Download Service Manual Full-Size Rough Terrain Series

MODELS SJ 9241 SJ 9250
Service Manual
Full-Size Rough Terrain Series
Part No. 143905AD February 2014
This manual is based on Serial Numbers:
SJ 9250
ANSI/CSA & AS
50,000,513 TO 50,000,745
SJ 9241
SJ 9250
CE
55,000,001 TO 55,000,032
50,000,513 TO 50,000,745
Please refer to the website www.skyjack.com for older Serial Numbers.
Skyjack Service Center
Parts & Service (Europe)
3451 Swenson Ave. St. Charles,
Illinois, 60174 USA
Phone: 630-262-0005
Toll Free: 1-800-275-9522
Fax: 630-262-0006
Email: [email protected]
Unit 1 Maes Y Clawdd
Maesbury Road Industrial Estate
Oswestry, Shropshire SY10 8NN UK
Phone: +44-1691-676-235
Fax: +44-1691-676-238
E-mail: [email protected]
Parts (North America)
Skyjack Brasil
Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
E-mail: [email protected]
Skyjack Australia Pty Ltd.
4 Coates Place
Wetherill Park
New South Wales 2164
Australia
Tel: +61 (0) 28786 3200
Fax: +61(0) 28786 3222
Alameda Júpiter, 710
Loteamento American Park Empresarial
Indaiatuba, SP, Brasil 13347-653
Tel: +55 19 3936 0132
SERVICE AND MAINTENANCE
Table of Contents
Section 1 - Scheduled Maintenance
Table of Contents
Section 2 - Maintenance Tables
Table of Contents
Section 3 - Schematics
Table of Contents
Section 4 - Troubleshooting
Table of Contents
Section 5 - Procedures
Table of Contents
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 3
Service and Maintenance
Operator’s Responsibility for Maintenance
The Safety Alert Symbol identifies important
safety messages on aerial platforms, 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.
This Safety Alert Symbol means attention!
Become alert! Your safety is involved.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
important
IMPORTANT indicates a procedure) essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.
SKYJACK, Page 4
Mid Size & Full Size
Rough Terrain Series
1
Section 1
schedule maintenance
Table of Contents
Operator’s Responsibility for Maintenance
Aerial Platform Definition...............................................................................................................................................7
Purpose of Equipment..................................................................................................................................................7
Use of Equipment.........................................................................................................................................................7
Manuals.........................................................................................................................................................................7
Operator........................................................................................................................................................................7
Service Policy and Warranty.........................................................................................................................................7
Optional Accessories....................................................................................................................................................7
Scope of this Manual....................................................................................................................................................8
Operator Safety Reminders..........................................................................................................................................9
Electrocution Hazard....................................................................................................................................................9
Safety Precautions......................................................................................................................................................10
Maintenance and Inspection Schedule......................................................................................................................13
Owner’s Annual Inspection Record............................................................................................................................13
Replacement Parts......................................................................................................................................................13
Maintenance and Service Safety Tips........................................................................................................................13
Hydraulic System & Component Maintenance and Repair.......................................................................................14
Maintenance Hints......................................................................................................................................................14
Service and Maintenance
About this Section.......................................................................................................................................................15
Service Bulletins..........................................................................................................................................................15
Maintenance and Inspection......................................................................................................................................15
Maintenance Instructions............................................................................................................................................15
Schedule Maintenance Inspections
1.1
1.2
Scheduled Maintenance Inspections...............................................................................................................18
Function Tests..................................................................................................................................................28
Tables
1.1 Owner’s Annual Inspection Record.....................................................................................................................16
1.2 Maintenance and Inspection Checklist...............................................................................................................17
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 5
Operator’s Responsibility for Maintenance
Service and Maintenance
SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.
Aerial Platform Definition
A mobile device that has an adjustable position platform supported from ground level by a structure.
Purpose of Equipment
The SKYJACK Rough Terrain’s mid and full size aerial platforms are designed to transport and raise personnel, tools
and materials to overhead work areas.
Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.
Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.
Service & Maintenance
The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.
All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.
Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial platform
with the labels found within this manual. If any labels are damaged or missing, replace them immediately.
Service Policy and Warranty
SKYJACK warrants each new SJRT series work platform to be free of defective parts and workmanship for the first
24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or
labor. Contact the SKYJACK Service Department for warranty statement extensions or exclusions.
Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard
and Optional Features” in Table 2.1 of the operating manual. Operating instructions for these options (if equipped)
are located in section 2 of the operating manual.
For non-standard components or systems, contact the SKYJACK Service Department at
North America & Asia:
( : 800 275-9522
7 : 630 262-0006
Europe:
( : 44 1691-676-235
7 : 44 1691-676-239
Include the model and serial number for each applicable aerial platform.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 7
Service and Maintenance
Operator’s Responsibility for Maintenance
Scope of this Manual
a.
This manual applies to the ANSI/SIA, CSA and CE versions of the Mid Size and Full Size Rough Terrain aerial
platform models listed on Table 2.1.
- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-2006 standard.
- Equipment identified with “CSA” meets the CSA B354.2-01 standard.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery Directive
98/37/EC and/or 89/392/EE, EMC Directive 89/336/EEC, Directive 2000/14/EC and the corresponding EN
standards.
b.
CSA (Canada) and CE (Europe)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.
c.
ANSI/SIA (United States)
Operators are required by the current ANSI/SIA A92.6 standards to read and understand their responsibilities
in the manual of responsibilities before they use or operate this aerial platform.
SKYJACK, Page 8
Mid Size & Full Size
Rough Terrain Series
Operator’s Responsibility for Maintenance
Service and Maintenance
WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!
Operator Safety Reminders
A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.
You, as a careful operator, are the best insurance against an accidenvt. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.
Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.
Any modifications from the original design are strictly forbidden without written permission from SKYJACK.
Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized
power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This aerial
platform does not provide protection from contact with or proximity to an electrically charged conductor.
DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.
DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS.
DANGER
Avoid Power Lines
Minimum Safe Approach Distance
ANSI/SIA A92.6-2006
and CSA B354.2-01 Requirements
Voltage Range
(Phase to Phase)
Minimum Safe Approach Distance
(Feet)
0 to 300V
Avoid Contact
Over 300V to 50KV
10
Over 50KV to 200KV
15
Over 200KV to 350KV
20
Over 350KV to 500KV
25
Over 500KV to 750KV
35
Over 750KV to 1000KV
45
CE Guidance Note
“Avoidance of danger from overhead lines”
Adhere strictly to the governmental rulings
and regulations applicable in your country.
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
60023AD
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 9
Service and Maintenance
Operator’s Responsibility for Maintenance
Safety Precautions
Know and understand the safety precautions before going on to next section.
warning
Failure to heed the following safety precautions could result in tip over, falling,
crushing, or other hazards leading to
death or serious injury.
• KNOW all national, state/provincial and local
rules which apply to your aerial platform and jobsite.
• TURN the (emergency) main power disconnect
switch off when leaving the aerial platform unattended. Remove the key to prevent unauthorized
use of the aerial platform.
• WEAR all the protective clothing and personal
safety devices issued to you or called for by job
conditions.
• DO NOT wear loose clothing, dangling neckties,
scarves, rings, wristwatches
or other jewelry while operating this aerial platform.
• AVOID entanglement
ropes, cords or hoses.
with
• AVOID falling. Stay within the
boundaries of the guardrails.
• DO NOT raise the aerial platform in windy or gusty conditions.
• DO NOT increase the lateral
surface area of the platform.
Increasing the area exposed
to the wind will decrease aerial
platform stability.
• DO NOT drive or elevate the
aerial platform if it is not on a
firm level surface. Do not drive
elevated near depressions
or holes of any type, loading
docks, debris, drop-offs and
surfaces that may affect the
stability of the aerial platform.
• If operation in areas with holes or dropoffs is absolutely necessary, elevated driving
shall not be allowed. Position
the aerial platform horizontally
only with the platform fully
lowered. After ensuring that
all 4 wheels or outriggers (if
equipped) have contact with
level firm surface, the aerial
platform can be elevated. After elevation, the drive function
must not be activated.
• Elevated driving must only
be done on a firm level surface.
• DO NOT ascend or descend
a grade when elevated. When
fully lowered, ascending or
descending, only grades up to
rated maximum listed in Table
2.1 are permissible.
• DO NOT operate on surfaces
not capable of holding the
weight of the aerial platform including the rated
load, e.g. covers, drains, and trenches.
SKYJACK, Page 10
Mid Size & Full Size
Rough Terrain Series
Operator’s Responsibility for Maintenance
Service and Maintenance
Safety Precautions (Continued)
Know and understand the safety precautions before going on to next section.
• DO NOT operate an aerial platform that has
ladders, scaffolding or other devices mounted
on it to increase its size or work height. It is
prohibited.
• DO NOT exert side forces on
aerial platform while elevated.
• DO NOT lower the platform
unless the area below is clear
of personnel and obstructions.
• ENSURE that there are no
personnel or obstructions in the
path of travel, including blind
spots.
• DO NOT use the aerial platform
as a crane. It is prohibited.
• DO NOT sit, stand or climb on
the guardrails. It is prohibited.
• BE AWARE of blind spots
when operating the aerial
platform.
• STUNT driving and horseplay are prohibited.
• DO NOT climb on scissor arm assembly. It is
prohibited.
• ENSURE ALL tires are in good condition and lug
nuts are properly tightened.
• DO NOT alter or disable limit switches or other
safety devices.
• BE
AWARE of overhead
obstructions or other possible
hazards around the aerial
platform when driving or lifting.
• DO NOT use the aerial platform without
guardrails, locking pins and the entry gate/chain/
bar in place.
• DO NOT raise the platform
while the aerial platform is on a truck, fork lift or
other device or vehicle.
• BE
AWARE of crushing
hazards. Keep all body parts
inside platform guardrail.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 11
Service and Maintenance
Operator’s Responsibility for Maintenance
Safety Precautions (Continued)
Know and understand the safety precautions before going on to next section.
• DO NOT exceed the rated capacity of the aerial
platform. Do make sure the load is evenly distributed on the platform.
• DO NOT attempt to free a snagged platform with
lower controls until personnel are removed from
the platform.
• DO NOT position the aerial platform against another object to steady the platform.
• DO NOT place materials on the guardrails or materials that exceed the confines of the guardrails
unless approved by Skyjack.
Fall Protection
As per the ANSI A92.6-2006 standard, “The guardrail system of the aerial platform provides fall protection. If occupant(s) of the platform are required
to wear personal fall protection equipment (PFPE),
occupants shall comply with instructions provided
by the aerial platform manufacturer (remanufacturer) regarding anchorage(s).”
If additional fall protection is required, by an employer or the authority having jurisdiction, Skyjack
recommends the use of a fall restraint system to
keep an occupant within the confines of the platform, and thus not expose the occupant to any
fall hazard requiring a fall arrest.
All personal fall protection equipment must comply with applicable governmental regulations and
must be inspected and used in accordance with
the manufacturer’s recommendations.
All personal fall protection equipment must be attached only to approved anchorage points within
the platform of the aerial platform.
SKYJACK, Page 12
WARNING
Entering and exiting the aerial platform
should only be done using the three
points of contact.
• Use only equipped access openings.
• Enter and exit only when the aerial
platform is in the fully retracted position.
• Do use three points of contact to enter and exit
the platform. Enter and exit the platform from
the ground only. Face the aerial platform when
entering or exiting the platform.
• Three points of contact means that two hands
and one foot or one hand and two feet are in
contact with the aerial platform or the ground at
all times during entering and exiting.
WARNING
An operator should not use any aerial
platform that:
• does not appear to be working properly.
• has been damaged or appears to have worn or
missing parts.
• has alterations or modifications not approved by
the manufacturer.
• has safety devices which have been altered or
disabled.
• has been tagged or blocked out for non-use or
repair.
Failure to avoid these hazards could
result in death or serious injury.
Jobsite Inspection
• Do not use in hazardous locations.
• Perform a thorough jobsite inspection prior to
operating the aerial platform, to identify potential
hazards in your work area.
• Be aware of moving equipment in the area. Take
appropriate actions to avoid collision.
Mid Size & Full Size
Rough Terrain Series
Operator’s Responsibility for Maintenance
Maintenance and Inspection Schedule
The actual operating environment of the work platform
governs the use of the maintenance schedule. The
inspection points covered in Table 1.2. Maintenance
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at
what intervals the maintenance and inspections are to
be performed.
Owner’s Annual Inspection Record
It is the responsibility of the owner to arrange quarterly
and annual inspections of the aerial platform. Table 1.1.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name,
and the person responsible for the inspection of the
work platform.
Replacement Parts
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect
stability of the aerial platform and must not be used
without manufacturer’s consent.
All replacement tires must be of the same size and load
rating as originally supplied tires; to maintain safety and
stability of aerial platform.
Consult SKYJACK’s Service Department for optional
tires specifications and installation.
WARNING
Any unit that is damaged or not operating properly must be immediately tagged
and removed from service until proper
repairs are completed.
Mid Size & Full Size
Rough Terrain Series
Service and Maintenance
Maintenance and Service Safety Tips
Maintenance and repair should only be performed by
personnel who are trained and qualified to service this
aerial platform.
All maintenance and service procedures should be
performed in a well lighted and well ventilated area.
Anyone operating or servicing this aerial platform
must read and completely understand all operating
instructions and safety hazards in this manual and
operating manual.
All tools, supports and lifting equipment to be used
must be of proper rated load and in good working order
before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
components while servicing.
All service personnel must be familiar with employer
and governmental regulations that apply to servicing
this type of equipment.
Keep sparks and flames away from all flammable or
combustible materials.
Properly dispose of all waste material such as
lubricants, rags, and old parts according to the relative
law provisions obtaining in the country.
Before attempting any repair work, turn Battery
Disconnect Switch to the “OFF” position.
Preventive maintenance is the easiest and least
expensive type of maintenance.
SKYJACK, Page 13
Service and Maintenance
Operator’s Responsibility for Maintenance
Hydraulic System & Component
Maintenance and Repair
Oil change intervals will depend on the
care used in keeping the oil clean, and the
operating conditions. Dirt and/or moisture
cotamination will dictate that the oil should
be changed more often. Under normal use
and operating conditions, the hydraulic oil
should be changed every two years. Refer
to Table 1.2 of this manual.
The following points should be kept in mind when
working on the hydraulic system or any component:
1.
2.
3.
4.
5.
6.
Any structure has limits of strength and durability.
To prevent failure of structural parts of hydraulic
components, relief valves which limit pressure to
safe operating values are included in the hydraulic
circuits.
Tolerance of working parts in the hydraulic system
is very close. Even small amounts of dirt or
foreign materials in the system can cause wear
or damage to components, as well as general
faulty operation of the hydraulic system. Every
precaution must be taken to assure absolute
cleanliness of the hydraulic oil.
Whenever there is a hydraulic system failure
which gives reason to believe that there are metal
particles or foreign materials in the system, drain
and flush the entire system and replace the filter
cartridges. A complete change of oil must be
made under these circumstances.
Whenever the hydraulic system is drained, check
the magnets in the hydraulic reservoir for metal
particles. If metal particles are present, flush the
entire system and add a new change of oil. The
presence of metal particles also may indicate the
possibility of imminent component failure. A very
small amount of fine particles is normal.
All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
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.
When removing any hydraulic component, be sure
to cap and tag all hydraulic lines involved. Also,
plug the ports of the removed components.
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.
SKYJACK, Page 14
7.
All hydraulic components must be disassembled
in spotlessly clean surroundings. During
disassembly, pay particular attention to the
identification of parts to assure proper reassembly.
Clean all metal parts in a clean mineral oil solvent.
Be sure to thoroughly clean all internal passages.
After the parts have been dried thoroughly, lay
them on a clean, lint-free surface for inspection.
8.
Replace all O-rings and seals when overhauling
any component. Lubricate all parts with clean
hydraulic oil before reassembly. Use small
amounts of petroleum jelly to hold O-rings in
place during assembly.
9.
Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
component, and bleed any air from the system
when required.
10. All hydraulic connections must be kept tight. A
loose connection in a pressure line will permit
the oil to leak out or air to be drawn into the
system. Air in the system can cause damage
to the components and noisy or erratic system
operation.
Maintenance Hints
Three simple maintenance procedures have the
greatest effect on the hydraulic system performance,
efficiency and life. Yet, the very simplicity of them may
be the reason they are so often overlooked. What are
they? Simply these:
1. Change filters annually. The filters will need
to be changed more often depending on
the operating conditions. Dirty, dusty, high
moisture environments may cause the
hydraulic system to be contaminated more
quickly.
2. Maintain a sufficient quantity of clean
hydraulic oil of the proper type and viscosity
in the hydraulic reservoir.
3. Keep all connections tight.
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
About this Section
This section contains the maintenance and inspection
schedule that is to be performed.
References are made to the procedures in section 5
that outline detailed step-by-step instructions for checks
and replacements.
Service Bulletins
Before performing any scheduled maintenance
inspection procedure, refer to service bulletins found
in our web site: www.skyjack.com for updates related
to service and maintenance of this aerial platform.
Maintenance and Inspection
Death or injury can result if the aerial platform is not kept
in good working order. Inspection and maintenance
should be performed by competent personnel who
are trained and qualified on mantenance of this aerial
platform.
WARNING
Failure to perform each procedure as presented and scheduled may cause death,
serious injury or substantial damage.
Note
Preventive maintenance is the easiest and
least expensive type of maintenance.
Service and Maintenance Inspections
Maintenance Instructions
This manual consists of four schedules to be done for
maintaining on an aerial platform. Inspection schedule
frequency is shown below:
Inspection Schedule
Daily
Frequently
Annually
Bi-annually
A
A+B
A+B+C
A+B+C+D
• Make copies of the maintenance and inspection
checklist to be used for each inspection.
• Check the schedule on the checklist for the type of
inspection to be performed.
• Place a check in the appropriate box after each
inspection procedure is completed.
• Use the maintenance and inspection checklist and
step-by-step procedures in section 5 to perform
these inspections.
• If any inspection receives a fail, tag and remove the
aerial platform from service.
• If any aerial platform component(s) has been
repaired, an inspection must be performed again
before removing the tag. Place a check in the repair
column.
Legend
P = Pass
F = Fail
R = Repaired
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following configuration:
- Aerial platform parked on a flat and level
surface
- Disconnect the battery by turning the main
power disconnect switch to the “OFF” position.
• Repair any damaged or malfunction components
before operating aerial platform.
• Keep records on all inspections.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 15
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Table 1.1 Owner’s Annual Inspection Record
Model Number: ____________________________
Recording
Date
Recording
Year #
Owner’s
Name
Inspected
By
1
2
Serial Number: ____________________________
3
4
5
6
7
8
9
60564AA
As described earlier in this section, this decal is located on the control compartment cowling. It must be completed after an annual
inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13 months.
SKYJACK, Page 16
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST
Serial Number:
Model:
Hourmeter Reading:
Name (Printed):
Date:
Time:
Signature:
Each item shall be inspected using the the appropriate section of the Skyjack service manual.
As each item is inspected, write the apropriate grade in the box.
Inspection Schedule
INSPECTION FREQUENCY
Daily
A
‰ DAILY
Frequently*†
A+B
P
- PASS
‰ FREQUENTLY
Annually†
A+B+C
F
- FAIL
‰ ANNUALLY
Bi-annually†
A+B+C+D
R
- REPAIRED
‰ BI-ANNUALLY
Schedule
P
F
Schedule Maintenance Inspections
Labels
Limit Switches
Emergency Lowering Access Rod
(If Equipped)
Schedule
R
P
A
A, B
A, B
Electrical and Control Components
Base Weldment
A, B
Axles
A, B
Steer Cylinder Assembly
A, B
Tie Rod
A, B
Main Power Disconnect Switch
A, B
Ladder
A, B
A, B
Outriggers (If Equipped)
A, B
Battery
A, B
A, B, C
Manual
A, B
Function Tests
Platform Control Console
Electrical Panel
A, B
Tilt Sensor (If Equipped)
A, B
Test Emergency Stop
Load/Tilt Sensor - CE
A, B
Test Lift Enable
A, B
Test Platform Raising/Lowering
A, B
Test Enable Trigger Switch
A, B
Test Steering
A, B
Engine Compartment
Engine Control Console
Radiator
A, B
A, B, C
A, B
Muffler and Exhaust
A, B
Test Horn
A, B
Engine Tray
A, B
Test Driving
A, B
Hydraulic Pump
A, B
Test Brake
A, B
Engine Air Filter
A, B
Test Speed Limit
A, B
Engine Oil Level
A, B
Test Lowering Warning - CE
A, B
Test Powerdeck Enable
(If equipped)
A, B
Test Extension Platform(s)
(If equipped)
A, B
Test Tilt Sensor (If Equipped)
A, B
Engine Fuel Filter
A, B, C
Fuel and Hydaulic Oil Supply
Fuel Tank
A, B
Fuel Leaks
A, B
Hydraulic Tank
A, B, C
Hydraulic Oil
A, B, C
Platform Assembly
Lanyard Attachment Anchors
R
A, B
Wheel/Tire Assembly
Base Control Switches
Manifolds
F
Base
Base Control Console
Test Emergency Stop
A
A, B
Test Base Lift Enable
A, B
AC Outlet on Platform
A, B
Test Lower/Neutral/Raise Switch
A, B
Platform Control Console
A, B
Powered Extension Control Console
(If Equipped)
A, B
A, B
Test Emergency Lowering
(Models 71xx, 8831/41 & 9241)
Test Emergency Lowering
(Model 8243, 8850 & 9250)
A, B
A, B
A, B
Lift Mechanism
Scissor Guards (If Equipped)
A, B
Sliders
A, B
Maintenance Support
A, B
Test Emergnecy Powered Extension
Platform Retraction Switch
(Model 8850 & CE - 9250)
Scissor Assembly
A, B
Test Main Power Discconect Switch
Scissor Bumpers
A, B
Lift Cylinder(s)
A, B
110AC
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.7 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual.
* Perform scheduled inspection every three months or 150 hours.
† Refer to Skyjack's webiste @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 17
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Model 71xx
Model 88xx
Platform Control
Console
Platform
Assembly
Scissor
Assembly
Limit Switch
Outrigger
Ladder
Electrical/Hydraulic
Compartment
Base
Ladder
1.1 Scheduled Maintenance Inspections
Begin the scheduled maintenance inspections by
checking each item in sequence for the conditions listed
in this section.
WARNING
To avoid injury, do not operate an aerial
platform until all malfunctions have been
corrected.
WARNING
To avoid possible injury, ensure aerial
platform power is off during your visual
and daily maintenance inspections.
Electrical
Maintaining the electrical components is essential
to good performance and service life of the aerial
platform.
Inspect the following areas for chafed, corroded
and loose wires:
• base to platform cables and wiring harness
• engine compartment electrical panel
• engine wiring harness
• hydraulic/electrical wiring harnesses
Hydraulic
Maintaining the hydraulic components is essential
to good performance and service life of the aerial
platform.
SKYJACK, Page 18
Electrical/Hydraulic
Compartment
Base
Limit Switch
Perform a visual inspection around the following
areas:
• hydraulic tank filter, fittings, hoses, emergency
power unit (if equipped) and base surfaces
• engine compartment fittings, hoses, main
pump, and filter
• all hydraulic cylinders
• all hydraulic manifolds
• the underside of the base
• ground area under the aerial platform
• outriggers
1.1-1 Labels
Refer to the labels section in this manual and determine
that all labels are in place and are legible.
1.1-2 Limit Switches
Detecting limit switch malfunction is essential to safe
aerial platform operation. Ensure limit switches are
properly secured with no signs of visible damage and
movement is not obstructed.
Visually inspect all limit switch located inside the
scissor arms and the outrigger assemblies for the
following:
• broken or missing actuator arm
• missing fasteners
• loose wiring
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Typical Model 71xx shown
Emergency Lowering
Access Rod
Electrical Panel
Main Manifold
(Emergency) Main
Power Disconnect
Switch
Load/Tilt
Sensor
Motion Control Manifold
Cushion Cylinder
1.1-3 Emergency Lowering Access Rod
(All models except 9250)
-- Ensure rod is properly secured and there is
no visible damage.
1.1-4 Electrical and Control Components
-- Ensure all compartment latches are secure
and in proper working order.
• Main Power Disconnect Switch
-- Turn main power disconnect switch to
“ ” off position.
-- Ensure all cables are secure and switch
is in proper working condition.
• Base Control Switches
-- Ensure there are no signs of visible
damage and all switches are in their
neutral positions.
• Battery
Proper battery condition is essential to
good performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage
and hazardous conditions.
Brake Manifold
Base Control
Switches
WARNING
Battery acid is extremely corrosive
- Wear proper eye and facial protection as well as appropriate protective
clothing. If contact occurs, immediately
flush with cold water and seek medical
attention.
1. Check battery case for damage.
2. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or
wire brush.
3. Ensure all battery connections are tight.
4. If applicable, check battery fluid level. If plates
are not covered by at least 1/2 in. (13 mm)
of solution, add distilled or demineralized
water.
5. Replace battery if damaged or incapable of
holding a lasting charge.
WARNING
WARNING
Explosion hazard. Keep flames
and sparks away. Do not smoke
near batteries.
Mid Size & Full Size
Rough Terrain Series
Use original or manufacturer-approved
parts and components for the aerial
platform.
SKYJACK, Page 19
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Typical Model 71xx shown
Emergency Lowering
Access Rod
Electrical Panel
Main Manifold
Emergency Main
Power Disconnect
Switch
Load/Tilt
Sensor
Motion Control Manifold
Cushion Cylinder
Brake Manifold
Base Control
Switches
• Manifolds
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
-- Ensure there are no loose wires or
missing fasteners.
• Electrical Panel
-- Ensure panel is properly secured and
there is no visible damage.
-- Ensure there are no loose wires or
missing fasteners.
• Tilt Sensor (If Equipped)
-- Ensure tilt sensor is properly secured and
there is no visible damage.
• Load/Tilt Sensor - CE
-- Ensure load/tilt sensor is properly secure
and there is no visible damage.
SKYJACK, Page 20
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Typical Model 71xx shown
Muffler and Exhaust
Engine
Radiator
Engine Control
Console
Engine Air Filter
Hydraulic Pump
Engine Tray
Battery
1.1-5 Engine Compartment
WARNING
Beware of hot engine components.
1. Pull on the two latches to pull out engine
compartment.
• Engine Control Console
-- Ensure muffler and exhaust system are
properly secured, with no evidence of
damage.
• Radiator
-- Ensure radiator is secure.
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Muffler and Exhaust
-- Ensure muffler and exhaust system are
properly secured, with no evidence of
damage.
• Engine Tray
-- Ensure there are no loose or missing
parts and no visible damage to the engine
tray. Ensure that both tray-securing bolts
are in place.
• Hydraulic Pump
-- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure all bolts are properly tightened.
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
-- Check coolant level and add as
needed.
C - Annual Inspection
-- For recommand coolant change, refer to
engine manual.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 21
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Typical Model 71xx shown
Muffler and Exhaust
Engine
Radiator
Engine Control
Console
Engine Air Filter
Hydraulic Pump
Engine Tray
Battery
• Engine Air Filter
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Enigne Fuel Filter
-- Ensure there are no loose or missing
parts and there is no visible damage.
B - Frequent Inspection
-- For engine air filter maintenance
procedure, refer to engine manual.
C - Annual Inspection
-- For engine fuel filter replacement
procedure, refer to engine manual.
C - Annual Inspection
-- For engine air filter replacement
procedure, refer to engine manual.
• Engine Oil Level
-- Maintaining the engine components
is essential to good performance and
service life of the aerial platform.
Check oil level on dipstick
-- Oil level should be between the “L” and
“H” marks.
B - Frequent Inspection
-- For recommand oil change, refer to
engine manual
SKYJACK, Page 22
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Typical Model 71xx shown






Propane Tank
Fuel Tank
1.1-6 Fuel and Hydraulic Oil Supply
• Fuel Tank
IMPORTANT
Before using your aerial platform ensure
there is enough fuel for expected use.
-- Ensure fuel filler cap is secure.
-- Ensure tank shows no visible damage
and no evidence of fuel leakage.
• Fuel Leaks
-- Ensure there are no fuel leaks.
DANGER
Engine fuels are combustible. Inspect
the aerial platform in an open, well-ventilated area away from heaters, sparks
and flames. Always have an approved
fire extinguisher within easy reach.
Hydraulic Tank
• Hydraulic Tank
-- Ensure hydraulic filler cap is secure.
-- Ensure tank shows no visible damage
and no evidence of hydraulic leakage.
• Hydraulic Oil
-- Ensure platform is fully lowered, and
outriggers retracted, and then visually
inspect the sight gauge located on the
side of the hydraulic oil tank. Check oil
level against label that indicates minimum
and maximum oil levels.
C - Annual Inspection
-- For hydraulic oil replacement procedure,
refer to section 5.
-- Ensure fuel pump, fuel filter, hoses and
fittings show no visible damage and no
evidence of fuel leakage.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 23
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Platform
Railing
Platform Control
Console
1.1-7 Platform Assembly
WARNING
Ensure that you maintain three points of
contact to mount/dismount platform.
1. Use the ladder of aerial platform to access
platform.
2. Close the gate.
-- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure all fasteners are securely in
place.
-- Ensure all railings are properly positioned
and secured.
-- Ensure gate is in good working order.
• Lanyard Attachment Anchors
-- Ensure attachment rings are secure and
have no visible damage.
Platform
Assembly
• Platform Control Console
-- Ensure all switches and controller are
returned to neutral and are properly
secured.
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Powered Extension Control Console
(If Equipped)
-- Ensure all switches are returned to
neutral and are properly secured.
-- Ensure there are no loose or missing
parts and there is no visible damage.
WARNING
Ensure that you maintain three points of
contact to mount/dismount platform.
3. Use the ladder to dismount from platform.
• AC Outlet on Platform
-- Ensure outlet has no visible damage and
free from dirt or obstructions.
SKYJACK, Page 24
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Scissor Assembly
Slider
Scissor Bumper
Maintenance
Support
Limit Switch
Lift Cylinder
1.1-8 Lifting Mechanism
• Scissor Guards (If Equipped)
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Scissor Bumpers
-- Ensure bumpers are secure and shows
no sign of visible damage.
• Sliders
-- Ensure sliders are secure and there is no
visible damage.
• Lift Cylinder(s)
-- Ensure each lift cylinder is properly
secured, there are no loose or missing
parts and there is no evidence of
damage.
-- Ensure sliders’ path of travel are free from
-- Ensure all fittings and hoses are properly
dirt and obstructions.
1. Raise the platform until there is adequate
clearance to swing down the maintenance
support.
• Maintenance Support
-- Ensure maintenance support is properly
secured and shows no visible damage.
tightened and there is no evidence of
hydraulic leakage.
2. Raise the platform until there is adequate
clearance to swing up the maintenance
support into storage bracket.
3. Fully lower the platform.
• Scissor Assembly
-- Ensure scissor assembly shows no visible
damage and no signs of deformation in
weldments.
-- Ensure all pins are properly secured.
-- Ensure cables and wires are properly
routed and shows no signs of wear and/
or physical damage.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 25
Service and Maintenance Inspections
Section 1 - Scheduled Maintenance
Typical Model 71xx shown - Bottom View
Ladder
Manual Storage
Box
Base
Weldment
Wheel/Tire
Assembly
Axles
Steer Cylinder
Assembly
Tie Rod
1.1-9 Base
• Base Weldment
-- Ensure there are no visible cracks in
welds or structure and there are no signs
of deformation.
• Wheel/Tire Assembly
The aerial platform is either equipped with
air tires or foam-filled tires. Tire and/or wheel
failure could result in an aerial platform
tipover. Component damage may also result
if problems are not discovered and repaired
in a timely fashion.
WARNING
Air filled tires are not permitted on some
models. Refer to Table 2.3.
WARNING
An over-inflated tire can explode and
may cause death or serious injury.
--
Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
--
Check each wheel for damage and cracked
welds.
--
Check each lug nut for proper torque to
ensure none are loose.
SKYJACK, Page 26
To maximize stability, it is essential to maintain
proper pressure in all air-filled tires.
--
Check each tire with an air pressure gauge
and add air as needed.
Refer to Table 2.3 for wheel/tire specifications.
• Axles
-- Ensure axles are properly secured,
there are no loose or missing parts, all
fittings and hoses are properly tightened
and there is no evidence of hydraulic
leakage.
• Steer Cylinder Assembly
-- Ensure steer cylinder assembly is properly
secured, there are no loose or missing
parts, all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.
• Tie Rod
-- Ensure there are no loose or missing
parts, tie rod end studs are locked and
there is no visible damage.
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Service and Maintenance Inspections
Typical Model 71xx shown - Bottom View
Ladder
Manual Storage
Box
Base
Weldment
Wheel/Tire
Assembly
Axles
Steer Cylinder
Assembly
Tie Rod
• Ladder
-- Ensure there are no loose or missing
parts and there is no visible damage.
• Outriggers (If Equipped)
-- Ensure there are no loose or missing
parts and there is no visible damage.
1.1-10 Manuals
Ensure a copy of operating manual, and other
important documents are enclosed in manual
storage box.
-- Check to be sure manual storage box is
present and in good condition.
-- Ensure manuals are legible and in good
condition.
-- Always return manuals to the manual
storage box after use.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 27
Function Tests
Section 1 - Scheduled Maintenance
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
1.2 Function Tests
Function tests are designed to discover any malfunctions
before aerial platform is put into service. The operator
must understand and follow step-by-step instructions
to test all aerial platform functions.
WARNING
Never use a malfunctioning aerial
platform. If malfunctions are discovered,
aerial platform must be tagged and
placed out of service. Repairs to aerial
platform may only be made by a qualified
service technician.
For CE, select off/platform/base key switch to “
platform position.
4.
On engine control console, select off/on/start
switch to “ ” on position.
5.
For ANSI/CSA with dual fuel engine, select fuel
supply by moving fuel switch to either “
gasoline or “
1.2-1 Platform Control Console
1.
Turn main power disconnect switch to “ ” on
position.
2.
On base control console, pull out “
stop button.
SKYJACK, Page 28
” liquid propane gas position.
Ensure that you maintain three points of
contact when using the ladder to mount/
dismount platform.
6.
Use the ladder of aerial platform to access
platform.
7.
Close the gate.
8.
On platform control console, insert key into off/lift/
drive key switch and select “
9.
” emergency
”
WARNING
After repairs are completed, operator must perform a
pre-operation inspection and a series of function tests
again before putting aerial platform into service.
Prior to performing function tests, be sure to read
and understand Section 2.10 - Start Operation of the
operating manual.
”
3.
” lift position.
” emergency stop button. A beeping
Pull out “
sound should be audible and light should come
on.
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Function Tests
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
WARNING
If beeping sound is not audible and light
does not come on, aerial platform must
be tagged and placed out of service.
10. Select low/high throttle switch to “
position.
” low throttle
caution
Do not start the engine in the high throttle
position.
11. To start the engine:
• Test Emergency Stop
” emergency stop button.
1. Push in“
Result: Engine should shut down and
aerial platform functions should not
operate.
• Test Lift Enable
1. Pull out “
” emergency stop button.
2. Restart the engine.
• If (ANSI/CSA) dual fuel engine is cold,
depress and hold “
• If engine is not cold, depress and hold “
”
engine start pushbutton to start the engine.
” choke pushbutton (if
equipped) with engine “
to start the engine.
3. Select and hold raise/off/lower switch to
“
” start pushbutton
” raise position without pressing lift
“
” enable pushbutton.
Result: Platform should not rise.
• If diesel engine is cold, select and hold
“
” glow plug pushbutton for 15 to
20 seconds or until indicator light goes
off. Depress and hold “
” engine start
pushbutton to start the engine.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 29
Function Tests
Section 1 - Scheduled Maintenance
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
• Test Platform Raising/Lowering
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Press and hold lift “
” enable pushbutton,
then select and hold raise/off/lower
switch to “ ” raise position and raise
the platform to an approximate height of
1 ft. (30.5 cm). Release switch to stop.
Result: Platform should rise.
2. Press and hold lift “
” enable pushbutton,
then select and hold raise/off/lower switch
to “ ” lower position and lower the
platform fully. Release switch to stop.
Result: Platform should lower.
• Test Enable Trigger Switch
1. Ensure outriggers are fully retracted.
3. Select off/lift/drive key switch to “
drive position.
”
4. Without activating “ ” enable trigger
switch, attempt to drive and steer the aerial
platform.
Result: Drive and steer functions should
not operate.
• Test Steering
1. Activate and hold enable trigger switch,
and then press rocker switch on top of
controller to “
” left and “
”
right.
Result: Steer wheels should turn left and
right.
• Test Horn
” horn pushbutton.
1. Push “
Result: Horn should sound.
2. Ensure path of intended motion is clear.
SKYJACK, Page 30
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Drive/Steer Enable
Trigger Switch
Function Tests
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
• Test Brake
• Test Driving
1. Ensure path of intended motion is clear.
2. Activate and hold “
switch.
WARNING
Brake will engage instantly when
controller handle is released, causing
aerial platform to stop immediately.
”enable trigger
3. Slowly move controller fully ” forward,
and then return handle to center
position.
Result: Aerial platform should move in
forward direction, and then come to a
stop.
4. Slowly move controller fully “ ”
backward, and then return handle to center
position.
Result: Aerial platform should move in
reverse direction, and then come to a
stop.
1. Ensure path of intended motion is clear.
2. Activate and hold “
switch.
3. Drive aerial platform “ ” forward. Test
brake by releasing controller handle.
Result: Aerial platform should come to a
stop.
4. Drive aerial platform “
Mid Size & Full Size
Rough Terrain Series
” enable trigger
” forward. Test
brake again by releasing “ ” enable
trigger switch only.
Result: Aerial platform should come to an
instant and abrupt stop.
SKYJACK, Page 31
Function Tests
Section 1 - Scheduled Maintenance
Drive/Steer Enable
Trigger Switch
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Off/Lift/Drive Key
Switch
Engine Start
Pushbutton
Emergency Stop
Button
Lift Enable
Pushbutton
• Test Speed Limit
• Test Lowering Warning - CE
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Ensure path of intended motion is clear.
2. Select off/lift/drive key switch to “
position.
” lift
3. Raise the platform to an approximate
height of 13 ft. (4 m).
1. Select off/lift/drive key switch to “
position.
” lift
2. Fully lower the platform.
Result: Platform should stop lowering at
an approximate height of 2.5 meters and
an alarm should sound.
3. Release platform raise/off/lower switch,
ensure area around scissor is clear, then
continue lowering the platform.
4. Lower the platform fully.
• Test Powerdeck Enable (If Equipped)
4. Select off/lift/drive key switch to “
”
drive position and attempt to drive forward
or reverse.
Result: Aerial platform should move slower
than when it was in stowed position.
1. Select and hold extend/retract switch to
the “
SKYJACK, Page 32
“ extend position without
selecting “
” enable switch.
Result: Platform should not extend.
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Drive/Steer Enable
Trigger Switch
Function Tests
Rocker Switch
Drive/Steer
Controller
Torque Switch
Low/High Throttle
Switch
Low/High Speed Range
Switch
Operation Light
Horn
Pushbutton
Raise/Off/Lower
Switch
Glow Plug/Choke
Pushbutton
Engine Start
Pushbutton
Lift Enable
Pushbutton
• Test Extension Platform(s)
(If Equipped)
1. Extend each extension platform to about
1 ft. (30.5 cm).
Result: Each extension platform should
extend.
2. Retract each extension platform fully.
Result: Each extension platform should
fully retract.
Off/Lift/Drive Key
Switch
Emergency Stop
Button
2. Use the ladder to dismount from
platform.
3. On base control console, slowly raise the
platform.
Result: When platform reaches an
appropriate height, a warning signal
should sound and platform stop raising
as lift and drive controls should be
disabled.
• Test Tilt Sensor (If Equipped)
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
WARNING
Ensure that there are no personnel
or obstructions in the path of travel,
including blind spots.
1. Move the aerial platform on to a slope not
greater than 4.5°.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 33
Function Tests
Section 1 - Scheduled Maintenance
Base Control Console
Platform Lower/Neutral/
Raise Switch
Emergency Stop
Button
Lift Enable
Pushbutton
Emergency Lowering
Valve
• Test Lower/Neutral/Raise Switch
1.2-2 Base Control Console
1.
On engine control console, select
“
” start position to start the engine.
For ANSI/CSA & AS
1. On base control console, select and
hold “
• Test Emergency Stop
” emergency stop button.
1. Push in “
Result: Engine should shut down and
aerial platform functions should not
operate.
” emergency stop button and
2. Pull out “
restart engine.
2. Select and hold “
For ANSI/CSA & AS
1. On base control console, select and hold
” lift enable
switch and fully “
” lower the platform
with lower/neutral/raise switch.
Result: Platform should fully lower.
off/platform/base key switch to “
” to raise
position without selecting “
lift enable switch.
Result: Platform should not rise.
”
” to raise
lower/neutral/raise switch “
position without selecting off/platform/base
”
” raise the platform
base position and “
with lower/neutral/raise switch.
Result: Platform should rise.
2. Select and hold off/platform/base key
switch to “
For CE
1. On base control console, select and hold
” raise the platform with lower/neutral/
“
raise switch.
Result: Platform should rise.
For CE
1. On base control console, select and hold
• Test Base Lift Enable
lower/neutral/raise switch “
” lift enable switch and
” base position and fully
“
” lower the platform with lower/
neutral/raise switch.
Result: Platform should fully lower.
key switch to “
” base position.
Result: Platform should not rise.
SKYJACK, Page 34
Mid Size & Full Size
Rough Terrain Series
Section 1 - Scheduled Maintenance
Function Tests
Base Control Console
Platform Lower/Neutral/
Raise Switch
Emergency Stop
Button
Lift Enable
Pushbutton
Emergency Lowering
Valve
• Test Emergency Lowering
(Models 71xx, 8831/41 & 9241)
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Raise the platform to an approximate
height of 13 ft. (4 m).
2. Locate holding valve manual override
knob at the base of each lift cylinder.
Depress and turn counterclockwise.
If necessary, use emergency lowering
access rod that is located on the base of
the aerial platform.
3. On hydraulic/electrical compartment, pull
out and hold emergency lowering valve to
fully lower the platform.
Result: The platform should fully lower.
Mid Size & Full Size
Rough Terrain Series
4. To restore normal operation, depress and
turn holding valve manual override knobs
clockwise.
• Test Emergency Lowering
(Model 8243, 8850 & 9250)
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
1. Raise the platform to an approximate
height of 13 ft. (4 m).
2. In hydraulic/electrical compartment,
depress and hold emergency lowering
pushbutton to activate the auxiliary
lowering valves. Pull out and hold the
emergency lowering valve to fully lower
platform.
Result: The platform should fully lower.
SKYJACK, Page 35
Function Tests
Section 1 - Scheduled Maintenance
Base Control Console
Platform Lower/Neutral/
Raise Switch
Emergency Stop
Button
Off/Platform/Base
Key Switch
Emergency Lowering
Valve
• Test Emergency Powered
Extension Platform Retraction
Switch (Models 8850 & CE - 9250)
1. Extend both powered extension platforms
to about 0.5 meter.
1.2-4 Test Main Power Disconnect Switch
1.
On hydraulic/electrical compartment, turn main
power disconnect switch to “ ” off position.
Result: Engine should shut down and aerial
platform functions should not operate.
” emergency stop button to
2. Push in “
shut down the engine.
3. Pull out “
” emergency stop button.
WARNING
Ensure that you maintain three points
of contact when using the ladder to
mount/dismount platform.
4. Use the ladder to dismount from
platform.
5. On hydraulic/electric tray, push the
emergency powered extension platform
retraction switch.
Result: Extension platforms should
retract.
SKYJACK, Page 36
Mid Size & Full Size
Rough Terrain Series
Section 2
maintenance tables and diagrams
Table of Contents
Tables
2.1a Specifications and Features - ANSI/CSA...........................................................................................................2
2.1b Specifications and Features - CE.......................................................................................................................3
2.1c Specifications and Features - AS.......................................................................................................................4
2.2a Maximum Platform Capacities(Evenly Distributed) - ANSI/CSA........................................................................6
2.2b Maximum Platform Capacities(Evenly Distributed w/ Optional #7 Tires) - ANSI/CSA....................................7
2.2c Maximum Platform Capacities(Evenly Distributed) - CE...................................................................................8
2.2d Maximum Platform Capacities(Evenly Distributed) - AS....................................................................................9
2.3a Tire Specifications - ANSI/CSA........................................................................................................................10
2.3b Tire Specifications - CE....................................................................................................................................11
2.3c Tire Specifications - AS....................................................................................................................................12
2.4a Floor Loading Pressure - ANSI/CSA................................................................................................................15
2.4b Floor Loading Pressure - CE............................................................................................................................16
2.4c Floor Loading Pressure - AS............................................................................................................................17
2.5 Rough Terrain Scissor Fluids...........................................................................................................................18
2.6 Torque Specifications.......................................................................................................................................20
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 1
2
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.1a Specifications and Features - ANSI/CSA
Mid Size RTs
MODEL
Weight*
7127
7135
8243
8850
8831
8841
9250
8,420 lb.
8,850 lb.
10,600 lb.
11,460 lb.
9,670 lb.
10,570 lb.
14,700 lb.
3819 kg
4014 kg
4808 kg
5198 kg
4386 kg
4794 kg
6668 kg
Width
Length
Platform Size
Height
Working
Platform Elevated
Platform Lowered
Full Size RTs
71.5”
87”
92”
1.82 m
2.21 m
2.34 m
150”
137.5”
176”
3.81 m
3.5 m
4.47 m
64” x 117”
68” x 133”
74” x 168”
1.63 m x 2.97 m
1.73 m x 3.39 m
1.88 m x 4.27 m
33’
41’
49’
56’
37’
47’
56’
10.1 m
12.5 m
14.9 m
17.1 m
11.3 m
14.3 m
17.1 m
27’
35’
43’
50’
31’
41’
50’
8.2 m
10.7 m
13.1 m
15.2 m
9.4 m
12.5 m
15.2 m
60.5”
67.5”
75”
82”
59”
69”
79”
1.54 m
1.71 m
1.91 m
2.08 m
1.5 m
1.75 m
2.01 m
Drive
Tires
Speed
7.9 m
Please refer to Table 2-7 for tire specification and usage.
Normal Drive
Engine
(RPM)
26’
Full
Elevated Drive
3.5 mph
3.0 mph
2.0 mph
5.6 km/h
4.8 km/h
3.2 km/h
0.35 mph
0.6 mph
0.56 km/h
0.97 km/h
Raise (Rated Load)
43 sec.
41 sec.
45 sec.
46 sec.
58 sec.
56 sec.
67 sec.
Lower (Rated Load)
46 sec.
44 sec.
58 sec.
52 sec.
44 sec.
53 sec.
72 sec.
Kubota (Dual Fuel)
2050 (Low) / 3500 (High)
GM (Dual Fuel)
Gradeability
N/A
1400 (Low) / 2800 (High)
Kubota (Diesel)
N/A
1400 (Low) / 2800 (High)
900 (Idle) /1400 (Low) / 2800 (High)
30%
30%
25%
60348AG-ANSI-R
*
Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 4WD machines on air tires (except for
Model 8850) with a manual extension platform (Mid Size RTs) and no extension platforms (Full Size RTs).
SKYJACK, Page 2
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.1b Specifications and Features - CE
Model
Height
Weight*
Mid Size RTs
7127
7135
8831
8841
9241
9250
3724 kg
4392 kg
4554 kg
4962 kg
6718 kg
7407 kg
Width
1.82 m
2.21 m
2.34 m
Length
3.81 m
3.5 m
4.55 m
Platform Size
1.63 m x 2.97 m
1.73 m x 3.39 m
1.85 m x 4.39 m
Working
10.2 m
12.7 m
11.4 m
14.5 m
14.5 m
17.2 m
Platform Elevated
8.2 m
10.7 m
9.4 m
12.5 m
12.5 m
15.2 m
Platform Lowered
1.54 m
1.73 m
1.50 m
1.75 m
1.68 m
2m
Full
7.9 m
Full
Drive
7.9 m
Speed
Tires
Engine
(RPM)
Full Size RTs
Refer to Table 2.6 for tire specification and usage.
Normal Drive
5.6 km/h
4.8 km/h
3.8 km/h
Elevated Drive
0.56 km/h
0.97 km/h
0.72 km/h
Raise (Rated Load)
31 sec.
38 sec.
58 sec.
56 sec.
62 sec.
64 sec.
Lower (Rated Load)
46 sec.
43 sec.
44 sec.
53 sec.
59 sec.
86 sec.
Kubota (Diesel)
Gradeability
1400 (Low) / 2800 (High)
1400 (Low) / 2800 (High)
30%
30%
25%
25%
60348AI-CE-R
*
Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 4WD aerial
platforms on air tires with a manual extension platform (Models 7127 & 7135) and no extension platforms (Models
8831 & 8841). For models 9241 & 9250, values shown are for standard 4WD on foam tires with two powered
extension platforms.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 3
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.1c Specifications and Features - AS
Model
Height
Weight*
7127
7135
8243
8850
8831
8841
9250
4046 kg
4241 kg
4917 kg
5588 kg
4636 kg
5044 kg
6895 kg
2.08 m
2.31 m
Width
1.82 m
Length
3.81 m
Platform Size
1.63 x 2.97 m
2.34 m
3.58 m
3.5 m
4.47 m
1.64 x 2.93 m
1.73 x 3.39 m
1.88 x 4.27 m
10.1 m
12.5 m
15.1 m
17.2 m
11.28 m
14.3 m
17.1 m
Platform Elevated
8.2 m
10.7 m
13.1 m
15.2 m
9.4 m
12.5 m
15.2 m
Platform Lowered
1.54 m
1.73 m
1.9 m
2.08 m
1.50 m
1.75 m
2.01 m
Full
Full
Tires
Speed
2.21 m
Working
Drive
Engine
(RPM)
Full Size RTs
Mid Size RTs
Full
7.9 m
Refer to Table 2.6 for tire specification and usage.
Normal Drive
4.8 km/h
4.8 km/h
5.6 km/h
5.6 km/h
3.2 km/h
Elevated Drive
0.58 km/h
0.45 km/h
0.8 km/h
0.8 km/h
0.8 km/h
Raise (Rated Load)
31 sec.
38 sec.
48 sec.
47 sec.
58 sec.
56 sec.
67 sec.
Lower (Rated Load)
46 sec.
43 sec.
52 sec.
61 sec.
44 sec.
53 sec.
72 sec.
1400 (Low) / 2800 (High)
Kubota (Diesel)
Gradeability
30%
30%
25%
60348AI-AS
*
Weights are approximate; refer to serial nameplate for specific weight. Values shown are for standard 2WD aerial platforms on foam-filled tires with a
manual extension platform (Mid Size RTs) and no extension platforms (Full Size RTs).
SKYJACK, Page 4
Mid Size & Full Size
Rough Terrain Series
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.2a Maximum Platform Capacities
(Evenly Distributed) - ANSI/CSA
Total
9250
8841
8831
8850 8243 7135 7127
MODEL
Capacity
One Extension
Platform
1500 lb.
One Extension
Platform
1000 lb.
One Extension
Platform
1000 lb.
681 kg
454 kg
454 kg
800 lb.
One Extension
Platform
363 kg
No Extension
Platform
1134 kg
2500 lb.
One Extension
Platform
2000 lb.
Two Extension
Platforms
1700 lb.
No Extension
Platform
1700 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
No Extension
Platform
2000 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
908 kg
771 kg
771 kg
681 kg
681 kg
907 kg
681 kg
681 kg
First Extension
Number of
Occupants
5
4
3
3
Capacity
500 lb.
227 kg
350 lb.
159 kg
350 lb.
159 kg
300 lb.
136 kg
Number of
Occupants
6
5
1
Not Available
1
Not Available
1
Not Available
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
5
Not Available
500 lb.
2
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
5
5
Number of
Occupants
Not Available
5
5
Capacity
2
6
6
Second Extension
Not Available
500 lb.
2
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
Not Available
500 lb.
227 kg
2
60376AE-ANSI-R
NOTE:
Occupants and materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
SKYJACK, Page 6
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.2b Maximum Platform Capacities
(Evenly Distributed w/ Optional #7 Tires) - ANSI/CSA
Total
9250
8841
8831
7135 7127
MODEL
One Extension
Platform
One Extension
Platform
Capacity
1500 lb.
681 kg
900 lb.
408 kg
No Extension
Platform
2000 lb.
One Extension
Platform
1700 lb.
Two Extension
Platforms
1400 lb.
No Extension
Platform
1250 lb.
One Extension
Platform
1250 lb.
Two Extension
Platforms
1250 lb.
No Extension
Platform
1500 lb.
One Extension
Platform
1500 lb.
Two Extension
Platforms
1500 lb.
908 kg
771 kg
635 kg
567 kg
567 kg
567 kg
681 kg
681 kg
681 kg
First Extension
Number of
Occupants
5
3
Capacity
500 lb.
227 kg
300 lb.
136 kg
Number of
Occupants
5
5
1
Not Available
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
5
Not Available
500 lb.
2
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
5
5
Number of
Occupants
Not Available
5
5
Capacity
2
6
6
Second Extension
Not Available
500 lb.
2
227 kg
Not Available
500 lb.
227 kg
500 lb.
227 kg
2
2
Not Available
500 lb.
227 kg
2
60376AE-ANSI-R
NOTE:
Occupants and materials are not to exceed rated load.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 7
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.2c Maximum Platform Capacities
(Evenly Distributed) - CE
Total
9250 9241
8841
8831
7135 7127
MODEL
First Extension
Second Extension
Capacity
Number of
Occupants
Capacity
Number of
Occupants
One Extension Platform
681 kg
5
227 kg
2
Not Available
One Extension Platform
454 kg
4
159 kg
1
Not Available
No Extension Platform
1134 kg
6
One Extension Platform
908 kg
6
227 kg
2
Two Extension Platform
771 kg
6
227 kg
2
No Extension Platform
771 kg
5
One Extension Platform
681 kg
5
227 kg
2
Two Extension Platform
681 kg
5
227 kg
2
227 kg
2
Two Extension Platform
681 kg
5
227 kg
2
227 kg
2
Two Extension Platform
681 kg
5
227 kg
2
227 kg
2
Capacity
Number of
Occupants
Not Available
Not Available
227 kg
2
Not Available
Not Available
60376AF-CE-R
NOTE:
Occupants and materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires except for models 9250 and 9241 which are
equipped with foam-filled tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
Wind Speed
BEAUFORT
SCALE
m/s
km/h
ft/s
mph
3
3.4 – 5.4
12.5 – 19.4
11.5 – 17.75
5 – 12.0
Papers and thin branches move, flags wave
4
5.4 – 8.0
19.4 – 28.8
17.75 – 26.25
12.0 – 18
Dust is raised, paper whirls up, and small
branches sway.
5
8.0 – 10.8
28.8 – 38.9
26.25 – 35.5
18 – 24.25
Shrubs with leaves start swaying. Wave crests are
apparent in ponds or swamps.
6
10.8 – 13.9
38.9 – 50.0
35.5 – 45.5
24.5 – 31
Tree branches move. Power lines whistle. It is
difficult to open an umbrella.
7
13.9 – 17.2
50.0 – 61.9
45.5 – 65.5
31 – 38.5
Whole trees sway. It is difficult to walk against the
wind.
Ground Conditions
60338AC
SKYJACK, Page 8
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.2d Maximum Platform Capacities
(Evenly Distributed) - AS
Total
MODEL
First Extension
Second Extension
Capacity
Number of
Occupants
Capacity
Number of
Occupants
Capacity
Number of
Occupants
7127
One Extension
Platform
681 kg
5
227 kg
2
Not Available
7135
One Extension
Platform
454 kg
4
159 kg
1
Not Available
8243
One Extension
Platform
454 kg
3
159 kg
1
Not Available
8850
One Extension
Platform
363 kg
3
136 kg
1
Not Available
No Extension
Platform
1134 kg
6
One Extension
Platform
908 kg
6
227 kg
2
Two Extension
Platforms
681 kg
6
227 kg
2
No Extension
Platform
771 kg
5
One Extension
Platform
681 kg
5
227 kg
2
Two Extension
Platforms
681 kg
5
227 kg
2
No Extension
Platform
908 kg
5
One Extension
Platform
681 kg
5
227 kg
2
Two Extension
Platforms
681 kg
5
227 kg
2
8831
8841
9250
Not Available
Not Available
227 kg
2
Not Available
Not Available
227 kg
2
Not Available
Not Available
227 kg
2
60376AE-AS
NOTE:
Occupants AND materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires except for model 9250A which is equipped with foam filled
tires.
Refer to capacity label at sides of platform for additional information and for models equipped with options.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 9
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.3a Tire Specifications - ANSI/CSA
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
Fill Specification
#6F
#6F
#7F
8841
9250
10
8
Foam
8831
Air
S
S
S
N/A
S
S
S
O
O
O
N/A
O
O
O
O
O
O
N/A
O
O
O
75*
(517.1)*
75*
(517.1)*
45*
(310.3)*
10
FULL SIZE
8850
#7A
Pressure (Factory)
(kPa)
8243
#6A
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
31-15.5-15
GOODYEAR TERRA XTRAC
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
31-15.5-15
GOODYEAR TERRA XTRAC
Ply
Rating
7135
#6A
Fill
Type
7127
Tire Size
Usage†
MID SIZE
10
N/A
O
O
O
S
O
O
O
10
N/A
O
O
O
O
O
O
O
8
N/A
O
O
O
O
O
O
O
60378AE-ANSI-R
*
Factory preset @ 20°C, Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal
conditions.
†
Usage: (S)tandard Or (O)ptional
(N/A) Not Available
Backspace
Rim Backspace Diagram
Inboard
A
Outboard
SECTION A-A
Rim Size
Serial Number
#6 & #6F
#7 & #7F
A
Backspace
7127
Contact Skyjack Service
Department
7135
8831
8841
8243
8850
9250
3-3/4”
3-3/4”
4-3/4”
4-3/4”
3-3/4”
3-3/4”
3-3/4”
95 mm
95 mm
121mm
121mm
95 mm
95 mm
95 mm
All models are 4-3/8”
60380AC-ANSI
SKYJACK, Page 10
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.3b Tire Specifications - CE
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
†
Fill Specification
Tire Size
#6A
#6A
#7A
#6F
#6F
#7F
Fill
Type
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
31-15.5-15
GOODYEAR TERRA XTRAC
10-16.5
CARLISLE US LOADER
10-16.5 OTR OUTRIGGER
(Non-Marking)
31-15.5-15
GOODYEAR TERRA XTRAC
Usage
MID SIZE
FULL SIZE
Ply
Rating
Pressure (Factory)
(kPa)
7127
7135
8831
8841
9241
9250
10
517.1*
S
S
S
S
N/A
N/A
10
517.1*
O
O
O
O
N/A
N/A
8
310.3*
N/A
N/A
N/A
N/A
N/A
N/A
10
N/A
O
O
O
O
S
S
10
N/A
O
O
O
O
N/A
N/A
8
N/A
O
O
O
O
N/A
N/A
Air
Foam
60378AF-CE-R
*
†
Factory preset @ 20°C. Check pressures regularly as tires can lose pressure over time and over different ambient
temperatures even under normal conditions.
Usage: (S)tandard Or (O)ptional
(N/A) Not Available
Backspace
Rim Backspace Diagram
A
Inboard
Outboard
SECTION A-A
Rim Size
#6 & #6F
#7 & #7F
A
Backspace
7127
7135
8831
8841
9241
9250
95 mm
95 mm
121 mm
121 mm
95 mm
95 mm
All models are 135 mm
N/A
60380AE-CE-R
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 11
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.3c Tire Specifications - AS
WARNING
Air pressure can affect stability. Temperature changes can affect air pressure. It is important to
visually inspect all tires for proper tire inflation prior to use. Tires should be checked by end user
on a daily basis. Tire inflation pressures must be checked weekly with a calibrated gauge. If the
measured pressure is less than the specification, reinflate to the pressure specified below. Tires
must not be inflated above the recommended specification. Do not intermix tires of different types
on one aerial platform. Use only tires of type originally supplied.
Fill Specification
Tire Size
#6A
Fill Type
10-16.5
CARLISLE US LOADER
#6A
10-16.5 OTR OUTRIGGER
(Non-Marking)
#6F
10-16.5
CARLISLE US LOADER
Ply Rating
Pressure
(Factory)
MID SIZE
FULL SIZE
Psi (kPa)
7127
7135
8243
8850
8831
8841
9250
10
75*
(517.1)*
O
O
O
O
O
O
O
10
75*
(517.1)*
O
O
O
O
O
O
O
10
N/A
S
S
S
S
S
S
Air
Foam
Usage†
S
60378AE-AS
•
Factory preset @ 20°C, Check pressures regularly as tires can lose pressure over time and over different
ambient temperatures even under normal conditions.
†
Usage: (S)tandard Or (O)ptional
(N/A) Not Available
Backspace
Rim Backspace Diagram
Inboard
A
Outboard
SECTION A-A
Backspace
Rim Size
Serial Number
A
7127
Contact Skyjack Service
Department
#6A & #6F
7135
8243
8850
8831
8841
9250
121mm
95 mm
95 mm
95 mm
95 mm
121mm
121mm
95 mm
4.75 in.
3.75 in.
3.75 in.
3.75 in.
3.75 in.
4.75 in.
4.75 in.
3.75 in.
60380AE-AS
SKYJACK, Page 12
Mid Size & Full Size
Rough Terrain Series
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Floor Loading Pressure
Locally Concentrated Pressure (LCP):
Overall Uniform Pressure (OUP):
Foot Print Area = Length x Width
= πr2
Base Area = Length x Width
LCP =
Weight of Aerial Platform + Capacity
Foot Print Area x 4 (Tires)
OUP =
Weight of Aerial Platform + Capacity
Base Area
Length
Width
Width
Length
Width
Diameter
Length
WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.
SKYJACK, Page 14
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.4a Floor Loading Pressure - ANSI/CSA
MODEL
7127
7127
Outrigger Pads
7135
7135
Outrigger Pads
8243
8243
Outrigger Pads
8850
8850
Outrigger Pads
8831
8831
Outrigger Pads
8841
8841
Outrigger Pads
9250
9250
Outrigger Pads
Total Aerial Platform Load
Total Aerial Platform
Weight
WHEEL
LCP **
OUP **
kg/m2
lb.
kg
lb.
kg
psi
kPa
psf
min*
7920
3592
3168
1437
101.7
701.2
150.0
732.4
max*
12180
5525
4872
2210
121.1
835.0
230.7
1126.4
min*
9360
4246
3744
1698
47.7
328.8
155.5
759.2
max*
12180
5525
4872
2210
62.1
427.9
202.3
987.9
min*
8850
4014
3540
1606
106.8
736.4
167.6
818.4
max*
11980
5434
4792
2174
120.4
830.1
226.9
1107.9
min*
9790
4441
3916
1776
49.9
343.9
162.6
794.1
max*
12110
5493
4844
2197
61.7
425.5
201.2
982.2
min*
10600
4808
4240
1923
115.0
792.9
169.9
829.5
max*
11980
5434
4792
2174
120.4
830.1
192.0
937.4
min*
10600
4808
4240
1923
54.0
372.4
176.1
859.8
max*
12920
5860
5168
2344
65.8
453.9
214.6
1047.9
min*
11460
5198
4584
2079
118.4
816.3
167.8
819.3
max*
12530
5684
5012
2273
122.3
843.2
183.5
895.8
min*
11460
5198
4584
2079
58.4
402.6
196.2
958.2
max*
12530
5684
5012
2273
63.8
440.2
214.6
1047.6
min*
9670
4386
3868
1754
110.9
764.6
148.8
726.4
max*
13350
6055
5340
2422
125.0
861.8
205.4
1002.9
min*
10540
4781
4216
1912
53.7
370.3
157.1
767.0
max*
14300
6486
5720
2594
72.9
502.4
213.1
1040.6
min*
10570
4794
4228
1918
114.9
792.2
162.6
794.0
max*
13830
6273
5532
2509
126.4
871.5
212.8
1038.9
min*
11440
5189
4576
2076
58.3
401.9
170.5
832.5
max*
14820
6722
5928
2689
75.5
520.7
220.9
1078.4
min*
14700
6668
5880
2667
128.9
888.7
179.5
876.4
max*
17470
7924
6988
3170
135.6
934.9
213.3
1041.5
min*
14700
6668
5880
2667
74.9
516.4
145.5
710.7
max*
18410
8351
7364
3340
93.8
646.8
182.3
890.0
60379AE-ANSI-R
*
**
min - Total aerial platform weight with no options
max - Aerial platform weight + all options + capacity
LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct
contact with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values
above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface
directly underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the
indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined
by the engineer or architect for that particular structure.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 15
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.4b Floor Loading Pressure - CE
Total Aerial
Platform
Weight
WHEEL
LCP **
OUP **
kg
kg
kPa
kg/m2
min*
3592
1437
701
732
max*
5525
2210
835
1126
min*
4246
1698
329
759
max*
5525
2210
428
988
min*
4014
1606
736
818
max*
5434
2174
830
1108
min*
4441
1776
344
794
max*
5493
2197
426
982
min*
4386
1754
765
726
max*
6055
2422
862
1003
min*
4781
1912
370
767
max*
6486
2594
502
1041
min*
4794
1918
792
794
max*
6273
2509
872
1039
min*
5189
2076
402
833
max*
6722
2689
521
1078
min*
6718
2687
1408
887
max*
7448
2979
1495
893
min*
6718
2687
520
700
max*
7448
2979
577
705
min*
7407
2963
1490
969
max*
8137
3255
1576
975
min*
7407
2963
573
765
max*
8137
3255
630
770
MODEL
7127
7127
Outrigger Pads
7135
7135
Outrigger Pads
8831
8831
Outrigger Pads
8841
8841
Outrigger Pads
9241
9241
Outrigger Pads
9250
9250
Outrigger Pads
Total Aerial Platform Load
60379AF-CE-R
*
**
min - Total aerial platform weight with no options
max - Aerial platform weight + all options + capacity
LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform
presses on the areas in direct contact with the floor. The floor covering (tile, carpet, etc.)
must be able to withstand more that the indicated values above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform
imparts on the whole surface directly underneath it. The structure of the operating surface
(beams, etc.) must be able to withstand more than the indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure
and is generally determined by the engineer or architect for that particular structure.
SKYJACK, Page 16
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.4c Floor Loading Pressure - AS
MODEL
7127
7127
Outrigger Pads
7135
7135
Outrigger Pads
8243
8243
Outrigger Pads
8850
8850
Outrigger Pads
8831
8831
Outrigger Pads
8841
8841
Outrigger Pads
9250
9250
Outrigger Pads
min*
Total Aerial Platform Load
Total Aerial Platform
Weight
WHEEL
LCP **
OUP **
kg
kg
kPa
kg/m2
3592
1437
701.2
732.4
max*
5525
2210
835.0
1126.4
min*
4246
1698
328.8
759.2
max*
5525
2210
427.9
987.9
min*
4014
1606
736.4
818.4
max*
5434
2174
830.1
1107.9
min*
4441
1776
343.9
794.1
max*
5493
2197
425.5
982.2
min*
4808
1923
792.9
829.5
max*
5434
2174
830.1
937.4
min*
4808
1923
372.4
859.8
max*
5860
2344
453.9
1047.9
min*
5198
2079
816.3
819.3
max*
5684
2273
843.2
895.8
min*
5198
2079
402.6
958.2
max*
5684
2273
440.2
1047.6
min*
4386
1754
764.6
726.4
max*
6055
2422
861.8
1002.9
min*
4781
1912
370.3
767.0
max*
6486
2595
502.4
1040.6
min*
4794
1918
792.2
794.0
max*
6273
2509
871.5
1038.9
min*
5189
2076
401.9
832.5
max*
6722
2689
520.7
1078.4
min*
6668
2667
888.7
876.4
max*
7924
3170
934.9
1041.5
min*
6668
2667
516.4
710.7
max*
8351
3340
646.8
890.0
60379AE-AS
*
**
min - Total aerial platform weight with no options (with air-filled tires)
max - Aerial platform weight + all options
LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform
presses on the areas in direct contact with the floor. The floor covering (tile, carpet, etc.)
must be able to withstand more that the indicated values above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform
imparts on the whole surface directly underneath it. The structure of the operating surface
(beams, etc.) must be able to withstand more than the indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure
and is generally determined by the engineer or architect for that particular structure.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 17
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.5 Rough Terrain Scissor Fluids
AXLE OIL
Axle Type
Cushman
Front
Dana
Front / Rear
Cushman
*Qty.
(Liters)
*Qty.
(Gallons)
Oil Type
Recommended Equivalent Oil
2.4
0.634
Gear Oil, 80W-90 GL5
-
Gear Oil, ESI 80W-90
Chevron Gear Lubricant Delo ESI 80W-90,
Caltex Gear Lubricant ESI 80W-90,
Caltex RPM Borate EP 80W-90,
Texaco Star Gear Lubricant 80W-90
Rear
1
0.264
*All fuel capacity quantities are in standard liter or US gallons (liquid).
**Use distilled water and 50/50 mix of anti-freeze/water.
Center Drive Type
Center Drive
*Qty.
(Liters)
1
CENTER DRIVE OIL
*Qty.
Oil Type
(Gallons)
0.26
Gear Oil, 80W-90 GL5
Recommended Equivalent Oil
-
*All fuel capacity quantities are in standard liter or US gallons (liquid).
**Use distilled water and 50/50 mix of anti-freeze/water.
HYDRAULIC OIL
Model
*Qty.
(Liters)
*Qty.
(Gallons)
SJRT-68XX
86.88
22.95
80.48
21.26
Oil Type
SJRT-7127
SJRT-7135
SJRT-8243
SJRT-8850
SJRT-8831
SJRT-8841
SJRT-8831E
ATF Dexron III
75.71
20
67.38
17.8
SJRT-8841E
SJRT-9241
SJRT-9250
*All fuel capacity quantities are in standard liter or US gallons (liquid).
**Use distilled water and 50/50 mix of anti-freeze/water.
SKYJACK, Page 18
Mid Size & Full Size
Rough Terrain Series
Section 2 - Maintenance Tables and Diagrams
Service and Maintenance
Table 2.5 Rough Terrain Scissor Fluids (Continued)
ENGINE OIL
Engine Type
*Qty.
(Liters)
*Qty.
(Gallons)
Kubota D902
3.9
1.03
Kubota D1105
5.1
1.35
Kubota DF972
3.4
0.9
3.5
0.98
Nissan A15
GM 1.6
Oil Type, Viscosity
Engine Oil, SAE 10W-30
Recommended Equivalent Oil
(Viscosity - API Service Designation)
10W30 - API Service Designation CG-4,
CF-4, CF, CD, SH.
10W30 - API Service Designation SF/CC.
*All fuel capacity quantities are in standard liter or US gallons (liquid).
**Use distilled water and 50/50 mix of anti-freeze/water.
Component Type
*Qty.
(Liters)
ENGINE COOLANT
*Qty.
(Gallons)
3.1
0.82
11.4
3.01
**Coolant Type
Kubota D902
Kubota D1105
Anti-freeze / Water
Kubota DF972
Nissan A15
GM 1.6
Extended life anti-freeze / Water
*All fuel capacity quantities are in standard liter or US gallons (liquid).
**Use distilled water and 50/50 mix of anti-freeze/water.
ENGINE FUEL
Tank
Diesel
Gasoline / Liquid Propane
Model
*Qty.
(Liters)
*Qty.
(Gallons)
Kubota D902
Kubtoa D1105
SJRT-68xx
86.88
22.95
3
N/A
SJRT-7127
SJRT-7135
SJRT-8243
80.48
21.26
49.21
13
64.35
17
SJRT-8850
SJRT-8831
SJRT-8841
SJRT-9241
SJRT-9250
N/A
Kubota DF972
GM 1.6
Nissan A15
3
N/A
N/A
3
3
*All fuel capacity quantities are in standard liter or US gallons (liquid).
**Use distilled water and 50/50 mix of anti-freeze/water.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 19
Service and Maintenance
Section 2 - Maintenance Tables and Diagrams
Table 2.6 Torque Specifications
Directional valve mounting bolts
Wheel mounting bolts
Center drive sprocket mounting bolts
Hydraulic drive motor mounting bolts
Positive battery post cable/fuse nut
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
08
28-32 lbf.in
135-145 lbf.ft
110-115 lbf.ft (242 LOCTITE)
120 lbf.ft (242 LOCTITE)
90 lb-in
Cartridge
Size
58
38
20
240
27.12
10
25
300
33.90
3.16 - 3.61 Nm
183 – 196 Nm
149 – 156 Nm
162 Nm
10.2 Nm
12
35
420
47.46
16
50
600
67.80
Coils
Size
All coils
4 to 5
48 to 60
5.42 to 6.78
SAE Plugs
Torque
Lbf.ft (max)
Lbf.in (max)
Nm (max)
Torque
2
Lbf.ft (max)
3
Lbf.in (max)
36
Nm (max)
4.07
Newton-meter = Nm
4
10
120
13.56
5
6
Size
15
180
20.34
Pound-force foot = lbf.ft
8
10
12
16
25
30
35
300
360
420
33.90
40.68
47.46
Pound-force inch = lbf.in
60022AC
SKYJACK, Page 20
Mid Size & Full Size
Rough Terrain Series
Section 3
System component identification and schematics
Table of Contents
Charts
3.1 3.2 Hydraulic Symbol Chart............................................................................................................................ 3
Electrical Symbol Chart............................................................................................................................ 4
Parts List
3.3 3.4 Hydraulic Component Parts List............................................................................................................... 5
Electrical Component Parts List .............................................................................................................. 8
Diagrams and Schematics
3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35 3.36 Platform Control Console Wiring - All Options (ANSI/CSA)................................................................... 15
Platform Control Console Wiring - All Options (CE)............................................................................. 16
Control Cable Assemblies Diagram....................................................................................................... 17
Outrigger & Hydraulic Generator Control Console Wiring.................................................................... 18
Base Control Console Wiring (ANSI/CSA)............................................................................................. 19
Base Control Console Wiring (CE)......................................................................................................... 20
Hydraulic Schematic (Cushman Axles) (Model 9241)........................................................................... 21
Hydraulic Schematic (Cushman Axles) (Model 9250)........................................................................... 22
Hydraulic Schematic (Dana Axles)......................................................................................................... 23
Hydraulic Manifold Components & Port Identifications......................................................................... 24
Main Manifold Wiring Diagram............................................................................................................... 25
Oil Cooler - Electrical Panel Diagram (ANSI/CSA Dual Fuel Engine).................................................... 26
Hydraulic Generator - Electrical Panel Diagram (ANSI/CSA Dual Fuel Engine)................................... 27
Hydraulic Generator - Electrical Panel Diagram (ANSI/CSA Diesel Engine) ........................................ 28
Hydraulic Generator - Electrical Panel Diagram (CE)............................................................................ 29
Emergency Lowering System - Wiring Diagram (ANSI/CSA) (Model 9250)......................................... 30
Emergency Lowering System - Wiring Diagram (CE) (Model 9250)..................................................... 31
Emergency Lowering System - Electrical Wiring Diagram (CE) (Model 9241)..................................... 32
AutoLeveling Outrigger Connection Diagram........................................................................................ 33
Powered Extension Platform - Electrical Wiring Diagram (Model 9250)................................................ 34
Horn, Light & Beeper Wiring Diagram (ANSI/CSA) (Model 9250)......................................................... 35
Horn, Light, Beeper & Load Sensing Wiring Diagram........................................................................... 36
Electrical Inverter Wiring Diagram.......................................................................................................... 37
Engine Wiring Diagram - Kubota Diesel Engine.................................................................................... 39
Engine Harnesses - GM Dual Fuel Engine . ......................................................................................... 40
Electrical Panel Diagram - ANSI/CSA (All Option)................................................................................. 41
Electrical Panel Diagram - CE (All Option)............................................................................................ 42
Electrical Schematic - ANSI/CSA & AS (All Option with Kubota Diesel Engine) .................................. 43
Electrical Schematic - CE (All Option with Kubota Diesel Engine)........................................................ 44
Electrical Schematic - ANSI/CSA & AS (All Options with GM Dual Fuel Engine)................................. 45
Electrical Schematic - ANSI/CSA & AS (No Options with GM Dual Fuel Engine)................................ 46
Interface & Engine Electrical Schematic - GM Dual Fuel Engine ........................................................ 47
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 1
3
3.1 Hydraulic Symbol Chart
LINE CROSSING
VARIABLE
DISPLACEMENT
PUMP
SHUTTLE VALV
VELOCITY FUSE
LINE JOINED
HAND PUMP
ACCUMULATOR,
GAS CHARGED
SINGLE ACTING
CYLINDER
HYDRAULIC
TANK
RELIEF VALVE
CUSHION
CYLINDER
DOUBLE ACTING
CYLINDER
HYDRAULIC
FILTER WITH
BYPASS
PRESSURE
REDUCING
VALVE
PRESSURE
SWITCH
ELECTRIC
MOTOR
FIXED ORIFICE
MOTION
CONTROL VALVE
SPRING APPLIED
HYDRAULIC
RELEASED
BRAKE
ENGINE
ADJUSTABLE
FLOW CONTROL
FLOW DIVIDER
COMBINER
BRAKE
CYLINDER
FIXED
DISPLACEMENT
PUMP
CHECK VALVE
COUNTER
BALANCE VALVE
ROTARY
ACTUATOR
THREE POSITION
FOUR WAY
PROPORTIONAL
OIL COOLER
SERIES
PARALLEL
HYDRAULIC
MOTOR
TWO POSITION
TWO WAY
NORMALLY
CLOSED
TWO POSITION
TWO WAY
NORMALLY
OPEN
TWO POSITION
THREE WAY
PRESSURE
TRANSDUCER
MAIN LINES S
SERVO
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
VALVE COIL
TWO POSITION
THREE WAY
THREE POSITION
FOUR WAY
CLOSED CENTER
CLOSED PORT
PILOT LINES D
DOUBLE ACTING
DOUBLE
RODDED
BI DIRECTIONAL
HYDRAULIC
MOTOR
THREE POSITION
FOUR WAY
CLOSED CENTER
OPEN PORT
THREE POSITION
FOUR WAY
PROPORTIONAL
VARIABLE
DISPLACEMENT
HYDRAULIC MOTOR
UICK
DISCONNECT
SKYJACK, Page 3
3.2 Electrical Symbol Chart
ANGLE
TRANSDUCER
WIRE CROSSING
HOURMETER
KEY SWITCH
WIRES JOINED
LIGHT
FOOT SWITCH
PRESSURE
TRANSDUCER
BATTERY
HYDRAULIC
VALVE COIL
TOGGLE SWITCH
LIMIT SWITCH
N.O.
GROUND
PROPORTIONAL
HYDRAULIC
VALVE COIL
PUSH BUTTON
LIMIT SWITCH
N.O. HELD
CLOSED
FUSE
ELECTRIC
MOTOR
ROTARY SWITCH
LIMIT SWITCH
N.C.
CIRCUIT
BREAKER
HORN
LIMIT SWITCH
LIMIT SWITCH
N.C. HELD OPEN
BATTERY
CHARGE
INDICATOR
EMERGENCY
STOP BUTTON
CAM OPERATED
LIMIT SWITCH
SILICON
CONTROLLED
RECTIFIER
CAPACITOR
RESISTOR
TILT SWITCH
PROXIMITY
SWITCH
POTENTIOMETER
LEVEL SENSOR
SINGLE POLE
SINGLE THROWN
RELAY
PNP
TRANSISTOR
SINGLE POLE
DOUBLE THROW
RELAY
DOUBLE POLE
SINGLE THROW
RELAY
DOUBLE POLE
DOUBLE THROW
RELAY
NPN
TRANSISTOR
TRIPLE POLE
DOUBLE THROW
RELAY
DIODE
TRANSISTOR
PRESSURE/
VACUUM
SWITCH
TEMPERATURE
SWITCH
SKYJACK, Page 4
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.3 Hydraulic Component Parts List
Index
No.
Skyjack
Part No.
Qty.
2H-13A
2H-13A-1
2H-13A-2
2H-13A-3
2H-13A-4
2H-14B
2H-17A
2H-17B
2H-18A
2H-25
2H-30A
2H-30A-1
2H-30A-2
2H-86C
2H-98-1
2H-98-2
2H-98-3
2H-98-4
3H-20A
4H-15B
4H-16B
4H-23A
4H-24A
4H-26
4H-26A
4H-27
4H-27A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
BP1
C1
C2
C3
C4
C5
C6
103655
107269
103655
107269
103655
103655
103655
103655
114365
103655
103656
102626
112218
103656
103655
104412
103655
103655
103655
103655
103623
139256
139256
128318
128318
128318
128318
128318
128318
128318
128318
128318
128318
128318
128318
128318
128318
133441
120349
120353
120349
120353
120353
120353
120422
120422
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
Description
VALVE, Main lowering
VALVE, Lift cylinder holding (Model 9241)
VALVE, Lift cylinder holding (Model 9250)
VALVE, Lift cylinder holding (Model 9241)
VALVE, Lift cylinder holding (Model 9250)
VALVE, Lift cylinder holding (Model 9250)
VALVE, Lift cylinder holding (Model 9250)
VALVE, Lift
VALVE, Large pump dump
VALVE, Outrigger holding
VALVE, Small pump dump
VALVE, Quick brake
VALVE, Free-wheeling
VALVE, Brake dump
VALVE, Brake feed
VALVE, Hydraulic generator (option)
VALVE, Auxiliary lowering (Model 9250)
VALVE, Auxiliary lowering (Model 9250)
VALVE, Auxiliary lowering (Model 9250)
VALVE, Auxiliary lowering (Model 9250)
VALVE, Series/parallel
VALVE, Reverse drive (includes 4H-16B)
VALVE, Forward drive (includes 4H-15B)
VALVE, Right steer (includes 4H-24A)
VALVE, Left steer (includes 4H-23A)
VALVE ASSEMBLY, Front platform extend (option) (includes 4H-27A)
VALVE ASSEMBLY, Rear platform extend (option) (includes 4H-27)
VALVE ASSEMBLY, Front platform retract (option) (includes 4H-26A)
VALVE ASSEMBLY, Rear platform retract (option) (includes 4H-26)
VALVE ASSEMBLY, Left front outrigger retract (includes 4H-75)
VALVE ASSEMBLY, Right front outrigger retract (includes 4H-76)
VALVE ASSEMBLY, Right rear outrigger retract (includes 4H-77)
VALVE ASSEMBLY, Left rear outrigger retract (includes 4H-78)
VALVE ASSEMBLY, Left front outrigger extend (includes 4H-71)
VALVE ASSEMBLY, Right front outrigger extend (includes 4H-72)
VALVE ASSEMBLY, Right rear outrigger extend (includes 4H-73)
VALVE ASSEMBLY, Left rear outrigger extend (includes 4H-74)
BRAKE PACK (alternate) (Cushman axles)
CYLINDER, Lift (Model 9241)
CYLINDER, Lift (Model 9250)
CYLINDER, Lift (Model 9241)
CYLINDER, Lift (Model 9250)
CYLINDER, Lift (Model 9250)
CYLINDER, Lift (Model 9250)
CYLINDER, Brake
CYLINDER, Brake
Parts list continued on the following page.
SKYJACK, Page 5
3.3 Hydraulic Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
C7
C8
C9
C10
C11
C12
C13
C14
CBV1
CBV2
CV1
CV2
CV3
CV4
CV5
CV6
CV7
CV11
CV12
CV13
CV14
DCMI
F1
GM1
HP2
M1
MB1
MB2
MB3
MB4
MB5
MB6
MB7
MB8
MB9
MB5
MB6
MB7
MB8
120405
1
133474
1
107752
1
132694
1
132694
1
132694
1
132694
1
120255
1
120255
1
132249
1
132249
1
104624
1
104624
1
104624
1
104415
1
104415
1
104415
1
104415
1
132248
1
132248
1
132248
1
132248
1
300248
109568
1
104254
1
113875
1
110652
1
109311
1
114178
1
103137
1
130443
1
118345
1
130444
1
106688
1
118345
1
118345
1
118345
1
125430
1
125430
1
113494
1
118345
1
118345
1
125430
1
125430
1
SKYJACK, Page 6
CYLINDER, Steer (Dana axles)
CYLINDER, Steer (Cushman axles)
CYLINDER, Cushion
CYLINDER, Front Left outrigger
CYLINDER, Front Right outrigger
CYLINDER, Rear Right outrigger
CYLINDER, Rear Left outrigger
CYLINDER, Front extension platform
CYLINDER, Rear extension platform
COUNTER BALANCE VALVE, Motion control
COUNTER BALANCE VALVE, Motion control
CHECK VALVE, Small pump
CHECK VALVE, Large pump
CHECK VALVE, Lift
CHECK VALVE, Left front outrigger
CHECK VALVE, Right front outrigger
CHECK VALVE, Right rear outrigger
CHECK VALVE, Left rear outrigger
CHECK VALVE, Motion control
CHECK VALVE, Motion control
CHECK VALVE, Motion control
CHECK VALVE, Motion control
DC MOTOR, 12V
FILTER ASSEMBLY, Return
• ELEMENT, Filter
GENERATOR MOTOR, Hydraulic (option)
PUMP, Cavity hand (Cushman axles)
MOTOR, Main 2-Speed hydraulic drive
MANIFOLD BLOCK, Main
MANIFOLD BLOCK, Emergency lowering
MANIFOLD BLOCK, Holding valve (Model 9241)
MANIFOLD BLOCK, Holding valve (ANSI/CSA, Model 9250)
MANIFOLD BLOCK, Holding valve (CE, Model 9250)
MANIFOLD BLOCK, Holding valve (Model 9241)
MANIFOLD BLOCK, Holding valve (Model 9250)
MANIFOLD BLOCK, Holding valve (Model 9250)
MANIFOLD BLOCK, Holding valve (Model 9250)
MANIFOLD BLOCK, Lower lift line
MANIFOLD BLOCK, Upper lift line (Model 9250)
MANIFOLD BLOCK, Controlled lowering
MANIFOLD BLOCK, Holding valve (Model 9250)
MANIFOLD BLOCK, Holding valve (Model 9250)
MANIFOLD BLOCK, Lower lift line
MANIFOLD BLOCK, Upper lift line (Model 9250)
Parts list continued on the following page.
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.3 Hydraulic Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
MB9
MB10
MB11
MB12
MB13
MB14
MB15
MB16
MC1
O1
O2
O5
O7
OC1
P1
P3
PS1
PT1
QD1
R1
R2
R3
R4
R5
R6
R8
V1
V2
V6
MANIFOLD BLOCK, Controlled lowering
MANIFOLD BLOCK, Disc brake (Cushman axles)
MANIFOLD BLOCK, Outrigger
MANIFOLD BLOCK, Hydraulic generator valve (option)
MANIFOLD BLOCK, Front powered platform
MANIFOLD BLOCK, Rear powered platform
MANIFOLD BLOCK, Free-wheeling valve
MANIFOLD BLOCK, Motion control
MOTION CONTROL ASSEMBLY
ORIFICE, Main (.096 diameter) (Model 9250)
ORIFICE, Lift cylinder (Ø 0.094)
ORIFICE, Controlled lowering (Ø 0.055)
ORIFICE, Lift line (Ø 0.120”) (Model 9241)
OIL COOLER, Hydraulic generator (option)
PUMP, Hydraulic dual (0.488/0.854)
PUMP, Power platform
PRESSURE SWITCH (option) (trips at 2400 psi)
TRANSDUCER, Pressure QUICK DISCONNECT, System pressure
RELIEF VALVE, System
RELIEF VALVE, Lift
RELIEF VALVE, Lift cylinder (Model 9241)
RELIEF VALVE, Cylinder (Model 9250)
RELIEF VALVE, Lift cylinder (Model 9241)
RELIEF VALVE, Cylinder (Model 9250)
RELIEF VALVE, Cylinder (Model 9250)
RELIEF VALVE, Cylinder (Model 9250)
RELIEF VALVE, Power platform (Set at 500psi)
VALVE, Emergency lowering
VALVE, Controlled lowering
VALVE, Auto reset (Cushman axles)
113494
111943
111970
103137
111291
111291
103615
132261
132244
131927
105501
108721
125244
114284
110460
113173
102863
134432
122419
104534
104534
106557
104534
106557
104534
104534
104534
113286
107271
113556
113752
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
AB
SKYJACK, Page 7
3.4 Electrical Component Parts List
RELAY DIAGRAM
COMMON
COIL
CONTROL
(B+)
12 VOLT
RELAY
(SPDT)
SINGLE
POLE
DOUBLE
THROW
COIL
CONTROL
(B-)
NORMALLY
CLOSED
CONTACT
NORMALLY
OPEN
CONTACT
COMMON
COIL
CONTROL
(B+)
COIL
CONTROL
(B-)
12 VOLT
RELAY
(DPDT)
DOUBLE
POLE
DOUBLE
THROW
NORMALLY
CLOSED
CONTACT
NORMALLY
CLOSED
CONTACT
NORMALLY
OPEN
CONTACT
SKYJACK, Page 8
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.4 Electrical Component Parts List
Index
No.
Skyjack
Part No.
Qty.
1TD
2D37
9CR2
9CR3
9BCR
9CR1
10ACR1
10ACR2
10BCR1
12BCR
13CR
13DCR
14CR
14DCR
15CR
16CR
17CR
17ACR
17DCR
18CR
20CR
23CR
24CR
28CR
28CR1
28CR2
28ECR1
28ECR2
30CR
31CR
31ACR
32CR
32ACR
34BCR
35CR
49CR
56CR
61CR
65CR
86ACR
86BCR
97ACR-1
97ACR-2
99CR
2002CR
103207
147131
127131
127131
111787
111787
103207
127035
103316
103207
127035
103316
103316
103316
103316
103316
103316
103316
103316
127131
103316
103316
103316
103316
103207
103207
103316
103207
103316
103316
103316
127035
103207
147125
142308
103316
103207
103316
143805
127131
127131
103316
103207
103207
111787
300242
143805
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AB
Description
RELAY, Drive Time Delay (DPDT)
SOLENOID, Stop (Diesel Engines)
RELAY, Outrigger enable
RELAY, Outrigger enable proof
CONTACTOR, Powered Extension 12 Volt (CE)
CONTACTOR, 12 Volt (powered extension platform option)
RELAY, Engine run
RELAY, 12 Volt DPDT (Hydraulic generator/oil cooler)
RELAY, Engine On (SPDT) (ANSI/CSA)
RELAY, Engine On (DPDT) (CE)
RELAY, Joystick Enable Switch
RELAY, Down (SPDT) (ANSI/CSA)
RELAY, Down (down) (CE)
RELAY, Up (SPDT) (ANSI/CSA)
RELAY, Up (CE)
RELAY, Reverse Drive (DPDT)
RELAY, Forward Drive (DPDT)
RELAY, 2nd Speed/Large pump (SPDT)
RELAY, Small Pump (SPDT)
RELAY, Outrigger lift disable
RELAY, 3rd Speed (SPDT)
RELAY, Series/Parallel (SPDT)
RELAY, Right Steer (SPDT)
RELAY, Left Steer (SPDT)
RELAY, Tilt Switch (DPDT)
RELAY, Tilt (CE)
RELAY, Down enable (CE)
RELAY, Auxiliary tilt (CE)
RELAY, Auxiliary down enable (CE)
RELAY, Brake (SPDT)
RELAY, Choke/Glow Plug (SPDT)
RELAY, Kubota Diesel Engine Glow Plug
RELAY, Engine Start (DPDT)
SOLENOID, Engine starter (Kubota Diesel)
RELAY, 12V 40A, Starter (GM)
RELAY, Low/High Throttle (SPDT)
RELAY, Tilt override (DPDT)
RELAY, Horn (SPDT)
RELAY, 12V 20A/35A, Fuel pump (GM)
RELAY, Outrigger Drive Enable
RELAY, Outrigger lift enable (SPDT)
RELAY, 12 Volt SPDT (hydraulic generator)
RELAY, 12 Volt DPDT (hydraulic generator stop)
CONTACTOR, Powered Extension Platform (CE)
RELAY, Powered Extension Platform (CE)
SOLENOID, Powered Extension Platform Motor
RELAY, 20A/35A 12V, Power
Parts list continued on the following page.
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 9
3.4 Electrical Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
2H-13A
2H-13A-1
2H-13A-2
2H-13A-3
2H-13A-4
2H-13A-5
2H-14B
2H-17A
2H-17B
2H-18A
2H-25
2H-30A
2H-30A-1
2H-30A-2
2H-86C
2H-98-1
2H-98-2
2H-98-3
2H-98-4
2P-56
3H-20A
4H-15B
4H-16B
4H-23A
4H-24A
4H-26
4H-26A
4H-27
4H-27A
4H-71
4H-72
4H-73
4H-74
4H-75
4H-76
4H-77
4H-78
AT1
B1
B2
BP-29
103613
104410
104410
104410
104410
104410
103613
106272
103613
103613
103613
103613
103613
103613
106272
104410
104410
104410
104410
142324
103613
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
128321
130440
103295
108789
103056
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
COIL, Main Lowering Valve
COIL, Lift Cylinder Holding Valve (ANSI/CSA)
COIL, Lift Cylinder Holding Valve
COIL, Lift Cylinder Holding Valve
COIL, Lift Cylinder Holding Valve (Model 9250)
COIL, Lift Cylinder Holding Valve (CE, Model 9250)
COIL, Lift Valve
COIL, Large Pump Dump Valve
COIL, Outrigger Holding Valve
COIL, Small Pump Dump Valve
COIL, 12 Volt brake valve
COIL, Free-wheeling Valve
COIL, Brake Dump Valve
COIL, Brake Feed Valve
COIL, Hydraulic generator option valve
COIL, Lift Cylinder Auxiliary Holding Valve (Model 9250)
COIL, Lift Cylinder Auxiliary Holding Valve (Model 9250)
COIL, Lift Cylinder Auxiliary Holding Valve (Model 9250)
COIL, Lift Cylinder Auxiliary Holding Valve (Model 9250)
SOLENOID, Propane lockoff valve (GM Dual Fuel Engine)
COIL, Series/Parallel Drive Valve
COIL, Reverse Drive Valve
COIL, Forward Drive Valve
COIL, Right Steer Valve
COIL, Left Steer Valve
COIL, Front Powered Extension Extend - 12 Volt (Includes 4H-27)
COIL, Rear Powered Extension Extend - 12 Volt (Includes 4H-27A)
COIL, Front Powered Extension Retract - 12 Volt (Includes 4H-26)
COIL, Rear Powered Extension Retract - 12 Volt (Includes 4H-26A)
COIL, 12 Volt front left outrigger up
COIL, 12 Volt front right outrigger up
COIL, 12 Volt rear right outrigger up
COIL, 12 Volt rear left outrigger up
COIL, 12 Volt front left outrigger down
COIL, 12 Volt front right outrigger down
COIL, 12 Volt rear right outrigger down
COIL, 12 Volt rear left outrigger down
TRANSDUCER, Angle (CE)
BATTERY, 12 Volt (starting)
BATTERY, 12 Volt (auxiliary)
BEEPER (7.5 - 16 VDC) (ANSI/CSA)
Parts list continued on the following page.
SKYJACK, Page 10
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.4 Electrical Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
CAP1
CAP2
CB1
CB3
CB4
CEL1
CM1
CPS1
CRD1
CRD2
CRD3
DA1
DA2
DA3
DA4
DA5
DA6
DA7
DA8
DA9
DA10
DA11
DA12
DA13
D02-XX
DXX
DCM1
ECU1
EGP1
F2
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
117967
103319
103319
117326
117326
117326
133133
130439
143530
115283
115280
148300
134417
127688
129434
127684
129284
134304
127685
127926
129303
132807
129213
105657
104313
134305
700166
102921
300248
146085
KUBOTA
111282
119469
120658
121504
143806
143809
143808
143807
143808
143808
143810
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AR
AR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
BEEPER (XL-600 9-28 VDC) (CE)
CAPACITOR, 50 Volt, 1000MFD
CAPACITOR, 50 Volt, 1000MFD (CE)
CIRCUIT BREAKER, 20 Amp
CIRCUIT BREAKER, 20 Amp
CIRCUIT BREAKER, 20 Amp (hydraulic generator option)
LIGHT, Check engine (GM)
MODULE, Load sensing control (CE)
SENSOR, Crankshaft position (GM)
CABLE ASSEMBLY, 32 pin control console
CABLE ASSEMBLY, 32 pin scissor control (Model 9250)
CABLE ASSEMBLY, 32 pin scissor control (Model 9241)
CABLE ASSEMBLY, 32 pin electrical panel
DIODE ASSEMBLY (with 1 diode) (D28A) (ANSI/CSA)
DIODE ASSEMBLY (with 1 diode) (D30A)
DIODE ASSEMBLY (with 1 diode) (D44) (ANSI/CSA)
DIODE ASSEMBLY (with 1 diode) (D10E) (CE)
DIODE ASSEMBLY (with 1 diode) (D20A) (CE)
DIODE ASSEMBLY (with 1 diode) (D86C-1) (Hydraulic generator option CE)
DIODE ASSEMBLY (with 1 diode) (D86C-2) (Hydraulic generator option CE)
DIODE ASSEMBLY (with 1 diode) (D14B-2) (Hydraulic generator option CE)
DIODE ASSEMBLY (with 2 diodes) (D17A, D18A)
DIODE ASSEMBLY (with 2 diodes) (D15A, D16A) (ANSI/CSA)
DIODE ASSEMBLY (with 2 diodes) (D15A-2, D16A-2) (CE)
DIODE ASSEMBLY (with 4 diodes) (D15A-1, D16A-1, D23A, D24A) (ANSI/CSA)
DIODE ASSEMBLY (with 4 diodes) (D15A-1, D16A-1, D23A, D24A) (CE)
DIODE, Small
DIODE, Common
MOTOR, Powered Extension Platform 12 Volt
UNIT, Emission Control (GM)
PLUG, Engine glow (Diesel Fuel Engines)
FUSE, Powered Extension Platform (100 Amp)
FUSE, Inverter Option (200 Amp)
FUSE, Powered Extension Electrical Panel (10 Amp)
FUSE, 20 Amp (Dual Fuel Engines)
FUSE, 5 Amp, VSW (GM)
FUSE, 20 Amp, ECM (GM)
FUSE, 15 Amp, Fuel pump (GM)
FUSE, 10 Amp, EPR (GM)
FUSE, 15 Amp, Fuel pump (GM)
FUSE, 15 Amp, Starter (GM)
FUSE, 60 Amp, Alternator (GM)
Parts list continued on the following page.
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 11
3.4 Electrical Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
FAN
FL-22
FL-29
FP
G
GPL1
GPT1
H1
HTS-34A
IGC1
INV1
LED1
LED2
LED3
LS1
LS4
LS5
LS61
LS62
LS63
LS64
LS65
LS66
LS67
LS68
M
MS1
OCM1
OL1
OPS1
OXS1
OXS2
PRV1
PS1
PT1
RA1
RL-22
RL-29
115384
126677
103743
142302
142309
137138
132884
132883
146652
106370
143527
124047
123629
147229
147229
147229
119375
115658
119296
115658
115658
115658
115658
115658
115658
115658
115658
142308
147125
143518
132804
133133
102838
142315
142299
142340
102863
134432
-
107098
107098
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
1
1
FAN, Oil cooler
FLASHING LIGHT, 12 Volt
FLASHER
PUMP, Fuel (GM)
ALTERNATOR (Dual Fuel Engines)
ALTERNATOR (Diesel Fuel Engines)
LIGHT, Glow Plug Indicator (Diesel Fuel Engines)
TIMER, Glow Plug (Diesel Fuel Engines)
HORN, 12 Volt
SOLENOID, High Throttle (Diesel Fuel Engines)
COIL, Ignition (GM)
INVERTER, 1500 WATT (110/220V) (CE)
INVERTER, 1500 WATT (ANSI/SIA & CSA)
POWER INDICATOR LIGHT (Platform control console)
POWER INDICATOR LIGHT (Base control console)
POWER INDICATOR LIGHT (Platform control console)
LIMIT SWITCH, 26 Ft. lift Cut-out
LIMIT SWITCH, End-of-stroke
LIMIT SWITCH, Elevation/High Speed Cut-out
LIMIT SWITCH, Outrigger Left Front Up
LIMIT SWITCH, Outrigger Right Front Up
LIMIT SWITCH, Outrigger Right Rear Up
LIMIT SWITCH, Outrigger Left Rear Up
LIMIT SWITCH, Outrigger Left Front Down
LIMIT SWITCH, Outrigger Right Front Down
LIMIT SWITCH, Outrigger Right Rear Down
LIMIT SWITCH, Outrigger Left Rear Down
MOTOR, Engine starter (Dual Fuel Engines)
MOTOR, Engine starter (Diesel Fuel Engines)
SENSOR, Manifold Absolute Pressure (GM)
MODULE, Outrigger Auto-Level Control
LIGHT, Outrigger Indicator
OIL PRESSURE SWITCH (Diesel Fuel Engines)
SENSOR, Heated exhaust oxygen (GM)
SENSOR, Oxygen post-cat (GM)
PROPANE REGULATOR/VAPORIZER (GM)
PRESSURE SWITCH (option) (trips at 2400 psi)
TRANSDUCER, Pressure (CE)
ACTUATOR, Throttle Body (Dual Fuel Engines)
LIGHT, Optional rotating amber beacon
BEACON, Rotating Amber (Option)
Parts list continued on the following page.
SKYJACK, Page 12
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.4 Electrical Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
RST2
108788
S1
119726
S2
147054
S3
147054
147053
S4
147053
147053
S5
147054
S6
147053
S7
132537
S7-1
122869
S7-2
122877
S7-3
122877
S7-4
122869
S7-5
122869
S7-6
122869
S7-7
122872
S8
147054
S9
147054
S9A
102853
S9B
127132
S10
147054
147053
S11
102853
S11A
102853
S12
102853
S13
147054
S14
147054
S15
147054
S20
102853
S20A
127132
S21
102853
S21A
127132
S22
102853
S22A
127132
S23
102853
S23A
127132
S24
102853
S29
147054
S30
124446
1
1
2
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
RESISTOR, 3 Ohm/100W
SWITCH, Main Power Disconnect
TOGGLE SWITCH, Up/Off/Down (Base control console)
N.O. CONTACT, Off/Lift/Drive select key switch (Platform)
N.C. CONTACT, Off/Lift/Drive select key switch (Platform)
N.C. CONTACT, Emergency stop switch (Platform) (ANSI/CSA)
N.C. CONTACT, Off/Lift/Drive select key switch (Platform) (CE)
N.O. CONTACT, Up/Down switch (Platform)
N.C. CONTACT, Emergency stop switch (Base control console)
CONTROLLER ASSEMBLY, Drive/steer
• SWITCH W/ACTUATOR, 2nd Speed
• SWITCH, Right steer
• SWITCH, Left steer
• SWITCH W/ACTUATOR, Reverse drive
• SWITCH W/ACTUATOR, Forward drive
• SWITCH W/ACTUATOR, 3rd Speed
• SWITCH, Enable push button
N.O. CONTACT, Horn switch (Platform)
N.O. CONTACT, Lift enable switch (Platform)
SWITCH, Outrigger enable
SWITCH, Outrigger enable
SWITCH, N.O. contact (Base control console) (ANSI/CSA)
SWITCH, N.O. contact (Base control console) (CE)
SWITCH, N.C. contact (Base control console) (CE)
TOGGLE SWITCH, Front platform extend/retract (Platform)
TOGGLE SWITCH, Rear platform extend/retract (Platform)
SWITCH, Hydraulic Generator (Platform)
N.O. CONTACT, Choke switch or Glow plug switch (Platform)
N.O. CONTACT, Low/high throttle switch (Platform)
N.O. CONTACT, Engine start switch (Platform)
TOGGLE SWITCH, Left Front Outrigger Up/down
SWITCH, Front left outrigger up/down toggle
TOGGLE SWITCH, Right Front Outrigger Up/down
SWITCH, Front right outrigger up/down toggle
TOGGLE SWITCH, Right Rear Outrigger Up/down
SWITCH, Rear right outrigger up/down toggle
TOGGLE SWITCH, Left Rear Outrigger Up/down
SWITCH, Rear left outrigger up/down toggle
SWITCH, Auto-Level Outrigger
N.O. CONTACT, Low/high range (Platform)
SWITCH, Engine off/on (Engine panel)
Parts list continued on the following page.
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 13
3.4 Electrical Component Parts List (Continued)
Index
No.
Skyjack
Part No.
Qty.
Description
Parts list continued from the previous page.
S31
S33
S34
S34A
S41
S51
S52
TPS1
TPS2
TT
102853
115574
102853
102853
114373
103141
103141
143743
113400
143827
103336
SKYJACK, Page 14
1
1
1
1
1
1
1
1
1
1
1
SWITCH, Engine glow plug (Engine panel) (Diesel Fuel Engines)
SWITCH, Gas/Propane Fuel Select Toggle (GM)
TOGGLE SWITCH, Front powered platform enable
TOGGLE SWITCH, Rear powered platform enable
TOGGLE SWITCH, High/Low Torque (Platform)
N.O. CONTACT, Emergency lowering switch (CE, Model 9250)
N.O. CONTACT, Powered extension emergency retraction switch
TEMPERATURE SENSOR, Coolant (Dual Fuel Engines)
TEMPERATURE SWITCH, Engine (Kubota Diesel)
TEMPERATURE SENSOR, Air intake (Dual Fuel Engines)
METER, Hour
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.5 Platform Control Console Wiring - All Options (ANSI/CSA)
CONTROL BOX HARNESS
24 BLUE/BLACK
12 BROWN/RED
23 BLACK/WHITE
16 WHITE / BLACK
12A BROWN/RED
15 BLUE
19 ORANGE/BLACK
12A BROWN/RED
18B RED/BLACK
PIN # - FUNCTION
PIN 1 - LEFT
PIN 2 - JOYSTICK VS+
PIN 3 - RIGHT
PIN 4 - FORWARD
PIN 5 - STEERING VS+
PIN 6 - REVERSE
PIN 7 - 2nd SPEED
PIN 8 - ENABLE VS+
PIN 9 - 3rd SPEED
JOYSTICK HARNESS
24 WHITE/RED
12 WHITE/BLACK
23 WHITE
16 YELLOW
12A WHITE/GREEN
15 GREY
19 BROWN
12A WHITE/BLUE
18B RED/BLACK
KEY SWITCH
POWER ON LIGHT
00
12A
X1
X2
3
4
2
NC 1
10
NO
JOYSTICK CONTROL
WITH ENABLE
34
10
08
13
4
12
NORM./HIGH
TORQUE
14
UP/DOWN
EMERGENCY STOP
09
18B
20B
HIGH/LOW RANGE
08
00
10
18
20
1
4
NO 3
9A
NO 3
X1
4
X2
00
10
NO 3
2
NC 1
7A
5
6
08
02
4
2
NC 1
09
THROTTLE
10
2
3
4
NO 3
12
LIFT
ENABLE
31
32
9A
START
HYDR.
GEN
16
7
6
15
14
5
4
13
12
3
2
11
10
1
9
19
20
23 24
31
32
34
49
18GA
18GA
18GA
18GA
18GA
18GA
18
18GA
16
18GA
15
18GA
14
18GA
13
HORN
BACK VIEW
MALE
MALE
8
10
49
NOT USED OR
GLOW PLUG
OR CHOKE
BACK VIEW
(16) WHITE BLACK
(15) BLUE
(14) BLACK
(13) ORANGE
(10) BLUE WHITE
(09) ORANGE RED
(7A) RED
(02) WHITE
09
7A
18GA
18GA
02
18GA
NO
18GA
4
18GA
3
NO
4
00
3
NO
4
18GA
3
NO
18GA
3
4
GREEN WHITE (34)
GREEN BLACK (32)
RED WHITE (31)
BLUE BLACK (24)
BLACK WHITE (23)
BLACK WHITE RED (20)
ORANGE BLACK (19)
RED BLACK (18)
(77) GREEN BLACK WHITE
(76) RED GREEN
(75) WHITE RED
(74) BLACK RED
(73) ORANGE GREEN
(72) WHITE BLACK RED
(71) BLUE RED
(49) GREEN
24
32
23
22
31
30
21
20
29
28
19
18
27
26
17
25
RED BLACK GREEN (NOT USED)
WHITE RED GREEN (NOT USED)
BLACK RED GREEN (NOT USED)
ORANGE BLACK WHITE (85)
RED BLACK WHITE (78)
GROUND (00)
BLUE BLACK WHITE (GROUND) TO TERMINAL STRIP
M147234AE
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 15
3.6 Platform Control Console Wiring - All Options (CE)
CONTROL BOX HARNESS
24 BLUE/BLACK
12 BROWN/RED
23 BLACK/WHITE
16 WHITE /BLACK
12A BROWN/RED
15 BLUE
19 ORANGE/BLACK
12A BROWN/RED
18B RED/BLACK
KEY SWITCH
10
12A
START
HYDR.
GEN
CHOKE/
GLOW PLUG
16
7
6
15
14
5
4
13
12
3
2
11
10
1
9
4
16GA
34
49
18GA
16GA
16GA
32
18GA
16GA
16GA
31
18GA
18GA
16GA
23 24
18GA
16GA
16GA
20
18GA
18GA
16GA
19
18GA
60
16GA
10D
16GA
7C
18
18GA
16
16GA
15
18GA
16GA
16GA
16GA
00
14
18GA
HORN
MALE
MALE
8
09
7A
18GA
02
BACK VIEW
BACK VIEW
(16) WHITE BLACK
(15) BLUE
(14) BLACK
(13) ORANGE
(10) BLUE WHITE
(09) ORANGE RED
(7A) RED
(02) WHITE
16GA
49
13
18GA
31
16GA
32
10
18GA
9A
LIFT
ENABLE
20
NO
18GA
4
16GA
3
NO
18GA
3
4
18GA
NO
4
16GA
3
NO
4
18GA
3
18
08
10
16GA
10
20B
HIGH/LOW RANGE
00
09
18B
1
UP/DOWN
EMERGENCY STOP
5
6
4
4
NORM./HIGH
TORQUE
14
NO 3
2
NC 1
10D
9A
12
13
34
NO 3
X1
4
X2
7A
10
2
3
60
NO
00
NO 3
2
NC 1
7C
JOYSTICK CONTROL
WITH ENABLE
3
4
10
X1
X2
2
08
02
10
18GA
2
08
JOYSTICK HARNESS
24 WHITE/RED
12 WHITE/BLACK
23 WHITE
16 YELLOW
12A WHITE/GREEN
15 GREY
19 BROWN
12A WHITE/BLUE
18B RED/BLACK
THROTTLE
18GA
4
12
09
POWER ON/LOAD SENSING LIGHT
NO 3 NC 1 NC 1
12
PIN # - FUNCTION
PIN 1 - LEFT
PIN 2 - JOYSTICK VS+
PIN 3 - RIGHT
PIN 4 - FORWARD
PIN 5 - STEERING VS+
PIN 6 - REVERSE
PIN 7 - 2nd SPEED
PIN 8 - ENABLE VS+
PIN 9 - 3rd SPEED
GREEN WHITE (34)
GREEN BLACK (32)
RED WHITE (31)
BLUE BLACK (24)
BLACK WHITE (23)
BLACK WHITE RED (20)
ORANGE BLACK (19)
RED BLACK (18)
(77) GREEN BLACK WHITE
(76) RED GREEN
(75) WHITE RED
(74) BLACK RED
(73) ORANGE GREEN
(72) WHITE BLACK RED
(71) BLUE RED
(49) GREEN
24
32
23
22
31
30
21
20
29
28
19
18
27
26
17
25
RED BLACK GREEN (7C)
WHITE RED GREEN (10D)
BLACK RED GREEN (60)
ORANGE BLACK WHITE (85)
RED BLACK WHITE (78)
GROUND (00)
BLUE BLACK WHITE (GROUND) TO TERMINAL STRIP
M147223AE
SKYJACK, Page 16
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.7 Control Cable Assemblies Diagram
8
16
24
32
1
9
17
25
INSERTS 1-16
INSERTS: 17-32
PIN 1 - WHITE (02)
PIN 2 - RED (7A)
PIN 3 - ORANGE RED (09)
PIN 4 - BLUE WHITE (10)
PIN 5 - ORANGE (13)
PIN 6 - BLACK (14)
PIN 7 - BLUE (15)
PIN 8 - WHITE BLACK (16)
PIN 9 - RED BLACK (18)
PIN 10 - ORANGE BLACK (19)
PIN 11 - BLACK WHITE RED (20)
PIN 12 - BLACK WHITE (23)
PIN 13 - BLUE BLACK (24)
PIN 14 - RED WHITE (31)
PIN 15 - GREEN BLACK (32)
PIN 16 - GREEN WHITE (34)
GROUND TERMINAL - BLUE BLACK WHITE
PIN 17 - GREEN (49)
PIN 18 - BLUE RED (71)
PIN 19 - WHITE BLACK RED (72)
PIN 20 - ORANGE GREEN (73)
PIN 21 - BLACK RED (74)
PIN 22 - WHITE RED (75)
PIN 23 - RED GREEN (76)
PIN 24 - GREEN BLACK WHITE (77)
PIN 25 - RED BLACK WHITE (78)
PIN 26 - ORANGE BLACK WHITE (85)
PIN 27 - BLACK RED GREEN (60)
PIN 28 - WHITE RED GREEN (10D)
PIN 29 - RED BLACK GREEN (7C)
PIN 30 - EMPTY
PIN 31 - EMPTY
PIN 32 - EMPTY
GROUND TERMINAL - EMPTY
TO CONTROL BOX
BACK VIEW
FEMALE
17
25
1
9
8
16
24
32
1
9
17
25
(34) GREEN WHITE
(32) GREEN BLACK
(31) RED WHITE
(24) BLUE BLACK
(23) BLACK WHITE
(20) BLACK WHITE RED
(19) ORANGE BLACK
(18) RED BLACK
16
8
15
14
7
6
13
5
12
4
11
3
10
2
9
1
WHITE BLACK (16)
BLUE (15)
BLACK (14)
ORANGE (13)
BLUE WHITE (10)
ORANGE RED (09)
RED (7)
WHITE (02)
24
32
8
16
BACK VIEW
(GROUND) BLUE BLACK WHITE TO (00)
GROUND
FEMALE
TO CONTROL BOX
(7D) RED BLACK GREEN
(10D) WHITE RED GREEN
(60) BLACK RED GREEN
(85) ORANGE BLACK WHITE
(78) RED BLACK WHITE
32
24
31
23
30
22
29
21
28
20
27
19
26
18
25
17
GREEN BLACK WHITE (77)
RED GREEN (76)
WHITE RED (75)
BLACK RED (74)
ORANGE GREEN (73)
WHITE BLACK RED (72)
BLUE RED (71)
GREEN (49))
M115279AD_M115284AE
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 17
86
09
85
1
2
3
79
35D
2
1
70
2
1
35C
35D
35C
3
TO OUTRIGGER ENABLE SWITCH
PIN 1 - 35D PURPLE/WHITE
PIN 2 - 35C x 3 (WHITE/BLACK,
BLUE/WHITE & GREEN/WHITE)
PIN 3 - 35D PURPLE/WHITE
TO HYDRAULIC GENERATOR SWITCH
PIN 1 - 86 WHITE
PIN 2 - 09 BLACK
PIN 3 - 85 GREEN
35D
35D
TO AUTO OUTRIGGER SWITCH
PIN 1 - 79 GREEN
PIN 2 - 35D PURPLE/WHITE
PIN 3 - 70 GREEN/BLACK
3
3.8 Outrigger & Hydraulic Generator Control Console Wiring
35D
70A
02
TO OUTRIGGER LIGHT
70A RED/WHITE
02 WHITE
TO ELECTRIC PAN
86 WHITE
09 BLACK
85 GREEN
HYDRAULIC GENERATOR CONTROL CABLE
1
2
3
4
5
6
8
9
7
10
11 12
13 14 15
OUTRIGGER CONTROL CABLE
M129301AB
SKYJACK, Page 18
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
TO ELECTRIC PANE
PIN 1 - 02 WHITE
PIN 2 - 35C WHITE/
PIN 3 - 70 GREEN/B
PIN 4 - 70A RED/WH
PIN 5 - 71 ORANGE
PIN 6 - 72 RED
PIN 7 - 73 BLUE
PIN 8 - 74 BLACK
3.9 Base Control Console Wiring (ANSI/CSA)
10F-BLUE/WHITE(1.75")
10E-BLUE/WHITE(4")
10E
10E
10E
NC 3
NC 3
NC 3
4
4
4
10A
14
13
2
10A
X1
X2
02
07
NC 1
7A
BASE CONTROL STATION.-6 WIRES
02 - WHITE
07 - RED
7A - RED/WHITE
10A - BLUE/WHITE
13 - ORANGE/RED
14 - BLACK/RED
BASE CONTROLS
CONTACT ORIENTATION
BACK VIEW
UP/DOWN SWITCH
N.O. CONTACT
PIN 4 - 13 ORANGE/RED
PIN 3 - 10E BLUE/WHITE
10E
10E
ENABLE SWITCH
N.O. CONTACT
PIN 4 - 10A BLUE/WHITE
PIN 3 - 10E BLUE/WHITE(2)
10E
NC 3
NC 3
NC 3
4
4
4
7A
10A
02
14
UP/DOWN SWITCH
N.O. CONTACT
PIN 4 - 14 BLACK/RED
PIN 3 - 10E BLUE/WHITE
13
2
NC 1
X2
X1
07
10A
E-STOP SWITCH N.C. CONTACT / LED-2 LIGHT
PIN 1 - 07 RED
PIN 2 - 7A RED/WHITE
PIN X1 - 10A BLUE/WHITE
PIN X2 - 02 WHITE
M147223AC
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 19
3.10 Base Control Console Wiring (CE)
7A
10E
10E
10E
NO 3
NC 1
NO 3
NO 3
4
2
4
4
14E
10D
BASE CONTROLS - 9 WIRES
02 - WHITE
07 - RED
7A - RED/WHITE
7C - RED/GREEN/BLACK
10A - BLUE/WHITE
10D - WHITE/RED/GREEN
10E - BLUE/WHITE
13D - ORANGE/RED
14E - BLACK/RED
13D
07
7C
2
NC 1
X2
X1
10A
02
BASE CONTROLS
CONTACT ORIENTATION
BACK VIEW
10E
PLTF/BASE SWITCH
N.O. CONTACT
PIN 3 - 10E BLUE/WHITE
PIN 4 - 10D WHITE/RED/GREEN
10E
NO 3 NC 1
NO 3
NO 3
2
4
4
4
PLTF/BASE SWITCH
N.C. CONTACT
PIN 1 - 7A RED
PIN 2 - 7C RED/GREEN/BLACK
10D
UP/DOWN SWITCH
N.O. CONTACT
PIN 4 - 14E BLACK
PIN 3 - 10E BLUE/WHITE
7A
7C
7C
14E
02
UP/DOWN SWITCH
N.O. CONTACT
PIN 4 - 13D ORANGE
PIN 3 - 10E BLUE/WHITE
13D
2
NC 1
X2
X1
10A
07
E-STOP SWITCH N.C. CONTACT / LED-2 LIGHT
PIN 1 - 07 RED
PIN 2 - 7C RED/WHITE
PIN X1 - 10A BLUE/WHITE
PIN X2 - 02 WHITE
M129301AB
SKYJACK, Page 20
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
B
C
C2
LIFT
CYLINDER
C1
LIFT
CYLINDER
MB4 HOLDING VALVE
MANIFOLD BLOCK
2H-13A-2
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
P3
R3
RELIEF
VALVE
MB7 LIFT LINE
MANIFOLD BLOCK
MB13 POWERED
EXTENSION
MANIFOLD BLOCK
4H-27
RETRACT
VALVE
A B
P T
P T
MB2
MANUAL LOWERING
VALVE MANIFOLD
MB9 CONTROLLED
V2
CONTROLLED LOWERING
MANIFOLD BLOCK
LOWERING
VALVE
HYDRAULIC
GENERATOR OPTION
CV3
CHECK
VALVE
GM1
GENERATOR
MOTOR
MB12
HYDRAULIC
GENERATOR VALVE
MANIFOLD
2H-86C
HYDRAULIC
GENERATOR
VALVE
ENGINE
LARGE
PUMP
SMALL
PUMP
P1 DUAL
INLET
PUMP
OC1 OIL COOLER
DUAL FUEL EFI
C8
CUSHION
CYLINDER
CBV2
CASE DRAIN
PUMP/MOTOR/TANK UNIT
WITH DIRECTIONAL VALVE
MB10 DISC BRAKE
MANIFOLD BLOCK
SIDE EXTENSION
DECK 9226 OPTION
W
ORIFICE
Ø 0.030
(QTY 6)
A
B
P
T
M
C15 SIDE EXTENSION
FRONT LIFT CYLINDER
PILOT
OPERATED
CHECK
VALVES
C16 SIDE EXTENSION
REAR LIFT CYLINDER
P T
2H-30A-1
BRAKE
DUMP
VALVE
C9 LEFT FRONT
OUTRIGGER CYLINDER
C12 LEFT REAR
OUTRIGGER CYLINDER
4H-24A
LEFT
STEER
VALVE
CV4
CHECK
VALVE
A
B
C10 RIGHT FRONT
OUTRIGGER CYLINDER
CV5
CHECK
VALVE
C11 RIGHT REAR
OUTRIGGER CYLINDER
CV6
CHECK
VALVE
X
CV7
CHECK
VALVE
MB11 OUTRIGGER
MANIFOLD BLOCK
4H-78
LEFT REAR
OUTRIGGER
EXTEND
VALVE P
T
4H-15B
REVERSE
DRIVE
VALVE
2H-17A LARGE
PUMP DUMP
VALVE
2H-18A
SMALL
PUMP DUMP
VALVE
V
C7 STEER
CYLINDER
4H-16B
FORWARD
DRIVE
VALVE P
T
2H-30A-2
BRAKE
FEED
VALVE
CV2 CHECK
VALVE
OC1 OIL COOLER
DIESEL OPTION
4H-23A
RIGHT
STEER
VALVE
R2 LIFT
RELIEF
VALVE
2H-14B
LIFT
VALVE
CV14
A B
2H-13A MAIN
LOWERING
VALVE
PRESSURE SWITCH
OPTION
PS1
PRESSURE
SWITCH
M1
TWO STAGE
HYDRAULIC
MOTOR
BP1
BRAKE
PACK
2H-25
QUICK
BRAKE
VALVE
MB15 FREE
WHEEL MANIFOLD
2H-30A
FREE WHEEL
VALVE
3H-20A
SERIES/PARALLEL
VALVE
4H-26A
EXTEND
VALVE
HP2
HAND
PUMP
V6
AUTO
RESET
VALVE
CBV1
CV11
Đ
CV13
MB1 MAIN MANIFOLD
V1
MANUAL LOWERING
VALVE
BASE/DRIVE ASSEMBLY
R8
RELIEF
VALVE
O7
LIFT LINE
ORIFICE Ø 0.120
O5
CONTROLLED
LOWERING
ORIFICE Ø 0.055
4H-27A
RETRACT
VALVE
4H-26
EXTEND
VALVE
H
MC1 MOTION CONTROL VALVE ASSEMBLY
CV12
A B
G
MB16 MOTION CONTROL MANIFOLD BLOCK
MB14 REAR
POWERED EXTENSION
MANIFOLD BLOCK
DCM1
M
RESERVOIR
F
C14 REAR
EXTENSION
CYLINDER
C13 FRONT
EXTENSION
CYLINDER
MB3 HOLDING VALVE
MANIFOLD BLOCK
O2
LIFT
ORIFICE
Ø 0.094
PT1
PRESSURE
OVERLOAD
TRANSDUCER
R4
RELIEF
VALVE
POWERED EXTENSION
PLATFORM OPTION
2H-13A-1
HOLDING
VALVE
PRESSURE
OVERLOAD
TRANSDUCER
OPTION
AB
3.11 Hydraulic Schematic (Cushman Axles) (Model 9241)
D
E
A
B
4H-75
LEFT FRONT
OUTRIGGER
EXTEND
VALVE P
T
A
B
4H-76
RIGHT FRONT
OUTRIGGER
EXTEND
VALVE P
T
A
B
4H-77
RIGHT REAR
OUTRIGGER
EXTEND
VALVE P
T
A
B
Y
CV1 CHECK
VALVE
2H-17B
OUTRIGGER
HOLDING
VALVE
R1
SYSTEM
RELIEF
VALVE
4H-74
LEFT REAR
OUTRIGGER
RETRACT
VALVE
4H-71
LEFT FRONT
OUTRIGGER
RETRACT
VALVE
4H-72
RIGHT FRONT
OUTRIGGER
RETRACT
VALVE
4H-73
RIGHT REAR
OUTRIGGER
RETRACT
VALVE
QD1 SYSTEM PRESSURE
QUICK DISCONNECT
Z
F1
FILTER
RESERVOIR
M148310AD
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 21
A
B
C
3.12 Hydraulic Schematic (Cushman Axles) (Model 9250)
D
E
POWERED EXTENSION
PLATFORM OPTION
C14 REAR
EXTENSION
CYLINDER
C13 FRONT
EXTENSION
CYLINDER
F
G
H
V
MC1 MOTION CONTROL VALVE ASSEMBLY
MB16 MOTION CONTROL MANIFOLD BLOCK
BASE/DRIVE ASSEMBLY
C4 LIFT CYLINDER
C3 LIFT CYLINDER
MB5 HOLDING VALVE
MANIFOLD
MB6 HOLDING VALVE
MANIFOLD
O2
LIFT
ORIFICE
Ø 0.094
C2 LIFT CYLINDER
MB4 HOLDING VALVE
MANIFOLD
2H-98-4
AUXILIARY
LOWERING
VALVE
2H-98-4
AUXILIARY
LOWERING
VALVE
2H-13A-4
HOLDING
VALVE
2H-13A-3
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
R6
RELIEF
VALVE
R5
RELIEF
VALVE
MB3 HOLDING VALVE
MANIFOLD
2H-98-2
AUXILIARY
LOWERING
VALVE
2H-13A-2
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
R4
RELIEF
VALVE
2H-98-1
AUXILIARY
LOWERING
VALVE
PRESSURE
OVERLOAD
TRANSDUCE
OPTION
2H-13A-1
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
PT1
PRESSURE
OVERLOAD
TRANSDUCER
MB14 REAR
POWERED EXTENSION
MANIFOLD BLOCK
4H-27
RETRACT
VALVE
DCM1
P3
A
B
P
T
M
RESERVOIR
MB9
CONTROLLED
LOWERING
MANIFOLD
B
P
T
C8
CUSHION
CYLINDER
CBV2
W
CASE DRAIN
MB10 DISC BRAKE
MANIFOLD BLOCK
2H-25
QUICK
BRAKE
VALVE
V2
CONTROLLED
LOWERING
VALVE
CV14
BP1
BRAKE
PACK
V6
AUTO
RESET
VALVE
2H-30A
FREE WHEEL
VALVE
M1
TWO STAGE
HYDRAULIC
MOTOR
CV13
HP2
HAND
PUMP
MB15 FREE
WHEEL MANIFOLD
3H-20A
SERIES/PARALLEL
VALVE
4H-26A
EXTEND
VALVE
R8
RELIEF
VALVE
R3
RELIEF
VALVE
O5
CONTROLLED
LOWERING
ORIFICE
Ø 0.055
A
CBV1
CV11
CV12
4H-27A
RETRACT
VALVE
4H-26
EXTEND
VALVE
MB7
LIFT LINE
MANIFOLD
MB8
LIFT LINE
MANIFOLD
MB2
MANUAL LOWERING
VALVE MANIFOLD
MB13 POWERED
EXTENSION
MANIFOLD BLOCK
C1 LIFT CYLINDER
C7 STEER
CYLINDER
MB1 MAIN MANIFOLD
2H-13A MAIN
LOWERING
VALVE
V1
MANUAL LOWERING
VALVE
O1 MAIN LOWERING
VALVE ORIFICE
Ø 0.096
HYDRAULIC
GENERATOR OPTION
CV3
CHECK
VALVE
GM1
GENERATOR
MOTOR
MB12
HYDRAULIC
GENERATOR VALVE
MANIFOLD
CV2 CHECK
VALVE
OC1 OIL COOLER
DIESEL OPTION
ENGINE
LARGE
PUMP
OC1 OIL COOLER
DUAL FUEL EFI
P
T
C12 LEFT REAR
OUTRIGGER CYLINDER
4H-24A
LEFT
STEER
VALVE
2H-30A-1
BRAKE
DUMP
VALVE
P
A
T
B
CV1 CHECK
VALVE
CV5
CHECK
VALVE
X
C11 RIGHT REAR
OUTRIGGER CYLINDER
CV7
CHECK
VALVE
CV6
CHECK
VALVE
MB11 OUTRIGGER
MANIFOLD BLOCK
4H-15B
REVERSE
DRIVE
VALVE
R1
SYSTEM
RELIEF
VALVE
C10 RIGHT FRONT
OUTRIGGER CYLINDER
C9 LEFT FRONT
OUTRIGGER CYLINDER
CV4
CHECK
VALVE
2H-17A LARGE
PUMP DUMP
VALVE
2H-18A
SMALL
PUMP DUMP
VALVE
SMALL
PUMP
P1 DUAL
INLET
PUMP
2H-30A-2
BRAKE
FEED
VALVE
B
4H-16B
FORWARD
DRIVE
VALVE
R2 LIFT
RELIEF
VALVE
2H-14B
LIFT
VALVE
2H-86C
HYDRAULIC
GENERATOR
VALVE
4H-23A
RIGHT
STEER
VALVE
A
2H-17B
OUTRIGGER
HOLDING
VALVE
4H-78
LEFT REAR
OUTRIGGER
EXTEND
VALVE
P
T
A
4H-75
LEFT FRONT
OUTRIGGER
EXTEND
VALVE
P
A
B
T
B
4H-74
LEFT REAR
OUTRIGGER
RETRACT
VALVE
4H-71
LEFT FRONT
OUTRIGGER
RETRACT
VALVE
4H-76
RIGHT FRONT
OUTRIGGER
EXTEND
VALVE
P
A
4H-77
RIGHT REAR
OUTRIGGER
EXTEND
VALVE
P
T
B
T
4H-72
RIGHT FRONT
OUTRIGGER
RETRACT
VALVE
A
B
Y
4H-73
RIGHT REAR
OUTRIGGER
RETRACT
VALVE
QD1 SYSTEM PRESSURE
QUICK DISCONNECT
Z
F1
FILTER
RESERVOIR
SKYJACK, Page 22
M139727AC
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
B
3.13 Hydraulic Schematic (Dana Axles)
D
E
C
F
C3 LIFT CYLINDER
MB5 HOLDING VALVE
MANIFOLD
MB6 HOLDING VALVE
MANIFOLD
O2
LIFT
ORIFICE
Ø 0.094
C2 LIFT CYLINDER
2H-98-4
AUXILIARY
LOWERING
VALVE
2H-98-4
AUXILIARY
LOWERING
VALVE
2H-13A-4
HOLDING
VALVE
2H-13A-3
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
R6
RELIEF
VALVE
R5
RELIEF
VALVE
2H-13A-2
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
R4
RELIEF
VALVE
PRESSURE
OVERLOAD
TRANSDUCE
OPTION
2H-13A-1
HOLDING
VALVE
O2
LIFT
ORIFICE
Ø 0.094
PT1
PRESSURE
OVERLOAD
TRANSDUCER
MB13 POWERED
EXTENSION
MANIFOLD BLOCK
DCM1
P3
MB9
CONTROLLED
LOWERING
MANIFOLD
A
B
P
T
M
R3
RELIEF
VALVE
RESERVOIR
O5
CONTROLLED
LOWERING
ORIFICE
0.055
Ø
4H-27A
RETRACT
VALVE
4H-26
EXTEND
VALVE
CBV1
CV11
MB15 FREE
WHEEL MANIFOLD
3H-20A
SERIES/PARALLEL
VALVE
M1
TWO STAGE
HYDRAULIC
MOTOR
4H-26A
EXTEND
VALVE
CV13
CV14
2H-30A
FREE WHEEL
VALVE
C8
CUSHION
CYLINDER
CBV2
R8
RELIEF
VALVE
W
CASE DRAIN
C5 BRAKE
CYLINDER
V2
CONTROLLED
LOWERING
VALVE
CV12
MB14 REAR
POWERED EXTENSION
MANIFOLD BLOCK
4H-27
RETRACT
VALVE
MB7
LIFT LINE
MANIFOLD
MB8
LIFT LINE
MANIFOLD
MB2
MANUAL LOWERING
VALVE MANIFOLD
2H-98-1
AUXILIARY
LOWERING
VALVE
BASE/DRIVE ASSEMBLY
C14 REAR
EXTENSION
CYLINDER
C13 FRONT
EXTENSION
CYLINDER
MB3 HOLDING VALVE
MANIFOLD
2H-98-2
AUXILIARY
LOWERING
VALVE
V
MB16 MOTION CONTROL MANIFOLD BLOCK
C1 LIFT CYLINDER
MB4 HOLDING VALVE
MANIFOLD
H
MC1 MOTION CONTROL VALVE ASSEMBLY
POWERED EXTENSION
PLATFORM OPTION
C4 LIFT CYLINDER
G
C7 STEER
CYLINDER
C6 BRAKE
CYLINDER
MB1 MAIN MANIFOLD
4H-23A
RIGHT
STEER
VALVE
O1 MAIN LOWERING
VALVE ORIFICE Ø 0.096
HYDRAULIC
GENERATOR OPTION
CV3
CHECK
VALVE
GM1
GENERATOR
MOTOR
MB12
HYDRAULIC
GENERATOR VALVE
MANIFOLD
OC1 OIL COOLER
DIESEL OPTION
OC1 OIL COOLER
DUAL FUEL EFI
C12 LEFT REAR
OUTRIGGER CYLINDER
4H-24A
LEFT
STEER
VALVE
C10 RIGHT FRONT
OUTRIGGER CYLINDER
C9 LEFT FRONT
OUTRIGGER CYLINDER
CV5
CHECK
VALVE
CV4
CHECK
VALVE
X
C11 RIGHT REAR
OUTRIGGER CYLINDER
CV6
CHECK
VALVE
CV7
CHECK
VALVE
MB11 OUTRIGGER
MANIFOLD BLOCK
2H-30A-1
BRAKE
DUMP
VALVE
4H-78
LEFT REAR
OUTRIGGER
EXTEND
VALVE
4H-15B
REVERSE
DRIVE
VALVE
4H-76
RIGHT FRONT
OUTRIGGER
EXTEND
VALVE
4H-75
LEFT FRONT
OUTRIGGER
EXTEND
VALVE
4H-77
RIGHT REAR
OUTRIGGER
EXTEND
VALVE
Y
2H-17A LARGE
PUMP DUMP
VALVE
2H-18A
SMALL
PUMP DUMP
VALVE
SMALL
PUMP
P1 DUAL
INLET
PUMP
2H-30A-2
BRAKE
FEED
VALVE
CV2 CHECK
VALVE
B
4H-16B
FORWARD
DRIVE
VALVE
R2 LIFT
RELIEF
VALVE
2H-14B
LIFT
VALVE
2H-86C
HYDRAULIC
GENERATOR
VALVE
LARGE
PUMP
A
2H-13A MAIN
LOWERING
VALVE
V1
MANUAL LOWERING
VALVE
CV1 CHECK
VALVE
R1
SYSTEM
RELIEF
VALVE
2H-17B
OUTRIGGER
HOLDING
VALVE
4H-74
LEFT REAR
OUTRIGGER
RETRACT
VALVE
4H-71
LEFT FRONT
OUTRIGGER
RETRACT
VALVE
4H-72
RIGHT FRONT
OUTRIGGER
RETRACT
VALVE
4H-73
RIGHT REAR
OUTRIGGER
RETRACT
VALVE
QD1 SYSTEM PRESSURE
QUICK DISCONNECT
Z
F1
FILTER
RESERVOIR
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
M116174AJ
SKYJACK, Page 23
A
3.14 Hydraulic Manifold Components & Port Identifications
C
D
E
B
TO
TO OUTRIGGER
2H-17A
MANIFOLD RETURN
LARGE PUMP
FILTER
DUMP VALVE
2H-30A-2
BRAKE FEED
MANIFOLD
VALVE
PLUG
4H-24A
LEFT STEER
VALVE
TO
LARGE
PUMP
TO
SMALL
PUMP
R2
LIFT
RELIEF
VALVE
TO BRAKE
CYLINDER
TO MAIN
MANIFOLD
TO EMERGENCY
LOWERING
V
TO
MOTION
CONTROL
VALVE
TO
BRAKE
CYLINDER
V6
BRAKE RELEASE
OVERRIDE VALVE
HP2
HAND PUMP
(Model 9250)
R1
SYSTEM
RELIEF
VALVE
W
O1
LOWERING
ORIFICE
2H-30A-1
BRAKE
DUMP
4H-16B
VALVE
FORWARD
DRIVE
VALVE
TO OUTRIGGER
MANIFOLD
TEST
PORT
2H - 25
QUICK BRAKE
VALVE
2H-18A
SMALL PUMP
DUMP VALVE
CV2
CHECK
VALVE
TO MOTION
CONTROL
VALVE
H
Auto Reset
Brake Manifold
CV2
CHECK
VALVE
TO STEER
CYLINDER
G
TO EMERGENCY
LOWERING MANIFOLD
TO HYDRAULIC
TANK
CV3
CHECK
VALVE
4H-15B
REVERSE
DRIVE
VALVE
4H-23A
RIGHT STEER
VALVE
F
2H-13A
LOWERING
VALVE
MANIFOLD
PLUG
4H - 72A
OUTRIGGER
RIGHT FRONT
RETRACT
4H - 71A
OUTRIGGER
LEFT FRONT
RETRACT
4H - 74A
OUTRIGGER
LEFT REAR
RETRACT
4H - 73A
OUTRIGGER
RIGHT REAR
RETRACT
X
2H - 17B
OUTRIGGER
HOLDING
VALVE
4H - 78A
OUTRIGGER
LEFT REAR
EXTEND
Y
4H - 75A
OUTRIGGER
LEFT FRONT
EXTEND
OPTIONAL
TEST
PORT
2H-14B
LIFT
VALVE
TO LIFT CONTROL
LOWERING BLOCK
Main Manifold
Outrigger Manifold
4H - 77A
OUTRIGGER
RIGHT REAR
EXTEND
4H - 76A
OUTRIGGER
RIGHT FRONT
EXTEND
Z
OUTRIGGER
CYLINDER
M50152AB HMC-Pl2 HMC-Pl1
SKYJACK, Page 24
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
B
C
3.15 Main Manifold Wiring Diagram
D
E
F
G
BRAKE DUMP VALVE
30A - BROWN (2x)
02 - WHITE
LARGE PUMP DUMP VALVE
17A - BLUE/RED
02 - WHITE
MAIN DISCONNECT
03 - BLUE (14 AWG)
POWER DECK CONTACTOR
09 - ORANGE/RED
02 - WHITE
QUICK BRAKE VALVE
25 - ORANGE/GREEN
02 - WHITE
FREE WHEELING VALVE
30A - BROWN
02 - WHITE
SMALL PUMP DUMP VALVE
18A - RED/BLACK
02 - WHITE
H
V
TO ELECTRIC PANEL - 14 WIRES
00 - WHITE (14 AWG)
02 - WHITE
03 - BLUE (14 AWG)
09 - ORANGE/RED
13A - ORANGE
14B - BLACK
15B - BLUE
16B - WHITE/BLACK
17A - BLUE/RED
18A RED/BLACK
23A - BLACK/WHITE
24A - BLUE/BLACK
25 - ORANGE/GREEN
30A - BROWN
W
BRAKE FEED VALVE
30A - BROWN (2x)
02 - WHITE
LOWERING VALVE
13A - ORANGE (2x)
02 - WHITE (2x)
HOLDING VALVE HARNESS
13A - ORANGE
02 - WHITE
FORWARD VALVE
BLACK HEIRSHMAN
PIN 1 - 16B WHITE/BLACK
PIN 2 - 02 WHITE
BATTERY NEGATIVE
00 - WHITE (14 AWG)
X
LIFT VALVE
14B - BLACK
02 - WHITE
REVERSE VALVE
GREY HEIRSHMAN
PIN 1 - 15B BLUE
PIN 2 - 02 WHITE
RIGHT STEER VALVE
BLACK HEIRSHMAN
PIN 1 - 23A BLACK/WHITE
PIN 2 - 02 WHITE
Y
LEFT STEER VALVE
GREY HEIRSHMAN
PIN 1 - 24A BLUE/BLACK
PIN 2 - 02 WHITE
Z
M129218AD
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 25
A
B
3.16 Oil Cooler - Electrical Panel Diagram (ANSI/CSA Dual Fuel Engine)
C
D
E
F
G
H
V
87a
D73
10ACR2
W
10
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
11 12
4
OIL COOLER RELAY - 10ACR2
PIN 30 - 85A ORG/BLK/WHT
PIN 85 - 10A BLU/WHT
PIN 86 - 2A BLK/RED
PIN 87 - 86D BLK
PIN 87a - N/U
2A
85A
9
5
D76
D71
86D
8
ENABLE
10A
D77
D78
D72
7
4
JUMP J17E
X
00
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
85
30
D75
65CR
J17E
17BCR
J17D
61CR
87
D74
REAR RIGHT
FRONT RIGHT
9CR2
FRONT LEFT
9CR3
35C
78
73
77
74
71
75
72
76
CN20
REAR LEFT
D17B-1
17B
02
78
73
77
74
71
75
72
76
CN21
10A
D17B-2
86
2A
CN14
04
17
86A
10A
09
44
01
02
02
36A
61
36
BACK VIEW
TO OIL COOLER FAN
86D - BLACK
00 - WHITE
00
02
02
07
09
10A
13A
29
14B
17A
18A
33 20A
25
30
15A
16A
21
23A
24A
35
02
00
05
03
85A
03
Y
86D
00
Z
M134195AC_2
SKYJACK, Page 26
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
3.17 Hydraulic Generator - Electrical Panel Diagram (ANSI/CSA Dual Fuel Engine)
C
D
E
B
F
G
H
V
HYDRAULIC GENERATOR INTERNAL WIRING
OUTRIGGER ELECTRIC PANEL
12 PIN CONNECTOR PLUG - CN14
CN14
04
17
86A
10A
09
44
01
02
02
36A
61
36
BACK VIEW
PIN 3 - 86A ORG/BLK/WHT
10
11 12
4
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
05
41
32
34B
CR
D76
ENABLE
02
32A
GROUND
JUMP J17E
W
LOAD NEUTRAL
86
09
00
00
32
CR
43
34A
D14B-3
TO OIL COOLER FAN
86D - BLACK
00 - WHITE
R
LOAD
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
41
D75
65CR
J17D
17BCR
J17E
61CR
43
42 34B
2A
9
2A
86D
8
D71
85A
D78
D72
FRONT RIGHT
FRONT LEFT
7
NORTH AMERICAN COLOURS
BLACK
WHITE
GREEN
10A
D73
D77
D74
REAR RIGHT
35C
78
73
77
74
71
75
72
76
9CR2
04
17
86A
10A
09
35
01
02
02
36A
61
36
9CR3
REAR LEFT
17B
02
78
73
77
74
71
75
72
76
D17B-1
CN20
LOAD
LOAD NEUTRAL
GROUND
10ACR2
10A
D17B-2
D86C-2
CN21
10A
13A
29
14B
17A
18A
33
20A
25
30
15A
16A
21
23A
24A
35
D86
110V 15A GENERATOR
85A
09
86B
14A
10A
17
44
2A
86B
02 86A
02
28
02
35
86B
CR
86A
CR
28
CR
85
86C
35
CR
28A
14B
85
01
19A
RED
02
00
05
03
85A
03
BLK
04
86D
D86C-1
85
X
00
GROUND
02
LOAD NEUTRAL
LOAD
86C
TO HYDRAULIC GENERATOR SOLENOID
86C - BLACK
02 - WHITE
86
87
87a
30
85
OIL COOLER RELAY - 10ACR2
PIN 30 - 85A ORG/BLK/WHT PIN 87 - 86D BLK
PIN 87a - N/U
PIN 85 - 10A BLU/WHT
PIN 86 - 2A BLK/RED
220V 15A GENERATOR
RED
BLK
Y
Z
M134191AD_1
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 27
A
3.18 Hydraulic Generator - Electrical Panel Diagram (ANSI/CSA Diesel Engine)
C
D
E
B
AB
F
G
H
V
BACK VIEW
OUTRIGGER ELECTRIC PANEL
12 PIN CONNECTOR PLUG - CN14
10 11 12
4
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
34A
ENABLE
02
GROUND
LOAD NEUTRAL
W
LOAD
32A
110V 15A GENERATOR
86
JUMP J17E
09
00
02
32
CR
43
D14B-3
00
R
RED
BLK
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
32
34B
CR
D76
65CR
42 34B
D75
J17D
17BCR
J17E
61CR
05
41
10A
9
10A
2A
8
41
D71
85A
D78
D72
FRONT RIGHT
FRONT LEFT
7
43
NORTH AMERICAN COLOURS
BLACK
WHITE
GREEN
2A
D73
D77
D74
REAR RIGHT
REAR LEFT
17B
02
78
73
77
74
71
75
72
76
35C
78
73
77
74
71
75
72
76
04
17
86A
10A
09
35
01
02
02
36A
61
36
9CR2
10ACR2
86D
D17B-2
CN20
9CR3
TO OIL COOLER FAN
86C - BLACK
00 - WHITE
LOAD
LOAD NEUTRAL
GROUND
D86C-2
CN21
D17B-1
PIN 3 - 86A ORG/BLK/WHT
HYDRAULIC GENERATOR INTERNAL WIRING
04
17
86A
10A
09
44
01
02
02
36A
61
36
CN14
02
07
09
10A
13A
29
14B
17A 18A
33 20A
25
30
15A
16A
21
23A 24A
35
7A
D86
85A
09
86B
14A
10A
17
44
2A
86B
02 86A
02
28
02
35
86B
CR
86A
CR
28
CR
85
86C
02
35
CR
14B
01
05
19A
GROUND
LOAD NEUTRAL
28A
85
00
X
LOAD
03
220V 15A GENERATOR
04
86C
D86C-1
85
85A
03
RED
BLK
00
02
86C
TO HYDRAULIC GENERATOR SOLENOID
86C - BLACK
02 - WHITE
86
87
87a
30
85
Y
HYDR GEN CONTROL CABLE
09 - BLACK
85 - GREEN
86 - WHITE
OIL COOLER RELAY - 10ACR2
PIN 30 - 85A ORG/BLK/WHT
PIN 85 - 10A BLU/WHT
PIN 86 - 2A BLK/RED
PIN 87 - 86D BLK
PIN 87a - N/U
Z
M141691AD
SKYJACK, Page 28
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
B
C
AB
3.19 Hydraulic Generator - Electrical Panel Diagram (CE)
D
E
F
G
H
CN14
OUTRIGGER ELECTRIC PANEL
12 PIN CONNECTOR PLUG
04
17
86A
10A
09
44
01
02
02
36A
61
36
BACK VIEW
43
41
05
42 34B
41
32
D74
8
9
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
4
34B
CR
D76
43
ENABLE
02
32A
86
JUMP J17E
W
09
D14B-2
D17A
16GA
18GA
09
86B
10A
17
10C
2A
86B
02 86A
02 28E
02
35
86A
CR
28E
CR2
00
02
02
02
09
13D
10A
14D
10D
10E
14E
10A
14B
34B
07
17A
7A
25
33
7C
60
18A
35B
85
19A
13C
02
00
05
03
44
X
D18A
D14B-1
D14E-1
35
CR
85
86C
86D
D86
85A
86B
CR
D14E-2
NOTE: EACH STRANDED
WIRE AT THE TERMINAL
STRIP MUST BE TERMINATED
WITH A FERRULE
TO OIL COOLER FAN
86D - BLACK
00 - WHITE
34A
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
32
CR
D75
65CR
J17E
17BCR
J17D
61CR
R
2A
10 11 12
10A
2A
85A
86D
D78
D72
7
V
10A
D73
10ACR2
D77
REAR RIGHT
FRONT RIGHT
FRONT LEFT
04
17
86A
10A
09
35
01
02
02
36B
61
36
9CR2
35C
78
73
77
74
71
75
72
76
CN20
9CR3
REAR LEFT
D17B-1
17B
02
78
73
77
74
71
75
72
76
CN21
D71
D17B-2
D86C-2
PIN 3 - 86A ORG/BLK/WHT
D86C-1
85
85A
03
00
02
HYDRAULIC GENERATOR INTERNAL WIRING
86C
EUROPEAN COLOURS
LOAD
BROWN
LOAD NEUTRAL BLUE
GROUND
GREEN/YELLOW
TO HYDRAULIC GENERATOR SOLENOID
86C - BLACK
02 - WHITE
86
87
87a
30
85
OIL COOLER RELAY - 10ACR2
PIN 30 - 85A ORG/BLK/WHT
PIN 85 - 10A BLU/WHT
PIN 86 - 2A BLK/RED
PIN 87 - 86D BLK
PIN 87a - N/U
Y
HYDR GEN CONTROL CABLE
09 - BLACK
85 - GREEN
86 - WHITE
GROUND
LOAD NEUTRAL
GROUND
LOAD NEUTRAL
LOAD
LOAD
110V 15A GENERATOR
220V 15A GENERATOR
RED
BLK
RED
BLK
Z
M149512AC
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 29
A
B
3.20 Emergency Lowering System - Wiring Diagram (ANSI/CSA) (Model 9250)
C
D
E
F
G
H
V
RST2
GRAY
GRAY
GRAY
GRAY
W
LIFT CYLINDER MANIFOLD
TYP (4 PLACES)
NOTE: ALL CABTIRES
RUN IN TRACK WITH
CONTROL CABLE
X
B1 - MAIN BATTERY
TOP VIEW
GRAY
98 - BLACK
00 - WHITE
Y
BLACK
B2 - AUX. BATTERY
S51
97 - BLACK
98 - WHITE
Z
BACK VIEW
PIN 3 - 97 BLACK
PIN 4 - 98 WHITE
M11443AA
SKYJACK, Page 30
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
3.21 Emergency Lowering System - Wiring Diagram (CE) (Model 9250)
C
D
E
B
F
G
H
POWER DECK RETRACT
97A - BLACK
00 - WHITE
EMERGENCY POWER DECK
RETRACT CONTACTOR
97A - BLACK (2x)
02 - WHITE (2x)
EMERGENCY POWER
DECK RETRACT RELAY
PIN 1 - 100A RED
PIN 4 - 9B ORANGE/RED
PIN 9 - 100 RED
PIN 12 - 09 ORANGE/RED
PIN 13 - 02 WHITE
PIN 14 - 97A GREEN, BLACK
V
TO POWER DECK CONTROL BOX - FRONT
TO POWER DECK CONTROL BOX - REAR
TO POWER DECK DIRECTIONAL VALVES
UNDERNEATH
PLATFORM
POWER DECK CONTACTOR
9B - ORANGE/RED
02 - WHITE (2x)
W
TO POWER DECK MOTOR CONTACTOR
00 - WHITE
103B - BLACK
99 - GREEN
TO ENGINE
X
RST2
Y
GRAY
GRAY
GRAY
GRAY
B1 MAIN BATTERY
S52
98 - BLACK
00 - WHITE
BACK VIEW
LIFT CYLINDER MANIFOLD
TYP (4 PLACES)
EMERGENCY DECK RETRACTION
PIN 3 - 97 BLACK
PIN 4 - 97A GREEN
B2 AUX. BATTERY
Z
MANUAL LOWERING VALVE
S51
97 - BLACK
97A - GREEN
98 - WHITE
EMERGENCY LOWERING
PIN 3 - 97 BLACK (2x)
PIN 4 - 98 WHITE
GRAY
BLACK
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
M11442AA
SKYJACK, Page 31
A
3.22 Emergency Lowering System - Electrical Wiring Diagram (CE) (Model 9241)
C
D
E
B
F
G
H
POWER DECK RETRACT
97A - BLACK
00 - WHITE
02
97A
02
09
02
EM RETRACT
TO POWER DECK DIRECTIONAL VALVES
9B
103B
100A
V
TO POWER DECK CONTROL BOX - FRONT
TO POWER DECK CONTROL BOX - REAR
97A
100
97A
97
EMERGENCY POWER DECK
RETRACT CONTACTOR
97A - BLACK (2x)
02 - WHITE (2x)
103
A
NOTE: OPEN UP THE HARNESS AND PULL OUT
THE 09 ORANGE/RED WIRE SO THAT IT IS 5"
HIGHER. CUT OFF THE RING TERMINAL AND
CONNECT TO EMERGENCY P.D. RETRACT RELAY
27
26
09
12A
12D
09
26A
27A
02
26A
27A
MANIFOLD
103B
UNDERNEATH
PLATFORM
27
26
02
02
02
BASE FEED
POWER DECK CONTACTOR
9B - ORANGE/RED
02 - WHITE (2x)
02
9B
103A
97A
CTRL BOX
10
N
02
120844AB
EMERGENCY POWER
DECK RETRACT RELAY
PIN 1 - 100A RED
PIN 4 - 9B ORANGE/RED
PIN 9 - 100 RED
PIN 12 - 09 ORANGE/RED
PIN 13 - 02 WHITE
PIN 14 - 97A GREEN, BLACK
PMP PWR
02
12D
12A
02
W
103B
NOTE: TRIM BATTERY BOOT
FOR ADDITIONAL CABLE
103B
103B
00
00
103
103
103
99
103
NOTE: FASTEN TO PUMP BODY
103
103
TO POWER DECK MOTOR CONTACTOR
00 - WHITE
103B - BLACK
99 - GREEN
2
TO ENGINE
00
ENABLE
03
2
96
100A
100
X
00
100
D96
00
00
100
00
97
00
97
Y
97
00
BACK VIEW
EMERGENCY DECK RETRACTION
PIN 3 - 97 BLACK
PIN 4 - 97A GREEN
NOT CONNECTED
98
(TIE- WRAP TO THE CABLE)
MANUAL LOWERING VALVE
Z
97 - BLACK
97A - GREEN
98 - WHITE
M148308AA_1
SKYJACK, Page 32
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
H
LEFT REAR OUTRIGGER:
PIN 1 - BLACK (10A)
PIN 2 - WHITE (68A)
PIN 3 - GREEN (01)
PIN 4 - RED (64)
BACK VIEW
PIN 1 - BLACK ( )
PIN 2 - WHITE ( )
PIN 3 - GREEN ( )
PIN 4 - RED ( )
FEMALE
2
3
1
4
V
5
4
1
2
3
4
5
6
D76
REAR LEFT
REAR RIGHT
D71
D72
D78
D77
D74
W
D73
OUTR MANIFOLD
PIN 1 - 78 BLACK/WHITE PIN 1 - 75 ORANGE/BLACK PIN 1 - 76 RED/BLACK
PIN 1 - 77 BLUE/BLACK
PIN 2 - 02 WHITE
PIN 2 - 02 WHITE
PIN 2 - 02 WHITE
TEN PIN CONNECTOR PLUG CN21 PIN 2 - 02 WHITE
PIN 1 - 17B WHITE/BLACK
PIN 2 - 02 WHITE
PIN 3 - 78 BLACK/WHITE
76
77
78
75
02
02
02
02
PIN 4 - 73 BLUE
PIN 5 - 77 BLUE/BLACK
GREY
GREY
GREY
GREY
PIN 6 - 74 BLACK
PIN 7 - 71 ORANGE
PIN 8 - 75 ORANGE/BLACK
PIN 9 - 72 RED
PIN 10 - 76 RED/BLACK
2
6
D75
CN14
1
FRONT LEFT
FRONT RIGHT
CN21
2
JUMP J17E
3
ENABLE
BACK VIEW
OUTR CTRL BOX
9
8
7
6 5
4
3
2
1
TO LIMIT SWITCHES
PIN 1 - 65 GREEN/BLACK
PIN 2 - 65A GREEN/WHITE
PIN 3 - 66A BLUE/WHITE
PIN 4 - 67A RED/WHITE
PIN 5 - 68A WHITE
PIN 6 - N/U
BACK VIEW
J17D
J17E
17B
02
78
73
77
74
71
75
72
76
CN20
LEFT REAR
TO CONTROL MODULE
PIN 1 - 65 GREEN/BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE
PIN 5 - 68A WHITE
PIN 6 - N/U
D36
04
17
86A
10A
09
44
01
02
02
36A
61
36
9CR2
RIGHT REAR
9CR3
RIGHT FRONT
35C
78
73
77
74
71
75
72
76
65CR
LEFT FRONT
CN22
SIXTEEN PIN CONNECTOR PLUG
INSTALLED TO CABTIRES ON MACHINE CN22
PIN 1 - 61 RED
PIN 2 - 62 GREEN
PIN 3 - 62 RED
PIN 4 - 63 GREEN
PIN 5 - 63 RED
PIN 6 - 64 GREEN
PIN 7 - 64 RED
PIN 8 - 01 GREEN
PIN 9 - 10A BLACK (2)
PIN 10 - 10A BLACK (2)
PIN 11 - 10A BLACK (2)
PIN 12 - 10A BLACK (2)
PIN 13 - (N/U)
PIN 14 - (N/U)
PIN 15 - (N/U)
PIN 16 - 65 GREEN/BLACK
D17B-1
D17B-2
17BCR
OUTRIGGER LIMIT SWITCHES
61CR
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
TO OUTRIGGER PCB CN20
PIN 1 - 35C WHITE/BLACK
PIN 2 - 78 BLACK/WHITE
PIN 3 - 73 BLUE
PIN 4 - 77 BLUE/BLACK
PIN 5 - 74 BLACK
PIN 6 - 71 ORANGE
PIN 7 - 75 ORANGE/BLACK
PIN 8 - 72 RED
PIN 9 - 76 RED/BLACK
1
RIGHT REAR OUTRIGGER:
PIN 1 - BLACK (10A)
PIN 2 - WHITE (67A)
PIN 3 - GREEN (64)
PIN 4 - RED (63)
2
RIGHT FRONT OUTRIGGER:
PIN 1 - BLACK (10A)
PIN 2 - WHITE (66A)
PIN 3 - GREEN (63)
PIN 4 - RED (62)
G
1
LEFT FRONT OUTRIGGER:
PIN 1 - BLACK (10A)
PIN 2 - WHITE (65A)
PIN 3 - GREEN (62)
PIN 4 - RED (61)
F
2
TO OUTRIGGER LIMIT SWITCHES
3.23 AutoLeveling Outrigger Connection Diagram
D
E
C
1
B
2
A
1
02
02
X
17B
02
17B - WHITE/BLACK
02 - WHITE
7
8
9
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
10 11 12
4
OCM1 - OUTRIGGER CONTROL MODULE
BLACK
BLACK
3
2
1
6
5
4
9
8
7
BACK VIEW
3
2
1
6
5
4
9
8
7
12 11 10
CONTROL MODULE - P2
PIN 1 - 68A WHITE
PIN 2 - 67A RED/WHITE
PIN 3 - 66A BLUE/WHITE
PIN 4 - 65A GREEN/WHITE
PIN 5 - 70 GREEN/BLACK
PIN 6 - 79 GREEN
PIN 7 - 70A RED/WHITE
PIN 8 - 65 GREEN/BLACK
PIN 9 - N/U
PIN 10 - 35 BROWN/RED
PIN 11 - 02 WHITE (2x)
PIN 12 - 10A BLUE/WHITE
1
2
02
TO CONTROL BOX
PIN 1 - 02 WHITE
PIN 2 - 35C WHITE/BLACK
PIN 3 - 70 GREEN/BLACK
PIN 4 - 70A RED/WHITE
PIN 5 - 71 ORANGE
PIN 6 - 72 RED
PIN 7 - 73 BLUE
PIN 8 - 74 BLACK
TO "ELECTRIC PANEL"
PIN 1 - 02 WHITE
PIN 2 - 35C WHITE/BLACK
PIN 3 - 70 GREEN/BLACK
PIN 4 - 70A RED/WHITE
PIN 5 - 71 ORANGE
PIN 6 - 72 RED
PIN 7 - 73 BLUE
PIN 8 - 74 BLACK
PIN 9 - 75 ORANGE/BLACK
PIN 10 - 76 RED/BLACK
PIN 11 - 77 BLUE/BLACK
PIN 12 - 78 BLACK/WHITE
PIN 13 - 79 GREEN
PIN 14 - 35C WHITE/BLACK
PIN 15 - 35C WHITE/BLACK
PIN 9 - 75 ORANGE/BLACK
PIN 10 - 76 RED/BLACK
PIN 11 - 77 BLUE/BLACK
PIN 12 - 78 BLACK/WHITE
PIN 13 - 79 GREEN
PIN 14 - 35C BLUE/WHITE
PIN 15 - 35C GREEN/WHITE
74
PIN 1 - 74 BLACK
PIN 2 - 02 WHITE
35C WHITE/BLACK
70 GREEN/BLACK
79 GREEN
35D
2
1
5
9
4
6
8
3
3
5
7
6
11 12
7
10
8
13 14 15
9 10
TO ELECTRIC PANEL
02 - WHITE
10A BLUE/WHITE
35 BROWN/RED
79
70
35C
35C
35C BLUE/WHITE
35C GREEN/WHITE
1
71
PIN 1 - 71 ORANGE
PIN 2 - 02 WHITE
BLACK
2
1
02
72
PIN 1 - 72 RED
PIN 2 - 02 WHITE
Y
2
02
1
73
PIN 1 - 73 BLUE
PIN 2 - 02 WHITE
70A
1
2
4
2
02
BLACK
02
TO CONTROL MODULE - P4
PIN 1 - 78 BLACK/WHITE (2x)
PIN 2 - 77 BLUE/BLACK (2x)
PIN 3 - 76 RED/BLACK (2x)
PIN 4 - 75 ORANGE/BLACK (2x)
PIN 5 - 74 BLACK (2x)
PIN 6 - 73 BLUE (2x)
PIN 7 - 72 RED (2x)
PIN 8 - 71 ORANGE (2x)
PIN 9 - 35C WHITE/BLACK (2x)
BACK VIEW
35D PURPLE/WHITE
70A RED/WHITE
02 WHITE
TO "CONTROL BOX"
TEN PIN CONNECTOR PLUG
PIN 1 - 74 BLACK
PIN 2 - 73 BLUE
PIN 3 - 78 BLACK/WHITE
PIN 4 - 77 BLUE/BLACK
PIN 5 - 35D PURPLE/WHITE
PIN 6 - N/U
PIN 7 - 71 ORANGE
PIN 8 - 72 RED
PIN 9 - 75 ORANGE/BLACK
PIN 10 - 76 RED/BLACK
Z
M50333AC_1
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 33
SKYJACK, Page 34
TO POWER DECK DIRECTIONAL VALVE
F
TO CONTACTOR
00 - WHITE
103B - BLACK
99 - GREEN
TO POWER DECK MOTOR CONTACTOR
TO ENGINE
3.24 Powered Extension Platform - Electrical Wiring Diagram (Model 9250)
C
D
E
TO POWER DECK CONTROL BOX - REAR
TO POWER DECK CONTROL BOX - FRONT
B1 MAIN BATTERY
NEGATIVE
B
POSITIVE
A
S1 MAIN DISCONNECT SWITCH
F2
100 AMP
FUSE
POWER DECK CONTACTOR
09 - ORANGE/RED
02 - WHITE
TO ELECTRIC PANEL
G
H
V
W
X
Y
Z
M50296AB
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
B
3.25 Horn, Light & Beeper Wiring Diagram (ANSI/CSA) (Model 9250)
C
D
E
F
G
H
V
ROTATING AMBER BEACON OPTION
HORN, LIGHT & BEEPER
FL-22
LIGHT
00 - WHITE
22 - GREEN
DUAL FLASHING LIGHT OPTION
FL -22-1
RL - 29
ROTATING BEACON
29 - RED
FL-22-2
W
X
FASTEN THE “00” WIRES ON THIS
BOLT WITH HARDWARE SUPPLIED
BP - 29
BEEPER
29 - RED
00 - BLACK
TO MAIN ELETRICAL PANEL
BP - 29
BEEPER
29 - RED
00 - BLACK
Y
GREEN - 22
WHITE - 02
GREEN - 22
WHITE - 02
TO MAIN ELECTRICAL PANEL
H1 - HORN
00 - WHITE
49A - GREEN
H1 - HORN
00 - WHITE
49A - GREEN
TO MAIN ELECTRICAL PANEL
Z
M47681AA_S3
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 35
A
B
C
3.26 Horn, Light, Beeper & Load Sensing Wiring Diagram
D
E
F
G
H
V
W
X
Y
Z
M134226AF
SKYJACK, Page 36
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
A
B
3.27 Electrical Inverter Wiring Diagram
D
E
C
INV1
F
G
H
ELECTRIC PANEL
V
34CR
VIOLET WIRE
W
F4
EXISTING CABLE
TERMINAL BLOCK (ANSI/CSA) - #33
S1
X
D34A
TO AC OUTLET
33
Y
POSTIVE
NEGATIVE
TERMINAL BLOCK (CE) - #33
B1
BATTERY
Z
EXISTING CABLE
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
M124092AD
SKYJACK, Page 37
A
B
3.28 Engine Wiring Diagram - Kubota Diesel Engine
D
E
C
F
G
H
ENGINE HARNESS FROM ELECTRIC PANEL
BLACK (N/U)
BLACK/WHITE (N/U)
87
103
103
6
87a
6
86
85
30
91A
31A
103
GLOW PLUG RELAY
02
00"
5.5
6.
6.00 000"
0"
MAIN STARTER
V
0"
PIN 1 - N/U
PIN 2 - N/U
PIN 3 - 02 WHITE
PIN 4 - 91A RED
PIN 5 - 32A GREEN/BLACK
PIN 6 - 90 RED
91A
02
02
4
1
ELECTRIC PANEL
BACK VIEW
1
2
3
4
5
6
DEUTSCH
5.00
GLOW PLUG TIMER
ALTERNATOR MAIN
PIN 30 - 103 RED
PIN 87 - 91A - RED
PIN 86 - 31A RED/WHITE
PIN 85 - 02 WHITE
PIN 87a - N/U
12
11
10
9
8
7
PIN 1 - 31A RED/WHITE
PIN 2 - 34A GREEN/WHITE
PIN 3 - 02 WHITE
PIN 4 - 32A GREEN/BLACK
PIN 5 - N/U
PIN 6 - N/U
PIN 7 - N/U
PIN 8 - N/U
PIN 9 - 2A BLACK/RED
PIN 10 - 37 BLUE/WHITE
PIN 11 - 07 RED
PIN 12 - 05 PURPLE/WHITE
BACK VIEW
PIN 1 - 31A ORANGE
PIN 2 - 34A WHITE/BLACK
PIN 3 - 02 WHITE
PIN 4 - 32A ORANGE/BLACK
PIN 5 - N/U
PIN 6 - N/U
PIN 7 - 33 GREEN
PIN 8 - 10A GREEN/BLACK
PIN 9 - 2A RED/BLACK
PIN 10 - 37 BLUE/BLACK
PIN 11 - 07 RED
PIN 12 - 05 BLUE
5
2
91A
2A - BLACK/RED
2B - WHITE
1
07
57 - BLACK/WHITE
02 - WHITE
31A - RED/WHITE
5A - PURPLE/WHITE
07
07
STARTER MOTOR
GLOW PLUG SWITCH
31A
31A
2
37
PRESSURE SWITCH
07
3
103
57
02
91A
103 - RED
57
91A
90 - RED
91A - RED
W
MAIN STARTER
2A
GLOW PLUG LIGHT
90
2B
90
32A
6
3
90
32A
STARTER SOLENOID
BACK VIEW - FEMALE
37 BLUE/WHITE
07
X
32A - GREEN/BLACK
FRONT VIEW - MALE
37 - IG
N/U - L
IG
WHITE "PIGTAIL" WIRE ON STARTER
L
4
2
05
1
07
32A
5
4
07
05
32A
05
3
05
5
6
OFF / ON / START SWITCH
6
ALTERNATOR TRIGGER
N/U - L
37 BLUE/WHITE
05 - PURPLE/WHITE
07 - RED
32A - GREEN/BLACK
TEMPERATURE SWITCH
2B - WHITE
2B
Y
FUEL VALVE ON ENGINE
37 - BLUE/WHITE
57 - BLACK/WHITE
FUEL VALVE GROUND
37
37
57
57
00
00 - WHITE
THROTTLE SOLENOID
34A - GREEN/WHITE
02 - WHITE
34A
02
00
Z
ENGINE GROUND
GLOW PLUG
00 - WHITE
91A - RED
91A
M147615AA_1
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 39
A
B
3.29 Engine Harnesses - GM Dual Fuel Engine
D
E
C
OXS2
GPS1
G
H
OXS1
2P-56
TPS2
F
V
TPS1
MS1
OPS1
W
X
IGC1
F8
CPS1
F12
32ACR
F7
F10
Y
F13
RA1
2002CR
PRV1
F9
56CR
Z
F11
GI1-4
GI1-3
GI1-2
GI1-1
M142448AA
SKYJACK, Page 40
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
3.30 Electrical Panel Diagram - ANSI/CSA (All Option)
D
E
CONTROL MODULE - P2
PIN 9 - 28 GREEN/RED
PIN 10 - 35 BROWN/RED
PIN 11 - 02 WHITE (2x)
PIN 12 - 10A BLUE/WHITE
9
5
6
2
3
31
05
34
32
10
2A
13
14
16
15
23
V
03
24
D78
9
10 11 12
4
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
34B
CR
31A
49A
34A
02
10A
05
10A
2A
10A
02 10B
02 13
02 14
02 15
02 16
02 23
02 24
02 30
10B
CR1
13
CR
14
CR
15
CR
16
CR
23
CR
24
CR
30
CR
10A
13A
14A
15A
16A
23A
24A
30A
36B
04
R
R
32
CR
02
10A
CR1
43
41
32A
42
04
R
04
R
04
R
04
R
40
37
30A
1000 uF
D14B-1
09
10A
13A
B
R
D13A
29
R
14B
D28A
D20A
D14B-2
B
17A 18A
33 20A
B D17A B D18A
31A
D15A-2 B D16A-2 B
25
B
30
D30
07
R
15A
16A
D15A-1
D16A-1
21
23A 24A
35
34A
32A
10A
15A
16A
18A
18A
17A
44
28
02
40
02 18
02 17A
02 17
02 20
18
CR
17A
CR
17
CR
20
CR
10A
20A
28
CR
R
07
14B 17A
13A
09
18A
33
1
TD
28A
25
23A
24A
14B
7A
15B
16B
R
R
17
44
02
35
35
CR
21
01
10A
10A
19A
W
02
07
7A
14
13
10A
20
D44
02
7A
D23A B D24A B
18
14A
09
02
02
49
CR
D71
D76
02
02
00
31
CR
R
JUMP J17E
R
00
32
37
00
02
41
R
D75
ENABLE
D30A
00
05
42 34B
05
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
41
02 49
R
2A
8
D72
29
FRONT RIGHT
FRONT LEFT
J17D
65CR
J17E
17BCR
43
02 31
05
7
D10
10A
D73
D77
D74
REAR RIGHT
35C
78
73
77
74
71
75
72
76
REAR LEFT
17B
02
78
73
77
74
71
75
72
76
04
17
86A
10A
09
44
01
02
02
36A
61
36
9CR2
TO FLASHER
PIN X - 22 RED
PIN L - 29
BLU/YEL
22
D17B-2
D17B-1
CN21
CN20
61CR
H
04
17
86A
10A
09
44
01
02
02
36A
61
36
49
D34
9CR3
G
14
8
1
13
7
4
1 2 3 4 5 6 7 8 9 10 11 12
CN14
F
10 11 12
05
OUTRIGGER ELECTRIC PANEL 12 PIN CONNECTOR PLUG - CN14
PIN 7 - 01 RED/BLUE
PIN 1 - 04 RED/BLUE
PIN 8 - 02 WHITE
PIN 2 - 17 BLUE/RED
PIN 9 - 02 WHITE
PIN 3 - 86A ORG/BLK/WHT
PIN 10 - 36A BLACK
PIN 4 - 10A BLUE/WHITE
PIN 11 - 61 BLACK
PIN 5 - 09 ORANGE/RED
PIN 12 - 36 BLACK/WHITE
PIN 6 - 44 RED
10A
C
2A
B
00
A
02
00
02
03
05
10A
X
D19
15B
TWO SPEED MOTOR
20A - BLACK
02 - WHITE
END OF STROKE
36A - BLACK
36B - BLK/WHT
02
19
16B
NOTE: THE 1000uF CAPACITOR IS NOT REQUIRED ON MACHINES
EQUIPPED WITH WET BRAKES.
20A
29
HIGH SPEED
10A - BLUE
35 - BROWN
22
49A
TO HORN/LIGHT/BEEPER
00 - WHITE
22 - RED
29 - BLACK
49A - GREEN
PLATFORM CONTROL BOX
CABLE CONNECTOR
BACK VIEW
FEMALE
(34) GREEN WHITE
(32) GREEN BLACK
(31) RED WHITE
(24) BLUE BLACK
(23) BLACK WHITE
(20) BLACK WHITE RED
(19) ORANGE BLACK
(18) RED BLACK
16
8
WHITE BLACK (16)
15
14
7
6
BLUE (15)
BLACK (14)
13
12
5
4
ORANGE (13)
BLUE WHITE (10)
(7D) RED BLACK GREEN
11
10
3
2
ORANGE RED (09)
RED (7)
9
1
WHITE (02)
BACK VIEW
TO JOYSTICK BOX
26' LIFT CUTOUT
61 - BLACK
36 - BLK/WHT
00
TO ENGINE
00
MAIN MANIFOLD HARNESS
00 - WHITE (14 AWG)
02 - WHITE
03 - BLUE (14 AWG)
09 - ORANGE/RED
13A - ORANGE
14B - BLACK
15B - BLUE
16B - WHITE/BLACK
17A - BLUE/RED
18A - RED/BLACK
23A - BLACK/WHITE
24A - BLUE/BLACK
25 - ORANGE/GREEN
30A - BROWN
ENGINE HARNESS
PIN 1 - 31A ORANGE
PIN 2 - 34A WHITE/BLACK
PIN 3 - 02 WHITE
PIN 4 - 32A ORANGE/BLACK
PIN 5 - N/U
PIN 6 - N/U
PIN 7 - 33 GREEN
PIN 8 - 10A GREEN/BLACK
PIN 9 - 2A RED/BLACK
PIN 10 - 37 BLUE/BLACK
PIN 11 - 07 RED
PIN 12 - 05 BLUE
BLACK (TIED BACK)
BLACK/WHITE (TIED BACK)
Y
FEMALE
32
31
30
24 GREEN BLACK WHITE (77)
23 RED GREEN (76)
LEGEND:
22
WHITE RED (75)
21
20
BLACK RED (74)
MAIN MANIFOLD HARNESS
(10D) WHITE RED GREEN
29
28
(60) BLACK RED GREEN
(85) ORANGE BLACK WHITE
27
26
19
18
ORANGE GREEN (73)
WHITE BLACK RED (72)
ENGINE HARNESS
(78) RED BLACK WHITE
25
17
BLUE RED (71)
GREEN (49)
BACK VIEW
Z
PLATFORM CONTROL BOX
BASE CONTROLS
(GROUND) BLUE BLACK WHITE TO (00)
GROUND
M147881AC
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
SKYJACK, Page 41
9
5
6
2
3
31
05
49
32
15
05
8
1
10A
7
4
H
10 13A
2A
16
15
16
23
V
03
24
4
5
6
7
8
9
3
1
2
3
4
5
6
2
1
2
3
1
ENABLE
41
05
02 49
42 34B
41
32
31
CR
49
CR
34B
CR
31A
49A
34A
31A
49A
34A
R
05
R
R
02
10A
05
05
13A
36B
04
2A
10A
02
10B
02 13D
02 14D
02 15
02 16
04
02 23
04
02 24
02 30
13D
CR
14D
CR
15
CR
16
CR
23
CR
24
CR
30
CR
10C
13B
14A
15A
16A
23A
24A
30A
D15A-1
D16A-1
D23A
D24A
R
R
04
R
04
R
10A
CR1
D71
32
CR
02
43
41
32A
42
40
37
32A
10A
37
10C
JUMP J17E
23A
W
24A
30A
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
D75
65CR
43
02 31
2A
4
10A
9
D72
8
1000 uF
D73
D74
D77
10 11 12
7
D76
FRONT RIGHT
FRONT LEFT
J17D
17BCR
J17E
61CR
G
10 11 12
05
D78
35C
78
73
77
74
71
75
72
76
9CR2
REAR RIGHT
04
17
86A
10A
09
44
01
02
02
36B
61
36
17B
02
78
73
77
74
71
75
72
76
D17B-1
CN21
CN20
9CR3
F
D10
D17B-2
CN14
REAR LEFT
1 2 3 4 5 6 7 8 9 10 11 12
CONTROL MODULE - P2
PIN 10 - 35 BROWN/RED
PIN 11 - 02 WHITE (2x)
PIN 12 - 10A BLUE/WHITE
2A
OUTRIGGER ELECTRIC PANEL 12 PIN CONNECTOR PLUG - CN14
PIN 1 - 04 RED/BLUE
PIN 7 - 01 RED/BLUE
PIN 8 - 02 WHITE
PIN 2 - 17 BLUE/RED
PIN 9 - 02 WHITE
PIN 3 - 86A ORG/BLK/WHT
PIN 10 - 36B YELLOW
PIN 4 - 10A BLUE/WHITE
PIN 11 - 61 BLACK
PIN 5 - 09 ORANGE/RED
PIN 12 - 36 BLACK/WHITE
PIN 6 - 44 RED
NOTE: ON SJ9241 ONLY, JUMPER WIRE
IS BETWEEN 61 & 36 (PIN 11 & 12)
3.31 Electrical Panel Diagram - CE (All Option)
D
E
C
00
B
02
A
04
17
86A
10A
09
44
01
02
02
36A
61
36
28E
28
20
18
D15A-2 D16A-2
D30
60
14A
1B
14B
1B
15A
16A
18A
18A
17A
44
02
28E
02
28
02
40
02 18
02 17A
02 17
02 20
28E
CR2
28
CR2
18
CR
17A
CR
17
CR
20
CR
13C
13C
10A
20A
28E
CR1
28
CR1
15B
D14E-2
D17A
D10E
13B
02 28
1000 uF
14D
10A
02 28E
14C
10A
14C
R
16B
01
R
17
10C
02
35
35
CR
21
10A
35B
19A
00
02
03
05
44
X
D19
TWO SPEED MOTOR
20A - BLACK
02 - WHITE
00 00
02 02 02 02 09 09 13D
02
D13
D14
13
14
10D 10E 10A 14B
D18A
D14B-1
D14E-1
00
02
02
02
09
13D
10A
14D
10D
10E
14E
10A
14B
34B
07
17A
7A
25
33
7C
60
18A
15B
D34
07 17A 7A 25
16B
19
35B
NOTE: THE 1000uF CAPACITOR IS NOT REQUIRED
ON MACHINES EQUIPPED WITH WET BRAKES.
D20A
33
7C 60 18A
34
TO JOYSTICK BOX
MAIN MANIFOLD HARNESS
ENGINE HARNESS
26' LIFT CUTOUT
61 - BLACK
36 - BLK/WHT
NOTE: LIMIT SWITCH NOT USED ON SJ9241
PLATFORM CONTROL BOX
BASE CONTROL BOX
LOAD SENSE CONTROL MODULE
ENGINE HARNESS
PIN 1 - 31A ORANGE
PIN 2 - 34A WHITE/BLACK
PIN 3 - 02 WHITE
PIN 4 - 32A ORANGE/BLACK
PIN 5 - N/U
PIN 6 - N/U
PIN 7 - 33 GREEN
PIN 8 - 10A GREEN/BLACK
PIN 9 - 2A RED/BLACK
PIN 10 - 37 BLUE/BLACK
PIN 11 - 07 RED
PIN 12 - 05 BLUE
BLACK (TIED BACK)
BLACK/WHITE (TIED BACK)
LOAD SENSE CONTROL MODULE
02 - WHITE
10C - BLUE/BLACK
10E - BLUE/WHITE
13D - ORANGE
14D - BLACK
15 - BLUE
16 - WHITE/BLACK
28 - GREEN/BLACK
28E - GREEN/WHITE
35B - RED/BLACK
49A - GREEN
60 - BLACK/WHITE
RED (TIED BACK)
RED/WHITE (TIED BACK)
ORANGE/BLACK (TIED BACK)
PLATFORM CONTROL BOX
CABLE CONNECTOR
BACK VIEW
BACK VIEW
FEMALE
FEMALE
(34) GREEN WHITE 16
(32) GREEN BLACK 15
(31) RED WHITE 14
(24) BLUE BLACK 13
(23) BLACK WHITE 12
8
WHITE BLACK (16)
32
7
6
BLUE (15)
BLACK (14)
31
30
5
4
ORANGE (13)
BLUE WHITE (10)
(20) BLACK WHITE RED 11
(19) ORANGE BLACK 10
3
2
ORANGE RED (09)
RED (7A)
1
WHITE (02)
(18) RED BLACK 9
Y
(GROUND) BLUE BLACK WHITE TO (00)
GROUND
(7C) RED BLACK GREEN
(10D) WHITE RED GREEN
29
28
24 GREEN BLACK WHITE (77)
23 RED GREEN (76)
22 WHITE RED (75)
21 BLACK RED (74)
20 ORANGE GREEN (73)
(60) BLACK RED GREEN
(85) ORANGE BLACK WHITE
27
26
19 WHITE BLACK RED (72)
18 BLUE RED (71)
(78) RED BLACK WHITE
25
17 GREEN (49))
Z
BACK VIEW
1 2 3 4 5 6
LEGEND:
MAIN MANIFOLD HARNESS
00 - WHITE (14 AWG)
02 - WHITE
03 - BLUE (14 AWG)
09 - ORANGE/RED
13A - ORANGE
14B - BLACK
15B - BLUE
16B - WHITE/BLACK
17A - BLUE/RED
18A - RED/BLACK
23A - BLACK/WHITE
24A - BLUE/BLACK
25 - ORANGE/GREEN
30A - BROWN
12 11 10 9 8 7
HIGH SPEED
10A - BLACK
35 - BLK/WHT
TO ENGINE
20A
M147867AC
SKYJACK, Page 42
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
08
NO
NC
NC
HELD
OPEN
10
DR
LFT 09
S3
KEY SWITCH
OFF/LIFT/DRIVE
(IN OFF POSITION)
12
S7-7
JOYSTICK
ENABLE
IN
OUT
IN
OUT
D26
D26A
02
12BCR
99
00
00
S8
HORN
ON
15
23
24
S7-2
RIGHT
S7-3
LEFT
18
02
19
20
16
S41
HIGH/LOW
TORQUE
09
14
S7-4
REV
18B
20B
OFF
UP
DN
13
S7-5
FWD
S7-6
3RD
SPEED
S7
JOYSTICK
CONTROLLER
S7-1
2ND
SPEED
12
S29
HIGH/LOW
RANGE
09
S12
HYDRAULIC
GENERATOR
SWITCH
9A
LEVEL
ALL UP
35C
35D
S23
S22
S21
S20
DN
UP
DN
UP
DN
UP
DN
UP
GREEN
GREEN/BLACK
RED/WHITE
WHITE
79
70
70A
02
76
73
77
74
78
RED
RED/BLACK
BLUE
BLUE/BLACK
BLACK
BLACK/WHITE
75
72
76
73
77
74
78
72
75
ORANGE
ORANGE/BLACK
71
71
02
70A
70
79
35C
WHITE/BLACK
35C
FF
28
EE
09
35
44
09
35
D19
D10
34B
9CR2
35B
09
35C
9CR3
35C
10A
HOURMETER
2A
10A
TT
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
NORMALLY OPEN
HELD CLOSED
LS5
19
05
05
05
05
05
05
07
32
31CR
41
10A
10A
HH
D18A
D86
33
S2
02
02
LEFT
REAR
05
9CR1
10BCR1
KK
LS63
RIGHT
REAR
63
36B
GG
1A
LS62
RIGHT
FRONT
75
71
76
DN
DN
75
UP
UP
71
S21A
FRONT RIGHT
04
04
04
86A
85
72
16
73
78
DN
DN
78
CUT J36
2A
86B
74
D78
100B
D75
36A
J17E
21
D74
10A
66A
68A
D73
10A
65A
LEFT FRONT
LS65
1TD
D71
CUT
J17D
17B
FL-22
00
CAP1
40
4H-15B
2H-25
32
GLOW PLUG RELAY
THROTTLE RELAY
51
TIME DELAY #1
REVERSE RELAY
RIGHT RIGHT
84
85
OUTRIGGER DRIVE
ENABLE RELAY
OUTRIGGER
LIFT DISABLE RELAY
OUTRIGGER
CONTROL MODULE
97
98
110
65 = P2-8
AUTO LEVEL
118
119
120
70 = P2-5
70A = P2-7
02 = P2-11
D02-31
D02-30
4H-78
D02-29
4H-74
D02-28
4H-77
D02-27
4H-73
D02-26
4H-76
D02-25
4H-72
D02-24
4H-75
4H-71
AUTO RETRACT
117
79 = P2-6
LEFT FRONT UP
OUTRIGGER SOLENOID
LEFT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
RIGHT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT REAR UP
OUTRIGGER SOLENOID
RIGHT REAR DOWN
OUTRIGGER SOLENOID
LEFT REAR UP
OUTRIGGER SOLENOID
LEFT REAR DOWN
OUTRIGGER SOLENOID
123
124
125
126
127
128
129
GROUND
122
121
OUTRIGGER ENABLE
116
35C = P4-9
OUTRIGGER LIGHT
POWER
115
10A = P2-12
LEFT FRONT DOWN
RIGHT FRONT DOWN
RIGHT REAR DOWN
LEFT REAR DOWN
114
113
112
LIFT ENABLE
65A = P2-4
66A = P2-3
67A = P2-2
111
TILT OVERRIDE/
HIGH DRIVE CUTOUT
109
28 = P2-9
68A = P2-1
LEFT REAR DOWN
108
35 = P2-10
TILT
RIGHT REAR DOWN
106
107
78 = P4-1
RIGHT FRONT DOWN
LEFT FRONT DOWN
LEFT REAR UP
RIGHT REAR UP
RIGHT FRONT UP
105
104
103
102
101
100
LEFT FRONT UP
OUTRIGGER
ENABLE RELAY
96
99
OUTRIGGER
PROOF RELAY
95
94
93
OUTRIGGER LIFT
ENABLE RELAY
91
OUTRIGGER
HOLDING SOLENOID
92
90
89
88
87
LEFT RELAY
FORWARD RELAY
83
86
3RD SPEED
RELAY
82
81
SMALL PUMP DUMP
VALVE SOLENOID
RIGHT STEERING
VALVE SOLENOID
LEFT STEERING
VALVE SOLENOID
79
80
FORWARD
VALVE SOLENOID
78
BRAKE RELAY
QUICK BRAKE VALVE (NOTE: FOR
MACHINES WITH WET BRAKES ONLY)
REVERSE
VALVE SOLENOID
77
76
75
74
73
72
CAPACITOR (NOTE: REMOVED ON
MACHINES WITH WET BRAKES)
70
71
SERIES/PARELLEL
VALVE SOLENOID
2ND SPEED/LARGE
PUMP RELAY
69
TILT OVERIDE
RELAY
SERIES/PARELLEL
RELAY
68
LIFT VALVE
SOLENOID
LARGE PUMP DUMP
VALVE SOLENOID
SMALL PUMP RELAY
HYDR. GENERATOR
STOP RELAY
HYDR. GENERATOR
RELAY
HYDR. GENERATOR
SOLENOID
67
66
65
64
63
62
61
60
59
58
57
OIL COOLER FAN
OIL COOLER RELAY
56
UP RELAY
55
54
53
DOWN RELAY
START RELAY
50
52
BEEPER
49
48
ROTATING AMBER
BEACON OPTION
47
ENGINE ON RELAY
45
46
BRAKE FEED
VALVE SOLENOID
44
FREE-WHEELING
VALVE SOLENOID
BRAKE DUMP
VALVE SOLENOID
43
TILT SW. RELAY
41
42
ALL FUNCTION
FLASHING LIGHT
MAIN LOWERING
VALVE SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
40
39
38
37
36
35
34
20 A BREAKER
HORN
31
33
AUXILIARY 12V BATTERY
HORN RELAY
30
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
28
29
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
27
BASE CONTACTOR
REAR DECK
IN SOLENOID
REAR DECK
OUT SOLENOID
FRONT DECK
IN SOLENOID
FRONT DECK
OUT SOLENOID
P.M.T. CONTACTOR
26
25
24
23
22
21
20
19
18
17
16
12V BATTERY
P.M.T. UNIT
MOTOR
ALTERNATOR
15
ENGINE STARTER
EL. MOTOR
14
TEMPERATURE
SWITCH
ENGINE STARTER
CONTACTOR
DIESEL VALVE
SOLENOID
ENGINE
GLOW PLUGS
13
12
11
10
9
8
7
6
GLOW PLUG
INDICATOR
HIGH THROTTLE
SOLENOID
5
4
GLOW PLUG
TIMER
GLOW PLUG
RELAY
3
2
1
NEGATIVE
-
77 = P4-2
76 = P4-3
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
D02-23
2H-17B
D02-22
2H-18A
D02-21
D02-20
4H-24A
D02-19
4H-23A
16B 4H-16B
D02-18
II,JJ
1000 MFD
D02-17
15B
D02-16
3H-20A
D02-15
D02-14
2H-14B
2H-17A
D02-13
CB3
02
00
00
2H-86C
00
BP-29
D02-12
D02-11
2H-30A-2
D02-10
2H-30A-1
2H-30A
29
D17B-2
PP
67A
D72
18A
LS67
F
D14B-3
RIGHT REAR
10A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
LS66
LEFT REAR
10A
LS68
D14B-2
FAN
29
RL-29
D30A
FL-29
22
D02-9
2H-13A
D02-8
2H-13A-1
D02-7
2H-13A-2
D02-6
2H-13A-3
D02-5
2H-134
H1
HORN
D02-4
D02-3
2H-98-4
D02-2
2H-98-3
B1
M
INV1
2H-98-1
34A
FLASHER
40
17ACR
17A
D17B-1
25
12V
*104
D02-1
2H-98-2
ALL MOTION
ALARM
D13A
D20A
30A
98
OUTRIGGER DOWN LIMIT SWITCHES
NORMALLY CLOSED HELD OPEN
D76
D36
65
17E
D77
17DCR
17D
D23A
D34A
B2
TPS1
ENGINE
TEMPERATURE
SWITCH
2B
D02-39
57
2D37
EGP1
D02-38
HTS-34A
02
INVERTER OPTION
200 AMP
30CR
30
D30
04
20A
65CR
20CR
20
D14B-1
86C
D16A-2
10A
04
13A
12V
97
85A
14B
90
32ACR
D57
F4
FUSE
91A
GPL1
32A
GPT1
S51
AUX. EMERGENCY
LOWERING
85
86BCR
37
32A
G
D28A
13CR
D15A-2
D24A
02
103
31ACR
31A
02
09
13
28A
D15A-1
74
NN
2A
86D
28CR
10A
D16A-1
17CR
36
UP
77
BB
17
10A
10A
D96
31A
KUBOTA DIESEL ENGINE
(*) KUBOTA SUPPLIED WIRE
LED-2
POWER ON LIGHT
17A
10ACR2
61
UP
73
100
96
28
10A
RST2
3 OHM
D86C-1
10A
85A
100
MM
S23A
REAR LEFT
03
AUXILIARY EMERGENCY
LOWERING SYSTEM
103
16A
LS1
S31
GLOW PLUG
SWITCH
S1
MAIN POWER
DISCONNECT
26' LIFT CUTOUT
NORMALLY CLOSED
16CR
23A
15CR
1A
14A
07
32A
2B
D86C-2
15A
14CR
77
15
24A
61CR
61
01
14
86B
23CR
24CR
23
86ACR
S22A
REAR RIGHT
24
72
03
20A BREAKER
CB1
F2
FUSE
POWER DECK OPTION
49A
04
04
76
61
04
LEFT
FRONT
S20A
FRONT LEFT
62
LS61
26' DRIVE
CUTOUT
JUMPER
END OF STROKE
NORMALLY CLOSED
LS4
36A
D17A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
35E
64
05
49CR
D02-32
HYDRAULIC GENERATOR
OPTION
10B
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
D44
LS64
S9B
OUTRIGGER
ENABLE
35C
10A
01
18A
18CR
28CR
17
44
10A
CC
85A
15A BREAKER
CB4
14
UP
01
18
41
42
13
03
10A
49
09
05
02
OPS1 OIL
PRESSURE
SWITCH
S30 MAIN
ENGINE SW
OFF/ON/START
100 AMP
02
37
37
103A
37
2A
2A
10A
32A
32A
34A
34A
33
31A
31A
05
05
10ACR1
10A
2A
DOWN
10E
35CR
S10
34A
32A
34BCR
10A
19A
10A
35
10A
10A
02
32CR
34B
ENABLE
31
10A
10A
10A
10A
10A
43
31A
07
07
G
REAR
LEFT
35D
FRONT
RIGHT 35D
REAR
RIGHT
S24
OL1
OUTRIGGER
LIGHT
02
35D
FRONT
LEFT
35D
AUTO
MODE
35D
35C
65
BLUE/WHITE
24
BLUE/BLACK
35C
23
BLACK/WHITE
35C
15
BLUE
GREEN/WHITE
16
D34
28
7A
F
35C
18
RED/BLACK
02
WHITE
WHITE/BLACK
19
ORANGE/BLACK
09
20
ORANGE/RED
86
14
BLACK
85
13
ORANGE
WHITE
34
GREEN/WHITE
GREEN
32
GREEN/BLACK
09
31
RED/WHITE
(BLACK)
10
CRD3
BLUE/WHITE
CRD2
00
49
00
103B
7A
BLACK/WHITE/RED
86
85
09
CRD1
BLUE/BLACK/WHITE
GREEN
RED
S6
EMERGENCY
STOP
SWITCH
3.32 Electrical Schematic - ANSI/CSA & AS (All Option with Kubota Diesel Engine)
C
D
E
S9A
OUTRIGGER
ENABLE
OUTRIGGER OPTION
WITH AUTO LEVELLING
09
S5
UP/DOWN
34
S9
LIFT
ENABLE
32
S15
ENGINE START
31
10
00
49
00
103B
S14
LOW/HIGH THROTTLE
10
LED-3
POWER ON LIGHT
10
D02-37
D02-36
4H-27A
D02-35
4H-26A
S13
GLOW PLUG SWITCH
10
4H-26
D02-33
103B
D02-34
4H-27
99CR
LED-1
POWER ON LIGHT
D27A
12A
D27
JOYSTICK
ENABLE
RELAY
12B
12
27A
26A
27
26
M
7A
BASE
B
08
S11A
S11
POWER DECK OPTION
103C
S34A
ENABLE
S34
ENABLE
10 AMP
103B
00
7A
CONTROL BOX
A
103C
F5
103C FUSE
DCM1
P.M.T. UNIT
MOTOR
08
S4
EMERGENCY
STOP
SWITCH
H
AB
V
W
X
Y
Z
M148225AD
SKYJACK, Page 43
SKYJACK, Page 44
35D
35D
FRONT
RIGHT 35D
REAR
LEFT
LEVEL
ALL UP
S23
S22
S21
S20
DN
UP
DN
UP
DN
UP
DN
UP
35C
79
70
71
75
WHITE/BLACK
GREEN
GREEN/BLACK
RED/WHITE
WHITE
ORANGE
ORANGE/BLACK
35C
79
70
70A
02
71
75
73
77
74
78
BLUE
BLUE/BLACK
BLACK
BLACK/WHITE
76
73
77
74
78
76
RED
RED/BLACK
72
72
02
70A
35C
BLUE/WHITE
35C
35
44
09
9CR2
35B
09
35C
9CR3
35C
10A
10A
10A
CC
10A
10A
01
HH
KK
GG
LS63
RIGHT
REAR
63
LS62
RIGHT
FRONT
LS61
75
71
76
DN
DN
71
UP
UP
LEFT
FRONT
S21A
FRONT RIGHT
62
S20A
FRONT LEFT
75
OUTRIGGERS SHOWN IN
RETRACTED POSITION
35E
64
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
LEFT
REAR
LS64
S9B
OUTRIGGER
ENABLE
35C
18CR
18A
10A
18
01
1B
1A
26' DRIVE
CUTOUT
JUMPER
76
61
61CR
61
01
24CR
72
77
DN
UP
77
16CR
16
15A
20A
14A
16A
D86C-1
BB
NN
36
73
73
78
DN
UP
S23A
REAR LEFT
78
J36 (SJ9241 ONLY)
MM
61
LS1
26' LIFT CUTOUT
N.C. (SJ9250 ONLY)
1A
74
74
2A
10A
17
86D
10ACR2
85A
D86C-2
23A
20CR
15CR
15
24A
23CR
23
S22A
REAR RIGHT
24
72
04
04
04
04
04
44
20
36B
14DCR
14D
ANGLE
TRANSDUCER
AT1
28ECR1
28E
D78
17E
D34A
D75
65CR
J17E
18A
D74
D73
D17B-1
36A
21
30CR
30
D30
LS68
LS66
66A
68A
LS67
LS65
65A
LEFT FRONT
10A
16A
15A
D71
CUT
J17D
17B
D17B-2
PP
67A
RIGHT REAR
10A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10A
D72
D14B-2
F
FAN
40
LEFT REAR
10A
29
BP-29
04
25
22
02
D02-4
22
FL-22
2H-98-3
CB3
02
2H-30A
D02-13
3H-20A
D02-12
4H-15B
4H-16B
THROTTLE RELAY
P.M.T. CONTACTOR
35
HORN RELAY
HORN
52
PRESSURE TRANSDUCER
SERIES/PARELLEL
VALVE SOLENOID
BRAKE FEED
VALVE SOLENOID
RIGHT STEERING
VALVE SOLENOID
RIGHT RIGHT
OUTRIGGER DRIVE
ENABLE RELAY
LIFT ENABLE
OUTRIGGER ENABLE
AUTO RETRACT
AUTO LEVEL
OUTRIGGER LIGHT
GROUND
128
129
130
131
79 = P2-6
70 = P2-5
70A = P2-7
02 = P2-11
D02-31
D02-30
4H-78
D02-29
4H-74
D02-28
4H-77
D02-27
4H-73
D02-26
4H-76
D02-25
4H-72
D02-24
4H-75
LEFT FRONT UP
OUTRIGGER SOLENOID
LEFT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
RIGHT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT REAR UP
OUTRIGGER SOLENOID
RIGHT REAR DOWN
OUTRIGGER SOLENOID
LEFT REAR UP
OUTRIGGER SOLENOID
LEFT REAR DOWN
OUTRIGGER SOLENOID
133
134
135
136
137
138
140
141
132
POWER
127
35C = P4-9
4H-71
LEFT FRONT DOWN
126
10A = P2-12
RIGHT FRONT DOWN
RIGHT REAR DOWN
125
124
123
65A = P2-4
66A = P2-3
67A = P2-2
LEFT REAR DOWN
TILT
121
65 = P2-8
122
TILT OVERRIDE/
HIGH DRIVE CUTOUT
120
N/U = P2-9
68A = P2-1
LEFT REAR DOWN
119
RIGHT REAR DOWN
RIGHT FRONT DOWN
LEFT FRONT DOWN
LEFT REAR UP
RIGHT REAR UP
RIGHT FRONT UP
LEFT FRONT UP
OUTRIGGER
CONTROL MODULE
35 = P2-10
117
116
115
114
113
112
111
110
OUTRIGGER
LIFT DISABLE RELAY
OUTRIGGER
ENABLE RELAY
108
109
OUTRIGGER
PROOF RELAY
107
106
105
OUTRIGGER LIFT
ENABLE RELAY
104
OUTRIGGER
HOLDING SOLENOID
103
102
101
100
99
LEFT RELAY
REVERSE RELAY
97
98
FORWARD RELAY
96
3RD SPEED
RELAY
SMALL PUMP DUMP
VALVE SOLENOID
95
94
93
92
LEFT STEERING
VALVE SOLENOID
90
91
89
BRAKE RELAY
QUICK BRAKE VALVE (NOTE: FOR
MACHINES WITH WET BRAKES ONLY)
REVERSE
VALVE SOLENOID
TIME DELAY #1
CAPACITOR (NOTE: REMOVED ON
MACHINES WITH WET BRAKES)
FORWARD
VALVE SOLENOID
88
87
86
85
84
83
FREE-WHEELING
VALVE SOLENOID
BRAKE DUMP
VALVE SOLENOID
81
2ND SPEED/LARGE
PUMP RELAY
82
80
79
78
77
SERIES/PARELLEL
RELAY
ELEVATION/HI SPD
CUTOUT RELAY
75
76
LIFT VALVE
SOLENOID
LARGE PUMP DUMP
VALVE SOLENOID
SMALL PUMP RELAY
HYDR. GENERATOR
STOP RELAY
HYDR. GENERATOR
RELAY
HYDR. GENERATOR
SOLENOID
74
73
72
71
70
69
68
67
66
65
OIL COOLER FAN
OIL COOLER RELAY
64
UP RELAY
DOWN RELAY
BEEPER
FLASHING LIGHT
ROTATING AMBER
BEACON OPTION
63
62
61
60
59
58
57
CONTROL MODULE
ANGLE TRANSDUCER
55
56
54
53
TILT RELAY
49
51
AUX. TILT RELAY
48
50
MAIN LOWERING
VALVE SOLENOID
DOWN
ENABLE RELAY
45
AUX. DOWN
ENABLE RELAY
HOLDING VALVE
SOLENOID
44
47
HOLDING VALVE
SOLENOID
43
46
HOLDING VALVE
SOLENOID (SJ9250 ONLY)
BASE CONTACTOR
HOLDING VALVE
SOLENOID (SJ9250 ONLY)
42
ENGINE ON RELAY
41
20 A BREAKER
AUXILIARY HOLDING
VALVE SOLENOID
40
39
38
37
36
EMERGENCY EXT. DECK
RETRACT CONTACTOR
EMERGENCY EXT. DECK
RETRACT RELAY
34
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
33
AUXILIARY 12V BATTERY
REAR DECK
IN SOLENOID
32
31
30
29
28
FRONT DECK
IN SOLENOID
REAR DECK
OUT SOLENOID
27
FRONT DECK
OUT SOLENOID
26
25
24
23
22
12V BATTERY
START RELAY
21
19
20
18
17
ALTERNATOR
GLOW PLUG RELAY
16
ENGINE STARTER
EL. MOTOR
TEMPERATURE
SWITCH
ENGINE STARTER
CONTACTOR
DIESEL VALVE
SOLENOID
ENGINE
GLOW PLUGS
15
14
13
12
11
10
9
8
7
GLOW PLUG
INDICATOR
HIGH THROTTLE
SOLENOID
6
5
GLOW PLUG
TIMER
GLOW PLUG
RELAY
4
118
II,JJ
1
2
3
78 = P4-1
77 = P4-2
76 = P4-3
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
D02-23
2H-17B
D02-22
2H-18A
D02-21
4H-24A
D02-20
D02-19
4H-23A
16B
D02-18
2H-25
D02-17
15B
D02-16
D02-15
2H-30A-2
CAP1
D02-11
2H-14B
2H-17A
D02-10
2H-86C
D02-9
D02-8
2H-13A
D02-7
2H-13A-2
D02-6
2H-13A-3
D02-5
2H-13A-4
2H-13A-5
00
00
D02-14
2H-30A-1
1TD
B2
00
D02-3
2H-98-4
H1
HORN
RL-22
D20A
D02-1
2H-98-2
D02-2
30A
D14B-1
98
12V
B1
M
INV1
2H-98-1
34A
12V
*104
04
65
D76
F4
FUSE
200 AMP
17ACR
17A
TPS1
INVERTER OPTION
OUTRIGGER DOWN LIMIT SWITCHES
NORMALLY CLOSED HELD OPEN
D77
17DCR
17D
D36
10A
D24A
D16A-2
D16A-1
D23A
D15A-2
17CR
17A
2A
86B
13A
97
86C
17
2B
D02-40
57
2D37
EGP1
D02-39
HTS-34A
02
ENGINE
TEMPERATURE
SWITCH
S51
AUX. EMERGENCY
LOWERING
85A
14B
103
90
GPT1
32ACR
D57
GPL1
91A
AUXILIARY
EMERGENCY
LOWERING
SYSTEM
SJ9250 ONLY
85
10A
37
32A
G
09
86BCR
13DCR
13D
13B
D15A-1
14C
28CR1
28
28CR2
28
13C
103
31ACR
31A
02
32A
NEGATIV
-
G
REAR
RIGHT
S24
35C
OL1
OUTRIGGER
LIGHT
02
35D
FRONT
LEFT
35D
AUTO
MODE
35D
S9A
OUTRIGGER
ENABLE
35C
FF
10A
16 = P2-7
GREEN/WHITE
65
EE
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
NORMALLY CLOSED
LS5
PRESSURE
TRANSDUCER
PT1
10A
D96
28ECR2
28E
96
03
100
31A
KUBOTA DIESEL ENGINE
(*) KUBOTA SUPPLIED WIRE
F
35C
24
35
36B
86B
RST2
3 OHM
97
POWER DECK OPTION
97A
S52 EMERGENCY
DECK RETRACION
CB1
103
S1
MAIN POWER
DISCONNECT
2B
32A
07
S31
GLOW PLUG
SWITCH
3.33 Electrical Schematic - CE (All Option with Kubota Diesel Engine)
C
D
E
OUTRIGGER OPTION
WITH AUTO LEVELLING
BLUE/BLACK
24
23
15
16
18
02
D19
44
17
10C
19A
86ACR
END OF STROKE
JUMPER
36A
D17A
85
86A
35B = P2-10
S7-3
LEFT
BLUE
BLACK/WHITE
WHITE/BLACK
16
23
RED/BLACK
18
15
WHITE
02
19
35B
35
10C
35CR
D18A
33
D86
HYDRAULIC GENERATOR
OPTION
D02-32
9BCR
15 = P2-8
S7-2
RIGHT
S7-4
REV
S7-5
FWD
18B
ORANGE/BLACK
19
20
85A
9B
100A
14D = P2-3
S7-6
3RD
SPEED
S7
JOYSTICK
CONTROLLER
S7-1
2ND
SPEED
BLACK/WHITE/RED
10A
CB4
10E = P2-2
20
09
34B
03
15A BREAKER
28 = P3-4
S41
HIGH/LOW
TORQUE
85
09
60 = P3-3
86
2A
10A
09
02 = P2-11
ORANGE/RED
86
D14E-1
49A
10C = P2-12
20B
09
GREEN
WHITE
85
D14
D13
10C
05
49
05
10C
49CR
05
10A
02 = P3-5
ON
09
14
13
10A
10A
10B
10BCR1
28E = P3-6
OFF
(BLACK)
BLACK
14
09
ORANGE
60
BLACK/RED/GREEN
60
13
49
05
10B
CAP2
100
97ACR-1
97ACR-2
D02-33
97
13D = P2-4
09
S12
HYDRAULIC
GENERATOR
SWITCH
UP
DN
CRD3
GREEN
CRD2
49
CRD1
00
97A
97A
103B
100 AMP
20A BREAKER
05
03
103A
OPS1 OIL
PRESSURE
SWITCH
F2
FUSE
02
29 = P3-2
S29
HIGH/LOW
RANGE
9A
S5
LIFT
UP/DOWN
08
S8
HORN
BLUE/BLACK/WHITE
97A
00
05
34BCR
42
60A = P4-2
12BCR
00
00
97A
00
103B
D14E-2
32CR
34B
41
02
02
37
2A
32A
22 = P3-1
02
12A
12
60
LED-3
POWER ON LIGHT
00
D02-38
D02-37
4H-27A
D02-36
4H-26A
103B
D34
32
41
LED-2
POWER ON
LIGHT-BASE
2A
37
900 = P4-7
ENABLE
RELAY
S9
LIFT
ENABLE
60
4H-26
D02-34
D02-35
4H-27
99CR
103B
34
31CR
31
10A
TT
10A
32A
34A
31A
S30 MAIN
ENGINE SW
OFF/ON/START
CM1
12B
12
D97A-2
D97A-1
D27A
D26A
D27
LED-1
POWER ON LIGHT
27A
26A
27
26
99
GREEN/WHITE
34
32
D10E
10ACR1
2A
HOURMETER
33
34A
31A
05
07
910 = P4-6
12
JOYSTICK
ENABLE
09
IN
OUT
IN
OUT
M
GREEN/BLACK
32
31
UP
10A
10A
10A
34A
05
07
910A = P4-9
DR 12
S11A
S11
D26
00
RED/WHITE
31
D10
10E
10E
43
07
902 = P4-8
NO
S34A
ENABLE
S34
ENABLE
103B
10
S14
LOW/HIGH THROTTLE
BLUE/WHITE
10
10E
DN
14E
05
13D
S2
UP/DOWN
SELECTOR
SWITCH
05
05
10D
7C
S6
EMERGENCY
STOP
28B = P4-3
10
F5
FUSE
10 AMP
POWER DECK OPTION
103C
103C
103C
10
S15
ENGINE START
DCM1
P.M.T. UNIT
MOTOR
10
S13
GLOW PLUG SWITCH
10D
WHITE/RED/GREEN
10D
10
7C
RED/BLACK/GREEN
7C
NO
10E
NCHO
7A
S10
IDLE/PLTF/BASE
KEY SWITCH
(IN IDLE POSITION)
B
NC
LFT 09
10
7A
RED
BASE
7A
CONTROL BOX
A
10
NC HELD
OPEN
08
S3
KEY SWITCH
OFF/LIFT/DRIVE
(IN OFF POSITION)
10D
08
S4
EMERGENCY
STOP
SWITCH
H
AB
V
W
X
Y
Z
M147856AD
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
08
NO
NC
NC
HELD
OPEN
DR
LFT 09
10
12
S7-7
JOYSTICK
ENABLE
IN
D26
D26A
02
12BCR
99
00
00
S8
HORN
ON
19
02
ORANGE/BLACK
WHITE
02
15
23
24
BLUE
BLACK/WHITE
BLUE/BLACK
15
23
24
S7-4
REV
S7-2
RIGHT
S7-3
LEFT
S24
LEVEL
ALL UP
35C
35D
35D
REAR
LEFT
S23
S22
DN
UP
DN
UP
DN
UP
DN
UP
78
74
77
73
76
72
75
71
72
76
73
77
74
78
RED
RED/BLACK
BLUE
BLUE/BLACK
BLACK
BLACK/WHITE
02
WHITE
02
75
70A
RED/WHITE
70A
71
70
GREEN/BLACK
70
ORANGE
79
GREEN
35C
ORANGE/BLACK
35C
WHITE/BLACK
35C
79
35C
BLUE/WHITE
35
44
09
35
LS5
D19
34B
9CR2
35B
09
35C
9CR3
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
NORMALLY OPEN
HELD CLOSED
19
D10
35C
10A
02
10A
05
09
9CR1
32
01
10A
10A
HH
D18A
D86
14
33
S2
02
02
KK
GG
1A
LS63
RIGHT
REAR
63
LS62
RIGHT
FRONT
62
16
75
71
71
76
72
72
77
73
73
DN
78
DN
UP
UP
UP
74
74
D78
2A
86C
85
D76
D75
36A
J17E
D73
D17B-1
21
LS68
68A
66A
65A
LEFT FRONT
10A
LS65
RIGHT REAR
10A
LS67
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10A
LS66
LEFT REAR
10A
29
1TD
CAP1
40
D02-23
2H-17B
D02-22
D02-21
2H-18A
D02-20
4H-24A
D02-19
4H-23A
16B 4H-16B
D02-18
2H-25
D02-17
FRONT DECK
IN SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
32
START RELAY
THROTTLE RELAY
51
REVERSE RELAY
RIGHT RIGHT
86
OUTRIGGER DRIVE
ENABLE RELAY
OUTRIGGER
LIFT DISABLE RELAY
OUTRIGGER
CONTROL MODULE
98
99
TILT OVERRIDE/
HIGH DRIVE CUTOUT
108
109
110
35 = P2-10
28 = P2-9
65 = P2-8
AUTO LEVEL
118
119
120
70 = P2-5
70A = P2-7
02 = P2-11
D02-31
D02-30
4H-78
D02-29
4H-74
D02-28
4H-77
D02-27
4H-73
D02-26
4H-76
D02-25
4H-72
D02-24
4H-75
4H-71
AUTO RETRACT
117
79 = P2-6
LEFT FRONT UP
OUTRIGGER SOLENOID
LEFT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
RIGHT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT REAR UP
OUTRIGGER SOLENOID
RIGHT REAR DOWN
OUTRIGGER SOLENOID
LEFT REAR UP
OUTRIGGER SOLENOID
LEFT REAR DOWN
OUTRIGGER SOLENOID
123
124
125
126
127
128
129
GROUND
122
121
OUTRIGGER ENABLE
116
35C = P4-9
OUTRIGGER LIGHT
POWER
115
10A = P2-12
LEFT FRONT DOWN
RIGHT FRONT DOWN
RIGHT REAR DOWN
LEFT REAR DOWN
114
113
112
LIFT ENABLE
65A = P2-4
66A = P2-3
67A = P2-2
111
LEFT REAR DOWN
107
78 = P4-1
68A = P2-1
RIGHT REAR DOWN
106
77 = P4-2
TILT
RIGHT FRONT DOWN
105
76 = P4-3
LEFT FRONT DOWN
LEFT REAR UP
RIGHT REAR UP
RIGHT FRONT UP
104
103
102
101
LEFT FRONT UP
OUTRIGGER
ENABLE RELAY
97
100
OUTRIGGER
PROOF RELAY
96
95
94
OUTRIGGER LIFT
ENABLE RELAY
93
OUTRIGGER
HOLDING SOLENOID
92
91
90
89
88
LEFT RELAY
FORWARD RELAY
85
87
3RD SPEED
RELAY
83
84
82
SMALL PUMP DUMP
VALVE SOLENOID
RIGHT STEERING
VALVE SOLENOID
LEFT STEERING
VALVE SOLENOID
80
81
FORWARD
VALVE SOLENOID
79
BRAKE RELAY
QUICK BRAKE VALVE (NOTE: FOR
MACHINES WITH WET BRAKES ONLY)
REVERSE
VALVE SOLENOID
TIME DELAY #1
CAPACITOR (NOTE: REMOVED ON
MACHINES WITH WET BRAKES)
78
77
76
75
74
73
72
SERIES/PARELLEL
VALVE SOLENOID
69
2ND SPEED/LARGE
PUMP RELAY
TILT OVERIDE
RELAY
SERIES/PARELLEL
RELAY
68
71
LIFT VALVE
SOLENOID
67
70
LARGE PUMP DUMP
VALVE SOLENOID
66
65
64
SMALL PUMP RELAY
HYDR. GENERATOR
STOP RELAY
63
HYDR. GENERATOR
RELAY
61
HYDR. GENERATOR
SOLENOID
OIL COOLER RELAY
62
60
59
58
57
56
OIL COOLER FAN
UP RELAY
55
DOWN RELAY
53
54
52
BEEPER
49
50
48
ROTATING AMBER
BEACON OPTION
GLOW PLUG/
CHOKE RELAY
47
ENGINE ON RELAY
45
46
BRAKE FEED
VALVE SOLENOID
44
FREE-WHEELING
VALVE SOLENOID
BRAKE DUMP
VALVE SOLENOID
43
TILT SW. RELAY
41
42
ALL FUNCTION
FLASHING LIGHT
MAIN LOWERING
VALVE SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
40
39
38
37
36
35
34
20 A BREAKER
HORN
31
33
AUXILIARY 12V BATTERY
HORN RELAY
30
AUXILIARY HOLDING
VALVE SOLENOID
28
29
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
27
BASE CONTACTOR
REAR DECK
IN SOLENOID
REAR DECK
OUT SOLENOID
26
25
24
23
22
21
P.M.T. CONTACTOR
FRONT DECK
OUT SOLENOID
20
12V BATTERY
P.M.T. UNIT
MOTOR
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
NEGATIV
-
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
II,JJ
1000 MFD
15B 4H-15B
D02-16
3H-20A
D02-15
D71 OCM1
CUT
J17D
17B
2H-17A
D02-14
2H-14B
CB3
02
00
00
2H-86C
00
D02-13
29
BP-29
D02-12
D02-11
2H-30A-2
D02-10
2H-30A-1
D17B-2
PP
67A
D72
18A
40
17ACR
D14B-3
F
FAN
FL-22
2H-30A
22
D02-9
2H-13A
D02-8
2H-13A-1
D02-7
2H-13A-2
RL-29
D30A
D02-5
D02-6
2H-13A-3
FLASHER
FL-29
INV1
B1
TO ENGINE
BLOCK
2H-134
H1
HORN
D02-4
D02-3
2H-98-4
D02-2
2H-98-3
D02-1
2H-98-2
2H-98-1
34A
D14B-2
ALL MOTION
ALARM
17A
D20A
25
98
D13A
30A
B2
D74
30CR
30
D30
04
20A
65CR
D36
65
D34A
200 AMP
100B
OUTRIGGER DOWN LIMIT SWITCHES
NORMALLY CLOSED HELD OPEN
D77
17DCR
17D
10A
17E
D23A
2A
86D
D14B-1
20CR
20
D16A-2
04
D28A
86BCR
14B
12V
97
12V
INVERTER OPTION
F4
FUSE
S51
AUX. EMERGENCY
LOWERING
13A
10ACR2
D16A-1
D24A
02
13CR
D15A-2
17A
86B
85A
09
10A
85A
13
28A
10A
28CR
D15A-1
17CR
36
NN
78
CUT J36
LS1
61
MM
DN
DN
BB
17
10A
D86C-1
26' LIFT CUTOUT
NORMALLY CLOSED
16CR
16A
UP
77
1A
15A
14A
D86C-2
23A
15CR
10A
10A
D96
LED-2
POWER ON LIGHT
96
28
RST2
3 OHM
HYDRAULIC GENERATOR
OPTION
S23A
REAR LEFT
61CR
61
01
15
24A
86B
23CR
24CR
23
86ACR
14CR
100
S22A
REAR RIGHT
24
86A
85
14
100
AUXILIARY EMERGENCY
LOWERING SYSTEM
03
S1
MAIN POWER
DISCONNECT
103
S21A
FRONT RIGHT
76
04
04
04
04
03
POWER DECK OPTION
49A
04
05
CB1
100 AMP
20A BREAKER
103A
F2
FUSE
TO ENGINE
STARTER
GM EFI DUAL FUEL ENGINE
S20A
FRONT LEFT
75
61
04
LEFT
FRONT
LS61
26' DRIVE
CUTOUT
JUMPER
OUTRIGGERS SHOWN IN
RETRACTED POSITION
35E
64
36B
49CR
END OF STROKE
NORMALLY CLOSED
LS4
36A
D17A
10BCR1
10B
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
LEFT
REAR
LS64
S9B
OUTRIGGER
ENABLE
35C
10A
CC
18A
10A
18
85A
D44
01
18CR
28CR
17
44
10A
19A
CB4
15A BREAKER
03
UP
DOWN
10E
35CR
S10
10A
35
10A
10A
10A
42
41
34BCR
32CR
34B
ENABLE
31
10A
10A
10A
05
49
D02-32
37
37
10A
02
2A
10A
32A
33
10ACR1
2A
10A
32A
34A
31A
34A
10A
31CR
41
43
31A
05
07
G
REAR
RIGHT
FRONT
RIGHT 35D
S21
S20
OL1
OUTRIGGER
LIGHT
02
35D
FRONT
LEFT
35D
AUTO
MODE
35D
S9A
OUTRIGGER
ENABLE
28
EE
09
05
HOURMETER
2A
10A
TT
07
F
35C
FF
D34
28
05
05
05
05
05
7A
3.34 Electrical Schematic - ANSI/CSA & AS (All Options with GM Dual Fuel Engine)
C
D
E
GREEN/WHITE
35C
16
65
18
S7-5
FWD
RED/BLACK
18
20
19
WHITE
20
86
GREEN
BLACK/WHITE/RED
85
14
BLACK
09
13
ORANGE
(BLACK)
34
GREEN/WHITE
09
86
85
09
32
GREEN/BLACK
ORANGE/RED
09
14
31
RED/WHITE
WHITE/BLACK
18B
20B
S41
HIGH/LOW
TORQUE
OFF
UP
DN
13
10
CRD3
BLUE/WHITE
CRD2
00
BLUE/BLACK/WHITE
CRD1
49
GREEN
00
103B
16
S7-6
3RD
SPEED
S7
JOYSTICK
CONTROLLER
S7-1
2ND
SPEED
12
S29
HIGH/LOW
RANGE
09
S12
HYDRAULIC
GENERATOR
SWITCH
9A
OUTRIGGER OPTION
WITH AUTO LEVELLING
09
S5
UP/DOWN
34
S14
LOW/HIGH THROTTLE
S9
LIFT
ENABLE
32
31
10
00
49
00
103B
S15
ENGINE START
10
LED-3
POWER ON LIGHT
10
D02-37
D02-36
4H-27A
D02-35
4H-26A
S13
GLOW PLUG/CHOKE
10
4H-26
D02-33
103B
D02-34
4H-27
99CR
LED-1
POWER ON LIGHT
D27A
12A
D27
JOYSTICK
ENABLE
RELAY
12B
12
27A
26A
27
26
M
7A
S6
EMERGENCY
STOP
SWITCH
B
08
S3
KEY SWITCH
OFF/LIFT/DRIVE
(IN OFF POSITION)
IN
OUT
S11A
OUT
POWER DECK OPTION
S34A
ENABLE
S11
00
RED
BASE
A
103C
S34
ENABLE
103B
7A
CONTROL BOX
Refer to 3.29
103C
10 AMP
F5
103C FUSE
DCM1
P.M.T. UNIT
MOTOR
08
S4
EMERGENCY
STOP
SWITCH
H
V
W
X
Y
Z
M147858AB
SKYJACK, Page 45
08
SKYJACK, Page 46
NO
NC
NC
HELD
OPEN
DR
LFT 09
10
12
S7-7
JOYSTICK
ENABLE
12BCR
WHITE
02
24
LEVEL
ALL UP
35C
35D
S23
S22
S21
S20
DN
UP
DN
UP
DN
UP
DN
UP
ORANGE
78
74
77
BLACK/WHITE
BLACK
BLUE/BLACK
BLUE
RED/BLACK
76
73
RED
ORANGE/BLACK
72
75
71
WHITE
RED/WHITE
70A
02
GREEN/BLACK
GREEN
70
79
35C
78
74
77
73
76
72
75
71
02
70A
70
79
35C
35C
35C
65
24
23
FF
D34
28
28
EE
D10
35
44
09
35
LS5
D19
05
10B
10BCR1
10A
9CR2
35B
09
35C
9CR3
TILT OVERRIDE/
HIGH DRIVE CUTOUT
LIMIT SWITCH
NORMALLY OPEN
HELD CLOSED
19
05
07
35C
10A
32
31CR
41
17
44
01
10A
10A
S2
LEFT
REAR
KK
GG
1A
LS63
RIGHT
REAR
63
LS62
RIGHT
FRONT
75
71
76
DN
DN
71
UP
UP
14
05
49
04
04
04
04
03
23CR
61CR
61
01
72
72
77
DN
UP
16
73
85A
BB
17
10A
78
DN
UP
78
74
74
NN
CUT J36
36
61
MM
LS1
D78
65CR
D76
D36
65
D75
36A
J17E
30CR
30
D30
04
20A
21
D74
D73
D17B-1
25
LS68
66A
68A
LS67
LS65
65A
LEFT FRONT
10A
D02-5
D71
CUT
J17D
00
ENGINE ON RELAY
39
UP RELAY
LEFT RELAY
OUTRIGGER DRIVE
ENABLE RELAY
78
OUTRIGGER
LIFT DISABLE RELAY
OUTRIGGER
CONTROL MODULE
84
94
95
28 = P2-9
65 = P2-8
103
104
105
70 = P2-5
70A = P2-7
02 = P2-11
D02-30
D02-29
4H-78
D02-28
4H-74
D02-27
4H-77
D02-26
4H-73
D02-25
4H-76
D02-24
4H-72
D02-23
4H-75
4H-71
AUTO RETRACT
102
79 = P2-6
LEFT FRONT UP
OUTRIGGER SOLENOID
LEFT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT FRONT UP
OUTRIGGER SOLENOID
RIGHT FRONT DOWN
OUTRIGGER SOLENOID
RIGHT REAR UP
OUTRIGGER SOLENOID
RIGHT REAR DOWN
OUTRIGGER SOLENOID
LEFT REAR UP
OUTRIGGER SOLENOID
LEFT REAR DOWN
OUTRIGGER SOLENOID
108
109
110
111
112
113
114
GROUND
OUTRIGGER LIGHT
107
106
OUTRIGGER ENABLE
101
35C = P4-9
AUTO LEVEL
POWER
100
10A = P2-12
LEFT FRONT DOWN
RIGHT FRONT DOWN
RIGHT REAR DOWN
LEFT REAR DOWN
99
98
97
LIFT ENABLE
TILT
65A = P2-4
66A = P2-3
67A = P2-2
96
LEFT REAR DOWN
93
35 = P2-10
68A = P2-1
RIGHT REAR DOWN
92
78 = P4-1
TILT OVERRIDE/
HIGH DRIVE CUTOUT
RIGHT FRONT DOWN
91
LEFT FRONT DOWN
LEFT REAR UP
RIGHT REAR UP
RIGHT FRONT UP
77 = P4-2
89
88
87
86
LEFT FRONT UP
OUTRIGGER
ENABLE RELAY
83
85
OUTRIGGER
PROOF RELAY
81
82
80
79
OUTRIGGER LIFT
ENABLE RELAY
77
76
75
74
OUTRIGGER
HOLDING SOLENOID
RIGHT RIGHT
71
72
73
FORWARD RELAY
REVERSE RELAY
70
3RD SPEED
RELAY
69
68
67
SMALL PUMP DUMP
VALVE SOLENOID
RIGHT STEERING
VALVE SOLENOID
LEFT STEERING
VALVE SOLENOID
65
66
FORWARD
VALVE SOLENOID
64
BRAKE RELAY
QUICK BRAKE VALVE (NOTE: FOR
MACHINES WITH WET BRAKES ONLY)
REVERSE
VALVE SOLENOID
TIME DELAY #1
CAPACITOR (NOTE: REMOVED ON
MACHINES WITH WET BRAKES)
63
62
61
60
59
58
57
SERIES/PARELLEL
VALVE SOLENOID
2ND SPEED/LARGE
PUMP RELAY
56
TILT OVERIDE
RELAY
SERIES/PARELLEL
RELAY
53
54
55
LIFT VALVE
SOLENOID
LARGE PUMP DUMP
VALVE SOLENOID
SMALL PUMP RELAY
OIL COOLER RELAY
OIL COOLER FAN
52
51
50
49
48
47
46
45
DOWN RELAY
THROTTLE RELAY
44
START RELAY
43
GLOW PLUG/
CHOKE RELAY
42
41
40
BEEPER
37
38
BRAKE FEED
VALVE SOLENOID
36
FREE-WHEELING
VALVE SOLENOID
BRAKE DUMP
VALVE SOLENOID
35
TILT SW. RELAY
33
34
ALL FUNCTION
FLASHING LIGHT
MAIN LOWERING
VALVE SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
HOLDING VALVE
SOLENOID
32
31
30
29
28
27
26
90
II,JJ
24
20 A BREAKER
HORN
23
25
AUXILIARY 12V BATTERY
HORN RELAY
22
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
20
21
AUXILIARY HOLDING
VALVE SOLENOID
AUXILIARY HOLDING
VALVE SOLENOID
12V BATTERY
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
NEGATIV
-
76 = P4-3
75 = P4-4
74 = P4-5
73 = P4-6
72 = P4-7
71 = P4-8
OCM1
D02-22
2H-17B
D02-21
2H-18A
D02-20
D02-19
4H-24A
D02-18
4H-23A
16B 4H-16B
D02-17
2H-25
D02-16
15B 4H-15B
1000 MFD
CAP1
40
3H-20A
D02-14
D02-13
2H-14B
CB3
02
00
2H-17A
00
BP-29
D02-15
29
D02-12
D02-11
2H-30A-2
D02-10
2H-30A-1
1TD
17B
FL-22
2H-30A
22
D02-9
2H-13A
D02-8
2H-13A-1
D02-7
2H-13A-2
D02-6
2H-13A-3
D17B-2
PP
40
67A
D72
F
FAN
RIGHT REAR
10A
OUTRIGGERS SHOWN IN
RETRACTED POSITION
RIGHT FRONT
10A
LS66
LEFT REAR
10A
D14B-2
D30A
FL-29
B1
TO ENGINE
BLOCK
2H-134
H1
HORN
D02-4
D02-3
2H-98-4
D02-2
2H-98-3
FLASHER
18A
17ACR
17A
2H-98-1
12V
D02-1
2H-98-2
ALL MOTION
ALARM
D13A
D20A
30A
B2
98
OUTRIGGER DOWN LIMIT SWITCHES
NORMALLY CLOSED HELD OPEN
D77
17DCR
17D
10A
17E
D23A
2A
86D
D14B-1
20CR
20
D16A-2
04
13A
D28A
10ACR2
14B
10A
D15A-2
D24A
02
13CR
D15A-1
17A
13
28A
85A
28CR
10A
D16A-1
17CR
26' LIFT CUTOUT
NORMALLY CLOSED
16CR
16A
S23A
REAR LEFT
73
1A
15A
03
10A
10A
12V
97
S51
AUX. EMERGENCY
LOWERING
AUXILIARY EMERGENCY
LOWERING SYSTEM
LED-2
POWER ON LIGHT
96
28
03
RST2
3 OHM
15A BREAKER
CB4
100
103
100
S1
MAIN POWER
DISCONNECT
D96
GM EFI DUAL FUEL ENGINE
TO ENGINE
STARTER
23A
15CR
77
15
24A
14A
49A
24CR
23
14CR
49CR
S22A
REAR RIGHT
24
D17A
04
76
61
04
LEFT
FRONT
S21A
FRONT RIGHT
62
LS61
26' DRIVE
CUTOUT
JUMPER
S20A
FRONT LEFT
75
OUTRIGGERS SHOWN IN
RETRACTED POSITION
35E
64
36B
END OF STROKE
NORMALLY CLOSED
LS4
36A
02
42
D18A
02
41
CB1
20A BREAKER
05
37
02
2A
10A
32A
33
37
33
31A
34A
10ACR1
2A
10A
HOURMETER
2A
10A
TT
34A
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
HH
14
13
34BCR
34B
D44
UP
LS64
S9B
OUTRIGGER
ENABLE
35C
10A
CC
18A
10A
18
01
18CR
28CR
35CR
S10
10A
19A
10A
35
10A
10A
10A
02
32A
43
DOWN
10E
32CR
ENABLE
31
10A
10A
10A
10A
10A
31A
05
07
G
REAR
LEFT
35D
FRONT
RIGHT 35D
REAR
RIGHT
S24
OL1
OUTRIGGER
LIGHT
02
35D
FRONT
LEFT
35D
AUTO
MODE
35D
BLUE/WHITE
WHITE/BLACK
35C
GREEN/WHITE
BLUE/BLACK
15
16
18
02
19
20
09
14
13
34
32
31
10
00
49
05
05
05
05
7A
3.35 Electrical Schematic - ANSI/CSA & AS (No Options with GM Dual Fuel Engine)
C
D
E
F
S9A
OUTRIGGER
ENABLE
35C
23
S7-3
LEFT
BLACK/WHITE
BLUE
15
S7-4
REV
S7-2
RIGHT
RED/BLACK
ORANGE/BLACK
19
18
CRD3
BLACK/WHITE/RED
ORANGE/RED
09
20
BLACK
14
ORANGE
GREEN/WHITE
GREEN/BLACK
RED/WHITE
BLUE/WHITE
CRD2
WHITE/BLACK
18B
20B
S41
HIGH/LOW
TORQUE
UP
13
CRD1
BLUE/BLACK/WHITE
16
S7-5
FWD
S7-6
3RD
SPEED
S7
JOYSTICK
CONTROLLER
S7-1
2ND
SPEED
12
S29
HIGH/LOW
RANGE
9A
OUTRIGGER OPTION
WITH AUTO LEVELLING
09
DN
S5
UP/DOWN
34
S9
LIFT
ENABLE
S14
LOW/HIGH THROTTLE
31
32
10
10
S15
ENGINE START
S13
GLOW PLUG/CHOKE
12A
02
JOYSTICK
ENABLE
RELAY
12B
12
00
LED-3
POWER ON LIGHT
10
00
GREEN
7A
S6
EMERGENCY
STOP
SWITCH
B
08
S3
KEY SWITCH
OFF/LIFT/DRIVE
(IN OFF POSITION)
00
49
RED
BASE
Refer to 3.29
10
S8
HORN
7A
CONTROL BOX
A
LED-1
POWER ON LIGHT
08
S4
EMERGENCY
STOP
SWITCH
H
V
W
X
Y
Z
M147857AB
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
Full-Size Rough Terrain Series
Models 9241 & 9250
143905
37
10A
10A
CEL1
S33
1003
PROP
37
10A
32A
1003
50
11
B (PURPLE)
A (PINK)
F (LT BLUE/PINK)
G (GREEN/YELLOW)
H (TAN/BROWN)
D (PINK/YELLOW)
C (BLACK/RED)
E (DK BLUE)
J (PURPLE/YELLOW)
F8
TO MAIN
DISCONNECT
(RED/TAN)
FUSE 15A
STARTER
F12
FUSE 15A
FUEL PUMP
F11
(PINK/YELLOW)
FUSE 5A
VSW
F7
6
FUSE 10A
EPR
F9
2002CR
(PINK/DK GREEN)
(WHITE)
2
3
PRV1
1 7
(RED/LT BLUE)
FUSE 20A
ECM
(RED)
32ACR
56CR
(RED)
F13
32BCR
(WHITE)
FUSE 60A
ALTERNATOR
(RED)
FUSE 15A
IGNITION
F10
B
C
A
D
4
6
5
4
D
S
2P-56
IG
TO BATTERY
GROUND
G
M
OPS1
C
GPS1
A B
3
RA1
2
1
3
MS1
1 2
TPS2
B A
TPS1
B A
C
OXS2
A B
B
OXS1
C D
D
IGC1
A
GI1-3
GI1-2
GI1-4
GI1-1
5V EXT 1
5V EXT 2
5V RTN
FPP1
FPP2/IVS
AUX PWM 1
AUX PWM 3
AUX PWM 3 RECIR
19 (LT GREEN/RED)
49 (LT GREEN/PURPLE)
50 (LT GREEN/BLACK)
9 (DK BLUE/ORANGE)
10 (PURPLE/YELLOW)
88 (DK BLUE)
86 (BLACK/RED)
85 (PINK/YELLOW)
VSW
5V RTN
20 (BLACK/LT GREEN)
45 (PINK/TAN)
CAN 1 -
15 (BLUE/WHITE)
(STARTER) AUX PWM4
CAN 1 +
14 (BLUE/PINK)
89 (PINK/BLACK)
CAN TERM +
13 (WHITE/ORANGE)
MIL
(FRP) AUX AND PUD 1
54 (WHITE/LT GREEN)
80 (GREEN/YELLOW)
(FRT) AUX ANA PU 3
48 (LT GREEN/WHITE)
AUX DIG 1
PC RX
56 (ORANGE)
42 (TAN/BROWN)
PC TX
55 (DK GREEN)
EGOH 4
TPS 1
5 (PURPLE/LT BLUE)
75 (WHITE/BLACK)
57
TPS 2
6 (LT BLUE/DK BLUE)
OIL PRES
DBW +
82 (PINK/WHITE)
FPUMP
DBW -
83 (TAN/ORANGE)
53 (LT BLUE)
MAP
7 (LT GREEN)
84 (TAN/BLACK)
56
IAT
68
67
ALTERNATOR
ENGINE STARTER
EL. MOTOR
66
ENGINE STARTER
SOLENOID
65
STARTER RELAY
CHECK ENGINE
LIGHT
GAS/PROPANE
SELECTOR SWITCH
PROPANE LOCKOFF
SOLENOID
FUEL PUMP
RELAY
OIL PRESSURE
SWITCH
ENGINE START
SWITCH
FUEL PUMP
MAIN ENGINE
SWITCH
PROPANE
REGULATOR/VAPORIZER
GASOLINE
PRESSURE SENSOR
THROTTLE
ACTUATOR
M.A.P. SENSOR
LPG TEMPERATURE
SENSOR
ENGINE COOLANT
TEMPERATURE SENSOR
POWER RELAY
OXYGEN SENSOR
POST-CAT
OXYGEN SENSOR
PRE-CAT
IGNITION COIL
GAS INJECTOR
CYLINDER #3
64
63
62
61
60
59
58
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
39 (YELLOW/GRAY)
26
25
24
EGT
SPK COIL 1A
31 (YELLOW)
23
41 (WHITE/RED)
SPK COIL 2A
33 (YELLOW/RED)
GAS INJECTOR
CYLINDER #2
22
GAS INJECTOR
CYLINDER #4
21
ECT
INJ 2 LS
62 (BROWN/LT GREEN)
GAS INJECTOR
CYLINDER #1
20
CRANKSHAFT
POSITION SENSOR
19
18
VBAT
INJ 1 LS
61 (BROWN/LT BLUE)
17
16
40 (TAN/WHITE)
CRANK +
21 (PURPLE/WHITE)
15
60 (RED/TAN)
CRANK -
22 (WHITE/PURPLE)
VBAT
GND TEMP
81 (BLACK)
13
14
RELAY
GND TEMP
69 (BLACK)
79 (RED/TAN)
PWM 5
77 (BROWN/WHITE)
11
12
71 (WHITE/LT BLUE)
GOV 1
51 (GRAY/DK BLUE)
EGOH 2
GOV 2
52 (GRAY/ORANGE)
9
10
EGO 2
PWM 5 RECIRC
78 (WHITE/BROWN)
8
73 (BLACK/YELLOW)
TACH
58 (GRAY)
7
2 (DK GREEN/WHITE)
AUX PWM 2
87 (TAN)
EGOH 1
AUX ANA PU 2
47 (YELLOW/DK BLUE)
5
6
EGO 1
AUX ANA PU 1
46 (DK BLUE/YELLOW)
4
1 (DK GREEN/ORANGE)
AUX DIG 2
43 (TAN/RED)
3
72 (BLACK/WHITE)
AUX DIG 3
44 (TAN/BLACK)
ECU
F
2A
10A
32A
33
34A
FP
3002
CONNECTOR 1
32A
07
START
ON
OFF
K (DK BLUE/ORANGE)
R (LT GREEN/BLACK)
S (LT GREEN/PURPLE)
M (LT GREEN/RED)
L (BLACK/LT GREEN)
N (BLUE/PINK)
P (BLUE/WHITE)
7 (BLUE/PINK)
8 (BLUE/WHITE)
3
2
CPS1
1
SPEED -
26 (RED/BLACK)
1
2
3.36 Interface & Engine Electrical Schematic - GM Dual Fuel Engine
C
D
E
10A
05
S30
DIAGNOSTIC
4 (ORANGE)
3 (DK GREEN)
2 (LT GREEN/RED)
1 (BLACK/LT GREEN)
A (UNUSED)
S (PINK/DK GREEN)
E (BLACK)
C (BROWN/WHITE)
K (GRAY/DK BLUE)
J (GRAY/ORANGE)
SPEED +
25 (RED/WHITE)
NEGATIV
-
B
05
07
2A
33
B (WHITE/BROWN)
D (GRAY)
F (TAN)
G (YELLOW/DK BLUE)
H (DK BLUE/YELLOW)
(TWIST WIRES 10 TURNS (360 DEG)/FOOT FULL LENGTH)
AUX ANA PD 1
8 (TAN/DK GREEN)
ECU1
A
34A
CONNECTOR 2
L (TAN/RED)
M (TAN/BLACK)
N (RED/WHITE)
P (RED/BLACK)
R (TAN/DK GREEN)
GM EFI DUAL FUEL ENGINE
G
H
V
W
X
Y
Z
M148223AA_1
SKYJACK, Page 47
Section 4
Troubleshooting Information
Table of Contents
Introduction...................................................................................................................................................................5
Electrical System
4.1-1
4.1-2
4.1-3
4.1-4
4.1-5
4.1-6
4.1-7
4.1-8
4.1-9
4.1-10
4.1-11
4.1-12
4.1-13
4.1-14
4.1-15
4.1-16
4.1-17
4.1-18
4.1-19
4.1-20
4.1-21
4.1-22
4.1-23
4.1-24
4.1-25
4.1-26
4.1-27
4.1-28
4.1-29
4.1-30
4.1-31
4.1-32
4.1-33
4.1-34
4.1-35
4.1-36
4.1-37
4.1-38
4.1-39
4.1-40
4.1-41
All Controls Inoperative....................................................................................................................................6
No Power to Platform (ANSI/CSA)...................................................................................................................6
No Power to Platform (CE)..............................................................................................................................6
All Functions Inoperative from Platform .........................................................................................................7
Engine will Not Crank from Platform...............................................................................................................7
Engine will Not Crank from Platform Controls (Additional for GM Dual Fuel)................................................8
Engine will Not Crank from Base Controls (GM dual fuel)..............................................................................9
Engine will Not Crank from Base Controls (Kubota diesel)............................................................................9
Engine Cranks but Stops Cranking after a few seconds................................................................................9
Glow Plugs Inoperative from Engine Controls ...............................................................................................9
Glow Plugs Inoperative from Platform (Additional).......................................................................................10
Engine Cranks but will Not Start (Kubota diesel)..........................................................................................10
Engine Cranks but will Not Start (GM dual fuel)...........................................................................................10
Mid Throttle Inoperative (on demand) (GM Dual Fuel).................................................................................12
High Throttle Inoperative ..............................................................................................................................12
High Throttle Inoperative (additional for GM dual fuel).................................................................................13
Drive and Steer Inoperative ..........................................................................................................................13
Brakes will Not Release.................................................................................................................................14
Steer Right Inoperative..................................................................................................................................15
Steer Left Inoperative.....................................................................................................................................15
Reverse Drive Inoperative..............................................................................................................................16
Forward Drive Inoperative..............................................................................................................................16
First Drive Speed and Steering Inoperative..................................................................................................17
Second Drive Speed Inoperative...................................................................................................................17
Third Drive Speed Inoperative.......................................................................................................................18
High/Low Range Speed Inoperative.............................................................................................................19
Up Circuit Inoperative from Platform or Base................................................................................................19
Platform will Not Lift from Platform or Base Controls with Outriggers Extended.........................................20
Platform will Not Lift from Platform or Base Controls with Outriggers Retracted
(lift operates correctly with outriggers extended)..........................................................................................22
Up Circuit Inoperative from Base (ANSI/CSA)..............................................................................................22
Up Circuit Inoperative from Base (CE)..........................................................................................................22
Down Circuit Inoperative from Platform or Base...........................................................................................23
Down Circuit Inoperative from Base (ANSI/CSA)..........................................................................................24
Down Circuit Inoperative from Base (CE).....................................................................................................24
Powered Extension Platform Inoperative......................................................................................................25
Powered Extension Platform will Not Extend................................................................................................25
Powered Extension Platform will Not Retract................................................................................................26
Hydraulic Generator Inoperative...................................................................................................................26
Hydraulic Generator will Not Shut Off from Generator Switch......................................................................27
All Outriggers Inoperative (Auto-level and manual)......................................................................................27
All Outriggers Inoperative (Auto-level and manual from platform controls).................................................28
Full Size RT’s
Engine Powered
SKYJACK, Page 1
4
Table of Contents (Continued)
4.1-43
4.1-44
4.1-45
4.1-46
4.1-47
4.1-48
4.1-49
4.1-50
4.1-51
All Outriggers Inoperative (Auto-level)
A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not on Constant.................................28
All Outriggers Inoperative (Auto Level)
B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing..............................................29
Left Front Outrigger Inoperative Manually.....................................................................................................30
Right Front Outrigger Inoperative Manually..................................................................................................30
Right Rear Outriggers Inoperative Manually.................................................................................................30
Left Rear Outriggers Inoperative Manually....................................................................................................31
Individual Outrigger Functions Inoperative (auto-level) ...............................................................................31
Auto-level Inoperative....................................................................................................................................31
Auto All Up Inoperative (Retract)...................................................................................................................32
Hydraulic System
4.2-1
4.2-2
4.2-3
4.2-4
4.2-5
4.2-6
4.2-7
4.2-8
4.2-9
4.2-10
4.2-11
4.2-12
4.2-13
4.2-14
4.2-15
4.2-16
4.2-17
4.2-18
4.2-19
4.2-20
4.2-21
All Functions Inoperative...............................................................................................................................33
Steering Inoperative.......................................................................................................................................33
Steer and First Drive Speed Inoperative.......................................................................................................33
Lift and Second Drive Speed Inoperative......................................................................................................33
Drive Inoperative............................................................................................................................................33
Reverse Drive Inoperative..............................................................................................................................34
Forward Drive Inoperative..............................................................................................................................34
Brakes will Not Release.................................................................................................................................34
Brakes will Not Release (Internal Brake).......................................................................................................34
Brake Slips (Internal Brake)...........................................................................................................................34
Brake Drags or Runs Hot (Internal Brake).....................................................................................................35
Up Circuit Inoperative....................................................................................................................................35
Down Circuit Inoperative...............................................................................................................................35
Powered Extension Platform Inoperative......................................................................................................35
Hydraulic Generator Inoperative...................................................................................................................36
All Outriggers Inoperative..............................................................................................................................36
Left Front Outrigger Inoperative....................................................................................................................36
Right Front Outrigger Inoperative..................................................................................................................36
Right Rear Outrigger Inoperative...................................................................................................................36
Left Rear Outrigger Inoperative.....................................................................................................................36
Outriggers Drift In..........................................................................................................................................36
Load Sensing System
4.3-1
4.3-2
4.3-3
4.3-4
4.3-5
4.3-6
4.3-7
4.3-8
4.3-9
4.3-10
Flash Code F01:
Flash Code F02:
Flash Code F03:
Flash Code F04:
Flash Code F05:
Flash Code F06:
Flash Code F08:
Flash Code F09:
Flash Code F10:
Flash Code F11:
SKYJACK, Page 2
Check HWFS.....................................................................................................................37
Not Ground Mode.............................................................................................................37
Not Stopped......................................................................................................................37
Tilted..................................................................................................................................37
Bad Height........................................................................................................................37
Check Elev........................................................................................................................37
Check Elev........................................................................................................................37
Bad Height........................................................................................................................37
Bad Height........................................................................................................................37
Not Up...............................................................................................................................37
Full Size RT’s
Engine Powered
Table of Contents (Continued)
4.3-11
4.3-12
4.3-13
4.3-14
4.3-15
4.3-16
4.3-17
4.3-18
4.3-19
4.3-20
4.3-21
4.3-22
4.3-23
4.3-24
4.3-25
4.3-26
4.3-27
4.3-28
4.3-29
4.3-30
4.3-31
4.3-32
4.3-33
4.3-34
4.3-35
4.3-36
4.3-37
4.3-38
Flash Code F12:
Flash Code F13:
Flash Code F14:
Flash Code F15:
Flash Code F16:
Flash Code F17:
Flash Code F18:
Flash Code F19:
Flash Code F20:
Flash Code F21:
Flash Code F22:
Flash Code F23:
Flash Code F24:
Flash Code F25:
Flash Code F26:
Flash Code F27:
Flash Code F30:
Flash Code F31:
Flash Code F32:
Flash Code F33:
Flash Code F34:
Flash Code F40:
Flash Code F42:
Flash Code F43:
Flash Code F44:
Flash Code F45:
Flash Code F46:
Flash Code F47:
Full Size RT’s
Engine Powered
Too Many...........................................................................................................................38
Low Height Range............................................................................................................38
Bad Height........................................................................................................................38
Check Elev........................................................................................................................38
Low Elev.open...................................................................................................................38
High Elev.open..................................................................................................................38
Low Elev.close..................................................................................................................38
High Elev.close.................................................................................................................39
Height<>0%.....................................................................................................................39
Height<>0%.....................................................................................................................39
Height<>100%.................................................................................................................39
Height<>100%.................................................................................................................39
Too Many...........................................................................................................................39
Check Elev........................................................................................................................39
Check Elev........................................................................................................................39
Bad Height........................................................................................................................40
Bad Heights......................................................................................................................40
Reject Curve......................................................................................................................40
Reject Curve......................................................................................................................40
Reject Curve......................................................................................................................40
Reject Curve......................................................................................................................40
Reject Delta.......................................................................................................................40
Low Pressure....................................................................................................................41
High Pressure...................................................................................................................41
Low Pressure....................................................................................................................41
High Pressure...................................................................................................................41
Check Elev........................................................................................................................41
Check Elev........................................................................................................................41
SKYJACK, Page 3
Section 4 - Troubleshooting Information
Service and Maintenance
Introduction
The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur.
If a specific trouble is not listed, isolate the major component in which the trouble
occurs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.
The content of this section is separated into “probable cause” and “remedy.” The information preceded by a number represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it.See example below for clarification.
1. Probable Cause
-- Remedy
Full Size RT’s
Engine Powered
SKYJACK, Page 5
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System
4.1-1 All Controls Inoperative
1. Battery disconnected or discharged.
-- Reconnect battery. Recharge if discharged.
2. Loose or dirty battery cables.
-- Clean and tighten battery cables.
3. Open or defective main power disconnect switch S1.
-- Close switch. Replace if defective.
4. Loose or broken wire #03 from main power disconnect switch S1 to circuit breaker CB1.
-- Check continuity. Replace if defective.
5. Tripped or defective circuit breaker CB1.
-- Reset breaker. Check for defective wiring. Replace breaker if defective.
6. Loose or broken wire #05 from breaker CB1 to relay 10BCR1.
-- Check continuity. Replace if defective.
7. Loose or broken wire #05 from relay 31CR to base engine switch S30.
-- Check continuity. Replace if defective.
8. Loose or broken wire #00 from battery B1 to base terminal block TB-1.
-- Check continuity. Replace if defective.
9. Loose or broken wire #00 from base terminal block TB-1 to circuit breaker CB3.
-- Check continuity. Replace if defective.
10. Tripped or defective circuit breaker CB3.
-- Reset breaker. Check for defective wiring. Replace breaker if defective.
11. Loose or broken wire #02 from circuit breaker CB3 to base terminal block TB-1.
-- Check continuity. Replace if defective.
4.1-2 No Power to Platform (ANSI/CSA)
1. Open or defective base engine switch S30.
-- Check switch. Replace if defective.
2. Loose or broken wire #07 from base engine switch S30 to base terminal block TB-1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #07 from base terminal block TB-1 to emergency stop switch S6.
-- Check continuity. Replace if defective.
4. Open or defective emergency stop switch S6.
-- Check switch. Replace if defective.
5. Loose or broken wire #7A from emergency stop switch S6 to base terminal block TB-1.
-- Check continuity. Replace if defective.
6. Loose or broken wire #7A from base terminal block TB-1 to emergency stop switch S4.
-- Check continuity. Replace if defective.
7. Open or defective emergency stop switch S4.
-- Check switch. Replace if defective.
4.1-3 No Power to Platform (CE)
1. Open or defective base engine switch S30.
-- Check switch. Replace if defective.
2. Loose or broken wire #07 from engine start switch S30 to base terminal block TB-1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #07 from base terminal block TB-1 to emergency stop switch S6.
-- Check continuity. Replace if defective.
4. Open or defective emergency stop switch S6.
-- Check switch. Replace if defective.
SKYJACK, Page 6
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
5. Loose or broken wire #7C from emergency stop switch S6 to platform/base switch S10.
-- Check continuity. Replace if defective.
6. Open or defective platform/base switch S10.
-- Select platform on switch. Check switch. Replace if defective.
7. Loose or broken wire #7A from platform/base switch S10 to platform emergency stop switch S4.
-- Check continuity. Replace if defective.
8. Open or defective platform emergency stop switch S4.
-- Check switch. Replace if defective.
4.1-4 All Functions Inoperative from Platform
1. Loose or broken wire #08 from emergency stop switch S4 to off/lift/drive key switch S3.
-- Check continuity. Replace if defective.
2. Open or defective off/lift/drive key switch S3.
-- Check switch. Replace if defective.
3. Loose or broken wire #10 from off/lift/drive key switch S3 to platform terminal block.
-- Check continuity. Replace if defective.
4. Loose or broken wire #10 from platform terminal block to diode D10 located at relay 10BCR1.
-- Check continuity. Replace if defective.
5. Open diode D10 or diode D10 is not connected at relay 10BCR1.
-- Check diode. Replace if defective.
All Functions Inoperative (Additional for machines with Load Sensing System) (CE)
1. Loose or broken wire #10C from base terminal strip to control module CM1 at pin #P2-12.
-- Check for 12 Volts at P2-12. If no voltage present, check wire continuity. Replace if defective.
2. Loose or broken wire #28 from control module CM1 at pin #P3-4 to 28CR1 tilt relay and 28CR2 Down
Enable Relay.
-- Check for 12 Volts at P3-4. If voltage present, check for 12 Volts at wire #28A on outrigger
connector plug CN-14 at pin #1. If voltage present, check for 12 Volts on wire #28A at 28ACR1
Relay and 28ACR2 Relay. If voltage present, check operation of relays. If no voltage present,
check wire continuity. Replace if defective.
3. Loose or broken wire #28E from control module CM1 at pin #P3-6 to 28ECR1 auxiliary tilt relay and
28ECR2 auxiliary down enable relay.
-- Check for 12 Volts at P3-6. If voltage present, check for 12 Volts at wire #28E at 28ECR1 and
28ECR2 relays. If voltage present, check operation of relays. If no voltage present, check wire
continuity. Replace if defective.
4. Defective pressure transducer PT1 or angle transducer AT1 or related wiring.
-- Refer to transducer troubleshooting charts.
4.1-5 Engine will Not Crank from Platform
1. Open or defective key switch S3.
-- Check switch. Replace if defective.
2. Loose or broken wire #10 from key switch S3 to start switch S15.
-- Check continuity. Replace if defective.
3. Defective start switch S15.
-- Check switch. Replace if defective.
4. Loose or broken wire #32 from start switch S15 to relay 32CR.
-- Check continuity. Replace if defective.
5. Defective relay 32CR.
-- Check relay. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 7
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
6. Loose or broken wire #41 from relay 32CR to relay 10ACR1.
-- Check continuity. Replace if defective.
7. Loose or broken wire #02 from relay 10ACR1 to base terminal block.
-- Check continuity. Replace if defective.
8. Loose or broken wire #05 from base terminal block to relay 32CR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #32A from relay 32CR to starter contactor 32ACR.
-- Check continuity. Replace if defective.
10. Defective starter contactor 32ACR.
-- Check contactor. Replace if defective.
11. Loose or broken wire #00 from starter contactor 32ACR to engine ground.
-- Check continuity. Replace if defective.
12. Loose or broken wire #103 from main power disconnect switch S1 to starter contactor 32ACR. (Kubota
Diesel)
-- Check continuity. Replace if defective.
13. Loose or broken wire #103 from main power disconnect switch S1 to starter contactor 32BCR. (GM
Dual Fuel)
-- Check continuity. Replace if defective.
14. Loose or broken wire #104 from starter contactor 32ACR to starter motor. (Kubota Diesel)
-- Check continuity. Replace if defective.
15. Defective starter motor.
-- Check motor. Repair or replace if defective.
4.1-6 Engine will Not Crank from Platform Controls (Additional for GM Dual Fuel)
1. Loose or broken wire #10A from base terminal block TB1 to engine harness plug.
-- Check continuity. Replace if defective.
2. Loose or broken wire #10A from engine harness plug to GM engine connector 1.
-- Check continuity. Replace if defective.
3. Loose or broken pink wire from GM engine connector 1 to fuse F7.
-- Check continuity. Replace if defective.
4. Defective fuse F7.
-- Check fuse. Replace if defective
5. Loose or broken pink/tan wire from fuse F7 to ECU connector pin #45.
-- Check continuity. Replace if defective
6. Loose or broken red wire from battery positive to ECU fuse F8.
-- Check continuity. Replace if defective.
7. Defective fuse F8.
-- Check fuse. Replace if defective.
8. Loose or broken red/tan wire from fuse F8 to ECU connector pin #60 and pin #79.
-- Check continuity. Replace if defective.
9. Loose or broken black wire from engine ground to ECU connector pin #69 and #81.
-- Check continuity. Replace if defective.
10. Loose or broken light blue/pink wire from GM engine connector 1 to relay 32ACR.
-- Check continuity. Replace if defective.
11. Loose or broken pink/black wire from ECU connector pin #89 to relay 32ACR.
-- Check continuity. Replace if defective.
12. Defective relay 32ACR.
-- Check relay. Replace if defective.
13. Loose or broken red wire from battery positive to starter fuse F12.
-- Check continuity. Replace if defective.
SKYJACK, Page 8
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
14. Defective fuse F12.
-- Check fuse. Replace if defective.
15. Loose or broken red/tan wire from fuse F12 to relay 32ACR.
-- Check continuity. Replace if defective.
16. Loose or broken white wire from relay 32ACR to start solenoid 32BCR.
-- Check continuity. Replace if defective.
17. Defective starter solenoid 32BCR.
-- Check solenoid. Replace if defective.
18. Loose or broken battery cable from starter solenoid 32BCR to starter motor.
-- Check continuity. Replace if defective.
19. Defective starter motor.
-- Check motor. Repair or replace if defective.
4.1-7 Engine will Not Crank from Base Controls (GM dual fuel)
1. Loose or broken wire #10A from base terminal block TB1 to engine harness plug.
-- Check continuity. Replace if defective.
2. Loose or broken wire #10A from engine harness plug to base start switch S30.
-- Check continuity. Replace if defective.
3. Defective base start switch S30.
-- Check switch. Replace if defective.
4. Loose or broken wire #32A from base start switch S30 to GM engine connector 1.
-- Check continuity. Replace if defective.
4.1-8 Engine will Not Crank from Base Controls (Kubota diesel)
1. Loose or broken wire #05 from base terminal block to base engine switch S30.
-- Check continuity. Replace if defective.
2. Loose or broken jumper wire #05 on base engine switch S30.
-- Check continuity. Replace if defective.
3. Defective engine start switch S30.
-- Check switch. Replace if defective.
4. Loose or broken wire #32A from engine start switch S30 to starter contactor 32ACR.
-- Check continuity. Replace if defective.
4.1-9 Engine Cranks but Stops Cranking after a few seconds
1. Loose or broken jumper wire #41 on relay 32CR.
-- Check continuity. Replace if defective.
2. Loose or broken wire #02 from relay 32CR to base terminal block TB-1.
-- Check continuity. Replace if defective.
4.1-10 Glow Plugs Inoperative from Engine Controls
1. Loose or broken wire #07 from engine start switch S30 to glow plug switch S31.
-- Check continuity. Replace if defective.
2. Defective glow plug switch S31.
-- Check switch. Replace if defective.
3. Loose or broken wire #31A from glow plug switch S31 to glow plug relay 31ACR.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from glow plug relay 31ACR to base terminal block TB1.
-- Check continuity. Replace if defective.
5. Loose or broken wire #103 from starter solenoid 32ACR to relay 31ACR.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 9
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
6. Loose or broken wire #91A from relay 31ACR to engine glow plugs EGP1.
-- Check continuity. Replace if defective.
7. Defective glow plug relay 31ACR.
-- Check relay. Replace if defective.
8. Defective glow plugs.
-- Check glow plugs. Replace if defective.
4.1-11 Glow Plugs Inoperative from Platform (Additional)
1. Loose or broken wire #10 from key selector switch S3 to glow plug switch S13.
-- Check continuity. Replace if defective.
2. Defective glow plug switch S13.
-- Check switch. Replace if defective.
3. Loose or broken wire #31 from glow plug switch S13 to glow plug relay 31CR.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from relay 31CR to base terminal block TB1.
-- Check continuity. Replace if defective.
5. Loose or broken wire #05 from base terminal block TB1 to relay 31CR.
-- Check continuity. Replace if defective.
6. Loose or broken wire #31A from relay 31CR to glow plug relay 31ACR.
-- Check continuity. Replace if defective.
7. Defective relay 31CR.
-- Check relay. Replace if defective.
4.1-12 Engine Cranks but will Not Start (Kubota diesel)
1. Loose or broken wire #37 from base terminal block to diesel valve solenoid 2D37.
-- Check continuity. Replace if defective.
2. Loose or broken wire #57 from starter contactor 32ACR to diesel valve solenoid 2D37.
-- Check continuity. Replace if defective.
3. Defective fuel valve solenoid 2D37.
-- Check solenoid. Replace if defective.
4. Defective glow plug circuit.
-- See glow plugs inoperative above. Repair if necessary.
4.1-13 Engine Cranks but will Not Start (GM dual fuel)
NOTE
For additional engine troubleshooting refer to diagnostic trouble codes
for use with the check engine light.
1. Loose or broken red wire from battery positive to relay 2002CR.
-- Check continuity. Replace if defective.
2. Loose or broken red/tan wire from ECU fuse F8 to relay 2002CR.
-- Check continuity. Replace if defective.
3. Loose or broken white/ light blue wire from ECU connector pin #71 to relay 2002CR.
-- Check continuity. Replace if defective.
4. Defective relay 2002CR.
-- Check relay. Replace if defective.
5. Loose or broken pink/dark green wire from relay 2002CR to ignition fuse F10.
-- Check continuity. Replace if defective
SKYJACK, Page 10
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
6. Defective fuse F10.
-- Check fuse. Replace if defective
7. Loose or broken pink/dark green wire from fuse F10 to ignition coil IGC1 pin #D.
-- Check continuity. Replace if defective.
8. Loose or broken black wire from ignition coil IGC1 pin #C to engine ground.
-- Check continuity. Replace if defective.
9. Defective ignition coil IGC1.
-- Refer to section 5 of this manual for Ohm specifications. Replace if defective.
10. Loose or broken pink/dark green wire from fuse F10 to gas injectors GI-1, GI-2, GI-3 and GI-4.
-- Check continuity. Replace if defective.
11. Loose or broken pink/white wire from ECU connector pin #82 to throttle actuator RA1.
-- Check continuity. Replace if defective.
12. Loose or broken tan/orange wire from ECU connector pin #83 to throttle actuator RA1.
-- Check continuity. Replace if defective.
13. Loose or broken light green/red wire from ECU connector pin #19 to throttle actuator RA1.
-- Check continuity. Replace if defective.
14. Loose or broken black/light green wire from ECU connector pin #20 to throttle actuator RA1.
-- Check continuity. Replace if defective.
15. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA1.
-- Check continuity. Replace if defective.
FUEL RELATED PROBLEMS
(GASOLINE ONLY)
16. Loose or broken pink/tan wire from fuse F7 to fuel pump relay 56CR.
-- Check continuity. Replace if defective.
17. Loose or broken red wire from battery positive to fuel pump relay 56CR.
-- Check continuity. Replace if defective.
18. Loose or broken tan/black wire from ECU connector pin #42 to fuel pump relay 56CR.
-- Check continuity. Replace if defective.
19. Defective fuel pump relay 56CR.
-- Check relay. Replace if defective.
20. Loose or broken pink/yellow wire from fuel pump relay 56CR to fuse F11.
-- Check continuity. Replace if defective.
21. Defective fuse F11.
-- Check fuse. Replace if defective.
22. Loose or broken pink/yellow wire from fuse F11 to fuel pump FP.
-- Check continuity. Replace if defective.
23. Loose or broken pink/yellow wire from fuse F11 to ECU connector pin #85.
-- Check continuity. Replace if defective
24. Defective fuel pump FP.
-- Check fuel pump by putting 12 volts and a ground to it. Replace if defective.
25. Loose or broken wire #3002 from fuel pump FP to GM engine connector 1.
-- Check continuity. Replace if defective.
26. Loose or broken black/red wire from GM engine connector to ECU connector pin #86.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 11
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
(PROPANE ONLY)
NOTE
The fuel select switch is defaulted to gasoline. The engine will run on
gasoline if propane is selected from the switch and either the switch
is bad or a wire is loose or broken from the switch. This is providing
there is nothing wrong on the gasoline side of the system. Disconnect
fuel pump to test propane side.
27. Loose or broken wire #10A from engine harness plug to fuel select switch S33.
-- Check continuity. Replace if defective.
28. Defective fuel select switch S33.
-- Check switch. Replace if defective.
29. Loose or broken wire #50 from fuel select switch S33 to GM engine connector 1.
-- Check continuity. Replace if defective.
30. Loose or broken tan/brown wire from GM engine connector 1 to ECU connector pin #42.
-- Check continuity. Replace if defective.
31. Loose or broken pink/tan wire from fuse F7 to propane lock off 2P-56.
-- Check continuity. Replace if defective.
32. Loose or broken white/black wire from ECU connector pin #75 to propane lock off 2P-56.
-- Check continuity. Replace if defective.
33. Defective propane lock off 2P-56.
-- Check lock off. Replace if defective.
34. Loose or broken pink/dark green wire from fuse F10 to fuse F9.
-- Check continuity. Replace if defective.
35. Defective fuse F9.
-- Check fuse. Replace if defective.
36. Loose or broken red/light blue wire from fuse F9 to propane regulator PRV1.
-- Check continuity. Replace if defective.
37. Loose or broken black wire from engine ground to propane regulator PRV1.
-- Check continuity. Replace if defective.
4.1-14 Mid Throttle Inoperative (on demand) (GM Dual Fuel)
1. Open diode D17A or D18A.
-- Check diode. Replace if defective
2. Loose or broken wire #33 from base terminal block TB1 to engine harness plug.
-- Check continuity. Replace if defective.
3. Loose or broken wire #33 from engine harness plug to GM engine connector 2.
-- Check continuity. Replace if defective.
4. Loose or broken gray/dark blue wire from GM engine connector to ECU connector pin #51.
-- Check continuity. Replace if defective.
5. Loose or broken purple/light blue wire from ECU connector pin #5 to throttle actuator RA1.
-- Check continuity. Replace if defective.
4.1-15 High Throttle Inoperative
1. Loose or broken wire #10 from key switch S3 to high/low throttle switch S14.
-- Check continuity. Replace if defective.
2. Defective high/low throttle switch S14.
-- Check switch. Replace if defective.
SKYJACK, Page 12
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
3. Loose or broken wire #34 from high/low throttle switch S14 to diode D34 at relay 34BCR. (ANSI/CSA
only)
-- Check continuity. Replace if defective.
4. Loose or broken wire #34 from high/low throttle switch S14 to diode D34 at base terminal block TB-1.
(CE only)
-- Check continuity. Replace if defective.
5. Open or loose diode D34.
-- Check diode. Replace if defective.
6. Loose or broken wire #34B from base terminal block TB-1 to relay 34BCR. (CE only)
-- Check continuity. Replace if defective.
7. Defective relay 34BCR.
-- Check relay. Replace if defective.
8. Loose or broken wire #42 from relay 34BCR to relay 10ACR1.
-- Check continuity. Replace if defective.
9. Defective relay 10ACR1.
-- Check relay. Replace if defective.
10. Loose or broken wire #02 from relay 10ACR1 to base terminal block TB1.
-- Check continuity. Replace if defective.
11. Loose or broken wire #05 from base terminal block TB1 to relay 32CR.
-- Check continuity. Replace if defective.
12. Defective relay 32CR.
-- Check relay. Replace if defective.
13. Loose or broken wire #43 from relay 32CR to relay 34BCR.
-- Check continuity. Replace if defective.
14. Loose or broken wire #34A from relay 34BCR to engine harness plug.
-- Check continuity. Replace if defective.
15. Loose or broken wire #34A from engine harness plug to high throttle solenoid HTS-34A. (Kubota
Diesel)
-- Check continuity. Replace if defective.
4.1-16 High Throttle Inoperative (additional for GM dual fuel)
1. Loose or broken wire #34A from engine harness plug to GM engine connector 2.
-- Check continuity. Replace if defective.
2. Loose or broken gray/orange wire from GM engine connector 2 to ECU connector pin #52.
-- Check continuity. Replace if defective.
3. Loose or broken light blue/dark blue wire from ECU connector pin #6 to throttle actuator RA1.
-- Check continuity. Replace if defective.
4. Defective throttle actuator RA1.
-- Check actuator. Replace if defective.
4.1-17 Drive and Steer Inoperative
1. Outriggers not fully retracted
-- Fully retract outrigger cylinders
2. Key switch S3 in lift position.
-- Turn switch to drive position.
3. Defective drive contacts in key switch S3.
-- Check contacts. Replace if defective.
4. Loose or broken wire #12 from key switch S3 to joystick enable switch S7-7.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 13
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
5. Defective joystick enable switch S7-7.
-- Check switch. Replace if defective.
6. Loose or broken wire #12A from joystick enable relay 12BCR to speed, steer and direction switches
S7-1 to S7-6.
-- Check continuity. Replace if defective.
7. Loose or broken wire #12B from joystick enable switch S7-7 to joystick enable relay 12BCR.
-- Check continuity. Replace if defective.
8. Defective joystick enable relay 12BCR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from joystick enable relay 12BCR to controller harness.
-- Check continuity. Replace if defective.
10. Loose or broken wire #10A from base terminal block to relay 28CR (ANSI/CSA) or relay 28ECR1
(CE).
-- Check continuity. Replace if defective.
11. Defective relay 28CR (ANSI/CSA) or relay 28ECR1 (CE).
-- Check relay. Replace if defective.
12. Loose or broken wire #1B from relay 28ECR1 to relay 28CR1. (CE only)
-- Check continuity. Replace if defective.
13. Defective relay 28CR1. (CE only)
-- Check relay. Replace if defective.
14. Loose or broken wire #1 from relay 28CR (ANSI/CSA) or 28CR1 (CE) to pin #7 on connector CN14 at
the outrigger board.
-- Check continuity. Replace if defective.
15. Left rear outrigger limit switch LS64 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
16. Right rear outrigger limit switch LS63 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
17. Right front outrigger limit switch LS62 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
18. Left front outrigger limit switch LS61 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
19. Defective drive enable relay 61CR.
-- Check relay. Replace if defective.
20. Loose or broken wire #4 from pin #1 on connector CN14 at the outrigger board to relay 30CR.
-- Check continuity. Replace if defective.
4.1-18 Brakes will Not Release
1. Loose or broken wire #30 from diodes D15A-2 and D16A-2 to relay 30CR.
-- Check continuity. Replace if defective.
2. Defective relay 30CR.
-- Check relay. Replace if defective.
3. Loose or broken wire #02 from relay 30CR to base terminal block TB-1.
-- Check continuity. Replace if defective.
4. Loose or broken wire #4 from pin #1 on plug CN14 at outrigger board to relay 30CR.
-- Check continuity. Replace if defective.
5. Loose or broken wire #30A from relay 30CR to brake dump valve 2H-30A-1 or brake feed valve
2H-30A-2.
-- Check continuity. Replace if defective.
6. Defective valve coil brake dump 2H-30A-1 or brake feed 2H-30A-2.
-- Check continuity through coil. Replace if defective.
SKYJACK, Page 14
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
7. Loose or broken wire #02 from valve coil brake dump 2H-30A-1 or brake feed 2H-30A-2 to base terminal
block TB-1.
-- Check continuity. Replace if defective.
8. Loose or broken wire #30 from relay 30CR to diode D30 at base terminal block TB-1. (CE only)
-- Check continuity. Replace if defective.
9. Open diode D30.
-- Check diode. Replace if defective.
10. Loose or broken wire #25 from diode D30 to base terminal block TB-1. (Internal Brakes only)
-- Check continuity. Replace if defective.
11. Loose or broken wire #25 from base terminal block TB-1 to quick brake valve coil 2H-25. (Internal
Brakes only)
-- Check continuity. Replace if defective.
12. Defective quick brake valve coil 2H-25. (Internal Brakes only)
-- Check continuity through coil. Replace if defective.
13. Loose or broken wire #02 from quick brake valve 2H-25 to base terminal block TB-1. (Internal Brakes
only)
-- Check continuity. Replace if defective.
4.1-19 Steer Right Inoperative
1. Defective steer right switch S7-2 in joystick S7.
-- Check switch. Replace if defective.
2. Loose or broken wire #23 from steer right switch S7-2 to platform terminal block.
-- Check continuity. Replace if defective.
3. Loose or broken wire #23 from platform terminal block to relay 23CR.
-- Check continuity. Replace if defective.
4. Defective relay 23CR.
-- Check relay. Replace if defective.
5. Loose or broken wire #04 from base terminal block to relay 23CR.
-- Check continuity. Replace if defective.
6. Loose or broken wire #23A from relay 23CR to base terminal block.
-- Check continuity. Replace if defective.
7. Loose or broken wire #02 from relay 23CR to base terminal block.
-- Check continuity. Replace if defective.
8. Loose or broken wire #23A from base terminal block to steer right valve coil 4H-23A.
-- Check continuity. Replace if defective.
9. Defective steer right valve coil 4H-23A.
-- Check coil. Replace if defective.
10. Loose or broken wire #02 from steer right valve coil 4H-23A to base terminal block.
-- Check continuity. Replace if defective.
11. Open diode D23A.
-- Check diode. Replace if defective.
4.1-20 Steer Left Inoperative
1. Defective steer left switch S7-3 in joystick S7.
-- Check switch. Replace if defective.
2. Loose or broken wire #24 from steer left switch S7-3 to platform terminal block.
-- Check continuity. Replace if defective.
3. Loose or broken wire #24 from platform terminal block to relay 24CR.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 15
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4. Defective relay 24CR.
-- Check relay. Replace if defective.
5. Loose or broken wire #04 from base terminal block to relay 24CR.
-- Check continuity. Replace if defective.
6. Loose or broken wire #24A from relay 24CR to base terminal block.
-- Check continuity. Replace if defective.
7. Loose or broken wire #02 from relay 24CR to base terminal block.
-- Check continuity. Replace if defective.
8. Loose or broken wire #24A from base terminal block to steer left valve coil 4H-24A.
-- Check continuity. Replace if defective.
9. Defective steer left valve coil 4H-24A.
-- Check coil. Replace if defective.
10. Loose or broken wire #02 from steer left valve coil 4H-24A to base terminal block.
-- Check continuity. Replace if defective.
11. Open diode D24A.
-- Check diode. Replace if defective.
4.1-21 Reverse Drive Inoperative
1. Defective drive reverse switch S7-4 in joystick S7.
-- Check switch. Replace if defective.
2. Defective joystick S7.
-- Check joystick. Replace if defective.
3. Loose or broken wire #15 from joystick S7 to platform terminal block.
-- Check continuity. Replace if defective.
4. Loose or broken wire #15 from platform terminal block to relay 15CR.
-- Check continuity. Replace if defective.
5. Defective relay 15CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #02 from relay 15CR to base terminal block.
-- Check continuity. Replace if defective.
7. Loose or broken wire #04 from base terminal block to relay 15CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #15A from relay 15CR to time delay relay 1TD.
-- Check continuity. Replace if defective.
9. Defective time delay relay 1TD.
-- Check relay. Replace if defective.
10. Loose or broken wire #15B from time delay relay 1TD to reverse valve coil 4H-15B.
-- Check continuity. Replace if defective.
11. Defective reverse valve coil 4H-15B.
-- Check coil. Replace if defective.
12. Loose or broken wire #02 from reverse valve coil 4H-15B to base terminal block.
-- Check continuity. Replace if defective.
13. Open diode D15A-1 or D15A-2.
-- Check diodes. Replace if defective.
4.1-22 Forward Drive Inoperative
1. Defective drive forward switch S7-5 in joystick S7.
-- Check switch. Replace if defective.
2. Defective joystick S7.
-- Check joystick. Replace if defective.
SKYJACK, Page 16
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
3. Loose or broken wire #16 from joystick S7 to platform terminal block.
-- Check continuity. Replace if defective.
4. Loose or broken wire #16 from platform terminal block to relay 16CR.
-- Check continuity. Replace if defective.
5. Defective relay 16CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #02 from relay 16CR to base terminal block.
-- Check continuity. Replace if defective.
7. Loose or broken wire #04 from base terminal block to relay 16CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #16A from relay 16CR to time delay relay 1TD.
-- Check continuity. Replace if defective.
9. Defective time delay relay 1TD.
-- Check relay. Replace if defective.
10. Loose or broken wire #16B from time delay relay 1TD to forward valve coil 4H-16B.
-- Check continuity. Replace if defective.
11. Defective forward valve coil 4H-16B.
-- Check coil. Replace if defective.
12. Loose or broken wire #02 from forward valve coil 4H-16B to base terminal block.
-- Check continuity. Replace if defective.
13. Open diode D16A-1 or D16A-2.
-- Check diodes. Replace if defective.
4.1-23 First Drive Speed and Steering Inoperative
1. Loose or broken wire #21 from base terminal block to relay 17ACR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
1. Loose or broken wire #21 from diode D24A to relay 17ACR. (CE only)
-- Check continuity. Replace if defective.
2. Defective relay 17ACR.
-- Check relay. Replace if defective.
3. Loose or broken wire #18A from relay 17ACR to small pump dump valve solenoid 2H-18A.
-- Check continuity. Replace if defective.
4. Defective small pump dump valve coil 2H-18A.
-- Check coil. Replace if defective.
5. Loose or broken wire #02 from small pump dump solenoid 2H-18A to base terminal block.
-- Check continuity. Replace if defective.
4.1-24 Second Drive Speed Inoperative
1. Defective second speed switch S7-1 in joystick S7.
-- Check switch. Replace if defective.
2. Defective joystick S7.
-- Check joystick. Replace if defective.
3. Loose or broken wire #19 from controller S7-1 to platform terminal block.
-- Check continuity. Replace if defective.
4. Loose or broken wire #19 from platform terminal block to diode D19 at relay 35CR.
-- Check continuity. Replace if defective.
5. Loose or Open diode D19.
-- Tighten diode. Check diode. Replace if defective.
6. Loose or broken wire #10A from base terminal block to high drive/tilt override limit switch LS5.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 17
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
7. Misadjusted or defective high drive/tilt override limit switch LS5.
-- Adjust switch. Replace if defective.
8. Loose or broken wire #35 from high drive/tilt override limit switch LS5 to base terminal block.
-- Check continuity. Replace if defective.
9. Loose or broken wire #35 from base terminal block to relay 35CR.
-- Check continuity. Replace if defective.
10. Loose or broken wire #02 from relay 35CR to base terminal block.
-- Check continuity. Replace if defective.
11. Defective relay 35CR.
-- Check relay. Replace if defective.
12. Loose or broken wire #17 from relay 35CR to relay 17CR.
-- Check continuity. Replace if defective.
13. Defective relay 17CR.
-- Check relay. Replace if defective.
14. Loose or broken wire #02 from relay 17CR to base terminal block.
-- Check continuity. Replace if defective.
15. Loose or broken wire #10A from base terminal block to relay 17CR.
-- Check continuity. Replace if defective.
16. Loose or broken wire #17A from relay 17CR to base terminal block.
-- Check continuity. Replace if defective.
17. Loose or broken wire #17A from relay 17CR to relay 17ACR.
-- Check continuity. Replace if defective.
18. Defective relay 17ACR.
-- Check relay. Replace if defective.
19. Loose or broken wire #02 from relay 17ACR to base terminal block.
-- Check continuity. Replace if defective.
20. Loose or broken wire #17A from base terminal block to large pump dump valve solenoid 2H-17A.
-- Check continuity. Replace if defective.
21. Loose or broken wire #02 from large pump dump valve solenoid 2H-17A to base terminal block.
-- Check continuity. Replace if defective.
22. Defective large pump dump valve solenoid 2H-17A.
-- Check solenoid. Replace if defective.
4.1-25 Third Drive Speed Inoperative
1. High/Low torque switch S41 in high torque position or defective.
-- Turn high/low torque switch to low torque position. Replace if defective.
2. Defective third speed switch S7-6 in joystick S7.
-- Check switch. Replace if defective.
3. Defective joystick S7.
-- Check joystick. Replace if defective.
4. Loose or broken wire #18B from controller S7-6 to low/high torque switch S41.
-- Check continuity. Replace if defective.
5. Loose or broken wire #18 from low/high torque switch S41 to platform terminal block.
-- Check continuity. Replace if defective.
6. Loose or broken wire #18 from platform terminal block to relay 18CR.
-- Check continuity. Replace if defective.
7. Defective relay 18CR.
-- Check relay. Replace if defective.
8. Loose or broken wire #02 from relay 18CR to base terminal block.
-- Check continuity. Replace if defective.
SKYJACK, Page 18
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
9. Loose or broken wire #10A from base terminal block to relay 18CR.
-- Check continuity. Replace if defective.
10. Loose or broken wire #18A from relay 18CR to small pump dump valve 2H-18A.
-- Check continuity. Replace if defective.
11. Loose or broken wire #02 from small pump dump valve 2H-18A to base terminal block.
-- Check continuity. Replace if defective.
12. Defective small pump dump valve solenoid 2H-18A.
-- Check solenoid. Replace if defective.
4.1-26 High/Low Range Speed Inoperative
1. Loose or broken wire #12 from joystick enable switch S7-7 to high/low range switch S29.
-- Check continuity. Replace if defective.
2. Defective high/low range switch S29.
-- Check switch. Replace if defective.
3. Loose or broken wire #20B from high/low range switch S29 to high/low torque switch S41.
-- Check continuity. Replace if defective.
4. Defective high/low torque switch S41.
-- Check switch. Replace if defective.
5. Loose or broken wire #20 from high/low torque switch S41 to relay 20CR.
-- Check continuity. Replace if defective.
6. Defective relay 20CR.
-- Check relay. Replace if defective.
7. Loose or broken wire #02 from relay 20CR to base terminal block.
-- Check continuity. Replace if defective.
8. Loose or broken wire #10A (ANSI/CSA) or wire #10C (CE) from base terminal block to relay 35CR.
-- Check continuity. Replace if defective.
9. Defective relay 35CR.
-- Check relay. Replace if defective.
10. Loose or broken wire #44 from relay 35CR to relay 20CR.
-- Check continuity. Replace if defective.
11. Loose or broken wire #20A from relay 20CR to base terminal block TB-1.
-- Check continuity. Replace if defective.
12. Loose or broken wire #20A from base terminal block to series parallel valve coil 3H-20A.
-- Check continuity. Replace if defective.
13. Defective series/parallel valve coil 3H-20A.
-- Check coil. Replace if defective.
14. Loose or broken wire #02 from series/parallel valve coil 3H-20A to base terminal block.
-- Check continuity. Replace if defective.
4.1-27 Up Circuit Inoperative from Platform or Base
1. Lift/Off/Drive switch S3 in drive position or defective.
-- Select lift position. Check switch. Replace if defective.
2. Loose or broken wire #09 from lift/off/drive switch S3 to lift enable switch S9.
-- Check continuity. Replace if defective.
3. Defective lift enable switch S9.
-- Check switch. Replace if defective.
4. Loose or broken wire #9A from enable switch S9 to up/down switch S5.
-- Check continuity. Replace if defective.
5. Defective up/down switch S5.
-- Check switch. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 19
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
6. Loose or broken wire #14 from up/down switch S5 to relay 14CR. (ANSI/CSA)
-- Check continuity. Replace if defective.
7. Loose or broken wire #14 from up/down switch S5 to diode D14 at base terminal block TB-1. (CE)
-- Check continuity. Replace if defective.
8. Loose or Open diode D14. (CE)
-- Tighten diode. Check diode. Replace if defective.
9. Loose or broken wire #14D from base terminal block to relay 14DCR (CE).
-- Check continuity. Replace if defective.
10. Loose or broken wire #02 from relay 14CR (ANSI/CSA) or 14DCR (CE) to base terminal block.
-- Check continuity. Replace if defective.
11. Defective relay 14CR (ANSI/CSA) or 14DCR (CE).
-- Check relay. Replace if defective.
12. Loose or broken wire #36A from pin #10 on connector CN14 at the outrigger board to terminal block
TB-1.
-- Check continuity. Replace if defective.
13. Loose or broken wire #36A from terminal block TB-1 to end of stroke limit switch LS4.
-- Check continuity. Replace if defective.
14. Defective end of stroke limit switch LS4.
-- Check switch. Replace if defective.
15. Loose or broken wire #36B from end of stroke limit switch LS4 to relay 14CR.
-- Check continuity. Replace if defective.
16. Defective relay 14CR.
-- Check relay. Replace if defective.
17. Loose or broken wire #14A from relay 14CR to relay 28CR.
-- Check continuity. Replace if defective.
18. Loose or broken wire #14B from relay 28CR to base terminal block.
-- Check continuity. Replace if defective.
19. Loose or broken wire #14B from base terminal block to lift valve solenoid 2H-14B.
-- Check continuity. Replace if defective.
20. Loose or broken wire #02 from lift valve solenoid 2H-14B to base terminal block.
-- Check continuity. Replace if defective.
21. Defective lift valve solenoid 2H-14B.
-- Check solenoid. Replace if defective.
13. Open diode D14B-1.
-- Check diode. Replace if defective.
4.1-28 Platform will Not Lift from Platform or Base Controls with Outriggers Extended
1. Outriggers not extended enough.
-- Extend outriggers to take weight off tires (refer to operator section).
2. Loose or broken wire #10A from terminal block TB-1 to pin #4 on connector CN14 at the outrigger
board.
-- Check continuity. Replace if defective.
3. Loose or broken wire #10A from outrigger board to outrigger limit switch LS68.
-- Check continuity. Replace if defective.
4. Defective outrigger limit switch LS68.
-- Check switch. Replace if defective.
5. Loose or broken wire #68A from outrigger limit switch LS68 to outrigger control module at pin P2-1.
-- Check continuity. Replace if defective.
6. Loose or broken wire #10A from outrigger board to outrigger limit switch LS67.
-- Check continuity. Replace if defective.
SKYJACK, Page 20
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
7. Defective outrigger limit switch LS67.
-- Check switch. Replace if defective.
8. Loose or broken wire #67A from outrigger limit switch LS67 to outrigger control module at pin P2-2.
-- Check continuity. Replace if defective.
9. Loose or broken wire #10A from outrigger board to outrigger limit switch LS66.
-- Check continuity. Replace if defective.
10. Defective outrigger limit switch LS66.
-- Check switch. Replace if defective.
11. Loose or broken wire #66A from outrigger limit switch LS66 to outrigger control module at pin P2-3.
-- Check continuity. Replace if defective.
12. Loose or broken wire #10A from outrigger board to outrigger limit switch LS65.
-- Check continuity. Replace if defective.
13. Defective outrigger limit switch LS65.
-- Check switch. Replace if defective.
14. Loose or broken wire #65A from outrigger limit switch LS65 to outrigger control module at pin P2-4.
-- Check continuity. Replace if defective.
15. Check for power on wire #65 at outrigger control module at pin P2-8.
-- If no voltage present, proceed to outrigger control module troubleshooting.
16. Loose or broken wire #65 from outrigger control module at pin P2-8 to outrigger board CN22 pin
#16.
-- Check continuity. Replace if defective.
17. Defective lift enable relay 65CR.
-- Check relay. Replace if defective.
18. Defective lift disable relay 17DCR.
-- Check relay. Replace if defective.
19. Loose or broken wire #36A from pin #10 on connector CN14 at the outrigger board to terminal block
TB-1.
-- Check continuity. Replace if defective.
20. Loose or broken wire #36A from terminal block TB-1 to end of stroke limit switch LS4.
-- Check continuity. Replace if defective.
21. Defective end of stroke limit switch LS4.
-- Check switch. Replace if defective.
22. Loose or broken wire #36B from end of stroke limit switch LS4 to relay 14CR.
-- Check continuity. Replace if defective.
23. Defective relay 14CR.
-- Check relay. Replace if defective.
24. Loose or broken wire #14A from relay 14CR to relay 28CR.
-- Check continuity. Replace if defective.
25. Loose or broken wire #14B from relay 28CR to base terminal block.
-- Check continuity. Replace if defective.
26. Loose or broken wire #14B from base terminal block to lift valve solenoid 2H-14B.
-- Check continuity. Replace if defective.
27. Loose or broken wire #02 from lift valve solenoid 2H-14B to base terminal block.
-- Check continuity. Replace if defective.
28. Defective lift valve solenoid 2H-14B.
-- Check solenoid. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 21
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4.1-29 Platform will Not Lift from Platform or Base Controls with Outriggers Retracted
(lift operates correctly with outriggers extended)
1. Outriggers not fully retracted.
-- Fully retract outrigger cylinders.
2. Loose or broken wire #1 from relay 28CR (ANSI/CSA) or 28CR1 (CE) to pin #7 on connector CN14 at
the outrigger board.
-- Check continuity. Replace if defective.
3. Loose or broken wire #1 from outrigger board to outrigger limit switch LS64.
-- Check continuity. Replace if defective.
4. Defective outrigger limit switch LS64.
-- Check switch. Replace if defective.
5. Loose or broken wire #64 from outrigger limit switch LS64 to outrigger board.
-- Check continuity. Replace if defective.
6. Loose or broken wire #64 from outrigger board to outrigger limit switch LS63.
-- Check continuity. Replace if defective.
7. Defective outrigger limit switch LS63.
-- Check continuity. Replace if defective.
8. Loose or broken wire #63 from outrigger limit switch LS63 to outrigger board.
-- Check continuity. Replace if defective.
9. Loose or broken wire #63 from outrigger board to outrigger limit switch LS62.
-- Check continuity. Replace if defective.
10. Defective Limit Switch LS62.
-- Check switch. Replace if defective.
11. Loose or broken wire #62 from outrigger limit switch LS62 to outrigger board.
-- Check continuity. Replace if defective.
12. Loose or broken wire #62 from outrigger board to outrigger limit switch LS61.
-- Check continuity. Replace if defective.
13. Defective outrigger limit switch LS61.
-- Check switch. Replace if defective.
14. Loose or broken wire #61 from outrigger limit switch LS61 to outrigger board .
-- Check continuity. Replace if defective.
15. Open diode D36 on outrigger board.
-- Check diode. Replace if defective.
4.1-30 Up Circuit Inoperative from Base (ANSI/CSA)
1. Loose or broken wire #10A from base terminal block to base enable switch S10.
-- Check continuity. Replace if defective.
2. Defective base enable switch S10.
-- Check switch. Replace if defective.
3. Loose or broken wire #10E from base enable switch S10 to base up/down switch S2.
-- Check continuity. Replace if defective.
4. Defective base up/down switch S2.
-- Check switch. Replace if defective.
5. Loose or broken wire #14 from base up/down switch S2 to base terminal block TB-1.
-- Check continuity. Replace if defective.
4.1-31 Up Circuit Inoperative from Base (CE)
1. Loose or broken wire #7C from base emergency stop switch S6 to platform emergency stop switch
S4.
-- Check continuity. Replace if defective.
SKYJACK, Page 22
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
2. Defective platform emergency stop switch S4.
-- Check switch. Replace if defective.
3. Loose or broken wire #10D from platform emergency stop switch S4 to idle/platform/base key switch
S10.
-- Check continuity. Replace if defective.
4. Defective idle/platform/base key switch S10.
-- Check switch. Replace if defective.
5. Loose or broken wire #10E from idle/platform/base key switch S10 to up/down switch S2.
-- Check continuity. Replace if defective.
6. Loose or broken wire #14E from up/down switch S2 to base terminal block.
-- Check continuity. Replace if defective.
7. Defective up/down switch S2.
-- Check switch. Replace if defective.
8. Loose or Open diode D14E-1 or D10E.
-- Tighten diode. Check diode. Replace if defective.
9. Loose or broken wire #10E from base terminal block to control module CM1 at pin #P2-2.
-- Check continuity. Replace if defective.
4.1-32 Down Circuit Inoperative from Platform or Base
1. Lift/Off/Drive switch S3 in drive position or defective.
-- Select lift position. Check switch. Replace if defective.
2. Loose or broken wire #09 from lift/off/drive switch S3 to lift enable switch S9.
-- Check continuity. Replace if defective.
3. Defective lift enable switch S9.
-- Check switch. Replace if defective.
4. Loose or broken wire #9A from enable switch S9 to up/down switch S5.
-- Check continuity. Replace if defective.
5. Defective up/down switch S5.
-- Check switch. Replace if defective.
6. Loose or broken wire #13 from up/down switch S5 to relay 13CR. (ANSI/CSA)
-- Check continuity. Replace if defective.
7. Loose or broken wire #13 from up/down switch S5 to diode D13 at base terminal block TB-1. (CE)
-- Check continuity. Replace if defective.
8. Loose or Open diode D13. (CE)
-- Tighten diode. Check diode. Replace if defective.
9. Loose or broken wire #13D to relay 13DCR (CE).
-- Check continuity. Replace if defective.
10. Loose or broken wire #02 from relay 13CR (ANSI/CSA) or 13DCR (CE) to base terminal block TB-1.
-- Check continuity. Replace if defective.
11. Defective relay 13CR (ANSI/CSA) or 13DCR (CE).
-- Check relay. Replace if defective.
12. Loose or broken wire #10A from base terminal block to relay 13CR. (ANSI/CSA only)
-- Check continuity. Replace if defective.
13. Loose or broken wire #13A from relay 13CR (ANSI/CSA) or 13DCR (CE) to base terminal block.
-- Check continuity. Replace if defective.
14. Loose or broken wire #13A from base terminal block to holding valve solenoid 2H-13A-1 or 2H-13A-2
or 2H-13A-3 or 2H-13A-4.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 23
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
15. Loose or broken wire #02 from holding valve solenoid 2H-13A-1 or 2H-13A-2 or 2H-13A-3 or 2H-13A-4
to base terminal block TB-1.
-- Check continuity. Replace if defective.
16. Defective holding valve solenoid 2H-13A-1 or 2H-13A-2 or 2H-13A-3 or 2H-13A-4.
-- Check solenoid. Replace if defective.
17. Loose or broken wire #13A from base terminal block to lowering valve solenoid 2H-13A.
-- Check continuity. Replace if defective.
18. Loose or broken wire #02 from lowering valve solenoid 2H-13A to base terminal block.
-- Check continuity. Replace if defective.
19. Defective lowering valve solenoid 2H-13A.
-- Check solenoid. Replace if defective.
No Down Function (Additional for machines with Load Sensing System) (CE)
1. Loose or broken wire #02 from base terminal strip TB-1 to down enable relay 28CR2 or auxiliary down
enable relay 28ECR2.
-- Check continuity. Replace if defective.
2. Defective down enable relay 28CR2 or auxiliary down enable relay 28ECR2.
-- Check relay. Replace if defective.
3. Loose or broken wire #28 from control module CM1 at pin #P3-4 to down enable relay 28CR2.
-- Check continuity. Replace if defective.
4. Loose or broken wire #28E from control module CM1 at pin #P3-6 to auxiliary down enable relay
28ECR2.
-- Check continuity. Replace if defective.
5. Loose or broken wire #10A from base terminal block to auxiliary down enable relay 28ECR2.
-- Check continuity. Replace if defective.
6. Loose or broken wire #13C from auxiliary down enable relay 28ECR2 to down enable relay 28CR2.
-- Check continuity. Replace if defective.
7. Loose or broken wire #13B from down enable relay 28CR2 to down relay 28DCR.
-- Check continuity. Replace if defective.
4.1-33 Down Circuit Inoperative from Base (ANSI/CSA)
1. Loose or broken wire #10A from base terminal block to base enable switch S10.
-- Check continuity. Replace if defective.
2. Defective base enable switch S10.
-- Check switch. Replace if defective.
3. Loose or broken wire #10E from base enable switch S10 to base up/down switch S2.
-- Check continuity. Replace if defective.
4. Defective base up/down switch S2.
-- Check switch. Replace if defective.
5. Loose or broken wire #13 from base up/down switch S2 to base terminal block TB-1.
-- Check continuity. Replace if defective.
4.1-34 Down Circuit Inoperative from Base (CE)
1. Loose or broken wire #7C from base emergency stop switch S6 to platform emergency stop switch
S4.
-- Check continuity. Replace if defective.
2. Defective platform emergency stop switch S4.
-- Check switch. Replace if defective.
SKYJACK, Page 24
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
3. Loose or broken wire #10D from platform emergency stop switch S4 to idle/platform/base key switch
S10.
-- Check continuity. Replace if defective.
4. Defective idle/platform/base key switch S10.
-- Check switch. Replace if defective.
5. Loose or broken wire #10E from idle/platform/base key switch S10 to up/down switch S2.
-- Check continuity. Replace if defective.
6. Loose or broken wire #13D from up/down switch S2 to base terminal block TB-1.
-- Check continuity. Replace if defective.
7. Defective up/down switch S2.
-- Check switch. Replace if defective.
4.1-35 Powered Extension Platform Inoperative
1. Loose or broken battery cable from main power disconnect switch S1 to fuse F2 (100 Amp).
-- Check continuity. Replace if defective.
2. Open fuse F2.
-- Check fuse. Replace if open.
3. Loose or broken battery cable #103A from fuse F2 to contactor 9CR1.
-- Check continuity. Replace if defective.
4. Defective contactor 9CR1.
-- Check contactor. Replace if defective.
5. Loose or broken battery cable #103B from contactor 9CR1 to motor contactor 99CR.
-- Check continuity. Replace if defective.
6. Defective motor contactor 99CR.
-- Check contactor. Replace if defective.
7. Loose or broken wire #103B from battery cable #103B to fuse F5.
-- Check continuity. Replace if defective.
8. Defective fuse F5.
-- Check fuse. Replace if defective.
9. Loose or broken wire #103C from fuse F5 to powered platform enable switch S34 or S34A.
-- Check continuity. Replace if defective.
10. Loose or broken wire #103D from enable switch S34or S34A to platform extend retract switch S11 or
S11A.
-- Check continuity. Replace if defective.
11. Defective platform extend/retract switch S11 or S11A.
-- Check switch. Replace if defective.
12. Defective platform enable switch S34 or S34A.
-- Check switch. Replace if defective.
13. Loose or broken battery cable #00 from platform power unit DCM1 to battery B1.
-- Check continuity. Replace if defective.
14. Defective platform power unit DCM1.
-- Check power unit. Repair or replace if defective.
4.1-36 Powered Extension Platform will Not Extend
1. Defective platform extend/retract switch S11 or S11A.
-- Check switch. Replace if defective.
2. Loose or broken wire #26 or #26A from platform extend/retract switch S11 or S11Ato platform extend
valve coil 4H-26 or 4H-26A.
-- Check continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 25
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
3. Open diode D26 or D26A.
-- Check diode. Replace if defective.
4. Defective platform extend valve coil 4H-26 or 4H-26A.
-- Check coil. Replace if defective.
5. Loose or broken wire #00 from platform extend valve coil 4H-26 or 4H-26A to battery cable #00.
-- Check continuity. Replace if defective.
4.1-37 Powered Extension Platform will Not Retract
1. Defective platform extend/retract switch S11 or S11A.
-- Check switch. Replace if defective.
2. Loose or broken wire #27 or #27A from platform extend/retract switch S11 or S11A to platform retract
valve coil 4H-27 or 4H-27A.
-- Check continuity. Replace if defective.
3. Open diode D27 or D27A.
-- Check diode. Replace if defective.
4. Defective platform retract valve coil 4H-27 or 4H-27A.
-- Check coil. Replace if defective.
5. Loose or broken wire #00 from platform retract valve coil 4H-27 or 4H-27A to battery cable #00.
-- Check continuity. Replace if defective.
4.1-38 Hydraulic Generator Inoperative
1. Key switch S3 in drive position.
-- Turn switch to lift position.
2. Loose or broken wire #9 from base terminal block TB-1 to generator relay 86BCR.
-- Check continuity. Replace if defective.
3. Loose or broken wire #9 from generator relay 86BCR to generator switch S12.
-- Check continuity. Replace if defective.
4. Defective generator switch S12.
-- Check switch. Replace if defective.
5. Loose or broken wire #85 from generator switch S12 to generator relay 86ACR.
-- Check continuity. Replace if defective.
6. Loose or broken wire #85 from generator relay 86ACR to generator relay 86BCR.
-- Check continuity. Replace if defective.
7. Loose or broken wire #86B from generator relay 86ACR to generator relay 86BCR.
-- Check continuity. Replace if defective.
8. Defective relay 86ACR.
-- Check relay. Replace if defective.
9. Defective relay 86BCR.
-- Check relay. Replace if defective.
10. Open diode D86C-1.
-- Check diode. Replace if defective.
11. Loose or broken wire #17 from diodes D86B-1 to relay 17CR.
-- Check continuity. Replace if defective.
12. Loose or broken wire #2A from relays 10ACR2 and 86BCR to relay 10ACR1.
-- Check continuity. Replace if defective.
13. Loose or broken wire #85A from circuit breaker CB4 to relay 86BCR.
-- Check continuity. Replace if defective.
14. Tripped or defective circuit breaker CB4.
-- Reset circuit breaker. Replace if defective.
SKYJACK, Page 26
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
15. Loose or broken wire #3 from circuit breaker CB4 to circuit breaker CB1.
-- Check continuity. Replace if defective.
16. Loose or broken wire #86C from relay 86BCR to generator valve coil 2H-86C.
-- Check continuity. Replace if defective.
17. Loose or broken wire #02 from base terminal block to generator valve coil 2H-86C.
-- Check continuity. Replace if defective.
18. Defective generator valve coil 2H-86C.
-- Check coil. Replace if defective.
4.1-39 Hydraulic Generator will Not Shut Off from Generator Switch
1. Defective generator switch S12.
-- Check switch. Replace if defective.
2. Loose or broken wire #86 from generator switch S12 to diode D86.
-- Check continuity. Replace if defective.
3. Open diode D86.
-- Check diode. Replace if defective.
4. Defective relay 86ACR.
-- Check relay. Replace if defective.
5. Loose or broken wire #02 from base terminal block to relay 86ACR.
-- Check continuity. Replace if defective.
4.1-40 All Outriggers Inoperative (Auto-level and manual)
WARNING
Scissors lift must be below high speed limit switch for outriggers to function.
NOTE
For the outriggers to function the upper control console must be in
the lift position.
1. No power on wire #44 at relay 35CR.
-- If no power is present ensure there is power on wire #35 and relay 35CR operates correctly.
2. Loose or broken wire #44 from relay 35CR to pin #6 on connector CN14 on outrigger board.
-- Check for continuity. Replace if defective.
3. No power at wire #9 at pin #5 on connector CN14 on outrigger board.
-- If no power is present check for continuity on wire #9 back to base terminal block TB-1. Replace
if defective.
4. Defective relay 9CR2 or 9CR3 on outrigger board.
-- Check relays. Replace if defective.
5. Defective relay 17DCR on outrigger board.
-- Check relay. Replace if defective.
6. Open or broken jumper J17E on outrigger board.
-- Check jumper. Replace if defective.
7. Open diode D17B-1 on outrigger board.
-- Check diode. Replace if defective.
8. Loose or broken wire #17 from pin #2 on connector CN14 on outrigger board to relay 35CR or relay
17CR.
-- Check for continuity. Replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 27
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
9. Loose or broken wire #17B from pin #1 or wire #02 from pin #2 on connector CN21 on outrigger
board to outrigger holding valve coil 2H-17B.
-- Check for continuity. Replace if defective.
10. Defective outrigger holding valve coil 2H-17B.
-- Check coil. Replace if defective.
4.1-41 All Outriggers Inoperative (Auto-level and manual from platform controls)
1. Loose or broken wire #35C from pin #1 on connector CN20 on outrigger board through outrigger
cables and plugs to the outrigger enable switch S9A in the control console.
-- Check for continuity. Replace if defective.
2. Loose or broken wire #35D from outrigger enable switch S9A to pin #5 on the outrigger control console
plug.
-- Check for continuity. Replace if defective.
3. Defective outrigger enable switch S9A.
-- Check switch. Replace if defective.
4.1-42 All Outriggers Inoperative (base controls)
1. Defective outrigger enable switch S9B.
-- Check switch. Replace if defective.
4.1-43 All Outriggers Inoperative (Auto-level)
A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not on Constant
1. Loose or broken wire #10A from pin #1 of the tilt switch connector to pin P2-12 on the outrigger control
module OCM1.
-- Check for continuity. Replace if defective.
2. Loose or broken wire #10A from pin #1 of the tilt switch connector to main terminal block TB-1.
-- Check for continuity. Replace if defective.
3. Loose or broken wire #02 from pin #3 of the tilt switch connector to pin P2-11 on the outrigger control
module OCM1.
-- Check for continuity. Replace if defective.
4. Loose or broken wire #02 from pin #3 of the tilt switch connector to main terminal block TB-1.
-- Check for continuity. Replace if defective.
5. Defective outrigger control module OCM1.
-- Replace.
--
SKYJACK, Page 28
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
4.1-44 All Outriggers Inoperative (Auto Level)
B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing
Flash Code
1/1
1/2
Probable Cause
1.
1.
Level the machine.
1.
2.
At least one outrigger is not fully
retracted.
Defective outrigger rod limit switch
(LS61, LS62, LS63, LS64) or wiring.
Defective diode (D36) on outrigger
board.
Outriggers are all down and the machine
is not fully level.
Power on wire #70 or #79 at power on.
1.
Lower the scissor stack below high speed limit switch.
Check for input voltage on wire #35 at pin P2-10 of the outrigger
control module (OMC1). Replace if defective.
Fully retract all outriggers.
2.
Replace defective or damaged switch(es) or wiring.
3.
Check for continuity. Replace if defective.
1.
Move machine to less sloped terrain if it will not lift.
1.
Power on wire #70 or #79 when
manually operating outriggers.
Low or no voltage on wire #35c.
Loose or broken wire on #35c.
2.
Excessive vibration.
Defective outrigger control module.
Outriggers are being manually
controlled.
Error occured while self diagnosing the
hardware fail safe.
1.
2.
1.
Check for power on wire #70 or #79 at pin P2-5 or P2-6 of the
outrigger control module. Replace defective component.
Check for power on wire #70 or #79 while manually operating an
outrigger.
Check battery and charging system to ensure minimum 9 volts.
Check for input voltage on wire #35c at pin P4-9 of outrigger
control module (OCM1).
Outrigger control module cannot read tilt sensor.
Replace.
Indicates function activated. No repair necessary.
Low input voltage to outrigger control
module.
Startup error occurred while self
diagnosing.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
Internal failure of OCM1.
1.
1.
2.
1.
2/2
2.
3.
2/1
1.
1.
5/5
5/2
7/1
6/6
7/8
5/1
7/7
7/5
7/2
8/1
8/2
8/3
8/4
8/5
7/6
Remedy
Outriggers are all up and machine is
tilted.
Machine is elevated.
Loose or broken wire # 35.
2.
1.
2.
1.
2.
1.
1.
1.
1.
1.
2.
1.
1.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Check for minimum 9 volts between wire #02 at pin P2-11 and wire
#10A at pin P2-12 at outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
Turn off power to reset the outrigger control module. Turn power
back on and see if the code has cleared. If problem persists,
replace outrigger control module.
60416AA
Full Size RT’s
Engine Powered
SKYJACK, Page 29
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4.1-45 Left Front Outrigger Inoperative Manually
1. Defective left front outrigger switch S20 at platform, or S20A at base.
-- Check switch. Replace if defective.
2. Loose or broken wire #71 from outrigger control console to pin #6 on connector CN20 at outrigger
board (retract), or from wire #75 to pin #7 (extend).
-- Check continuity. Replace if defective.
3. Open diode D71 (retract) or D75 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #71 from pin #7 on connector CN21 at outrigger board to valve coil 4H-71 (retract)
, or wire #75 from pin #8 to 4H-75 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-71 (retract) or 4H-75 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
4.1-46 Right Front Outrigger Inoperative Manually
1. Defective right front outrigger switch S21 at platform, or S21A at base.
-- Check switch. Replace if defective.
2. Loose or broken wire #72 from outrigger control console to pin #8 on connector CN20 at outrigger
board (retract), or from wire #76 to pin #9 (extend).
-- Check continuity. Replace if defective.
3. Open diode D72 (retract) or D76 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #72 from pin #9 on connector CN21 at outrigger board to valve coil 4H-72
(retract), or wire #76 from pin #10 to 4H-76 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-72 (retract) or 4H-76 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
4.1-47 Right Rear Outriggers Inoperative Manually
1. Defective right rear outrigger switch S22 at platform, or S22A at base.
-- Check switch. Replace if defective.
2. Loose or broken wire #73 from outrigger control console to pin #3 on connector CN20 at outrigger
board (retract), or from wire #77 to pin #4 (extend).
-- Check continuity. Replace if defective.
3. Open diode D73 (retract) or D77 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #73 from pin #4 on connector CN21 at outrigger board to valve coil 4H-73
(retract), or wire #77 from pin #4 to 4H-77 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-73 (retract) or 4H-77 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
SKYJACK, Page 30
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Electrical System (Continued)
4.1-48 Left Rear Outriggers Inoperative Manually
1. Defective left rear outrigger switch S23 at platform, or S23A at base.
-- Check switch. Replace if defective.
2. Loose or broken wire #74 from outrigger control console to pin #5 on connector CN20 at outrigger
board (retract), or from wire #78 to pin #2 (extend).
-- Check continuity. Replace if defective.
3. Open diode D74 (retract) or D78 (extend) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #74 from pin #6 on connector CN21 at outrigger board to valve coil 4H-74
(retract), or wire #78 from pin #3 to 4H-78 (extend).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-74 (retract) or 4H-78 (extend) to pin #2 on connector
CN21 at the outrigger board.
-- Check continuity. Replace if defective.
4.1-49 Individual Outrigger Functions Inoperative (Auto-level)
1. Loose or broken wire #71- #75 (depending on function not working) at pins 1-8 of outrigger control
module plug P4.
-- Check connections of outrigger functions not working (refer to Section 5 for pin reference
chart). Replace if defective.
2. No output from outrigger control module OCM1 at pins 1-8 of outrigger control module plug P4.
-- Turn off power to reset the outrigger control module. Turn power back on and retest. If problem
persists, replace outrigger control module.
4.1-50 Auto-level Inoperative
1. Loose or broken wire #35D from outrigger enable switch S9A to auto mode outrigger switch S24.
-- Check continuity. Replace if defective.
2. Defective auto mode outrigger switch S24.
-- Check switch. Replace if defective.
3. Loose or broken wire #10A at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-12. If no voltage present, check continuity of wire. Replace if
defective.
4. Loose or broken wire #35 at pin #P2-10 on outrigger control module OCM1.
-- Check for power at P2-10. If no voltage present, check continuity of wire. Replace if
defective.
5. Loose or broken wire #02 at pin #P2-11 on outrigger control module OCM1.
-- Check for ground at P2-11. If no ground present, check continuity of wire. Replace if
defective.
6. Loose or broken wire #70 from auto mode outrigger switch S24 to pin #P2-5 on outrigger control
module OCM1.
-- Check continuity. Replace if defective.
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Engine Powered
SKYJACK, Page 31
Service and Maintenance
Section 4 - Troubleshooting Information
Electrical System (Continued)
4.1-51 Auto All Up Inoperative (Retract)
1. Loose or broken wire #35D from outrigger enable switch S9A to auto mode outrigger switch S24.
-- Check continuity. Replace if defective.
2. Defective auto mode outrigger switch S24.
-- Check switch. Replace if defective.
3. Loose or broken wire #10A at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-12. If no voltage present, check continuity of wire. Replace if
defective.
4. Loose or broken wire #35 at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-10. If no voltage present, check continuity of wire. Replace if
defective.
5. Loose or broken wire #02 at pin #P2-11 on outrigger control module OCM1.
-- Check for ground at P2-11. If no ground present, check continuity of wire. Replace if
defective.
6. Loose or broken wire #70 from auto mode outrigger switch S24 to pin #P2-5 on outrigger control
module OCM1.
-- Check continuity. Replace if defective.
SKYJACK, Page 32
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Hydraulic System
4.2-1 All Functions Inoperative
1. Hydraulic oil level low.
-- Refill tank to proper level.
2. Defective pump P1.
-- Check pump. Repair or replace if defective.
3. Broken engine to pump coupler.
-- Check coupler. Replace if defective.
4. Open relief valve R1.
-- Check valve. Replace if defective.
4.2-2 Steering Inoperative
1. Stuck or defective brake feed valve 2H-30A-2.
-- Check valve. Repair or replace if defective.
2. Stuck or defective steer right valve 4H-23A or steer left valve 4H-24A.
-- Check valves. Replace if defective.
3. Steer cylinder C7 damaged or bypassing internally.
-- Check cylinder. Repair or replace if defective.
4.2-3 Steer and First Drive Speed Inoperative
1. Small pump dump valve 2H-18A stuck open.
-- Check valve. Repair or replace if defective.
2. Worn or defective small pump section of pump P1.
-- Check pump. Repair or replace if defective.
3. Check valve CV1 or CV2 stuck.
-- Check valves. Clean or replace if defective.
4.2-4 Lift and Second Drive Speed Inoperative
1. Large pump dump valve 2H-17A stuck open.
-- Check valve. Repair or replace if defective.
2. Worn or defective large pump section of pump P1.
-- Check pump. Repair or replace if defective.
3. Check valve CV1 or CV2 stuck.
-- Check valves. Clean or replace if defective.
4.2-5 Drive Inoperative
1. Stuck or defective drive reverse valve 4H-15B or drive forward valve 4H-16B.
-- Check valves. Repair or replace if defective.
2. Defective motion control valve MC1.
-- Check valve. Repair or replace if defective.
3. Missing or defective check balls in series/parallel valve manifold 3H-20A.
-- Repair or replace balls. Refer to Section 5 for proper location.
4. Stuck or defective main series/parallel valve spool V3 in drive motor.
-- Check valve. Repair or replace if defective.
5. Defective drive motor M1.
-- Check motor. Repair or replace if defective.
6. Free wheeling valve 2H-30A stuck.
-- Check valve. Repair or replace if defective.
7. Cushion cylinder C8 bypassing internally.
-- Check cylinder. Repair or replace if defective.
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Engine Powered
SKYJACK, Page 33
Service and Maintenance
Section 4 - Troubleshooting Information
Hydraulic System (Continued)
4.2-6 Reverse Drive Inoperative
1. Stuck or defective drive valve 4H-15B.
-- Check valve. Repair or replace if defective.
2. Stuck or defective check valve in motion control assembly MC1.
-- Check valves. Clean or replace if defective.
4.2-7 Forward Drive Inoperative
1. Stuck or defective drive valve 4H-16B.
-- Check valve. Repair or replace if defective.
2. Stuck or defective check valve in motion control assembly MC1.
-- Check valves. Clean or replace if defective.
4.2-8 Brakes will Not Release
1. Stuck or defective brake feed valve 2H-30A-2.
-- Check valve. Repair or replace if defective.
2. Stuck or defective brake dump valve 2H-30A-1.
-- Check valve. Repair or replace if defective.
3. Stuck or defective brake valve 2H-25. (If equipped)
-- Check valve. Repair or replace if defective.
4. Stuck or defective auto reset valve V6. (If equipped)
-- Check valve. Repair or replace if defective.
5. Defective disc brake pack BP1. (Internal brake)
-- Check brake pack. Repair or replace if defective.
6. Defective brake cylinder C5 or C6. (External brake cylinders)
-- Check cylinder. Repair or replace if defective.
4.2-9 Brakes will Not Release (Internal Brake)
1. Bad o-rings internal to brake. (If release piston will not hold pressure, brake will not release.)
-- Check for hydraulic oil in axle. Replace o-rings if defective.
2. Discs frozen. (These brakes are designed for only limited dynamic braking. A severe emergency stop
or prolonged reduced release pressure operation may result in this type of damage.)
-- Check for abnormal wear. Replace disc stack if defective.
4.2-10 Brake Slips (Internal Brake)
1. Excessive pressure in hydraulic system. (If there is back pressure in the actuation line of the brake,
holding torque will be reduced)
-- Check filters, hose size, restrictions in other hydraulic components.
2. Oil in brake if designed for dry use. (Wet linings generate 67% of the dry torque rating. If the brake has
oil in it, check the type of oil hydraulic or gearbox. i. Gearbox oil ii. Hydraulic oil)
-- Replace oil seal in brake. Check motor seal. Check piston seals.
NOTE
Internal components will need to be inspected, cleaned and replaced
as required.
3. Disc plates worn. (The thickness of the disc stack sets the torque level. A thin stack reduces torque.)
-- Check brake’s holding torque is sufficient.
-- i) Make sure the machine is parked on level ground.
-- ii) Locate the brake feed valve (2H30A-2) on the main manifold. Disconnect the electrical
connectors from this valve. This will prevent the hydraulic system from releasing the brake.
SKYJACK, Page 34
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Hydraulic System (Continued)
-- iii) With the engine running, machine in drive mode, engine on high idle, high torque selected
and low speed range selected, hold the enable switch on the joystick and push the joystick
forward as if you were to drive forward. This provides torque from the drive motor to the
unreleased brake.
-- v) If the brake slips and the machine starts to move in this condition, either the brake plates
are worn or the springs have broken. Both the springs and the brake plates must be replaced
to return the brake to its original holding torque.
4.2-11 Brake Drags or Runs Hot (Internal Brake)
1. Low brake pressure.
-- Place pressure gauge in brake line. Brakes use system pressure. (Minimum 335 psi
required)
2. Bearing failure (If the bearing should fail, a large amount of drag can be generated)
-- Replace bearing
4.2-12 Up Circuit Inoperative
1. Stuck or defective lift valve 2H-14B.
-- Check valve. Repair or replace if defective.
2. Stuck check valve CV3.
-- Check valve. Replace if defective.
3. Misadjusted or defective lift relief valve R2.
-- Adjust valve. Replace if defective.
4. Stuck or defective lowering valve 2H-13A.
-- Check valve. Repair or replace if defective.
5. Stuck or defective manual lowering valve V1.
-- Check valve. Repair or replace if defective.
6. Open or defective brake feed valve 2H-30A-2.
-- Check valve. Repair or replace if defective.
7. Open manual override on holding valve 2H-13A-1 or 2H-13A-2 or 2H-13A-3 or 2H-13A-4.
-- Depress and turn manual override clockwise to close. Replace if defective.
8. Stuck holding valve 2H13A-1 or 2H13A-2 or 2H-13A-3 or 2H-13A-4.
-- Check valves. Repair or replace if defective.
4.2-13 Down Circuit Inoperative
1. Stuck or defective lowering valve 2H-13A.
-- Check valve. Repair or replace if defective.
2. Stuck holding valve 2H13A-1 or 2H13A-2 or 2H-13A-3 or 2H-13A-4.
-- Check valves. Repair or replace if defective.
3. Plugged lowering orifice O1.
-- Clean or replace orifice.
4.2-14 Powered Extension Platform Inoperative
1. Defective powered extension pump P3.
-- Check pump. Repair or replace if defective.
2. Misadjusted or defective relief valve R5.
-- Adjust valve. Replace if defective.
3. Stuck or defective deck extend valve 4H-26 or 4H-26A or retract valve 4H-27 or 4H-27A.
-- Check valves. Repair or replace if defective.
4. Defective powered extension cylinder C13 front or C14 rear.
-- Check cylinder. Repair or replace if defective.
Full Size RT’s
Engine Powered
SKYJACK, Page 35
Service and Maintenance
Section 4 - Troubleshooting Information
Hydraulic System (Continued)
4.2-15 Hydraulic Generator Inoperative
1. Stuck or defective hydraulic generator valve 2H-86C.
-- Check valve. Repair or replace if defective.
2. Misadjusted or defective flow control valve FC1.
-- Adjust valve. Replace if defective.
3. Stuck or defective large pump dump valve 2H-17A.
-- Check valve. Repair or replace if defective.
4. Defective hydraulic generator hydraulic motor GM1.
-- Check motor. Repair or replace if defective.
4.2-16 All Outriggers Inoperative
1. Stuck or defective outrigger holding valve 2H-17B.
-- Check valve. Repair or replace if defective.
4.2-17 Left Front Outrigger Inoperative
1. Stuck or defective retract valve 4H-71 or extend valve 4H-75.
-- Clean valve. Replace if defective.
2. Stuck or defective check valve CV5.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C9.
-- Repack cylinder. Replace if defective.
4.2-18 Right Front Outrigger Inoperative
1. Stuck or defective retract valve 4H-72 or extend valve 4H-76.
-- Clean valve. Replace if defective.
2. Stuck or defective Check valve CV6.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C10.
-- Repack cylinder. Replace if defective
4.2-19 Right Rear Outrigger Inoperative
1. Stuck or defective retract valve 4H-73 or extend valve 4H-77.
-- Clean valve. Replace if defective.
2. Stuck or defective check valve CV7.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C11.
-- Repack cylinder. Replace if defective
4.2-20 Left Rear Outrigger Inoperative
1. Stuck or defective retract valve 4H-74 or extend valve 4H-78.
-- Clean valve. Replace if defective.
2. Stuck or defective check valve CV4.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C12.
-- Repack cylinder. Replace if defective
4.2-21 Outriggers Drift In
1. Defective check valve left front (CV4), right front (CV5), right rear (CV6) or left rear (CV7)
-- Clean valve. Replace if defective.
2. Outriggers cylinder bypassing left front (C9), right front (C10), right rear (C11) or left rear (C12).
-- Repack cylinder. Replace if defective
SKYJACK, Page 36
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Load Sensing System - CE
4.3-1 Flash Code F01: Check HWFS
1. This message is given if the GP102 startup tests have not completed.
-- Check HELP message for more information.
4.3-2 Flash Code F02: Not Ground Mode
1. This message is given if the machine is not in ground mode, P2-2 must be high.
-- Calibration can only be carried out in ground mode.
4.3-3 Flash Code F03: Not Stopped
1. This message is given if the machine is not in ground mode, P2-2 must be high.
-- Check DIAGNOSTICS / SWITCHES to see which function switch is closed.
4.3-4 Flash Code F04: Tilted
1. This message is given if the machine is tilted.
-- Calibration must be carried out with the machine level. If the machine is level, use the SETUPS
/ TILT SETUPS to set the GP102 level.
4.3-5 Flash Code F05: Bad Height
1. This message is given if the height sensor output P4-3 is out of range at the start of calibration.
-- The height sensor output must be between 1.0V and 4.0V. Check DIAGNOSTICS / SENSORS
to see the output. A reading of 0V or 5V is probably due to a wiring problem.
4.3-6 Flash Code F06: Check Elev
1. This message is given if the elevation switch P2-10 is open at the start of calibration, when the operator
has confirmed the “PLATFORM DOWN?” question.
-- If the platform is down, check the elevation switch wiring.
4.3-7 Flash Code F08: Check Elev
1. This message is given if the elevation switch P2-10 is closed at the end of the DYNAMIC lift, when the
platform should be fully raised.
This message would occur if the UP switch was accidentally opened near the start of the DYNAMIC
lift.
-- If the platform is fully raised, check the elevation switch wiring.
4.3-8 Flash Code F09: Bad Height
1. This message is given if the height sensor output P4-3 is out of range at the start of the DYNAMIC lift.
-- The height sensor output must be between 1.0V and 4.0V. Check DIAGNOSTICS / SENSORS
to see the output.
4.3-9 Flash Code F10: Bad Height
1. This message is given if the height sensor output P4-3 is out of range at the end of the DYNAMIC lift.
-- The height sensor output must be between 1.0V and 4.0V. Check DIAGNOSTICS / SENSORS
to see the output. A reading of 0V or 5V is probably due to a wiring problem.
4.3-10 Flash Code F11: Not Up
1. This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP.
-- Select the UP function.
Full Size RT’s
Engine Powered
SKYJACK, Page 37
Service and Maintenance
Section 4 - Troubleshooting Information
Load Sensing System - CE (Continued)
4.3-11 Flash Code F12: Too Many
1. This message occurs if the DYNAMIC lift takes too long. This message could occur if the UP switch
was not released at the end of the dynamic lift.
-- If the machine takes more than two minutes to lift, the GP102 may need modification to avoid
this problem.
4.3-12 Flash Code F13: Low Height Range
1. This message occurs at the end of the DYNAMIC lift if the height sensor output did not change sufficiently
to give a reasonably accurate platform height estimate.
This message could occur if the UP switch was accidentally opened too early (when the platform is not
fully raised).
This message would occur if the UP switch was accidentally opened near the start of the DYNAMIC
lift.
-- If the platform is fully raised, check the elevation switch wiring.
4.3-13 Flash Code F14: Bad Height
1. This message occurs if the height sensor output P4-3 is out of range during the DYNAMIC lift.
-- The height sensor output must be between 1.0V and 4.0V. Check DIAGNOSTICS / SENSORS
to see the output. A reading of 0V or 5V is probably due to a wiring problem.
4.3-14 Flash Code F15: Check Elev
1. This message is given if the elevation switch P2-10 is open when the platform has been fully lowered
after the DYNAMIC lift.
This message would occur if the DOWN switch was accidentally opened before the platform was fully
lowered.
-- If the platform is fully lowered, check the elevation switch.
4.3-15 Flash Code F16: Low Elev.open
1. This message is given if the elevation switch P2-10 opened during lift at a too low height (below 5%).
-- If it opens below 5%, the pressure is probably too unpredictable to allow reliable detection
of an overloaded platform when initially raised. Check CALIBRATIONS / HEIGHT CALS; the
“ElevUp” value shows the recorded height where the switch opened.
4.3-16 Flash Code F17: High Elev.open
1. This message is given if the elevation switch P2-10 opened during lift at a too high height
(above 25%).
-- If it opens above 25%, the platform is too high when the overloaded platform is detected!
Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where
the switch opened.
4.3-17 Flash Code F18: Low Elev.close
1. This message is given if the elevation switch P2-10 closed during lower at a too low height (below
5%).
-- If it closes below 5%, height sensor fault detection is compromised. Check CALIBRATIONS /
HEIGHT CALS; the “ElevDown” value shows the recorded height where the switch opened.
SKYJACK, Page 38
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Load Sensing System - CE (Continued)
4.3-18 Flash Code F19: High Elev.close
1. This message is given if the elevation switch P2-10 closed during lower at a too high height (above
25%).
-- When the switch is closed, overload detection is normally disabled but if the switch closes
above 25%, the platform is too high to allow disabled overload. Check CALIBRATIONS / HEIGHT
CALS; the “ElevUp” value shows the recorded height where the switch opened.
4.3-19 Flash Code F20: Height<>0%
1. This message occurs if the platform height is not 0% after the platform has been fully lowered during
either STATIC lift
-- The platform must return to the same height each time it is fully lowered. Check DIAGNOSTICS
/ SYSTEM to check the height.
4.3-20 Flash Code F21: Height<>0%
1. This message occurs if the platform height is not 0% before the platform is raised during either STATIC
lift.
-- The platform must be at 0% height when it is fully lowered. Check DIAGNOSTICS / SYSTEM
to check the height.
4.3-21 Flash Code F22: Height<>100%
1. This message occurs if the platform height is not 100% after the platform has been fully raised during
either STATIC lift.
-- The platform must return to the same height each time it is fully raised. Check DIAGNOSTICS
/ SYSTEM to check the height.
4.3-22 Flash Code F23: Height<>100%
1. This message occurs if the platform height is not 100% before the platform is lowered during either
STATIC lift.
-- The platform must be at 100% height when it is fully raised. Check DIAGNOSTICS / SYSTEM
to check the height.
4.3-23 Flash Code F24: Too Many
1. This message occurs if too many static measurements are taken during either STATIC lift or lower.
-- It is likely that there is a problem with the lift cylinder pressure; the GP102 should only need
about 10 measurements for most vehicles. The SETUPS / HEIGHT SETUPS / MIN LIFT time
could be increased to force a longer time between static measurements, but this should not
be necessary.
4.3-24 Flash Code F25: Check Elev
1. This message indicates a problem with the elevation switch P2-10 during the STATIC phases.
-- The switch is either staying closed to a higher height, or staying open to a lower height, than
that recorded during the DYNAMIC phase.
4.3-25 Flash Code F26: Check Elev
1. This message indicates a problem with the elevation switch P2-10 during the STATIC phases.
-- The switch is opening or closing at a different height than that recorded during the DYNAMIC
phase.
Full Size RT’s
Engine Powered
SKYJACK, Page 39
Service and Maintenance
Section 4 - Troubleshooting Information
Load Sensing System - CE (Continued)
4.3-26 Flash Code F27: Bad Height
1. This message indicates a problem with the height sensor output P4-3 during the STATIC phases.
-- The height sensor output must be between 1.0V and 4.0V at all times. Check DIAGNOSTICS /
SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem.
4.3-27 Flash Code F30: Bad Heights
1. This message indicates that the recorded heights are not increasing during either STATIC lift, or are
not decreasing during either STATIC lower.
-- It may be possible to cause this problem by repeatedly opening and closing the UP or DOWN
switch during the STATIC phases.
4.3-28 Flash Code F31: Reject Curve
1. The DYNAMIC pressure curve is unacceptable.
-- An initial pressure peak when the platform lifted cannot be found between 0% and 15% height.
Check the pressure sensor and lift cylinder hydraulics.
4.3-29 Flash Code F32: Reject Curve
1. The DYNAMIC pressure curve is unacceptable.
-- There should be a lowest pressure about halfway through the lift (ie: near 50% height); the
lowest pressure measured is at too low a height. Check the pressure sensor and lift cylinder
hydraulics.
4.3-30 Flash Code F33: Reject Curve
1. The DYNAMIC pressure curve is unacceptable.
-- There should be a lowest pressure about halfway through the lift (ie: near 50% height); the
lowest pressure measured is at too high a height. Check the pressure sensor and lift cylinder
hydraulics.
4.3-31 Flash Code F34: Reject Curve
1. The DYNAMIC pressure curve is unacceptable.
-- There is not enough difference between the initial pressure peak and the minimum pressure.
Check the pressure sensor and lift cylinder hydraulics.
4.3-32 Flash Code F40: Reject Delta
1. This message indicates that there is not enough difference between the loaded & empty pressure.
This message could also occur if the wrong pressure sensor was fitted (eg: a 5000psi sensor when a
2000psi one is needed).
This message could occur if the platform were not properly loaded during the STATIC LOADED phase,
or if the platform were not properly empty during the STATIC EMPTY phase.
-- Check CALIBRATIONS / HEIGHT CALS; the “Height” indicates the first height at which there
was insufficient difference and the “Up” and “Down” values show the loaded pressure (first)
and the difference between loaded and empty pressure (second).
SKYJACK, Page 40
Full Size RT’s
Engine Powered
Section 4 - Troubleshooting Information
Service and Maintenance
Load Sensing System - CE (Continued)
4.3-33 Flash Code F42: Low Pressure
1. This message indicates that the pressure is too low (0.5V or less) when the elevation switch opens
during the DYNAMIC lift.
This message would occur if the pressure sensor was disconnected, or if there were some other wiring
error.
-- Check DIAGNOSTICS / SENSORS to check the pressure.
4.3-34 Flash Code F43: High Pressure
1. This message indicates that the pressure is too high (4.5V or more) when the elevation switch opens
during the DYNAMIC lift.
This message would occur if the pressure sensor was disconnected, or if there were some other wiring
error.
-- Check DIAGNOSTICS / SENSORS to check the pressure.
4.3-35 Flash Code F44: Low Pressure
1. This message indicates that the pressure is too low (0.5V or less) at a STATIC measurement point.
This message would occur if the pressure sensor was disconnected, or if there were some other wiring
error.
-- Check DIAGNOSTICS / SENSORS to check the pressure.
4.3-36 Flash Code F45: High Pressure
1. This message indicates that the pressure is too high (4.5V or more) at a STATIC measurement point.
This message would occur if the wrong pressure sensor was fitted, or if there were some other wiring
error.
-- Check DIAGNOSTICS / SENSORS to check the pressure.
4.3-37 Flash Code F46: Check Elev
1. This message indicates that the elevation switch opened more than once during the DYNAMIC lift.
4.3-38 Flash Code F47: Check Elev
1. This message indicates that the elevation switch closed more than once during the DYNAMIC lower.
Full Size RT’s
Engine Powered
SKYJACK, Page 41
Section 5
Procedures
Table of Contents
Service and Maintenance
General..........................................................................................................................................................................3
Safety and Workmanship..............................................................................................................................................3
Base
5.1-1 Hydraulic System and BrakeAdjustment Procedure (If Equipped) . ................................................................3
5.1-2 Brake Assembly and Disassembly(If Equipped)...............................................................................................4
5.1-3 Holding Torque Testing Procedure....................................................................................................................6
5.1-4 Winching and Towing Procedures and Brake System......................................................................................6
5.1-5 System Lift and Pressure Adjustment................................................................................................................7
5.1-7 Wheel Bolt/Nut Inspection and Torquing Procedure.........................................................................................9
5.1-8 Wheel Reinstallation and Torquing Procedure..................................................................................................9
5.1-9 Front Axle Hub Procedure................................................................................................................................10
5.1-10Electronic Tilt Switch Setup Procedure............................................................................................................12
Tilt Switch Replacement...................................................................................................................................12
Reprogramming Existing Tilt Switch................................................................................................................14
Test and Verify Tilt Circuit.................................................................................................................................15
Engines
5.2-1
5.2-2
5.2-3
5.2-4
5.2-5
5.2-6
5.2-7
ECU Pin Reference Chart (GM).......................................................................................................................16
Throttle Actuator (GM)......................................................................................................................................17
GM Map and IAT Sensor (GM).........................................................................................................................18
Engine Coolant Temperature Sensor (GM).....................................................................................................19
LPG Temperature Sensor (GM)........................................................................................................................20
Fuse Block Layout (GM)...................................................................................................................................21
Kubota Dual Fuel (DF972) Resistance Checks................................................................................................22
Outriggers Option
5.3-1
5.3-2
5.3-3
5.3-4
5.3-5
5.3-6
5.3-7
Auto-Leveling Outrigger PC Board Layout......................................................................................................23
Outrigger Mechanical Limit Switch Wiring Diagram........................................................................................24
Auto-Leveling Outrigger Setting and Error Codes...........................................................................................25
Auto-Leveling Outrigger Error Code Breakdown.............................................................................................26
Hand Held Calibration/Diagnostic Tool Key Functions....................................................................................27
Outrigger Control Module Instructions............................................................................................................28
Auto-Leveling Outrigger Control Module Pin Reference Chart.......................................................................31
Load Sensing System - CE
5.4-1
5.4-2
5.4-3
5.4-6
5.4-7
5.4-8
Control Module Pin Reference Chart...............................................................................................................32
LED Error Codes - Quick Reference Chart......................................................................................................33
LED Error Codes - Code Breakdown Chart.....................................................................................................34
Control Module Load Calibration - Code Messages & Definitions..................................................................36
Control Module Load Calibration Procedure...................................................................................................40
Curve/Group Codes Chart...............................................................................................................................44
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 1
5
Section 5 - Procedures
Service and Maintenance
General
The following information is provided to assist you in
the use and application of servicing and maintenance
procedures contained in this chapter.
HOLD ACTUATOR ARM
TO FULL COUNTER-CLOCKWISE
1/2”
Safety and Workmanship
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment.
Always be conscious of weight. Never attempt to move
heavy parts without the aid of a mechanical device. Do
not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that
adequate support is provided.
BRAKE ADJUSTER
Base
5.1-1 Hydraulic System and Brake
Adjustment Procedure (If Equipped)
1. Ensure aerial platform is on a firm level surface
and block wheels to prevent rolling in either
direction.
2.
3.
Turn emergency main power disconnect switch
to OFF position.
Locate brake manifold in hydraulic/electric side
cabinet.
4.
Depress and turn red knurled knob on brake valve
counter-clockwise to a fully closed position or
depress black knob (current manifold).
5.
Grasp red plunger and rapidly depress until
plunger can no longer be depressed and brake
is fully released.
6.
7.
Inspect caliper and brake pads for binding. Pads
should move freely on the pins.
Remove pin from brake cylinder clevis and brake
actuating lever. Rotate actuating lever counterclockwise to the end of its stroke.
Diagram 5.1 Brake Adjustment
9.
Reinstall clevis pin back into the clevis actuating
lever.
10. Remove plastic plug located on the end of the
caliper shaft. See Diagram 5.2.
HOLD ACTUATOR ARM
TO FULL COUNTER-CLOCKWISE
1/2”
BRAKE ADJUSTER
Diagram 5.2 Plug Removal and Replacement
11. Using a 1/4” Allen wrench, turn brake adjuster
counter-clockwise until it bottoms out. Turn
Allen wrench clockwise 1/2 turn clockwise to set
adjustment.
12. Replace plastic plug back into the end of the
caliper shaft.
13. Depress red knurled knob on brake valve and
turn clockwise to a fully open position.
14. Remove Wheel blocks. Turn emergency main
power disconnect switch to ON position. Operate
drive several times to seat pads to brake disc.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 3
Service and Maintenance
Section 5 - Procedures
5.1-2 Brake Assembly and Disassembly
(If Equipped)
NOTE
This literature services various models in
this brake series. The components shown
in Diagram 5.3 may appear different than
what is found in your brake.
Assembly (Refer to Diagram 5.3)
1. Use an alkaline wash to clean parts before
assembly.
2.
Press new oil seal into cover until it is flush with
bearing shoulder. Note direction of seal.
3.
Install shaft, dowel pins, spring retainer and
new spring in cover. Be sure to install springs
according to pattern and color recorded during
disassembly.
4.
Position new return plate on springs.
Pressure plate is under spring tension
of approximately 1633 kgf (3600 lb). The
two cap screws must be loosened evenly
to relieve this force. If a hydraulic press
is available, 2041 kgf (4500 lb) minimum,
the pressure plate can be held in position
while removing the cap screws.
NOTE
Be careful to avoid contaminating friction
surfaces with oil.
5.
Install new rotor discs and new stator discs
in the same sequence as recorded during
disassembly.
2.
Remove case seal from cover.
6.
3.
Remove piston from pressure plate.
Install new back-up rings and new o-rings on
piston. Note order of o-rings and back-up rings.
Insert piston into pressure plate.
4.
Remove o-rings and back-up rings from piston.
7.
Install new case seal on cover.
5.
Before removing stator discs and rotor discs,
record the stacking arrangement for reassembly
purposes. Remove stator discs, rotor discs, return
plate and shaft from cover.
8.
Position pressure plate on cover aligning dowel
pins with holes in pressure plate.
9.
Install cap screws and tighten evenly to draw
pressure plate to cover. Torque cap scerws 74.6
N-m (55 lb-ft).
Disassembly (Refer to Diagram 5.3)
1. Remove pressure plate from cover by
removing cap screws.
CAUTION
6.
7.
Before removing springs, record the pattern and
color for reassembly purposes. Remove dowel
pins, springs and spring retainer from cover.
Press oil seal from cover.
Spring Chart
CAUTION
Model
Yellow
Spring (14)
Red
Spring (14)
Blue
Spring (14)
21-100-114
16
0
0
SKYJACK, Page 4
NOTE
A hydraulic press will simplify installation of
pressure plate on cover. Clamp pressure
plate in position while tightening cap
screws.
If hydrostatic testing is performed
on brake assembly, release pressure
must not exceed 69 bar (1000 psi)
unless six additional bolts are used for
supplemental clamping.
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
Diagram 5.3 Multiple Disc Brake Assembly
Oil Seal
Cover
Dowel Pins
Spring Retainer
Springs
Return Plate
Rotor Discs
Stator Discs
Shaft
Back-Up Rings
O-Rings
Piston
Back-Up Rings
O-Rings
Case Seal
Pressure Plate
Cap Screws
M11512AA
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 5
Service and Maintenance
Section 5 - Procedures
5.1-3 Holding Torque Testing Procedure
1. Ensure aerial platform is on a firm level surface.
2.
Locate brake feed valve (2H30A-2) on main
manifold and disconnect electrical connectors
from valve. This will prevent the hydraulic system
from releasing the brake.
3.
With engine running (aerial platform in drive mode,
engine on high idle, high torque selected and low
speed range selected), hold enable switch on
controller and push controller forward as if you
were to drive forward. This provides torque from
the drive motor to unreleased brake.
4.
If brake slips and aerial platform starts to move
in this condition, either brake plates are worn
or springs have broken. Both brake plates and
springs must be replaced to return brake to its
original holding torque.
WARNING
Do not manually disengage parking
brakes if work platform is on a slope.
4
Diagram 5.5 Brake Release Hand Pump and Brake
Valve Plunger
1.
Ensure aerial platform is on a firm level surface.
2.
Locate brake feed valve (2H30A-2) on main
manifold and disconnect electrical connectors
from valve. This will prevent the hydraulic system
from releasing the brake.
3.
With engine running (aerial platform in drive
mode, engine on high idle, high torque selected
and low speed range selected), hold enable
switch on controller and push controller forward
as if you were to drive forward. This provides
torque from drive motor to unreleased brake.
4.
If brake slips and aerial platform starts to move
in this condition, either brake plates are worn
or springs have broken. Both brake plates and
springs must be replaced to return brake to its
original holding torque.
5.1-4 Winching and Towing Procedures and
Brake System
WARNING
When towing, do not drive onto a
downward slope or brake the towing
vehicle rapidly.
Disc Brake System
2
3
5
1
Diagram 5.4 Disc Brake System
Disc Brake -This device disengages the brake disc
(1) when driving forward or in reverse. A hydraulic
brake cylinder (2), linked to a disc caliper (3), engages
and disengages a brake disc on the rear axle drive
shaft yoke. The brake must be manually disengaged
for pushing, towing or winching. Do not push or
tow the work platform onto a downward slope or pull
the platform down an incline towards the winch. The
special procedure for manually disengaging the parking
brake is as follows:
SKYJACK, Page 6
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.1-5 System Lift and Pressure Adjustment
All adjustments must be made with a calibrated
hydraulic gauge. Refer to the serial number nameplate
located on the rear of the aerial platform for system and
lift pressure values.
Lift Pressure Adjustment
System Relief Pressure Adjustment
1. Locate right steer hydraulic line on main manifold.
(Refer to Hydraulic Manifold Component and Port
Identification found in Section 3 for location.)
1.
Locate lift line on main manifold. (Refer to Hydraulic
Manifold Component and Port Identification found
in Section 3 for location.)
2.
Open manual lowering valve with platform fully
lowered. Remove lift line from main manifold.
3.
Install a 3000 psi gauge into lift line port fitting
on main manifold. Plug lift line going to lift
cylinders.
4.
Loosen locknut on lift relief valve (R2). (Refer
to Hydraulic Manifold Component and Port
Identification found in Section 3 for location.)
5.
Close the manual lowering valve.
6.
Using base controls in hydraulic/electric cabinet,
depress and hold up pushbutton switch.
7.
Observe reading on pressure gauge. Adjust lift
relief valve (R2) to pressure listed on the serial
number nameplate.
2.
Tee in a calibrated 3000 psi gauge into the right
steer line.
3.
Remove operator’s control console from guardrail
and disconnect it from scissors control cable.
4.
Locate electrical panel cable plug in
hydraulic/electric cabinet.
5.
Disconnect scissors control cable and connect
operator’s control console cable.
6.
At main manifold, loosen locknut on system
relief valve (R1). (Refer to Hydraulic Manifold
Component and Port Identification found in
Section 3 for location.)
7.
WARNING
Fully lower the platform.
On platform control console, select “drive”
position with lift/drive switch.
8.
Engage right steer switch on top of controller
handle and hold.
9.
Observe reading on pressure gauge. Adjust
system relief valve (R1) to pressure listed on the
serial number nameplate.
NOTE
Turning the stem on relief valve clockwise
will increases pressure. Turning the
stem counter-clockwise will decreases
pressure.
10. Release steer switch and retighten locknut on
system relief valve (R1).
NOTE
Turning the stem on relief valve clockwise
will increases pressure.
Turning the
stem counter-clockwise will decreases
pressure.
8.
Release up pushbutton and retighten locknut on
lift relief valve (R2).
9.
Remove gauge from lift line port fitting and
reconnect lift line to main manifold.
WARNING
Ensure aerial platform does not lift more
than rated load.
11. Remove gauge from steer line.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 7
Service and Maintenance
5.1-6 Change Hydraulic Oil
Note
Samples of hydraulic oil should be drawn
from the reservoir and tested annually.
These samples should be taken when the
oil is warmed through normal operation of
the system. The sample should be analyzed
by a qualified lubrication specialist to
determine if it is suitable for continued use.
Oil change intervals will depend on the
care used in keeping the oil clean, and the
operating conditions. Dirt and/or moisture
cotamination will dictate that the oil should
be changed more often. Under normal use
and operating conditions, the hydraulic oil
should be changed every two years. Refer
to Table 1.2 of this manual.
1. Ensure aerial platform is on a firm level
surface, fully lowered, and outriggers
(if equipped) fully retracted.
Section 5 - Procedures
4. Place suitable container under the hydraulic
tank.
5. Remove oil drain plug and allow all hydraulic
oil to drain into container.
6. Install oil drain plug with new seal ring and
tighten firmly.
7. Refill hydraulic tank with new oil as per
specifications. (Refer to section 2 of this
manual)
8. Check for leakage.
9. Clean up any oil that may have spilled
during this procedure.
10. Check hydraulic oil level. (The hydraulic oil
level should be at or slightly above the top
mark on the sight gauge)
Note
Refer to your national/local regulations
on how to dispose of used filter and oil.v
2. Allow hydraulic oil to warm up.
3. Turn main power disconnect switch to off
position.
SKYJACK, Page 8
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.1-7 Wheel Bolt/Nut Inspection and Torquing
Procedure
It is necessary to check the torque on all wheel
nuts and wheel bolts at pre-delivery, after 8 hours of
operation and at weekly intervals using the following
procedure:
1.
Confirm that each wheel fastener is torqued to
140 ± 5 ft-lb. All fasteners must be torqued using
the tightening sequence shown below.
1
3
1.
Inspect wheel fastener threads for damage of
defects. Replace if defective.
2.
Clean the mounting surfaces of the hub and wheel
rim of debris, rust, excess paint, etc.
3.
Mount wheel on the hub, centering mounting
holes on the wheel studs or bolt holes. Use
appropriate lifting device as required.
4.
Install wheel nuts or wheel bolts and hand tighten
to center the rim.
5.
Torque nuts or bolts to approximately 50 ft-lb using
the tightening sequence in procedure 5.1-7.
6.
Torque again to 100 ft-Ib using the same
sequence.
7.
Torque again to 140 ft-lb using the same
sequence.
8.
Repeat the tightening sequence to confirm that
none have changed from 140 ft-lb. If any are
found below 140 ft-lb, repeat complete sequence
until there is no change in torque values. If
possible, drive the machine prior to checking
torques.
9.
Check torque values after 8 hours of operation
and then at weekly intervals.
4
5
2
Diagram 5.4 Wheel Fastener Tightening Sequence
2.
5.1-8 Wheel Reinstallation and Torquing
Procedure
When a wheel/tire assembly has been removed or
replaced, it will be necessary to follow the procedure
below to ensure proper installation:
Again, confirm that each wheel fastener is torqued
to the specified tolerance. Re-torque as necessary
until all fasteners are properly torqued.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 9
Service and Maintenance
Section 5 - Procedures
5.1-9 Front Axle Hub Procedure
For front axle hub components, refer to your aerial
platform’s parts manual.
7
11
5
10
4
9
8
6
3
2
1
NOTE
Keep work area clean and visibly free from
contamination at all times.
1.
Ensure aerial platform is parked on a firm,
level surface. Chock or block the wheels to
keep the aerial platform from rolling forward or
backward.
2.
Fully lower the platform.
3.
Using a suitable lifting device or outriggers
(if equipped), lift the end of the aerial platform
with the steer axle.
CAUTION
Use a suitably-rated support stand to
support aerial platform while performing
the following operations.
4.
Turn emergency main power disconnect switch
to “ ” off position.
5.
Remove wheel assembly.
6.
Remove dust cap (item 1) to access internal
components of hub assembly.
Pull cotter pin (item 2) out of spindle arm (item 11)
and then remove castle nut (item 3), washer (item
4) and outer bearing cone (item 5). Dispose of
dust cap, cotter pin, castle nut, washer, and outer
bearing cone.
7.
SKYJACK, Page 10
8.
Flip hub over and then remove and discard inner
bearing cone (item 8) and grease seal (item
10).
9.
Remove and discard both inner and outer bearing
cups (items 6 & 8) from hub.
10. Remove grease from spindle arm and hub and
look for signs of visible damage. If damage is
found on the hub or on the spindle arm, contact
Service Department immediately using information
found in page 2 for further instructions.
11. Press new bearing cups (items 6 & 8) into hub.
12. Pack replacement inner and outer bearings by
either pressing wheel bearing grease into each
roller by hand or using a bearing packer and
grease gun. Ensure that grease is forced into all
surfaces of the bearing.
NOTE
Use only recommended wheel bearing
grease - NLGI (National Lubricating Grease
Institute) Grade #2 or equivalent.
NOTE
The bearings must be packed before
installing.
13. Install replacement inner bearing in the race and
then seat the new grease seal. Flip hub over and
install replacement outer bearing.
14. Install hub on the spindle.
15. Install replacement washer and replacement
castle flanged nut. Hand tighten the castle flanged
nut until it touches the washer. Turn hub by hand
to ensure smooth running. No resistance should
be felt at this time.
16. Take a torque wrench and set it at 30 ft-lb, and
while continuously rotating hub, tighten castle
flanged nut. While hub is being turned and nut
tightened, resistance will increase.
17. Using an open-ended wrench, loosen castle
flanged nut a 1/4 turn while turning the wheel hub.
It should turn easily. The nut should not come
completely loose.
18. Using a torque wrench set to 15 ft-lb, tighten
castle flanged nut. Turn wheel hub and check for
smooth turning.
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
19. Check for alignment of the castle flanged nut with
one of the cross holes in spindle arm. If required,
loosen nut to align with nearest hole. Use an
open-ended wrench to be able to see the cross
holes. The nut should not be turned more than
15 degrees. Secure with new cotter pin. Check
again for smooth turning of wheel hub. The wheel
hub should turn but with slight resistance.
20. Grab the top and bottom of the hub and check
for play. There should be no evidence of play.
21. Install dust cap back on hub assembly.
22. Install wheel assembly. Torque nuts or bolts to
140 ft-lb.
23. Repeat steps 5 to 22 for the other hub
assembly.
24. Lower the aerial platform.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 11
Service and Maintenance
5.1-10 Electronic Tilt Switch Setup Procedure
The following information is supplied for replacement
or reprogramming of the electronic tilt switch. Also
included are test and verification instructions. Follow
the appropriate procedures below.
Tilt Switch Replacement
Section 5 - Procedures
controls are powered up.
8.
Turn main disconnect switch to “ ” ON position.
9.
Select off/lift/drive key switch to “
or “
” lift position
” drive position.
10. Pull out “
” all emergency stop buttons.
11. Verify switch is powered. (Red or green LED will
be continually blinking)
Y AXIS
X AXIS
Red LED
Red LED
Green LED
Green LED
12. Program the Tilt Switch
a. Press and release the set up button 3
times.
b.
c.
1.
Ensure aerial platform is parked on a firm level
surface.
2.
Fully lower the platform.
3.
Chock or block wheels to keep the aerial platform
from rolling forward or backward.
4.
” emergency stop buttons and turn
Push in “
main disconnect switch to “ ” off position.
5.
Disconnect tilt switch from 4 pin connector.
d.
Observe program delay
/ stabilization time.
(Only the red LED will
blink for 4 seconds)
Both LEDs will
flash for 1 second.
Results: The switch is
learning the new zero
position.
Both LEDs will turn
on solid for 1 second.
Results: The new zero
position has been
learned.
Red LED
Green LED
Red LED
Green LED
Red LED
Green LED
Note
Ensure part number of old and new tilt
switch are the same.
6.
Remove old tilt switch from mount.
7.
Install new switch to mount (in the same orientation
as the old switch) and connect switch plug to 4
pin connector.
NOTE
The tilt circuit is only powered when
SKYJACK, Page 12
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
e.
Service and Maintenance
The green LED will flash and then the
red LED will turn on solid for 2 seconds.
13. Turn main disconnect switch to “
14. Push in “
Red LED
Red LED
Green LED
Green LED
” off position
” emergency stop buttons.
15. Remove chock or wheel blocks.
16. Proceed to Test and Verify Tilt Circuit.
Results: The switch is verifying the new
zero position.
f.
The green LED
will turn on solid.
Results: The switch
is ready for normal
operation.
Mid Size & Full Size
Rough Terrain Series
Red LED
Green LED
SKYJACK, Page 13
Service and Maintenance
Section 5 - Procedures
Reprogramming Existing Tilt Switch
Light Indicators
8.
Set up button is located on this
face next to harness
b.
R
Gre ed LE
en
D
LE
D
1.
Reprogram the Tilt Switch
a. Press and hold the set
up button for 3 seconds.
Results: Both LEDs will
be OFF.
Red LED
Green LED
Both LEDs will flash.
Red LED
Green LED
IMPORTANT
Step “c” must be completed within
a 5 second period or the switch will
automatically exit program mode and
return to normal operation using previously
stored data.
Ensure aerial platform is parked on a firm level
surface.
c.
Press and release set up button 3 times.
2.
Fully lower the platform.
d.
3.
Chock or block wheels to keep the aerial platform
from rolling forward or backward.
If 5 second period has expired prior
completion, repeat Step “a”, “b” and “c”.
e.
Observe program delay
/ stabilization time.
(Only the red LED will
blink for 4 seconds)
NOTE
The tilt circuit is only powered when
controls are powered up.
4.
Turn main disconnect switch to “ ” ON position.
5.
Select off/lift/drive key switch to “
or “
f.
” lift position
” drive position.
g.
” all emergency stop buttons.
6.
Pull out “
7.
Verify switch is powered. (Red or green LED will
be continually blinking)
h.
Red LED
Red LED
Green LED
Green LED
Both LEDs will
flash for 1 second.
Results: The switch is
learning the new zero
position.
Both LEDs will turn
on solid for 1 second.
Results: The new
zero position has been
learned.
Red LED
Green LED
Red LED
Green LED
Red LED
Green LED
The green LED will flash and then the
red LED will turn on solid for 2 seconds.
Red LED
Red LED
Green LED
Green LED
Results: The switch is verifying the new
zero position.
SKYJACK, Page 14
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
i.
9.
The green LED
will turn on solid.
Results: The switch
is ready for normal
operation.
Service and Maintenance
Test and Verify Tilt Circuit
Red LED
Turn main disconnect switch to “
position.
10. Push in “
Light Indicators
Green LED
Set up button is located on this
face next to harness
” off
R
Gre ed LE
en
D
LE
D
” emergency stop buttons.
11. Remove chock or wheel blocks.
12. Proceed to Test and Verify Tilt Circuit.
Operations of Tilt Switch
The following describes the LED’s and what they
indicate.
Green LED
Illuminated whenever both tilt
axes are within the specified
degrees of the zero/ home
learned position.
Flashes when transitioning in
or out of tilt angle limits, but
built in time delay has not fully
occurred.
Red LED
Illuminated whenever tilt on one
or more axes is more than the
specified degrees out from the
zero/ home position.
Green & Red LED
On together, no blinking when
fault detected.
Tilt Circuit Test
1.
Mid Size & Full Size
Rough Terrain Series
Refer to section 2 for test tilt sensor procedure.
SKYJACK, Page 15
Service and Maintenance
Section 5 - Procedures
Engines
5.2-1 ECU Pin Reference Chart (GM)
61
75
31
76
45
1
90
46
60
15
16
LOCK TAB
30
Diagnostics
Diagnostics
Pin #
Wire Color
Description
Pin #
Wire Color
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
DK GRN/ORN
DK GRN/WHT
EMPTY
EMPTY
PPL/LT BLUE
LT BLU/DK BLU
LT GRN
TAN/DK GRN
DK BLU/ORN
PPL/YEL
EMPTY
EMPTY
WHT/ORN
BLU/PNK
BLU/WHT
EMPTY
EMPTY
EMPTY
LT GRN/RED
BLK/LT GREEN
PPL/WHT
WHT/PPL
EMPTY
EMPTY
RED/WHT
RED/BLK
EMPTY
EMPTY
EMPTY
EMPTY
YEL
EMPTY
YEL/RED
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
YEL/GRY
TAN/WHT
WHT/RED
TAN/BRN
TAN/RED
TAN/BLK
PNK/TAN
EGO1 Signal
EGO2 Signal
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
DK BLU/YEL
YEL/DK BLU
LT GRN/WHT
LT GRN/PPL
LT GRN/BLK
GRY/DK BLU
GRY/ORN
LT BLU
WHT/LT GRN
DK GRN
ORN
EMPTY
GRY
EMPTY
RED/TAN
BRN/LT BLU
BRN/LT GRN
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
BLK
EMPTY
WHT/LT BLU
BLK/WHT
BLK/YEL
EMPTY
WHT/BLK
EMPTY
BRN/WHT
WHT/BRN
RED/TAN
GRN/YEL
BLK
PNK/WHT
TAN/ORN
TAN/BLK
PNK/YEL
BLK/RED
TAN
DK BLU
PNK/BLK
EMPTY
Not used
Not used
Output to gasoline temp sensor
Not used
Not used
Mid throttle input
High throttle input
Input from oil pressure switch
Signal from gasoline pressure sensor
To diagnostic connector (PC)
To diagnostic connector (PC)
Throttle position 1 signal
Throttle position 2 signal
MAP Signal
Not Used
Not Used
Not Used
Connected to pin #14 below
CAN + to propane regulator
CAN – from propane regulator
5 volt + from ECU to sensors
5 volt – to ECU from sensors
+V from crank position sensor
-V from crank position sensor
Not used
Not used
Output to spark coil 1
Output to spark coil 2
Output to IAT (part of MAP)
Output to ECT
Output to EGT
Propane selected
Not used
Not used
12 volt input
Not used
Battery positive
To injector #1 and #4
To injector #2 and #3
Ground from engine block
Negative supply to power relay 2002CR
EGO 1 Heater ground
EGO 2 Heater ground
Negative supply to propane lock off
Negative supply to relay 10BCR2
Not used
Battery positive
To check engine light (MIL)
Ground from engine block
Positive to throttle actuator motor
Negative from throttle actuator motor
Negative supply to fuel pump relay 56CR
Fuel pump excite wire
Negative supply to fuel pump
Not used
Not used
Negative supply to starter relay 32ACR
60594AA
SKYJACK, Page 16
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.2-2 Throttle Actuator (GM)
DBW+
4
PNK/WHT
MOTOR
DBW-
TPS1
SIGNAL
SENSOR GROUND
TPS1
SIGNAL
1
6
2
TAN/ORG
PPL/LT BLU
BLK/LT GRN
5
LT BLU/DK BLU
3
LT GRN/RED
5 VOLTS
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 17
Service and Maintenance
Section 5 - Procedures
5.2-3 GM Map and IAT Sensor (GM)
1
2
3
4
BLK/LT GRN
SENSOR GROUND
YEL/GRY 5 VOLTS
INTAKE AIR TEMPERATURE SIGNAL (IAT)
LT GRN/RED
5 VOLTS
LT GRN
MANIFOLD ABSOLUTE PRESSURE SIGNAL
(MAP)
IAT Sensor Resistance
TEMPERATURE
°F
TOLERANCE ±10%
OHMS
248
110
239
125
221
162
203
214
185
284
167
383
149
522
131
721
104
1,200
77
2,063
50
3,791
23
7,419
-4
15,614
-22
26,854
-31
35,763
-40
48,153
60597AA
SKYJACK, Page 18
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.2-4 Engine Coolant Temperature Sensor (GM)
A
B
TAN/WHITE
5 VOLTS
BLK/LT GREEN
SENSOR GROUND
TEMPERATURE
SENSOR
RESISTANCE
Temperature Sensor
Resistance
TEMPERATURE
F
TOLERANCE ±10%
OHMS
242.4
231.9
211.6
201.4
181.9
163.1
144.9
127.4
102.4
78.9
49.9
23.5
-5.7
-21.7
-30.8
-40
101
121
175
209
302
434
625
901
1,556
2,689
5,576
11,562
28,770
49,715
71,589
99,301
60595AA
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 19
Service and Maintenance
Section 5 - Procedures
5.2-5 LPG Temperature Sensor (GM)
A
B
WHITE/RED
5 VOLTS
BLK/LT GREEN
SENSOR GROUND
TEMPERATURE
SENSOR
RESISTANCE
Temperature Sensor
Resistance
TEMPERATURE
DEGREES F
TOLERANCE ±10%
OHMS
220
200
190
180
170
160
140
120
100
80
70
60
40
20
0
-20
-40
153.7
214.6
255.4
305.5
367.3
444.1
660.6
1008
1582
2554
3284
4259
7357
13214
24705
48300
99318
60596AA
SKYJACK, Page 20
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.2-6 Fuse Block Layout (GM)
EMPTY
EMPTY
F13 60A ALT
Mid Size & Full Size
Rough Terrain Series
32ACR
STARTER
RELAY
56CR
FUEL
PUMP
RELAY
2002CR
POWER
RELAY
F7
5 AMP
VSW
F8
20 AMP
ECU
F11
15 AMP
FUEL PUMP
F10
15 AMP
IGNITION
F9
10 AMP
EPR
F12
15 AMP
STARTER
SKYJACK, Page 21
Service and Maintenance
Section 5 - Procedures
5.2-7 Kubota Dual Fuel (DF972) Resistance Checks
Resistance of Pick-Up Sensor
1. Disconnect connector from sensor.
2. Measure the resistance with an ohmmeter.
3. If resistance is not within factory specifications,
replace it.
Resistance
Factory
Specification
A-B
1.85 to 2.45kΩ at 20°C
Resistance of Ignition Coil
1. Disconnect connector from ignition coil.
2. Measure the resistance with an ohmmeter.
3. If resistance is not within factory specifications,
replace it.
Resistance
Factory
Specification
B
A
B
C
A
A-B
1.87 to 2.53Ω at 20°C
A-C
10.4 to 15.6Ω at 20°C
A: Terminal (+) C: High Tension Cord
B: Terminal (-)
Resistance of Ignitor
1. Disconnect connector from ignitor.
2. Measure the resistance with an ohmmeter.
3. If resistance is not within the factory specifications,
replace it.
A
C
E
G
B
D
F
H
1
IMPORTANT
To replace the ignitor with a service part, make sure the ignitor has the same part cord No / ID mark as
the old one. (See the information label #1.)
Ignitor Check Chart
Negative
Positive
A
A
B
C
D
E
F
G
H
10 to 40 kΩ
10 to 40 kΩ
11 to 47 kΩ
infinity
infinity
infinity
infinity
0.33 to 1.3
kΩ
1.8 to 7.3 kΩ
infinity
infinity
infinity
infinity
1.5 to 6.0 kΩ
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
infinity
B
10 to 40 kΩ
C
10 to 40 kΩ
0.33 to 1.3
kΩ
D
11 to 47 kΩ
1.8 to 7.3 kΩ
1.5 to 6.0 kΩ
E
infinity
infinity
infinity
infinity
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
2 megohm
(minimum)
F
G
H
infinity
infinity
infinity
infinity
infinity
infinity
infinity
60434AA
SKYJACK, Page 22
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
Outrigger Option
D73
D78
17BCR
D72
61CR
J17E
ENABLE
D75
65CR
J17D
D76
9CR2
D74
REAR RIGHT
FRONT RIGHT
9CR3
35C
78
73
77
74
71
75
72
76
CN20
D77
REAR LEFT
FRONT LEFT
D17B-1
17B
02
78
73
77
74
71
75
72
76
CN21
D71
D17B-2
CN14
04
17
86A
10A
09
44
01
02
02
36A
61
36
5.3-1 Auto-Leveling Outrigger PC Board Layout
D36
61
62
62
63
63
64
64
01
10A
10A
10A
10A
65
CN22
M50318AA
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 23
Service and Maintenance
Section 5 - Procedures
5.3-2 Outrigger Mechanical Limit Switch Wiring Diagram
O.R. UP SWITCH (NO) - BLUE & BROWN
O.R. UP SWITCH (NO) - BLUE & BROWN
BACK VIEW - MALE
BACK VIEW - MALE
3
2
4
1
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
BACK VIEW - FEMALE
LEFT FRONT OUTRIGGER
3 PIN 1 - BLACK (10A)
PIN 2 - BLACK / WHITE (65A)
PIN 3 - BLUE (62)
4 PIN 4 - BROWN (61)
2
1
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
2
4
1
RIGHT FRONT OUTRIGGER
PIN 1 - BLACK (10A)
PIN 2 - WHITE (66A) BACK VIEW - FEMALE
PIN 3 - GREEN (63)
2
3
PIN 4 - RED (62)
1
4
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
RIGHT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
LEFT FRONT
SIXTEEN PIN CONNECTOR PLUG
OUTRIGGER PCB ON ELECTRICAL PANEL
PIN 1 - 61 RED
PIN 2 - 62 GREEN
PIN 3 - 62 RED
PIN 4 - 63 GREEN
PIN 5 - 63 RED
PIN 6 - 64 GREEN
PIN 7 - 64 RED
PIN 8 - 01 GREEN
3
PIN 9 - 10A BLACK (2)
PIN 10 - 10A BLACK (2)
PIN 11 - 10A BLACK (2)
PIN 12 - 10A BLACK (2)
PIN 13 - (N/U)
PIN 14 - (N/U)
PIN 15 - (N/U)
PIN 16 - 65 GREEN / BLACK
RIGHT FRONT
RIGHT REAR
LEFT REAR
TO CONTROL MODULE
PIN 1 - 65 GREEN / BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE
PIN 5 - 68A WHITE
PIN 6 - (N/U)
O.R. UP SWITCH (NO) - BLUE & BROWN
O.R. UP SWITCH (NO) - BLUE & BROWN
BACK VIEW - MALE
3
2
4
1
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
BACK VIEW - FEMALE
2
1
LEFT REAR OUTRIGGER
3 PIN 1 - BLACK (10A)
PIN 2 - WHITE (68A)
PIN 3 - GREEN (01)
4 PIN 4 - RED (64)
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
BACK VIEW - MALE
PIN 1 - BLACK
PIN 2 - BLACK / WHITE
PIN 3 - BLUE
PIN 4 - BROWN
3
2
4
1
RIGHT REAR OUTRIGGER
PIN 1 - BLACK (10A)
PIN 2 - WHITE (67A) BACK VIEW - FEMALE
PIN 3 - GREEN (64)
2
3
PIN 4 - RED (63)
1
4
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
RIGHT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE)
M11449AC
SKYJACK, Page 24
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.3-3 Auto-Leveling Outrigger Setting and Error Codes
Reading the Codes:
In order to read the fault codes, a sequence of pauses and flashes can be seen on the LED mounted on the outrigger
control module. The codes are continuously displayed by the LED until the fault is cleared, the outrigger control
module is reset and no longer detects the fault, or idle timeout becomes active.
The sequence is as follows:
1. Half second flashes followed by half second pauses indicate the first digit.
2. A 2.5 second pause.
3. Half second flashes followed by half second pauses indicate the second digit
4. A 5 second pause.
Repeat steps 1-4
Since the outrigger control module only reports one error, only one code can be read from the LED per instance.
If the error is cleared and another error is present, it will then be presented.
LED Error Codes
EVERYTHING OK
ON
VEHICLE TILTED
1/1
OUTRIGGERS CANNOT BE MOVED!
1/2
OUTRIGGERS NOT HOME
2/2
NOT FULLY LEVEL
2/1
RELEASE OUTRIGGER DEMAND!
5/5
CHECK OUTRIGGER SUPPLY (P4-9)
5/2
CANNOT LEVEL : BAD TILT SENSOR
7/1
OUTRIGGERS MANUALLY CONTROLLED!
6/6
TESTING HWFS
7/8
B+ SUPPLY TOO LOW
5/1
STARTUP!
7/7
FAULT: BAD SLAVE MICRO
7/5
FAULT: BAD TILT SENSOR
7/1
FAULT: BAD HWFS
7/2
FAULT: P2-5 FAULTY
8/1
FAULT: P2-6 FAULTY
8/2
FAULT: P2-8 STUCK ON
8/3
FAULT: P2-8 ALWAYS ON
8/4
FAULT: P2-8 ALWAYS OFF
8/5
FAULT: HWFS STALLED!
Mid Size & Full Size
Rough Terrain Series
7/6
60402AB
SKYJACK, Page 25
Service and Maintenance
Section 5 - Procedures
5.3-4 Auto-Leveling Outrigger Error Code Breakdown
RELEASE OUTRIGGER DEMAND!
5/5
Check inputs on P2 pins 5 & 6 - the “auto-level” or “auto-retract” input is active at power-on
or when it is not allowed to carry out the function.
OUTRIGGERS CANNOT BE MOVED!
1/2
Check input on P2 pin 10 – “auto-level” or “auto-retract” has been requested but the platform
is elevated.
NOT FULLY LEVEL
2/1
The outrigger legs are all down (touching the ground) but the platform is not fully level.
OUTRIGGERS NOT HOME
2/2
The outrigger legs are not all down (touching the ground) and also are not all home (fully
retracted).
B+ SUPPLY TOO LOW
CHECK OUTRIGGER SUPPLY (P4-9)
5/1
5/2
Check that the battery voltage is not too low.
VEHICLE TILTED
1/1
These is not a true fault – move the vehicle to level ground!
TESTING HWFS
7/8
STARTUP!
7/7
These are not true faults unless they do not clear – the start-up tests should only occur for a
short time.
OUTRIGGERS MANUALLY CONTROLLED!
6/6
This is not a true fault – the outriggers are being manually operated (one or more outrigger
legs on P4 pins 1-8 is high, when the outrigger control module is not active.
CANNOT LEVEL (BAD TILT SENSOR)
FAULT: BAD TILT SENSOR
FAULT: BAD HWFS
FAULT: BAD SLAVE MICRO
FAULT: HWFS STALLED!
FAULT: P2-5 FAULTY
FAULT: P2-6 FAULTY
FAULT: P2-8 STUCK ON
FAULT: P2-8 ALWAYS ON
FAULT: P2-8 ALWAYS OFF
7/1
7/1
7/2
7/5
7/6
8/1
8/2
8/3
8/4
8/5
These are internal faults. If the fault persists after the power has been reset, the outrigger control
module may need to be replaced.
SKYJACK, Page 26
60412AB
Mid Size & Full Size
Rough Terrain Series
AD
5.3-5
Hand Held Calibration/Diagnostic Tool Key Functions
WARNING
Only trained and authorized personnel shall be permitted to service an aerial platform.
WARNING
Read all instructions closely before attempting each phase of this procedure.
SYMBOL
KEY FUNCTIONS
ESC/ENTER BUTTONS
To move back and forth between menu and sub-menu
LEFT/RIGHT BUTTONS
Select menus and setting to be adjusted
UP/DOWN BUTTONS
Adjust setting values
Outrigger Settings
Model
O.R. Setting
Mid Size & Full Size
Rough Terrain Series
9241
9250
8
5
SKYJACK, Page 27
Service and Maintenance
Section 5 - Procedures
5.3-6 Outrigger Control Module Instructions
When EZcal hand-held device is connected to the OCM1 control module, a two line displays shows various menus
and settings. At any time the top line of the display describes the currently selected menu and the bottom line shows
the currently selected item in that menu.
Six buttons on EZcal allow easy navigation through the menus:
 and  change the selected item (the bottom line display)
ENTER enters the selected new menu when available (top line display changes)
 and  adjusts the selected item when available
ESC exits the current menu back to the previous menu
TOP LEVEL MENU OPTIONS
HELP
Select this menu to see a description of current OCM1 status
DIAGNOSTICS Select this menu to see switch input status & logged data
ACCESS LEVEL Select this menu & enter correct code to enable adjustments and calibrations
ADJUSTMENTS Select this menu to see and adjust OCM1 settings
NOTE: this menu provides for adjustments which might be needed for different work activities
SETUPS
Select this menu to carry out initial set-up of the OCM1
NOTE: this menu provides for set-ups which are needed to configure the OCM1 for a particular vehicle
HELP MENU OPTIONS
(help message)
A message displays current OCM1 status, indicating if everything is OK or if there is an error code (see LED Error Codes - Table 5.3)
DIAGNOSTIC MENU OPTIONS
SYSTEM
Select this menu to see general OCM1 system information
SWITCHES
Select this menu to see switch input status
OUTPUTS
Select this menu to see OCM1 output status
LOG
Select this menu to see logged information
DIAGNOSTIC / SYSTEM MENU OPTIONS
OUTRIGGERS
Displays various status during the auto-level function
TILT
Displays vehicle tilt in “X” and “Y” orientations measured by integral sensor
TILTED
Displays whether vehicle is tilted (YES or NO)
BATTERY
Displays battery supply voltage (on P2-12)
DIAGNOSTIC / SWITCHES MENU OPTIONS
LR/P2-1
High when the left rear outrigger is in contact with the ground
RR/P2-2
High when the right rear outrigger is in contact with the ground
RF/P2-3
High when the right front outrigger is in contact with the ground
LF/P2-4
High when the left front outrigger is in contact with the ground
EXTEND/P2-5
High to activate the auto-level function
RETRACT/P2-6 High to activate the auto-retract function
ELEV/P2-10
High when the scissor stack is stowed (“elevated” input indicates that the vehicle is stowed).
SKYJACK, Page 28
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
DIAGNOSTIC / OUTPUTS MENU OPTIONS
LAMP/P2-7
Displays state of outrigger control box light
STABLE/P2-8
Displays state of stable (all legs touching the ground) output
TILT/P2-9
Displays state of tilt
LRe/P4-1
Displays state of left rear outrigger extend valve
RRe/P4-2
Displays state of right rear outrigger extend valve
RFe/P4-3
Displays state of right front outrigger extend valve
LFe/P4-4
Displays state of left front outrigger extend valve
LRr/P4-5
Displays state of left rear outrigger retract valve
RRr/P4-6
Displays state of right rear outrigger retract valve
RFr/P4-7
Displays state of right front outrigger retract valve
LFr/P4-8
Displays state of left front outrigger retract valve
P4-9 MON
Displays the voltage to the outrigger valve (can only be seen when operating in auto-
level or retract)
DIAGNOSTIC / LOG MENU OPTIONS
MAX.BATTERY Displays maximum recorded battery supply voltage
OCM1 version Displays part number and software version of GP106
EZcal version
Displays software version of EZcal
ACCESS LEVEL MENU OPTIONS
CODE xxxx
“ACCESS LEVEL” 3 (allows viewing only)
“ACCESS LEVEL” 2 (allows setup on OCM1)
ADJUSTMENTS MENU OPTIONS (factory set - not adjustable)
Xtilt TRIP
Displays the tilt trip point in the “X” orientation
Ytilt TRIP
Displays the tilt trip point in the “Y” orientation
TILT ENTRY
Displays the tilt delay time
TILT EXIT
Displays the tilt delay time
Xlevel TRIP
Displays the tilt trip point in the “X” orientation during the auto-level function
Ylevel TRIP
Displays the tilt trip point in the “Y” orientation which applies during the auto-level function
MACHINE SETUP MENU OPTIONS (factory set - not adjustable)
DEFAULTS
Allows all adjustments & machine settings to be set to defaults
WARNING: all GP106 settings will be changed; use with caution!
CALIBRATE LEVEL Allows levelling of the integral tilt sensor of the GP106, when the vehicle is positioned on level ground (see Appendix Four)
TILT MODE
Allows configuration of the GP106 tilt output (P2-9):
1 – output turns on to light lamp when tilted
2 – output turns off to cutout functions when tilted
3 – output turns off to cutout functions when tilted AND elevated
TILT FILTER
Displays the filter applied to the tilt measurements during the auto-level function (used to minimize the effect of vehicle vibrations on the tilt measurement)
Xlevel TARGET
Displays the tilt in the “X” orientation at which the auto-level function will complete.
Ylevel TARGET
Displays the tilt in the “Y” orientation at which the auto-level function will complete.
tilt SLACK
Displays the amount of vehicle tilt exceeding the Xtilt TARGET and/or Ytilt TARGET in which the auto-level function will not attempt to level
EXAMPLE:
Xtilt TARGET=0.3°, Ytilt TARGET=0.7°, tilt SLACK=0.5°
If machine is tilted to 1.0° in the X and Y orientations, the auto-level function will attempt to level the X orientation (0.3+0.5<1.0) but will not attempt to level the Y orientation (0.7+0.5>1.0)
RANGE: 0.0° to 1.0°, default 0.3°
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 29
Service and Maintenance
Section 5 - Procedures
IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
Always follow the instructions of the Calibration instrument.
1.
Ensure aerial platform is parked on a firm and level surface.
2.
Elevate the scissors high enough to lay a level accross the base tubes. Ensure there is no debris on the base
and the level sits flat. Do not elevate aerial platform higher than the high speed/tilt override limit switch.
3.
Manually operate the outriggers and level the machine in 4 places: left side, right side, front and rear. All 4
outriggers must be firmly placed and all 4 tires are off the ground.
4.
Double check that the aerial platform is level at all 4 points.
5.
Connect the EZcal tool to the P1 connector on the CONTROL MODULE.
6.
The display will show “Help: Press Enter”.
By using Left/Right buttons, select the “Access Level (3 )” from the menu and press the ENTER button.
7.
The display will show “Access Level: Code (0000)”.
By using the Up/Down buttons, enter the Access Level Code (1 1  2  2) followed by pressing the ENTER
button.
8.
The display will show “Access Level 2”.
By using Left/Right buttons, select the “Setups” from the menu and press the ENTER button.
9.
The display will show “Setups: Change Defaults”.
Select the “Change Defaults” from the menu and press the ENTER button.
10. The display will show “Defaults, 0 = Custom”.
By using Up/Down buttons, select the “Defaults: Code Setting for your Model (For Default Code Refer to Table
5-3)” from the menu and press the ENTER button and followed by ESCAPE button.
11. The display will show “Setups Change Defaults”.
By using Left/Right buttons, select the “Calibrate Level” from the menu and press the ENTER.
12. The display will show “Calibrate Level: Yes: Enter, No: ESC”.
Select the “Yes” from the menu by press the ENTER button.
13. The display will show “Calibrate Level: Tilt 0.0’ , 0.0’”.
Select the “ESCAPE” from the menu once.
14. The display will show “Setups Calibrate Level”.
Select the “ESCAPE” from the menu once again.
15. The Calibration procedure is complete, unplug and remove the EZ-Cal.
16. Close the hydraulic/electric cabinet.
SKYJACK, Page 30
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.3-7 Auto-Leveling Outrigger Control Module Pin Reference Chart
LED
GP106 Control Module
PLUG
P1
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P4
P4
P4
P4
P4
P4
P4
P4
P4
PIN
#
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
WIRE #
AND COLOUR
68A White
67A Red/White
66A Blue/White
65A Green/White
70 Green/Black
79 Green
70A Red/White
65 Green/Black
28 Green
35 Green
02 White
10A Black
78 Black/White
77 Blue/Black
76 Red/Black
75 Orange/Black
74 Black
73 Blue
72 Red
71 Orange
35C White/Black
WIRE FUNCTION
The Calibration Connection
Input indicating that the LEFT REAR outrigger is in contact with the ground
Input indicating that the RIGHT REAR outrigger is in contact with the ground
Input indicating that the RIGHT FRONT outrigger is in contact with the ground
Input indicating that the LEFT FRONT outrigger is in contact with the ground
Input for AUTO-LEVEL function to extend the outriggers to level the machine
Input for AUTO-RETRACT function to retract the outriggers until the switch is released
Outrigger Light on Outrigger Control Box
STABLE output to indicate that all outriggers are in contact with the ground
TILT output to indicate that the machine is level (ANSI/CSA only)
Tilt override / High Drive Cutout
Negative Input
Main Power Input
Output used to extend the LEFT REAR outrigger
Output used to extend the RIGHT REAR outrigger
Output used to extend the RIGHT FRONT outrigger
Output used to extend the LEFT FRONT outrigger
Output used to retract the LEFT REAR outrigger
Output used to retract the RIGHT REAR outrigger
Output used to retract the RIGHT FRONT outrigger
Output used to retract the LEFT FRONT outrigger
Power input for outriggers
60401AB
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 31
Service and Maintenance
Section 5 - Procedures
Load Sensing System - CE
5.4-1 Control Module Pin Reference Chart
PLUG
P1
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P2
P3
P3
P3
P3
P3
P3
P4
P4
P4
P4
P4
P4
P4
P4
P4
PIN
#
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
SKYJACK, Page 32
WIRE #
AND COLOUR
Not Used
10E Black/White
14D Black
13D Orange
Not Used
Not Used
16 White/Black
15 Blue
Not Used
35B Red/Black
02 White
10C Red
22 Red
29 Black
60 Black/White
28 Green/Black
02 White
28E Green/White
Not Used
60A Green
28B Green
Not Used
Not Used
910 Black
902 White
900 White
910 Black
WIRE FUNCTION
The Calibration Connection
Not Used
Input Power From Base Terminal Strip To Confirm Lower Control Is Selected
Raise Platform Input
Lower Platform Input
Not Used
Not Used
Forward Direction Input
Reverse Direction Input
Not Used
Input From LS1 High Speed Limit Switch To Verify ON/OFF Limits
Negative Input From Base Terminal Strip
Main Power Input From Base Terminal Strip
Output To FL-22 Flashing Light
Output To BP-29 Beeper
Output To Overload Warning Light On Control Box
Output To 28CR1 Tilt Relay And 28CR2 Down Relay
Negative for Flashing Light and Beeper
Output To 28ECR1 Aux. Tilt Relay And 28ECR2 Aux. Down Relay
Not Used
Varied Input From Transducer
Varied Input From Angle Transducer
Not Used
Not Used
Positive Signal To Angle Transducer
Negative Signal To Angle Transducer
Negative Signal To Pressure Transducer
Positive Signal To Pressure Transducer
60303AD
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.4-2 LED Error Codes - Quick Reference Chart
HELP Message
EVERYTHING OK
IN GROUND MODE!
OVERLOAD FUNCTIONS DISABLED!
VEHICLE TILTED
VEHICLE OVERLOADED
WAITING FOR B+ ON P2-12
ARMGUARD ACTIVE!
TOO HIGH - DRIVE PREVENTED
TOO HIGH - LIFT UP PREVENTED
TESTING HWFS
IDLE TIMEOUT ACTIVE!
WAITING FOR NEUTRAL
ELEVATION SWITCH SHIFTED?
ELEVATION SWITCH STUCK?
NO LAST CALDATE!
LOAD NOT CALIBRATED
DRIVE/LIFT INPUTS FAULTY!
UP/DOWN SELECT INPUTS ACTIVE TOGETHER
INVALID LOAD - CHECK SENSORS
HEIGHT NOT CALIBRATED
INVALID HEIGHT - CHECK SENSOR
EMS INPUTS FAULTY!
B+ SUPPLY TOO LOW
P4-1 OR P5-1 SHORT TO 0V?
P3-4 SHORT TO SUPPLY!
P3-4 SHORT TO 0V?
P3-4 SHORT TO SUPPLY?
P3-6 SHORT TO 0V?
P3-6 SHORT TO SUPPLY?
FAULT: BAD TILT SENSOR
FAULT: BAD HWFS
FAULT: BAD SLAVE ANALOGS
FAULT: BAD STRAIN MONITORS
FAULT: BAD SLAVE MICRO
FAULT: HWFS STALLED!
STARTUP!
FACTORY OVERRIDE
LED indication
Steady on
Steady on
6/6
1/1
1/2
5/2
1/3
1/4
1/5
7/8
Always off
5/5
2/1
2/2
6/3
6/2
5/6
5/4
6/4
6/1
6/5
5/2
5/1
4/1
4/2
4/3
4/4
4/5
4/6
7/1
7/2
7/3
7/4
7/5
7/6
7/7
6/7
60405AA
Reading the Codes:
In order to read the fault codes, a sequence of pauses and flashes can be seen on the LED mounted on the GP102
module. The codes are continuously displayed by the LED until the fault is cleared, the GP102 reset and no longer
detects the fault, or idle timeout becomes active.
The sequence is as follows:
1. Quarter second flashes followed by quarter second pauses indicate the first digit.
2. A 1.5 second pause.
3. Quarter second flashes followed by quarter second pauses indicate the second digit
4. A 4 second pause. Repeat steps 1-4
Since the GP102 only reports one error, only one code can be read from the LED per instance. If the error is cleared
and another error is present, it will then be presented.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 33
Service and Maintenance
Section 5 - Procedures
5.4-3 LED Error Codes - Code Breakdown Chart
Diagnostic sequence dependant on LED flash code:
No Last Caldate
63
Load Not Calibrated
62
Height Not Calibration
An EZcal is required!
61
Waiting For Neutral
55
Drive/Lift Inputs Faulty!
56
Up/Down Select Inputs Active Together
54
EMS Inputs Faulty!
Check inputs on P2 pins 1,2,3,4,5,6,7,8.
52
P3-4 Short To Supply!
42
P3-4 Short To Supply?
44
P3-6 Short To Supply?
46
Disconnect plug P3. If fault clears there is a problem with the wiring from P3-4 or P3-6 to the rest of the vehicle.
Armguard Active!
23
Elevation Switch Shifted?
21
Elevation Switch Stuck?
22
If the 23 flash code is triggered by armguard, it will occur once then clean. This is not a true fault but just an indication
of the reason for the vehicle stop. If the 21 or 22 flash code is triggered by a fault with the elevation switch, it will not
clear. Check that the elevation switch correctly opens/closes when the platform is raised/lowered.
P3-4 Short To 0V?
43
P3-6 Short To 0V?
45
Disconnect plug P3. If fault clears there is a wiring fault from P3-4 or P3-6 to the rest of the vehicle.
Invalid Load - Check Sensors
45
Check the voltage out of the pressure transducer, into P4-2. It should be between 0.5V (zero pressure) and 4.5V
(maximum pressure) and should vary as the platform load & position varies.
Waiting For B+ on P2-12
52
B+ Supply Too Low
51
P4-1 Or P5-1 Short To 0V?
41
Check that the battery voltage is not too low.
Verify battery voltage on P2-12.
Disconnect plug P4 – if the fault clears there is a wiring fault from P4-1 to the rest of the vehicle.
SKYJACK, Page 34
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
5.4-4 LED Error Codes - Code Breakdown Chart (Continued)
Vehicle Tilted
11
Vehicle Overloaded
12
Too High - Drive Prevented
14
Too High - Lift Up Prevented
15
These are not true faults but an indication that vehicle movement is prevented. Remove excessive load from the
platform. Lower the platform if close to maximum height. Move the vehicle to level ground.
Invalid Height - Check Sensor
65
Check the voltage out of the height transducer, into P4-3. It should be between .4V and 4.6V and should vary as
the platform position varies.
Testing HWFS
78
Start Up!
77
These are not true faults unless they do not clear – the start-up tests should only occur for a short time.
Overload Functions Disabled!
66
Factory Override
67
These are not true faults – the GP102 has been configured to suppress overload functionality.
Idle Timeout Active!
Always Off
Fault: Bad Tilt Sensor
71
Fault: Bad HWFS
72
Fault: Bad Slave Analogs
73
Fault: Bad Strain Monitors
74
Fault: Bad Slave Micro
75
Fault HWFS Stalled!
76
Action a function to clear the idle timeout if it occurred. Ensure the GP102 is correctly mounted – incorrect
mounting can cause the “bad tilt sensor” diagnostic to occur. Otherwise there may be an internal problem with the
GP102.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 35
Service and Maintenance
Section 5 - Procedures
5.4-6 Control Module Load Calibration - Code Messages & Definitions
During calibration the following failure message may appear:
(Refer to 5.3-6 for hand held calibration/diagnostic tool key functions)
F01: Check HWFS
-- This message is given if the GP102 startup tests have not completed. Check HELP message for more
information.
F02: Not Ground Mode
-- This message is given if the machine is not in ground mode (P2-2 must be high).Calibration can only
be carried out in ground mode.
F03: Not Stopped
-- This message is given if any function switch is closed. Check DIAGNOSTICS / SWITCHES to see which
function switch is closed.
F04: Tilted
-- This message is given if the machine is tilted. Calibration must be carried out with the machine level.
If the machine is level, use the SETUPS / TILT SETUPS to set the GP102 level.
F05: Bad Height
-- This message is given if the height sensor output (P4-3) is out of range at the start of calibration. The
height sensor output must be between 0.9V and 4.1V. Check DIAGNOSTICS / SENSORS to see the
output. A reading of 0V or 5V is probably due to a wiring problem.
F06: Check Elev
-- This message is given if the elevation switch (P210) is open at the start of calibration, when the operator
has confirmed the “PLATFORM DOWN?” question. If the platform is down, check the elevation switch
wiring.
F08: Check Elev
-- This message is given if the elevation switch (P2-10) is closed at the end of calibration, when the platform
should be fully raised. This message would occur if the UP switch was accidentally opened near the
start of the lift. If the platform is fully raised, check the elevation switch wiring.
F09: Bad Height
-- This message is given if the height sensor output (P4-3) is out of range at the start of calibration. The
height sensor output must be between 0.9V and 4.1V. Check DIAGNOSTICS / SENSORS to see the
output.
F10: Bad Height
-- This message is given if the height sensor output (P4-3) is out of range at the end of calibration. The
height sensor output must be between 0.9V and 4.1V. Check DIAGNOSTICS / SENSORS to see the
output. A reading of 0V or 5V is probably due to a wiring problem.
F11: Not Up
-- This message occurs at the start of calibration if the operator selects a function other than UP.
SKYJACK, Page 36
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
F13: Low Height Range
-- This message occurs at the end of calibration if the height sensor output did not change sufficiently
to give a reasonably accurate platform height estimate. DIAGNOSTICS / SENSORS can be used to
check the height sensor output (P43) when the platform is fully lowered and fully raised; a difference
of at least 1V is to be expected. This message could occur if the UP switch was accidentally opened
too early (when the platform is not fully raised).
F15: Check Elev
-- This message is given if the elevation switch (P2-10) is open when the platform has been fully lowered
at the end of calibration. This message would occur if the DOWN switch was accidentally opened before
the platform was fully lowered. If the platform is fully lowered, check the elevation switch.
F16: Low Elev.open
-- This message is given if the elevation switch (P2 10) opened during lift at a too low height (below 5%).
Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the
switch opened.
F17: High Elev.open
-- This message is given if the elevation switch (P210) opened during lift at a too high height (above
25%).Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where
the switch opened.
F18: Low Elev.close
-- This message is given if the elevation switch (P210) closed during lower at a too low height (below
5%).Check CALIBRATIONS / HEIGHT CALS; the “ElevDown” value shows the recorded height where
the switch opened.
F19: High Elev.close
-- This message is given if the elevation switch (P210) closed during lower at a too high height (above
25%).Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where
the switch opened.
F20: Height<>0%
-- This message occurs if the platform height is not 0% after the platform has been fully lowered at the
end of calibration.The platform must return to the same height each time it is fully lowered. Check
DIAGNOSTICS / SYSTEM to check the height.
F28: Bad Height
-- This message indicates a problem with the height sensor output (P43) during calibration. The height
sensor output must be between 0.9V and 4.1V during calibration and between 0.4v and 4.6v during
normal operation. Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably
due to a wiring problem.
F42: Low Pressure
-- This message indicates that the pressure is too low (0.5V or less) when the elevation switch opens
during calibration. Check DIAGNOSTICS / SENSORS to check the pressure.
F43: High Pressure
-- This message indicates that the pressure is too high (4.5V or more) when the elevation switch opens
during calibration. Check DIAGNOSTICS / SENSORS to check the pressure.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 37
Service and Maintenance
Section 5 - Procedures
F44: Low Pressure
-- This message indicates that the pressure is too low (0.5V or less) at a measurement point. Check
DIAGNOSTICS / SENSORS to check the pressure.
F45: High Pressure
-- This message indicates that the pressure is too high (4.5V or more) at a measurement point. Check
DIAGNOSTICS / SENSORS to check the pressure.
F46: Check Elev
-- This message indicates that the elevation switch opened more than once during calibration lifting.
F47: Check Elev
-- This message indicates that the elevation switch closed more than once during calibration lowering.
F48: Bad Pressure
-- This message is given if the pressure sensor output (P4-2) is out of range at the start of calibration.
The height sensor output must be between 0.5V and 4.5V. Check DIAGNOSTICS / SENSORS to see
the output. A reading of 0V or 5V is probably due to a wiring problem.
F52: Too Few!
-- This message indicates that not enough measurements were recorded during calibration lifting or
lowering.
F98: Out of Range
-- This message indicates that the “fine tune” calibration is unacceptable. This probably is due to the
wrong load being in the platform (i.e: specifying “EMPTY” if the platform is loaded, or the other way
round) or (Having the incorrect pressure transducer installed).
During calibration the following information messages may appear:
Caldate:
-- This message is prompting for the date to be entered; it is stored to identify when the machine was
calibrated. The last calibrate date can be viewed in DIAGNOSTICS / LOG. Press LEFT & RIGHT to select
the flashing digits. Press UP & DOWN to change the flashing digits. Press ENTER when the entry is
complete. IMPORTANT: The date 00/00/00 is not allowed!
Finished
-- This message confirms that calibration is complete and successful.
Lift Empty
-- This message is displayed while the platform is being raised to the next measurement height, when an
EMPTY platform is being calibrated.
Lift Loaded
-- This message is displayed while the platform is being raised to the next measurement height, when a
LOADED platform is being calibrated.
Lifting
-- This message is displayed while the platform is being raised, during HEIGHT-only calibration.
Lower Empty
-- This message is displayed while the platform is being lowered to the next measurement height, when
an EMPTY platform is being calibrated.
SKYJACK, Page 38
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
Lower Loaded
-- This message is displayed while the platform is being lowered to the next measurement height, when
an EMPTY platform is being calibrated.
Lowering
-- This message is displayed while the platform is being lowered, during HEIGHT-only calibration.
Measuring #
-- This message is displayed when the platform is stopped during calibration, when the GP102 takes a
measurement. There will be a short delay while the machine is allowed to stabilize after movement is
stopped.
Must Go Down!
-- This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be
lowered.
Must Go Up!
-- This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be
raised.
Platform Down?
-- This message is prompting for confirmation that the platform is fully lowered. If necessary the DOWN
switch can be activated to lower the platform. Press ENTER to confirm when the platform is fully
lowered.
Platform Empty?
-- This message is prompting for confirmation that the platform is completely empty.Press ENTER to
confirm if the platform is empty.
Platform Loaded?
-- This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to
confirm if the platform is loaded.
Please Lift
-- This message is prompting for the platform to be raised. The UP switch should be closed.
Please Lower
-- This message is prompting for the platform to be lowered. The DOWN switch should be closed.
Please Wait
-- This message indicates that the GP102 is busy; the delay will be short (no more than 5s).
Total Data:
-- This message is displayed at the end of each phase, to confirm the number of measurements recorded
by the GP102.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 39
Service and Maintenance
Section 5 - Procedures
5.4-7 Control Module Load Calibration Procedure
1.
Move the aerial platform to a test area where the platform can be elevated to its maximum working height and
reach.
2.
Ensure the aerial platform is parked on a firm, level surface.
IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
IMPORTANT
Always follow the instructions of the Calibration instrument.
IMPORTANT
Make sure the aerial platform is on BASE mode.
NOTE
To ensure a good and clear contact, clean the wire terminals before attaching the jumper clip.
3.
Locate the main manifold inside the hydraulic/electric tray.
4.
Disconnect the black wire #14 from the lift coil.
5.
Locate the contactor on the electrical panel assembly.
6.
The jumper connection must be connected between the contractor (wire #19B) and the lift coil (instead of the
black wire #14)
7.
Connect the Easy-Cal tool to the P1 connector on the CONTROL MODULE.
8.
The display will show “Help: Press Enter”.
By using Left/Right buttons, select the “Access Level ( ? )” from the menu and press the ENTER button.
Contact Skyjack Service Department at:
(44) 1691-676 236 for your Access Level Code Number.
9.
The display will show “Access Level Code (xxxx)”.
By using the Up/Down buttons, enter the Access Level Code (xxxx) followed by pressing the ENTER
button.
10. The display will show “Access Level 2”.
By using Left/Right buttons, select the “Setups” from the menu and press the ENTER button.
11. The display will show “Machine Defaults”.
Select the “Machine Defaults” from the menu and press the ENTER button.
12. The display will show “Defaults, 0 = Custom”.
By using Left/Right buttons, select the “X = Group Code” from the menu and press the ENTER button.
SKYJACK, Page 40
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
13. The display will show “X=GROUP CODE”. (Refer to 5.4-8 for group code)
By using the Up/Down buttons, enter the “Group Code (?)” then by using Left/Right buttons, select the “Curve”
from the menu.
14. The display will show “X=CURVE”. (Refer to 5.4-8 for curve code)
By using the Up/Down buttons, enter the “Curve Code (?)” followed by pressing the ESCAPE button.
15. The display will show “Machine Defaults”.
By using Left/Right buttons, select the “Tilt Setups” from the menu and press the ENTER button.
16. The display will show “Tilt Setups: Calibrate Level”.
Select the “Tilt Setups: Calibrate Level” from the menu and press the ENTER button.
17. The display will show “Calibrate Level: Yes: Enter, No: ESC”.
Select the “Yes” from the menu by press the ENTER button.
18. The display will show “Calibrate Level: Tilt 0.0’ , 0.0’”.
Select the “ESCAPE” from the menu once.
19. The display will show “Tilt Setups Calibrate Level”.
Select the “ESCAPE” from the menu once again.
20. The display will show “Setups Tilt Setups”.
By using Left/Right buttons, select the “Load Setups” from the menu and press the ENTER button.
21. The display will show “Load Setups: Calibrate Load”.
Select the “Load Setups: Calibrate Load” from the menu and press the ENTER button.
22. At this point, elevate the aerial platform at full height, check the harness and making sure it is not stretched
tight, then lower down the platform.
23. The display will show “Calibrate Load: Platform Down?”.
Asking for confirmation that the platform is fully lowered?
Check that the platform is fully lowered then press the ENTER button to confirm.
24. The display will show “Calibrate: Loaded Empty? No”.
Asking for confirmation that the platform is empty?
Check that the platform is empty
25. By using the Up/Down buttons, enter the “Yes” followed by pressing the ENTER button.
26. The display will show “Calibrate Load: Please Lift......”.
Waiting for the lift switch to be activated.
27. Hold the lift switch and keep holding it until the platform is fully elevated.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 41
Service and Maintenance
Section 5 - Procedures
IMPORTANT
If the lift switch is released earlier than full-height position, the
calibration will have to be aborted and repeated from the beginning!
28. When the system detects the lift switch closed, the display will show “Calibrate Load: Lift Empty”.
29. After a delay, the system will stop the platform lifting and will take height & pressure measurements; the display
will show “MEASURING # xx” When the measurements have been taken, the platform will resume lifting.
NOTE
The Lifting......stopping.......measuring....lifting process will continue until the platform reaches full height.
30. When the platform reaches full height release the lift switch.
31. The display will briefly show “TOTAL DATA: 04” to indicate the number of measurements taken.
32. The display will show “Calibrate Load: Please Lower......”.
IMPORTANT
If the lower switch is released earlier than full-lower position, the
calibration will have to be aborted and repeated from the beginning!
33. Hold the lower switch and keep holding it until the platform is fully lowered.
34. When the system detects the lower switch closed, the display will show “Calibrate Load: Lower Empty”
35. After a delay, the system will stop the platform lowering and will take height & pressure measurements; the.
display will show “MEASURING #xx”. When the measurements have been taken, the platform will resume
lowering.
NOTE
The lowering......stopping.......measuring....lowering process will
continue until the platform is fully lowered.
36. When the platform is fully lowered (and height 0% is displayed), release the lower switch.
37. The display will show briefly “TOTAL DATA: 04” to indicate the number of measurements taken.
38. The display will show “Calibrate Load: Caldate: mm/dd/yy”.
It is recommended that the current date be entered here to provide easy taking of the data of last
calibration.
The current date must be entered using the LEFT/RIGHT and UP/DOWN buttons.
39. Press ENTER to complete date entry (the system will store it).
40. The display will show “Calibrate Load” option.
41. Press the ESC button to exit the “Calibrate Load” option.
SKYJACK, Page 42
Mid Size & Full Size
Rough Terrain Series
Section 5 - Procedures
Service and Maintenance
42. Remove the jumper wire and re-connect the black wire #14 to the coil removed earlier.
43. Close the hydraulic/electric tray.
NOTE
Continuing partially complete load calibration.
Once a calibration phase has been successfully completed, it is not required to do it again (unless of course
a change to the vehicle such as a replacement sensor requires that calibration be repeated). This is useful if
the calibration procedure is interrupted – the remaining phases can be completed at a later time.
If a calibration phase has been successfully completed, a “REDO” message is displayed:
REDO DYNAMIC: NO
REDO LOADED: NO
REDO EMPTY: NO
If the phase does not need to be repeated, just press ENTER to move on.
If the phase does need to be repeated, press UP or DOWN to change “NO” to “YES” then press ENTER.
Mid Size & Full Size
Rough Terrain Series
SKYJACK, Page 43
Service and Maintenance
Section 5 - Procedures
5.4-8 Curve/Group Codes Chart
Model
Number of Extension Decks
Curve
Code
Group
Code
7027/7127
1 Manual Extension Deck
24
7
7027/7127
1 Powered Extension Deck
25
7
7135
1 Manual Extension Deck
26
7
7135
1 Powered Extension Deck
27
7
8831
No Extension Deck
30
9
8831
1 Manual Extension Deck
31
9
8831
1 Powered Extension Deck
32
9
8831
2 Manual Extension Decks
33
9
8831
2 Powered Extension Decks
34
9
8841
No Extension Deck
40
10
8841
1 Manual Extension Deck
41
10
8841
1 Powered Extension Deck
42
10
8841
2 Manual Extension Decks
43
10
8841
2 Powered Extension Decks
44
10
9250
No Extension Deck
52
10
9250
1 Powered Extension Deck
53
10
9250
2 Powered Extension Decks
54
10
6832RT
1 Manual Extension Deck
56
15
6826RT
1 Manual Extension Deck
57
15
9241
2 Powered Extension Decks
58
15
60403AD
SKYJACK, Page 44
Mid Size & Full Size
Rough Terrain Series
Reliable lift solutions by people who care.
www.skyjack.com