Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
OPERATING
MAINTENANCE &
PARTS MANUAL
Serial Numbers 90876 and Below.
BOOM
Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
TABLE OF CONTENTS
SECTION 1 INTRODUCTION
PURPOSE OF EQUIPMENT ................................................................................................ Page 1
1
1
USE OF EQUIPMENT .......................................................................................................... Page 1 S
WARNINGS .......................................................................................................................... Page 1
DESCRIPTION ..................................................................................................................... Page 1
Figure 1-1A. Front Panel Labels ............................................................................................. Page 2
Figure 1-1B. Front Panel labels .............................................................................................. Page 3
E
Table 1-1. Specifications and Features .................................................................................. Page 4
2
WORK PLATFORM MAJOR COMPONENTS IDENTIFICATION
Figure 1-2. SKYJACK SJKB Boom Work Platform (Model SJKB-33C Shown) ................... Page 5 C
SECTION 2 OPERATION
OPERATOR QUALIFICATIONS ............................................................................................. Page 1
OPERATING CONTROL IDENTIFICATION
T
Base Controls - Electrical .................................................................................................. Page 3
Base Controls - Mechanical ............................................................................................... Page 4
Base Controls - Hydraulic .................................................................................................. Page 4 I
Platform Controls - Electrical ............................................................................................. Page 6
OPERATING PROCEDURES
Prestart Checks ................................................................................................................ Page 8
Start and Operation ........................................................................................................... Page 8
O 3
Shutdown Procedure .......................................................................................................... Page 9
Loading and Tie Down Procedure ....................................................................................... Page 9
BATTERY SERVICE AND CHARGING PROCEDURES N
Battery Service ................................................................................................................ Page 10
Battery Charging Procedures ........................................................................................... Page 10
BATTERY CHARGING OPERATIONS ................................................................................ Page 11
Table 2-1 - Maintenance and Inspection Schedule ............................................................... Page 12
Table 2-2 - Owners Annual Inspection Record ..................................................................... Page 13
Table 2-3 - Tire Specifications ............................................................................................. Page 13
I
4
Table 2-4 - Maximum Platform Capacities ........................................................................... Page 13
RECOMMENDED HYDRAULIC OILS.................................................................................. Page 13
Table 2-5 - General Specifications ....................................................................................... Page 14
N
SECTION 3 SYSTEMS COMPONENT IDENTIFICATION AND SCHEMATICS
5
TABLE OF CONTENTS ........................................................................................................ Page 1
SJKB33N Page i
WARNING
ANSI/SIA (United States)
You are required by ANSI/SIA A92.5 -1992 to read and understand YOUR RESPONSIBILITIES in the Manual Of
Responsibilities before you use or operate this work platform.
FAILURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the work platform
could result in death or serious injury.
You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this work platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
work platform. Any modifications from the original design are strictly forbidden without written permission from
SKYJACK, Inc.
Page ii SJKB33N
DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPER
AUTHORIZATION AND TRAINING. DEATH OR SERIOUS
INJURY COULD RESULT FROM IMPROPER USE OF THIS
EQUIPMENT!
NOTE
SKYJACK, Inc. is continuously improving and expanding product features on its equipment; therefore,
specifications and dimensions are subject to change without notice.
The Safety Alert Symbol identifies important safety messages on machines, 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.
The selling distributor or authorized dealer shall be C. Shipped in a container tagged or marked with the
responsible for the complete handling of customer claims RA number.
under this warranty. Heres what to do:
D. Shipped PREPAID. Any item(s) returned for
1. When a customer files a claim under this warranty, warranty by any other means may be refused and
contact Skyjacks Service Department to verify returned unless prior approval from Skyjack is
warranty coverage. NOTE: The complete serial number obtained.
of the work platform is required to verify the claim.
E. Items shipped to the dealer will be sent freight
2. When Skyjacks Service Department verifies warranty prepaid and added to the invoice.
coverage, they will also issue an RA (Return
Authorization) number for the return of any defective Failure to comply with the above procedures may delay
component(s). All items over $25.00 in value must approval and processing of the warranty claim and could
be returned to Skyjack, Inc. result in the denial of a warranty claim. Skyjacks dealers
accounts must be kept current in order to approve and
issue warranty credits. Skyjack reserves the right to
withhold issuance of warranty credits to a dealer if their
account is not in good standing. This is subject to change
without prior notice.
Page iv SJKB33N
SECTION 1
PURPOSE OF EQUIPMENT
INTRODUCTION
Specifications
Features
STANDARD EQUIPMENT
4 Foot Hydraulically Controlled Boom Jib
Variable Speed Drive and Function Controls
In-Line Elevating Assembly
Continuous Drive and Steer Directional Sensing
Electrical Dynamic Braking System
Two Spring-Applied Hydraulically-Released Parking Brakes
ANSI and CSA Standards Compliance
OPTIONAL EQUIPMENT
Operator Horn
All Function Motion Alarm
Descent Alarm
Travel Alarm
Flashing Amber Light
Spring-Loaded Half Gate
Spring Loaded Full Gate
On-Board 110VAC Generator
Lifting Lugs
Non Marking Tires
Additional Battery Boxes
Overload Sensing (France)
8 Meter Drive Cutout (Europe)
BOOM
JIB
PLATFORM
RISER
ARM
BASE
CONTROL
PANEL TURRET
DRIVE
BATTERY CHASSIS
CHARGER
Figure 1-2. SKYJACK SJKB-33N Boom Work Platform
NOTE
Replace all worn or damaged parts or labels discovered during this inspection.
It is the responsibility of the owner to arrange daily, weekly, monthly and annual inspections of the work platform. Table
2-2. Owners Annual Inspection Record is to be used for recording the date of inspection, owners name and the person
responsible for the inspection of this work platform.
Before attempting any repair work, disconnect the batteries by separating the 350A connectors.
1. OFF/PLATFORM/BASE SELECT KEY SWITCH - 8. JIB UP/DOWN TOGGLE SWITCH - This switch
Turning the key to the (off) position disconnects controls the up/down movement of the jib. To move the
power from the control circuit. When the (platform) jib upward, push and hold this toggle switch to the
position is selected, power is directed to the control (up) position. Release switch to stop. To move the
station on the platform. When the switch is held in the jib downward, push and hold this toggle switch to the
(base) position power is directed to the control (down) position. Release switch to stop.
station on the base.
9. EMERGENCY STOP BUTTON - When struck, this
red push-button switch disconnects power to the control
2. RISER UP/DOWN TOGGLE SWITCH - This switch
circuit. In the event of an emergency or at work platform
controls the up/down movement of the riser section. To
shut down, push button in. To restore power, simply pull
raise the riser section, push and hold this toggle switch
button out.
to the (up) position. Release switch to stop. To
lower the riser section, push and hold this toggle switch
NOTE
to the (down) position. Release switch to stop.
Depressing the Emergency Stop Button instantly
engages parking brakes.
1
1
2
Figure 2-7. Parking Brake Release Plunger
(Machines with Serial Number 90307 and above.)
3
1. PARKING BRAKE RELEASE PLUNGER
DANGER
Figure 2-8. Brake Override Valve and Parking Brake Figure 2-9. Foot Switch
Release Hand Pump
(Machines with Serial Number 90306 and below.) 1. FOOT SWITCH
1. BRAKE OVERRIDE VALVE PLUNGER 1. FOOT SWITCH - The foot switch is located on the
2. PARKING BRAKE RELEASE HAND PUMP platform. When the foot switch is depressed and held,
power is brought to the controls on the operators control
DANGER console. When the foot switch is released, the controls
on the operators control console are cutout.
DO NOT release the brakes on an incline without the
wheels chocked.
IMPORTANT NOTE
1. BRAKE OVERRIDE VALVE PLUNGER - Located on
the brake manifold and accessed thru a hole in the drive
chassis, when this black plunger on top of the brake The foot switch MUST be depressed and held to use
valve is depressed, the brake valve closes allowing use any control on the operators control console.
of the parking brake hand pump.
NOTE
The brake will automatically return to normal
operation when a drive function is selected.
Figure 2-10. Operators Control Console and Label 6. BOOM RETRACT/EXTEND SELECTOR PUSH-
BUTTON - This push-button enables the operator to
retract and extend the boom arm.
1. JIB UP/DOWN SELECTOR PUSH-BUTTON
2. RISER UP/DOWN SELECTOR PUSH-BUTTON 7. BOOM FUNCTION CONTROLLER - This lever-type
3. BOOM UP/DOWN SELECTOR PUSH-BUTTON control allows the operator to choose the direction and
4. TURRET ROTATION SELECTOR PUSH- vary the speed for each selected function.
BUTTON
5. PLATFORM LEVELING/ROTATION SELECTOR 8. DRIVE/STEER CONTROLLER - This lever-type
PUSH-BUTTON control allows the operator to drive in forward or reverse
6. BOOM RETRACT/EXTEND SELECTOR PUSH- and by using the rocker on top of the controller to steer
BUTTON left and right.
7. BOOM FUNCTION CONTROLLER
9. EMERGENCY STOP BUTTON - This red mushroom-
8. DRIVE/STEER CONTROLLER shaped button is designed to cut power to the platform
9. EMERGENCY STOP BUTTON controls when struck in the event of an emergency or at
10. TILT SENSOR INDICATOR LIGHT work platform shutdown. To restore power, simply pull
11. POWER ON INDICATOR LIGHT button out.
12. HORN PUSH-BUTTON (Optional)
NOTE
OPERATORS CONTROL CONSOLE - This metal
Depressing the Emergency Stop Button instantly
control station is located at the front of the platform. It
engages parking brakes.
can be disconnected and removed to safeguard against
unauthorized use. It contains the following controls:
10. TILT SENSOR INDICATOR LIGHT - This red light
IMPORTANT NOTE indicates that the work platform is on a slope which
exceeds the limits for safe operation. A horn will also
The foot switch MUST be depressed and held to use sound.
any control on the operators control console. Refer
to Operating Procedures for detailed instructions on 11. POWER ON INDICATOR LIGHT - This red light
operating these controls. indicates that the foot switch has been depressed and
power is available to operate the controls on the operators
NOTE control console.
On earlier models, a trigger switch on the controller 12. HORN PUSH-BUTTON (Optional) - The horn can
grip sounded the optional horn. be sounded by depressing this red push-button on the
controller handle.
2. Check overhead clearances. NOTE: For European models only, drive circuit will
cut out when the platform is elevated to 8 meters or
3. Make sure that the batteries are fully charged. above.
Disconnect battery charger from external power 10. TO STEER: Depress the rocker on the Drive/
source. Steer Controller handle in the direction you wish
to steer.
4. Make sure emergency lowering valves at the NOTE: On early machines the Function Selection
base of the riser, boom and jib cylinders are fully Button must be held the entire time a function is
closed. being performed. Later machines require that the
Function Selection Button be pushed only to begin a
function and then can be released until the controller
Start and Operation is returned to a neutral position.
1a. Make sure that the 350 Amp Battery Connectors
11. TO MOVE THE JIB UP: Depress and hold the
are not separated.
Jib Up/Down Selector Push-button , then slowly
1b. Turn the Control Circuit Disconnect Switch to move the Function Controller to the (up)
the ON position. (Serial Number 90306 and position. Release the controller to stop.
below.) 12. TO MOVE THE JIB DOWN: Depress and hold
the Jib Up/Down Selector Push-button, then
2. Pull out the Emergency Stop Button on the Base slowly move the Function Controller to the
Control Panel. (down) position. Release the controller to
stop.
NOTE:
Platform leveling from platform control console is
not available on European models.
CAUTION WARNING
SHOCK HAZARD
Contact with electrolytic acid can cause skin irritation To reduce the risk of electrical shock, connect charger
and damage clothing. Wear a protective apron, gloves only to a properly grounded single phase outlet. DO
and goggles when working with batteries. NOT use a extension cord longer than 25 feet.
DO NOT service the batteries without first separating 2. Connect charger AC plug to proper voltage
the 350 Amp battery connectors. Vapors emitted by source. Refer to charger nameplate for voltage
batteries can be ignited by a spark or arc. requirements.
2. Check battery fluid level in each battery. If plates 3. Charge batteries. DO NOT leave charger
are not covered, add distilled or demineralized unattended for more than two consecutive days.
water. Severe overcharging and battery damage will
result if charger fails to turn off.
3. Check each battery case for damage.
4. Disconnect charger from external power source.
4. Clean battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
brush.
5. Make sure all battery connections are tight.
6. Replace any battery that is damaged or
incapable of holding a lasting charge.
7. Reconnect the 350 Amp battery connectors.
MECHANICAL
Struct. damage/welds (1)
Parking brakes (2)
Tires and wheels (1)(2)(3)
Guides and slides (1)(2)
Railings and gates (2)(3)
Bolts and fasteners (3)
Rust (1)
Wheel bearings (2) and king pins (1)(6)
Turret gear (1)(2)(3)(6)
Turret gear box (1)(2)(3)
Pivot pins (1)
Steer cylinder ends (6)
Axle gear oil (12)
ELECTRICAL
Battery fluid level (1)
Control switches (1)(2)(3)
Cords and wiring (1)
Battery trays (11)
Battery terminals (1)(3)(11)
Terminals and plugs (1)(3)(11)
Generator and recepticals (2)
Limit switches (2)
Tilt sensor (2)
Directional sensing (2)
HYDRAULIC
Hydraulic fluid level (1)
Hydraulic leaks/hoses (1)(3)
Lift/lowering time (8)
Hydraulic cylinders (1)(2)(3)
Emergency lowering (2)
Lift capacity (5)
Hydraulic oil filter (7)
MISCELLANEOUS
Labels (1)(9) Manuals (10)
NOTES: (8) See Table 2-5. General Specifications. Mt40-500
(1) Visuallly inspect (2) Check operation (9) Replace if missing or illegible.
(3) Check tightness (4) Check oil level (10) Proper Operation Manual MUST be in manual
(5) Check releif valve setting. Refer to Serial Number Nameplate. enclosure. (11) Clean
(6) Lubricate (7) Replace (12) Change oil. *Record inspection date.
WARNING
Parking brakes will instantly engage causing the machine to stop immediately.
The machine should come to an instant and abrupt stop. If the machine does not stop instantly or if the machine pulls
to one side while stopping, the brake adjustment MUST be checked before putting the machine into service.
Table 2-2. Owners Annual Inspection Record
Tire
- Solid urethane used for filling MUST be 55 durometer installed at 105 psi.
BRAKE SYSTEM CAPACITY (Use Dextron II only) 1.5 pints (.71 liters)
TABLE OF CONTENTS
ELECTRICAL SYSTEM
FIGURE 3-1. BATTERY CHARGER DIAGRAM AND PARTS LIST. ............................................................. Page 3
FIGURE 3-2. OPERATORS CONTROL CONSOLE DIAGRAM PARTS LIST - S/N 90242 and Above ............. Page 4
FIGURE 3-2. OPERATORS CONTROL CONSOLE DIAGRAM - Serial Number 90242 and Above .................. Page 5
FIGURE 3-3. OPERATORS CONTROL CONSOLE DIAGRAM - Serial Number 90241 and Below .................. Page 6
FIGURE 3-3. OPERATORS CONTROL CONSOLE DIAGRAM PARTS LIST - S/N 90241 and Below .............. Page 7
FIGURE 3-4. LOAD SENSING OPTION DIAGRAM PARTS LIST (France) ...................................................... Page 8
3
FIGURE 3-4. LOAD SENSING OPTION DIAGRAM (France) .......................................................................... Page 9
FIGURE 3-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM - Serial Number 90307 and Above ............. Page 10
FIGURE 3-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST - S/N 90307 and Above ........ Page 11
FIGURE 3-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST - S/N 90306 and Below ........ Page 12
FIGURE 3-6. BASE CONTROL/ELECTRICAL PANEL DIAGRAM - Serial Number 90306 and Below ............. Page 13
FIGURE 3-7. FIGURE 3-8. ELECTRICAL SCHEMATIC PARTS LIST North American ................................... Page 14
FIGURE 3-7. ELECTRICAL SCHEMATIC North American - S/N 90307 and Above ........................................ Page 15
FIGURE 3-8. ELECTRICAL SCHEMATIC North American - S/N 90306 and Below ......................................... Page 16
FIGURE 3-9. ELECTRICAL SCHEMATIC Europe - Serial Number 90307 and Above ..................................... Page 17
FIGURE 3-10. ELECTRICAL SCHEMATIC Europe - Serial Number 90306 and Below .................................... Page 18
FIGURE 3-9. FIGURE 3-10. ELECTRICAL SCHEMATIC PARTS LIST Europe ............................................... Page 19
HYDRAULIC SYSTEM
FIGURE 3-11. HYDRAULIC SCHEMATIC PARTS LIST - Serial Number 90307 and Above ............................ Page 20
FIGURE 3-11. HYDRAULIC SCHEMATIC - Serial Number 90307 and Above ................................................. Page 21
FIGURE 3-12. HYDRAULIC SCHEMATIC PARTS LIST - Serial Number 90306 and Below ............................. Page 22
FIGURE 3-12. HYDRAULIC SCHEMATIC - Serial Number 90306 and Below .................................................. Page 23
FIGURE 3-13. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90299 and Above ....... Page 24
FIGURE 3-14. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90307 and Above .... Page 24
FIGURE 3-15. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90298 and Below ........ Page 25
FIGURE 3-16. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION - S/N 90306 and Below ..... Page 25
13
12
11 6
5
10
7
8 4
3 1
2
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
11 2
1
Typical Maintained On Switch Module Installation
7 10
6
5
4
8
19
TB4 21
12
14
13
15 17 20
16 18
10 11 2
21
5
8
4
19
9
12 TB4
22
13
14
17 20
15
18
16
TB4
3 5 4
22
8
20
9 12
13
11
16
TB1 TB2 TB3
23
18
17
15 3
5 14 2
24 21
4
19
10
25 25
SECTION 3, Page 10 8 Meter Drive Cut Out Option (Europe) SJKB-33N
FIGURE 3-5. BASE CONTROL/ELECTRICAL PANEL DIAGRAM PARTS LIST
(Machines with Serial Number 90307 and above.)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
9 27
10
24
14
11
15
13
20
26
22
21
5
17
7 16 3
25
4 6
12
23 1
19 18
B1 - B8 700193 BATTERY, 6 Volt 375 AH 8 S10 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
BC 700302 BATTERY CHARGER, 48 Volt (MAC#821) 1 103141 CONTACT BLOCK, N.O. (jib up/down selector push-button switch) 1
BCB1 700182 CONTROLLER BOARD, Boom function 1 S11 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
BP-27 103057 BEEPER, 24 Volt 1 103141 CONTACT BLOCK, N.O. (platform levelling/rotation selector push-button switch) 1
BP-29 103057 BEEPER, 24 Volt 1 S13 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
CB1 700158 CIRCUIT BREAKER, 10 Amp 1 103141 CONTACT BLOCK, N.O (turret rotation selector push-button switch). 1
CB2 700157 CIRCUIT BREAKER, 50 Amp (S/N 90306 and below.) 1 S14 102853 SWITCH, Toggle (boom up/down) 1
CB3 700158 CIRCUIT BREAKER, 10 Amp 1 S15 102853 SWITCH, Toggle (riser up/down) 1
CRD1 700190 CABLE ASSEMBLY, Base to operators control console 1 S16 102853 SWITCH, Toggle (boom retract/extend) 1
(Machines with serial number 90015 and above, refer to Figure 6-12.) S17 102853 SWITCH, Toggle (jib up/down) 1
(Ref.) CABLE ASSEMBLY, Base to operators control console 1 S18 102853 SWITCH, Toggle (platform rotation) 1
(Machines with serial number 90014 and below, refer to Figure 6-12.) S19 102853 SWITCH, Toggle (platform levelling) 1
D02-1 S20 102853 SWITCH, Toggle (turret rotation) 1
thru 700166 DIODE, Flyback 1Amp/400PIV 17 S21 (Ref.) CONTROLLER, Drive/steer (Refer to Figure 6-7.) 1
D02-18 S21-1 105733 SWITCH, Right steer 1
D7B-1 S21-2 105733 SWITCH, Left steer 1
thru 102921 DIODE, 6Amp/1000PIV AR S21-3 105733 SWITCH, Trigger 1
D41 S21-4 701240 SWITCH, Horn button (optional) 1
DCB1 700834 CONTROLLER BOARD, Drive/steer 1 S22 111356 SWITCH, Turret 1
DCM1 701007 DC MOTOR, Drive 20hp (9) 1 S26 700542 SWITCH, Brake pressure (S/N 90306 and below.) 1
DCM2 700675 DC MOTOR, Brake (S/N 90306 and below.) 1 701194 SWITCH, Brake pressure (S/N 90307 and above.) 1
DCM3 700668 DC MOTOR, Boom control 1 SM7-SM13 701525 SWITCH MODULE, Maintained on 7
F1 110855 FUSE, 10 Amp 1 SV1 700990 SEVCONTROL, Drive 1
F2 110855 FUSE, 10 Amp 1 SV2 700214 SEVCONTROL, Pump 1
F3 700228 FUSE, 300 Amp 1 TC1 700217 TACHOMETER CARD 1
F4 102756 FUSE, 200 Amp 1 TG1 700227 TACHOMETER GENERATOR 1
F5 700777 FUSE, 20 Amp 1 TS1 700552 TILT SWITCH 1
F6 700776 FUSE, 6.3 Amp 1 2H-21 702754 COIL, 24 Volt (dump valve) (S/N 90299 and above.) 1
F7 114866 FUSE, 1 Amp 1 700684 COIL, 24 Volt (dump valve) (S/N 90298 and below.) 1
FL-22A 103267 FLASHER, 24 Volt (optional) 1 3H-25 103605 COIL, 24 Volt (brake valve) (S/N 90306 and below.) 1
FL-22 104535 FLASHING LIGHT, 24 Volt (optional) 1 701298 COIL, 24 Volt (brake valve) (S/N 90307 and above.) 1
H1 102860 HORN, 24 Volt (optional) 1 4H-13
IL1 102671 INDICATOR LIGHT CONTACT BLOCK, Power on 1 thru 702755 COIL, 24 Volt (directional valves)
IL2 102671 INDICATOR LIGHT CONTACT BLOCK, Tilt sensor 1 4H-41 (Machines with Serial Number 90299 and above.) 16
LB1 thru LB8 102771 LIGHT BULB, 24 Volt (indicator lights and push-buttons) 8 4H13
LS1 111356 LIMIT SWITCH, Riser lift 1 thru 107439 COIL, 24 Volt (directional valves)
LS2 700160 LIMIT SWITCH, Boom telescope 1 4H41 (Machines with Serial Number 90298 and below.) 16
R1B 701081 RESISTOR, Line 1K 1 10ACR1 700219 CONTACTOR, Pump (boom control) 1
R19B 700800 RESISTOR, 2.2k 1 10ACR2 108589 RELAY, 40 Amp (sevcontrol) 1
S1 102600 SWITCH, Control circuit disconnect (S/N 90306 and below.) 1 10CR3 701078 CONTACTOR, Line 1
S2 103225 CONTACT BLOCK, N.C. (key switch) 2 10CR4 701236 RELAY, Charger interlock 1
103141 CONTACT BLOCK, N.O. (key switch) 2 15ACR 700218 CONTACTOR, Drive pump/motor 1
S3 103225 CONTACT BLOCK, N.C. (emergency stop switch) (platform) 1 16ACR 700218 CONTACTOR, Drive pump/motor 1
S4 103225 CONTACT BLOCK, N.C. (emergency stop switch (base) 1 17ACR1 108589 RELAY, 40 Amp (steer) 1
S5 700187 FOOT SWITCH 1 17ACR2 108589 RELAY, 40 Amp (steer) 1
S6 700181 CONTROLLER, Boom function 1 30ACR 108589 RELAY, 40 Amp (leveling interlock) 1
S7 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1 21CR 108589 RELAY, 40 Amp (flashing light) (optional) 1
103141 CONTACT BLOCK, N.O. (boom up/down selector push-button switch) 1 26CR 700156 CONTACTOR, Brake pump/motor (S/N 90306 and below.) 1
S8 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1 27CR 108589 RELAY, 40 Amp (tilt) 1
103141 CONTACT BLOCK, N.O. (riser up/down selector push-button switch) 1 49CR 108589 RELAY, 40 Amp (horn) (optional) 1
S9 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
103141 CONTACT BLOCK, N.O. (Boom retract/extend selector push-button switch) 1
B1 - B8 700193 BATTERY, 6 Volt 375 AH 8 S9 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
BC 700302 BATTERY CHARGER, 48 Volt (MAC#821) 1 103141 CONTACT BLOCK, N.O. (Boom retract/extend selector push-button switch) 1
BCB1 700182 CONTROLLER BOARD, Boom function 1 S10 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
BP-27 103057 BEEPER, 24 Volt 1 103141 CONTACT BLOCK, N.O. (jib up/down selector push-button switch) 1
BP-29 103057 BEEPER, 24 Volt 1 S11 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button
CB1 700158 CIRCUIT BREAKER, 10 Amp 1 (platform rotation selector push-button switch) 1
CB2 700157 CIRCUIT BREAKER, 50 Amp (S/N 90306 and below.) 1 S13 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1
CB3 700158 CIRCUIT BREAKER, 10 Amp 1 103141 CONTACT BLOCK, N.O. (turret rotation selector push-button switch) 1
CRD1 700190 CABLE ASSEMBLY, Base to operators control console 1 S14 102853 SWITCH, Toggle (boom up/down) 1
(Machines with serial number 90015 and above, refer to Figure 6-12.) S15 102853 SWITCH, Toggle (riser up/down) 1
(Ref.) CABLE ASSEMBLY, Base to operators control console 1 S16 102853 SWITCH, Toggle (boom retract/extend) 1
(Machines with serial number 90014 and below, refer to Figure 6-12.) S17 102853 SWITCH, Toggle (jib up/down) 1
D02-1 S18 102853 SWITCH, Toggle (platform rotation) 1
thru 700166 DIODE, Flyback 1Amp/400PIV 17 S19 102853 SWITCH, Toggle (platform levelling) 1
D02-18 S20 102853 SWITCH, Toggle (turret rotation) 1
D7B-1 S21 (Ref.) CONTROLLER, Drive/steer (Refer to Figure 6-7.) 1
thru 102921 DIODE, 6Amp/1000PIV AR S21-1 105733 SWITCH, Right steer 1
D41 S21-2 105733 SWITCH, Left steer 1
D81A 102921 DIODE, 6Amp/1000PIV 1 S21-3 105733 SWITCH, Trigger 1
DCB1 700834 CONTROLLER BOARD, Drive/steer 1 S21-4 701240 SWITCH, Horn button (optional) 1
DCM1 701007 DC MOTOR, Drive 20hp (9) 1 S22 111356 SWITCH, Turret 1
DCM2 700675 DC MOTOR, Brake (S/N 90306 and below.) 1 S26 700542 SWITCH, Brake pressure (S/N 90306 and below.) 1
DCM3 700668 DC MOTOR, Boom control 1 701194 SWITCH, Brake pressure (S/N 90307 and above.) 1
F1 110855 FUSE, 10 Amp 1 SM7-SM13 701525 SWITCH MODULE, Maintained on 7
F2 110855 FUSE, 10 Amp 1 SV1 700990 SEVCONTROL, Drive 1
F3 700228 FUSE, 300 Amp 1 SV2 700214 SEVCONTROL, Pump 1
F4 102756 FUSE, 200 Amp 1 TC1 700217 TACHOMETER CARD 1
F5 700777 FUSE, 20 Amp 1 TG1 700227 TACHOMETER GENERATOR 1
F6 700776 FUSE, 6.3 Amp 1 TS1 700552 TILT SWITCH 1
F7 114866 FUSE, 1 Amp 1 2H-21 702754 COIL, 24 Volt (dump valve) (S/N 90299 and above.) 1
FL-22A 103267 FLASHER, 24 Volt (optional) 1 700684 COIL, 24 Volt (dump valve) (S/N 90298 and below.) 1
FL-22 104535 FLASHING LIGHT, 24 Volt (optional) 1 3H-25 103605 COIL, 24 Volt (brake valve) (S/N 90306 and below.) 1
H1 102860 HORN, 24 Volt (optional) 1 701298 COIL, 24 Volt (brake valve) (S/N 90307 and above.) 1
IL1 102671 INDICATOR LIGHT CONTACT BLOCK, Power on 1 4H-13
IL2 102671 INDICATOR LIGHT CONTACT BLOCK, Tilt senso 1 thru 702755 COIL, 24 Volt (directional valves) 16
LB1 thru LB8 102771 LIGHT BULB, 24 Volt (indicator lights and push-buttons) 8 4H-41 (Machines with Serial Number 90299 and above.)
LS1 111356 LIMIT SWITCH, Riser lift 1 4H13
LS2 700160 LIMIT SWITCH, Boom telescope 1 thru 107439 COIL, 24 Volt (directional valves) 16
OWPI 702305 OVERLOAD WARNING PROCESSOR 1 4H41 (Machines with Serial Number 90298 and below.)
PS2-3 703054 SWITCH, Proximity (8m drive cutout) 2 10ACR1 700219 CONTACTOR, Pump (boom control) 1
R1B 701081 RESISTOR, Line 1K 1 10ACR2 108589 RELAY, 40 Amp (sevcontrol) 1
R19B 700800 RESISTOR, 2.2k 1 10CR1 108589 RELAY, 40 Amp seal (8m drive cutout) 1
S1 102600 SWITCH, Control circuit disconnect (S/N 90306 and below.) 1 10CR3 701078 CONTACTOR, Line 1
S2 103225 CONTACT BLOCK, N.C. (key switch) 2 10CR4 701236 RELAY, Charger interlock 1
103141 CONTACT BLOCK, N.O. (key switch) 2 15ACR 700218 CONTACTOR, Drive pump/motor 1
S3 103225 CONTACT BLOCK, N.C. (emergency stop switch) (platform) 1 16ACR 700218 CONTACTOR, Drive pump/motor 1
S4 103225 CONTACT BLOCK, N.C. (emergency stop switch) (base) 1 17ACR1 108589 RELAY, 40 Amp (steer) 1
S5 700187 FOOT SWITCH 1 17ACR2 108589 RELAY, 40 Amp (steer) 1
S6 700181 CONTROLLER, Boom function 1 30ACR 108589 RELAY, 40 Amp (leveling interlock) 1
S7 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1 21CR 108589 RELAY, 40 Amp (flashing light) (optional) 1
103141 CONTACT BLOCK, N.O. (boom up/down selector push-button switch) 1 26CR 700156 CONTACTOR, Brake pump/motor (S/N 90306 and below.) 1
S8 701524 CONTACT BLOCK SET W/1 N.O., Lighted push-button 1 27CR 108589 RELAY, 40 Amp (tilt) 1
103141 CONTACT BLOCK, N.O. (riser up/down selector push-button switch) 1 49CR 108589 RELAY, 40 Amp (horn) (optional) 1
81CR 108589 RELAY, 40 Amp seal (overload sensing) 1
AC1 700903 PRESSURE ACCUMULATOR, Brake (450 PSI) 1 RV1 700673 RELIEF VALVE, System (2600 PSI) 1
C1 700328 CYLINDER ASSEMBLY, Riser lift 1 RV2 700672 RELIEF VALVE, Turret rotation (900 PSI) 1
700452 KIT, Seal repair AR RV3 700672 RELIEF VALVE, Turret rotation (900 PSI) 1
C2 700332 CYLINDER ASSEMBLY, Boom lift 1 V1 103136 VALVE, Riser cylinder emergency lowering 1
700452 KIT, Seal repair AR V2 103136 VALVE, Boom cylinder emergency lowering 1
C3 700350 CYLINDER ASSEMBLY, Boom telescoping 1 V3 103136 VALVE, Emergency turret rotation 1
700455 KIT, Seal repair AR V4 701297 VALVE, Brake override 1
C4 700241 CYLINDER ASSEMBLY, Jib lift 1 V5 103136 VALVE, Jib cylinder emergency lowering 1
700456 KIT, Seal repair AR
C5 700333 CYLINDER ASSEMBLY, Platform levelling master 1
700454 KIT, Seal repair AR
C6 700388 CYLINDER ASSEMBLY, Platform levelling slave 1
700454 KIT, Seal repair AR
C7 700299 CYLINDER ASSEMBLY, Steer LH 1
700299 CYLINDER ASSEMBLY, Steer RH 1
700451 KIT, Seal repair AR
CB1-CB9 700568 COUNTERBALANCE VALVE (3000 PSI) 9
CB10 700670 COUNTERBALANCE VALVE (1800 PSI) 1
CB11 700670 COUNTERBALANCE VALVE (1800 PSI) 1
F1 704488 FILTER ASSEMBLY, Return 1
104254 ELEMENT, Filter AR
2H-21 700677 VALVE, Dump 1
3H-25 701298 VALVE, Brake 1
4H-13 701860 VALVE, Riser down (includes 4H-14) 1
4H-14 701860 VALVE, Riser up (includes 4H-13) 1
4H-23A 701861 VALVE, Right steer (includes 4H-24A) 1
4H-24A 701861 VALVE, Left steer (includes 4H-23A) 1
4H-30 701860 VALVE, Boom down (includes 4H-31) 1
4H-31 701860 VALVE, Boom up (includes 4H-30) 1
4H-32 701860 VALVE, Turret rotation clockwise (includes 4H-33) 1
4H-33 701860 VALVE, Turret rotation c-clockwise (includes 4H-32) 1
4H-34 701860 VALVE, Jib down (includes 4H-35) 1
4H-35 701860 VALVE, Jib up (includes 4H-34) 1
4H-36 701860 VALVE, Platform rotation left (includes 4H-37) 1
4H-37 701860 VALVE, Platform rotation right (includes 4H-36) 1
4H-38 701860 VALVE, Boom retract (includes 4H-39) 1
4H-39 701860 VALVE, Boom extend (includes 4H-38) 1
4H-40 701860 VALVE, Platform levelling down (includes 4H-41) 1
4H-41 701860 VALVE, Platform levelling up (includes 4H-40) 1
M1 700316 MOTOR, Turret rotation 1
704237 KIT, Seal Repair AR
O1 700679 ORIFICE, 0.100 diameter 1
O2 700680 ORIFICE, 0.060 diameter 1
O3 700682 ORIFICE, 0.025 diameter 1
O4 700682 ORIFICE, 0.025 diameter 1
P1 700669 PUMP, Hydraulic .194 ci/rev 1
PM1 700224 PUMP/MOTOR ASSEMBLY, Boom function 1
PR1 701296 PRESSURE REDUCING VALVE, Brake (650 PSI) 1
PS1 701194 PRESSURE SWITCH (off at 750 PSI) 1
RA1 700448 ROTARY ACTUATOR 1
701875 KIT, Seal repair AR
4H-31 CB-11
BOOM UP COUNTERBALANCE VALVE
VALVE 4H-34 4H-39
JIB DOWN BOOM TELESCOPE
4H-24A VALVE EXTEND VALVE PR1
LEFT STEER 4H-30 PRESSURE
VALVE BOOM DOWN REDUCING TO BRAKES
TO AC1
VALVE VALVE ACCUMULATOR
4H-37
PLATFORM ROTATION
4H-23A RIGHT VALVE TO PUMP
RV2 RIGHT STEER
2H-21 PRESSURE
RELIEF VALVE
VALVE DUMP VALVE
RV3
RELIEF
4H-32 VALVE
TURRET ROTATION 4H-33
CLOCKWISE VALVE TURRET ROTATION CAUTION - Brake system under pressure. Bleed pressure before servicing.
V3 C-CLOCKWISE VALVE
EMERGENCY TO PUMP
TURRET PRESSURE
ROTATION RETURN
VALVE TO TANK
TROUBLESHOOTING INFORMATION
TROUBLE PROBABLE CAUSE REMEDY
ELECTRICAL SYSTEM
4
3. 24V Disconnect Switch (S1) open 3. Close switch or replace if no continuity
or defective(S/N 90306 and below). reading.
7. Base Emergency Stop Switch (S3) 7. Check continuity thru switch, replace
open or defective. if defective.
9. Base Platform Select Switch (S2) 9. Check continuity thru switch, replace
defective. if defective.
All Controls 13. No power to wire #10 on line 13. Check wire #10 on line contactor
Inoperative (cont.) contactor (10CR3). (10CR3) for 24V with foot switch
depressed or base controls
selected. Repair as necessary.
4. Broken or loose wire #7C from (S5) 4. Check continuity. Replace if open.
to (S4) Emergency Stop.
Base Controls 1. Key Selector Switch (S2) open or 1. Check continuity. Replace if
Inoperative defective. defective.
Base Controls 7. Broken or loose #00 wire to battery 7. Check continuity. Replace if
Inoperative (cont.) plug. defective.
Down Circuit 1. Broken or loose 9A wire to switch (S8). 1. Check continuity. Replace if
Inoperative defective.
(Riser Only)
2. Defective switch (S8). 2. Check switch. If defective replace.
Telescope Out 4. Loose pin or broken wire #39 in boom 4. Check continuity. Replace if
Inoperative control cable. defective.
(cont.)
5. Defective coil (4H-39). 5. Check continuity. Replace if
defective.
Telescope In 1. Broken or loose 9E wire to switch (S9). 1. Check continuity. Replace if defective.
Inoperative
2. Defective switch (S9). 2. Check switch. Replace if defective.
Jib Down 1. Broken or loose 9A wire to switch (S10). 1. Check continuity. Replace if
Inoperative defective.
Platform Rotate 1. Broken or loose wires #11 or #11A. 1. Check continuity. Replace if
Left or Right defective.
Inoperative
2. Defective switch (S11). 2. Check switch. Replace if defective.
Turret Rotate 1. Broken or loose wires #11 or #11A. 1. Check continuity. Replace if
CW or CCW defective.
Inoperative
2. Defective switch (S13). 2. Check switch. Replace if defective.
Turret Rotate 4. Loose pin or broken wire #32 [CW] or 4. Check continuity. Replace if
CW or CCW #33 [CCW] in boom cable. defective.
Inoperative
(cont.) 5. Defective coil (4H-32) [CW] or 5. Check continuity. Replace if
(4H-33) [CCW]. defective.
Steering Does 1. Broken or loose wire #10 from D8 1. Check continuity. Replace if
Not Change diode to turret Switch (S22). defective.
Direction With
Boom Position. 2. Defective Turret Switch (S22). 2. Check switch. If defective replace.
Forward - Reverse 10. Broken or loose cable #1E from (F3) 10. Check continuity. Replace if
Drive Inoperative to contactor (15ACR) [R] or (16ACR) defective.
(cont.) [F].
12. Defective drive motor (DCM1). 12. Check motor. Replace if defective.
Forward - Reverse 1. Broken or loose #10 wire from 1. Check continuity. Replace if
Slow Speed Only terminal block (TB1) on base to lift defective.
Limit Switch (LS1).
Brake Not 1. Broken or loose wire #25 from drive 1. Check continuity. Replace if
Releasing Sevcon pin #1 to relay (26CR). defective.
(Serial # 90307
and above) 2. Defective relay (26CR). 2. Replace relay.
Brake Not 1. Broken or loose wire #25 from drive 1. Check continuity. Replace if
Releasing Sevcon pin #1 to relay (26CR). defective.
(Serial # 90306
and below) 2. Defective relay (26CR). 2. Replace relay.
10. Broken or loose wire #3B from 10. Check continuity. Replace if
(26CR) to motor (DCM2). defective.
12. Broken or loose wire #1B from 12. Check continuity. Replace if
motor (DCM2) to Battery Plug defective.
(BP1).
No Boom 1. Loose or broken wire #10A from 1. Check continuity, repair if defective.
Functions terminal B of Tachometer Card (TC1)
to pin #5 on Sevcon (SV2).
No Boom Functions 1. Loose or broken wire #8 from platform 1. Check continuity. Replace if
From Platform terminal block to Boom Function defective.
(Boom Operates Controller (S6).
from Base Controls)
2. Loose or broken wire #2 from platform 2. Check continuity. Replace if
terminal block to Boom Function defective.
Controller (S6).
NOTE: A Steady
Light on Drive
Sevcon Means
System is Ready
to Operate
2 Flash Fault 1. Selecting function before 1. Turn power on and operate foot
(Procedure power is on. switch before selecting function.
Fault)
2. Broken #2 wire at drive/steer 2. Check continuity. If defective
controller. replace.
6 Flash Fault No Drive 1. Broken #6 wire from drive/ 1. Check continuity. Replace if
steer controller (S21) to pin 14 defective.
on Drive Sevcon (SV1).
6 Flash Fault No Drive 3. Defective drive/steer control- 3C. Locate white/black wire on drive/steer
(cont.) (cont.) ler. controller board. Measure voltage at
(cont.) white/black wire with foot switch
depressed. It should read 2 volt DC.
If no voltage present replace
defective Potentiometer. If voltage
present replace defective Sevcon.
(Refer to Section 5 page 15)
11 Flash Fault 1. Tachometer Gen. defective. 1. Check output - 2.5 volts per 100
RPM.
2. Tachometer Gen. wires
reversed. 2. Switch wires at Tachometer Gen.
NOTE: A Steady
Light on Pump
Sevcon Means
System is
Ready to
Operate.
2 Flash Fault 1. Selecting function before 1. Turn power on and operate foot
(Procedure power is on. switch before selecting function.
Fault)
2. Broken #2 wire. 2. Check continuity. If defective
replace.
6 Flash Fault No Boom 3. Defective Boom Function 3C. Locate "Y" sig. terminal on Boom
(cont.) Functions Controller. Controller Board. Measure voltage
From (cont.) between "-" terminal and "Y" sig.
Platform terminal on Boom Controller Board
(cont.) with foot switch depressed. It should
read 2.2 to 2.5 DC volts. If no voltage
present replace defective Joy Stick.
If voltage present, move to step 3D.
6 Flash Fault No Boom 1. Loose or broken #19 wire from 1. Check continuity. Replace if
Function key switch to terminal block defective.
From Base (TB2) in base controls.
Controls
Only 2. Loose or broken #19 wire 2. Check continuity. Replace if
from key switch to pin #14 on defective.
Pump Sevcon (S2).
HYDRAULIC SYSTEM
No Boom 1. Dump Valve (2H-21) stuck open. 1. Inspect valve, replace if defective.
Functions
2. System Relief Valve (RV1) defective 2. Inspect valve, replace if defective.
or set low.
Up Circuit 1. Riser Up Valve (4H-14) not shifting 1. Clean valve and reinstall. Replace
Inoperative properly or contaminated. if defective.
(Riser Only)
2. Emergency lowering valve (V1) 2. Close valve.
open.
Down Circuit 1. Riser Down Valve (4H-13) not 1. Clean valve and reinstall. Replace if
Inoperative shifting properly or contaminated. defective.
(Riser Only)
2. Counter Balance Valve (CB1) not 2. Clean valve and reinstall. Replace if
shifting. defective.
2. Counter Balance Valve (CB1) open 2. Clean valve and reinstall. Replace
or defective. if defective.
Down Circuit 1. Boom Down Valve (4H-30) not 1. Clean valve and reinstall. Replace
Inoperative shifting properly or contaminated. if defective.
(Boom Only)
2. Counter Balance Valve (CB2) not 2. Clean valve and reinstall. Replace
shifting. if defective.
2. Counter Balance Valve (CB2) open 2. Clean valve and reinstall. Replace
or defective. if defective.
Boom Extend 1. Boom Extend Valve (4H-39) not 1. Clean valve and reinstall. Replace
Inoperative shifting properly or contaminated. if defective.
2. Counter Balance Valve (CB4) not 2. Clean valve and reinstall. Replace
shifting. if defective.
Boom Retract 1. Boom Retract Valve (4H-38) not 1. Clean valve and reinstall. Replace
Inoperative shifting properly or contaminated. if defective.
2. Counter Balance Valve (CB3) not 2. Clean valve and reinstall. Replace
shifting. if defective.
Jib Up 1. Jib Valve (4H-35) open or defective. 1. Clean valve and reinstall. Replace
Inoperative if defective.
2. Counter Balance Valve (CB6) not 2. Clean valve and reinstall. Replace
shifting. if defective.
Jib Down 1. Jib Down Valve (4H-34) open or 1. Clean valve and reinstall. Replace
Inoperative defective. if defective.
2. Counter Balance Valve (CB5) not 2. Clean valve and reinstall. Replace
shifting. if defective.
2. Counter Balance Valve (C5) open or 2. Clean valve and reinstall. Replace
defective. if defective.
Platform 1. Platform Rotate Right Valve (4H-37) 1. Clean valve and reinstall. Replace
Rotate Right not shifting or contaminated. if defective.
Inoperative
2. Counter Balance Valve (CB8) not 2. Clean valve and reinstall. Replace
shifting. if defective.
Platform 1. Level Up Valve (4H-41) not shifting 1. Clean valve and reinstall. Replace
Level Up or contaminated. if defective.
Inoperative
2. Orifice (O3) plugged. 2. Clean orifice.
Platform 1. Level Down Valve (4H-40) not 1. Clean valve and reinstall. Replace
Level Down shifting or contaminated. if defective.
Inoperative
2. Platform Master Leveling Cylinder 2. Reseal cylinder.
(C5) or (C6) by passing.
Turret 1. Turret Rotate Left [CW] Valve (4H- 1. Clean valve and reinstall. Replace
Rotate Left 32) not shifting or contaminated. if defective.
(Clockwise)
2. Relief Valve (RV3) set to low. 2. Adjust relief valve. Replace if
defective.
Turret 1. Turret Rotate Left [CCW] Valve (4H- 1. Clean valve and reinstall. Replace
Rotate Right 32) not shifting or contaminated. if defective.
(Counter Clockwise)
2. Relief Valve (RV2) set to low. 2. Adjust valve. Replace if defective.
No Steering 1. Steer Valve (4H-24A) or (4H-23A) 1. Clean valve and reinstall. Replace if
not shifting or contaminated. defective.
Brakes 1. Brake Valve (3H-25) not shifting. 1. Clean valve and reinstall. Replace if
Won't Release defective.
(Serial # 90307
and above) 2. By passing brake assembly. 2. Reseal brake assembly.
Brakes 1. Relief Valve (RV6) set to low or 1. Adjust relief valve. Replace if
Won't Release defective. defective.
(Serial # 90306
and below) 2. Brake Valve (3H-25) not shifting. 2. Clean valve and reinstall. Replace
if defective.
TABLE OF CONTENTS
2. Tolerance of working parts in the hydraulic 9. All hydraulic components must be disassembled
system is very close. Even small amounts of in spotlessly clean surroundings. During
dirt or foreign materials in the system can cause disassembly, pay particular attention to the
wear or damage to components, as well as identification of parts to assure proper
general faulty operation of the hydraulic system. reassembly. Clean all metal parts in a clean
Every precaution must be taken to assure mineral oil solvent. Be sure to thoroughly clean
absolute cleanliness of the hydraulic oil. all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
3. Samples of hydraulic oil should be drawn from surface for inspection.
the reservoir every six months. These samples
should be about two quarts and should be taken 10. Replace all o-rings and seals when overhauling
while the oil is warmed through normal operation any component. Lubricate all parts with clean
of the system. If possible, the sample should hydraulic oil before reassembly. Use small
be analyzed by a qualified lubrication specialist amounts of petroleum jelly to hold o-rings in
to determine whether it is suitable for further place during assembly.
use. The intervals between oil changes depend
on operating conditions and on the care used in 11. Be sure to replace any lost hydraulic oil when
keeping the oil clean. completing the installation of the repaired
component, and bleed any air from the system
4. Whenever there is a hydraulic system failure when required.
which gives reason to believe that there are metal
particles of foreign materials in the system, drain 12. All hydraulic connections must be kept tight. A
and flush the entire system and replace the filter loose connection in a pressure line will permit
cartridges. A complete change of oil must be the oil to leak out or air to be drawn into the
made under these circumstances. system. Air in the system can cause damage to
the components and noisy or erratic system
5. Whenever the hydraulic system is drained, operation.
check the magnets in the hydraulic reservoir for
metal particles. If metal particles are present, MAINTENANCE. Three simple maintenance procedures
flush the entire system and add a new change have the greatest effect on the hydraulic system
of oil. The presence of metal particles also may performance, efficiency and life. Yet, the very simplicity
indicate the possibility of imminent component of them may be the reason they are so often overlooked.
failure. A very small amount of fine particles is What are they? Simply these:
normal.
1. Change filters regularly.
6. DO NOT use synthetic or fire resistant oil in this
work platform. Use ATF Dexron III (ESSO) or 2. Maintain a sufficient quantity of clean hydraulic
equivalent hydraulic oil. For conditions causing oil of the proper type and viscosity in the
oil temperatures below -31F (-35 C) and above hydraulic reservoir.
122F (50 C) consult Skyjack, Inc.
3. Keep all connections tight.
CARTRIDGE VALVES
SIZE 08 38 58 10 12 16
COILS
SIZE 4 to 5
SAE PLUGS
SIZE 2 4 5 6 8 10 12 16
ft. lbs.
3 10 15 15 25 25 30 35
(max)
in. lbs.
36 120 180 180 300 300 360 400
(max)
MTWB-505
Table 5-2. Special Tools
DIAL INDICATOR SKYJACK PART 700592
WARNING
ADJUSTMENT PROCEDURE:
The following procedure is relevant for both the drive and pump controllers, except where otherwise noted. Both
controllers are preset to factory specifications but may be readjusted.
A hand-held calibrator (Figure 5-1, Skyjack part #701051) can be plugged into the controller adjustment socket and
used to digitally view or reset the parameters. The current value of these parameters will be shown on an LCD display.
Additionally, the calibrator can perform certain measurements that can be useful for diagnostic purposes.
The calibrator has a bar display, operated by the SELECT button, showing the parameters/ measurement selected and
an LCD display showing values that, provided they are parameters, may be adjusted using the +/- buttons.
This unit can also be used to perform certain tests on the control wiring and controller (joystick).
1. Remove electrical panel cover, located inside door on right side of machine.
2. Locate controller adjustment socket, as shown in Figure 5-2, and connect hand-held calibrator.
Power up the boom by selecting base or platform controls (foot switch must be engaged for platform controls
to be active) using key switch at electrical panel.
3. No LED segments on the bar display will be lit and the minutes/seconds count is displayed. The hours
count is displayed by pressing the (-) button and the 1000s of hours count is displayed by pressing the
(+) button as described later in this section. Pressing the select button reverts the calibrator to its normal
operation and the IMax LED will be lit.
4. When the desired parameters has been selected, on the left side of the calibrator, it may be adjusted by
pressing the + or - button on the right side of the calibrator. See Table 5-8. for adjustable parameters and
ranges.
5. When the calibrator is unplugged the Sevcontrol will memorize the new parameters settings.
Figure 5-1.
Front Back
Controller
Adjustment
Socket
Diagnostic LED
Drive Controller
Pump Controller
HOURS COUNTER:
The hours counter records pulsing hours, and is displayed when the calibrator is first plugged in. Once the SELECT
button is pressed, the calibrator reverts to normal operation.
Initially a minute/seconds count is displayed. By pressing the (-) button, hours are displayed
and by pressing the (+) button 1000s of hours are displayed.
Releasing the buttons reverts back to the minute/seconds display. The decimal point blinks every second during drive.
The counter will record up to 65,500 hours before rolling back to 0.
DIAGNOSTIC PROCEDURE:
WARNING
BATT Displays the current battery voltage. Pressing the (+) button displays the highest voltage,
for the machine, that the Sevcontrol has recorded.
MOTOR AMP Displays the motor current as the machine is being driven.
TEMP Displays the temperature of the MOSFET heat sink in C. Pressing the (+) button displays
the highest temperature recorded and pressing the (-) button displays the lowest
temperature recorded.
TEST This invokes the diagnostic test routines to check machine switches, joystick,
control wiring etc.
With the calibrator connected and the boom powered up, as described in the adjustment procedure. Use the SELECT
button to select the test segment. If the SELECT button is pressed at any time during the test, the test will be
terminated and the minute/seconds count will be displayed.
The first test displayed, for both drive and pump Sevcontrol, is the joystick input. This displays the input as 0-100% as
joystick is moved from min. to max.
Pressing the (+) and (-) buttons step through the tests as shown in Table 4-8. After the final test, the sequence will loop
back to the joystick input test, then test 1.
9 Not Used
10 Not Used
4 Not Used
5 Not Used
8 Not Used
9 Not Used
10 Not Used
Pin 1 - Brake contactor control. Brings B- through wire 25 to 26CR brake motor contactor in drive only.
Test between pin 1 and 10 wire (B+).
Pin 4 - Turret position. Determines where platform is in relation to base. Changes sequencing of 15ACR and 16ACR
contactors.
24 volts = platform over drive axle
0 volts = platform over steer axle
Test between pin 4 and 02 wire (B-).
Term B -24 volt output to boom pump motor, forward and reverse contactors, Pin 5 of traction and boom
Sevcons. From Term C through 20 Amp fuse on tachometer board. Wire 10A.
Test between term B and 02 wire (B-).
CAUTION
2. Locate tachometer generator on back of drive motor. Remove rubber boot from the rear of the tachometer
generator.
3. Mark the location of the wires attached to the generator and remove wires. NOTE: Wires must be reattached
to the same terminals as they were removed from or the Sevcon controller will not function when reassembled.
4. Remove the four 5/16-18 x 1-1/2" bolts securing the tachometer generator mounting plate to the rear of the
motor.
NOTE: Do not attempt to remove the tachometer generator from mounting plate until it has been determined to
be defective.
5. Remove the coupler half from the tachometer generator and attach generator to a drill with a 1000 RPM rating.
6. Attach a voltmeter to the terminals on the rear of the tachometer generator and set the meter for D.C. voltage.
7. Energize drill and read voltage on meter. At 1000 RPM you should read at least 20.8 volts. If reading is lower
than 20.8 volts, the tachometer generator is defective.
1. DRIVE AXLE
2. DRIVE MOTOR
3. COUPLER HALF
4. TACHOMETER GENERATOR MOUNTING PLATE
5. COUPLER HALF
6. TACHOMETER GENERATOR 6
5
3
All tests performed with foot switch depressed and voltages read between function and terminal on strip with wire 2.
Not used
Not used
All tests performed with foot switch depressed and joystick in neutral position.
5 volts
Wire 9
2.2 to 2.5 Volts
Wire 9A
Checking the adjustment of each brake on the rear axle requires the following procedure:
1. Chock the wheels to prevent the work platform from rolling when the brake is released. Remove the thumb
screws from the Rear Axle Cover and lift off to expose the rear axle.
2. Remove the Center Plug (17mm allen head) (Item #1) from each brake cover.
3. Starting with the left brake, insert the shaft of the Dial Indicator(Item #2, Skyjack part #700592) through the
hole in the brake cover and carefully tighten the gauge holder (clockwise) until no threads are exposed.
5. Locate the Parking Brake Release Hand Pump (refer to Section 2, Page 4). Follow the procedure to release the
parking brakes.
6. Read the Dial Indicator setting. The proper setting range is 1.8mm (0.080") to 2.2mm (0.085"). If the setting
is within this range, pull out the Brake Override Valve Plunger to engage the brakes, then perform the same
adjusting check on the right brake. Remove the Dial Indicator and reinstall Center Plug.
NOTE: If setting on either brake is not within the specified range, proceed to step 7.
7. Remove the Dial Indicator. Pull out the Brake Override Valve Plunger to engage the brakes. With a M19
socket and wrench, adjust the Actuator Shaft (Item #3) by tightening (clockwise) the Actuator Shaft Nut (Item
#4) to reach a lower setting or loosening (counterclockwise) the Actuator Shaft Nut (Item #4) to reach a higher
setting.
9. Repeat step 6. If setting is still not within the specified range, repeat steps 7 and 8 until setting is within
specified range.
NOTE: The brake will automatically return to normal operation when a drive function is selected.
4 Skyjack Part
2 No. 700592
WARNING
1. Bleed all brake pressure off by pumping the brake override valve 10 times, until system has no pressure.
(Fig. 5-9)
2. Install pressure gauge at the tee in the main brake line on the drive axle. (Fig. 5-10)
3. Lift drive axle off the ground so the drive wheels dont move the machine.
4. Engage drive slowly and check pressure gauge. It should read 650 psi.
5. If the pressure is low repeat step #1.
6. Remove the cap plug from pressure reducing valve using a 5/16 allen wrench. (Fig. 5-9)
7. Using an 3/8 allen wrench turn pressure reducing valve in a 1/4 of a turn. (Fig. 5-9)
8. Repeat steps #4, 5 & 7 until pressure reaches 650 psi.
9. Replace pressure reducing valve plug cap.
10. Repeat step #1.
11. Remove pressure gauge and connect brake lines.
12. Install pressure gauge at the test port between the brake manifold and the pressure switch. (Fig. 5-9)
13. Engage drive slowly and check pressure gauge. It should read 750 psi.
14. If the pressure is low repeat step #1.
15. Turn pressure switch body a 1/4 of a turn clockwise. (Fig. 5-9)
16. Repeat steps #13-15 until pressure reaches 750 psi.
17. Repeat step #1.
18. Remove pressure gauge.
19. Pressure adjustment BRAKE OVERRIDE VALVE
complete, lower machine V4
and test drive.
SYSTEM PRESSURE
TEST PORT
BRAKE VALVE
2H-?
STEP 12
PRESSURE TEST PORT
FOR ACCUMULATOR
PRESSURE (1000PSI)
BRAKE VALVE
3H-25
ADJUST PRESSURE
SWITCH UNTIL GAUGE
READS 750 PSI
A QUICK CONNECTION
PORT IS PROVIDED
BETWEEN THE
MANIFOLD AND THE
PRESSURE SWITCH
STEP 2
PRESSURE GAUGE
NOTE
The brake pump/motor should not run continuously while driving. The brake pressure switch (PS1) should signal the
pump/motor to run when the hydraulic pressure drops to about 250 PSI. It should shut off at 350 PSI. Both relief
valves (RV6 & RV7) should be set at 425 PSI. Before the pressure switch can be adjusted, both valves must be set
correctly.
1. Tee a 0-1000 PSI pressure gauge into either one of the brake lines going to the axle.
2. Push down on the brake override valve (black knob) located on the brake manifold.
3. Using the hand pump (red knob) on the brake manifold, pump up the brakes and adjust the relief valve (RV7)
to 425 PSI.
4. Connect one lead of the remote starter switch to wire #25 on the brake motor contactor located behind the
lower control panel on the turret. Connect the other lead to wire #2 on the circuit breaker (CB3).
6. Turn the black knurled knob on the pressure switch (PS1) clockwise 1 full turn.
7. Push and hold the remote starter switch button. The pump/motor should run. Adjust the relief valve (RV6)
located on the pump to 425 PSI.
8. While cycling the remote starter switch on and off, turn the knurled knob on the pressure switch (PS1) counter
clockwise until pump/motor shuts off at 350 PSI.
9. Remove gauge from brake line and test brakes for proper operation.
8
6 3
2
7
1
3
I.D. 3/16" 1/4" 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 3-1/2" 4"
GENERAL
The information contained in this section is designed to of the parts list. Descriptions preceded with an ()
aid the user in locating and identifying replacement parts. indicates a serviceable component or attaching hardware
Component parts of various assemblies and for the higher level assembly.
subassemblies comprising the work platform are illustrated
and accompanied by a descriptive parts list. Exploded
QUANTITIES (Units per Assy.)
drawings are used to show relative location of component
The quantities of each part that are required to complete
parts in disassembly order. If a part cannot be found in
the assembly. If quantity is (AR), it is understood that
this section, order by work platform model number and
the quantity may vary when machine is equipped with
serial number, giving a complete description of the part.
certain options. Order quantity as needed.
CUSTOMER___________________________________________________________________
DEALER______________________________________________________________________
6
DATE PURCHASED ____________________________________________________________
Description Page
Description Page
18
19
19
18
16 17
12 5
2
1
13
21
20
4
6 7 8 9
10
15 11
14
MA-SJB-01
18
19
19
18
16 17
12 5
2
1
13
21
20
4
6 7 8 9
10
15 11
14
MA-SJB-01
9 3
2
12
4
14
13 17
10
11
1 16
15
MA-SJB-02
SECTION 6, Page 8 SJKB-33N
FIGURE 6-2. OPERATORS CONTROL CONSOLE ASSEMBLY
(Machines with Serial Number 90242 and above)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
9 3
2
12
4
14
13 17
10
11
1 16
15
MA-SJB-02
9 3
4
12
14
8
7
5
13 18
10
11
16
17
15
MA-SJB-02
9 3
4
12
14
8
7
5
13 18
10
11
16
17
15
MA-SJB-02
SECTION 6, Page 14 SJKB-33N
FIGURE 6-3. OPERATORS CONTROL CONSOLE ASSEMBLY
(Machines with Serial Number 90241 and below)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
Parts list continued from Page 13.
10 103057 BEEPER, 24 Volt 1
11 103012 BLOCK, Terminal 2 1/2
700818 SCREW, Machine #8-32x3/4lg. 5
103986 NUT, #8-32 5
12 700093 LABEL, Control console, A, B 1
701472 LABEL, Control console, C 1
13 108589 RELAY, Sealed 40 Amp 1
103962 SCREW, Machine #10-32 x 1/2 lg. 1
104694 WASHER, Flat #10 1
104185 WASHER, Lock #10 1
104003 NUT, #10-32 1
14 102956 PLUG, Snap-in 7/8 dia. 1
15 (Ref.) CABLE ASSEMBLY, Foot switch 1
103256 CORD, Foot switch 18/2 30
103036 RELIEF, Strain 1
(Ref.) CONNECTOR ASSEMBLY, 5 Pole female 1
(For components, refer to Figure 6-5.)
(Ref.) CONNECTOR ASSEMBLY, 4 Pole female 1
(Machines with Serial Number 90014 and below only.
For components, refer to Figure 6-5.)
16 (Ref.) CONNECTOR ASSEMBLY, 32 Pole male 1
(For components, refer to Figure 6-4.)
17 700189 CABLE ASSEMBLY, Control 1
700162 CABLE, Control 18/30 30
103365 RELIEF, Strain 1
(Ref.) CONNECTOR, 28 Pole male 1
(Machines with Serial Number 90014 and below only.
For components, refer to Figure 6-5.)
18 102929 CLAMP, Hose G-8 Single 2
2
6
1
4
8
10
7
9
MA-SJB-03
1 2
3 4
MA-BOE-11
4
6
3
2
5 8
7
1
11 12
9
13
10
14
MA-SJB-04a
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
702406 CONTROLLER ASSEMBLY, Drive/steer
(Machines with Serial Number 90411 and above) -
700180 CONTROLLER ASSEMBLY, Drive/steer
(Machines with Serial Number 90410 and below) -
1 700833 GRIP ASSEMBLY, Controller 1
2 105733 SWITCH, Steer 2
3 105733 SWITCH, Trigger 1
4 105734 ACTUATOR, Rocker 1
5 700958 PIN, Rocker actuator 1
6 105735 CAP, Elastic 1
7 700953 GRIP HALF, Threaded 1
8 700954 GRIP HALF 1
9 700955 TRIGGER ASSEMBLY 1
700956 SPRING, Trigger 1
10 $ BASE ASSEMBLY, Controller 1
(Order Controller Assembly.) 1
11 700957 BOOT, Controller handle 1
12 701241 GASKET, Controller mounting
(Machines with Serial Number 90411 and above) 1
700959 GASKET, Controller mounting
(Machines with Serial Number 90410 and below) 1
13 700834 CONTROLLER BOARD, Drive/steer 1
14 700835 POTENTIOMETER ASSEMBLY 1
700836 KIT, Assembly hardware 1
SJKB-33N SECTION 6, Page 19
FIGURE 6-7. DRIVE/STEER CONTROLLER ASSEMBLY
(Machines with Serial Number 90151 and above with factory installed horn option.)
5 7
6
2 3
4 9
1
13
12
8
10
14
11
15
MA-SJB-04b
3
5
2
6
MA-SJB-05
2 7
8 9
10
12
4
5
11
6
11
14
1 13
3
MA-SJB-06
19
15
17
18 16
13
4
14
10
11
9
5
3
8
6
2
12
14
MA-SJB-07
12
13
14
15
11
10
4
1
6
3
7
5
9
2
8
11
MA-SJB-08
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
23
6
9
7
8 10
2
5
4
12
11
18 13
14
15
19
20
24
17 16
21
22
MA-SJB-09
SECTION 6, Page 28 SJKB-33N
FIGURE 6-12. BOOM ASSEMBLY (Main and Telescopic Section)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
23
6
9
7
8 10
2
5
4
12
11
18 13
14
15
19
20
24
17 16
21
22
MA-SJB-09
17
16
15
17
13
18
14
9 1
4
11
6
12
10
5
8
3
7
13
14
MA-SJB-10
SECTION 6, Page 32 SJKB-33N
FIGURE 6-13. BOOM TELESCOPING CYLINDER ASSEMBLY
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
7
18
17
2 5 1
4
9
3
14
11
12
13
16 8
4
10
16
15
MA-SJB-11
14
15 16
18
17
1
13
10
9
4
12
6
5
8
11
3
13
2 7
MA-SJB-12
SECTION 6, Page 36 SJKB-33N
FIGURE 6-15. RISER LIFT CYLINDER ASSEMBLY
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
17
15
18
16
19
14
12
9
4
11
6
13
5
8
10
3
7
14
MA-SJB-13
SECTION 6, Page 38 SJKB-33N
FIGURE 6-16. BOOM LIFT CYLINDER ASSEMBLY
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
12
11
13
5
4
6
8
10 3
7
9
2
11
MA-SJB-14
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
3
15
2
19
10
5
6
6
14
16
4
11
1
5
14
12
7
17
8
13
18
MA-SJB-15
18
4
19
14
21
22
16
31
30
17
7
20
5
2
3
24
11
13
12
26
25
23
27
1
8
15
29
28
10
32
MA-SJB-16a
18
4
19
14
21
22
16
31
30
17
7
20
5
2
3
24
11
13
12
26
25
23
27
1
8
15
29
28
10
32
MA-SJB-16a
18
19
4
21
14
22
16
7
17
2
3
5
20
11
24
13
26
12
23
1
8
25
6
15
10
27
MA-SJB-16
SECTION 6, Page 48 SJKB-33N
FIGURE 6-20. TURRET ASSEMBLY
(Machines with Serial Number 90306 and below.)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
18
19
4
21
14
22
16
7
17
2
3
5
20
11
24
13
26
12
23
1
8
25
6
15
10
27
MA-SJB-16
SECTION 6, Page 50 SJKB-33N
FIGURE 6-20. TURRET ASSEMBLY
(Machines with Serial Number 90306 and below.)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
Parts list continued from page49.
14 111135 PAD, Riser rest 2
103606 NUT, Hex 3/8-16 2
103999 WASHER, Lock 3/8 2
103472 WASHER, Flat 3/8 2
15 700224 PUMP/MOTOR ASSEMBLY, Boom function 1
700669 PUMP, Hydraulic 1
103073 FITTING, Elbow 90 #6orb-#6 1
700524 FITTING, Hose barb 90 #12orb-#8 1
103032 HOSE, 3/4 suction 4
106052 COUPLING 1
700668 MOTOR, 48 Volt 1
109174 BRUSH SET 1
109175 SPRING, Brush 8
103887 BOLT, Hex-hd 5/16-18 x 3/4 lg. 4
103996 WASHER, Flat 5/16 8
103404 WASHER, Lock 5/16 4
700523 BUSHING, Rubber 4
102972 CLAMP, Hose G-8 1
103632 SCREW, Self tap. 1/4-14 x 3/4 lg. 1
16 (Ref.) MANIFOLD ASSEMBLY, Main 1
(For components, refer to Figure 6-22.)
103871 BOLT, Hex-hd 3/8-16 x 1-3/4 lg. 4
103999 WASHER, Lock 3/8 4
103472 WASHER, Flat 3/8 4
17 700325 TANK ASSEMBLY, Hydraulic 1
(For components, refer to Figure 6-24.)
104606 NUT, Hex 3/8-16 3
103999 WASHER, Lock 3/8 3
103472 WASHER, Flat 3/8 3
18 700149 PANEL ASSEMBLY, Electrical 1
(For components, refer to Figure 6-28.)
103980 NUT, Hex 1/4-20 8
104000 WASHER, Lock 1/4 4
19 700213 PANEL ASSEMBLY, Sevcon 1
(For components, refer to Figure 6-28.)
100397 NUT, Hex 5/16-18 3
103404 WASHER, Lock 5/16 3
20 700532 SWITCH, Tilt 1
114866 FUSE, 250 Volt, 1 amp 1
103855 BOLT, Hex-hd 1/4-20 x 1/2 lg. 4
104000 WASHER, Lock 1/4 4
21 700445 WELDMENT, Electrical panel cover bracket 1
22 700475 PANEL COVER, Electrical 1
700624 NUT, Wing 1/4-20 2
103995 WASHER, Flat 1/4 2
23 700605 PROTECTOR, Cable 12 lg. 1
24 700160 SWITCH, Sealed limit (riser) 1
700549 BOLT, Soc-hd #10-32 x 3/4 lg. 2
104694 WASHER, Flat #10 2
104185 WASHER, Lock #10 2
25 102860 HORN, 24 Volt (OPTION) 1
26 701248 CABLE ASSEMBLY, Pump motor (pos) 1
27 701249 CABLE ASSEMBLY, Pump motor (neg) 1
7
17
8
11 14
1
16
13
10
17
12
16
15
2 3
4
5
8 9
MA-SJB-17a
17
18 19 8
16 7 11 14
1 13
16
10
17
12
16
15
2 3
4
5
8 9
6 3
7 8
MA-SJB-18a
6 3
7 8
MA-SJB-18
15
14
13
5
17
16 4
1
2
12 3
10
11
7
6 9
2 1
6
12
13
4 3
10
5
7
11
14
MA-SJB-19
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
700837 PANEL ASSEMBLY, Sevcon -
1 700216 PLATE, Base 1
2 700214 CONTROLLER, Pump 1
701082 RESISTOR ASSEMBLY, 2.2k - 3w 1
3 700990 CONTROLLER, Drive 1
4 102756 FUSE, 200 Amp pump 1
5 700228 FUSE, 300 Amp drive 1
6 700219 CONTACTOR, Pump (boom control) 1
7 700218 CONTACTOR, Directional 2
8 700222 FUSE HOLDER, Double 1
110855 FUSE, AGC 10 2
9 108589 RELAY, Sealed 40 Amp 1
10 700217 TACHOMETER BOARD 1
701080 RESISTOR, 2.2 K 1
700776 FUSE, 250 Volt, 6.3 Amp 1
700777 FUSE, 250 Volt, 20 Amp 1
11 700991 MOUNT PLATE, Tachometer board 1
12 701078 LINE CONTACTOR 1
701081 RESISTOR ASSEMBLY, 1k - 5w 1
701291 BRAIDED CABLE, 10 lg. 1
700220 BRAIDED CABLE, 7 lg. 3
700229 BRAIDED CABLE, 5 lg. 2
701083 CABLE ASSEMBLY, Line contactor to fuse 1
13 700963 CABLE/CONNECTOR ASSEMBLY 1
14 700925 HANDLE, Disconnect 1
SJKB-33N SECTION 6, Page 59
FIGURE 6-27. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY
(Machines with Serial Number 90307 and above.)
9 2
26
10 21
22
5 8
24
23 19
18 15
25
16
11
12
13
17
20 14
MA-SJB-20a
10 8
11
23
20 24 6 9
26
17
25
21
12 18
13
14 16
19
22
15
MA-SJB-20
SECTION 6, Page 62 SJKB-33N
FIGURE 6-28. BASE CONTROL/ELECTRICAL PANEL ASSEMBLY
(Machines with Serial Number 90306 and below.)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
23
20
33
21
22
30
4
29
7 15
2
9
26
14
27 13
5 10
16
1
8
25
11 12 6
28
31
19
17
24
18
32
MA-SJB-21
SECTION 6, Page 64 SJKB-33N
FIGURE 6-29. BASE, AXLES AND WHEELS
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
23
20
33
21
22
30
4
29
7 15
2
9
26
14
27 13
5 10
16
1
8
25
11 12 6
28
31
19
17
24
18
32
MA-SJB-21
SECTION 6, Page 66 SJKB-33N
FIGURE 6-29. BASE, AXLES AND WHEELS
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
9 10
6 5
16
8
4 13
18
16
17 3
12
2
11
15
14
MA-SJB-22
4
1
3
10
7
13
5
12
6 11
8
MA-SJB-23
3
6 2
13
14
12 10
8 5
1 11
4
MA-SJB-24
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
8 9
7 6 5
2
4
1
3
MA-SJB-25
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
17
11
21
9 13
4
15
14 19
5 8
3 1
2
10
7 6
12
18
16
20
MA-SJB-26
SECTION 6, Page 74 SJKB-33N
FIGURE 6-34. BATTERY CHARGER ASSEMBLY
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
$ Consult factory.
17
16
15
13
18
5 8 17 28
3 19
2
6
4
1
14
20
12
9 10
16
21
11
7
26
14
22 25
12 23
27
14
29
24
MA-SJB-27a
17
14
16
15
13
18
6
2
3 16
4 19
1 8
20
12
11
5
10
MA-SJB-27
SECTION 6, Page 78 SJKB-33N
FIGURE 6-36. HYDRAULIC HOSE CONNECTIONS - Turret/Base
(Machines with Serial Number 90306 and below)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
7
5
4
6
3
MA-SJB-29
77
76
72 78
80
81 75
71 79
28 29 45
26
27
30
31 64 65
35
34 33 67 68
36 74 69
25 22
17 19 66
40
43 44 82 37 16 12
32 27
42 70
47 26 13 10
45 23
11
63 24 21
7
27 18
26 20
54
73 15 14
55 2
9
38 8
41 39
62
1
46 6
61 5
48 4
50 58
60 3
49 56
53 59
51 57
52
MA-SJB-31
SECTION 6, Page 82 SJKB-33N
FIGURE 6-38. DRIVE AXLE (Haessler)(Machines with Serial Number 90409 and above, except for 90415 and 90416)
Units Units
Index Skyjack Description Index Skyjack Description
per per
No. Part No. 1 2 3 4 5 6 7 No. Part No. 1 2 3 4 5 6 7
Assy. Assy.
7 13
15
18
19
14
20
12 6
5 7
11
3
4
17
9
21
2
1
10
16
MA-SJB-30
SECTION 6, Page 84 SJKB-33N
FIGURE 6-39. DRIVE AXLE (Sige) (Serial Number 90408 and below)
Units
Index Skyjack Description
per
No. Part No. 1 2 3 4 5 6 7 Assy.
2 6
1
MA-WB-18a
$ Consult factory
4
6
1
MA-WB-18b
Index Skyjack Description Units
No. Part No. per
1 2 3 4 5 6 7 Assy.
$ Consult factory
700816 707991 707646 707409 708589 707993 707420 708675 708742 KIT, Service labels and nameplates -
(Consists of items 1-26.)
1 700026 707429 707495 702973 708042 707561 700026 708109 708176 LABEL, Danger 1
2 700028 708569 708567 708566 708575 708568 707734 708576 708577 LABEL, Design standards 1
3 700032 707433 707499 702983 708046 707565 700032 708113 708180 LABEL, Attached safety belt (large) 1
4 700035 707435 707501 702978 708048 707567 700035 708115 708182 LABEL, Annual inspection 1
5 700473 707439 707505 702981 708052 707571 700473 708119 708186 LABEL, Check battery level daily (on battery tray lid) 2
6 700107 707437 707503 702964 708050 707569 700107 708117 708184 LABEL, Attach safety belt (small) 2
7 700108 707438 707504 702980 708051 707570 700108 708118 708185 LABEL, Do not lift here 2
8 700551 707440 707506 702984 708053 707572 700551 708120 708187 LABEL, Warning hazards 2
9 110333 707427 707493 702965 708040 707559 110333 708107 708174 LABEL, AC supply (on plate below outlet) 1
10 108666 707426 707492 702975 708039 707558 108666 708039 708173 LABEL, Use original parts 1
11 106691 707424 707490 702977 708037 707556 106691 708104 708171 LABEL, Operators checklist 1
12 700029 707431 707497 702976 708044 707563 700029 708111 708178 LABEL, Tie down 2
13 106705 707425 707491 702963 708038 707557 106705 708105 708172 LABEL, Do not alter 3
14 701086 707443 707509 702962 708056 707575 701086 708123 708190 LABEL, Jib emergency lowering 1
15 701114 707445 707511 702961 708058 707577 701114 708125 708192 LABEL, Manual rotate valve (on turret vertical plate near manual rotate valve.) 1
16 701111 707444 707510 702967 708057 707576 701111 708124 708191 LABEL, Manual brake release (S/N 90307 and above)(on turret vertical plate near brake release) 1
113846 LABEL, Manual brake release (S/N 90306 and below)(on turret vertical plate near brake release) 1
17 700033 707434 707500 702966 708047 707566 700033 708114 708181 LABEL, Lead warning 1
18 701085 707442 707508 702974 708055 707574 701085 708122 708189 LABEL, Charger 1
19 700031 707432 707498 702979 708045 707564 700031 708112 708179 LABEL, Capacity 500 lbs. 2
20 700096 707446 707512 706726 708059 707578 701469 708126 708193 LABEL, Emergency lowering 2
21 117294 707428 707494 706860 708041 707560 117294 708108 708175 LABEL, Manual enclosed (Manual Enclosure) 1
22 702005 707451 707517 702969 708064 707583 702005 708131 708198 LABEL, Danger brake release (on turret vertical plate near brake release) 1
23 703727 707472 707538 706257 708084 707604 703727 708151 708218 LABEL, ATF only (on hydraulic tank) 1
24 701814 707450 707516 702968 708063 707582 701814 708130 708197 LABEL, Main disconnect (S/N 90307 and above) 1
700027 LABEL, Main disconnect (on plate above switch)(S/N 90306 and below.) 1
25 707447 707513 702972 708060 707579 701470 708127 708194 LABEL, Knob location Europe (on turret vertical plate near knob) 1
26 117023 117023 117023 117023 117023 117023 117023 117023 LABEL, CE Approval 3
27 700025 700025 700025 700025 700025 700025 700025 700025 700025 LABEL, Skyman 2
28 102631 102631 102631 102631 102631 102631 102631 102631 102631 LABEL, Skyjack 4
29 708016 708016 708016 708016 708016 708016 708016 708016 708016 LABEL, Made in USA 2
30 103125 103125 103125 103125 103125 103125 103125 103125 103125 LABEL, Blue/white striping 389
31 700034 700034 700034 700034 700034 700034 700034 700034 700034 LABEL, SJKB-33N 2
32 700030 700030 700030 700030 700030 700030 700030 700030 700030 LABEL, Serial number nameplate (Consult factory) 1
33 700093 701472 701472 701472 701472 701472 701472 701472 701472 LABEL, Control box 1
34 700094 708570 708570 708570 708570 708570 708570 708570 708570 LABEL, Electrical panel 1
35 708838 708836 708835 708839 708837 707736 708840 708841 LABEL, European load 1
1
4
8 20
21
10
35 2 11
12 26 9
26 29 13 28
28 14 13 34 26 29
6 27 33
16 22
25
20
5 23
30
27
15
18
27 17 30
13 24
19
7 31 19 7 31
32 12
MA-SJB-28