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Table of Contents
Section 3 – Schematics
Table of Contents
Section 4 – Troubleshooting
Table of Contents
Section 5 – Procedures
Table of Contents
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.
Tables
Table 1.1 Owner’s Annual Inspection Record............................................................................................................10
Table 1.2 Pre-Delivery / Maintenance Inspection Checklist.......................................................................................11
Operator’s Responsibility for Contact the SKYJACK Service Department for warranty
statement extensions or exclusions
Maintenance
SKYJACK is continuously improving and expanding
Operator Safety Reminders, Warnings, and
product features on its equipment; therefore, Precautions
specifications and dimensions are subject to change Operator safety is SKYJACK’s priority. The operator
without notice. should comply with all applicable safety-related
reminders, warnings and precautions found in the
Aerial Platform Definition Operating Manual. It should be read and understood
An Aerial platform is a mobile device that has an completely before operating the aerial platform.
adjustable position platform supported from ground
level by a structure. Maintenance and Inspection Schedule
The actual operating environment of the work platform
Purpose of Equipment governs the use of the maintenance schedule. The
The SKYJACK Rough Terrain Compact Series inspection points covered in Table 1.2 Maintenance
aerial platforms are designed to transport and raise and lnspection Checklist, indicates the areas of the
personnel, tools and materials to overhead work aerial platform to be maintained or inspected and at
areas. what intervals the maintenance and inspections are to
be performed.
Use of Equipment
Owner’s Annual Inspection Record
The aerial platform is a highly maneuverable, mobile
work station. Work platform elevation and elevated It is the responsibility of the owner to arrange quarterly
driving must only be done on a firm, level surface. and annual inspections of the aerial platform. Table 1.1
It can be driven over uneven terrain only when the Owner’s Annual lnspection Record is to be used for
platform is fully lowered. recording the date of the inspection, owner’s name,
and the person responsible for the inspection of the
Product Manuals work platform.
The Operating Manual is considered a fundamental
part of the aerial platform. It is a very important way to Replacement Parts
communicate necessary safety information to users Use only original replacement parts. Parts such
and operators. A complete and legible copy of this as batteries, wheels, railings, etc. with weight and
manual must be kept in the provided weather-resistant dimensions different from original parts will affect
storage compartment on the aerial platform at all stability of the work platform and must not be used
times. without manufacturer’s consent.
The Service Manual provides the customer with the Use only original filled tires for models which must be
servicing and maintenance procedures essential for so equipped. Consult factory.
the promotion of proper machine operation for its
intended purpose. All replacement tires must be of the same size and
load rating as original equipment to maintain safety
All information in this manual should be read and and stability of the work platform. Consult factory.
understood before any attempt is made to service the
machine. This manual may be revised after printing, so
WARNING
for the very latest issue go to the company’s website
at: www.skyjack.com. Any aerial platform that is damaged or not
operating properly must be immediately tagged
Service Policy and Warranty and removed from service until proper repairs are
SKYJACK warrants each new SJRT Compact Series completed.
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.
• All tools, supports and lifting equipment to be 1. Any structure has limits of strength and durability.
used must be of proper rated load and in good To prevent failure of structural parts of hydraulic
working order before any service work begins. components, relief valves which limit pressure to
Work area should be kept clean and free of safe operating values are included in the hydraulic
debris to avoid contaminating components while circuits.
servicing.
2. Tolerance of working parts in the hydraulic system
• All service personnel must be familiar with is very close. Even small amounts of dirt or foreign
employer and governmental regulations that apply materials in the system can cause wear or damage
to servicing this type of equipment. to components, as well as general faulty operation
of the hydraulic system. Every precaution must
• Keep sparks and flames away from all flammable be taken to assure absolute cleanliness of the
or combustible materials. hydraulic oil.
• Properly dispose of all waste material such as 3. Whenever there is a hydraulic system failure
lubricants, rags, and old parts according to the which gives reason to believe that there are metal
local law provisions in the country of operation. particles or foreign materials in the system, drain
and flush the entire system and replace the filter
• Before attempting any repair work, turn Battery cartridges. A complete change of oil must be
Disconnect Switch to the OFF position. made under these circumstances.
Preventive maintenance is the easiest and least 4. Whenever the hydraulic system is drained, check
expensive type of maintenance. 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.
Tables
**
1000AB
This decal is located on the scissor assembly. 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.
Pictorial Description
Inspection Date
Inspector Signature
**
Model:
Date/Time:
Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to the
applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection Intervals, etc.).
Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided.
Comments:
The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner. Furthermore, the
undersigned confirms that all discrepancies have been corrected prior to using this machine.
Limit Switch
Limit Switch
Outriggers
Outriggers
Base
Base Control
Console
Tilt Sensor
Main Power
Disconnect Switch
Radiator
Hydraulic Pump
Fuel Shut-off
Valve
Battery
• Always return manuals to the manual storage 1. Main Power Disconnect Switch (B)
box after use.
• Turn main power disconnect switch to off
1.1-2 Labels (B) position.
Refer to the labels section in the operating manual and • Ensure all cables are secure and switch is in
determine that all labels are in place and are legible. proper working condition.
Base Control
Console
Tilt Sensor
Main Power
Disconnect Switch
Radiator
Hydraulic Pump
Fuel Shut-off
Valve
Battery
WARNING WARNING
Risk of explosion. Keep flames and sparks away Risk of equipment failure. Use original or
from batteries. Do not smoke near batteries. manufacturer-approved parts and components for
the aerial platform.
Battery electrolyte is an acid that can cause severe 5. Hydraulic Pump (B)
burns to exposed skin. Wear proper eye and
facial protection as well as appropriate protective • Ensure there are no loose or missing parts and
clothing. If contact occurs, flush with cold water there is no visible damage.
and seek medical attention immediately. • Ensure all bolts are properly tightened.
• Ensure all fittings and hoses are properly
• Check battery case for damage. tightened and there is no evidence of hydraulic
leakage.
• Inspect batteries frequently. Clean battery
terminals and cable ends thoroughly with a 6. Radiator (B, C)
terminal cleaning tool or wire brush.
• Make sure all battery connections are tight. If
WARNING
applicable, check battery electrolyte fluid level
frequently. Risk of burns to exposed skin. Beware of hot
liquids and radiator components. Allow the engine
• Make sure electrolyte level covers the plates by
to cool before performing any maintenance.
at least 1/2 in. (13 mm) of solution. Use distilled or
demineralized water only.
• Ensure radiator is secure.
• Replace battery if damaged or incapable of
holding a lasting charge. • Ensure there are no loose or missing parts and
there is no visible damage.
Base Control
Console
Tilt Sensor
Main Power
Disconnect Switch
Radiator
Hydraulic Pump
Fuel Shut-off
Valve
Battery
• Check coolant level and add as needed. 11. Engine Air Filter (B, C)
• For recommended coolant change interval, refer • Ensure there are no loose or missing parts and
to engine manual. there is no visible damage.
7. Muffler and Exhaust (B) • For engine air filter maintenance procedure,
refer to engine manual.
• Ensure muffler and exhaust system are properly • For engine air filter replacement procedure, refer
secured, with no evidence of damage. to engine manual.
8. Engine Tray (B) 12. Fuel Leaks (B, C)
• Ensure there are no loose or missing parts and • Ensure there are no fuel leaks.
no visible damage to the engine tray.
• Ensure that fasteners/bolts/pins/latches are in WARNING
place.
Engine fuels are highly combustible. Inspect fuel
9. Engine Oil (B, C) system in a well ventilated area away from heaters,
sparks and flames to avoid the risk of explosion.
• Maintaining the engine components is essential Fuel leaked onto hot surfaces can cause a fire.
to good performance and service life of the Always have an approved fire extinguisher within
aerial platform. easy reach.
• Check oil level on dipstick.
• Ensure fuel pump, fuel filter, hoses and fittings
• Oil level should be between the L and H marks show no visible damage and no evidence of fuel
on the dipstick. leakage.
• For recommended oil change interval, refer to • For engine fuel filter replacement procedure,
engine manual. refer to engine manual.
10. Fuel Shut-off Valve (B) IMPORTANT
• Ensure there are no loose or missing parts and Close engine compartment before operating. Push
there is no visible damage. it in until the two latches lock to base.
Gear Type
Hydraulic
Flow Divider
Oil Filter
Oil Level
Gauge
Fuel Level
Main Gauge
Manifold
Hydraulic
Tank Fuel Tank
Fall Protection
Manuals Anchorage
Platform
Railing
Platform Control
Console
Platform
Assembly
• Ensure there are no loose or missing parts and • Ensure outlet has no visible damage and free
there is no visible damage. from dirt or obstructions.
3. Platform Control Console (B)
1.1-6 Platform Assembly
• Ensure all switches and controller are returned
CAUTION to neutral and are properly secured.
• Ensure there are no loose or missing parts and
Risk of slipping or falling. Always maintain three
there is no visible damage.
points of contact when mounting and dismounting
the platform.
CAUTION
• Use the ladder of aerial platform to access Risk of slipping or falling. Always maintain three
platform. points of contact when mounting and dismounting
• Close the gate. the platform.
• Ensure there are no loose or missing parts and
there is no visible damage. • Use the ladder to dismount from platform.
• Ensure all fasteners are securely in place.
4. Extension Deck (If Equipped) (B)
• Ensure all railings are properly positioned and
secured. • Ensure assembly is securely attached to the
• Ensure gate is in good working order. bottom of the platform.
• Ensure there are no loose or missing parts and
1. Fall Protection Anchorage (B) there is no visible damage or leaks.
Lift Cylinder
Maintenance
Support
Scissor Assembly
Scissor Bumper
Roller
Lift Cylinder
Maintenance
Support
Scissor Assembly
Scissor Bumper
Roller
• No rust.
Pin retainer bolts
• Pin has not rotated. in place
• Area is clear of dust/metal shavings.
• Pin retainer and retainer bolts are in place.
Lift Cylinder
Maintenance
Support
Scissor Assembly
Scissor Bumper
Roller
Overhead View
Steer Cylinder
Base Assembly
Weldment
Splitter Manifold
Wheel/Tire
Assembly
Tie Rod
Emergency Lowering
Access Rod
Overhead View
Steer Cylinder
Base Assembly
Weldment
Splitter Manifold
Wheel/Tire
Assembly
Tie Rod
Emergency Lowering
Access Rod
• Ensure steer cylinder assembly is properly • Ensure there are no loose or missing parts and
secured, there are no loose or missing parts, all there is no visible damage.
fittings and hoses are properly tightened and
there is no evidence of hydraulic leakage. 8. Outriggers (If Equipped) (B)
5. Splitter Manifold (B, C) • Ensure there are no loose or missing parts and
there is no visible damage.
• Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic 9. Emergency Lowering Access Rod (B)
leakage.
• Ensure rod is properly secured and there is no
• Ensure there are no loose wire connections or visible damage.
missing fasteners.
WARNING
Avoid hazardous situations. Never use a
malfunctioning aerial platform. If malfunctions
are discovered, tag the machine and take it out of
service. Have repairs made by a qualified service
technician.
Tables
Table 2.1 Specifications and Features........................................................................................................................26
Table 2.2 Floor Loading Pressure...............................................................................................................................28
2
Table 2.3 Maximum Platform Capacities (Evenly Distributed)...................................................................................29
Table 2.6 Torque Specifications for Fasteners (Imperial)...........................................................................................32
Table 2.7 Torque Specifications for Fasteners (Metric)..............................................................................................33
Table 2.8 Torque Specifications for Hydraulic Couplings & Hoses............................................................................34
Tables
Table 2.1 Specifications and Features
Compact RT’s
Model
6826 6832
Platform Size 56” x 99” 1.4 m x 2.5 m 56” x 99” 1.4 m x 2.5 m
Elevated Drive 0.39 mph 0.63 km/h 0.39 mph 0.63 km/h
Speed
Air-filled N/A
Foot Print Area = Tread Contact Area Base Area = Length x Width
Width
Length
Width
Diameter
Length
WARNING
Do not use tires other than those specified for this machine. Do not mix different types of tires.
Tires other than those specified can adversely affect stability. Failure to operate with matched,
approved tires in good condition can result in death or serious injury. Replace tires with the
exact, Skyjack-approved types only.
Outrigger Pads max* 9189 4168 3675 1667 47 323 296 1446
1014AB-ANSI
NOTE:
Occupants and materials are not to exceed rated load.
Refer to capacity label for additional information and for models equipped with options.
Hydraulic Oil
Model Capacity (Liters) Capacity (US Gallons) Oil Type
Engine Oil
Engine Type Capacity (Liters) Capacity (US Gallons) Engine Oil Type Recommended Equivalent Oil
Engine Coolant
Engine Type Capacity (Liters) Capacity (US Gallons) Coolant Type
Engine Fuel
Engine Type Capacity (Liters) Capacity (US Gallons) Fuel Type
60660AD
Cartridge
Size
Torque
8 38 58 10 12 16
Lb-ft (max) 20 25 35 50
Lb-in (max) 240 300 420 600
Nm (max) 27.12 33.9 47.46 67.8
Coils
Size
Torque
All coils
Lb-ft (max) 4 to 5
Lb-in (max) 48 to 60
Nm (max) 5.42 to 6.78
SAE Plugs
Size
Torque
2 4 5 6 8 10 12 16
Lb-ft (max) 3 10 15 25 30 35
Lb-in (max) 36 120 180 300 360 420
Nm (max) 4.07 13.56 20.34 33.9 40.68 47.46
Bolts
Type of Bolt Torque (ft-lb) Torque (Nm)
Directional valve mounting bolts 2.33 (28-32 in-lb) 3.16 - 3.61
Wheel mounting bolts 90 122
Wheel motor castle nut (front) 350 474.54
Wheel motor castle nut (back) 350 474.54
Center drive sprocket mounting bolts 110 - 115 (242 Loctite) 149 -156
Hydraulic drive motor mounting bolts 120 (242 Loctite) 162
Positive battery post cable/fuse nut 7.5 (90 in-lb) 10.2
Newton-meter = Nm Foot-Pound Force = ft-lb Inch-Pound Force = in-lb
60664AB
IMPERIAL BOLT TORQUE CHART IMPERIAL BOLT TORQUE CHART
SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8
Size Torque Type Size
Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in‐lb) (5) (4) (8) (6) (12) (9) ft‐lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in‐lb) (6) (5) (9) (7) (13) (10) ft‐lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in‐lb) (10) (8) (16) (12) (23) (17) ft‐lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in‐lb) (12) (9) (18) (13) (25) (19) ft‐lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in‐lb) (19) (14) (30) (22) (41) (31) ft‐lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in‐lb) (20) (15) (31) (23) (43) (32) ft‐lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
(in‐lb) (27) (21) (43) (32) (60) (45) ft‐lb 170 125 430 320 600 460
10-24 7/8-9
Nm 3.1 2.4 4.9 3.6 6.8 5.1 Nm 230 169 583 434 813 624
(in‐lb) (31) (23) (49) (36) (68) (51) ft‐lb 180 140 470 360 660 500
10-32 7/8-14
Nm 3.5 2.6 5.5 4.1 7.7 5.8 Nm 244 190 637 488 895 678
(in‐lb) / ft‐lb (66) (50) 8 (75) 12 9 ft‐lb 250 190 640 480 900 680
1/4-20 1-8
Nm 7.5 5.6 11 8.5 16 12 Nm 339 258 868 651 1220 922
(in‐lb) / ft‐lb (76) (56) 10 (86) 14 10 ft‐lb 270 210 710 530 1000 740
1/4-28 1-12
Nm 8.6 6.3 14 9.7 19 14 Nm 366 285 963 719 1356 1003
ft‐lb 11 8 17 13 25 18 ft‐lb 280 210 730 540 1020 760
5/16-18 1-14
Nm 15 11 23 18 34 24 Nm 380 285 990 732 1383 1030
ft‐lb 12 9 19 14 25 20 ft‐lb 350 270 800 600 1280 960
5/16-24 1 1/8-7
Nm 16 12 26 19 34 27 Nm 475 366 1085 813 1735 1302
ft‐lb 20 15 30 23 45 35 ft‐lb 400 300 880 660 1440 1080
3/8-16 1 1/8-12
Nm 27 20 41 31 61 47 Nm 542 407 1193 895 1952 1464
ft‐lb 23 17 35 25 50 35 ft‐lb 500 380 1120 840 1820 1360
3/8-24 1 1/4-7
Nm 31 23 47 34 68 47 Nm 678 515 1519 1139 2468 1844
ft‐lb 32 24 50 35 70 55 ft‐lb 550 420 1240 920 2000 1500
7/16-14 1 1/4‐12
Nm 43 33 68 47 95 75 Nm 746 569 1681 1247 2712 2034
ft‐lb 36 27 55 40 80 60 ft‐lb 670 490 1460 1100 2380 1780
7/16-20 1 3/8‐6
Nm 49 37 75 54 108 81 Nm 908 664 1979 1491 3227 2413
ft‐lb 50 35 75 55 110 80 ft‐lb 750 560 1680 1260 2720 2040
1/2-13 1 3/8‐12
Nm 68 47 102 75 149 108 Nm 1017 759 2278 1708 3688 2766
ft‐lb 55 40 90 65 120 90 ft‐lb 870 650 1940 1460 3160 2360
1/2-20 1 1/2‐6
Nm 75 54 122 88 163 122 Nm 1180 881 2630 1979 4284 3200
Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm ft‐lb 980 730 2200 1640 3560 2660
1 1/2‐12
NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite. Nm 1329 990 2983 2224 4827 3606
METRIC BOLT TORQUE CHART
Torque 8.8 10.9
Size
Units Dry Lubed Dry Lubed
(in‐lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in‐lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in‐lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in‐lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft‐lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft‐lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft‐lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft‐lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft‐lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft‐lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft‐lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft‐lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft‐lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft‐lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft‐lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft‐lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
Inch‐Pound Force = in‐lb Foot‐Pound Force = ft‐lb Newton‐Meter = Nm
NOTE: Lubed includes lubricants such as lubrizing, oil, grease or uncured Loctite.
HYDRAULIC COUPLING TORQUE CHART
O‐Ring Port Connectors
Steel Ports Non‐ferrous Ports
SAE Size
ft‐lb Nm ft‐lb Nm
4 14‐16 20‐22 9‐10 12‐13
6 24‐26 33‐35 15‐16 20‐21
8 50‐60 68‐78 30‐36 41‐47
10 72‐80 98‐110 43‐48 60‐66
12 125‐135 170‐183 75‐81 102‐110
16 200‐220 270‐300 120‐132 162‐180
20 210‐280 285‐380 126‐168 171‐228
24 270‐360 370‐490 162‐216 222‐294
32 ‐ ‐ ‐ ‐
HOSE END TORQUE CHART HOSE END TORQUE CHART
for JIC for Flat‐Face O‐Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft‐lb Nm ft‐lb Nm ft‐lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
‐4 1/4" 10 11 13 15 5 6 6.75 9 ‐4 1/4" 10 12 14 16
‐6 3/8" 17 19 23 26 12 15 17 20 ‐6 3/8" 18 20 24 27
‐8 1/2" 34 38 47 52 20 24 27.66 33 ‐8 1/2" 32 40 43 54
‐10 5/8" 50 56 69 76 34 40 46.33 55 ‐10 5/8" 46 56 60 75
‐12 3/4" 70 78 96 106 53 60 72.33 82 ‐12 3/4" 65 80 90 110
‐16 1" 94 104 127 141 74 82 100.5 111 ‐14 1" 65 80 90 110
‐20 1 1/4" 124 138 169 188 75 83 101.5 113 ‐16 1 1/4" 92 105 125 240
‐24 1 1/2 156 173 212 235 79 87 107 118 ‐20 1 1/2 125 140 170 190
‐32 2" 219 243 296 329 158 175 214 237 ‐24 2" 150 180 200 245
Table of Contents
Charts
3.1. Hydraulic Symbol Chart.......................................................................................................................................36
3.2. Electrical Symbol Chart.......................................................................................................................................37
3.3 AC Cord Color Code.............................................................................................................................................38
Parts List
3.4 Hydraulic Schematic Parts List.............................................................................................................................39
3.5 Electrical Parts List ...............................................................................................................................................41
3
3.8 Control Box Wiring Diagram.................................................................................................................................51
3.9 Outrigger / Hydraulic Generator Control Console Wiring Diagram.....................................................................52
3.10 Scissor Arm Control Cable Wiring Diagram.......................................................................................................53
3.11 Main Manifold Valve Harness Wiring Diagram...................................................................................................54
3.12a Kubota Engine Wiring Diagram – Dual Fuel System – S/N 37009728 & Below..............................................55
3.12b Kubota Engine Wiring Diagram – Dual Fuel System – S/N 37009729 & Above..............................................56
3.13 Kubota Engine Wiring Diagram (Diesel Fuel System).......................................................................................57
3.14 Outrigger Harness Wiring Diagram....................................................................................................................58
3.15 Hydraulic Generator Electrical Panel Assembly.................................................................................................59
3.16 All Motion Alarm Electrical Panel Diagram.........................................................................................................60
3.17 Telematics Harness Wiring Diagram...................................................................................................................61
3.18a Electrical Panel Wiring Diagram S/N 37000235 & above.................................................................................62
3.18b Electrical Panel Wiring Diagram S/N 37000234 & below.................................................................................63
3.19a Electrical Panel Diagram with Positive Air Shut Off Option S/N 37000235 & above.......................................64
3.19b Electrical Panel Diagram with Positive Air Shut Off Option S/N 37000234 & below.......................................65
3.20 Positive Air Shut Off Harness Wiring Diagram – Diesel Engine.........................................................................66
3.21a Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000235 & above.............................67
3.21b Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000234 & below..............................68
3.22a Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000235 & above..............................69
3.22b Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000234 & below..............................70
3.23a Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000235 & above....................................71
3.23b Electrical Schematic (All Option with Kubota Diesel Engine) 37000234 & below...........................................72
VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALV VELOCITY FUSE
PUMP
FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP
VARIABLE
PRESSURE PILOT LINES Dashed DISPLACEMENT
MAIN LINES Solid
TRANSDUCER HYDRAULIC MOTOR
QUICK
SERVO DISCONNECT
ANGLE
WIRE CROSSING HOURMETER KEY SWITCH
TRANSDUCER
LIMIT SWITCH
ELECTRIC
FUSE ROTARY SWITCH N.C.
MOTOR
BATTERY SILICON
EMERGENCY CAM OPERATED
CHARGE CONTROLLED
STOP BUTTON LIMIT SWITCH
INDICATOR RECTIFIER
PROXIMITY
CAPACITOR RESISTOR TILT SWITCH
SWITCH
SINGLE POLE
PNP
POTENTIOMETER LEVEL SENSOR SINGLE THROWN
TRANSISTOR
RELAY
TEMPERATURE
SWITCH
Note: Standard colors referenced from IEC 60445:2010, Annex A: Table A.1
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
M2
HYDRAULIC FRONT
GENERATOR RIGHT
OPTION WHEELMOTOR
C2
CASE DRAIN
M3
REAR
V
MB9 HYD 2H-86D UPPER RIGHT
WHEELMOTOR
LIFT
GENERATOR HYDRAULIC CYLINDER
MANIFOLD GENERATOR 6826/6832
M1
BLOCK VALVE O1 FRONT
Ø0.067 LEFT
WHEELMOTOR CASE DRAIN
FC1 M4
REAR
FLOW CONTROL 2H-13-2 (ANSI/CSA) LEFT
VALVE PT1
PRESSURE
R4
RELIEF
2H-13B-2 (CE)
HOLDING
WHEELMOTOR
OVERLOAD VALVE VALVE CV6
TRANSDUCER SPLITTER
OPTION (ANSI/CSA) MANIFOLD BLOCK MANIFOLD
C1 MB4 MB6
STANDARD (CE) LOWER CV5
LIFT R5
CYLINDER
MB10 FLOW 6826/6832 CV4
DRIVE
RELIEF
CONTROL O1 VALVE
MANIFOLD Ø0.067
CV3 CHECK
BLOCK VALVES
2H-13-1 (ANSI/CSA) W
GM1 GENERATOR R3
2H-13B-1 (CE)
HOLDING
C7
STEER
CYLINDER
OUTRIGGER
CYLINDER
OUTRIGGER
CYLINDER
OUTRIGGER
CYLINDER
OUTRIGGER
RELIEF
MOTOR VALVE
VALVE CYLINDER LEFT FRONT
C9
RIGHT FRONT
C10
RIGHT REAR
C11
LEFT REAR
C12
MANIFOLD BLOCK
MB3 04
VALVE VALVE VALVE VALVE
STEERING FD1 CUSHION CHECK CHECK CHECK CHECK
ORIFICE FLOW CYLINDER CV7 CV8 CV9 CV10
Ø0.055 DIVIDER C8
P-B P-A 03
AUXILIARY HYDRAULIC LOWERING
PRESSURE PORT DISCONNECT LIFT ORIFICE STEER-A STEER-B P-C BRAKE FD-A FD-B FD-C M-A M-B M-C M-D
Ø0.106 6826RT
Ø0.089 68 32 RT
HP2
V2
S5 HAND
FREEWHEEL
V1 4H-24 PUMP
VALVE
EMERGENCY LEFT STEER
LOWERING SANDWICH VALVE VALVE VALVE VALVE
A B VALVE
PULL
VALVE
MANIFOLD
MB5
S10
2H-20B
EXTEND
OUTRIGGER
EXTEND
OUTRIGGER
EXTEND
OUTRIGGER
EXTEND
OUTRIGGER X
HIGH SPEED LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
P T 4H-75 4H-76 4H-77 4H-78
S3 S5 VALVE
2H-13 (ANSI/CSA) 4H-23 P A P A P A P A
R2 RIGHT STEER
2H-13B (CE) A B A B S9
LIFT VALVE
LOWERING V6 4H-16B T B T B T B T B
RELIEF
VALVE AUTO PARALLEL
VALVE
RESET S8 P T S8 S9 P T FORWARD
VALVE 4H-16A 4H-15A 4H-15B DRIVE
FORWARD REVERSE PARALLEL VALVE VALVE VALVE VALVE VALVE
DRIVE DRIVE REVERSE RETRACT RETRACT RETRACT RETRACT
S4 VALVE VALVE DRIVE VALVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
S1 VALVE
3H-14A HOLDING LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
2H-17A (ANSI/CSA) LIFT OUTRIGGER 4H-71 4H-72 4H-73 4H-74
2H-17B (CE) S6
VALVE 2H-17C
LARGE CV2 3H-30
PUMP DUMP CHECK BRAKE
VALVE VALVE VALVE
CB2
PARALLEL
S7 COUNTERBALANCE
CV1 R1 4H-20A
SYSTEM 05 VALVE
CHECK 02 SERIES/PARALLEL
VALVE RELIEF LOWERING BRAKE VALVE
VALVE ORIFICE
Ø0.106 6826RT
ORIFICE
Ø0.028
CB1
MAIN
T-A Y
Ø0.089 68 32 RT COUNTERBALANCE
VALVE MB8 OUTRIGGER MANIFOLD BLOCK
S2
2H-18B (ANSI/CSA)
2H-18C (CE)
T-B SMALL
AUXILIARY PUMP DUMP
TANK PORT VALVE
LARGE F1
SMALL
PUMP FILTER
PUMP
ENGINE
Z
P1
PUMP
RESERVOIR
M194135AA
M2
FRONT
RIGHT
WHEELMOTOR
C2
CASE DRAIN
M3
REAR
V
UPPER RIGHT
LIFT WHEELMOTOR
CYLINDER
6826/6832
M1
O1 FRONT
Ø0.067 LEFT
WHEELMOTOR CASE DRAIN M4
REAR
2H-13-2 (ANSI/CSA) LEFT
PT1 R4 2H-13B-2 (CE) WHEELMOTOR
PRESSURE RELIEF HOLDING
OVERLOAD VALVE VALVE CV6
TRANSDUCER SPLITTER
OPTION (ANSI/CSA) MANIFOLD BLOCK MANIFOLD
C1 MB4 MB6
STANDARD (CE) LOWER CV5
LIFT R5
CYLINDER DRIVE
6826/6832 CV4 RELIEF
O1 VALVE
Ø0.067
CV3 CHECK
VALVES
2H-13-1 (ANSI/CSA)
2H-13B-1 (CE) CYLINDER CYLINDER CYLINDER CYLINDER
W
R3 C7
HOLDING STEER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
RELIEF VALVE LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
VALVE CYLINDER
C9 C10 C11 C12
MANIFOLD BLOCK
MB3 04
VALVE VALVE VALVE VALVE
STEERING FD1 CUSHION CHECK CHECK CHECK CHECK
ORIFICE FLOW CYLINDER CV7 CV8 CV9 CV10
Ø0.055 DIVIDER C8
P-A 03
HYDRAULIC LOWERING
DISCONNECT LIFT ORIFICE STEER-A STEER-B P-C BRAKE FD-A FD-B FD-C M-A M-B M-C M-D
Ø0.106 6826RT
Ø0.08968 32RT
P-B
AUXILIARY
PRESSURE PORT HP2
MB9 HYD 2H-86D HAND
V2
S5 FREEWHEEL
GENERATOR HYDRAULIC V1 4H-24 PUMP
VALVE
MANIFOLD GENERATOR EMERGENCY
LOWERING
LEFT STEER
SANDWICH VALVE VALVE VALVE VALVE
BLOCK VALVE A B VALVE
HYDRAULIC
PULL
VALVE
MANIFOLD
MB5
S10
2H-20B
EXTEND
OUTRIGGER
EXTEND
OUTRIGGER
EXTEND
OUTRIGGER
EXTEND
OUTRIGGER X
GENERATOR P T
HIGH SPEED LEFT FRONT
4H-75
RIGHT FRONT
4H-76
RIGHT REAR
4H-77
LEFT REAR
4H-78
GM1 GENERATOR OPTION S3 S5 VALVE
4H-23
MOTOR WITH R2
2H-13 (ANSI/CSA)
RIGHT STEER
P A P A P A P A
2H-13B (CE)
ADJUSTABLE LIFT
LOWERING
VALVE
V6
A B A B S9
T B T B T B T B
RELIEF 4H-16B
FLOW CONTROL VALVE
VALVE AUTO PARALLEL
RESET S8 P T S8 S9 P T FORWARD
VALVE 4H-16A 4H-15A 4H-15B DRIVE
FORWARD REVERSE PARALLEL VALVE VALVE VALVE VALVE VALVE
DRIVE DRIVE REVERSE RETRACT RETRACT RETRACT RETRACT
S4 VALVE VALVE DRIVE VALVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
S1 VALVE
3H-14A HOLDING LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
2H-17A (ANSI/CSA) 4H-71 4H-72 4H-73 4H-74
LIFT OUTRIGGER
2H-17B (CE) S6
VALVE 2H-17C
LARGE CV2 3H-30
PUMP DUMP CHECK BRAKE
VALVE VALVE VALVE
CB2
PARALLEL
S7 COUNTERBALANCE
CV1 R1 4H-20A
SYSTEM 05 VALVE
CHECK 02 SERIES/PARALLEL
VALVE RELIEF LOWERING BRAKE VALVE
VALVE ORIFICE
Ø0.106 6826RT
ORIFICE
Ø0.028
CB1
MAIN
T-A Y
Ø0.08968 32RT COUNTERBALANCE
VALVE MB8 OUTRIGGER MANIFOLD BLOCK
S2
2H-18B (ANSI/CSA)
2H-18C (CE)
T-B
SMALL
AUXILIARY
PUMP DUMP
TANK PORT
VALVE
LARGE F1
SMALL
PUMP FILTER
PUMP
ENGINE
Z
P1
PUMP
RESERVOIR
M137360AK
CB1 S9
MAIN 4H-16B
COUNTERBALANCE PARALLEL
VALVE FORWARD V
S7 DRIVE
4H-20A VALVE
SERIES/PARALLEL
VALVE
S8 S8
4H-15A 4H-16A
REVERSE FORWARD CB2 S9
DRIVE DRIVE PARALLEL 4H-15B W
VALVE VALVE COUNTERBALANCE PARALLEL
VALVE REVERSE
TO DRIVE
BRAKE O4 VALVE
BRAKE
ORIFICE S10
S6 2H-20B
3H-30D HIGH
BRAKE SPEED
VALVE VALVE
TO
LARGE S3
PUMP 2H-13(ANSI/CSA) X
2H13B(CE)
S5 LOWERING
4H-24 S1
V2 VALVE
LEFTSTEER 2H-17A (ANSI/CSA)
FREEWHEEL
VALVE 2H-17B (CE)
VALVE
LARGE
CV2 PUMP DUMP
HP2 CHECK VALVE
HAND VALVE
PUMP
R2
TO TO TO LIFT
V6 SMALL STEER LIFT RELIEF
S2 PUMP CYLINDER CYLINDER
AUTO VALVE
2H-18B (ANSI/CSA) Y
RESET
2H-18C (CE)
VALVE
SMALL
PUMP DUMP
VALVE
TO TO
TANK DRAIN
CV1
V1 R1 S4
S5 CHECK
EMERGENCY SYSTEM 3H-14A
LOWERING RELIEF LIFT
4H-23 VALVE Z
RIGHT STEER
PULL VALVE VALVE
VALVE
VALVE MAIN MANIFOLD VALVE ASSEMBLY
M138189AP_3C
4H-74A
4H-71A
OUTRIGGER
OUTRIGGER
LEFT REAR
4H-72A LEFT FRONT
OUTRIGGER RETRACT
RETRACT V
RIGHT FRONT
RETRACT
4H-78A
R5 OUTRIGGER
DRIVE LEFT REAR
RELIEF EXTEND
DRIVE
CV3 4H-73A W
CHECK
OUTRIGGER
VALVE
RIGHT REAR
RETRACT 4H-75A
OUTRIGGER
LEFT FRONT
EXTEND 2H-17C
OUTRIGGER
4H-76A HOLDING
CV5
4H-77A OUTRIGGER VALVE
CHECK
VALVE OUTRIGGER RIGHT FRONT
RIGHT REAR EXTEND X
EXTEND
CV4
CHECK
VALVE
CV6
CHECK
VALVE
M138075AB_1 M138045AB_1
S3 - LIFT/DRIVE SELECTOR
13 14 09
X2
X1
05 10
08 05 10
34
X
00
11 12
21 22 23 24
18 RED/BLACK PIN 9 - 3rd SPEED 18 RED/BLACK (14) BLACK ORANGE GREEN (60)
(13) ORANGE GREEN (49)
10
(10) BLUE RED GREEN WHITE (34)
9
(10) BLUE WHITE GREEN BLACK (32)
13 14 15 16 17 18 19 20
8
02
8B
8A
7
(08) BLACK RED BLUE BLACK (24)
6
(07) RED GREEN BLACK WHITE (23)
5
02
8B
8A
4
(05) WHITE BLACK RED ORANGE BLACK (19)
3
(05) WHITE RED RED BLACK (18)
2
JOYSTICK HARNESS REFERENCE (02) WHITE WHITE BLACK (16)
1
MALE QDC - 2nd/3rd SPD V+ 8B PURPLE CRD1 GROUND - GREEN BLACK WHITE Z
FEMALE QDC - ENABLE VS+ 8A WHITE/BLUE
MALE QDC - GROUND 02 WHITE
M166134AA
TO CONTROL BOX
TEN PIN CONNECTOR PLUG
PIN 1 - 74 BLACK
09
86
85
PIN 2 - 73 BLUE
PIN 3 - 78 BLACK/WHITE
1
2
3
PIN 4 - 77 BLUE/BLACK
PIN 5 - 35D PURPLE WHITE
TO AUTO OUTRIGGER SWITCH PIN 6 - NOT USED
PIN 1 - 79 GREEN PIN 7 - 71 ORANGE W
PIN 2 - 35D PURPLE/WHITE
35D
PIN 8 - 72 RED
79
70
PIN 3 - 70 GREEN/BLACK PIN 9 - 75 ORANGE/BLACK
1
3
2
35D
PIN 10 - 76 RED/BLACK
35C
TO OUTRIGGER ENABLE SWITCH 35D 70A
1
3
2
PIN 1 - 35D PURPLE/WHITE
35C
35D
35D
02
PIN 2 - 35C x 3 (WHITE/BLACK,
TO OUTRIGGER LIGHT
BLUE/WHITE & GREEN/WHITE)
70A RED/WHITE
PIN 3 - 35D PURPLE/WHITE
02 WHITE
X
4 5 6
7 8 9
10 11 12
13 14 15
OUTRIGGER CONTROL CABLE
TO ELECTRIC PANEL
PIN 1 - 02 WHITE PIN 9 - 75 ORANGE/BLACK
PIN 2 - 35C WHITE/BLACK PIN 10 - 76 RED/BLACK
PIN 3 - 70 GREEN/BLACK PIN 11 - 77 BLUE/BLACK
PIN 4 - 70A RED/WHITE PIN 12 - 78 BLACK/WHITE Z
PIN 5 - 71 ORANGE PIN 13 - 79 GREEN
PIN 6 - 72 RED PIN 14 - 35C BLUE/WHITE
PIN 7 - 73 BLUE PIN 15 - 35C GREEN/WHITE
PIN 8 - 74 BLACK
M129301AD
BACK VIEW V
12
24
(14) BLACK ORANGE GREEN (60)
11
23
(13) ORANGE GREEN (49)
10
22
(10) BLUE RED GREEN WHITE (34)
21
9
(10) BLUE WHITE GREEN BLACK (32)
20
8
(09) ORANGE RED RED WHITE (31)
19
7
(08) BLACK RED BLUE BLACK (24)
18
6
(07) RED GREEN BLACK WHITE (23) W
17
5
(07) RED BLACK WHITE RED (20)
16
4
(05) WHITE BLACK RED ORANGE BLACK (19)
15
3
(05) WHITE RED RED BLACK (18)
14
2
(02) WHITE WHITE BLACK (16)
13
1
GROUND - GREEN BLACK WHITE
MALE
X
BACK VIEW
13
1
RED/BLACK (18) (05) WHITE/RED
14
2
ORANGE/BLACK (19) (05) WHITE/BLACK/RED
15
3
BLACK/WHITE/RED (20) (07) RED
16
4
BLACK/WHITE (23) (07) RED GREEN
17
5
BLUE/BLACK (24) (08) BLACK/RED
18
6
RED/WHITE (31) (09) ORANGE/RED Y
19
7
GREEN/BLACK (32) (10) BLUE/WHITE
20
8
GREEN/WHITE (34) (10) BLUE/RED
21
9
GREEN (49) (13) ORANGE
22
10
ORANGE/GREEN (60) (14) BLACK
23
11
RED/BLACK/WHITE (NOT USED) (15) BLUE
24
12
(GROUND) GRN/BLK/WHT TO (00)
FEMALE
M137356AB
18B
02
LEFT STEER VALVE
GREY HIRSHMAN
PIN 1 - 24 BLUE/BLACK
PIN 2 - 02 WHITE
24
GREY
02
INSERT ORIENTATION
RIGHT STEER VALVE BOTTOM VIEW
W
BLACK HIRSHMAN
02
PIN 1 - 23 BLACK/WHITE
BLACK
23
PIN 2 - 02 WHITE
HIGH SPEED VALVE HYDRAULIC GENERATOR
20B - BLACK/RED/WHITE 86D - ORANGE/BLACK/WHITE
02 - WHITE PARALLEL FORWARD VALVE 02 - WHITE
02 BLACK HIRSHMAN
PIN 1 - 16B WHITE/RED
20B
02
INSERT ORIENTATION
14A LOWERING VALVE PIN 2 - 02 WHITE 86D
BOTTOM VIEW
LIFT VALVE 13 - ORANGE 16B 02
14A - BLACK 02 - WHITE 02 PARALLEL REVERSE VALVE
02 - WHITE GREY HIRSHMAN
BLAC PIN 1 - 15B BLUE/YELLOW
02
13
K PIN 2 - 02 WHITE
X
15B
PARALLEL REVERSE VALVE
GREY HIRSHMAN
02
GRE
PIN 1 - 15B BLUE/YELLOW
Y
LARGE PUMP DUMP VALVE PIN 2 - 02 WHITE
BRAKE FEED VALVE
TO ELECTRIC PANEL - 14 WIRES 17A - BLUE/RED 30 - BROWN
02 - WHITE 17A - BLUE/RED (ANSI/CSA), 17B - BLUE/RED (CE) 02 - WHITE 02 - WHITE
30
13 - ORANGE (ANSI/CSA), 13B - ORANGE 18B- RED/BLACK (ANSI/CSA), 18C - RED/BLACK (CE)
02
20A
17A
02
(CE) 20A - BLACK/WHITE/RED FORWARD VALVE
(SPLICE 1)
02
14A - BLACK 23 - BLACK/WHITE BLACK HIRSHMAN
02
13
02
15A - BLUE 24 - BLUE/BLACK PIN 1 - 16A WHITE/BLACK
15B - BLUE/YELLOW 30 - BROWN SERIES/PARALLEL VALVE PIN 2 - 02 WHITE
16A - WHITE/BLACK 86D - ORANGE/BLACK/WHITE 20A - BLACK/RED/WHITE
16B - WHITE/RED
BLACK
16A
02 - WHITE
02
02 INSERT ORIENTATION Y
BOTTOM VIEW
02 15A
GREY
HOLDING VALVE
13 - ORANGE
02 - WHITE
REVERSE VALVE
GREY HIRSHMAN
PIN 1 - 15A BLUE
HOLDING VALVE (UPPER) PIN 2 - 02 WHITE
HOLDING VALVE (LOWER) PIN 1 - 13 BLACK
1
13 - BLACK 13 PIN 1 - 13 BLACK PIN 2 - 02 WHITE
PIN 2 - 02 WHITE
1
02 - WHITE 02
2
Z
M139827AB
FLASHER
FL-29
V
3 1
2
2A
10
3 2 1
22
29
FUEL SELECT SWITCH S33
PIN 1 - 50 ORANGE
05 10
A 3A A
00
PIN 2 - 37 BLUE/WHITE 1
X1
PIN 3 - 11 BLUE 2 X2
3A 02 03 B B 02
32
31
10B
10B
A B
2B
A B
37
50
11
10B
32
31
13
A B C D E F
10E
10E 10 05 07 14E
AT CARBURETOR
ALTERNATOR MAIN ENGINE STARTER CONTACTOR
ENGINE GROUND
AT CARBURATOR STARTER SOLENOID X
1 8
ELECTRIC PANEL 32A - GREEN/BLACK
DEUTSCH
2
3
7
6 PIN 1 - N/U
4 5
PIN 2 - 34C GREEN/WHITE STARTER MOTOR
PRESSURE SWITCH (OPS1)
PIN 3 - 02 WHITE 57 - BLACK/WHITE
00
2A - BLACK/RED
11
50
PROPANE LOCKOFF SOLENOID AT PIN 4 - 32A GREEN/BLACK
2B - WHITE
00
PROPANE REGULATOR/VAPORIZOR PIN 5 - 2A BLACK/RED
PROPANE VALVE SOLENOID (2P-50-1) 2B 32A
50
11
00
PIN 6 - 37 BLUE/WHITE
50 - ORANGE BACK VIEW
PIN 7 - 3A BLUE 2A 57
00 - WHITE
PIN 8 - 31 RED/WHITE 37
GAS SOLENOID (2G-11) IGNITION COIL
3 2 1
11 - BLUE 37 BLUE/WHITE
00 - WHITE 00-WHITE
ALTERNATOR TRIGGER
00
50
PIN 1 - N/U
57
31CR
FUEL PUMP PIN 2 - 37 BLUE/WHITE
Y
00
50
POS - BLACK 87
PIN 3 - N/U
BACK VIEW
86
57
FUEL PUMP
00 - WHITE 34C - GREEN/WHITE 37 00 11 - BLUE
02 - WHITE 00 - WHITE CHOKE RELAY (31CR) D57
D57
31A
31
3A
02
+
11 - PIN 87 - 31A RED/WHITE
CHOKE SOLENOID (CS-31A) PIN 86 - 02 WHITE
37
34C PIN 30 - 3A BLUE
31A - RED/WHITE 00
02 - WHITE PIN 85 - 31 RED/WHITE
02
PIN 87a - NOT USED
37
31A
00 02 37
02
00 02 37
M137528AC
M198923AA
57A
37
00
321
DIESEL VALVE SOLENOID ENGINE STARTER
57A
37
00
57 - BLACK/WHITE
00 WHITE 103 - RED (10 GA)
37 BLUE/WHITE ALTERNATOR TRIGGER
PIN 1 - N/U
57A BLACK/WHITE PIN 2 - 37 BLUE/WHITE (18 GA)
PIN 3 - N/U
32A
ENGINE STARTER
CONTACTOR
103
57
32A - GREEN/BLACK
PRESSURE SWITCH
(OPS1)
ENGINE
2C
2B
GLOW PLUG 91A
2B - BLACK/RED
2C - WHITE
(EGP1)
91A - RED (10 GA)
(TPS1)
ALTERNATOR MAIN MAIN ENGINE STARTER FRAME GROUND 2C - WHITE
-ATTACH AT BELL HOUSING/AIR FILTER BRKT
00 -WHITE 2C
00
HIGH 34C
THROTTLE SOLENOID
(HTS-34C)
02 -WHITE
02
X
34C - GREEN/WHITE
FLASHER
FL-29 GLOW PLUG RELAY
GLOW PLUG TIMER (31CR)
PIN 30 - 103 RED (10 GA)
(GPT1) PIN 87 - 91A RED (10 GA)
6 5 4 PIN 85 - 31 RED/WHITE
PIN 1 - N/U 3 2 1 PIN 86 - 02 WHITE
2A
10
29
PIN 1 - N/U
90
02
32A
91A
05 10
A A PIN 2 - 34C GREEN/WHITE
91A
3A
103
00
1
31
02
X1
PIN 3 - 02 WHITE
2 X2
GLOW PLUG LIGHT
3A 02 03 B B 02 PIN 4
PIN 5
- 32A GREEN/BLACK
- 2A BLACK/RED
91A 02
GLOW PLUG
(GPL1)
90 - RED
LIGHT GPL1 PIN 6 - 37 BLUE/WHITE
DIESEL VALVE
Y
32
PIN 7 - 3A BLUE
31
10B
10B
91A
91A - RED A B
A B PIN 8 - 31 RED/WHITE PULL-IN RELAY
90 (3ACR)
10B
32
31
PIN 30 - 57 BLACK/WHITE
PIN 87a - 57A BLACK/WHITE
BACK VIEW PIN 85 - 3A BLUE
PIN 86 - 2B BLACK/RED
13 31 PIN 87 - N/U
1 8
91A 02 32A 37
DEUTSCH
D32A
31 32A 37 57 02 57A
D57
D02
A B C D E F
10E 2 7
3 6 32A
10E 10 05 07 14E 4 5
87
86
57
87a
85
57A 30
3A
2B
31
32A 37
D32A
31 32A
37 57 02 57A
D57
D02
32A Z
M137884AH
86A
36A
10A
01
61
09
02
02
36
04
44
17
D17B-2
CN21
D73
17B
D17B-1
71
02
78
73
77
75
72
76
74
REAR RIGHT
REAR LEFT
D74
CN20
D77
35C
71
78
73
77
75
72
76
74
OUTRIGGER ELECTRIC PANEL
D78
9CR3 9CR2
V
FRONT RIGHT
FRONT LEFT
D72
PIN 1 - 28A GREEN/WHITE
D71
PIN 2 - 17A BLUE/BLACK (ANSI/CSA)
D76
17B BLUE/BLACK (CE) 61CR 17DCR 65CR
J17D
D75
PIN 3 - 86A ORANGE/BLACK/WHITE ENABLE
J17E
PIN 4 - 10A BLUE/WHITE
10A
10A
10A
10A
10A
61
62
62
63
63
65
64
64
PIN 5 - 09 ORANGE (2x)
-
-
D36
CN22
PIN 6 - 44 RED
UP RELAY - 14CR JUMP J17E
PIN 7 - 28 GREEN/BLACK
PIN 30 - 36A YELLOW PIN 8 - 02 WHITE (2x)
PIN 85 - 14 BLACK PIN 9 - 02 WHITE/BLACK OUTRIGGER CONTROL BOX OUTRIGGER MANIFOLD LEFT REAR OUTR DOWN LEFT FRONT OUTR DOWN RIGHT FRONT OUTR DOWN RIGHT REAR OUTR DOWN
PIN 86 - 02 WHITE PIN 10 - 36A YELLOW OUTRIGGER LIMIT SWITCHES PIN 1 - 35C WHITE/BLACK (x2) PIN 1 - 17C WHITE/BLACK
PIN 87 - 14A BLK/WHT PIN 11 - 61 GREEN PIN 1 - 61 OUTR CTRL BOX - CN20 PIN 2 - 78 BLACK/WHITE (x2)
OUTR MANIFOLD - CN21 PIN 2 - 02 WHITE PIN 1 - 78 BLACK/WHITE PIN 1 - 75 ORANGE/BLACK PIN 1 - 76 RED/BLACK PIN 1 - 77 BLUE/BLACK
PIN 87a - N/U PIN 12 - 36 YELLOW PIN 2 - 62 GREEN OUTRIGGER LIMIT SWITCHES - CN22 PIN 3 - 73 BLUE (x2) PIN 3 - 78 BLACK/WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
02
78
02
75
02
76
02
77
14CR
36A
PIN 5 - 74 BLACK (x2)
PIN 5 - 63 RED PIN 6 - 71 ORANGE (x2) PIN 6 - 74 BLACK
02
1 2 3 4 5 6 7 8 9 10 11 12
14
D36-1
02
14
4
1
6
35C
PIN 11 - 10A BLACK (2x)
5
5
6
3
4
1
PIN 12 - 10A BLACK (2x) 02
BACK VIEW BACK VIEW 02
PIN 13 - 10A GREEN
PIN 14 - N/U TO CONTROL MODULE TO LIMIT SWITCHES
PIN 15 - N/U PIN 1 - 65 GREEN/BLACK PIN 1 - 65 GREEN/BLACK
17C
PIN 16 - 65 GREEN/BLACK PIN 2 - 65A WHITE PIN 2 - 65A GREEN/WHITE
36
1
5
2
6
3
7
4
8
5
9
6
3
74
02
02
72
02
73
02
71
PIN 3 - EMPTY PIN 9 - 43 RED/BLACK PIN 1 - 74 BLACK PIN 1 - 71 ORANGE PIN 1 - 72 RED PIN 1 - 73 BLUE
PIN 4 - 02 WHITE (2x) PIN 10 - 43A RED/WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE
PIN 5 - 2A ORANGE/BLACK PIN 11 - 86A ORANGE/BLACK/WHITE
PIN 6 - 09 ORANGE PIN 12 - 86D ORANGE/BLACK/WHITE LEFT REAR OUTR UP LEFT FRONT OUTR UP RIGHT FRONT OUTR UP RIGHT REAR OUTR UP
P2
P4
TILT SWITCH
PIN 1 - 10A BLACK
PIN 2 - 28 GREEN
PIN 3 - 02 WHITE
Y
TO OUTRIGGER LIMIT SWITCHES PIN 4 - 44 RED
2
1
BACK VIEW
DEUTSCH
4 1 DEUTSCH
LEFT FRONT OUTRIGGER: PIN 1 - 02 WHITE PIN 1 - 78 BLACK/WHITE PIN 1 - 68A WHITE
4
3
4 1
3 2
4 1
4 1
3 2
V
86ACR 86BCR 86CCR 14CR
OUTRIGGER OPTION
86B 43A
WIRE# 86BCR - HYDRAULIC GENERATOR LATCHING RELAY
86C
86B
86A
2A
02
02
86C 86D
W9 PIN 85 - 86B ORANGE/BLACK/WHITE
W5 PIN 86 - 2A ORANGE/BLACK D86 D86C D86D
W1 PIN 30 - 09 ORANGE
- PIN 87a - N/U
W2 PIN 87 - 86C ORANGE/BLACK/WHITE
36A
14A
02
14
36
W6 PIN 87 - 86D ORANGE/BLACK/WHITE
86 FROM HYDRAULIC Z
85 GENERATOR
09 CONTROL BOX
M146108AC/194256AA
0.500
(1.063 LEG LENGTH)
0.625
W
DETAIL A DETAIL B
X
D14A-3
D30
D14A-3
34A D30
17A
14A
14A
18A
35A
15A
15A
16A
16A
10A
28A
18B
10B
10E
14E
21
21
29
09
29
49
05
13
33
10
08
07
28
30
10
23
60
02
02
02
14
44
44
24
14A
29
29
30
DETAIL A DETAIL B Y
M139317AA
V
TO TELEMATICS DEVICE
37
D7
37 37
KEY KEY
02 02
D10
00
100
MAIN BATTERY
B1
Z
00
2
100
100
03
MAIN 2
TO ENGINE
DISCONNECT 103 103
2
SWITCH S1
103
103
M171108AA
LEGEND: S
M204232AA
10CR1 10CR2 10BCR 15CR 16CR 17CR 19CR 20CR 20ACR1 FLASHER HOURMETER
37 42 10A 15A 16A 17 20A FL-29 TT
10
10B
10 2A 2A 02 15 02 16 02 17 02 19 02 20 02 02
20A
41 18A 16B
CIRCUIT BREAKER
43 43A
20ACR2 28ACR1 34ACR 35CR 35ACR
CB1
2A
10
28ACR2 32CR1 32CR2 33CR
S
LEGEND: 15A 18A 17 3A 41 34B 43A 10A 34
15B 28C 28B 43
EMERGENCY STOP
28A
28A
20A
02 02 41 33 02 42 35 02 02
35A
34A
02 32 41 32
22
29
MAIN MANIFOLD HARNESS 18B 17A 32A 02 34C 34B 44 34A
S6
2A
35 CIRCUIT BREAKER
ENGINE HARNESS 15B 34
32A 34C
CB 3 POWER ON
LED-2
PLATFORM CONTROL BOX 05
1
10
A 3A
00
A
10E 10E X1
OUTR/GEN HARNESS 2
3A
X2
02 03 B B 02 GLOW PLUG T
LIGHT GPL1
TILT SWITCH 29
10 10 START SWITCH OR
31 S32 FUEL SELECT
HIGH SPEED LIMIT SWITCH
10A 02 02 3A
32
31
10B
10B
D07
A B SWITCH S33
D14A-3
D14E-1
D23
D0
A-2 A B
D17A
9
D15
D14A-1
D15A-1
D44-1
D24
10B
32
31
D13
05 3A
34A
35A
28A
17A
14A
14A
18A
15A
15A
16A
16A
10A
18B
10B
10E
14E
21
21
29
09
29
49
05
33
08
07
28
30
23
02
02
02
44
44
24
60
13
10
10
14
05 31 32
GLOW PLUG OR U
13
02 CHOKE SWITCH S31
D14E-2
10E
D08
D16A-2
A B C D E F
D1
0E
-2
8B
D44
D16
D1
D10
37 14E
A-1
10E 10 05 07
44 28 10A 02 02
LS5
MAIN MANIFOLD HARNESS
OUTR/GEN HARNESS
PLATFORM CONTROL BOX
02
HIGH SPEED LIMIT SWITCH
10A - BLUE
35 - BROWN
OUTRIGGER 12 PIN CONNECTOR PLUG UP RELAY - 14CR HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG 00 WHITE - 14GA
NO
BROWN
BLUE
PIN 1 - 28A GREEN/WHITE 02 WHITE PIN 1 - EMPTY PIN 7 - 14 BLACK (2x)
10A
35
14 BLACK
00
PIN 2 - 17A BLUE/BLACK (2x) PIN 2 - EMPTY PIN 8 - 17A BLUE/BLACK 00
PIN 3 - 86A ORANGE/BLACK/WHITE 14A BLK/WHT PIN 3 - EMPTY PIN 9 - 43 RED/BLACK W
PIN 4 - 10A BLUE/WHITE 36A YELLOW PIN 4 - 02 WHITE (2x) PIN 10 - 43A RED/WHITE
2
FL-22 TO FLASHING LIGHT PIN 5 - 09 ORANGE (2x) PIN 5 - 2A ORANGE/BLACK PIN 11 - 86A ORANGE/BLACK/WHITE F1 FUSE
& BEEPER
100
02 - WHITE
PIN 6 - 44 RED PIN 6 - 09 ORANGE PIN 12 - 86D ORANGE/BLACK/WHITE 300 AMP
PIN 7 - 28 GREEN/BLACK
FLASHING LIGHT 22 - GREEN
29 - BLACK PIN 8 - 02 WHITE (2x)
02 - WHITE
22 - GREEN PIN 9 - 02 WHITE/BLACK MAIN BATTERY
PIN 10 - 36A YELLOW
22 22
MAIN MANIFOLD HARNESS
PIN 11 - 61 GREEN B1
02 - WHITE 17A - BLUE/RED
PIN 12 - 36 YELLOW
13 - ORANGE 18B - RED/BLACK 03 BLUE - 14GA
02 14A - BLACK 20A - BLACK/WHITE/RED
02 86D TO ENGINE HARNESS X
02 15A - BLUE 23 - BLACK/WHITE PIN 1 - N/U
00
2
BP-29 15B - BLUE/YELLOW 24 - BLUE/BLACK PIN 2 - 34C GREEN/WHITE
100
29 29 16A - WHITE/BLACK 30 - BROWN PIN 3 - 02 WHITE TO ENGINE
03
36
36A
14A
1
2
3
4
2
02
DISCONNECT
14
PIN 5 - 2A BLACK/RED 103 103
36
BEEPER
2
BACK VIEW PIN 6 - 37 BLUE/WHITE
SWITCH S1
103
DEUTSCH
02 - BLACK PIN 7 - 3A BLUE
FEMALE
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
29 - RED
103
OUTRIGGER PIN 8 - 31 RED/WHITE
8
7
6
5
LIMIT SWITCHES BACK VIEW
1
2
WHITE/BLACK (16) (02) WHITE
13
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Y
1
14A
14
3
4
16
BACK VIEW
36
TILT SWITCH OR
RED/WHITE (31) (09) ORANGE/RED D36
19 20
GREEN/WHITE (34) (10) BLUE/RED NO OUTRIGGER JUMPER PLUG UP RELAY JUMPER NO HYDR GEN JUMPER PLUG PIN 2 - 28 GREEN
21 22
11 12
Z
RED/BLACK/WHITE (NOT USED) (15) BLUE
24
M146124AF
LEGEND: S
MAIN MANIFOLD HARNESS
ENGINE HARNESS
PLATFORM CONTROL BOX
OUTR/GEN HARNESS
T
TILT SWITCH
HIGH SPEED LIMIT SWITCH
POSITIVE AIR SHUT OFF
RESISTOR
M204247AA
10B
10 2A 2A
403A
02 15 02 16 02 17 02 19 02 20 02 02 02
20A
3A
41
3A 10A 10A
18A
21 44 44 16A
16B
403A
37A
37
FL-29
02
LEGEND:
02
CIRCUIT BREAKER
43 43A
2A
10
28ACR2 32CR1 32CR2 33CR
02 S
15A 18A 17 3A 41 34B 43A 10A 34
28A
28A
20A
02 02 41 33 02 42 35 02 02
35A
34A
02 32 41 32
22
29
18B 17A 02 34C 34B 44 34A
S6
32A
2 X2 GLOW PLUG
3A 02 03 B B 02 T
LIGHT GPL1
HIGH SPEED LIMIT SWITCH 29
10 10 START SWITCH OR
10A 02 02 3A 31 S32 FUEL SELECT
32
31
10B
10B
POSITIVE AIR SHUT OFF D07
A B SWITCH S33
D14A-3
D14E-1
D23
D0
A-2 A B
D17A
9
D15
D14A-1
D15A-1
D44-1
D24
10B
32
31
D13
05 3A
34A
35A
28A
17A
14A
14A
18A
15A
15A
16A
16A
10A
18B
10B
10E
14E
21
21
29
09
29
49
05
33
08
07
28
30
23
02
02
02
44
44
24
60
13
10
10
14
05 31 32
GLOW PLUG OR U
13
02 CHOKE SWITCH S31
D14E-2
10E
D08
02
D16A-2
A B C D E F
D1
0E
-2
8B
D44
D16
D1
D10
37 14E
A-1
10E 10 05 07
TILT SWITCH
ENGINE HARNESS
44 28 10A 02 02
LS5
MAIN MANIFOLD HARNESS
1
OUTR/GEN HARNESS
6
PLATFORM CONTROL BOX
7 2
8
9
3
4
POSITIVE AIR SHUT OFF
10 5 HIGH SPEED LIMIT SWITCH
RESISTOR
10A - BLUE
TO ALTERNATOR 35 - BROWN
OUTRIGGER 12 PIN CONNECTOR PLUG UP RELAY - 14CR HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG 00 WHITE - 14GA
NO
BROWN
49
BLUE
PIN P (YELLOW) PIN 1 - 28A GREEN/WHITE 02 WHITE PIN 1 - EMPTY PIN 7 - 14 BLACK (2x)
10A
35
TO HORN 14 BLACK
00
PIN 2 - 17A BLUE/BLACK (2x) PIN 2 - EMPTY PIN 8 - 17A BLUE/BLACK 00
02 - WHITE 14A BLK/WHT W
H1 49 - BLACK
02 PIN 3 - 86A ORANGE/BLACK/WHITE
36A YELLOW
PIN 3 - EMPTY PIN 9 - 43 RED/BLACK
2
PIN 4 - 10A BLUE/WHITE PIN 4 - 02 WHITE (2x) PIN 10 - 43A RED/WHITE
PIN 5 - 09 ORANGE (2x) PIN 5 - 2A ORANGE/BLACK PIN 11 - 86A ORANGE/BLACK/WHITE F1 FUSE
100
PIN 6 - 44 RED PIN 6 - 09 ORANGE PIN 12 - 86D ORANGE/BLACK/WHITE 300 AMP
PIN 7 - 28 GREEN/BLACK
PIN 8 - 02 WHITE (2x)
FL-22 TO FLASHING LIGHT PIN 9 - 02 WHITE/BLACK MAIN BATTERY
& BEEPER PIN 10 - 36A YELLOW
02 - WHITE
MAIN MANIFOLD HARNESS
PIN 11 - 61 GREEN B1
FLASHING LIGHT 22 - GREEN 02 - WHITE 17A - BLUE/RED
PIN 12 - 36 YELLOW
02 - WHITE 29 - BLACK 13 - ORANGE 18B - RED/BLACK 03 BLUE - 14GA
22 - GREEN 14A - BLACK 20A - BLACK/WHITE/RED TO ENGINE HARNESS
86D
03 X
15A - BLUE 23 - BLACK/WHITE PIN 1 - N/U 403 00
22 22
2
15B - BLUE/YELLOW 24 - BLUE/BLACK PIN 2 - 34C GREEN/WHITE AUX PIN BAT PIN
100
16A - WHITE/BLACK 30 - BROWN PIN 3 - 02 WHITE 20 AMP TO ENGINE
03
36
03
02
02 16B - WHITE/RED 86D - ORANGE/BLACK/WHITE PIN 4 - 32A GREEN/BLACK FUSE
36A
14A
1
2
3
4
2
02
14
02 PIN 5 - 2A BLACK/RED 103 103
36
MAIN
2
BP-29 BACK VIEW PIN 6 - 37 BLUE/WHITE
103
DEUTSCH
29 29 FEMALE
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
PIN 7 - 3A BLUE DISCONNECT
103
OUTRIGGER PIN 8 - 31 RED/WHITE
SWITCH S1
8
7
6
5
BEEPER LIMIT SWITCHES BACK VIEW
1
2
02 - BLACK WHITE/BLACK (16) (02) WHITE
13
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
1
14A
14
3
4
16
BACK VIEW
36
TILT SWITCH OR
RED/WHITE (31) (09) ORANGE/RED D36
19 20
11 12
M171645AB
403A
TO ELECTRICAL PANEL R
403A
POSITIVE AIR SHUT OFF
TO BREAKER 402
403 BLUE (AUX PIN)
403 02
02
02
02
POSI AIR SHUT S
02
OFF SWITCH
1 BACK VIEW
3
4
6
7 402 GREEN TO POSI AIR KILL SWITCH - PIN 2 2
8 402
10 403A
02 1
TO SOLENOID
BAT PIN
SWITCH
AUX PIN
U
TO ALTERNATOR TRIGGER
PIN 3 “P”-YELLOW (410)
03
100
03
03
2
103 W
103
103
TO BREAKER
06B
M171825AB_2
M166131AC
S10
PLTF/IDLE/BASE S6
KEY SWITCH EMERGENCY
S4 CONTROL BOX BASE (IN IDLE POSITION) STOP
EMERGENCY S2 KUBOTA DUAL FUEL ENGINE
STOP UP/DOWN NEGATIV
SWITCH -
07
08 07 RED 07 05 05 3A
1
13 ICM1
07 RED/GREEN 07 10E 10 10 02 37 00 IGNITION
14E 10E 2
CONTROL MODULE
LED-2 CPS1
POWER ON CRANKSHAFT
D10E 1 2 3 3 IGNITION COILS
E
LIGHT POSITION
SENSOR
10 05 WHITE/RED 05 00
4
IGC1 IGC2 IGC3
05 WHITE/BLACK/RED 05 3A 3A 31A CS-31A CHOKE
5
D02-16 SOLENOID
3A 43 43A 34B 34C 34C 34C HTS-34C HIGH THROTTLE
6
D02-17 SOLENOID
HYDR GEN
10 BLUE/WHITE 10 JUMPER 11 00
FP 7 FUEL PUMP
32ACR
10 BLUE/RED 10 3A 32A 32A 32A 32A 00 ENGINE STARTER
8
S33 FUEL CONTACTOR
HOURMETER SELECT SW 2G-11
10 11 00 GAS VALVE
TT OIL GAS 9
37 SOLENOID
PRESSURE
SWITCH 50 00 PROPANE VALVE
PROP 10
SOLENOID
ENGINE 10CR1 TPS1
2P-50-1
GLOW PLUG 10 10 2A 2A 2A 2B 00 TEMPERATURE
F
/CHOKE SW 11
SWITCH
OPS1 2P-50-2
31 10B 3A 3A 37 37 37 37 50 00 PROPANE VALVE
S13 12
S31 SOLENOID
GLOW PLUG/ D57
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 02
13 CHOKE RELAY
10CR2 31CR
ENGINE 10 10 2A 02 02 02
START SW 14
19 25 A BREAKER
25A BREAKER
08 BLACK/RED 08 D08
20
41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41
22 START RELAY
S14 32CR2
LOW/HIGH THROTTLE 08 34 GREEN/WHITE 34 34 34A 42
23 THROTTLE RELAY
D14E-2 34ACR
LED-1 33 POWER ON-
RST1 POWER ON 24
2.7K OHMS DEMAND RELAY
LIGHT 10BCR 33CR
00 02 02 60 60 ORANGE/GREEN 60 08 10B
25 MAIN POWER RELAY
CONTROL BOX
LIGHT JUMPER 3A 10A 2H-13-2 HOLDING VALVE
26
D02-1 SOLENOID
CRD1 CRD2 CRD3 2H-13-1
H
HOLDING VALVE
27
D02-2 SOLENOID
S8 13 2H-13
HORN MAIN LOWERING
28
D02-3 VALVE SOLENOID
08 49 GREEN 49 49
29 HORN
H1
D13 30
S3 17CR
LIFT/OFF/DRIVE 17
(IN LIFT POSITION) 31 SMALL PUMP RELAY
13 ORANGE 13 D28B
13 17 28B
A 32
NOHC D14A-1 D28C
18A 28C 29 29
D14E-1 33 BEEPER
BP-29
14 14 BLACK 14 14A 14A 3H-14A LIFT VALVE
B 34
D02-4 SOLENOID
NO OUTRIGGER
NOHC
I
JUMPER 1
35
D09
09 ORANGE/RED 09 35A THROTTLE ENABLE
08 36
09 RELAY
NOHC 35ACR D44-2 20ACR1
20A SERIES/PARELLEL
37
RELAY
TILT OVERRIDE/ 20ACR2
HIGH DRIVE CUTOUT 44 20A 20A SERIES/PARELLEL
LIMIT SWITCH 38
NORMALLY OPEN RELAY
35CR
10A 35 HELD CLOSED 35 ELEVATION/HI SPD
39
CUTOUT RELAY
LS5
20 20 SERIES/PARELLEL
40
RELAY
10A 44 20CR 4H-20A
10A SERIES/PARALLEL
41
VALVE SOLENOID
3.21b Electrical Schematic (No Option with Kubota Dual Fuel Engine) S/N 37000234 & below
D02-6
44 17 17 17 17A 17A 2H-17A LARGE PUMP DUMP
S7-1 42
D02-7 VALVE SOLENOID
2ND SPEED
J
19 19 ORANGE/BLACK 19 19
JOYSTICK ENABLE 43 LARGE PUMP RELAY
ENABLE RELAY 19CR D17A
33 20B 2H-20B HIGH SPEED
44
D02-5 VALVE SOLENOID
8CCR
08 8C 02 02 WHITE 02
45
S7-2 RIGHT D16B D15B
23 23 BLACK/WHITE 23 23 4H-23 RIGHT STEERING
46
D02-8 VALVE SOLENOID
S7-3 LEFT
24 24 BLUE/BLACK 24 24 4H-24 LEFT STEERING
47
D02-9 VALVE SOLENOID
D23 D15A-1 D15A-2 4H-15B
08 8A 8A 15A 15B PARALLEL REVERSE
8B 48
NCHO D02-10 VALVE SOLENOID
10A 15A 15A 4H-15A REVERSE
49
D02-11 VALVE SOLENOID
S7-4 REV
A 15 BLUE 15 15
50 REVERSE RELAY
K
28ACR2
02 JUMPER 2
59
M
N
O
M166131AA
Z
T
Y
X
S
R
W
AD
SECTION 3, Page 68
3.22a Electrical Schematic (All Option with Kubota Dual Fuel Engine) S/N 37000235 & above AD
A B C D E F G H I J K L M N O
Serial Number Breakdown
Reference Chart
Model Serial Number
SJ68RT 37000235 & above
R
TELEMATICS
OPTION
M166380AD
08 07 RED 07 05 05 3A
37000234 & below
1
07
13 ICM1
07 RED/GREEN 07 10E 10 10 02 37 00 IGNITION
14E 10E 2
CONTROL MODULE
LED-2 CPS1
POWER ON CRANKSHAFT
D10E LIGHT 1 2 3 3 IGNITION COILS
POSITION
SENSOR
10 05 WHITE/RED 05 00
4
B
D57
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 02
13 CHOKE RELAY
10CR2 31CR
ENGINE 10 10 2A 02 02 02
START SW 14
20
D
41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41
22 START RELAY
S14 32CR2
LOW/HIGH THROTTLE 08 34 GREEN/WHITE 34 34 34A 42
23 THROTTLE RELAY
D14E-2 34ACR
33 POWER ON-
24
DEMAND RELAY
10BCR 33CR
08 BLACK/RED 08 D08 10B
25 MAIN POWER RELAY
F4
LED-1 3A 10A FUSE INV1
RST1 POWER ON 26 INVERTER OPTION
2.7K OHMS LIGHT 125 AMP
00 02 02 60 60 ORANGE/GREEN 60 08 10 2H-13-2 HOLDING VALVE
27
D02-1 SOLENOID
CONTROL BOX
CRD1 CRD2 CRD3 LIGHT JUMPER 2H-13-1 HOLDING VALVE
28
D02-2 SOLENOID
S8
E
SERIES/PARELLEL
37
RELAY
TILT OVERRIDE/ 20ACR2
HIGH DRIVE CUTOUT 44 20A 20A SERIES/PARELLEL
LIMIT SWITCH 38
NORMALLY OPEN RELAY
35CR
HELD CLOSED 10A 35 35 ELEVATION/HI SPD
39
CUTOUT RELAY
LS5
20 20 SERIES/PARELLEL
40
RELAY
10A 44 20CR 4H-20A
10A SERIES/PARALLEL
41
D02-5 VALVE SOLENOID
16CR
21 18A 16A 16B 4H-16B PARALLEL FORWARD
S7-6 54
S7 D02-14 VALVE SOLENOID
3RD SPEED D18
JOYSTICK
18 18 RED/BLACK 18 18A 18B 2H-18B SMALL PUMP DUMP
CONTROLLER 55
D02-15 VALVE SOLENOID
33 D18B
56
09 D86C 2H-86D
43 86D HYDR. GENERATOR
60
S12 D02-16 SOLENOID
HYDRAULIC 09 09 86C
GENERATOR 61 HYDR. GENERATOR
RELAY
I
SWITCH
86CCR
85 85 86B 2A
62 HYDR. GENERATOR
ON LATCHING RELAY
09
86 D86 86BCR
86A
OFF 63 HYDR. GENERATOR
STOP RELAY
D14 86ACR
64
65
FF EE CC HH MM GG BB PP II,JJ
D17C-1 D17C-2 66
72
72 = P4-7 78 RIGHT FRONT UP
D73
73
73 = P4-6 79 RIGHT REAR UP
D74
74
74 = P4-5 80 LEFT REAR UP
D75
75
75 = P4-4 81 LEFT FRONT DOWN
D76
76
76 = P4-3 82 RIGHT FRONT DOWN
D77
77
77 = P4-2 83 RIGHT REAR DOWN
D78
78
78 = P4-1 84 LEFT REAR DOWN
44 TILT OVERRIDE/
44 = P2-10 85
HIGH DRIVE CUTOUT
28
L
28 = P2-9 86 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 87 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 88 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
OUTRIGGER OPTION 67A = P2-2 89 RIGHT REAR DOWN
WITH AUTO LEVELLING RIGHT REAR
LS66
10A 66A
66A = P2-3 90 RIGHT FRONT DOWN
RIGHT FRONT
LS65
35C GREEN/WHITE 35C 10A 65A
65A = P2-4 91 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER 35C BLUE/WHITE 35C 10A
ENABLE 10A = P2-12 92 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 93 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 79 = P2-6 94 AUTO RETRACT
M
MODE ALL UP
35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 95 AUTO LEVEL
M166380AB
Z
T
Y
X
S
R
W
AD
SECTION 3, Page 70
167955
Model
SJ68RT
A
CONTROLLER -7
+
- LIGHT
37000235 & above
401
37A 37 POSI AIR SHUT OFF
-6
403A RELAY
R40
410 -3 RESISTOR
330KOHM
-2
S10
IDLE/PLTF/BASE S6 -1
S4 CONTROL BOX BASE KEY SWITCH EMERGENCY
EMERGENCY S2 (IN IDLE POSITION) STOP
STOP UP/DOWN NEGATIV
SWITCH -
07 KUBOTA DIESEL ENGINE
08 07 RED 07 05 05 3A
1
07
13 GPT1
07 RED/GREEN 07 10E 10 10 02 32A 02 GLOW PLUG
14E 10E 2
TIMER
LED-2 90
POWER ON GLOW PLUG
D10E LIGHT GPL1 3
INDICATOR
WHITE/RED EGP1
10 05 05 103 91A 00 ENGINE
4
GLOW PLUGS
05 WHITE/BLACK/RED 05 34C 34C HTS-34C HIGH THROTTLE
5
SOLENOID
C
D02-26
3A 43 43A 34B 34C 3A 3A
6
3ACR
10 BLUE/WHITE 10 2B 3A DIESEL VALVE
7
PULL-IN RELAY
10 BLUE/RED 10 3A 32A 32A 32A 37 2D37 00 DIESEL VALVE
8
SOLENOID
HOURMETER D57
10 57 57A
TT OIL 9
PRESSURE 32ACR D02-27
SWITCH 32A 00 ENGINE STARTER
10
CONTACTOR
ENGINE 10CR1 TPS1
GLOW PLUG 10 10 2A 2A 2A D2A 2B 2C 2C 00 TEMPERATURE
/CHOKE SW 11
SWITCH
OPS1
31 10B 3A 3A 37A 37/37A 37/37A
S13 12
GLOW PLUG/ S31 JMPR4
D32A
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 GLOW PLUG
13
RELAY
10CR2 31CR
ENGINE 10 10 2A 02 02 02
D
START SW 14
20
41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41
22 START RELAY
S14 32CR2
E
D14E-2 34ACR
33 POWER ON-
24
DEMAND RELAY
10BCR 33CR
08 BLACK/RED 08 D08 10B
25 MAIN POWER RELAY
F4
LED-1 3A 10A FUSE INV1
RST1 POWER ON 26 INVERTER OPTION
2.7K OHMS LIGHT 125 AMP
00 02 02 60 60 ORANGE/GREEN 60 08 10 2H-13-2 HOLDING VALVE
27
D02-1 SOLENOID
CONTROL BOX
CRD1 CRD2 CRD3 LIGHT JUMPER 2H-13-1 HOLDING VALVE
28
D02-2 SOLENOID
S8 2H-13
13 MAIN LOWERING
HORN 29
D02-3 VALVE SOLENOID
08 49 GREEN 49 49
30 HORN
S3 H1 FLASHER
LIFT/OFF/DRIVE D13
29 29 22 FLASHING LIGHT
(IN LIFT POSITION) 31
F
FL-22 OPTION
17CR FL-29
13 13 ORANGE 13 17
A 32 SMALL PUMP RELAY
NOHC D28B
17 28B ALL MOTION ALARM
D14E-1 D30 D14A-3 33
OPTION
14 BLACK 14 D28C
14 18A 28C 29 29
B 34 BEEPER
BP-29
NOHC
14A 3H-14A LIFT VALVE
35
D02-4 SOLENOID
D09
09 ORANGE/RED 09 35A THROTTLE ENABLE
08 36
09 RELAY
NOHC 35ACR D44-2 D14A-1 20ACR1
20A SERIES/PARELLEL
37
RELAY
TILT OVERRIDE/ 20ACR2
HIGH DRIVE CUTOUT 44 20A 20A SERIES/PARELLEL
LIMIT SWITCH 38
NORMALLY OPEN RELAY
35CR
HELD CLOSED 10A 35 35 ELEVATION/HI SPD
39
CUTOUT RELAY
LS5
G
20 20 SERIES/PARELLEL
40
RELAY
10A 44 20CR 4H-20A
10A SERIES/PARALLEL
41
D02-5 VALVE SOLENOID
44 17 17 17 17A 17A 2H-17A LARGE PUMP DUMP
S7-1 42
D02-6 VALVE SOLENOID
2ND SPEED
19 19 ORANGE/BLACK 19 19
JOYSTICK ENABLE 43 LARGE PUMP RELAY
ENABLE RELAY 19CR D17A
33 20B 2H-20B HIGH SPEED
44
D02-7 VALVE SOLENOID
8CCR D16B
08 8C 02 02 WHITE 02
45
S7-2 RIGHT D15B
23 23 BLACK/WHITE 23 23 4H-23 RIGHT STEERING
46
D02-8 VALVE SOLENOID
S7-3 LEFT
24 24 BLUE/BLACK 24 24 4H-24 LEFT STEERING
47
D02-9 VALVE SOLENOID
D23 D15A-1 D15A-2 4H-15B
08 8A 8A 15A 15B PARALLEL REVERSE
8B 48
NCHO VALVE SOLENOID
H
D02-10
10A 15A 15A 4H-15A REVERSE
49
D02-11 VALVE SOLENOID
S7-4 REV
A 15 BLUE 15 15
50 REVERSE RELAY
15CR D24 D16A-1 D16A-2
30 3H-30 BRAKE
51
D02-12 VALVE SOLENOID
10A 16A 16A 4H-16A FORWARD
52
D02-13 VALVE SOLENOID
S7-5 FWD
B 16 WHITE/BLACK 16 16
53 FORWARD RELAY
16CR
21 18A 16A 16B 4H-16B PARALLEL FORWARD
S7-6 54
S7 D02-14 VALVE SOLENOID
3RD SPEED D18
JOYSTICK
18 18 RED/BLACK 18 18A 18B 2H-18B SMALL PUMP DUMP
CONTROLLER 55
D02-15 VALVE SOLENOID
33 D18B
56
44 14A
I
09 D86C 2H-86D
43 86D HYDR. GENERATOR
60
S12 D02-16 SOLENOID
HYDRAULIC 09 09 86C
GENERATOR 61 HYDR. GENERATOR
SWITCH RELAY
86CCR
85 85 86B 2A
62 HYDR. GENERATOR
ON LATCHING RELAY
09
86 D86 86BCR
86A
OFF 63 HYDR. GENERATOR
STOP RELAY
3.23a Electrical Schematic (All Option with Kubota Diesel Engine) S/N 37000235 & above
D14 86ACR
64
65
FF EE CC HH MM GG BB PP II,JJ
J
D17C-1 D17C-2 66
ENABLE RELAY
S20A S21A S22A S23A
44 35B 35C 35C 35E FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT 17D OUTRIGGER
75
LIFT DISABLE RELAY
S9B UP UP UP UP 17DCR
OUTRIGGER
OUTRIGGER 76
CUT J17D CONTROL MODULE
ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 77 LEFT FRONT UP
D72
72
72 = P4-7 78 RIGHT FRONT UP
D73
73
73 = P4-6 79 RIGHT REAR UP
D74
74
74 = P4-5 80 LEFT REAR UP
D75
75
75 = P4-4 81 LEFT FRONT DOWN
D76
76
76 = P4-3 82 RIGHT FRONT DOWN
D77
L
77
77 = P4-2 83 RIGHT REAR DOWN
D78
78
78 = P4-1 84 LEFT REAR DOWN
44 TILT OVERRIDE/
44 = P2-10 85
HIGH DRIVE CUTOUT
28
28 = P2-9 86 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 87 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 88 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
OUTRIGGER OPTION 67A = P2-2 89 RIGHT REAR DOWN
WITH AUTO LEVELLING RIGHT REAR
LS66
10A 66A
66A = P2-3 90 RIGHT FRONT DOWN
RIGHT FRONT
LS65
35C GREEN/WHITE 35C 10A 65A
65A = P2-4 91 LEFT FRONT DOWN
S9A LEFT FRONT
M
100
D02-19 OUTRIGGER SOLENOID
S21
72 RED 72 72 4H-72 RIGHT FRONT UP
FRONT 101
RIGHT UP OUTRIGGER SOLENOID
35D D02-20
76 RED/BLACK 76 76 4H-76 RIGHT FRONT DOWN
DN 102
D02-21 OUTRIGGER SOLENOID
S22
73 BLUE 73 73 4H-73 RIGHT REAR UP
REAR 103
RIGHT UP OUTRIGGER SOLENOID
35D D02-22
77 BLUE/BLACK 77 77 4H-77 RIGHT REAR DOWN
DN 104
D02-23 OUTRIGGER SOLENOID
S23
74 BLACK 74 74 4H-74 LEFT REAR UP
REAR 105
LEFT UP OUTRIGGER SOLENOID
35D D02-24
78 BLACK/WHITE 78 78 4H-78 LEFT REAR DOWN
DN 106
D02-25 OUTRIGGER SOLENOID
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SECTION 3, Page 71
167955
Model
SJ68RT
A
CONTROLLER -7
+
- LIGHT
37000234 & below
401
37A 37 POSI AIR SHUT OFF
-6
403A RELAY
R40
410 -3 RESISTOR
330KOHM
-2
S10
PLTF/IDLE/BASE S6 -1
S4 CONTROL BOX BASE KEY SWITCH EMERGENCY
EMERGENCY S2 (IN IDLE POSITION) STOP
STOP UP/DOWN NEGATIV
SWITCH -
07 KUBOTA DIESEL ENGINE
08 07 RED 07 05 05 3A
1
07
13 GPT1
07 RED/GREEN 07 10E 10 10 02 32A 02 GLOW PLUG
14E 10E 2
TIMER
LED-2 90
POWER ON GLOW PLUG
D10E LIGHT GPL1 3
INDICATOR
WHITE/RED EGP1
10 05 05 103 91A 00 ENGINE
4
GLOW PLUGS
05 WHITE/BLACK/RED 05 34C 34C HTS-34C HIGH THROTTLE
5
SOLENOID
C
D02-26
3A 43 43A 34B 34C 3A 3A
6
3ACR
10 BLUE/WHITE 10 2B 3A DIESEL VALVE
7
PULL-IN RELAY
10 BLUE/RED 10 3A 32A 32A 32A 37 2D37 00 DIESEL VALVE
8
SOLENOID
HOURMETER D57
10 57 57A
TT OIL 9
PRESSURE 32ACR D02-27
SWITCH 32A 00 ENGINE STARTER
10
CONTACTOR
ENGINE 10CR1 TPS1
GLOW PLUG 10 10 2A 2A 2A D2A 2B 2C 2C 00 TEMPERATURE
/CHOKE SW 11
SWITCH
OPS1
31 10B 3A 3A 37A 37/37A 37/37A
S13 12
GLOW PLUG/ S31 JMPR4
D32A
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 GLOW PLUG
13
RELAY
10CR2 31CR
ENGINE 10 10 2A 02 02 02
D
START SW 14
20
41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41
22 START RELAY
S14 32CR2
E
D14E-2 34ACR
33 POWER ON-
24
DEMAND RELAY
10BCR 33CR
08 BLACK/RED 08 D08 10B
25 MAIN POWER RELAY
F4
LED-1 3A 10A FUSE INV1
RST1 POWER ON 26 INVERTER OPTION
2.7K OHMS LIGHT 125 AMP
00 02 02 60 60 ORANGE/GREEN 60 08 10 2H-13-2 HOLDING VALVE
27
D02-1 SOLENOID
CONTROL BOX
CRD1 CRD2 CRD3 LIGHT JUMPER 2H-13-1 HOLDING VALVE
28
D02-2 SOLENOID
S8 2H-13
13 MAIN LOWERING
HORN 29
D02-3 VALVE SOLENOID
08 49 GREEN 49 49
30 HORN
S3 H1 FLASHER
LIFT/OFF/DRIVE D13
29 29 22 FLASHING LIGHT
(IN LIFT POSITION) 31
F
FL-22 OPTION
17CR FL-29
13 13 ORANGE 13 17
A 32 SMALL PUMP RELAY
NOHC D28B
17 28B ALL MOTION ALARM
D14E-1 D30 D14A-3 33
OPTION
14 BLACK 14 D28C
14 18A 28C 29 29
B 34 BEEPER
BP-29
NOHC
14A 3H-14A LIFT VALVE
35
D02-4 SOLENOID
D09
09 ORANGE/RED 09 35A THROTTLE ENABLE
08 36
09 RELAY
NOHC 35ACR D44-2 D14A-1 20ACR1
20A SERIES/PARELLEL
37
RELAY
TILT OVERRIDE/ 20ACR2
HIGH DRIVE CUTOUT 44 20A 20A SERIES/PARELLEL
LIMIT SWITCH 38
NORMALLY OPEN RELAY
35CR
HELD CLOSED 10A 35 35 ELEVATION/HI SPD
39
CUTOUT RELAY
LS5
G
20 20 SERIES/PARELLEL
40
RELAY
10A 44 20CR 4H-20A
10A SERIES/PARALLEL
41
D02-5 VALVE SOLENOID
44 17 17 17 17A 17A 2H-17A LARGE PUMP DUMP
S7-1 42
D02-6 VALVE SOLENOID
2ND SPEED
19 19 ORANGE/BLACK 19 19
JOYSTICK ENABLE 43 LARGE PUMP RELAY
ENABLE RELAY 19CR D17A
33 20B 2H-20B HIGH SPEED
44
D02-7 VALVE SOLENOID
8CCR D16B
08 8C 02 02 WHITE 02
45
S7-2 RIGHT D15B
23 23 BLACK/WHITE 23 23 4H-23 RIGHT STEERING
46
D02-8 VALVE SOLENOID
S7-3 LEFT
24 24 BLUE/BLACK 24 24 4H-24 LEFT STEERING
47
D02-9 VALVE SOLENOID
D23 D15A-1 D15A-2 4H-15B
08 8A 8A 15A 15B PARALLEL REVERSE
8B 48
NCHO VALVE SOLENOID
H
D02-10
10A 15A 15A 4H-15A REVERSE
49
D02-11 VALVE SOLENOID
S7-4 REV
A 15 BLUE 15 15
50 REVERSE RELAY
15CR D24 D16A-1 D16A-2
30 3H-30 BRAKE
51
D02-12 VALVE SOLENOID
10A 16A 16A 4H-16A FORWARD
52
D02-13 VALVE SOLENOID
S7-5 FWD
B 16 WHITE/BLACK 16 16
53 FORWARD RELAY
16CR
21 18A 16A 16B 4H-16B PARALLEL FORWARD
S7-6 54
S7 D02-14 VALVE SOLENOID
3RD SPEED D18
JOYSTICK
18 18 RED/BLACK 18 18A 18B 2H-18B SMALL PUMP DUMP
CONTROLLER 55
D02-15 VALVE SOLENOID
33 D18B
56
44 14A
I
09 D86C 2H-86D
43 86D HYDR. GENERATOR
60
S12 D02-16 SOLENOID
HYDRAULIC 09 09 86C
GENERATOR 61 HYDR. GENERATOR
SWITCH RELAY
86CCR
85 85 86B 2A
62 HYDR. GENERATOR
ON LATCHING RELAY
09
86 D86 86BCR
86A
3.23b Electrical Schematic (All Option with Kubota Diesel Engine) 37000234 & below
65
FF EE CC HH MM GG BB PP II,JJ
J
D17C-1 D17C-2 66
ENABLE RELAY
S20A S21A S22A S23A
44 35B 35C 35C 35E FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT 17D OUTRIGGER
75
LIFT DISABLE RELAY
S9B UP UP UP UP 17DCR
OUTRIGGER
OUTRIGGER 76
CUT J17D CONTROL MODULE
ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 77 LEFT FRONT UP
D72
72
72 = P4-7 78 RIGHT FRONT UP
D73
73
73 = P4-6 79 RIGHT REAR UP
D74
74
74 = P4-5 80 LEFT REAR UP
D75
75
75 = P4-4 81 LEFT FRONT DOWN
D76
76
76 = P4-3 82 RIGHT FRONT DOWN
D77
L
77
77 = P4-2 83 RIGHT REAR DOWN
D78
78
78 = P4-1 84 LEFT REAR DOWN
44 TILT OVERRIDE/
44 = P2-10 85
HIGH DRIVE CUTOUT
28
28 = P2-9 86 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 87 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 88 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
OUTRIGGER OPTION 67A = P2-2 89 RIGHT REAR DOWN
WITH AUTO LEVELLING RIGHT REAR
LS66
10A 66A
66A = P2-3 90 RIGHT FRONT DOWN
RIGHT FRONT
LS65
35C GREEN/WHITE 35C 10A 65A
65A = P2-4 91 LEFT FRONT DOWN
S9A LEFT FRONT
M
100
D02-19 OUTRIGGER SOLENOID
S21
72 RED 72 72 4H-72 RIGHT FRONT UP
FRONT 101
RIGHT UP OUTRIGGER SOLENOID
35D D02-20
76 RED/BLACK 76 76 4H-76 RIGHT FRONT DOWN
DN 102
D02-21 OUTRIGGER SOLENOID
S22
73 BLUE 73 73 4H-73 RIGHT REAR UP
REAR 103
RIGHT UP OUTRIGGER SOLENOID
35D D02-22
77 BLUE/BLACK 77 77 4H-77 RIGHT REAR DOWN
DN 104
D02-23 OUTRIGGER SOLENOID
S23
74 BLACK 74 74 4H-74 LEFT REAR UP
REAR 105
LEFT UP OUTRIGGER SOLENOID
35D D02-24
78 BLACK/WHITE 78 78 4H-78 LEFT REAR DOWN
DN 106
D02-25 OUTRIGGER SOLENOID
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Section 4
TROUBLESHOOTING INFORMATION
Table of Contents
Introduction
Electrical System
4.1-1 All Controls Inoperative..................................................................................................................................78
4.1-2 No Power To Platform....................................................................................................................................78
4.1-3 All Functions Inoperative from The Platform..................................................................................................79
4.1-4 Engine Does not Crank from Platform or Base Control Console..................................................................79
4.1-5 Engine Cranks But Does not Start – Kubota Diesel......................................................................................80
4.1-6 Engine Cranks But Does not Start – Kubota Dual Fuel.................................................................................81
4.1-7 Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models).................................................81
4.1-8 Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel)....................................................82
4.1-9 High Throttle Inoperative................................................................................................................................83
4.1-10 High Throttle On Demand Inoperative (Kubota Dual Fuel)...........................................................................84
4.1-11 Drive and Steer Inoperative (Machines without outriggers option)...............................................................84
4.1-12 Drive and Steer Inoperative (Machines with outriggers option)....................................................................85
4.1-13 Brakes Does not Release...............................................................................................................................86
4.1-14 Steer Right Inoperative...................................................................................................................................86
4.1-15 Steer Left Inoperative.....................................................................................................................................86
4.1-16 Reverse Drive Inoperative..............................................................................................................................87
4.1-17 Forward Drive Inoperative..............................................................................................................................88
4.1-18 First Drive Speed and Steering Inoperative...................................................................................................88
4
4.1-19 Second Drive Speed Inoperative...................................................................................................................89
4.1-20 Third Drive Speed Inoperative.......................................................................................................................90
4.1-22 High Drive Speed Inoperative........................................................................................................................91
4.1-21 Up Circuit Inoperative from Platform.............................................................................................................91
4.1-22 Up Circuit Inoperative from Base Control Console.......................................................................................92
4.1-23 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers)...................................92
4.1-24 Platform does not Lift from Platform or Base Control Console with Outriggers Retracted (Lift Operates
Correctly with Outriggers Extended).............................................................................................................92
4.1-25 Platform does not Lift from Platform or Base Control Console with Outriggers Extended...........................93
4.1-26 Platform does not Lift from Platform or Base Control Console with Outriggers Extended or Retracted......94
4.1-27 Down Circuit Inoperative from Platform.........................................................................................................95
4.1-28 Down Circuit Inoperative from Base..............................................................................................................95
4.1-29 Hydraulic Generator Inoperative....................................................................................................................95
4.1-30 Hydraulic Generator does not Shut Off from Generator Switch....................................................................96
4.1-31 All Outriggers Inoperative (Auto-Level and Manual).....................................................................................97
4.1-32 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)................................................97
4.1-33 All Outriggers Inoperative (Base Controls only)............................................................................................98
4.1-34 All Outriggers Inoperative (Auto Level only)..................................................................................................98
4.1-35 All Outriggers Inoperative (Auto Level only)..................................................................................................99
4.1-36 Left Front Outrigger Inoperative Manually...................................................................................................100
4.1-37 Right Front Outrigger Inoperative Manually................................................................................................100
4.1-38 Right Rear Outriggers Inoperative Manually................................................................................................100
4.1-39 Left Rear Outriggers Inoperative Manually..................................................................................................101
4.1-40 Individual Outrigger Functions Inoperative (Auto-Level) ............................................................................101
Hydraulic System
4.2-1 All Functions Inoperative .............................................................................................................................103
4.2-2 Steering Inoperative.....................................................................................................................................103
4.2-3 Lift, Steer and First Drive Speed Inoperative...............................................................................................103
4.2-4 Second Drive Speed Inoperative.................................................................................................................103
4.2-5 Drive Inoperative..........................................................................................................................................103
4.2-6 Drive Sluggish..............................................................................................................................................104
4.2-7 Reverse Drive Inoperative............................................................................................................................104
4.2-8 Forward Drive Inoperative............................................................................................................................104
4.2-9 Drive Inoperative When in Low Drive...........................................................................................................104
4.2-10 Drive Inoperative When in High Drive..........................................................................................................104
4.2-11 Brakes Does not Release.............................................................................................................................104
4.2-12 Up Circuit Inoperative..................................................................................................................................104
4.2-13 Down Circuit Inoperative..............................................................................................................................105
4.2-14 Hydraulic Generator Inoperative..................................................................................................................105
4.2-15 All Outriggers Inoperative............................................................................................................................105
4.2-16 Left Front Outriggers Inoperative.................................................................................................................105
4.2-17 Right Front Outriggers Inoperative..............................................................................................................106
4.2-18 Right Rear Outriggers Inoperative...............................................................................................................106
4.2-19 Left Rear Outriggers Inoperative..................................................................................................................106
4.2-20 Outriggers Drift In.........................................................................................................................................106
Introduction
The following pages contain Troubleshooting
Information for locating and correcting most service
problems that can develop.
1. Probable Cause
-- Remedy
Electrical System
2. Loose or broken wire #07 from key switch S10 to base terminal block TB-1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #07 from base terminal block TB-1 to platform emergency stop switch S4.
-- Check continuity. Replace if defective.
4. Open or defective platform emergency stop switch S4.
-- Check switch. Replace if defective.
4.1-4 Engine Does not Crank from Platform or Base Control Console
1. Loose or broken wire #8 from horn switch S8 to start switch S15 (Platform only).
-- Check continuity. Replace if defective.
2. Defective start switch S15 (Platform only).
-- Check switch. Replace if defective.
3. Loose or broken wire #32 from start switch S15 to base start switch S32 (Platform only).
-- Check continuity. Replace if defective.
4. Loose or broken wire #10E from key switch S10 to base terminal block TB-1 (Base only).
-- Check continuity. Replace if defective.
5. Defective key switch S10 (Base only).
-- Check switch. Replace if defective.
6. Open or defective diode D10E (Base only).
-- Check diode. Replace if defective.
7. Loose or broken wire #10B from base terminal block TB-1 to base choke/ glow plug switch S31(Base
only).
-- Check continuity. Replace if defective.
8. Loose or broken wire #10B from base choke/ glow plug switch S31 to base start switch S32 (Base
only).
-- Check continuity. Replace if defective.
9. Defective base start switch S32 (Base only).
-- Check switch. Replace if defective.
10. Loose or broken wire #32 from base start switch S32 to relay 32CR2.
-- Check continuity. Replace if defective.
11. Defective relay 32CR2.
-- Check relay. Replace if defective.
12. Loose or broken jumper wire #41 on relay 32CR2.
-- Check continuity. Replace if defective.
13. Loose or broken wire #02 from relay 32CR2 to base terminal block TB-1.
-- Check continuity. Replace if defective.
14. Ground not getting through N/C set of contacts on relay 10CR2 to relay 32CR2.
-- Check continuity through contacts. Replace if defective.
15. Loose or broken wire #3A from relay 10BC2 to relay 32CR1.
-- Check continuity. Replace if defective.
16. Loose or broken wire #32A from relay 32CR1 to engine harness.
-- Check continuity. Replace if defective.
17. Loose or broken wire #32 from relay 32CR2 to relay 32CR1.
-- Check continuity. Replace if defective.
18. Loose or broken wire #41 from relay 32CR2 to relay 32CR1.
-- Check continuity. Replace if defective.
19. Defective relay 32CR1.
-- Check relay. Replace if defective.
20. Loose or broken wire #32A from engine harness to starter contactor 32ACR.
-- Check continuity. Replace if defective.
21. Defective starter contactor 32ACR.
-- Check contactor. Replace if defective.
22. Loose or broken wire #00 from starter contactor 32ACR to base terminal block TB-1.
-- Check continuity. Replace if defective.
23. Loose or broken wire #103 from main power disconnect S1 to starter contactor 32ACR.
-- Check continuity. Replace if defective.
24. Loose or broken wire #57 from starter contactor 32ACR to starter motor.
-- Check continuity. Replace if defective.
25. Defective starter motor.
-- Check motor. Repair or replace if defective.
4.1-6 Engine Cranks But Does not Start – Kubota Dual Fuel
1. Open or defective diode D57. (Diode located in Engine harness. Refer to Engine wiring diagram- Dual
Fuel System)
-- Check diode. Replace if defective.
2. Loose or broken wire #37 from engine harness plug to coil pack 2 wire connector.
-- Check continuity. Replace if defective.
3. Loose or broken wire #00 from coil pack 2 wire connector to engine ground.
-- Check continuity. Replace if defective.
4. Loose or broken wire #00 from engine ground to crank position sensor.
-- Check continuity. Replace if defective.
5. Loose or broken wire #37 from ignition control module ICM1 to crank position sensor CPS1.
-- Check continuity. Replace if defective.
6. Defective ignition control module ICM1.
-- Refer to section 5 of this manual for Ohm specifications. Replace if defective.
7. Defective crank position sensor CPS1.
-- Refer to section 5 of this manual for Ohm specifications. Replace if defective.
8. Loose or broken wire #37 from engine harness plug to fuel select switch S33.
-- Check continuity. Replace if defective.
9. Defective fuel switch S33.
-- Check switch. Replace if defective.
10. While in gasoline, loose or broken wire #11 from fuel select switch S33 to fuel pump FP11 or gas valve
2G-11.
-- Check continuity. Replace if defective.
11. While in propane, loose or broken wire #50 from fuel select switch S33 to fuel lockoff 2P-50-1 or propane
lockoff 2P-50-2.
-- Check continuity. Replace if defective.
12. Loose or broken wire #00 from engine ground to propane lockoff 2P-50-1 or 2P-50-2 (propane) or to
gasoline 2G-11 or fuel pump FP11 (gasoline).
-- Check continuity. Replace if defective.
13. Defective propane lockoff 2P-50-1 or 2P-50-2 (propane) or gas valve 2G-11 or fuel pump FP11 (gasoline).
-- Check lockoffs, valve or pump. Replace if defective.
4.1-7 Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models)
1. Loose or broken wire #8 from start switch S15 to glow plug switch S13 (Platform only).
-- Check continuity. Replace if defective.
2. Defective glow plug switch S13 (Platform only).
-- Check switch. Replace if defective.
3. Loose or broken wire #31 from glow plug switch S13 to base glow plug switch S31 (Platform only).
-- Check continuity. Replace if defective.
4. Loose or broken wire #10B from base terminal block TB-1 to base glow plug switch S31 (Base only).
-- Check continuity. Replace if defective.
5. Defective base glow plug switch S31 (Base only).
-- Check switch. Replace if defective.
6. Loose or broken wire #31 from glow plug switch S31 to glow plug relay 31CR.
-- Check continuity. Replace if defective.
7. Loose or broken wire #02 from glow plug relay 31CR to base terminal block TB1.
-- Check continuity. Replace if defective.
8. Loose or broken wire #103 from engine starter to relay 31CR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #91A from relay 31CR to engine glow plugs EGP1.
-- Check continuity. Replace if defective.
10. Defective glow plug relay 31CR.
-- Check relay. Replace if defective.
11. Defective glow plugs.
-- Check glow plugs. Replace if defective.
4.1-8 Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel)
1. Loose or broken wire #8 from start switch S15 to choke switch S13 (Platform only).
-- Check continuity. Replace if defective.
2. Defective choke switch S13 (Platform only).
-- Check switch. Replace if defective.
3. Loose or broken wire #31 from choke switch S13 to base choke switch S31 (Platform only).
-- Check continuity. Replace if defective.
4. Loose or broken wire #10B from base terminal block TB-1 to base choke switch S31 (Base only).
-- Check continuity. Replace if defective.
5. Defective base choke switch S31 (Base only).
-- Check switch. Replace if defective.
6. Loose or broken wire #31 from base choke switch S31 to engine harness.
-- Check continuity. Replace if defective.
12. Loose or broken wire #02 from engine harness to choke solenoid CS-31A.
-- Check continuity. Replace if defective.
13. Defective choke solenoid CS-31A.
-- Check solenoid. Replace if defective.
1. Loose or broken wire #08 from lift / drive select switch S3 to low/high throttle switch S14.
-- Check continuity. Replace if defective.
2. Defective low/high throttle switch S14.
-- Check switch. Replace if defective.
3. Loose or broken wire #34 from low/high throttle switch S14 to relay 35ACR.
-- Check continuity. Replace if defective.
4. Open diode D09 (when in lift only).
-- Check diode. Replace if defective.
5. Open diode D44-2 (when in drive only).
-- Check diode. Replace if defective.
6. Loose or broken wire #35A from base terminal block TB-1 to relay 35ACR.
-- Check continuity. Replace if defective.
7. Defective relay 35ACR.
-- Check relay. Replace if defective.
8. Loose or broken wire #02 from relay 35ACR to terminal block TB1.
-- Check continuity. Replace if defective.
9. Loose or broken wire #34A from relay 35ACR to relay 34ACR.
-- Check continuity. Replace if defective.
10. Defective relay 34ACR.
-- Check relay. Replace if defective.
11. Loose or broken wire #42 from relay 34ACR to relay 10CR2.
-- Check continuity. Replace if defective.
12. Defective relay 10CR2.
-- Check relay. Replace if defective.
13. Loose or broken wire #2A from relay 10CR2 to relay 10CR1.
-- Check continuity. Replace if defective.
14. Loose or broken wire #3A from base terminal block TB1 to relay 32CR1.
-- Check continuity. Replace if defective.
15. Defective relay 32CR1.
-- Check relay. Replace if defective.
16. Loose or broken wire #43 from relay 32CR1 to relay 34ACR.
-- Check continuity. Replace if defective.
17. Loose or broken wire #34B from relay 34ACR to relay 33CR.
-- Check continuity. Replace if defective.
3. Loose or broken wire #08 from Lift/Drive select switch S3 to controller enable switch S7-7.
-- Check continuity. Replace if defective.
4. Defective controller enable switch S7-7.
-- Check switch. Replace if defective.
5. Loose or broken wire #8A from controller enable relay 8CCR to speed, steer and direction switches
S7-1 to S7-6.
-- Check continuity. Replace if defective.
6. Loose or broken wire #8C from controller enable switch S7-7 to controller enable relay 8CCR.
-- Check continuity. Replace if defective.
11. Loose or broken wire #28 from outrigger control module OCM1 at pin #P2-9 to outrigger connector
CN14 at pin #7.
-- Check continuity. Replace if defective.
12. 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.
13. 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.
14. 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.
15. 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.
16. Defective drive enable relay 61CR.
-- Check relay. Replace if defective.
17. Loose or broken wire #28A from pin #1 on connector CN14 at the outrigger board to terminal block
TB1.
-- Check continuity. Replace if defective.
2. Loose or broken wire #24 from steer left switch S7-3 to base terminal block TB1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #24 from base terminal block TB1 to steer left valve coil 4H-24.
-- Check continuity. Replace if defective.
4. Defective steer left valve coil 4H-24.
-- Check coil. Replace if defective.
5. Loose or broken wire #02 from steer left valve coil 4H-24 to base terminal block TB1.
-- Check continuity. Replace if defective.
6. Open diode D24.
-- Check diode. Replace if defective.
10. Loose or broken wire #16A from base terminal block TB1 to relay 20ACR1 (in parallel drive only).
-- Check continuity. Replace if defective.
11. Defective relay 20ACR1 (in parallel drive only).
-- Check relay. Replace if defective.
12. Loose or broken wire #16B from relay 20ACR1 to parallel forward valve coil 4H-16B (in parallel drive
only).
-- Check continuity. Replace if defective.
13. Loose or broken wire #02 from base terminal block TB1 to parallel forward valve coil 4H-16B (in parallel
drive only).
-- Check continuity. Replace if defective.
14. Defective parallel forward valve coil 4H-16B (in parallel drive only).
-- Check coil. Replace if defective.
15. Open diode D16A-1 or D16A-2.
-- Check diodes. Replace if defective.
13. Loose or broken wire #44 from base terminal block TB1 to relay 19CR.
-- Check continuity. Replace if defective.
14. Loose or broken wire #17 from relay 19CR to relay 17CR.
-- Check continuity. Replace if defective.
15. Defective relay 17CR.
-- Check relay. Replace if defective.
16. Loose or broken wire #02 from relay 17CR to base terminal block TB1.
-- Check continuity. Replace if defective.
17. Loose or broken wire #17 from relay 17CR to relay 28ACR2.
-- Check continuity. Replace if defective.
18. Loose or broken wire #17A from relay 28ACR2 to base terminal block TB1. (ANSI/CSA)
-- Check continuity. Replace if defective.
19. Defective relay 28ACR2.
-- Check relay. Replace if defective.
20. Loose or broken wire #17A from relay 28ACR2 to relay 28ECR2. (CE)
-- Check continuity. Replace if defective.
21. Defective relay 28ECR2. (CE)
-- Check relay. Replace if defective.
22. Loose or broken wire #17B from relay 28ECR2 to base terminal block TB1. (CE)
-- Check continuity. Replace if defective.
23. Loose or broken wire #17A from base terminal block TB1 to large pump dump valve coil 2H-17A. (ANSI/
CSA)
-- Check continuity. Replace if defective.
24. Loose or broken wire #17B from base terminal block TB1 to large pump dump valve coil 2H-17B. (CE)
-- Check continuity. Replace if defective.
25. Loose or broken wire #02 from large pump dump valve coil 2H-17A (ANSI/CSA) or 2H-17B (CE) to
base terminal block TB1.
-- Check continuity. Replace if defective.
26. Defective large pump dump valve coil 2H-17A (ANSI/CSA) or 2H-17B (CE).
-- Check coil. Replace if defective.
5. Loose or broken wire #14 from contact on lift/drive select switch S3 to base terminal block TB1.
-- Check continuity. Replace if defective.
4.1-24 Platform does not Lift from Platform or Base Control Console with
Outriggers Retracted (Lift Operates Correctly with Outriggers Extended)
1. Outriggers not fully retracted.
-- Fully retract outrigger cylinders.
2. Loose or broken wire #10A from base terminal block TB1 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 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.
16. Open diode D36-1 at pin #1 on CN22 on outrigger board.
-- Check diode. Replace if defective.
4.1-25 Platform does not Lift from Platform or Base Control Console 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 base terminal block TB1 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 board.
-- Check continuity. Replace if defective.
6. Loose or broken wire #10A from outrigger board to outrigger limit switch LS67.
-- Check continuity. Replace if defective.
7. Defective outrigger limit switch LS67.
-- Check switch. Replace if defective.
8. Loose or broken wire #67A from outrigger limit switch LS67 to outrigger board.
-- 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 board.
-- 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 board.
-- 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.
-- Check continuity. Replace if defective.
17. Open diode D14A-2 at base terminal block TB1.
-- Check diode. Replace if defective.
4.1-26 Platform does not Lift from Platform or Base Control Console with
Outriggers Extended or Retracted
1. Defective lift enable relay 65CR.
-- Check relay. Replace if defective.
2. Defective lift disable relay 17DCR.
-- Check relay. Replace if defective.
3. Loose or broken wire #14 from base terminal block TB1 to outrigger/ generator harness connector.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from base terminal block TB1 to outrigger/ generator harness connector.
-- Check continuity. Replace if defective.
5. Loose or broken wire #14 from base terminal block to control module CM1 at pin #P2-3 (CE).
-- Check continuity. Replace if defective.
6. Defective up relay 14CR.
-- Check relay. Replace if defective.
7. Loose or broken wire #36A from pin#10 on connector CN14 to up relay 14CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #14A from up relay 14CR to base terminal block TB1.
-- 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 #86B from generator relay 86ACR to generator relay 86BCR.
-- Check continuity. Replace if defective.
7. Defective relay 86ACR.
-- Check relay. Replace if defective.
8. Defective relay 86BCR.
-- Check relay. Replace if defective.
9. Loose or broken wire #2A from hour meter to relay 86BCR.
-- Check continuity. Replace if defective.
10. Loose or broken wire #86C from generator relay 86BCR to generator relay 86CCR.
-- Check continuity. Replace if defective.
11. Open diode D86C.
-- Check diode. Replace if defective.
12. Loose or broken wire #85 from diode D86C to relay 86ACR.
-- Check continuity. Replace if defective.
13. Loose or broken wire #02 from base terminal block TB1 to relay 86CCR.
-- Check continuity. Replace if defective.
14. Defective relay 86CCR.
-- Check relay. Replace if defective.
15. Loose or broken wire #43 from relay 32CR1 to relay 86CCR.
-- Check continuity. Replace if defective.
16. Loose or broken wire #86D from relay 86CCR to generator valve coil 2H-86D.
-- Check continuity. Replace if defective.
17. Loose or broken wire #02 from base terminal block to generator valve coil 2H-86D.
-- Check continuity. Replace if defective.
18. Defective generator valve coil 2H-86D.
-- Check coil. Replace if defective.
19. Open diode D86D.
-- Check diode. Replace if defective.
20. Loose or broken wire #17A from diode D86D to base terminal block TB1.
-- Check continuity. Replace if defective.
4.1-30 Hydraulic Generator does 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.
NOTE: For the outriggers to function the upper control box must be in the lift position and the scissor
stack stowed or fully retracted.
1. Loose or broken wire # 44 from base terminal block TB1 to pin #6 on connector CN14 on outrigger
board.
-- Check for continuity. Replace if defective.
2. 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 the main terminal block TB1.
Replace if defective.
3. Defective relay 9CR2 or 9CR3 on outrigger board.
-- Check relays. Replace if defective.
4. Open diode D17C-1 on outrigger board.
-- Check diode. Replace if defective.
5. Defective relay 17DCR on outrigger board.
-- Check relay. Replace if defective.
6. Open or defective fuse jumper J17E on outrigger board.
-- Check fuse. Replace if defective.
7. Loose or broken wire # 17A from pin #2 on connector CN14 on outrigger board to terminal block TB1.
-- Check for continuity. Replace if defective.
8. Loose or broken wire #17C at pin #1 or wire #02 at pin #2 on connector CN21 on outrigger board to
outrigger holding valve coil 2H-17C.
-- Check for continuity. Replace if defective.
9. Defective outrigger holding valve coil 2H-17C.
-- Check coil. Replace if defective.
4.1-32 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)
1. Loose or broken wires #35C at pin #1 on connector CN20 on outrigger board through outrigger cables
and plugs to the outrigger enable switch S9A in the control box.
-- 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.
Hydraulic System
Table of Contents
General
Base
5.1-2 Wheel Bolt / Nut Inspection and Torquing Procedure.................................................................................111
5.1-3 Wheel Reinstallation and Torquing Procedure............................................................................................111
5.1-4 Reconnecting the Platform Control Box for Use from the Ground .............................................................112
5.1-5 Tightening and Torque Recommendations for Hydraulic Couplings and Hoses ......................................113
5.1-6 Checking the Holding Valve.........................................................................................................................114
5.1-7 System Pressure Setting..............................................................................................................................115
5.1-8 Lift Pressure Setting.....................................................................................................................................116
5.1-9 Grease Points...............................................................................................................................................117
5.1-7 Electronic Tilt Switch Setup Procedure.......................................................................................................118
Engine
5.2-1 Kubota Dual Fuel (DF972 / WG752) Resistance Checks............................................................................121
5.2-2 Fan Belt Replacement and Adjustment.......................................................................................................122
5.2-3 Kubota Dual Fuel (DF972 / WG752) Engine Throttle Setting......................................................................123
5.2-4 Kubota Diesel (D902) Engine Throttle Setting.............................................................................................125
5.2-5 Replacing the Air Cleaner Element..............................................................................................................126
5.2-6 Replacing the Fuel Filter Element (Kubota D902).......................................................................................127
5.2-7 Bleeding the Fuel System of Air (Kubota D902)..........................................................................................127
5.2-8 Replacing the Oil Filter Cartridge.................................................................................................................128
5.2-9 Changing the Oil..........................................................................................................................................128
5.2-10 Checking and Replenishing the Radiator Coolant Level.............................................................................129
5.2-11 Draining and Refilling the Radiator..............................................................................................................129
Outriggers
5.3-1 Auto-Leveling Outrigger PC Board Layout..................................................................................................130
5.3-2 Outrigger Mechanical Limit Switch Wiring Diagram....................................................................................131
5.3-3 Auto-Leveling Outrigger Settings and Error Codes.....................................................................................132
5.3-4 Auto-Leveling Outrigger Error Code Breakdown........................................................................................133
5.3-5 Hand Held Calibration/Diagnostic Tool Key Functions...............................................................................134
5
5.3-6 Outrigger Control Module Instructions........................................................................................................135
5.3-7 Auto-Leveling Outrigger Control Module Pin Reference Chart...................................................................138
5.3-8 Outrigger Upper Limit Switch (LS61, LS62, LS63, LS64) Replacement and Adjustment...........................139
5.3-9 Outrigger Lower Limit Switch (LS65, LS66, LS67, LS68) Replacement and Adjustment...........................140
Platform
5.5-1 Gate Springe Hinge Adjustment..................................................................................................................143
General Base
The following information is provided to assist you in Winching and Towing Procedures and Parking
the use and application of servicing and maintenance Brake System
procedures contained in this chapter.
This section provides the operator with procedures
Safety and Workmanship about towing and winching and on how to manually
Your safety, and that of others, is the first consideration release the parking brake.
when engaging in the maintenance of equipment.
Always be conscious of weight. Never attempt to move WARNING
heavy parts without the aid of a mechanical device. Do
not allow heavy objects to rest in an unstable position. Ensure platform is fully lowered before winching
When raising a portion of the equipment, ensure that or towing. Sudden motion could cause the aerial
adequate support is provided. platform to become unstable. Death or serious
injury could result.
Hydraulic System
All service and repairs to the hydraulic system or
hydraulic components must be done in a clean work
environment. See Hydraulic System & Component WARNING
Maintenance and Repair on page 7. In emergency situations where machine functions
are not available and lowering is impeded by an
obstacle, the utmost care must be taken to move
the machine far enough to clear the obstacle. In
such cases operation must be extremely smooth
with no sudden movements and must not exceed
a speed of 2 in/sec. When pushing, towing or
winching, do not exceed 2 mph (3.2 km/h).
Do not push, tow or winch vehicle onto a slope, or
brake the towing vehicle rapidly. Do not pull the
aerial platform down an incline towards a winch.
WARNING
The parking brake MUST be re-engaged
immediately after reaching the desired
location.
5.1-2 Wheel Bolt / Nut Inspection and 5.1-3 Wheel Reinstallation and Torquing
Torquing Procedure Procedure
It is necessary to check the torque on all wheel nuts and When a Wheel/Tire Assembly has been removed or
wheel bolts at pre-delivery, after 8 hours of operation and replaced, it will be necessary to follow the procedure
at weekly intervals using the following procedure: below to ensure proper installation:
1. Confirm that each wheel fastener is torqued to 1. Inspect wheel fastener threads for damage and
90 ±5 ft•lb. All fasteners must be torqued using defects. Replace if defective.
the tightening sequence below.
2. Clean the mounting surfaces of hub and the wheel
rim of debris, rust, excess paint, etc.
1
3. Mount wheel on the hub, centering mounting holes
3 6 on the wheel studs or bolt holes. Use appropriate
lifting device as required.
2. Again, confirm that each wheel fastener is torqued 6. Tighten to 90 ft•lb using the same sequence.
to the specified tolerance. Re-torque as necessary
until all fasteners are properly torqued. 7. Repeat the torque sequence to confirm that none
have changed from 90 ft•lb. If any are found below
90 ft•lb, repeat complete sequence until there is
no change in torque values. If possible, drive the
machine prior to checking torques.
5.1-4 Reconnecting the Platform Control 6. Disconnect the existing control cable connector by
Box for Use from the Ground swinging down the latch on the side, and pulling
the connectors apart.
1. To facilitate servicing the aerial platform, the
platform control box may be removed from the
platform, and reconnected inside the hydraulic
cabinet, to allow functions to be accessed from
the ground.
1. All components must be free of damage or 2. Align the hose end or fitting to the mating
contamination. O-rings cannot be reused anytime component.
the component has been installed beyond finger
tight. Clean or replace components, as required. 3. Install the nut two or three turns by hand to assure
proper alignment. Jiggle the hose while tightening
2. Over tightening a coupling may result in to ensure the faces contact fully.
overstressing and/or cracking, and may lead to
leaking or failure. 4. Using a properly calibrated torque wrench, tighten
the coupling using a smooth, even motion until
3. When tightening hose couplings, ensure the hose an indication (audible click) is heard and felt.
does not twist on the adapter. Twisting will shorten Do NOT over tighten. For recommended torque
hose life and scar the sealing surfaces of swivel values. Refer to Table 2.8 Torque Specifications for
type couplings (JIC, 45°, etc.), which can create Hydraulic Couplings & Hoses.
leaks.
5. Apply a drop of torque seal to the connection.
4. When tightening hose couplings, use a torque
wrench (with crow’s foot) on the hose end hex
swivel nut, and a standard box wrench on the
hose end stem hex to hold the hose from twisting.
Box
Wrench
Torque Wrench
with Crow’s Foot
Torquing Using the Flats From Wrench FLATS FROM WRENCH RESISTANCE CHART
Resistance Method for JIC Hose Ends
This method is applicable for JIC (37°) and FFOR Size FFWR
(Flat Face O-ring) hose ends only, wherever the 37° Tube
Dash Frac. (in.) Swivel Nut
components are inaccessible with torque wrench/ Nut
crow’s foot tools, or when a properly calibrated torque -4 1/4" 2 1.5
wrench is not available.
-5 5/16" 2 2
1. Align the hose end or fitting to the mating -6 3/8" 1.5 1.5
component. -8 1/2" 1.5 1.25
2. Install the swivel hose end nut hand tight to the -10 5/8" 1.5 -
fitting to assure proper alignment. Jiggle the hose -12 3/4" 1.25 -
while tightening to ensure the faces contact fully. -16 1" 1 -
-20 1 1/4" 1 -
3. Tighten the nut using a box wrench until minor
resistance is felt. -24 1 1/2 1 -
-32 2" 1 -
4. Mark the position of the nut relative to the fitting
with a marking device (paint marker).
1.
2. or
3. Psi should
Pressure gauge
attached to quick System pressure match serial plate
disconnect fitting relief valve
5.1-8 Lift Pressure Setting 6. To create pressure, with the engine on and the lift/
off/lower switch in the lift position, tilt the joystick
forward, as though trying to raise the platform.
Checking the Pressure
Read the pressure on the gauge.
1. Bring the control box down from the platform to
7. If the pressure shown on the gauge matches that
the ground so it will be accessible while working
on the serial plate, no further action is needed.
(Refer to 5.1-4).
However, if it does not match that on the serial
2. Refer to the aerial platform’s serial plate for the plate, proceed to the next step.
correct lift pressure for the unit.
1.
Cap lift fitting
and plug
hose end
Use handle
to tip the
2. or
manifold
Release the latch forward
10. Reconnect the lift hose to the main manifold lift port
Lift pressure (Refer to 5.1-5).
relief valve
11. Remove the pressure gauge and reconnect the
Pressure gauge control box to the platform.
attached to quick
disconnect fitting
5.1-7 Electronic Tilt Switch Setup 7. Install the new switch in the same orientation
Procedure as the old switch. Connect switch plug to 4 pin
connector.
Machines that are not equipped with outriggers have
an electronic tilt switch located inside the engine NOTE: The tilt switch circuit is only powered when
compartment. During operation, the switch monitors controls are powered up.
machine tilt front to back, and side to side. Aerial
platform tilt is measured relative to a learned zero 8. Turn main power disconnect switch on.
position.
9. Select Off–Lift–Drive key switch to Lift position or
The zero position is calibrated using the following Drive position.
set-up procedure, based on the position of the
machine with the platform leveled and fully lowered. 10. Pull out all emergency stop buttons.
Two LED indicator lights on the top of the switch show 11. Verify switch is powered. The red and green LED
operating conditions. indicator lights should be flashing.
Y AXIS
X AXIS
Set-up Button
M62332AA
17. The green LED stays on continuously indicating 9. Both LEDs turn off, then begin flashing for a 5
the switch is ready for normal operation. second period.
18. Turn main power disconnect switch off. 10. During this 5 second period, press and release the
Set-up button 3 times.
19. Push in all emergency stop buttons.
11. The red LED then flashes for 4 seconds during a
20. Remove wheel chocks. stabilization period.
2. Fully lower the platform. Reprogramming the 14. The green LED stays on continuously indicating
switch learns the switch is ready for normal operation.
3. Chock or block wheels to keep the aerial platform NOTE: If the Set-up button is not pressed 3 times
from rolling forward or backward. during Step 10, the switch exits the program
mode and returns to normal operation using
NOTE: The tilt switch circuit is only powered when the previous zero point.
controls are powered up.
15. Turn main power disconnect switch off.
4. Turn main power disconnect switch on.
16. Push in all emergency stop buttons.
5. Select Off–Lift–Drive key switch to Lift position or
Drive position. 17. Remove wheel chocks.
LED Indicator
Lights
Set-up Button
M62332AA
Engine
5.2-1 Kubota Dual Fuel (DF972 / WG752) Resistance Checks
Resistance of Ignitor
5.2-2 Fan Belt Replacement and Test and Adjust the Deflection
Adjustment
7. Measure the fan belt deflection by depressing
the belt halfway between the fan drive pulley and
Kubota recommends inspecting the fan belt every 100 the alternator pulley, at about 22 ft•lb (98 N•m )
hours, and replacing it every 500 hours. of force.
1. Inspect the fan belt for any signs of damage, such Fan Alternator
as cracks or tears. Inspect the fan belt for signs of pulley
wear, which may include the belt sinking into the
pulley groove.
Fan
pulley
Replace the Fan Belt 8. If the deflection is greater than or 1/4–5/16 in (7–9 mm),
loosen the alternator adjustment bolt. Use a pry
3. Remove the alternator pulley cover, and loosen the between the alternator and engine block to adjust
alternator adjustment bolt. the position of the alternator. Tighten the bolt.
Adjustment bolt
Pulley cover
9. Retest the deflection, and continue to adjust as
needed until it falls within the range specified
above.
5.2-3 Kubota Dual Fuel (DF972 / WG752) High Throttle Check and Setting
Engine Throttle Setting
4. Push the solenoid plunger in, and hold it there.
Measure the rpm using a digital tachometer, as
Preparation described in Step 2.
1. Look for a piece of reflective tape on the fan belt
pulley. If the reflective tape is missing, attach a small
piece.
1. Turn threaded
link
2. Tighten nut
5.2-4 Kubota Diesel (D902) Engine High Throttle Check and Setting
Throttle Setting
4. Measure the rpm using a digital tachometer, as
described in Step 2.
Preparation
5. If the tachometer reads 3500 ±50 rpm , the high
1. Look for a piece of reflective tape on the fan belt throttle is already properly set. No further action is
pulley. If the reflective tape is missing, attach a small required. If the tachometer reading is outside of the
piece. correct range, proceed to the next step to adjust it.
2. When measuring the rpm using a digital 6. Adjust the high throttle by first loosening the jam
tachometer, aim the tachometer at this reflective nuts on either end of the long coupling nut, then
strip while the engine is running. turning the coupling nut and measuring the rpm
until it reaches 3500 ±50 rpm.
Coupling nut
Jam nuts
Low Throttle Check and Setting 5.2-5 Replacing the Air Cleaner Element
8. On the platform control box, set the low/high throttle
switch to low. Kubota recommends replacing the air cleaner element
once a year. More frequent changes may be needed in
9. With the engine in low throttle, measure the rpm dusty environments.
using a digital tachometer, as described in Step 2.
NOTE: The air cleaner uses a dry element. Never
10. If the tachometer reads 2050 ±50 rpm , the low apply oil to it.
throttle rpm is already properly set. No further
action is required. If the tachometer reading is 1. Unlatch and remove the air cleaner cap. Use a
outside of the range given above, proceed to the cloth to clean any dirt or dust from out of the cap.
next step to adjust it.
2. Remove the old air cleaner element by pulling it
11. Adjust the low idle by first loosening the low idle straight out.
stop jam nut, then turning the low idle stop screw
and measuring the engine speed until it reaches
2050 ±50 rpm.
Low idle
screw
Low idle
jam nut 3. Install a new air cleaner element, pushing firmly
to seat it.
5.2-6 Replacing the Fuel Filter Element 5.2-7 Bleeding the Fuel System of Air
(Kubota D902) (Kubota D902)
Kubota recommends replacing the fuel filter every 400 Bleeding the fuel system of air is required after chang-
hours. ing fuel hoses or filters, or after the fuel tank has
become empty.
1. Close the fuel filter lever (turn counterclockwise).
1. Allow the engine to cool, if it has been running.
2. Unscrew the retaining ring and remove the filter
cup. 2. Fill up the fuel tank with fuel.
3. Remove the old fuel filter element. 3. Open the fuel filter lever (vertical position).
Closed
Fuel Lever 4. Open the air vent plug on the top of the fuel injection
Open pump a few turns. Some air bubbles should come
Closed out.
Filter Element
Filter Cup
Retaining Ring
5.2-8 Replacing the Oil Filter Cartridge 5.2-9 Changing the Oil
Kubota recommends changing the oil every 200 hours.
Kubota recommends replacing the oil cartridge every
400 hours. 1. With the aerial platform on a level surface, start the
engine and warm it up for approximately 5 minutes.
Shut off the engine.
NOTE: Be sure to stop the engine before changing
the oil filter cartridge.
2. Place a container underneath the engine’s oil pan
drain plug.
1. Remove the old oil filter cartridge with a filter
wrench. 3. Remove the drain plug, and allow the oil to drain
completely.
5. Unscrew one of the oil filler caps and fill the engine
with new oil, up to the upper line on the dipstick.
Reinstall the cap.
5. Check for oil leaks around the gasket, and if no Dipstick Drain plug
leaks are found, check the oil level using the
dipstick.
5.2-10 Checking and Replenishing the 5.2-11 Draining and Refilling the Radiator
Radiator Coolant Level
Kubota recommends completely draining and replac-
Kubota recommends checking the coolant level daily. ing coolant once a year.
Checking and Replenishing Coolant NOTE: Do not remove the radiator cap until the
coolant had dropped below its boiling point.
1. Check the coolant level via the recovery tank.
Coolant should be between the FULL and LOW
marks. 1. Place containers under the drain plugs to catch the
coolant. One drain plug is located on the underside
2. If the coolant is too low, determine the cause and of the radiator, and the other on the body of the
remedy it by following Step A or B below: engine.
FULL
LOW
Drain plugs
Outriggers
5.3-1 Auto-Leveling Outrigger PC Board Layout
CN14
17A/B
28A
86A
36A
10A
28
61
09
02
02
36
44
D17B-2
CN21
D73
17C
D17B-1
71
02
78
73
77
75
72
76
74
REAR RIGHT
REAR LEFT
D74
CN20
D77
35C
71
78
73
77
75
72
76
74
D78
9CR3 9CR2
FRONT RIGHT
FRONT LEFT
D72
D71
D76
61CR 17DCR 65CR
J17D
D75
J17E ENABLE
10A
10A
10A
10A
10A
N/U
N/U
N/U
61
62
62
63
63
65
64
64
D36
CN22
O.R. UP SWITCH (NO) - BLUE & BROWN O.R. UP SWITCH (NO) - BLUE & BROWN
PIN 1 - BLACK
PIN 1 - BLACK PIN 2 - BLACK / WHITE
PIN 2 - BLACK / WHITE PIN 3 - BLUE
PIN 3 - BLUE PIN 4 - BROWN
PIN 4 - BROWN
BACK VIEW - MALE BACK VIEW - MALE
3 2 3 2
4 1 4 1
RIGHT FRONT OUTRIGGER
PIN 1 - BLACK (10A)
PIN 2 - WHITE (66A)
BACK VIEW - FEMALE PIN 3 - GREEN (63)
PIN 4 - RED (62) BACK VIEW - FEMALE
LEFT FRONT OUTRIGGER
2 3 2 3
PIN 1 - BLACK (10A)
PIN 2 - WHITE (65A)
PIN 3 - GREEN (62) 1 4
1 4
PIN 4 - RED (36)
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT FRONT OUTRIGGER SECTION VIEW RIGHT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE) (SHOWN IN THE RETRACTED STATE)
O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE
LEFT REAR OUTRIGGER SECTION VIEW RIGHT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE) (SHOWN IN THE RETRACTED STATE)
60402AA
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.
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
M62172AA
Outrigger Settings
O.R. Settings 7 7
1. Ensure aerial platform is parked on a firm and level 13. The display will show Calibrate Level: Tilt 0.0’ ,
surface. 0.0’.
Select the ESCAPE from the menu once.
2. Elevate the scissors high enough to lay a level
across the base tubes. Ensure there is no debris on 14. The display will show Setups Calibrate Level.
the base and the level sits flat. Do not elevate aerial Select the ESCAPE from the menu once again.
platform higher than the high speed/tilt override
limit switch. 15. The Calibration procedure is complete, unplug and
remove the EZcal.
3. Manually operate the outriggers and level the
machine in 4 places: left side, right side, front and 16. Close the hydraulic/electric cabinet.
rear. All 4 outriggers must be firmly placed and all
4 tires are off the ground.
LED
WIRE #
PIN
PLUG AND WIRE FUNCTION
#
COLOUR
P1 The Calibration Connection
P2 1 68A White Input indicating that the LEFT REAR outrigger is in contact with the ground
P2 2 67A Red/White Input indicating that the RIGHT REAR outrigger is in contact with the ground
P2 3 66A Blue/White Input indicating that the RIGHT FRONT outrigger is in contact with the ground
P2 4 65A Green/White Input indicating that the LEFT FRONT outrigger is in contact with the ground
P2 5 70 Green/Black Input for AUTO-LEVEL function to extend the outriggers to level the machine
P2 6 79 Green Input for AUTO-RETRACT function to retract the outriggers until the switch is released
P2 7 70A Red/White Outrigger Light on Outrigger Control Box
P2 8 65 Green/Black STABLE output to indicate that all outriggers are in contact with the ground
P2 9 28 Green TILT output to indicate that the machine is level (ANSI/CSA only)
P2 10 44 Green Tilt override / High Drive Cutout
P2 11 02 White Negative Input
P2 12 10A Black Main Power Input
P4 1 78 Black/White Output used to extend the LEFT REAR outrigger
P4 2 77 Blue/Black Output used to extend the RIGHT REAR outrigger
P4 3 76 Red/Black Output used to extend the RIGHT FRONT outrigger
P4 4 75 Orange/Black Output used to extend the LEFT FRONT outrigger
P4 5 74 Black Output used to retract the LEFT REAR outrigger
P4 6 73 Blue Output used to retract the RIGHT REAR outrigger
P4 7 72 Red Output used to retract the RIGHT FRONT outrigger
P4 8 71 Orange Output used to retract the LEFT FRONT outrigger
P4 9 35C White/Black Power input for outriggers
60401AC
2. Remove the washers, bolts, and nuts (x2) Limit Switch Adjustment
securing the limit switch to the bracket. Set aside 1. With the outriggers retracted, slide the limit switch
for reinstallation later. on the bracket until the plunger is depressed
against the actuator rod cap. Apply a small amount
of Loctite to the bolts, and tighten the bolts and
nuts.
5.3-9 Outrigger Lower Limit Switch (LS65, 6. Remove the cable from the split loom. Gently pull
LS66, LS67, LS68) Replacement and the cable down through the outrigger weldment,
Adjustment and through the rubber grommet. Retain the rubber
grommet. Discard the old limit switch and cable.
Machine Preparation
1. Ensure the aerial platform is parked on a firm level Limit Switch Replacement
surface. 1. Install a new limit switch (138059) to the mounting
block using the hardware removed earlier.
2. Fully retract the outriggers.
2. Feed the new cable through the rubber grommet,
3. Turn the main power disconnect switch to the OFF and place the grommet in the hole in the outrigger
position. weldment.
4. Chock or block the wheels to keep the aerial 3. Feed the cable up through the outrigger weldment,
platform from rolling forward or backward. until it comes out the top.
4. Cut the tie wraps and tape around the split loom
as needed to expose the limit switch cable.
4. Loosen the set screws (x2) on the limit switch cam, Platform
and rotate the cam until it depresses the limit switch
plunger. Apply a small amount of Loctite to both
set screws, and tighten them. 5.5-1 Gate Springe Hinge Adjustment
NOTE
High Speed Cutout should occur within the
tolerance zone of 81–87 (206–221).