Skyjack SJ63 AJ+ Service Manual
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Skyjack SJ63 AJ+ Service Manual

Skyjack SJ63 AJ+ Service Manual

Articulating booms
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SERVICE
MANUAL
SJ63 AJ+, SJ63 AJ
ARTICULATING BOOMS
229043AAA
January 2020
ANSI/CSA, CE, AS

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Summary of Contents for Skyjack SJ63 AJ+

  • Page 1 SERVICE MANUAL SJ63 AJ+, SJ63 AJ ARTICULATING BOOMS 229043AAA January 2020 ANSI/CSA, CE, AS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
  • Page 3 This manual is for MEWPs with serial numbers: SJ63 AJ+: A302 000 001 - A302 999 999 SJ63 AJ: A302 000 001 - A302 999 999 SJ63 AJ: B302 000 001 - B302 999 999...
  • Page 4 THIS SAFETY ALERT SYMBOL MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The Safety Alert Symbol identifies important safety messages on MEWPs, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

  • Page 5: Table Of Contents

    Table of Contents Section 1 – Scheduled Maintenance ......... . 15 Read and Heed .
  • Page 6 Torque Specifications for Hydraulic Couplings & Hoses ........39 Axle Torque Specifications .
  • Page 7 3.30 Load Circuit Wiring ..............86 3.31 Positive Air Shutoff Harness .
  • Page 8 4.2-13 No Turret Rotate Right from the Base or Platform Consoles ......119 4.2-14 No Turret Rotate Right from the Base Console .
  • Page 9 4.2-56 No Right Steer ..............131 4.2-57 The Directon Sensing is Inoperative .
  • Page 10 4.3-36 No Turret Right from the Platform Control Console ........155 4.3-37 No Toggle Switch Functions from the Platform Control Console .
  • Page 11 4.5-12 No Jib Down ..............179 4.5-13 No Platform Rotation Right .
  • Page 12 4.6-27 No Left Steer ..............193 4.6-28 The Axle Will Not Oscillate .
  • Page 13 5.4-20 Test Main Boom Limit Switch ........... . 232 5.4-21 Replace Limit Switch - Riser Boom .
  • Page 14 5.9-7 Fly Boom Relief Valve Adjustment (RV6) ..........279 5.9-8 Test Charge Pump Pressure on Drive Pump (RV10) .

  • Page 15: Section 1 - Scheduled Maintenance

    3000 hours, whichever occurs first. Any defective specifications and dimensions are subject to change part will be replaced or repaired by your local Skyjack without notice. dealer at no charge for parts or labor. In addition, all products have a 5 year structural warranty.

  • Page 16: Maintenance And Inspection Schedule

    MEWP . Before attempting any repair work, disconnect the main power connectors. Consult Skyjack’s Service Department for optional tires specifications and installation. Preventive maintenance is the easiest and least expensive type of maintenance.

  • Page 17: Hydraulic System & Component Maintenance And Repair

    Maintenance and Service Section 1 – Scheduled Maintenance 1.2-5 Hydraulic System & Component 7. All hydraulic components must be disassembled in spotlessly clean surroundings. During Maintenance and Repair disassembly, pay particular attention to The following points should be kept in mind when the identification of parts to assure proper working on the hydraulic system or any component: reassembly.
  • Page 18 Section 1 – Scheduled Maintenance Maintenance and Service 1.2-7 Railing Maintenance and Repair Skyjack MEWPs have been designed to ensure compliance with the relevant design standards applicable for that particular unit at the time of manufacture. As such, any repairs made to the...

  • Page 19: Scheduled Maintenance

    Inspection every 200 days Before performing any scheduled maintenance or 200 hours. inspection procedure, refer to service bulletins found in our web site: www.skyjack.com for updates related Annual B + C Perform Scheduled to service and maintenance of this MEWP .
  • Page 20 Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record Table 1.4 Owner’s Annual Inspection Record Inspection Date Inspector Signature WARNING Do not use the MEWP if there is no inspection recorded in the last 13 months. If you do not obey, there is a risk of death or serious injury.

  • Page 21: Pre-Delivery/Maintenance Inspection Checklist

    Pre-Delivery/Maintenance Inspection Checklist Section 1 – Scheduled Maintenance 1.5 Pre-Delivery/Maintenance Inspection Checklist Frequent/Periodic/Annual/PDI Checklist Articulating Booms and Telescopic Booms Serial Number: Product Owner: Starting with serial number A000 000 000 or B000 000 000 and above Product User: Date/Time: Model: Hourmeter Reading: Inspection Type (Choose one): Pre-delivery...

  • Page 22: Electrical

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6 Scheduled Maintenance 1.6-2 Hydraulic Do a check on these areas and make sure there are Inspections no signs of leakage: Do an inspection of the MEWP in this sequence. Hydraulic tank filter, fittings, hoses, emergency- ▪...
  • Page 23 Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-5 Engine Compartment 2. Make sure all the battery connections are tight. 3. If applicable, check the battery fluid level. Do the inspection that follows: If the plates do not have a minimum 13 mm ▪...
  • Page 24 Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections Hydraulic pump and motor Muffler and exhaust Make sure there are no loose or missing parts. Make sure that the muffler and exhaust ▪ ▪ systems are correctly attached with no visible Make sure there is no visible damage.
  • Page 25 Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance Radiator (B, C) Air filter (B,C) Make sure there are no loose or missing parts. Make sure there are no loose or missing parts. ▪ ▪ Make sure there is no visible damage. Make sure there is no visible damage.
  • Page 26 Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections Do the inspection that follows: Hydraulic Return Filter (B,C) Make sure all compartment latches are latched tightly Make sure the filter element is attached and ▪ and in good condition. tight. Turret transportation lock Make sure there is no visible damage or ▪...
  • Page 27 Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance Emergency Power Unit WARNING Make sure there are no loose or missing parts. ▪ Environmental hazard. Immediately remove Make sure there are no loose wires or missing ▪ gasoline, diesel fuel, engine oil, and hydraulic fasteners.

  • Page 28: Base

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-6 Base Brake Cylinder Base weldment Make sure there are no loose or missing parts. ▪ Make sure there are no visible cracks in Make sure all the fittings and hoses are ▪...
  • Page 29 Oscillating Cylinder Bolt Replacement. WARNING NOTE Do not use tires other than the tires that Skyjack The oscillating axle is locked when the MEWP is specifies for this MEWP . Do not mix different types in the elevated travel position or at the elevated of tires or use tires that are not in good condition.

  • Page 30: Platform

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-7 Platform Platform control console Railings and gates Make sure all switches and controllers are in ▪ the neutral position. Make sure there are no loose or missing parts, ▪ and there is no visible damage. Make sure there are no loose or missing parts, ▪...

  • Page 31: Boom Assembly

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-8 Boom Assembly Wear Pads Rotary actuator All fasteners are correctly tightened. ▪ There are no loose or missing parts, and there There are no loose or missing parts, and there ▪ ▪...

  • Page 32: Optional Equipment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-9 Optional equipment Cold or arctic weather package Do the inspection that follows, and make sure: The heater plugs are correctly attached with ▪ no visible damage. Generator There is no sign of engine oil leakage. ▪...

  • Page 33: Function Tests

    Function Tests Section 1 – Scheduled Maintenance 1.7 Function Tests Function tests are designed to discover any malfunctions before a MEWP is put into service. The operator must understand and follow the step-by-step instructions to test all MEWP functions. IMPORTANT Never use a malfunctioning MEWP .

  • Page 34: Section 2 - Maintenance Tables And Diagrams

    Section 2 – Maintenance Tables and Diagrams Table 2.1 Standard Hose Numbering System H1104 0081 2 LENGTH IN FRACTIONS FITTING (1/4" INCREMENTS) LENGTH OF HOSE IN ARRANGEMENT 1=1/4" WHOLE INCHES (See Schedule Below) HOSE SIZE 2=1/2" (See Chart Below) 3=3/4" Using the number above as an example, NOTE H1104 0081 2, this hose requires a 37°...
  • Page 35 Section 2 – Maintenance Tables and Diagrams Standard Hose Numbering System Hose S.A.E. Hose Hose End Fitting Hose End Fitting Prefix Specification REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI NO FITTING NO FITTING 100R4 NO FITTING NO FITTING 300 PSI REUSABLE, FEMALE, 37°...

  • Page 36: Torque Specifications For Fasteners (Us Imperial)

    Torque Specifications for Fasteners (US Imperial) Section 2 – Maintenance Tables and Diagrams Table 2.2 Torque Specifications for Fasteners (US Imperial) SAE2 SAE 5 SAE 8 SAE2 SAE 5 SAE 8 Torque Torque Size Size Type Type Lubed Lubed Lubed Dry Lubed Dry Lubed Dry Lubed ft-lb...

  • Page 37: Torque Specifications For Fasteners (Metric)

    Section 2 – Maintenance Tables and Diagrams Torque Specifications for Fasteners (Metric) Table 2.3 Torque Specifications for Fasteners (Metric) SAE2 SAE 5 SAE 8 Torque Size Type Lubed Lubed Lubed (in-lb) (54) (41) (78) (59) (12) M5 x 0.80 (in-lb) (92) (69) (133)

  • Page 38: Torque Specifications For Hydraulic Couplings & Hoses

    Torque Specifications for Hydraulic Couplings & Hoses Section 2 – Maintenance Tables and Diagrams Table 2.4 Torque Specifications for Hydraulic Couplings & Hoses Hydraulic Coupling Torque Chart O-Ring Port Connectors Steel Ports Non-ferrous Ports SAE Size ft-lb ft-lb 14-16 20-22 9-10 12-13 24-26...

  • Page 39: Axle Torque Specifications

    Section 2 – Maintenance Tables and Diagrams Axle Torque Specifications Table 2.5 Axle Torque Specifications Type of Bolt 10.9 12.9 Size of Bolt Normali Normali Normali Loctite 270 Loctite 270 Loctite 270 Loctite 242 Loctite 242 Loctite 242 (Nm) (Nm) (Nm) (Nm) (Nm)

  • Page 40: Axles Maintenance Intervals

    Axles Maintenance Intervals Section 2 – Maintenance Tables and Diagrams Table 2.6 Axles Maintenance Intervals Operation Component Frequency Lubricants Differential monthly Check Levels Planetary reduction every 200 hours SAE 80W-90 API GL-5 Gear box monthly Differential every 800 hours * Planetary reduction every 1000 hours * Oil Change...

  • Page 41: Mewp Torque Specifications

    Section 2 – Maintenance Tables and Diagrams MEWP Torque Specifications Table 2.7 MEWP Torque Specifications Location Description Torque (ft-lb) Torque (Nm) Base Trunnion Mount BOLT, Hex head (3/4"-10 x 5", Grade 8) Rear Axle Mount NUT, Torque lock (3/4"-10, Grade C) Axle Lock BOLT, Hex head (1/2"-13 x 2.25", Grade 8) Swing Drive Motor...

  • Page 42: Maximum Platform Capacity

    Do not use tires other than those specified for this machine. Do not mix different types of tires. Tires other than those specified can adversely affect stability. Failure to operate with matched, approved tires in good condition can result in death or serious injury. Replace tires with the exact, Skyjack-approved types only. IMPORTANT For proper function of each axle differential, all four wheels must have same tire size installed at all times.

  • Page 43: Floor Loading Pressure

    Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure Table 2.10 Floor Loading Pressure Total MEWP Load Gross MEWP Weight Model Wheel SJ63 AJ+ ANSI 10 250 22,560 5445 12,000 1064 14.6 SJ63 AJ CE 10 200 22,487 5080 11,199 1195 12.4...

  • Page 44: Hydraulic Specifications & Gear Oil

    Hydraulic Specifications & Gear Oil Section 2 – Maintenance Tables and Diagrams Table 2.11 Hydraulic Specifications & Gear Oil Description Metric Pumps Displacement - 2675 rpm 13.5 CC 2.48 CIR 28.7 gpm @ 2675 rpm Drive Pump Pressure 344.7 bar 5000 psi Drive Pump Charge Pump Displacement...

  • Page 45: Specifications & Features - Dimensions & Speeds

    Section 2 – Maintenance Tables and Diagrams Specifications & Features - Dimensions & Speeds Table 2.12 Specifications & Features - Dimensions & Speeds SJ63 AJ+ ANSI/CSA SJ63 AJ CE SJ63 AJ AS Height & Reach Working Height 69' 7" 21.21 m 21.38 m 21.38 m Platform Height...
  • Page 46 Specifications & Features - Dimensions & Speeds Section 2 – Maintenance Tables and Diagrams Table 2.12 Specifications & Features - Dimensions & Speeds SJ63 AJ+ ANSI/CSA SJ63 AJ CE SJ63 AJ AS Performance & Speeds Gradeability - Maximum Drive Speed - Stowed/Low Torque 4.5 mph 7.3 km/h 7.3 km/h...

  • Page 47: Engine Specifications

    Section 2 – Maintenance Tables and Diagrams Engine Specifications Table 2.13 Engine Specifications SJ63 AJ+, SJ63 AJ RPM Settings 900 Low / 1600 / 2600 High Horsepower @ 2600 rpm (intermittent) 55.4 kW / 75 hp Fuel Type Diesel Fuel Tank Capacity 31.7 gal.

  • Page 48: Dimension And Reach Diagrams - Sj63Aj

    Dimension and Reach Diagrams - SJ63AJ Section 2 – Maintenance Tables and Diagrams Diagram 2.14 Dimension and Reach Diagrams - SJ63AJ METERS (FEET) 21.34 (70) 19.81 (65) 2.44m 18.29 (60) 16.76 (55) 15.24 (50) 13.72 (45) 55° 12.19 (40) 10.67 (35) 9.14 (30)

  • Page 49: Axle Oscillation Diagrams

    Section 2 – Maintenance Tables and Diagrams Axle Oscillation Diagrams Table 2.15 Axle Oscillation Diagrams WARNING Do not raise the platform in work mode if it is not on a firm level surface. Axle oscillation free (travel mode) - drive speed 7.3 km/h (4.5 mph) max. Axle oscillation locked (work mode) - drive speed 0.8 km/h (0.5 mph) max.

  • Page 50: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 51: Electrical Symbol Chart

    Section 3 – System Component Identification and Schematics Electrical Symbol Chart Table 3.1 Electrical Symbol Chart CIRCUITS CROSSING LIMIT SWITCH KEY SWITCH HOURMETER NO CONNECTION LIMIT SWITCH CIRCUITS LIGHT FOOT SWITCH CONNECTED CLOSED LIMIT SWITCH HYDRAULIC BATTERY TOGGLE SWITCH VALVE COIL PROPORTIONAL LIMIT SWITCH PUSH BUTTON...

  • Page 52: Hydraulic Symbol Chart

    Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics Table 3.2 Hydraulic Symbol Chart VARIABLE DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE LINE CROSSING PUMP ACCUMULATOR, SINGLE ACTING LINE JOINED HAND PUMP GAS CHARGED CYLINDER HYDRAULIC CUSHION DOUBLE ACTING RELIEF VALVE CYLINDER CYLINDER TANK...

  • Page 53: Wire Number And Color Code

    Section 3 – System Component Identification and Schematics Wire Number and Color Code 3.3 Wire Number and Color Code WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE COLOR COLOR COLOR COLOR COLOR ORG/BLU YEL/WHT ORG/BRN GRN SHLD WHT/RED YEL/ORG GREY BLK SHLD...

  • Page 54: Hydraulic Parts List

    Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 2H-13A 159838 VALVE, Flow Control (Main boom lowering) 2H-21A 159821 VALVE, Control (Enable) 2H-21B 194492 VALVE, Control (Load Circuit Select)
  • Page 55 Section 3 – System Component Identification and Schematics Wire Number and Color Code 3.4 Hydraulic Parts List Index Skyjack Description Part No. 159841 VALVE, Counterbalance (Main boom) CB10 710088 VALVE, Counterbalance (Platform levelling cylinder - slave) CB11 710088 VALVE, Counterbalance (Platform levelling cylinder - slave)
  • Page 56 Wire Number and Color Code Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 139092 OIL COOLER, Hydraulic ORIFICE, Motor swash plate (0.015”) 159825 ORIFICE, Differential sensing (0.030”) 159824 ORIFICE, Platform override speed (0.040”) 159823 ORIFICE, Jib boom speed (0.078”)
  • Page 57 Section 3 – System Component Identification and Schematics Wire Number and Color Code 3.4 Hydraulic Parts List Index Skyjack Description Part No. 159804 VALVE, Fly boom 159803 VALVE, Platform level override 159840 VALVE CONTROLLER, Boom lowering flow control 229043AAA SJ63 AJ+, SJ63 AJ...

  • Page 58: Electrical Component Parts List

    Closed Normally Open Ground (B-) NORMALLY NORMALLY CLOSED OPEN CONTACT CONTACT Index Skyjack Description Part No. 01ACR 931298 RELAY, Micro 12 V DC, 30 amp Base control console) (ANSI) 01ACR 127131 RELAY, 12 Volt 40 Amp (Base control console - E-pump) (CE &...
  • Page 59 Section 3 – System Component Identification and Schematics Electrical Component Parts List 3.5 Electrical Parts List Index Skyjack Description Part No. 3H-26 159827 COIL, 12 Volt (Brake valve) 3H-45 159827 COIL, 12 Volt (Motor 2-speed valve) 3H-65 159827 COIL, 12 Volt (Axle lock valve)
  • Page 60 Electrical Component Parts List Section 3 – System Component Identification and Schematics 3.5 Electrical Parts List Index Skyjack Description Part No. 147229 LED BLOCK, Red (12 volts) (Base control console) 147229 LED BLOCK, Red (12 volts) (Platform control console) 138229...

  • Page 61: Rotary Manifold Port Identification

    Section 3 – System Component Identification and Schematics Rotary Manifold Port Identification 3.6 Rotary Manifold Port Identification Port 6 To Brake Manifold Port 2 To Brake Manifold Port 2 To Axle Lock Cylinder Port 4 To Brake Manifold Port 3 Port 9 To Drive Pump To Drive Motor...

  • Page 62: Brake Manifold Port Identification

    Brake Manifold Port Identification Section 3 – System Component Identification and Schematics 3.7 Brake Manifold Port Identification 3H-165 Differential Lock Valve 3H-45 2 Speed Motor Valve 3H-65 Axle Lock Valve 3H-26 Brake Release Valve To Rotary Manifold 2SPD To Rotary Manifold Brake Hand Pump To Rotary Manifold To Hydraulic Tank...

  • Page 63: Drive And System Pump And Port Identifications

    Section 3 – System Component Identification and Schematics Drive and System Pump and Port Identifications 3.8 Drive and System Pump and Port Identifications To High Pressure Shuttle To Rotary Manifold To Rotary Manifold To Rotary Manifold To Hydraulic Tank To High Pressure Shuttle To Hydraulic Tank To High Pressure Filter To Main Manifold...

  • Page 64: Drive Motor And Port Identifications

    Drive Motor and Port Identifications Section 3 – System Component Identification and Schematics 3.9 Drive Motor and Port Identifications To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold M154138AC-SM SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 65: Jib Valve And Port Identifications

    Section 3 – System Component Identification and Schematics Jib Valve and Port Identifications 3.10 Jib Valve and Port Identifications 3H-36 Platform Rotate Select To Bulkhead #1 To Platform Rotary Actuator To Platform Rotary Actuator To Bulkhead #1 M154206AC 229043AAA SJ63 AJ+, SJ63 AJ...

  • Page 66: Main Manifold And Port Identifications

    3.11 Main Manifold and Port Identifications To Return Filter To High Pressure Filter Gauge Pressure To Brake Manifold To Riser Cylinders To Riser Cylinders To Brake Manifold To Emergency Power Unit To Main Boom Lift Cylinder To System Pump To Main Boom Lift Cylinder To Turret Swing Drive To Master Cylinder To Turret Swing Drive...

  • Page 67: Main Manifold And Electrical Identifications

    3.12 Main Manifold and Electrical Identifications 5H-38 5H-33 Fly Boom 5H-24A 5H-30 2H-36 Turret Rotate Retract Valve Left Steer Valve Riser Boom Down Valve 2H-13A Platform Rotate Right Valve Boom Lowering Throttle Valve 5H-32 5H-23A 5H-39 5H-31 Flow Control Turret Rotate Right Steer Valve Fly Boom Riser Boom Up Valve...

  • Page 68: Main Manifold And Hydraulic Identifications

    3.13 Main Manifold and Hydraulic Identifications DSV1 System Relief Valve Differential Sensing Valve DSV4 DPOCV1 Differential Sensing Valve DPO Check Valve DSV3 Platform Levelling Relief Valve Differential Sensing Valve DSV2 Fly Boom Relief Valve Differential Sensing Valve DPOCV2 DPO Check Valve Platform Leveling Shuttle Valve Riser Boom Relief Valve Main Boom Relief Valve...

  • Page 69: Main Electrical Harness And Fuel Level Switch Harness

    3.14 Main Electrical Harness and Fuel Level Switch Harness STEER RIGHT JIB UP PLATFORM LEVEL DOWN RISER UP RISER DOWN PIN 1 - 23A BLACK/WHITE PIN 1 - 35 ORANGE/WHITE PIN 1 - 40 BLUE/RED PIN 1 - 31 RED/WHITE PIN 1 - 30 RED/GREEN PIN 2 - 02 WHITE (SPLICE #1) PIN 2 - 02 WHITE (SPLICE #2)

  • Page 70: Ecu Engine Wiring Diagram - Deutz

    3.15 ECU Engine Wiring Diagram - Deutz PIN 1 - 02 - WHITE PIN 2 - 106 - GREEN/PINK PIN 3 - PLUGGED PIN 4 - 76 - BROWN/BLUE PIN 5 - 74 - GREEN/GREY PIN 6 - PLUGGED PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 - PLUGGED...

  • Page 71: Glow Plug Harnesses - Deutz D2011

    3.16 Glow Plug Harnesses - Deutz D2011 11 - WHITE RELAY CONNECTOR PIN-OUT 30 - 11A - RED 85 - 54A - BLACK 86 - 11 - WHITE 87 - 11B - RED BASE CONTROL BOX TERMINAL STRIP WIRING 11 - WHITE 54A - BLACK M148472AB-SM 229043AAA...

  • Page 72: Glow Plug Harnesses - Deutz Td2.9L

    3.17 Glow Plug Harnesses - Deutz TD2.9L CONNECTOR J5 PIN 1 - 11C PIN 2 - 11A PIN 3 - AA PIN 4 - PLUGGED RELAY CONNECTION DETAIL TERM 30 - 11B (8GA) TERM 85 - 11A (18GA) TERM 86 - 11 (18GA) TERM 87 - 11C (8GA) CONNECTOR P1 SOCKET 1 - 11C (10GA)

  • Page 73: Engine Interface Harness - Gm

    3.18 Engine Interface Harness - GM ENGINE CONNECTOR 1 PIN 1 - 02 WHITE ENGINE CONNECTOR 2 PIN 2 - 54A PURPLE/RED PIN C - 00A WHITE PIN 3 - 57A BROWN/GREEN FEUL PUMP (+) FEUL PUMP (-) PIN E - 02 WHITE PIN 4 - 11 WHITE/ORANGE 3056 BLACK 3002 WHITE...

  • Page 74: Engine Interface Harness - Deutz Td2.9L

    3.19 Engine Interface Harness - Deutz TD2.9L (30A) 200,201 202, 203, D2.2 X17.1 SPL00 SPLK01 SPL103 SPL203 A23, A35, D2.1 M166166AA-1 SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 75: Lowering Throttle Valve Harness

    3.20 Lowering Throttle Valve Harness TO EVDR MODULE BACK VIEW PIN 1 - 09 - BLACK PIN 2 - 13 - GREEN PIN 3 - PLUGGED PIN 4 - PLUGGED PIN 5 - PLUGGED PIN 6 - PLUGGED PIN 7 - 02 - WHITE (SPLICE) PIN 8 - 02 - WHITE (SPLICE) M154357AA-SM 229043AAA...

  • Page 76: Platform Harnesses

    3.21 Platform Harnesses FOOT SWITCH TB 04A TB 08A 3H-36 PLATF. ROTATE SELECT SOL. TB 36A TB 02 PLATFORM CONTROL BOX WIRING SUPPR. D36-1 NOTE: DIODE D36-1 AND CAPACITOR CAP3 REMOVED ON 63AJ CE MACHINES TO JIB CYLINDER MANIFOLD SUPPR. ELECTRICAL SCHEMATIC (NOT COIL SPECIFIC) FOOT SWITCH...

  • Page 77: Platform Control Cables

    3.22 Platform Control Cables BASE & PLATFORM CONNECTIONS POSITION 1 - PURPLE/BLACK POSITION 2 - RED POSITION 3 - RED POSITION 4 - BLUE/WHITE CONTROL CABLE A POSITION 5 - RED/YELLOW/BLACK POSITION 6 - ORANGE POSITION 7 - BLACK POSITION 8 - ORANGE/BLUE POSITION 9 - BLACK/WHITE POSITION 10 - BLUE/BLACK POSITION 11 - BLUE YELLOW...

  • Page 78: Limit Switch Connections At The Base Control Box

    3.23 Limit Switch Connections at the Base Control Box BLACK WHITE BLACK WHITE FLY BOOM EXTENSION LIMIT SWITCH MAIN BOOM DOWN LIMIT SWITCH RISER DOWN LIMIT SWITCH DIRECTIONAL SENSING LIMIT SWITCH M153854AD M153855AD M153856AD M119348AB-SM SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 79: Load Sensing Connections - Ce & As

    3.24 Load Sensing Connections - CE & AS 4P-MALE 4P-FEMALE 3P-FEMALE PLATFORM CONTOL BOX WIRING 4" PIGTAIL TYP . M152502AA 229043AAA SJ63 AJ+, SJ63 AJ...

  • Page 80: All Motion Alarm Connections - Ce & As

    3.25 All Motion Alarm Connections - CE & AS ALARM PASS WIRES THROUGH TOP-MOST STRAIN RELIEF (LOOSEN GLAND FIRST) 02-WHITE 20-ORANGE/BLUE -WIRE INSTALLATION- M152361AA_S3 SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 81: Sge Wiring Diagram

    3.26 SGE Wiring Diagram 162A 162B-AJ Sensor Bar 09B-TBOOM E-pump 7CCR1 - Kill Drive D04D 162A-AJ 04-TBOOM NEW DIODE D09-2 delatch D09-2 4ECR 7CCR2 - Kill Dump Reset LOW FUEL Beacon (IF PRESENT) D09-1 Amber Siren NEW DIODE D09-1 7DCR - Kill Engine Delay on Timer BASE CONTROLS MODIFICATION - D07D...

  • Page 82: Hydraulic Generator And Oil Cooler Wiring - Base Control Box

    3.27 Hydraulic Generator and Oil Cooler Wiring - Base Control Box TOP VIEW RELAY SOCKET UPPER PLUG B TO GENERATOR SOLENOID VALVE Base Control Box - Generator TO EMERG. PUMP POWER STUD TO TEMPERATURE SWITCH CONNECTOR TO COOLER FAN CONNECTOR INSTALL UNDER COOLER MOUNTING BOLT Base Control Box - Oil Cooler...

  • Page 83: Generator Wiring - Upper Control Box

    3.28 Generator Wiring - Upper Control Box SPEED CONTROL JOYSTICK JOYSTICK New toggle & seal LEVEL TELE PLATFORM ROTATE IGNITION HORN E-STOP ABCDEFGH THROTTLE TORQUE E-PUMP New relay 57ACR1 08CR Remove 04A/04 jumper M169566AC 229043AAA SJ63 AJ+, SJ63 AJ...

  • Page 84: Welder Wiring - Ansi/Csa

    3.29 Welder Wiring - ANSI/CSA WHITE 8 GA GREEN 8 GA WHITE RED 8 GA BLACK 50AMP BLACK 8 GA 50AMP GREEN 50AMP LOCATED ON PLATFORM VIEW UNDER BREAKER BOX LID PLUGS INTO 110V POWER CORD TO PLATFORM M154353AB SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 85: Load Circuit Wiring

    3.30 Load Circuit Wiring 09CR 01ACR 21CR 45CR1 45CR2 49CR 56ACR 128B 128A INSTALL NEW RELAY & SOCKET INSTALL 21C ONTO END OF INTO NORMALLY CLOSED RELAY STACK SOCKET ON 21CR 86CR 59CR(CE) 60CR 78CR 79CR 57ACR2 76ACR 77CR COOLER IGN.

  • Page 86: Positive Air Shutoff Harness

    3.31 Positive Air Shutoff Harness TO ELECTRICAL PANEL BACK VIEW 403A RED POSITIVE AIR SHUT OFF MODULE 10 PIN CONNECTOR PLUG 402 GREEN PIN 1 -BLACK (401) PIN 6 -BLUE (403) 403 RED PIN 2 -EMPTY PIN 7 -WHITE (02) 02 WHITE (GROUND) PIN 3 -RED (403A) PIN 8 -WHITE (408)

  • Page 87: Hydraulic Schematic - Ansi/Csa

    3.32 Hydraulic Schematic - ANSI/CSA JIB LIFT BULKHEAD LOCATIONS #1 - AT RISER KNUCKLE #2 - TOP OF MAIN BOOM - AT EXT. CYL. ACCESS PLATFORM ROTATE #3 - TOP OF FLYBOOM - AT TIP BULKHEAD #1 POWER TRACK CARRIER ASSEMBLY SAE06 SAE06 PLATFORM LEVELING...

  • Page 88: Hydraulic Schematic - Ce & As

    3.33 Hydraulic Schematic - CE & AS PLATFORM ROTARY BULKHEAD LOCATIONS ACTUATOR DISPL: 132CC (8.05CIR) #1 - AT RISER KNUCKLE #2 - TOP OF MAIN BOOM - AT EXT. CYL. ACCESS CB13 CB12 #3 - TOP OF FLYBOOM - AT TIP 3300 PSI 3300 PSI SERIAL# 95300187 AND ABOVE...

  • Page 89: Platform Control Box Wiring - Ansi/Csa

    3.34 Platform Control Box Wiring - ANSI/CSA LOAD LOW CAP A3 JOYSTICK ZONE A2 JOYSTICK BORDER HIGH CAP GLAZIER JOYSTICK ACTIVE 04(RED) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R(RED/GREEN) R-SIGNAL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL...

  • Page 90: Platform Conrol Box Wiring - Ce - Deutz Tcd2.2

    3.35 Platform Conrol Box Wiring - CE - Deutz TCD2.2 A3 JOYSTICK A2 JOYSTICK PL10 A1 JOYSTICK 162A (YELLOW) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R (RED/GREEN) R-SIGNAL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL S20- BASKET...

  • Page 91: Platform Control Box Wiring - Ce - Deutz Td2.9L & D2011

    3.36 Platform Control Box Wiring - CE - Deutz TD2.9L & D2011 A3 JOYSTICK A2 JOYSTICK A1 JOYSTICK 162A (YELLOW) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R (RED/GREEN) R-SIGNAL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL S20- BASKET...

  • Page 92: Platform Control Box Wiring - Ce - Kubota Wg2503

    3.37 Platform Control Box Wiring - CE - Kubota WG2503 A3 JOYSTICK A2 JOYSTICK A1 JOYSTICK 162A (YELLOW) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R (RED/GREEN) R-SIGNAL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL S20- BASKET RED (+)

  • Page 93: Platform Control Box Wiring - As

    3.38 Platform Control Box Wiring - AS A3 JOYSTICK A2 JOYSTICK A1 JOYSTICK 162A (YELLOW) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R (RED/GREEN) R-SIGNAL 24 (BLUE/BLACK) LEFT WHT/RED 23 (BLACK/WHITE) RIGHT WHT/YEL S20- BASKET RED (+) POWER 04 (RED/YELLOW)

  • Page 94: Base Control Box Wiring - Ansi/Csa

    3.39 Base Control Box Wiring - ANSI/CSA CB's & SWITCH S8 ON LEFT SIDE OF CONNECTOR J1 PIN 1 - 56(fromCB3) PIN 2 - 103 PIN 3 - 103A BLACK PIN 4 - N/A PIN 5 - 74 PIN 6 - 09 NOTE: ZIP TIE PIN 7 - 02 LOOSE END...

  • Page 95: Base Control Box Wiring - Ansi/Csa With Positive Air Shut-Off Option

    3.40 Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option CB's & SWITCH S8 ON LEFT SIDE OF CONNECTOR J1 PIN 1 - 56C PIN 2 - 103 BLACK PIN 3 - 103A PIN 4 - 84 PIN 5 - 74 NOTE: ZIP TIE LOOSE END PIN 6 - 09...

  • Page 96: Base Control Box Wiring - Ce - Deutz Tcd2.2

    3.41 Base Control Box Wiring - CE - Deutz TCD2.2 CONNECTOR J1 PIN 1 - PLUGGED PIN 2 - PLUGGED PIN 3 - 56B PIN 4 - 56A 05-14ga D57D PIN 5 - PLUGGED PIN 6 - CAN H PIN 7 - PLUGGED 12ACR 162BCR 01ACR...

  • Page 97: Base Control Box Wiring - Ce - Deutz Td2.9L

    3.42 Base Control Box Wiring - CE - Deutz TD2.9L CONNECTOR J1 PIN 1 - 103 05-14ga D57D PIN 2 - 103A PIN 3 - 56B PIN 4 - 56A 162BCR 01ACR 21CR 36CR1 37CR 45CR1 45CR2 49CR 57DCR PIN 5 - PLUGGED PIN 6 - CAN H 128B PIN 7 - 203...

  • Page 98: Base Control Box Wiring - Ce - Deutz D2011

    3.43 Base Control Box Wiring - CE - Deutz D2011 05-14ga D57D 03A-14ga 162BCR 01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR 57DCR 128B 162B DIAGNOSE 128A 162A DEUTZ EDC BATTERY (B+) HARNESS 03 - BLACK E STOP TO E-PUMP POWER STUD 57ACR 36CR1 37CR...

  • Page 99: Base Control Box Wiring - As

    3.44 Base Control Box Wiring - AS 05-14ga D57D 03A-14ga 01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR 57DCR 128B DIAGNOSE 128A 162A BLACK DEUTZ EDC BATTERY (B+) HARNESS 03 - BLACK E STOP TO E-PUMP POWER STUD 57ACR 36CR1 37CR 59CR 60CR 78CR...

  • Page 100: Electrical Schematic - Ansi/Csa

    3.45 Electrical Schematic - ANSI/CSA 3.51 Engine Electrical Schematic - Deutz TD2.9L JMPR4 R4=330K ohm 3.45 Electrical Schematic - ANSI/CSA M231435AA-1 SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 101: Electrical Schematic - Ce - Deutz Tcd2.2

    3.46 Electrical Schematic - CE - Deutz TCD2.2 3.55 Engine Electrical Schematic - Deutz TCD2.2 3.46 Electrical Schematic - CE - Deutz TCD2.2 M224641AE-1 SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 102: Electrical Schematic - Ce - Deutz Td2.9

    3.47 Electrical Schematic - CE - Deutz TD2.9 3.51 Engine Electrical Schematic - Deutz TD2.9L ONLY WITH SGE OPTION 3.47 Electrical Schematic - CE - Deutz TD2.9 M223003AC-1 SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 103: Electrical Schematic - Ce - Deutz D2011

    3.48 Electrical Schematic - CE - Deutz D2011 ONLY WITH SGE OPTION 3.48 Electrical Schematic - CE - Deutz D2011 M222998AC SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 104: Electrical Schematic - Ce - Kubota Wg2503

    3.49 Electrical Schematic - CE - Kubota WG2503 3.54 Engine Electrical Schematic - Kubota WG2503 ONLY WITH SGE OPTION ONLY WITH SGE OPTION 3.49 Electrical Schematic - CE - Kubota WG2503 M172038AE-1 SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 105: Electrical Schematic - As - Deutz D2011

    3.50 Electrical Schematic - AS - Deutz D2011 ONLY WITH SGE OPTION ONLY WITH SGE OPTION 3.50 Electrical Schematic - AS - Deutz D2011 M222999AC SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 106: Engine Electrical Schematic - Deutz Td2.9L

    3.51 Engine Electrical Schematic - Deutz TD2.9L TO BATTERY TO BATTERY ENGINE B+ POST B- POST INTERFACE ENGINE HARNESS MAIN PANEL A02-16 WH A32-16 BK A03-16 WH A46-16 BK A04-16 WH A05-16 BK A16-16 WH A33-16 BK A18-16 WH A48-16 BK A37-18 WH A52-18 BK A53-18 RD...

  • Page 107: Engine Interface Wiring - Deutz Td2.9L

    3.52 Engine Interface Wiring - Deutz TD2.9L D2.2 - 94 PIN 75 80 31 32 TO ECU 203-18 BK SPLK01 SPL00 202-18 WH TO COOLANT 204-18 RD SENSOR 09A-18 BK TO ALTERNATOR K82-18 BK K44-18 BK K85-18 BK A45-18 BK A44-18 BK A44-18 BK A43-18 BK...

  • Page 108: Engine Electrical Schematic - Deutz D2011

    3.53 Engine Electrical Schematic - Deutz D2011 TO BASE BOX TO ENGINE INTERFACE HARNESS TO ENGINE ENCLOSURE HARNESS ENGINE T0 RELAY T0 RELAY T0 RELAY T0 RELAY 56ACR 57ACR 68CR 00ACR 57BCR (N ...) Hinweise: 1. Gerätebezeichnung nach H829908 Teil 1, z.B. 56(FROM CB3) SP54A_2 MOTOR...

  • Page 109: Engine Electrical Schematic - Kubota Wg2503

    3.54 Engine Electrical Schematic - Kubota WG2503 MAIN PANEL INTERFACE ENGINE HARNESS ENGINE KUBOTA EFI DUAL FUEL ENGINE ECU1 R (ORANGE/YELLOW) 12 (ORANGE/YELLOW) AUX ANA PD 1 (TWIST WIRES 10 TURNS (360 DEG)/FOOT FULL LENGTH) P (RED/BLACK) 29 (RED/WHITE) SPEED + N (RED/WHITE) 30 (RED/BLACK) SPEED -...

  • Page 110: Engine Electrical Schematic - Deutz Tcd2.2

    3.55 Engine Electrical Schematic - Deutz TCD2.2 ENGINE DISPLAY - 12 PIN MOUNTED ON ENGINE ENGINE A58-18 BK 84-18 BK (T-ONLY) A34-18 BK A11-18 BK A18-16 WH A48-16 BK A02-16 WH TO BATTERY TO BATTERY B+ POST B- POST A32-16 BK A04-16 WH A05-16 BK A16-16 WH...

  • Page 111: Engine Interface Harness - Deutz Tcd2.2

    3.56 Engine Interface Harness - Deutz TCD2.2 D2.2 - 94 PIN 31 32 TO ECU SPL02 K68-18 BK K87-18 WH TO COOLANT K13-18 RD SENSOR SPLK01 SPL00 R1=120 ohm 09A-18 BK TO ALTERNATOR K09-18 BK K08-18 BK K43-18 BK K81-16 BK K58-18 WH D2.1 - 60 PIN K46-18 BK...

  • Page 112: Section 4 - Troubleshooting Information

    Section 4 – Troubleshooting Information 4.1 Introduction The following pages contain a table of Troubleshooting for locating and correcting most service trouble which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting will localize the trouble more quickly than any other method.

  • Page 113: Electrical System - Ansi/Csa

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2 Electrical System - ANSI/CSA 4.2-1 All Controls are Inoperative from the Base or Platform Console NOTE Functions may be disabled by the dual load zone system or the overload system. Please first make sure the boom is at or below level and fully retracted, the platform is level and free of added weight, and there are no faults in the dual load or overload systems.
  • Page 114 Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 17. Loose or broken wire #09 from base terminal Check continuity. Replace if defective. block to base control module connector J1 pins 1, 2, 3, and/or 4. 18. Loose or broken wire #02 from base control Check continuity.

  • Page 115: All Controls Are Inoperative From The Base Console

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 34. Loose, broken, or defective 120 ohm CAN Check that resistance between CAN H and CAN L termination resistor(s) between CAN H and is appoximately 60 ohms (2 x 120 ohm in parallel). CAN L teminals in platform and/or base terminal Check connections.

  • Page 116: The Engine Will Not Crank From The Base

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 7. Defective relay 57DCR. Check relay. Replace if defective. 8. Loose or broken 57A wire from connector P4 Check schematic applicable to the engine equipped pin 8 to start input on ECU or 57ACR relay if on the machine to determine ECU pin # or relay if equipped.

  • Page 117: No Boom Up From The Base Or Platform Controls

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-7 No Boom Up from the Base or Platform Controls 1. Loose or broken wire #14 from base control Check continuity. Replace if defective module connector J2 pin 5 base terminal block to turret harness plug pin #2 2.

  • Page 118: 11 No Boom Down From The Base Console

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 4.2-11 No Boom Down from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to boom switch S12 2. Defective boom switch S12 Check continuity through switch while activating boom down function between wires #10A and #13B.

  • Page 119: 15 No Turret Rotate Right From The Platform Console

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-15 No Turret Rotate Right from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block to joystick controller A1 2. Loose or broken wire #02 from platform terminal Check continuity.

  • Page 120: 19 No Riser Up From The Base Or Platform Consoles

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 4.2-19 No Riser Up from the Base or Platform Consoles 1. Loose or broken wire #31 from base control Check continuity. Replace if defective module connector J2 pin 3 to turret harness plug pin #8 2.

  • Page 121: 23 No Riser Down From The Base Console

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-23 No Riser Down from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to boom switch S25 2. Defective riser switch S25 Check continuity through switch while activating riser down function between wires #10A and #30B.

  • Page 122: 27 No Telescope Out From The Platform Console

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 4.2-27 No Telescope Out from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block totelescope switch S18 2. Defective boom switch S18 Check continuity through switch while activating telescope out function between wires #04 and #39A.

  • Page 123: 31 No Platform Level Up From The Base Or Platform Consoles

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-31 No Platform Level Up from the Base or Platform Consoles 1. Loose or broken wire #41 from base control Check continuity. Replace if defective module connector J2 pin #7 to turret harness plug pin #16 2.

  • Page 124: 35 No Platform Level Down From The Base Console

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 4.2-35 No Platform Level Down from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to platform level switch S16 2. Defective platfrom level switch S16 Check continuity through switch while activating platfrom level down function between wires #10A and #40B.

  • Page 125: 38 No Platform Rotate Right From The Base Or Platform Consoles

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-38 No Platform Rotate Right from the Base or Platform Consoles 1. Loose or broken wire #37 from platform control Check continuity. Replace if defective module connector J12 pin #1 to platform terminal strip 2.

  • Page 126: 41 No Platform Rotate Left From The Base Or Platform Consoles

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 4.2-41 No Platform Rotate Left from the Base or Platform Consoles 1. Loose or broken wire #36 from platform control Check continuity. Replace if defective module connector J12 pin #2 to platform terminal strip 2.

  • Page 127: 45 No Jib Up From The Base Console

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-45 No Jib Up from the Base Console 1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective to jib switch S17 2. Defective jib switch S17 Check continuity through switch while activating jib up function between wires #10A and #35B.

  • Page 128: 49 No Jib Down From The Platform Console

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 4.2-49 No Jib Down from the Platform Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective block to jib switch S21 2. Defective jib switch S21 Check continuity through switch while activating jib down function between wires #04 and #34A.

  • Page 129: 53 No Reverse Drive

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-53 No Reverse Drive 1. No output from base control module at connector Check for correct output voltage. J2 pin #2 to wire #15 2. Loose or broken wire 15 from base control Check continuity.

  • Page 130: 56 No Right Steer

    Electrical System - ANSI/CSA Section 4 – Troubleshooting Information 5. Loose or broken wire #02 from turret harness Check continuity. Replace if defective plug to left steer valve 4H-24 6. Defective left steer valve coil 4H-24 Check continuity and resistance through coil. Replace if defective 4.2-56 No Right Steer 1.

  • Page 131: Weight

    Section 4 – Troubleshooting Information Electrical System - ANSI/CSA 4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below Weight 1. Load sense mis-calibration Refer to calibration procedure for recalibration of load cell 2. Load cell circuit not operating Check wiring from load cell to platform control module.

  • Page 132: Electrical System - Ce & As

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3 Electrical System - CE & AS 4.3-1 All Controls are Inoperative 1. Battery disconnected or discharged. Connect battery or recharge. 2. Loose or broken wire #03 from battery to circuit Check continuity.

  • Page 133: No Power To Platform

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-2 No Power To Platform 1. Open or defective key select switch S2. Close switch. Replace if defective. 2. Loose or broken wire #07A from key select Check continuity. Replace if defective. switch S2 to plug A pins # 2 &...

  • Page 134: The Engine Will Not Crank From The Base

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-4 The Engine Will Not Crank from the Base 1. Loose or broken wire #10 from base terminal Check continuity. Replace if defective. block to base start switch S5. 2.

  • Page 135: The Engine Will Not Crank From The Platform Or Base When Equipped With Elevate/Trackunit Telematics Ready

    Section 4 – Troubleshooting Information Electrical System - CE & AS 6. Loose or broken wire #03A from circuit breaker Check continuity. Replace if defective. CB3 to relay 09CR. 7. Tripped or defective circuit breaker CB3. Reset circuit breaker. Check continuity through circuit breaker.

  • Page 136: The Engine Cranks But Will Not Start (Deutz Diesel)

    Electrical System - CE & AS Section 4 – Troubleshooting Information 9. Loose or broken wire 57B from 57DCR pin 87 to Check continuity. Replace if defective. engine starter contactor coil. 10. Defective telematics module. Check telematics assembly; repair or replace as required.

  • Page 137: 10 The Engine Cranks But Will Not Start (Gm Dual Fuel)

    Section 4 – Troubleshooting Information Electrical System - CE & AS 13. Loose or broken red wire from battery positive to Check continuity. Replace if defective. starter fuse F12. 14. Defective fuse F12. Check fuse. Replace if defective. 15. Loose or broken red/tan wire from fuse F12 to Check continuity.
  • Page 138 Electrical System - CE & AS Section 4 – Troubleshooting Information 14. Loose or broken pink/dark green wire from fuse Check continuity. Replace if defective. F10 to gas injectors GI-1, GI-2, GI-3 and GI-4. 15. Loose or broken pink/white wire from ECU Check continuity.

  • Page 139: 11 The Glow Plug Circuit Is Inoperative

    Section 4 – Troubleshooting Information Electrical System - CE & AS Fuel Related Problems (Propane only) NOTE The fuel select switch is defaulted to gasoline. The engine will run on gasoline if propane is selected from the switch and either the switch is bad or a wire is loose or broken from the switch. This is providing there is nothing wrong on the gasoline side of the system.

  • Page 140: 12 All Controls Are Inoperative From The Base Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 3. Loose or broken wire #11A from fuse holder FU1 Check continuity. Replace if defective. to relay 54ACR. 4. Loose or broken wire #11B from relay 54ACR to Check continuity. Replace if defective. glow plugs.

  • Page 141: 13 No Main Boom Down, Riser Down Or Turret Rotate From Base Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 12. Loose or broken wire #162A from base terminal Check continuity. Replace if defective. block to relay 21CR. NOTE For further CE/AS troubleshooting refer to Load Sensing System. 13. Defective relay 21CR. Check relay.

  • Page 142: 15 No Boom Down From The Base Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-15 No Boom Down from the Base Control Console 1. Loose or broken wire #10C from resistor R1 to Check continuity. Replace if defective. boom down switch S12. 2. Defective boom switch S12. Check continuity through switch while activating down function between wires #10C and #13.

  • Page 143: 17 No Riser Down From The Base Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-17 No Riser Down from the Base Control Console 1. Loose or broken wire #10C from boom switch Check continuity. Replace if defective. S12 to riser down switch S25. 2.

  • Page 144: 19 No Turret Rotate Right From The Base Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-19 No Turret Rotate Right from the Base Control Console 1. Loose or broken wire #10C from resistor R1 to Check continuity. Replace if defective. turret rotate switch S13. 2.

  • Page 145: 21 No Telescope Extend From The Base Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-21 No Telescope Extend from the Base Control Console 1. Loose or broken wire #10A from ignition/enable Check continuity. Replace if defective. switch S5 to telescope switch S14. 2. Defective telescope switch S14. Check continuity through switch while activating extend function between wires #10A and #39.

  • Page 146: 23 Platform Rotates Too Quickly

    Electrical System - CE & AS Section 4 – Troubleshooting Information 9. Defective platform rotate switch S20. (Platform Check continuity through switch while activating controls only) rotate left function between wires #8C and #36 as well as #8E and 35/34. If no continuity found, replace switch.

  • Page 147: 25 No Platform Rotate Right From The Base Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 3. Loose or broken wire #10D from platform rotate Check continuity. Replace if defective. switch S16 to diode D10D. 4. Open or defective diode D10D. Check diode. Replace if defective. 5.

  • Page 148: 26 No Jib Up From The Base Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 9. Loose or broken wire #02 in main harness cable Check for continuity between pin #23 on or its connectors. main harness connector and rotate right/ jib down connector. Check for loose or corroded connections on cable connectors.

  • Page 149: 28 No Manual Platform Level Up From The Base Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-28 No Manual Platform Level Up from the Base Control Console 1. Loose or broken wire #10A from rotate switch Check continuity. Replace if defective. S16 to platform level switch S15. 2.
  • Page 150 Electrical System - CE & AS Section 4 – Troubleshooting Information 3. Loose or broken wire #4 emergency stop switch Check continuity. Replace if defective. S4 to platform terminal block. 4. Loose or broken pin jumper between #04 Check continuity. Replace if defective. and #04B on platform terminal block (without generator option only).

  • Page 151: 31 No Boom Up From The Platform Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-31 No Boom Up from the Platform Control Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective. block to joystick controller A1. 2. Loose or broken wire #02 from platform terminal Check continuity.

  • Page 152: 33 No Riser Up From The Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 5. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with #20B. foot on footswitch check section 5 for valve driver test procedure.

  • Page 153: 34 No Riser Down From The Platform Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 9. Loose or broken wire #31 from base connector Check continuity. Replace if defective. plug A pin #13 to base terminal block. 10. Loose or broken wire #31 from base terminal Check continuity.

  • Page 154: 35 No Turret Left From The Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-35 No Turret Left from the Platform Control Console 1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective. block to joystick controller A1. 2. Loose or broken wire #02 from platform terminal Check continuity.

  • Page 155: 37 No Toggle Switch Functions From The Platform Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 5. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with #20B. foot on footswitch check section 5 for valve driver test procedure.

  • Page 156: 39 No Telescope Out From The Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with #20B. foot on footswitch check section 5 for valve driver test procedure.

  • Page 157: 40 No Platform Rotate Left From The Platform Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 10. Loose or broken wire #02 from main harness Check continuity. Replace if defective. plug to telescope out valve 5H-39. 11. Defective telescope out valve coil 5H-39. Check continuity and resistance through coil. Replace if defective.

  • Page 158: 41 No Platform Rotate Right From The Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 17. Loose or broken wire #35 from base terminal Check continuity. Replace if defective. block to main harness plug pin #12. 18. Loose or broken wire #35 in main harness cable Check for continuity between pin #12 on main or its connectors.

  • Page 159: 42 No Jib Up From The Platform Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 14. Loose or broken wire #34 from platform rotate Check continuity. Replace if defective. switch S20 to plug A pin#16 in platform control console. 15. Loose or broken wire #34 in boom cable A or its Check for continuity between pins #16 on cable A.

  • Page 160: 43 No Jib Down From The Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 10. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with #20C. foot on footswitch check section 5 for valve driver test procedure.

  • Page 161: 44 No Manual Platform Level Up From The Platform Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS 10. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with #20C. foot on footswitch check section 5 for valve driver test procedure.

  • Page 162: 45 No Manual Platform Level Down From The Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 7. Loose or broken wire #41 from base connector Check continuity. Replace if defective. plug B pin #11 to base terminal block. 8. Loose or broken wire #41 from base terminal Check continuity.

  • Page 163: 46 Mid Throttle Inoperative

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-46 Mid Throttle Inoperative 1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective. block to throttle switch S10. 2. Open or defective diode D08. (Generator option Check diode.

  • Page 164: 47 High Throttle Inoperative

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-47 High Throttle Inoperative 1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective. block to throttle switch S10. 2. Open or defective diode D08. (Generator option Check diode.

  • Page 165: 48 Brake Will Not Release

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-48 Brake will not Release 1. No output on pin #10 from valve driver to wire Check pin #10 for 12 volts. If no voltage present #26 when operating a drive function. with foot on footswitch check section 5 for valve driver test procedure.

  • Page 166: 50 Differential Lock Engages Momentarily But Will Not Stay Engaged

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-50 Differential Lock Engages Momentarily but will not stay Engaged NOTE Differential Lock will engage without light being illuminated. Check bulb. 1. Loose or broken wire #26A at diode D26A. Check continuity.

  • Page 167: No Forward Drive

    Section 4 – Troubleshooting Information Electrical System - CE & AS 5. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective. joystick A2 to valve driver pin #27. (Drive only) 6. Loose or broken wires #23 and #24 from drive Check continuity.

  • Page 168: 54 No High Speed Drive

    Electrical System - CE & AS Section 4 – Troubleshooting Information 6. Loose or broken wire #15 from base plug B pin Check continuity. Replace if defective. #4 to reverse drive valve 4H-15. 7. Loose or broken wire #02 from base terminal Check continuity.

  • Page 169: 55 No Elevated Drive

    Section 4 – Troubleshooting Information Electrical System - CE & AS 13. Loose or broken wire #59 from platform terminal Check continuity. Replace if defective. block to valve driver pin #31. 14. Defective valve driver channel input for high drive See section 5 for test procedure on valve driver.

  • Page 170: 56 No Left Steer

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4. Loose or broken wire #28 in cable B or its Check for continuity between pins #7 on cable B. connectors. Check for loose or corroded connections on cable connectors.

  • Page 171: 58 Direction Sensing Inoperative

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-58 Direction Sensing Inoperative 1. Loose or broken wire #09 from base terminal Check continuity. Replace if defective. block to limit switch LS1. 2. Open or defective limit switch LS1. Adjust limit switch if required.

  • Page 172: Load Sensing System - Ce & As

    Load Sensing System - CE & AS Section 4 – Troubleshooting Information 4.4 Load Sensing System - CE & AS 4.4-1 Green Power LED is not Flashing 1. Loose or broken wires #60 and #02 at platform Check for connections. Check for voltage (12V). terminal block.

  • Page 173: Audible Alarm Does Not Turn On

    Section 4 – Troubleshooting Information Load Sensing System - CE & AS 4.4-6 Audible Alarm does not turn ON 1. Defective alarm BP3. Check alarm. Replace if defective. 2. Open or defective diode D118. Check diode. Replace if defective. 3. Load cell circuit not operating. Check for connections with wires #02 and #118 at platform terminal block.

  • Page 174: Hydraulic System - Ansi/Csa

    Hydraulic System - ANSI/CSA Section 4 – Troubleshooting Information 4.5 Hydraulic System - ANSI/CSA 4.5-1 All Controls are Inoperative 1. Broken or defective drive pump shaft or coupling. Check pump shaft and coupling. Replace if defective. 2. Hydraulic oil level low. Check oil level.

  • Page 175: No Riser Boom Up

    Section 4 – Troubleshooting Information Hydraulic System - ANSI/CSA 4. Stuck or defective check valve CV5. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective relief valve RV5. Set valve to specifications. Check o-rings and clean valve.

  • Page 176: No Turret Rotate Left

    Hydraulic System - ANSI/CSA Section 4 – Troubleshooting Information 4.5-7 No Turret Rotate Left 1. Stuck or defective rotate left valve 5H-32. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice.

  • Page 177: No Boom Extend

    Section 4 – Troubleshooting Information Hydraulic System - ANSI/CSA 4.5-9 No Boom Extend 1. Stuck or defective extend valve 5H-39. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective check valve CV6. Clean valve. Check operation of valve. Repair or replace valve as required.

  • Page 178: 12 No Jib Down

    Hydraulic System - ANSI/CSA Section 4 – Troubleshooting Information 4.5-12 No Jib Down 1. Stuck or defective flow enable valve 2H-42. Clean valve. Check O-rings on valve. Check opera- tion of valve. Repair or replace valve as required. 2. Stuck or defective check valve CV8. Clean valve.

  • Page 179: 15 The Platform Will Not Level Down Manually

    Section 4 – Troubleshooting Information Hydraulic System - ANSI/CSA 4.5-15 The Platform will not Level Down Manually 1. Plugged or defective orifice OR3. Check orifice. Replace if plugged or defective. 2. Stuck or defective platform level down valve 5H- Clean valve. Check operation of valve. Repair or replace valve as required.

  • Page 180: 17 The Brake Will Not Release

    Hydraulic System - ANSI/CSA Section 4 – Troubleshooting Information 8. Stuck or defective check valve CV4. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 9. Defective leveling cylinder C4 or slave cylinder Check seals on cylinder.

  • Page 181: 19 The Differential Lock Will Not Engage

    Section 4 – Troubleshooting Information Hydraulic System - ANSI/CSA 4.5-19 The Differential Lock will not Engage 1. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective or misadjusted pressure reducing valve Set valve to specifications.

  • Page 182: 23 No High Speed Drive

    Hydraulic System - ANSI/CSA Section 4 – Troubleshooting Information 4.5-23 No High Speed Drive 1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Defective shift valve V5 in drive motor M1. Check motor.

  • Page 183: 27 Axle Will Not Lock

    Section 4 – Troubleshooting Information Hydraulic System - ANSI/CSA 4.5-27 Axle Will Not Lock NOTE The axle is in constant float if the boom is fully retracted and is horizontal or below. 1. Axle lockout valve 3H-65 is stuck in shifted Clean valve.

  • Page 184: Hydraulic System - Ce & As

    Hydraulic System - CE & AS Section 4 – Troubleshooting Information 4.6 Hydraulic System - CE & AS 4.6-1 All Controls are Inoperative 1. Broken or defective drive pump shaft or coupling. Check pump shaft and coupling. Replace if defective. 2.

  • Page 185: No Riser Boom Up

    Section 4 – Troubleshooting Information Hydraulic System - CE & AS 4. Stuck or defective check valve CV5. Clean valve. Check operation of valve. Repair or replace valve as required. 5. Stuck or defective relief valve RV5. Set valve to specifications. Check o-rings and clean valve.

  • Page 186: No Turret Rotate Left

    Hydraulic System - CE & AS Section 4 – Troubleshooting Information 4.6-7 No Turret Rotate Left 1. Stuck or defective rotate left valve 5H-32. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice.

  • Page 187: No Boom Extend

    Section 4 – Troubleshooting Information Hydraulic System - CE & AS 4.6-9 No Boom Extend 1. Stuck or defective extend valve 5H-39. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective check valve CV6. Clean valve.

  • Page 188: 12 Jib Up/ Down Slow

    Hydraulic System - CE & AS Section 4 – Troubleshooting Information 4.6-12 Jib Up/ Down Slow 1. Stuck or defective rotate select valve 2H-36. Clean valve. Check operation of valve. Repair or replace valve as required. 4.6-13 No Jib Down 1.

  • Page 189: 16 Platform Rotates Too Quickly

    Section 4 – Troubleshooting Information Hydraulic System - CE & AS 4.6-16 Platform Rotates too Quickly 1. Stuck or defective rotate select valve 2H-36. Clean valve. Check operation of valve. Repair or replace valve as required. 4.6-17 Platform will not Level Down Manually 1.

  • Page 190: 19 Brake Will Not Release

    Hydraulic System - CE & AS Section 4 – Troubleshooting Information 6. Stuck or defective relief valve RV3. Set valve to specifications. Check O-rings and clean valve. Repair or replace valve as required. 7. Stuck or defective counterbalance valve CB10. Clean valve.

  • Page 191: 21 Differential Lock Will Not Engage

    Section 4 – Troubleshooting Information Hydraulic System - CE & AS 4.6-21 Differential Lock will not Engage 1. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2.

  • Page 192: 25 No High Speed Drive

    Hydraulic System - CE & AS Section 4 – Troubleshooting Information 4.6-25 No High Speed Drive 1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2.

  • Page 193: 29 The Axle Will Not Lock

    Section 4 – Troubleshooting Information Hydraulic System - CE & AS 4.6-29 The Axle Will Not Lock NOTE Axle is in constant float if boom is fully retracted and is horizontal or below. 1. Axle lockout valve 3H-65 is stuck in shifted Clean valve.

  • Page 194: Section 5 - Procedures

    Before performing routine maintenance underneath the riser, support it using a suitably rated lifting device (refer to Figure 01), or cylinder chocks on both riser cylinders. Contact Skyjack Parts to order chocks. WARNING Remove all material and personnel from the platform while using the maintenance support(s).

  • Page 195: Platform

    Section 5 – Procedures Platform 5.2 Platform 5.2-1 Human Machine Interface (HMI) Maintaining proper calibration is essential for the good performance of the MEWP . To access the OC1-1 console, open the platform control cover. The OCI-1 has an integrated multi segment, two line display with membrane keys that allow it to be used as the main interface to system controls and adjustments.

  • Page 196: Ocm Character Functions Charts

    Platform Section 5 – Procedures 5.2-3 OCM Character Functions Charts SCM Keypad Function Attribute Keys Short Form THRESH Threshold Menu/Select (M/S) RAMPDN Ramp Down /- RAMPUP Ramp Up LOWRNG Low Range /+ Save/Exit (S/E) MAXOUT Maximum Output 1345AA 5.2-4 OCM Function Channel Names - CE & AS SCM Function (Channel) Names DRIVE REV Fn01A Drive Reverse...

  • Page 197: Ocm Operating Values Chart - Ce & As

    Section 5 – Procedures Platform 5.2-5 OCM Operating Values Chart - CE & AS Input Expected Value Description AI 1 0.5V to 8.5V Drive Joystick AI 2 0.5V to 8.5V Turret Rotation Joystick AI 3 0.5V to 8.5V Boom Elevation Joystick AI 4 0.5V to 7.5V Flow Enable Rotary Potentiometer...

  • Page 198: How To Select Functionality - Ce & As

    Platform Section 5 – Procedures 5.2-6 How to Select Functionality - CE & AS   STARTING  MODE: NO CONFIG      +  SCREEN  FUNCTIONS OFF     MENU    ENTER PASSWORD  UNLOCK SETUP?  SOFTWARE REVISION  0**  PRESS SELECT  +  MODEL SERIAL NUMBER  SELEC 0 (FLASHING)  (FLASHING)  5X      ...

  • Page 199: How To View Ocm Operation - Ce & As

    Section 5 – Procedures Platform 5.2-7 How to View OCM Operation - CE & AS As a joystick or toggle switch is being activated, the OCM screen will display the active function and % output. Also, the following procedure will allow monitoring of all input and output channels: MODE= XX/XX LTD CE Models STARTING...

  • Page 200: How To Unlock And Modify Ocm Settings - Ce & As

    Platform Section 5 – Procedures 5.2-8 How to Unlock and Modify OCM Settings - CE & AS MODE= XX/XX LTD CE Models FUNCTIONS OFF ▲ STARTING ▬▬▬ ┼ SCREEN ANSI/CSA MODE= XX/XX STD Models FUNCTIONS OFF MENU ▲ UNLOCK SETUP? SOFTWARE REVISION ▬▬▬▬...

  • Page 201: Ocm Pin Reference - Ansi/Csa

    Section 5 – Procedures Platform 5.2-9 OCM Pin Reference - ANSI/CSA P3/P13 WHITE P1/P11 BLACK P2/P12 GREY P1 (Black) Master Controller: SMB1-105 Wire Function Input/Output Type I/O Name Label Power Power Power Power Not used Vreg 5v CAN H CANH to Engine ECU & Telematics J1939 CAN CAN L CANL to Engine ECU &...
  • Page 202 Platform Section 5 – Procedures P2 (Grey) Master Controller: SMB1-105 Wire Function Input/Output Type I/O Name Label Drive Forward Analog Output PWM01 PWM02 Drive Reverse Analog Output PWM00 PWM01 Riser Up Analog Output PWM07 PWM08 Riser Down Analog Output PWM06 PWM07 Boom Up Analog Output...
  • Page 203 Section 5 – Procedures Platform P3 (White) Master Controller: SMB1-105 Wire Function Input/Output Type I/O Name Label Load Zone Border Lamp Digital Output DOUT1 Emergency Pump Relay Digital Output DOUT8 Steer Right Digital Output DOUT7 118A Overload Alarm/lamp Digital Output DOUT6 Axle Lock Digital Output...
  • Page 204 Platform Section 5 – Procedures P11 (Black) Slave Controller: SMB1-106 Wire Function Input/Output Type I/O Name Label Power Power Power Power Speed control supply (T Booms) Vreg 5v Not Used J1939 CAN Not Used J1939 CAN CAN 2H CANH To PLTF SMB1-106 CANopen CAN 2L CANL To PLTF SMB1-106...
  • Page 205 Section 5 – Procedures Platform P12 (Grey) Slave Controller: SMB1-106 Wire Function Input/Output Type I/O Name Label Platform Rotation Right PWM01 PWM17 Platform Rotation Left PWM00 PWM16 Not Used PWM07 PWM23 Not Used PWM06 PWM22 Not Used PWM05 PWM21 Not Used PWM04 PWM20 Not Used...
  • Page 206 Platform Section 5 – Procedures P13 (White) Slave Controller: SMB1-106 Wire Function Input/Output Type I/O Name Label Not Used DOUT19 Low Fuel Indicator Lamp DOUT26 EcoStart Indicator Light DOUT25 Tilt Audible Indicator DOUT24 Regen Lamp (EU Stage 5 engine) DOUT23 SGE Alarm DOUT30 O/L Lamp...

  • Page 207: 10 Ocm Pin Voltage Reference - Ce & As

    Section 5 – Procedures Platform 5.2-10 OCM Pin Voltage Reference - CE & AS All voltages given are with OCM controller at maximum % adjustable settings. All voltages should be tested with key on, engine off and foot switch depressed. All tests should be performed with platform over drive axle, boom fully stowed and on flat level surface.
  • Page 208 Platform Section 5 – Procedures Pin 10 - 12 volt output on wire 26 brake valve 3H-26. 12V=Drive selected Test between pin 10 and 02 wire. Pin 11- 12 volt output on wire 27 to tilt alarm relay 27CR. Test between pin 11 and 02 wire Pin 12 - Riser down selected.
  • Page 209 Section 5 – Procedures Platform Pin 24 - Battery negative. Wire 02. Pin 25 - Battery negative. Wire 02. Pin 26 - Battery negative. Wire 02. Pin 27 - Accelerator input. Wire D from drive joystick controller. Neutral position= 4.2 volts to 4.8 volts. Forward function= 4.9 volts to 8.5 volts.

  • Page 210: 11 Platform Controller Voltage References

    Platform Section 5 – Procedures 5.2-11 Platform Controller Voltage References Boom/Turret (A1) Controller Boom Up 12 Volts RED (+) POWER 04 RED/YEL Neutral BLK(-) GROUND 02 WHT Position Turret Rotate Left Turret Rotate Right WHT(X) X-SIGNAL 4.2 - 4.8 Pin 28 Volts BLU(Y) Y-SIGNAL...
  • Page 211 Section 5 – Procedures Platform Drive (A2) Controller  12 Volts Drive Forward 04 YEL POWER 02 WHT GROUND Neutral  Position     D‐SIGNAL Pin 27 4.2 ‐ 4.8  Volts 24 BLU/BLK LEFT WHT/RED Pin 17 23 BLK/WHT RIGHT WHT/YEL Pin 18 Drive Reverse Reference Analog Input AI 1 Neutral Position = 4.2 ‐ 4.8 Volts 12 Volts  12 Volts   Forward = 4.9 ‐ 8.5 Volts @ full stroke Right Steer  Left Steer  Reverse = 4.1 ‐ 0.5 Volts @ full stroke Selected Selected Riser (A3) Controller Riser Up 04 RED/YEL POWER...

  • Page 212: Load Sensing System - Ce & As

    5.3-1 Load Sensing System Overload Status The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The deck steel structure is isolated from the MEWP . The load cell is permanently bolted between the deck and the rotary actuator mount.

  • Page 213: Verify Proper Operation Of The Load Sensing System

    Section 5 – Procedures Load Sensing System - CE & AS 5.3-2 Verify Proper Operation of the Load Sensing System Overload Status Chart Indicator Load Cell Audible MEWP Weight Light LED Display Alarm Functions Error - OFF Alarm - OFF Zero/Tare - ON (orange) Power - FLASHING (green) (Zero)

  • Page 214: Calibration Of Load Sensing System (With "Teach In" Handset)

    Load Sensing System - CE & AS Section 5 – Procedures 5.3-3 Calibration of Load Sensing System (with “Teach In” Handset) WARNING Do not interrupt system power during this procedure. Do not rest your hand or foot on the platform during this procedure. 1.

  • Page 215: Boom

    Section 5 – Procedures Boom 5.4 Boom 5.4-3 Cable Carrier Repair To repair the cable carrier, simply use a screwdriver. 5.4-1 Check Wear Pads Snap each crossbar off from either side of the chain, either by hand or by using the screwdriver as a lever. Install new crossbars by snapping the links together.

  • Page 216: Boom Section Wear Pad Replacement

    Boom Section 5 – Procedures 5.4-5 Boom Section Wear Pad CAUTION Replacement There is a risk of personal injury or equipment damage if repositioning the boom during this If wear pads inside the boom sections are worn and procedure. Use the base controls with auxiliary cannot be shimmed to meet the specification, they power (engine off) to reposition safely.

  • Page 217: Platform And Jib Boom Removal

    Section 5 – Procedures Boom 5.4-6 Platform and Jib Boom Removal 5. Mark and disconnect the jib cylinder hoses from the jib/platform rotate manifold. Cap hoses and fittings to prevent contamination 6. Connect lifting slings to the jib boom and NOTE platform.

  • Page 218: Operating Machine Functions From The Base Controls

    Boom Section 5 – Procedures 5.4-7 Operating Machine Functions from 5.4-8 Fly Boom Removal the Base Controls CAUTION There is a risk of personal injury or equipment CAUTION damage if repositioning boom with the platform removed. Use the base controls. There is a risk of personal injury or equipment damage if repositioning boom with platform removed.
  • Page 219 Section 5 – Procedures Boom 4. Locate the limit switch on the side of the main 6. Remove the cover plate on the counterweight boom at the platform end of the lower e-chain end of the upper pivot. tube. Pull in the limit switch arm and place a 7.

  • Page 220: Change Wear Pads On Extension Cylinder Support

    Boom Section 5 – Procedures 9. Place a 5 cm (2 in) wooden block under the 5.4-9 Change Wear Pads on Extension base end of the cylinder to support it. Cylinder Support 10. Place a suitable stand ahead of the machine that can bear the weight of the fly boom.

  • Page 221: 10 Fly Boom Installation

    Section 5 – Procedures Boom 5.4-10 Fly Boom Installation 5. Install top and side wear pads in the main boom. Apply Loctite 242 or 243 to the wear pad fasteners on assembly. 1. Put the end of the fly boom / extension cylinder assembly into the platform end of the main boom.

  • Page 222: 11 Platform/Jib Installation

    Boom Section 5 – Procedures 5.4-11 Platform/Jib Installation 5.4-12 Platform Control Console Connection Procedure: 1. Lift the platform/jib assembly and slide it into CAUTION place so the fly boom nose and slave cylinder There is a risk of personal injury or equipment holes line up.

  • Page 223: 13 Extension Cylinder Removal

    Section 5 – Procedures Boom 5.4-13 Extension Cylinder Removal Procedure: 1. Extend the fly boom outward to access the rod end pin on the extension cylinder. NOTE If removing the cylinder to service it or change the wear pads, follow this procedure rather than removing the fly boom section.
  • Page 224 Boom Section 5 – Procedures 7. Remove the master cylinder rod end pin. Lay 10. Remove the extension cylinder base-end pin the end of the cylinder down to rest on the cross and spacers. tube. Retract the cylinder rod so it is out of the way.
  • Page 225 Section 5 – Procedures Boom 13. Pull the cylinder out until the mounting bolts 15. Once the cylinder support is removed, the wear for the cylinder support on the rod end are pads can be replaced. Apply Loctite 242 or 243 accessible inside the main boom support to the wear pad fasteners on assembly.

  • Page 226: 14 Extension Cylinder Installation

    Boom Section 5 – Procedures 5.4-14 Extension Cylinder Installation 6. Continue sliding the cylinder inwards until the pin for the base end can be installed. 7. Use a pry bar to lift the end of the cylinder up to 1. Begin sliding the extension cylinder into the align the hole.

  • Page 227: 15 Main Boom Lift Cylinder Removal

    Section 5 – Procedures Boom 9. Reconnect the master cylinder hydraulic hoses. 5.4-15 Main Boom Lift Cylinder Removal CAUTION There is a risk of personal injury or equipment damage. Always use suitable lifting equipment and safe rigging practices when performing the following procedure.

  • Page 228: 16 Lift Cylinder Installation

    Boom Section 5 – Procedures 8. Place a lifting strap that straddles the boom 5.4-16 Lift Cylinder Installation under the rod end of the cylinder. Lift it lightly to tighten the strap. 1. Attach the lifting sling to the cylinder. Lift and guide it into the riser assembly from the platform end of the machine.

  • Page 229: 17 Riser Cylinder Removal

    Section 5 – Procedures Boom 5.4-17 Riser Cylinder Removal 5.4-18 Riser Cylinder Installation CAUTION 1. Lift the cylinder into the riser assembly. Line There is a risk of personal injury or equipment up and insert the base-end pin. Install the pin damage.

  • Page 230: 19 Replace Limit Switch - Main Boom

    Boom Section 5 – Procedures 5.4-19 Replace Limit Switch - Main Boom 9. Install the new main boom limit switch and retaining hardware. The main boom limit switch is located at the base of NOTE the main boom where the main boom connects to Ensure proper contact is made between the the upper pivot assembly.

  • Page 231: 20 Test Main Boom Limit Switch

    Section 5 – Procedures Boom 5.4-20 Test Main Boom Limit Switch 5.4-21 Replace Limit Switch - Riser Boom 1. In the engine compartment, turn the main power The riser boom limit switch is located on the inside disconnect switch to the on position . face of the lower pivot weldment where the third 2.

  • Page 232: 22 Test Riser Boom Limit Switch

    Boom Section 5 – Procedures 5.4-22 Test Riser Boom Limit Switch 5.4-23 Replace Limit Switch - Fly Boom The fly boom limit switch is located on the outside 1. Turn the main power disconnect switch to the on face of the main boom weldment and is mounted in position between the cable track assembly and the main boom 2.

  • Page 233: 24 Test Fly Boom Limit Switch

    Section 5 – Procedures Boom 9. Install the new fly boom limit switch and 5.4-24 Test Fly Boom Limit Switch retaining hardware. 1. In the engine compartment, turn the main power disconnect switch to the on position . NOTE 2. On the base control console, turn the base/off/ Ensure proper contact is made between the steel platform key switch to the platform position roller lever and the cam surface of the fly boom.

  • Page 234: Turret

    Turret Section 5 – Procedures 5.5 Turret 5.5-2 Adjust the Turret Rotation Gear Backlash Adjusting the backlash clearance will allow proper mating between the turret rotation gear and the swing 5.5-1 Check and Replace the High drive motor gear. Pressure Filter WARNING 1.

  • Page 235: Swing Drive Motor Removal

    Section 5 – Procedures Turret 4. Support the boom with an overhead crane or other suitably rated supporting device. Do not lift the boom. 5. Turn the main power disconnect switch to the off position 6. Loosen the mounting fastener on the swing drive motor.

  • Page 236: Check The Swing Drive Oil

    Turret Section 5 – Procedures 5.5-4 Check the Swing Drive Oil 5.5-5 Change the Swing Drive Oil 1. Remove the plug from the fill port on the NOTE back of the swing drive. The oil change must be performed on a flat, level 2.

  • Page 237: Check Rotation Bearing For Axial Wear

    Section 5 – Procedures Turret 5.5-6 Check Rotation Bearing for Axial 5.5-7 Turret Rotation Gear Bolt Torque Wear Sequence WARNING 1. Position the boom so that it is centered over the front drive and steer axle and is horizontal to the Maintaining proper torque is essential to safe ground.

  • Page 238: Electronic Tilt Switch Setup Procedure

    Turret Section 5 – Procedures 5.5-8 Electronic Tilt Switch Setup 8. Verify the switch is powered (the red or green LED will be continually blinking). Procedure Tilt Switch Replacement Red LED Red LED Y AXIS Green LED Green LED X AXIS 9.
  • Page 239 Section 5 – Procedures Turret Reprogramming the Existing Tilt Switch IMPORTANT Step “c” must be completed within a 5 second The set up button is located on period, or the switch will automatically exit Indicators Lights this face next to the harness program mode and return to normal operation using the previously stored data.

  • Page 240: Battery Replacement

    Turret Section 5 – Procedures Verify Tilt Circuit 5.5-9 Battery Replacement Indicator Lights 1. Turn the main power disconnect switch to the off position Operations of the Tilt Switch The following describes the LED’s and what they indicate. Illuminated whenever both tilt axes are within the specified degrees of the zero/ home learned position.

  • Page 241: Deutz Diesel Engine

    Section 5 – Procedures Deutz Diesel Engine 5.6 Deutz Diesel Engine 5. Remove the oil drain plug and allow all engine oil to drain into the container. WARNING Maintaining the engine components is essential to the good performance and service life of the MEWP . Dispose of oil in accordance with local and federal regulations.

  • Page 242: Replace The Fuel Filter

    Deutz Diesel Engine Section 5 – Procedures 5.6-2 Replace the Fuel Filter 5.6-4 Check the Engine Belt 1. Remove the bolt securing the engine tray to the The MEWP will not operate properly with a loose turret. or defective belt. Continuous usage may cause component damage.

  • Page 243: Deutz Td2.9L Fault Codes

    Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification The air mass flow AFS_dm is greater than or equal to AFS_PhysRng.Min_C. 2-2-6 Physical range check is low for air mass flow sensor. 2-2-6 Air inlet filter temperature, plausibility error.
  • Page 244 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification Physical range check low for burner dosing valve (DV2) downstream pressure; Shut off regeneration. 523912 7-2-2 When burner injector is actuated, the measured pressure does not rise above 1250mbar abs (expected: about 2400mbar).
  • Page 245 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 523698 5-9-1 Shut off request from supervisory monitoring function. 523969 7-7-4 Fault entry for override control mode. 523717 5-9-5 Timeout error of CAN-transmit-frame AmbCon; Weather environments. 523603 3-3-8 Timeout Error of CAN-receive-frame AMB;...
  • Page 246 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 3219 6-4-9 DFC SAE J1939 error. 523766 1-1-8 Timeout error of CAN-Receive-Frame Active TSC1AE. 523767 1-1-8 Timeout error of CAN-Receive-Frame Passive TSC1AE. 523768 1-1-9 Timeout error of CAN-Receive-Frame Active TSC1AR.
  • Page 247 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification Sensor error SCR-System environment temperature. 3-1-2 DPF-System air inlet temperature, signal range check high. Sensor error SCR-System environment temperature. 3-1-2 DPF-System air inlet temperature, signal range check low. 2-1-2 Sensor camshaft speed, disturbed signal.
  • Page 248 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 523916 7-1-9 Sensor HCI dosing valve (DV1) downstream pressure: Plausibility error. HCI dosing valve (DV1) downstream pressure: Physical range check high. 523916 7-1-9 Shut off regeneration.
  • Page 249 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 523759 1-6-2 Special pattern for special cases No detailed information! 523760 1-6-3 Special pattern for special cases No detailed information! Injector 1 (in firing order): Short circuit. Injector 2 (in firing order): Short circuit.
  • Page 250 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 523612 ECU reported internal software error. 523612 ECU reported internal software error. 523612 ECU reported internal software error. 523612 ECU reported internal software error. 523612 Diagnostic fault check to report the accelerator pedal position error.
  • Page 251 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification Plausibility Check. 2-1-1 No detailed information! 2-2-4 Sensor error oil pressure; signal range check high. 2-2-4 Sensor error oil pressure sensor; signal range check low. 2-3-1 High oil pressure;...
  • Page 252 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 6-9-3 Delta pressure across venturi in EGR line above physical high limit. Plausibility Check fault for deviation of desired and actual EGR-mass flow, 6-9-3 where the latter is calculated out of EGR Delta Pressure Sensor.
  • Page 253 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification Rail pressure metering unit, Rail pressure disrupted. Maximum positive 523613 1-3-4 deviation of rail pressure exceeded. Rail pressure metering unit, Rail pressure disrupted. Maximum positive 523613 1-3-4 deviation of rail pressure in metering unit exceeded (RailMeUn1).
  • Page 254 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 523721 6-8-9 Sensor DEF supply module temperature; plausibility error (normal condition). Sensor DEF supply module temperature; plausibility error (cold start 523721 6-8-9 condition).
  • Page 255 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 5-1-3 SVS lamp: powerstage over temperature 5-1-3 SVS lamp; short circuit to battery 5-1-3 SVS lamp; short circuit to ground 523612 5-5-5 Softwarereset CPU SWReset_0 523612...
  • Page 256 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range 1023 5-9-4 check low. Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve 1024 5-9-4 (4.1;6.1;7.8).
  • Page 257 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification HMI engine derate service state. 1219 524018 7-8-6 DPF wasn’t regenerated, power reduction phase 1 (manuell regeneration request). HMI engine derate stop state. 1220 524022 7-8-6...
  • Page 258 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 1264 523922 8-5-5 Burner Shut Off Valve; blocked open. Timeout error of CAN-Receive-Frame ComMS_Sys1TO (error memory Slave); 1285 524038 8-2-4 Master-Slave internal CAN message. Timeout error of CAN-Receive-Frame ComMS_Sys2TO (error memory Slave);...
  • Page 259 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 1341 524035 5-5-5 Injector diagnostics; time out error in the SPI communication. 1342 524036 5-5-5 Injector diagnostics Slave; time out error in the SPI communication. Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO;...
  • Page 260 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 1439 524034 8-1-6 Disc separator; short circuit to ground. 1440 524030 8-1-5 EGR actuator; internal error. 1441 524031 8-1-5 EGR actuator, calibration error. 1442 524032 8-1-5...
  • Page 261 Section 5 – Procedures Deutz Diesel Engine 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 1677 524106 1-9-5 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1 (EGR actuator) 1678 524107 9-3-1 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2 (EGR actuator). 1679 524109 9-3-3 Timeout error of CAN-Receive-Frame ComRxEGRTVActr (EGR actuator).
  • Page 262 Deutz Diesel Engine Section 5 – Procedures 5.6-6 Deutz TD2.9L Fault Codes Code SPN FMI Blink Code Error Identification 1759 2791 4-1-5 EGR actuator supply voltage is below minimum threshold. 1760 2791 4-1-5 EGR actuator, learning process out of range. 1761 2791 4-1-5...

  • Page 263: Kubota Wg2503 Dual Fuel Engine

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.7 Kubota WG2503 Dual Fuel the units and a bar graph. 2. Dual Screen. This mode is used to monitor two Engine parameters at a time. The screen also displays the associated parameter icon and units. Maintaining the engine components is essential to good performance and service life of the MEWP .

  • Page 264: Diagnostic Trouble Codes

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.7-2 Diagnostic Trouble Codes (J1939) (J1939) Detected Item/Hardware ‐Mechanical Misalignment between cam and crank ‐Fuel Pressure Abormality (Low Side) ‐Fuel Pressure Abormality (High Side) ‐Sensor/Wiring Harness Open/Short To Ground ‐Sensor Malfunction ‐Sensor/Wiring Harness Short To Power ‐Sensor Malfunction ‐Sensor/Wiring Harness Open/Short To Ground ‐Sensor Malfunction ‐Sensor/Wiring Harness Short To Power ‐Sensor Malfunction ‐Intake air temperature abnormality (High Side Stage 1) ‐Sensor/Wiring Harness Open/Short To Ground ‐Sensor Malfunction ‐Sensor/Wiring Harness Short To Power ‐Sensor Malfunction ‐Engine Coolant Temperature Abnormality (High Side Stage 1) ‐Sensor/Wiring Harness Short To Ground ‐Sensor Malfunction ‐Sensor/Wiring Harness Short To Power ‐Sensor Malfunction ‐Throttle Position Sensor Malfunction ‐Throttle Position Sensor 1 Signal Voltage Low ‐Throttle Position Sensor 1 Signal Voltage High ‐Intake Air Temperature Higher Than Expected Stage 2 ‐Open feed circuit to O2 heater ‐Open heater ground circuit...
  • Page 265 Section 5 – Procedures Kubota WG2503 Dual Fuel Engine (J1939) (J1939) Detected Item/Hardware ‐Operating in a hot environment ‐Sensor out of calibration ‐Engine Coolant Temperature Exceeds Stage 2 ‐Engine over speed condition, stuck throttle, large vacuum leak into intake manifold  after throttle blade ‐Throttle Position Sensor Malfunction ‐Throttle position sensor circuit in the harness short to ground 3673 ‐Throttle position sensor malfunction ‐Throttle position sensor circuit in the harness short to power 3673 ‐Throttle position sensor malfunction ‐Loss of 12.0 V feed to injector  ‐Open injector coil ‐Open or shorted to ground injector driver circuit in engine harness ‐Injector coil shorted internally ‐Injector driver circuit shorted to voltage between injector and ECM ‐Loss of 12.0 V feed to injector  ‐Open injector coil ‐Open or shorted to ground injector driver circuit in engine harness ‐Injector coil shorted internally ‐Injector driver circuit shorted to voltage between injector and ECM ‐Loss of 12.0 V feed to injector  ‐Open injector coil ‐Open or shorted to ground injector driver circuit in engine harness ‐Injector coil shorted internally ‐Injector driver circuit shorted to voltage between injector and ECM ‐Loss of 12.0 V feed to injector  ‐Open injector coil ‐Open or shorted to ground injector driver circuit in engine harness ‐Injector coil shorted internally...
  • Page 266 Kubota WG2503 Dual Fuel Engine Section 5 – Procedures (J1939) (J1939) Detected Item/Hardware ‐Cam+ or Cam‐ circuits in wrong connector terminal slot ‐Loss of feed voltage to Cam sensor ‐Loss of sensor feed ‐Open sensor ground ‐Open or shorted to ground signal wire ‐Sensor malfunctioning ‐Loss of feed voltage to Cam sensor ‐Loss of signal or ground circuits ‐Faulty sensor 3050 ‐Low Oil Pressure ‐Wiring harness open/short/damage ‐Battery abnormality ‐System voltage abnormality (High Side) ‐Faulty ECU ‐ROM Malfunction ‐ Faulty ECU ‐Faulty ECU ‐Open coil in relay 1348 ‐Open in relay driver circuit in engine harness ‐Relay pull in coil shorted internally 1347 ‐Relay driver circuit shorted to ground in wire harness ‐Shorted relay pull in coil 1347 ‐Relay driver circuit shorted to voltage in wire harness ‐Wiring harness short to ground 1079 ‐ECM malfunction ‐Wiring harness short to 12.0 V power...
  • Page 267 Section 5 – Procedures Kubota WG2503 Dual Fuel Engine (J1939) (J1939) Detected Item/Hardware • high fuel supply pressure to the gaseous fuel control or faulty pressure regulator 1152 4236 • a non‐responsive HEGO sensor • exhaust leaks upstream or near the HEGO sensor • reduced fuel supply pressure to the gaseous fuel control system 1153 4236 • a fuel supply or manifold leak • a non‐responsive HEGO sensor • high fuel supply pressure to the gaseous fuel control or faulty pressure regulator 1154 4236 • a non‐responsive HEGO sensor • exhaust leaks upstream or near the HEGO sensor 1155 4236 • reduced fuel supply pressure • an injector that is stuck closed • high fuel supply pressure to the fuel injection system 1156 4236 • a non‐responsive HEGO sensor • an injector that is stuck open • exhaust leaks upstream or near the HEGO sensor • reduced fuel supply pressure to the gaseous fuel control system 1161 4237 • a fuel supply or manifold leak • a non‐responsive HEGO sensor • high fuel supply pressure to the gaseous fuel control or faulty pressure regulator...
  • Page 268 Kubota WG2503 Dual Fuel Engine Section 5 – Procedures (J1939) (J1939) Detected Item/Hardware • Wiring harness open/short/damage 2116 • FPP malfunction • IVS malfunction • Wiring harness open/short/damage 2122 • FPP malfunction • Wiring harness open/short/damage 2123 • FPP malfunction • Wiring harness open/short/damage 2127 • FPP malfunction • Wiring harness open/short/damage 2128 • FPP malfunction 2135 • TPS malfunction • Wiring harness open/short/damage 2139 • FPP malfunction • IVS malfunction • Wiring harness open/short/damage 2140 • FPP malfunction • IVS malfunction • a short to ground or open circuit in the harness 2300 1268 • an open internal to the primary coil • a short to power in the harness...

  • Page 269: Ecu Pin Reference Chart (Kubota Wg2503)

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.7-3 ECU Pin Reference Chart (Kubota WG2503) Wire Colour Description Wire Colour Description YELLOW 18 SPK_COIL 1A BLANK AUX ANA PUD 1 YELLOW/BLACK 18 SPK_COIL 1B PURPLE/LT_BLUE 18 TPS 1 YELLOW/RED 18 SPK_COIL 2A LT_BLUE/DK_BLUE 18 TPS 2 BLACK 16 SPK_GRND DK_GREEN/PURPLE 18 AUX DIG 1 YELLOW/WHITE 18 SPK_COIL 2B TAN/RED 18 AUX DIG 2 BLANK SPK_COIL 3A BLACK/YELLOW 18...

  • Page 270: Fuse Box (Kubota Wg2503)

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.7-4 Fuse Box (Kubota WG2503) Starter Relay Fuel Pump Power Relay Relay 15 A Fuse 15 A Fuse 15 A Fuse 5 A Fuse 10 A Fuse 5 A Fuse RED 8 ALTERNATOR 60A RED 8 PINK/TAN 18...

  • Page 271: Map Sensor (Kubota Wg2503)

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.7-5 MAP Sensor (Kubota WG2503) TAMP Sensor 5V ext 1 MAP Signal 5V rtn 1 5.7-6 IAT Sensor (Kubota WG2503) TAMP Sensor 5V rtn 1 Thermistor 229043AAA SJ63 AJ+, SJ63 AJ...

  • Page 272: Ect (Kubota Wg2503)

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.7-7 ECT (Kubota WG2503) ECT Sensor 5V rtn 1 Thermistor 5.7-8 TPS & Engine Speed (Kubota WG2503) Electronic Throttle Body DBW+ H-Bridge Motor DBW- TPS1 5V ext 1 TPS1 5V rtn 1 TPS2 TPS2 5V ext 1...

  • Page 273: Fuel Temperature Sensor (Kubota Wg2503)

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.7-9 Fuel Temperature Sensor (Kubota WG2503) FP/FT Sensor 5V ext 1 FRP Signal 5V rtn 1 FRP Signal 5.7-10 Oil Pressure Sensor (Kubota WG2503) Oil Pressure Switch + 5 V Pressure Voltage 229043AAA SJ63 AJ+, SJ63 AJ...

  • Page 274: Hydraulic Tank

    Hydraulic Tank Section 5 – Procedures 5.8 Hydraulic Tank 5.8-2 Change the Hydraulic Oil 1. Turn the engine on and allow the hydraulic oil to Maintaining the hydraulic components and warm up. hydraulic oil at the proper level are essential to good 2.

  • Page 275: Manifold And Hydraulic Pumps

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9 Manifold and Hydraulic 3. Drive the MEWP forward or reverse. The pressure gauge reading should be 38 bar (550 Pumps psi). Stop the MEWP . Follow the next steps for adjusting the relief valve pressure if needed. If no adjustment is required continue to step 8.

  • Page 276: Hydraulic System Relief Valve Adjustment (Rv1)

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.9-2 Hydraulic System Relief Valve 5.9-3 Turret Rotate Relief Valve Adjustment (RV1) Adjustment (RV2) 1. Adjust the pressure compensator valve on the 1. Locate the GP port on the main manifold and System pump to 220 bar (3200 psi).

  • Page 277: Platform Level Relief Valve Adjustment (Rv3)

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9-4 Platform Level Relief Valve 5.9-5 Riser Boom Down Relief Valve Adjustment (RV3) Adjustment (RV4) 1. Locate the GP port on the main manifold, 1. Locate the GP Port on the main manifold, and remove the cap.

  • Page 278: Main Boom Down Relief Valve Adjustment (Rv5)

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.9-6 Main Boom Down Relief Valve 5.9-7 Fly Boom Relief Valve Adjustment Adjustment (RV5) (RV6) 1. Locate the GP Port on the main manifold, 1. Locate the GP Port on the main manifold, and remove the cap.

  • Page 279: Test Charge Pump Pressure On Drive Pump (Rv10)

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9-8 Test Charge Pump Pressure on 5.9-9 Test Forward Drive Pressure on Drive Pump (RV10) Drive Pump NOTE 1. Locate test port TP3 on the drive pump. Make sure charge pump pressure test is 2.

  • Page 280: 10 Test Reverse Drive Pressure On Drive Pump

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.9-10 Test Reverse Drive Pressure on 5.9-11 Hydraulic Standby Pressure Drive Pump Adjustment NOTE 1. Locate the GP port on the main manifold. Make sure the charge pump pressure test is completed first. 1.

  • Page 281: 12 Hydraulic High Pressure Adjustment

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9-12 Hydraulic High Pressure 5. Adjust the system pump pressure by turning the Adjustment adjusting stem either clockwise to increase the pressure, or counterclockwise to decrease the pressure. 1. Locate the GP Port on the main manifold.

  • Page 282: Axles

    Axles Section 5 – Procedures 5.10 Axles 5.10-2 Check the Oil Level in the Torque Hubs 5.10-1 Change the Oil in the Axles 1. Drive the MEWP to rotate the hub until the plug is in the 3 or 9 o’clock position. Shut off the 1.

  • Page 283: Check The Oil Level In The Axle Gearbox

    Section 5 – Procedures Axles 5.10-4 Check the Oil Level in the Axle 5.10-5 Change the Oil in the Axle Gearbox Gearbox 1. Place a suitable container under the gearbox. 1. Remove the fill plug from the gear box. 2. Remove the fill plug. 2.

  • Page 284: Oscillating Cylinder Bolt Replacement

    Axles Section 5 – Procedures 5.10-6 Oscillating Cylinder Bolt 5.10-7 Oscillating Cylinder Replacement Replacement CAUTION The oscillating axle cylinder weighs approximately If upon inspection it is determined that the oscillating 19.5 kg (43 lb), so a second person to assist with cylinder bolts have missing or damaged torque seal, the removal and replacement would be helpful.
  • Page 285 Section 5 – Procedures Axles 4. Remove and set aside the cylinder fittings, 7. Adjust the oscillating cylinder position until ensuring they stay clean. there is continuous contact between the cylinder mounting surface and the mounting plate, and between the mounting plate and the cylinder shoulder, with no gaps.

  • Page 286: Bleed The Oscillating Axle Cylinders

    Axles Section 5 – Procedures 10. Remove the plugs and reconnect the hoses to 5.10-9 Pin Brake Adjustments the cylinder fittings, torquing the larger hose end to 28 Nm (21 ft-lb) and the smaller hose end to 1. To manually release the brake give a light blow 16 Nm (12 ft-lb).
  • Page 287 Section 5 – Procedures Axles 4. Tighten the jam nut. Repeat this procedure on 7. Release the pressure from the cylinder and the other side. check that the rod returns and stops in a position where it projects out from the cylinder head by 5 mm (3/16").

  • Page 288: 10 Brake Inspection

    Axles Section 5 – Procedures 5.10-10 Brake Inspection 1. Remove the oil level plug from one of the braking axle arms, as shown below. 2. Insert a 4.5 mm feeler gauge into the drain port. 3. Use the gauge to check the gap between the disks (A).

  • Page 289: Grease Points

    Section 5 – Procedures Grease Points 5.11 Grease Points Maintaining proper lubrication is essential for the good performance and service life of the MEWP . If the bearing and gear of the MEWP are improperly greased, it could result in component damage. 5.11-1 Grease the Turret Ring Gear 1.

  • Page 290: Grease The Axles

    Grease Points Section 5 – Procedures 5.11-3 Grease the Axles 1. Open the axle cover plates and locate the grease fittings. 2. Pump grease into the grease fittings. 5.11-4 Grease the Drive Shaft 1. Locate the grease fittings on the drive shaft u-joints, and pump grease into the fittings. SJ63 AJ+, SJ63 AJ 229043AAA...

  • Page 291: Options

    Section 5 – Procedures Options 5.12 Options 5.12-1 Generator Troubleshooting Problem Cause Remedy Generator not rotating - Motor not turning - Check for proper hydraulic flow - Directional valve not working - Check voltage to coil - Bad coil or valve - Broken drive key - Check and replace Frequency falls under load...

  • Page 292: Generator Frequency/Voltage Check & Adjustment

    Options Section 5 – Procedures 5.12-2 Generator Frequency/Voltage Check & Adjustment Check the Frequency and Voltage 1. On the base control box, turn the base/off/platform key switch to the platform position. 2. On the platform control box, ensure the generator switch is in the off position 3.
  • Page 293 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.

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