazard-related. For Your Safety! ‘These precautions should be followed at alll times. Failure to follow these precautions could result in injury to yourself and others, DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPER AUTHORIZATION AND TRAINING. DEATH OR SERIOUS INJURY COULD RESULT FROM IMPROPER USE OF THIS EQUIPMENT! Page i Sulll Series - Dual Power Pack Option a ct. 2000 ee =2\warnine Explosive Fuel! |Gesoline is extremely flammable and its vapors can lexplode if ignited. Store gasoline only in approved, |unoccupied buildings, away from sparks or flames. Do not fil the fuel tank while the engine is hot or running, |since spilled fuel could igr ‘comes in contact with lhot parts or sparks from ignition. Do not start the engine near sped uel, Never use gasoline asa cleaning agent. /A\ WARNING Hot Parts! Engine components can get extremely hot from operation. ‘To prevent severe bums, do not touch these areas while tho engine is running-or immediately after itis tumed off, Never operate the engine with heat shields or guards removed. Z\warnine Rotating Parts! IKeephands, fet, halt, and clothing away from all moving lparts to prevent injury. Never operate the engine with covers, shrouds, of guards removed. A\ caution Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical ‘shock. Z\Wwarnine Lethal Exhaust Gases! Engine exhaust gases contain potsonous carbon monoxide, and.can cause death Inhaled Avoid inhaling exhaust fumes, and never an the engine In closed lbuilding or confined area. NOTE California Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of Califomia to cause cancer, birth detects, or other reproductive harm. SERVICE POLICY AND WARRANTY SKYJACK, Inc. warrants each new Dual Power Pack to be free of defective parts and workmanship during the first 12. months. Refer to Warranty Statement on Page iv for details. NOTE SKYJACK, Inc. is continuously improving and expanding product features on i's equipment; therefore, specifications and dimensions are subject to chango without notice, ? This Safety Alert Symbol Means Attention! Become Alert! Your Safety Is Involved. ‘The Safety Alert Symbol identities important safely messages on machines, safely signs, in manuals, or elsewhere. ‘When you see this symbol, be alert to the possibilty of personal injury or death. Follow the instructions in the safety message. ‘SCOPE OF THIS MANUAL This manual applies to the ANSUSIA, CSA and CE versions of the Dual Power Pack for the Sulll Series work platform models. (4620, 4626, 4890, 4892, 6826 and 6832) Equipment identified with “ANSVCSA* meets the ANSI/SIA-A92.6 -1990 or ANSI/SIA-A92.6 -1999 standards. Equipment identified with "CSA" meets the CAN3- 8954.28.3-Me2 standards. Equipment Identified with "CE" meets the requirements for the European countries, ie. Machinery Directive 89/392/EEC and EMC Directive 89/336/EEC and the corresponding EN standards. ‘Sulll Series - Dual Power Pack Option Page ili ‘Oct, 2000WARRANTY STATEMENT SKYJACK, Inc. warrants each new work platform to be free of defective parts and workmanship. During tho first full year, labor and replacement parts will be provided by the local authorized Skyjack dealer without charge. For the following 48 months, structural components found to be defective will be replaced or repaired al no charge. A warranty registration card Is supplied with each work platform. The warranty is only effective when the warranty card has been completed and retumed to Skyjack within 15 days from the time of billing When work platforms are put into stock, the warranty poriod does not start until the work platform has been ‘shipped to the dealers customer. if a unit is put into service and no warranty card has been mailed to Skylack, Inc., the warranty period will commence 15 days from the date the dealer was invoiced for the work platform, All warranty claims are subject to approval by ‘Skylack’s Service Department. Skyjack, Inc. reserves the right to limit or adjust claims with regard to defective parts, labor or travel time based on usual and customary guidelines. Parts purchased from ‘sources other than Skyjack will not be covered under this warranty. Misuse or improper operation, lack of normal maintenance and inspections as outlined in this Operating/Maintonance and Parts Manual, alterations to original design and/or components or accidents will void all warranty. Batteries are not covered by this warranty. ‘The above mentioned warranty statement is exclusive and no other warranty whether written, oral or implied shall apply. Skylack excludes any implied warranty ‘of merchantability and fitness and accepts no liability for consequential damages or for other negligence. WARRANTY PROCEDURES ‘The selling distributor or authorized dealer shall be responsible for the complete handling of customer claims under this warranty. Here's what to do: 1. When a customer files a claim under this warranty, contact Skyjack’s Service Department to verify warranty coverage. NOTE: The complete serial number of the work platform is required to verify ‘the claim. 2. When Skyjack’s Service Department verifies warranty coverage, they will also issue an RA (Return Authorization) number for the return of any defective component(s). All items over $25.00 in value must be retumed to Skyjack, Ine. Pageiv 3, Fill out a Warranty Claim Form from dealer's supply of claim forms. Then notity Skyjack’s Service Department of the warranty claim number on the form used. 4, The distributor/dealer should then file a warranty claim with Skyjack, Inc, describing the nature of tho defect, probable cause, work performed, travel hours, and labor hours listed separately. Warranty labor will be paid at a rate of $42.00 per hour. The travel allowance will be paid at the same hourly rate within the dealers specitiod territory, limited to a maximum of four (4) hours. If a part has serviceable components, PLEASE replace the bad component. For instance, if you have a bad switch on a controller, please replace the switch Hydraulic cylinders should be resealed, unless they are damaged beyond repair. Engine fallures should be directed to your local engine distributor and covered by the manufacturers warranty. Skyjack will accommodate you and your labor. Labor rates and travel allowances are subject to change without notice, 5. Warranty claims must be received by Skyjack within 15 working days from the date of the repair. Warranty claims received with insufficient information will be returned for correction or ‘completion. 6. Materials retumed for warranty inspection must have the following procedures: A. Caretully packaged to prevent additional damage during shipping. B. Drained of all contents and all open ports capped or plugged. C. Shipped in a container tagged or marked with the RA number. D. Shipped PREPAID, Any item(s) rotumed for warranty by any other means may be rofused and returned unless prior approval from Skyjack is obtained. E. Items shipped to the dealer will be sent freight prepaid and added to the invoice. Failure to comply with the above procedures may delay ‘approval and processing of the warranty claim and ‘could result in the denial of a warranty claim. Skyjack’s dealer's accounts must be Kept current in order to approve and issue warranty credits. Skyjack reserves the right to withhold issuance of warranty credits to a dealer if their account is not in good standing. This is subject to change without prior notice. Sulll Series - Dual Power Pack Option Oct, 2000SECTION 1 INTRODUCTION Purpose Of Equipment The SKYJACK Dual Power Pack for the Suill Series Work Platform is designed to provide combustion engine power to create an auxiliary source of hydraulic and electrical power. Use Of Equipment The SKYJACK Dual Power Pack Option allows for greater range and versatility of he SJIIl mobile work platform. Although there is greater flexibility, the platform must stil be operated within operating parameters, therefore, ling and driving MUST be on a flat, level, and compacted surface. Warnings The operator MUST read and completely understand ALL wamings in this manual and on the work platform. Ensure the presence and legibility of all labels by compating them to the ones outlined in their respective manuals, If any labels are damaged or missing, replace them immediately. Sulll Serles - Dual Power Pack Oct. 2000 Description The Dual Power Pack Option unit consists of two pats; the engine enclosure and the operator contro box located below the platform control box on the railing. The Engine Enclosure The internal combustion engine is housed on astee! enclosure that is mounted to the rear of the work platform base. This housing also contains the fuel supply (LPG or diesel), and the electrical circuitry required for the unit's operation The Control Box A secondary control box is affixed to the bottom of, the platform control box which is mounted at the right front of the platform. This box controls the activation and operation of the Dual Power Pack. Serial Number Nameplate The serial number nameplate, located at the front of the enclosure, lists the model number, serial number, assembly weight, voltage, system pressure and date manufactured. Use this information for proper operation and maintenance and when ordering service parts. SECTION 1, Page 1Table 1-1. Specifications Model Kubota Diesel Kubota Kohler Diesel Propane 440 bs 470 bs Welght 200 kg 219 Kg a7" Width ee Length 228" (without arms) os? m Length 22.5" (with Arms) 1.08m Engine Horsepower 6hp 95 hp 13hp Engine Speed 3600 RPM SECTION 1, Page 2 ‘Sulll Series - Dual Power Pack Option ‘Oct. 2000Dual Power Pack Major Component Identification OPERATOR'S CONTROLBOX x ENGINE ENCLOSURE Figure 1-1. Sul Series Work Platform With Dual Power Pack (Model 6832 shown) Sulll Series - Dual Power Pack SECTION 1, Page 3 Oct. 2000Notes t a SECTION 1, Page 4 Sse onon Sulll Series - Dual Power Pack OptionSECTION 2 OPERATION Operating Controls Identification The following descriptions are for identification, ‘explanation and locating purposes only. A qualified ‘operator MUST read and completely understand these descriptions before operating this Dual Power Pack. Both standard and optional controls are identified in this section. Therefore, some controls may be included that are not furnished on your Dual Power Pack. Platform Controls Figure 2-1. Power Pack Control Unit The platform control box for the Dual power pack option controls the function of the unit, 1- Battery/Engine selector - Switches between battery and engine for source of power. 2- Alternator switch - Enables or disables the alternator to charge the piatform’s batteries. 3-Momentary contact switch. The function of this switch depends on the fuel used by the unit. - For Diesel Engines: Activates both the gow plug and the starter motor. - For Propane Engines: Activates the starter motor. ‘Sulll Series - Dual Power Pack Option Electrical Panel Figure 2-2. Engine Electrical Pane! ‘The Electrical Panel s located in the engine housing, It contains the following control: 1-15 Amp Circult Breaker - Inthe event of a power overload or positive circuit grounding, circuit breaker will pop out. Make the necessary corrections, then depress the push-button to reset. SECTION 2, Page 1 Oct, 2000Operator Qualifications Only trained and authorized persons should use this Dual Power Pack, Safe use of this unitrequires the operator to understand the limitations and warnings, operating procedures and operator's. responsibility for maintenance. Accordingly, the operator MUST understand and be familiar with this operating manual, its wamings and instructions and ALL wamings and instructions on the work platform. Operator also MUST be familiar with employer's work rules and related government regulations and be able to demonstrate his/her ability to understand and operate THIS make and mode! Dual Power Pack in the presence of a qualified person. Operating Procedures Setup Procedure The following steps are normally required for equip- ment being put into service for th: ime. After the equipment has been unloaded: 1. Remove all packing materials and inspect for damage incurred during transport. NOTE Report any damage to dolivery cartier immediately. 2. Inspect engine enclosure thoroughly and remove any foreign objects. Ensure all bolts and fasteners are tightened, SECTION 2, Page 2 Oct. 2000 Installation Of The Dual Power Pack 1. On most later SJIll models, the installer must ensure the work platform's ladder is in the Proper mounting position before installing the Dual Power Pack: 46XX and 48XX Models - The ladder must be installed in a manner such that the bent legs containing the mounting holes are on the “outside” or facing away from the work platform (this is a 180° rotation from normal operating position). The existing bolts and spacer blocks are to be used. The spacer is used between the ladder and the Dual Power Pack’s retaining bracket. Refer to figure 2-3. With Dual Power 9 Without Dual Power Unit Attached Figure 2-3. Ladder Mounting For 46XX & 48XX 1+ Ladder 2- Dual Power Unit Retaining Bracket 3 Spacer Sulll Series - Dual Power Pack Option68XX Models - The ladder must be mounted directly to the Dual Power Pack's retaining bracket. Therefore it may be necessary to remove “the stand-offs” or spacers between the ladder and Work platform and fasten them to the sides of the ladder for storage. They are to be re-installed when the platform is returned to regular use (without the Dual Power Pack), Refer to figure 2-4, with Dual Power Unit Attached Without Dual Power Unit Attached Figure 2-4. Ladder Mounting For 68XX 1- Ladder 2. Spacer 3+ Dual Power Unit Retaining Bracket Note the original ladder position and mounting holes used as itis necessary toretum the ladder toit's original position immediately after the Dual Power Packs removed. Sulll Series - Dual Power Pack Option ct. 2000 2. if your work platform is equipped with a Base Control Box mounted on the rear of the base it must be reoriented so that it remains accessible. {your platform is not equipped with this control station, continue to Step 3. Figure 2-5. Plattorm Base Control Box Option The Base mounted control box (Figure 2-5, Item 1) must be removed and reinstalled perpendicular to the base using the quarter turn, fasteners provided on the mounting bracket. Figure 2-6. Dual Powér Enclosure 1- D-Rings 2- Locking 3+ Support Arms 3. Lift the unit, using the four D-Rings provided, with a crane or similar lifting device, AX DANGER CRUSHING HAZARD| DO NOT USE THE HAND RAILS TO LIFT THE UNIT! SECTION 2, Page 34, Position the unit so that the support arms align with the forklift boots on the rear of the work platform. 5. Slide the unit in and align the Locking pin holes. 6. Insert BOTH locking pins and ensure the locking balls are exposed on the opposite side to entry. 7. Remove dust caps from the machine’s hydraulic supply posts and connect the mating hoses supplied on the DUAL POWER PACK (unattach them from the side of the enclosure). Figure 2-7. Connectors 1+ Battery Connector 2+ Contiol Connectors (2) 8, Connect the battery plug and the two color matched control cable connectors between the unit and work platform. SECTION 2, Page 4 Operating Procedures Prestart Checks 1, Carefully read and completely understand ALL of SECTION 2, OPERATION, in this manual, the engine manufacturers manual and ALL ‘wamings and instruction labels orvin the Dual Power Pack enclosure. WARNING EXPLOSION HAZARD Keep flames and sparks away. DO NOT smoke near batteries. 2. Unlock and swing out the battery tray and hydraulic/electric tray located on the work platform. 3. In the battery tray, check the water level in all four batteries. If plates are not covered, carefully add distilled or demineralized water. If needed, check the specific gravity in each battery, It should be 1.260 to 1.275, (This reading will not be correct if you just added water to the batteries.) NOTE: Failure to perform this check may result in damage to the alternator. FIRST AID Immediately flush eyes with cold water if electrolytic, acid is splattered into them, Seek medical attention if discomfort continues, Sulll Series - Dual Power Pack Option Oct. 20004. Inthe hydraulic/electric tray, check the hydraulic cillevel (scissors MUST be fully lowered) in the tank. Level should be at or slightly above the top mark on the gauge. If required, add a quality grade hydraulic oil. Refer to “RECOMMENDED HYDRAULIC OILS” for recommendations. NOTE; Failure to perform this check may result in damage to the hydraulic pump. 5, Swing the hydraulic/electric tray to locked closed position. 6. Inspect all hoses, fittings, fasteners, wires, cables, valves, etc. for leaks, tightness, hidden damage and foreign material. 7. Perform the OPERATORS CHECKLIST found below. OPERATOR’S CHECKLIST INSPECT AND/OR TEST THE FOLLOWING| DAILY OR AT BEGINNING OF EACH SHIFT 1 OPERATING AND EMERGENCY CONTROLS. SAFETY DEVICES AND WELDS. PERSONAL PROTECTIVE DEVICES. BATTERY FLUID LEVEL. HYDRAULIC RESERVOIR LEVEL. HYDRAULIC AND FUEL SYSTEM(S) FOR LEAKS, LOOSE OR MISSING PARTS. CABLES AND WIRING HARNESSES. PLACARDS, WARNINGS, CONTROL MARKINGS AND OPERATING MANUALS. 10 FUNCTION OF LOCKING PINS. 11 ENGINE OILLEVEL. oason oan Sulll Series - Dual Power Pack Option Oct, 2000 Starting And Operation Starting 1. Ensure there is a supply of fuel, Diesel fuel should be clean and fresh. The supply of propane should be properly secured in the unit and the propane valve should be opened. Ensure there are no leaks or spills from the fuel container or supply lines in or around the enclosure. Check to be sure the hydraulic ‘supply and return lines are connected or serious damage will result. Figure 2-8, Duat. Powen Contnot Boxes 1+ Emergency Stop 2. BATTERY/ENGINE Selector 3+ Switch - ON/OFF or BASE/OFF/PLATFORM. 4- Switch - ALTERNATOR ON/OFF 5- Switch - STARTER (STARTERAND GLOW PLUG SWITCH FOR DIESEL ENGINES). SECTION 2, Page 5From The Platform 1. Ensure the Keyswitch on the engine enclosure is in the RUN position for propane engines, or the ON position for diesel engines. Use the built-in ladder on the Dual Power Unit to gain access the work platform deck. Latch the entry chain/gate and attach personal safety hamesses to provided safety rings (if equipped). Pull out the Emergency Stop Button. (On CE models, the base control box's Emergency Stop Button must also be pulled out) On the platform control box, tum the key switch to the “ON” position (ANSV/SIA and CSA) (or the "PLATFORM" position on CE models with the “PLATFORM/OFFIBASE” keyswitch). ‘On the Power Unit control box, ensure the “ENGINE/BATTERY” selector switch is on “ENGINE”. For Propane: Engage the starter switch by moving the toggle switch to the right. For Diesel: Engage the starter switch by moving the switch to the right. A cold engine may require a prewarming of the glow plug. This can be achieved by moving the toggle to the left and holding the position for 10 to 20 seconds, then retuming to the start position to activate the starter. SECTION 2, Page 6 Oct. 2000 From The Enclosure 1. Pull out the Emergency Stop Button on the platform control box. (On CE models, the base control box's Emergency Stop Button must also be pulled out) ‘The “ENGINE/BATTERY” selector switch on the platform control box must also be on “ENGINE”. On the platform control box, tum the key switch to the “ON? position (ANSISIA and CSA) (or the "PLATFORM or "BASE" position on CE models with the *PLATFORM/OFFIBASE” keyswitch). ‘On the engine enclosure, tur the key switch tothe “START” position. Acold diesel engine may require a prewarming of the glow plug. This can be achieved by moving the key switch to the "GLOW’ position and holding the position for 10 to 20 seconds, then turning to the start position to activate the starter. The key will hen Tetumn to the “ON” (or "RUN') position. Sulll Series - Dual Power Pack OptionOperating The Power Pack To Switch Between Energy Sources Use the “BATTERY/ENGINE” switch to operate the platform between the desired power source. Se- locting “ENGINE” produces hydraulic power trom the pump which is directly coupled to the engine. Selecting “BATTERY” stops the engine and reverts to electrical power stored in the battery cells and produces hydraulic power from the pump directly coupled to the electric motor. Since the engine will only operate with the switch in the ENGINE posi- tion, it is therefore necessary to restart the engine if you switch to “ENGINE” from “BATTERY”. Alternator ‘The Dual Power Pack can be used to provide elec- trical energy to charge the batteries. To charge the batteries simply toggle the "ALTERNATOR" switch toturn the alternator on or off. When on, with the ‘engine running, electric current is transmitted to the platforms battery tray to recharge the batteries. To reduce starting load, the alternator should be ‘switched off when starting the Dual Power Unit. Hydraulic Pump ‘The hydraulic pump is activated immediately onco the engine is running, itis directly coupled to the output shaft of the engine, The pump provides hy- draulic flow for iting and driving, therefore greatly reducing the demand on the batteries. Ensure the supply and return hoses are connected prior to starting the unit or damage may result to the pump. NOTE: The Dual Power Pack Is NOT designed to supply both hydraulic and electric power simulta- neously. Sulll Series - Dual Power Pack Option Shutdown Procedure From The Platform «Fully lower the platform, 2. To tum off the engine and continue to use the platiorm, switch “ENGINE/BATTERY” selector tothe BATTERY position and resume operation of the platform. 8. To shutdown For an extended period of time, switch “ENGINE/BATTERY” selector to the BATTERY position, or turn the control box keyswitch to "OFF" position and remove the key, ‘or push in Emergency Stop Button. 4, Rotate Emergency Battery Disconnect Switch ‘onthe platform base tothe “OFF” position. (On ‘CE machines also push in Emergency Stop Button located on Base Control Box). The Keyswitch on the enclosure should be returned to the ‘OFF" position and the key removed. 5. On propane units, if leaving the machine unattended for a long period of time, be sure to close the valve on the cylinder and to purge the fuel from the LPG lines. Figure 2-9. Platform Emergency Battery Disconnect SECTION 2, Page 7 Oct, 2000From The Base 1. Fully lower the platform. 2. Turn Key Switch on engine enclosure to “OFF” and remove. The engine will stop. To resume ‘operation of the Dual Power Unit, this key must be returned to the ON (or RUN) position. 3, Push in Emergency Stop Button(s). 4. Rotate Emergency Battery Disconnect Switch on the platform base to “OFF" position. (On CE machines also push in Emergency Stop Button located on Base Control Box.) 5. On propane units, if leaving the machine unattended for a long period of time, be sure to close the valve on the cylinder and to purge the fuel from the LPG lines Battery Service & Charging Procedures Battery Service AN WARNING EXPLOSION HAZARD Refer to the operating manual supplied with the work platform for proper battery service and charging procedures. DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPER AUTHORIZATION AND TRAINING. DEATH OR SERIOUS INJURY COULD RESULT FROM IMPROPER USE OF THIS EQUIPMENT! SECTION 2, Page 8 Sulll Series - Dual Power Pack Option Oct. 2000‘Table 2-1. Owner's Annual Inspection Record MODEL NUMBER. ‘SERIAL NUMBER, RECORDING DATE RECORDING =CORDIN 1 2 3 4 5 6 7 ° ‘OWNER'S NAME He INSPECTED EY Table 2-2. Owner's Annual Inspection Record [_taiy—[Weekty [Won Sonths | ewonihe [12 wonihe Enaine Fuel leaks x x [Engine ois Hal Hat Engine APH S G Fuel fiter F F Belts/Hoses: A&C A&C Muffler Boas Bcad Air clesner x T ‘Ral Fuel tank cap Bae Bac ‘Mechanical ‘Strctural damagenvelds K x Locking Pins/Retainers: Aas c BEC Bolts and fasteners A c A&C Fst K A Electrical Battery fuid level x x Gonirol switenes aab Kae Cords & wiing A A Battery terminals REC Rac ‘Genorator/recopiadie a B AGB Terminals & plugs c c Hydraulic. Hyaraulc of a HEQ Hysraulo hosen/itings Kar c ACaP [Hydraulic ol & ol iter E s Miscellaneous Labels end manual [AKEM | KEM Notes ‘A. Visually hapedt Replace missing or Wegibe B. Check operation. L._Gheck only when cooled. ©. Check tightness. M, Proper manual must bein box E Lubricate P. Check for leaks. F. Replace. Q. Have cil eample tested. G. Rofor to Table 1-1 specifications and feetues. * Record inspection date end signature H. Check ellievel 1 Refer to engine manual J. Check noise level Sulll Series - Dual Power Pack Option SECTION 2, Page 9 series - Dual Power. p ean ageSECTION 2, Page 10 Sulll Series - Dual Power Pack Option Oct. 2000SECTION 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table Of Contents Description Page No, Electrical/Hydraulic Symbols Figure3-1. Relay Funotion Chart Figute3-2. Electrical Symbol Chart Figute 3-3. Hydraulic Symbol Chart one Electrical System Figure 8-4. Control Box (Standard) (Ansi/Sia And Csa)... Figure 3-5. Control Box With All Options (Ansi/Sia And Csa) Figure 3-6, Control Box With Hom Option (Ce)... Figure 8-7. Control Box With All Options (Ce) Figure 3-8. Dual Powor Control Box Figure 3-9. Electrical Schematic (Kohl Figure 3-10. Electrical Schematic (Kubota). Figure 3-11. Electrical Panel Diagram (Ansi/Sia And Csa) . Figure 3-12, Electrical Panel Assembly (Ce). Figure 3-13. Engine Electrical Panel Assembly (Kohler) Figure 3-14, Engine Electrical Panol Assembly (Kubota)... Hydraulic System Figure 3-15. Hydraulic Schematic. Figure 3-16. Hydraulic Manifold Component And Port Ident Sulll Series - Dual Power Pack Option SECTION 3, Page 1 Oct. 2000NOTES 3, Page 2 a SECTION 3, Page ae SJlll Series - Dua Power Pack OptionFIGURE 3-1, RELAY FUNCTION CHART ‘SUPPLY (B+) (Common) NS CONTROL (B+)~—_ de a6 __—-GrOUND (8) NORMALLY NORMALLY cLoseD OPEN cONTACT conTacT RELAY NO. RELAY FUNCTION 40CRt Transfer ce 100R2 Starting Interlock Enable/Stop = 10CR3 Propane Flow Control Module Enable - 32cR | Start Relay 31CR Glow Plug 59CR i Alternator ‘Sulll Series - Dual Power Pack Option SECTION 3, Page 3 Oct. 2000FIGURE 3-2. ELECTRICAL SYMBOL CHART [| RELAY, SINGLE ciRoutrs “TS EMERGENCY STOP —}— CROSSING NO ap BUTTON ; Leeds CONNECTION o> _ THROW oO [] RELAY, SINGLE CIRCUITS: i KEY SWITCH ane POLE DOUBLE CONNECTED aa ES THRow : Cc L] RELAY, DOUBLE + ' | Battery FOOT SWITCH Xo POLE SINGLE cbt THROW eX” ~ ET eusy,novece if |— GROUND i= TOGGLE SWITCH ot POLE DOUBLE i cL THROW a a RELAY, TRIPLE ~ FUSE |’ BUSH BUTTON = POLE DOUBLE poy SWITCH oS THROW circum ereacern |) eta 7, ROTARY SWITCH DIODE - SILICON Q) VOUT METER -<"—__LIMIT SWITCH NO. Ca CONTROLLED re RECTIFIER 7 LIMIT SWITCH N.O. 27 —»"T_ HELD CLOSED 5 [- CAPACITOR —) _ DISPLACEMENT === PILOTLINES Dashed | ) ELECTRIC MOTOR J Ree MBC =| THREE WAY VALVE w | FLOWDIVIDER FS] Two PosiTion ENGINE EE comaner [fTHREE WAY VALVE 2 FTTON a FED 7 COUNTER ogy THREE POST q FOUR WAY CLOSED ) paspracenenr rue | SLRS SANE ave | MUILHLCE Genoese UNIDIRECTIONAL eu VARIABLE A 7, THREE POSITION TX DISPLACEMENT Pump | [ELECTRICAL ATTIT,|TK FouR way cLosep <4) BIDIRECTIONAL Eevee er’ CENTER OPEN 5 ae wa THREE Position ( k HAND PUMP “{Ebker VELOCITY FUSE Tl JF” FOUR WAY CLOSED Cc ' THREE POSITION ob. RELIEF VALVE SINGLEACTING | YITTTY)Y FOUR Wav OPEN LL] CYLINDER CENTER OPEN PORT (||, PRESSURE DOUBLE ACTING MUS) REDUCING VALVE CYLINDER Crete DOUBLE ACTING Creep onirice ; BOUBLE RODDED | aH seRVO ‘SPRING APPLIED feiwif- BRAKE CYLINDER Ei} HYDRAULICALLY Mf RELEASED BRAKE Sulll Series - Dual Power Pack Option Oct. 2000 SECTION 3, Page 5FIGURE 3-4. CONTROL BOX (STANDARD) (ANSI/SIA and CSA) REE seroron to PS» 8 cE) eae Pm2- nav Le oe (00a. a Ui ie aut roe by will © tC ene ty] Big @ ©) cease 3 . sit La sina Rac $13-63 SECTION 3, Page 6 q - eo Sulll Serles - Dual Power Pack OptionFIGURE 3-4. CONTROL BOX (STANDARD) (ANSI/SIA and CSA) index | Skyjack Description we No. | PartNo a 1 (Ref) | CONTROL BOX ASSEMBLY - 2 | 119129 |KIT-2 POLE, Deutsch plug 1 3 | 102730 | WIRE, Blue AR 4 | 107712 | CABTIRE CONNECTOR, 5-Pin male 1 5 | 103255 | CABLE, Cabtire 18/4” AR 6 | 107711 | CABTIRE CONNECTOR, 5-Pin female 1 ‘Sulll Series - Dual Power Pack Option SECTION 3, Page 7 Oct. 2000FIGURE 3-5, CONTROL BOX With All Options (ANSUSIA and CSA) Ll f = is PINT = 66 (BLUES @ ate He mon toa Fae a pF tatine 1) 10) omc Sccscacecasare] Re F $u3-64 SECTION 3, Page 8 - Page ee Sulll Serles - Dual Power Pack OptionFIGURE 3-5. CONTROL BOX With All Options (ANSI/SIA and CSA) tndox | skyack Description - Wo. Pert No, ene 1 (Ref) | CONTROL BOX ASSEMBLY : 2 119129 _ | KIT-2 POLE, Deutsch plug 1 3 102730 | WIRE, Blue AR 4 107712 | CABTIRE CONNECTOR, 5-Pin male 1 5 103255 | CABLE, Cabtire 18/4” AR 6 107711 | CABTIRE CONNECTOR, 5-Pin female 1 Sulll Series ~ Dual Power Pack Option SECTION 3, Page 9 Oct. 2000FIGURE 3-6. CONTROL BOX With Horn Option (CE) sae Daum LEVEL een pig taste 4 wy eee Pas bie ne ren = |e pa cA 843-65 Sulll Serles - Dua! Power Pack Option ‘Oct, 2000 SECTION 3, Page 10FIGURE 3-6. CONTROL BOX With Horn Option (CE) Unite Indox ‘Skyjack Description Wor | bon a 1 (Ref.) CONTROL BOX ASSEMBLY = 2 119129 KIT-2 POLE, Deutsch plug 1 3 102730 | WIRE, Blue AR 4 107712 | CABTIRE CONNECTOR, 5-Pin male 1 5 103255, CABLE, Cabtire 18/4” AR 6 107711 CABTIRE CONNECTOR, 5-Pin female 1 Sulll Series - Dual Power Pack Option ct. 2000 SECTION 3, Page 11FIGURE 3-7, CONTROL BOX With ALL OPTIONS (CE) pp cc vey rai -ei8e mae m2 I 813-66 STION 8, Pi : SECT age 12 peas Sulll Series - Dual Power Pack OptionFIGURE 3-7. CONTROL BOX With ALL OPTIONS (CE) Units 1 (Ref.) CONTROL BOX ASSEMBLY, c 2 119129 | KIT-2 POLE, Deutsch plug 1 3 102730 | WIRE, Blue AR 4 107712 | CABTIRE CONNECTOR, 5-Pin male He 5 103255 | CABLE, Cabtire 18/4” AR 6 107711 | CABTIRE CONNECTOR, 5-Pin female 1 Sdlll Series - Dual Power Pack Option ct, 2000 SECTION 3, Page 13FIGURE 3-8. DUAL POWER CONTROL BOX earns 83-67 4 - SECTION 3, Page 1 pecans Sulll Series - Dual Power Pack OptionFIGURE 3-8. DUAL POWER CONTROL BOX Unite ‘Syfock scription 7 Port No. fat 1 118539 | BOX, Base control, Propane 1 2 118539 | BOX, Base control, Diesel 1 3 115643 | BRACKET, Control box 1 103855 |» BOLT, Hex-hd 1/4-20 x 1/2" Ig 8 103995 _|* WASHER, Flat 1/4” 8 104000 |* WASHER, Lock 1/4” 8 103980 | NUT, Hex 1/4" 8 4 | 102730 | WIRE, Blue 16" 5 | 117596 KIT, (2-Pole) Deutsch receptacie 1 6 111181 | GUARD, Toggle switch, 3 7 | 103255 CABLE, Cabtire 18/4" AR 8 107711 | CABTIRE CONNECTOR, 5-Pin female 1 9 | 102853 | SWITCH, Toggle 1 jo | 115574 | SWITCH, Toggle 2 Sulll Series - Dual Power Pack Option Oot, 2000 SECTION 3, Page 15FIGURE 3-9, ELECTRICAL SCHEMATIC (KOHLER) SS-1117AB SECTION 3, Page 16 Sulll Series - Dual Power Pack O} ag ae series Power Pack OptionFIGURE 3-9. ELECTRICAL SCHEMATIC (KOHLER) a Description Bats No ron BI $ BATTERY, 6V B2 $s BATTERY, 6V B3 $ BATTERY, 6V. Ba $ BATTERY, 6V. ci 103101 CONTACTOR, SPNO- CBI 117325, BREAKER, Circuit 15 Amp CB3 117325 BREAKER, Circuit 15 Amp IDCM1 106576 MOTOR, DC 24V. Fl 117619 FUSE, 300A St 119725 SWITCH, N.O. Main Power Disconnect s3 103141 SWITCH, N.O, On/Off Key S4 103225 SWITCH, N.C. Emergency stop $8 | 103141 | SWITCH, N.O. Operator horn HocR1} 100589 | RELAY, 24V HocR2) 108629 | RELAY, 24 V HOCR3} 108589 | RELAY, 24 V 32CR} 108589 | RELAY, 24V 53CR| 108589 | RELAY, 24V 9CCR} 108589 | RELAY, 24V SH19B] 105610 | COIL, 24V 2 prong 2P50] 111618 | SOLENOID, Propane (Ref.) | Parts Supplied With Engine, Refer to nearest Kohler Service Dealer ofan reac hing gfe eaten eat ead 8 - Purcliase locally Sulll Series - Dual Power Pack Option SECTION 3, Page 17 ‘ct. 2000FIGURE 3-10. ELECTRICAL SCHEMATIC (KUBOTA) a | 4 i ' (mA rey : aay i Y 4 sa i i ii ' a -- Ht fe HH saa Ae ee ae ‘SS-1118AB SECTION 3, Page 18 ‘SUlll Series - Dual Power Pack Option Oct, 2000FIGURE 3-10. ELECTRICAL SCHEMATIC (KUBOTA) Index jack Description ae "No | pon : Ss A 112419, ENGINE, Kubota 6 HP 1 B 117017 | ENGINE, Kubota 9.5 HP 1 BI $s BATTERY, 6V 1 B2 $s BATTERY, 6V 1 B3 $ BATTERY, 6V 1 Ba $ BATTERY, 6V 1 cl 103101 CONTACTOR, SPNO 1 CBI 117325 BREAKER, Circuit 15 Amp. 1 CB3 117325 BREAKER, Circuit 15 Amp 1 IDCM1 106576 MOTOR, DC 24V 1 D10B 102921 DIODE 2 D32A 102921 DIODE 7 Fi T7619, FUSE, 300A 1 Si 119725, SWITCH, N.O. Main Power Disconnect. 1 S3 103144 SWITCH, N.O. On/Off Key 1 S4 103225 | SWITCH, N.C. Emergency stop 4 sa 103141 | SWITCH, N.O. Operator hom. 1 OCR1 108589 RELAY, 24V a HOCR2} 108589 | RELAY, 24 V rs 3iCR 108589 RELAY, 24V 1 32ACR} 103207 RELAY, 24V 1 32CR 108589 | RELAY, 24V 1 53CR 108589, RELAY, 24V 1 9CCR) 108589. RELAY, 24V 1 ISH19B] 105610 | COIL, 24V 2 prong 1 2037 (Ref.) Parts Supplied With Engine, Refer to nearest Kubota Service Dealer - $ - Purchase locally all Series - Dual Power Pack Option SECTIONS, Page 19 ct. 2000FIGURE 3-11. ELECTRICAL PANEL DIAGRAM (ANSI/SIA AND CSA) een FASE IRE es e @ — : © SP-1038AA Inder | Shyleck ~Doserintion Unit No. | Parte, a, 1 120011 |HARNESS, Base dual power (Models 4620, 4626, 4830) 1 119959 HARNESS, Base dual power (Models 6826, 6832) 1 110632 |+ CONNECTOR, Battery 3-Prong 2 102950 |» TERMINAL, Battory 5/16 4 102938 + TERMINAL, 9/8 2 113584 + HEATSHRINK, Black 1/2 18 2 | 102936 |TERMINAL 1 3 103256 |CABLE, Cabtire 18/2 64" Ig, 4 107711 |CONNECTOR, 5 Pin female 1 5 | 103256 |CABLE, Cabtire 19/2 7a" Ig 6 | 1o8se9 RELAY 24v 1 SECTION 3, Page 20 et. 2000 Sulll Series - Dual Power Pack OptionFIGURE 3-12. ELECTRICAL PANEL ASSEMBLY (CE) index | sya Description Unite No. | PartNo. itt 1 | 120011 |HARNESS, Base dual power (Models 4620, 4626, 4890) 1 119959 | HARNESS, Base dual power (Models 6826, 6832) 1 110632 _|+ CONNECTOR, Battery 3-Prong 2 102950 |+ TERMINAL, Battery 5/16 4 102938 |+ TERMINAL, 3/8 2 119584 |+ HEATSHRINK, Black 1/2 18 2 | 102936 |TERMINAL 1 3 | 103256 |CABLE, Cabtire 19/2 \64" Ig. 4 | 107711 |CONNECTOR, 5 Pin female 1 5 | 103256 |CABLE, Cabtire 18/2 74" i. 6 | 108589 |RELAY, 24 Volt 1 Sul Series - Dual Power Pack Option ‘Oct, 2000 SECTION 3, Page 21FIGURE 3-13. ENGINE ELECTRICAL PANEL ASSEMBLY (KOHLER) SP-1035AA SECTI - ECTION 3, Page 22 eee Sulll Serles - Dual Power Pack OptionFIGURE 3-13. ENGINE ELECTRICAL PANEL ASSEMBLY (KOHLER) Shyeck Description Units Part to. an, 1 106417 | PANEL, Wiring 1 2 103101 | CONTACTOR, SPNO 1 3 103011 | BLOCK Terminal 1 4 110450 | ENGINE 13 HP Kohler 1 5 | 107712 | CONNECTOR, Cabtire 5 Pin Male 2 6 108589 | RELAY, 24V 2 7 103256 | CABTIRE, 18/2 SJ 33" 8 103257 | CABTIRE, 18/3 SJ 36" 9 120741 | ASSEMBLY, Wire 1 10 | 111639 | MODULE, LPG Flow Control il 11 | 120742 | ASSEMBLY, Plug And Wire Al 12 | 106407 | ALTERNATOR, 24V Delco 1 13 | 117325 | BREAKER, Circuit 15 Amp 1 14 | 120974 | HARNESS, Kolher Engine Wire 1 15 | 120744 | HARNESS, Kolher Dual Power Panel 1 16 | 117696 | BOOT, Rubber #4Awg Terminal 3 17 | 103261 | ADAPTER, Spade Terminal 2 18 (Ref.) | Parts Supplied With Engine, Refer to nearest Kohler Service Dealer - 19 | 103024 | CLIP, a8 1 Sulll Series - Dual Power Pack Option SECTION 3, Page 23 Oct. 2000FIGURE 3-14. ENGINE ELECTRICAL PANEL ASSEMBLY (KUBOTA) ‘SP-1036AA SECTIONS, Page 24 Sulll Series - Dual Power Pack Option ‘Oct. 2000FIGURE 3-14, ENGINE ELECTRICAL PANEL ASSEMBLY (KUBOTA) tae i Description Units Ne | Patt: fot A 112419 ENGINE, Kubota 6 HP 1 B 117017 ENGINE, Kubota 9.5 HP 1 1 106417 | PANEL, Wiring 1 2 103101 CONTACTOR, SPNO 1 3 103011 | BLOCK Terminal 1 4 102929 | CLIP, G10 1 5 107712 |CONNECTOR, Cabtire 5 Pin Male 2 6 108589 RELAY, 24 V 3 7 103256 | CABTIRE, 18/2 SJ 54” 8 103255 | CABTIRE, 16/4 SU 45" 9 103148 | CABLE, Welding #4 Awg Alternator 16” 10 103148 | CABLE, Welding #4 Awg (9.5 HP) Alternator Solenoid 40” 103148 | CABLE, Welding #4 Awg (6 HP) Alternator Solenoid ar Ww 103148 | CABLE, Welding #4 Awg (9.5 HP) Engine Starter 58" 103148 | CABLE, Welding #4 Awg (6 HP) Engine Starter 53" 12 103148 | CABLE, Welding #4 Awg (9.5 HP) Engine Ground 54” 103148 | CABLE, Welding #4 Awg (6 HP) Engine Ground 53” 13 110632 | CONNECTOR, Battery q 14 106407 | ALTERNATOR, 24V Delco 1 15 117325 | BREAKER, Circuit 15 Amp 1 16 102921 DIODE 2 7 117696 | BOOT, Rubber #4Awg Terminal a 18 122956 | TIMER, Stop Solenoid 1 19 (Ret.) Parts Supplied With Engine, Refer to nearest Kubola Service Dealer fe SUlll Series - Dual Power Pack Option SECTION 3, Page 25 Oct. 2000FIGURE 3-15, HYDRAULIC SCHEMATIC TRAGER a ack sR IC BUICK Bi DISCONNECTS . 7 ge “none | BELINE q ek [S- —@) i be LO VALE HYDRAULIC mune ra ‘ we @ HYORRLIC © © fun HMDRALIC TICK al uct /SKmAECIS eT RETURN al LJ SS-TI16AB Findox | eiyleck Deveription ate No, | PartNo. a, A (Ref) | Kubota Engine 6.0 HP, - B (Ret) | Kubota Engine 9.5 HP. : c (Ref) | Kolher Engine 13 HP, - 1 | 114044 | PUMP, Hydraulic, 194 cu. inv rev- ow, A 1 110068 PUMP, Hydraulic, .323 cu. in/ rev - cw, B& C 1 2 | 114910 | COUPLER, Quick disconnect female #12 1 114911 CAP, Quick disconnect dust 1 3 |. 114909 |COUPLER, Quick disconnect female #4P 1 114912 CAP, Quick disconnect dust 1 4 | 114904 J QUICK DISCONNECT, Nipple 3/4 1 114906 CAP, Quick disconnect aluminium 1 5 | 114905 | QUICK DISCONNECT, Nipple 1/4 1 114907 | CAP, Quick disconnect steel 1 6 116741 VALVE, Check valve in-line 1 7 | 114268 | MANIFOLD ASSEMBLY, Dual power : 106392 [+ BLOCK, Manifold 1 106273 |* VALVE, 3-Way (dual power) 1 SECTION 3, Page 26 ‘SUI Serles - Dual Power Pack Option Oct, 2000FIGURE 3-16. HYDRAULIC MANIFOLD COMPONENT AND PORT IDENTIFICATION DUAL POWER TRANSFER MANIFOLD. TO ENGINE PUMP TRANSFER VALVE TO MAIN MANIFOLD. ‘SP-1032AA Sulll Series - Dual Power Pack Option SECTION 3, Page 27 Oct. 2000