Skyjack SJ46 AJ+ Service Manual
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Skyjack SJ46 AJ+ Service Manual

Skyjack SJ46 AJ+ Service Manual

Articulating booms
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SERVICE
MANUAL
SJ46 AJ+, SJ46 AJ, SJ51 AJ
ARTICULATING BOOMS
229042ABA
August 2020
ANSI/CSA, CE, AS

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Summary of Contents for Skyjack SJ46 AJ+

  • Page 1 SERVICE MANUAL SJ46 AJ+, SJ46 AJ, SJ51 AJ ARTICULATING BOOMS 229042ABA August 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: SJ46 AJ+: A301 000 001 - A301 999 999 SJ46 AJ: B301 000 001 - B301 999 999 SJ51 AJ: B301 000 001 - B301 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 ......... . 13 Read and Heed .
  • Page 6 Torque Specifications for Fasteners (Metric) ..........36 Torque Specifications for Hydraulic Couplings &...
  • Page 7 3.26 Limit Switch Connections - CE & AS ..........86 3.27 Load Sensing Cable Connections - CE &...
  • Page 8 4.2-9 No Boom Up from the Platform Console ......... . . 122 4.2-10 No Boom Down from the Base or Platform Consoles .
  • Page 9 4.2-52 No Forward Drive ............. 133 4.2-53 No Reverse Drive .
  • Page 10 4.5-6 No Riser Boom Down ............182 4.5-7 Riser Boom Down Jerky .
  • Page 11 5.2-12 SCM Calibration Flowchart - ANSI/CSA ..........210 5.2-13 Fly Boom Switch Voltage References .
  • Page 12 5.8-7 ECT (Kubota WG2503) ............260 5.8-8 TPS &...

  • Page 13: 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 14: Maintenance And Service

    MEWP . Before attempting any repair work, disconnect the main power conenctors. Consult Skyjack’s Service Department for optional tires specifications and installation. Keep personnel clear of components, systems or unsupported loads that may move unexpectedly WARNING during maintenance procedures.

  • Page 15: 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 16: Railing Maintenance And Repair

    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 17: Scheduled Maintenance

    Scheduled Maintenance Section 1 – Scheduled Maintenance 1.3 Scheduled Maintenance 1.3-3 Maintenance Instructions This manual consists of four schedules to be done This section contains the maintenance and inspection for maintaining on a MEWP . Inspection schedule schedule that is to be performed. frequency is shown below: References are made to the procedures in Section 5 that outline detailed step-by-step instructions for...

  • Page 18: Owner's Annual Inspection Record

    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 19: 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 20: Scheduled Maintenance Inspections

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-2 Hydraulic 1.6 Scheduled Maintenance 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 21: Engine Compartment

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-5 Engine Compartment B - Frequent Inspection 1. Do an inspection of the battery case for damage. Do the inspection that follows: Clean the battery terminals and cable ends ▪ Make sure all compartment latches are latched tightly thoroughly with a terminal cleaning tool or wire and in good condition.
  • Page 22 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 23 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 24: Control Compartment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-6 Control Compartment C - Annual Inspection For the hydraulic oil replacement procedure, ▪ Do the inspection that follows: refer to 5.7-1 Hydraulic Oil Replacement. Make sure all compartment latches are latched tightly Hydraulic Return Filter (B,C) and in good condition.
  • Page 25 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 26: Base

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-7 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 27 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 28: Platform

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-8 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 29: Boom Assembly

    Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance 1.6-9 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 30: 10 Optional Equipment

    Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections 1.6-10 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 31: 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 step-by-step instructions to test all MEWP functions. IMPORTANT Never use a malfunctioning MEWP . If malfunctions are discovered, the MEWP must be tagged and placed out of service.

  • Page 32: 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 33 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 34: 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 35: 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 36: 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 37: Mewp Torque Specifications

    Section 2 – Maintenance Tables and Diagrams MEWP Torque Specifications Table 2.5 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 38: Axle Torque Specifications

    Axle Torque Specifications Section 2 – Maintenance Tables and Diagrams Table 2.6 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 39: Axle Maintenance Intervals

    Section 2 – Maintenance Tables and Diagrams Axle Maintenance Intervals Table 2.7 Axle 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 40: 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 the proper functioning of each axle differential, all four wheels must have same tire size installed at all times.

  • Page 41: Floor Loading Pressure

    Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure Table 2.10 Floor Loading Pressure Total MEWP Load Gross MEWP Weight Wheel Model SJ46 AJ+ ANSI 6000 13,200 3000 6,600 1090 SJ46 AJ CE & AS 7180 15,830 3527 7,775 10.9 SJ51 AJ CE &...

  • Page 42: Hydraulic Specifications

    Hydraulic Specifications Section 2 – Maintenance Tables and Diagrams Table 2.11 Hydraulic Specifications Description Metric Pumps Displacement - 2000 rpm 46 CC 2.8 CIR 24.3 gpm @ 2000 rpm Drive Pump Pressure 345 bar 5000 psi Drive Pump Charge Pump Displacement 13.9 CC 0.85 CIR Charge Pump Pressure...

  • Page 43: Hydraulic & Gear Oils

    Section 2 – Maintenance Tables and Diagrams Hydraulic & Gear Oils Table 2.12 Hydraulic & Gear Oils SJ46 AJ+ SJ46 AJ & SJ51 AJ Description Temperature Range ANSI/CSA CE & AS Hydraulic Oil Cooler Option 38°C to 45°C (100°F to 115°F) Oil cooler option recommended Shell Tellus T46, Standard Hydraulic Oil...

  • Page 44: Specifications & Features - Dimensions & Speeds

    Specifications & Features - Dimensions & Speeds Section 2 – Maintenance Tables and Diagrams Table 2.13 Specifications & Features - Dimensions & Speeds SJ46 AJ+ ANSI/CSA SJ46 AJ CE & AS SJ51 AJ CE & AS Height & Reach Working Height 15.93 m 52' 3-1/4"...
  • Page 45 Section 2 – Maintenance Tables and Diagrams Specifications & Features - Dimensions & Speeds Table 2.13 Specifications & Features - Dimensions & Speeds SJ46AJ ANSI/CSA SJ46AJ CE & AS SJ51AJ CE & AS Performance & Speeds Gradeability - Maximum 7.7 km/h (Deutz D2011) 7.7 km/h (Deutz D2011) Drive Speed - Stowed/Low Torque 7.7 km/h 4.8 mph...

  • Page 46: Engine Specifications

    Engine Specifications Section 2 – Maintenance Tables and Diagrams Table 2.14 Engine Specifications SJ46 AJ+, SJ46 AJ & SJ51 AJ RPM Settings 900 Low / 1600 / 2600 High Horsepower @ 2600 rpm (intermittent) 55.4 kW / 75 hp Fuel Type Diesel Fuel Tank Capacity 47 gal (170.3 L)

  • Page 47: Reach & Dimension Diagrams - Sj46 Aj+ Ansi/Csa

    Section 2 – Maintenance Tables and Diagrams Reach & Dimension Diagrams - SJ46 AJ+ ANSI/CSA Table 2.15 Reach & Dimension Diagrams - SJ46 AJ+ ANSI/CSA METERS (FEET) 16.76 (55) 15.24 (50) 13.72 (45) 12.19 (40) 10.67 (35) 9.14 (30) 7.62 (25) 6.10 (20)

  • Page 48: Reach & Dimension Diagrams - Sj46 Aj Ce & As

    Reach & Dimension Diagrams - SJ46 AJ CE & AS Section 2 – Maintenance Tables and Diagrams Diagram 2.16 Reach & Dimension Diagrams - SJ46 AJ CE & AS Feet (Meters) (16.76) (15.24) (13.72) (12.19) (10.67) (9.14) (7.62) (6.10) (4.57) (3.05) (1.52) (-1.52)

  • Page 49: Reach & Dimension Diagrams - Sj51 Aj Ce & As

    Section 2 – Maintenance Tables and Diagrams Reach & Dimension Diagrams - SJ51 AJ CE & AS Diagram 2.17 Reach & Dimension Diagrams - SJ51 AJ CE & AS Feet (Meters) (18.28) (16.76) (15.24) (13.72) (12.19) (10.67) (9.14) (7.62) (6.10) (4.57) (3.05) (1.52)

  • Page 50: Axle Oscillation Diagram

    Axle Oscillation Diagram Section 2 – Maintenance Tables and Diagrams Table 2.18 Axle Oscillation Diagram WARNING Do not raise the platform in work mode if the MEWP it is not on a firm level surface. Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max. Axle oscillation free (travel mode) - drive speed 7.7 km/h (4.8 mph) max.

  • Page 51: Section 3 - System Component Identification And Schematics

    Section 3 – System Component Identification and Schematics SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 52: Electrical Symbol Chart

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

  • Page 53: Hydraulic Symbol Chart

    Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics Table 3.2 Hydraulic Symbol Chart THREE POSITION FIXED FOUR WAY LINE CROSSING SHUTTLE VALVE DISPLACEMENT CLOSED CENTER PUMP OPEN PORT VARIABLE CUSHION PRESSURE LINE JOINED DISPLACEMENT CYLINDER SWITCH PUMP DOUBLE ACTING MAIN LINES MOTION...

  • Page 54: 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 55: Hydraulic Parts List

    Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 2H-21A 166039 VALVE (Dump) 2H-42 231438 VALVE, Proportional 3H-21 195036 VALVE, Control (Load Circuit) 3H-26 159827 VALVE, Control (Brake Release)
  • Page 56 Section 3 – System Component Identification and Schematics Hydraulic Parts List 3.4 Hydraulic Parts List Index Skyjack Description Part No. 149488 VALVE, Counterbalance (Riser Down) 149488 VALVE, Counterbalance (Riser Down) 149228 VALVE, Counterbalance (Platform Level, Slave) 149228 VALVE, Counterbalance (Platform Level, Slave)
  • Page 57 Hydraulic Parts List Section 3 – System Component Identification and Schematics 3.4 Hydraulic Parts List Index Skyjack Description Part No. 160800 COOLER, Oil (Oil Cooler Option) 167353 ORIFICE, Main Control (Platform Rotate) 167352 ORIFICE, Main Control (Jib) 166056 ORIFICE, Main Control (Boom Extend)

  • Page 58: Electrical 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 Electrical Parts List Section 3 – System Component Identification and Schematics 3.5 Electrical Parts List Index Skyjack Description Part No. 4H-13 159819 COIL, 12 Volt (Boom down valve) 4H-14 159819 COIL, 12 Volt (Boom up valve) 4H-23A 159819 COIL, 12 Volt (Right steer valve)
  • Page 60 Section 3 – System Component Identification and Schematics Electrical Parts List 3.5 Electrical Parts List Index Skyjack Description Part No. 122420 QUICK DISCONNECT (CE & AS) 110999 RESISTOR, 5 ohm 25 W 151643 RESISTOR, 250 ohm 1 W 163021 RESISTOR, 120 ohm 1/2 W 164859 RESISTOR, 2.2k ohm 1/2 W...

  • Page 61: Brake Manifold Components And Ports

    Brake Manifold Components and Ports Section 3 – System Component Identification and Schematics 3.6 Brake Manifold Components and Ports 3H-65 Axle Lock Valve 3H-45 2 Speed Valve 3H-26 Brake Valve 3H-165 Differential Lock Valve To Rotary Manifold To Rotary Manifold To Rotary Manifold To Hydraulic...

  • Page 62: Rotary Manifold Ports

    Section 3 – System Component Identification and Schematics Rotary Manifold Ports 3.7 Rotary Manifold Ports Port 7 To Drive Pump Port 8 To Drive Pump Port 9 To Hydraulic Tank Port 1 To Main Manifold Port 5 To Main Manifold Port 3 To Axlelock Cylinder Port 2...

  • Page 63: Drive And System Pump Ports

    Drive and System Pump Ports Section 3 – System Component Identification and Schematics 3.8 Drive and System Pump Ports To Brake Manifold To Hydraulic Tank To Hydraulic Tank To Rotary Manifold To Rotary Manifold To Rotary Manifold To High Pressure Filter To Brake Manifold To Hydraulic Tank SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 64: Drive And System Pump Ports

    Section 3 – System Component Identification and Schematics Drive and System Pump Ports 3.9 Drive and System Pump Ports For machines with the Welder Option To Brake Manifold To Hydraulic Tank (Pump Case Drain) To Rotary Manifold To Hydraulic Tank (System Suction) To Rotary Manifold...

  • Page 65: Drive Motor Ports

    Drive Motor Ports Section 3 – System Component Identification and Schematics 3.10 Drive Motor Ports To Rotary Manifold To Rotary Manifold To Rotary Manifold To Rotary Manifold SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 66: Jib Valve Ports

    Section 3 – System Component Identification and Schematics Jib Valve Ports 3.11 Jib Valve Ports 4H-34 4H-37 Jib Down Valve Platform Right Rotate Valve 4H-35 4H-36 Jib Up Valve Platform Left Rotate Valve To Jib Cylinder To Bulkhead #2 To Jib Cylinder To Bulkhead #1 To Bulkhead #2 To Bulkhead #1...

  • Page 67: Pressure Reducing Valve Ports

    Pressure Reducing Valve Ports Section 3 – System Component Identification and Schematics 3.12 Pressure Reducing Valve Ports To Rotary Manifold Port 6 To Hydraulic Tank To Brake Manifold 2SPD Port SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 68: Main Manifold Ports

    3.13 Main Manifold Ports TEST 1 TEST 3 TEST 5 TEST 2 TEST 4 To Lift Cylinder To Jib Valve To Jib Valve To Boom Extension Cylinder To Hi Pressure Filter To Boom Extension Cylinder To Master Cylinder To Emergency Power Unit To Lift Cylinder To Master Cylinder To Brake Manifold...
  • Page 69 3.13 Main Manifold Electrical Components 4H-40 Platform Leveling Valve 3H-38 2H-34A Boom Retract Valve Jib Boom Valve 4H-41 Platform Leveling Valve 4H-32 3H-39 Turret Rotate Left Valve Boom Extend Valve 4H-30 Riser Down Valve 2H-36A 4H-33 Platform Rotate Valve Turret Rotate Right Valve 4H-31 Riser Up Valve 4H-24A...
  • Page 70 3.13 Main Manifold Hydraulic Components Check Valve DSV5 Differential Sensing Valve DSV4 Differential Sensing Valve Shuttle Valve Shuttle Valve Check Valve Relief Valve PFC1 Check Valve Priority Flow Check Valve Control Valve Relief Valve CV10 Check Valve CV11 Check Valve CV12 Check Valve Shuttle Valve...

  • Page 71: Generator Control Valve And Manifold

    3.14 Generator Control Valve and Manifold 3500W Generator 12kW Generator (Welder option) 2H-85 Generator Valve To High Pressure Filter To Hydraulic Tank To Oil Cooler MAIN 3H-85 To Main Manifold Generator Valve CV15 Check Valve 3H-85 Generator Valve To Shuttle Valve To Generator To Drive/System Pump RV11...

  • Page 72: Main Harness And Fuel Level Switch Harness

    3.15 Main Harness and Fuel Level Switch Harness PIN 24 THIS CORNER PIN 1 - 13 - ORANGE PIN 13 - 38 - ORANGE/RED PIN 2 - 14 - BLACK PIN 14 - 39 - BLACK/RED PIN 3 - 21A - WHITE/RED PIN 15 - 40 - BLUE/RED PIN 4 - 23A - BLACK/WHITE PIN 16 - 41 - BLUE/PURPLE...

  • Page 73: Interface Harness - Deutz D2.9L

    3.16 Interface Harness - Deutz D2.9L TO X22 T0 RELAY T0 RELAY CONNECTOR 56ACR 76ACR R=120 ohm TO BASE BOX SP105 TO ENGINE ENCLOSURE HARNESS SP104 56(FROM CB3) 56ACR 76ACR 103A 103A NOTE: The relays are mounted to the outside of the base SP09 control box.

  • Page 74: Interface Harness - Deutz D2011

    3.17 Interface Harness - Deutz D2011 T0 RELAY T0 RELAY T0 RELAY T0 RELAY TO ENGINE TO BASE BOX 56ACR 57ACR 68CR 00ACR HARNESS ENCLOSURE 56(FROM CB3) SP54A_2 SP02B 00A(ENGINE RUN= GND) SP54A_3 D54A SP09 56ACR 68CR NOTE: 57ACR 00ACR SP02 SP02A The relays are mounted...

  • Page 75: Engine Interface Harness - Deutz D2.2

    3.18 Engine Interface Harness - Deutz D2.2 D2.2 - 94 PIN 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 A43-18 BK...

  • Page 76: Interface Harness - Kubota

    3.19 Interface Harness - Kubota TO ENGINE TO BASE BOX HARNESS ENCLOSURE CANH 00A(ENGINE RUN= GND) CANL CANH CANL CONNECTOR J1 CONNECTOR J3 PIN 1 - PLUGGED SOCKET 1 - PLUGGED PIN 2 - PLUGGED SOCKET 2 - 68 PIN 3 - PLUGGED SOCKET 3 - 57A PIN 4 - PLUGGED SOCKET 4 - 11...

  • Page 77: Ecu Engine Wiring Diagram - Deutz D2011

    3.20 ECU Engine Wiring Diagram - Deutz D2011 PIN 1 - 02 - WHITE PIN 2 - 106 - GREEN/PINK PIN 3 - 96 - WHITE/GREY PIN 4 - 76 - BROWN/BLUE PIN 5 - 74 - GREEN/GREY PIN 6 - PLUGGED PIN 7 - PLUGGED PIN 8 - PLUGGED PIN 9 -...

  • Page 78: Glow Plug Harnesses - Deutz D2.9L

    3.21 Glow Plug Harnesses - Deutz D2.9L 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 79: Glow Plug Harnesses - Deutz D2011

    3.22 Glow Plug Harnesses - Deutz D2011 TO AIR BOX LEFT CYLINDER RELAY SOCKET DETAIL CENTER CYLINDER RIGHT CYLINDER SOCKET #87 BASE CONTROL BOX TERMINAL BLACK - 54A STRIP TO ENGINE STARTER M148653AA1 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 80: Platform Harnesses

    3.23 Platform Harnesses JIB / PLATFORM ROTATE VALVE HARNESS CAVITY WIRE COLOUR DESCRIPTION ORANGE/BLK JIB DOWN WHITE (SPLICE 2) GROUND PLATFORM CONTROL BOX WIRING CAVITY WIRE COLOUR DESCRIPTION ORANGE/WHITE JIB UP 02 WHITE (SPLICE 2) GROUND CAVITY WIRE COLOUR DESCRIPTION RED/PURPLE ROTATE CW 02 WHITE (SPLICE 1)

  • Page 81: Platform Control Cables

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

  • Page 82: Limit Switch Connections - Ansi/Csa

    3.25 Limit Switch Connections - ANSI/CSA Base Control Box Terminal Strip Black (09) Black/White (17) Black (09) Black/White (29A) Black (09) Black/White (59) Black (29) Black/White (29A) LS1 - Direction Sensing LS2 - Fly Stowed Limit LS3 - Main Boom LS6 - Riser Stowed Limit Switch Switch...

  • Page 83: Limit Switch Connections - Ce & As

    3.26 Limit Switch Connections - CE & AS 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 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 84: Load Sensing Cable Connections - Ce & As

    3.27 Load Sensing Cable Connections - CE & AS 4P-MALE 4P-FEMALE 3P-FEMALE PLATFORM CONTOL BOX WIRING 4" PIGTAIL TYP . M152502AA SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 85: All Motion Alarm Connections - Ce & As

    3.28 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 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 86: Flashing Amber Light Connections

    3.29 Flashing Amber Light Connections WHITE-02 BLACK - 20 CONTROL COMPARTMENT BASE CONTROL BOX LAYOUT TO LAMP CONNECTOR M148528AA_S3 SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 87: Sge Wiring Diagram

    3.30 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 88: Oil Cooler And 3.5 Kw Generator Base Control Box Wiring

    3.31 Oil Cooler and 3.5 kW Generator Base Control Box Wiring Base Control Console - Base Control Console - Oil Cooler Wiring 3.5 kW Generator Wiring INSERT BLACK WIRE ‘85’ INTO PLUG ‘B’ - POSITION ‘21’ 01CR 49CR 86CR -DETAIL A- PLUG B INSERT WHITE WIRE ‘02’...

  • Page 89: Generator (3.5 Kw) Platform Control Box Wiring

    3.32 Generator (3.5 kW) Platform Control Box Wiring SPEED CONTROL JOYSTICK JOYSTICK LEVEL TELE PLATFORM ROTATE IGNITION HORN E-STOP ABCDEFGH THROTTLE TORQUE E-PUMP 08CR M152583AA 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 90: Oil Cooler And 12 Kw Generator Base Control Box Wiring

    3.33 Oil Cooler and 12 kW Generator Base Control Box Wiring Oil Cooler Wiring 12 kW Generator Wiring CONNECT 21B TO PIN 21, CONNECTOR B 01CR 49CR 86CR 57ACR 79CR TO TERMINAL SECTION A-A BLOCK 85 SEE TOP VIEW RELAY SOCKET TO TERMINAL TO TERMINAL BLOCK ‘09’...

  • Page 91: Generator (12 Kw) Platform Control Box Wiring

    3.34 Generator (12 kW) Platform Control Box Wiring SPEED CONTROL JOYSTICK JOYSTICK LEVEL TELE PLATFORM ROTATE IGNITION HORN E-STOP ABCDEFGH THROTTLE TORQUE E-PUMP 08CR M169581AC 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 92: 12Kw Generator Electrical Connections

    3.35 12kW Generator Electrical Connections GENERATOR WIRING DIAGRAM (REF) LOCATED ON PLATFORM WHITE 8 GA GREEN 8 GA RED 8 GA 8 GA JUMPER BLACK 8 GA WHITE 8 GA WHITE 8 GA BLACK 8 GA RED 8 GA RED 8 GA BLACK 8 GA GREEN 8 GA WELDER CABLE...

  • Page 93: Load Circuit Wiring - No Generator

    3.36 Load Circuit Wiring - No Generator M194959AB 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 94: Load Circuit Wiring - 3.5 Kw Generator

    3.37 Load Circuit Wiring - 3.5 kW Generator M194959AD-2 SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 95: Load Circuit Wiring - 7.5 Or 12.5 Kw Generator

    3.38 Load Circuit Wiring - 7.5 or 12.5 kW Generator M194959AD-3 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 96: Hydraulic Schematic - Ansi/Csa

    3.39 Hydraulic Schematic - ANSI/CSA RISER RISER CYLINDER CYLINDER PLATFORM LEVELING JIB LIFT SLAVE CYLINDER CYLINDER BOOM ROTATE SWING DRIVE C2/C11 MASTER MAIN BOOM LIFT FLY BOOM EXTENSION CYLINDER CYLINDER CYLINDER PLATFORM ROTARY ACTUATOR RELIEF VALVE 2500 PSI CB14 500 PSI 500 PSI CB15 3300 PSI...

  • Page 97: Hydraulic Schematic - Ce & As

    3.40 Hydraulic Schematic - CE & AS RISER RISER CYLINDER CYLINDER PLATFORM LEVELING JIB LIFT SLAVE CYLINDER CYLINDER BOOM ROTATE SWING DRIVE C2/C11 MASTER MAIN BOOM LIFT FLY BOOM EXTENSION CYLINDER CYLINDER CYLINDER PLATFORM ROTARY ACTUATOR RELIEF VALVE 2500 PSI CB14 500 PSI 500 PSI...

  • Page 98: Platform Control Box Wiring - Ansi/Csa

    3.41 Platform Control Box Wiring - ANSI/CSA A3 JOYSTICK A2 JOYSTICK GLAZIER JOYSTICK ACTIVE 04(RED) POWER 04 (RED/YELLOW) POWER 02 (WHITE) GROUND 02 (WHITE) GROUND BLACK D-SIGNAL R(RED/GREEN) R-SIGNAL 24A (BLUE/BLACK) LEFT WHT/RED 23A (BLACK/WHITE) WHT/YEL RIGHT S20-PLTF DUAL FUEL READY S19-LEVEL S18-TELE S21-JIB...

  • Page 99: Platform Control Box Wiring - Ce

    3.42 Platform Control Box Wiring - CE A3 JOYSTICK A2 JOYSTICK 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 RED (+) POWER 04 (RED/YELLOW) BLK (-) GROUND...

  • Page 100: Platform Control Box Wiring - As

    3.43 Platform Control Box Wiring - AS A3 JOYSTICK A2 JOYSTICK 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 RED (+) POWER 04 (RED/YELLOW) BLK (-) GROUND...

  • Page 101: Base Control Box Wiring - Ansi/Csa

    3.44 Base Control Box Wiring - ANSI/CSA CONNECTOR J4 CB's & PIN 1 - 56(fromCB3) SWITCH S8 PIN 2 - 103 PIN 3 - 103A ON LEFT PIN 4 - 84 PIN 5 - 74 PIN 6 - 09 SIDE OF PIN 7 - 02 PIN 8 - 57A PIN 9 - 54A...

  • Page 102: Base Control Box Wiring - Ansi/Csa With Positive Air Shut-Off Option

    3.45 Base Control Box Wiring - ANSI/CSA with Positive Air Shut-Off Option CB's & SWITCH S8 ON LEFT SIDE OF BLACK CONNECTOR J4 NOTE: ZIP TIE PIN 1 - 56C LOOSE END PIN 2 - 103 NOTE: FOR D2011 ENGINE REPLACE 103A ON POSITION 3 PIN 3 - 103A DIAGNOSE...

  • Page 103: Base Control Box Wiring - Ce Deutz D2.2

    3.46 Base Control Box Wiring - CE Deutz D2.2 CONNECTOR (FEMALE) DETAIL C PIN1 - 05 PURPLE PIN2 - 77 BROWN PIN3 - 01B PURPLE/BLACK PIN4 - n/a CONNECTOR J1 PIN5 - 09F YELLOW PIN 1 - 103 PIN6 - 02 WHITE PIN 2 - 103A PIN 3 - 56B PIN 4 - 56A...

  • Page 104: Base Control Box Wiring - Ce Deutz D2011

    3.47 Base Control Box Wiring - CE Deutz D2011 05-14ga D57D 03A-14ga 01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR 57DCR 128B DIAGNOSE 128A 162A DEUTZ EDC 00-16ga HARNESS BATTERY (B+) E STOP 57ACR 162BCR 59CR 60CR 78CR 79CR 03 - BLACK 12 GAUGE Ă5/16" S2-KSW CONNECT TO E-PUMP POWER STUD 162B...

  • Page 105: Base Control Box Wiring - As

    3.48 Base Control Box Wiring - AS 05-14ga D57D 03A-14ga 01ACR 07CR 09CR 21CR 45CR1 45CR2 49CR 57DCR 128B DIAGNOSE 128A SPARE SPARE 162A BLACK BATTERY (B+) DEUTZ EDC 03 - BLACK 12 GAUGE Ă5/16" HARNESS CONNECT TO E-PUMP POWER STUD E STOP 57ACR 59CR...

  • Page 106: Electrical Schematic - Ansi/Csa

    3.49 Electrical Schematic - ANSI/CSA JMPR4 R4=330K ohm 3.49 Electrical Schematic - ANSI/CSA M231435AB SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 107: Electrical Schematic - Ce With Deutz D2.2

    3.50 Electrical Schematic - CE with Deutz D2.2 3.50 Electrical Schematic - CE with Deutz D2.2 M224639AD-1 SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 108: Electrical Schematic - Ce & As With D2011

    3.51 Electrical Schematic - CE & AS with D2011 ONLY WITH SGE OPTION 3.51 Electrical Schematic - CE & AS with D2011 M222992AC SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 109: Electrical Schematic - As

    3.52 Electrical Schematic - AS ONLY WITH SGE OPTION 3.52 Electrical Schematic - AS M222993AC SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 110: Interface & Engine Electrical Schematic - Deutz D2.9L

    3.53 Interface & Engine Electrical Schematic - Deutz D2.9L TO BATTERY TO BATTERY MAIN PANEL INTERFACE ENGINE HARNESS ENGINE D2.9/D2.2/TD2.9 B+ POST B- POST 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...

  • Page 111: Interface & Engine Electrical Schematic - Deutz D2011

    3.54 Interface & Engine Electrical Schematic - Deutz D2011 TO BASE BOX INTERFACE HARNESS TO ENGINE TO ENGINE ENGINE D2011 00ACR ENCLOSURE 09CR HARNESS 57BCR (N ...) Hinweise: 1. Ger ätebezeichnung nach H829908 Teil 1, z.B. MOTOR max. Spulenstrom 400mA D5/xx.1 z.B.

  • Page 112: Engine Electrical Schematic - Deutz D2.2

    3.55 Engine Electrical Schematic - Deutz D2.2 13 15 19 35 44 48 53 57 61 64 65 75 80 92 71 A15-18 BK 00-10 WH 86C-10 RD SPLK01 SPL00 203-18 BK 202-18 WH 204-18 RD A45-18 BK A35-18 BK A23-18 BK A20-16 WH A19-16 BK...

  • Page 113: Interface & Engine Electrical Schematic - Kubota Wg2503

    3.56 Interface & Engine Electrical Schematic - Kubota WG2503 MAIN PANEL INTERFACE ENGINE HARNESS ENGINE Kubota WG2503 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 114: 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 115: 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 116 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 117: 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 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124: 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 125: 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 126: 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 127: 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 128: 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 129: 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 130: 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 131: 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 132: 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 133: 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 134: 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 B+ cable from battery to battery Check continuity.

  • Page 135: No Power

    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 136: Engine Will Not Crank

    Electrical System - CE & AS Section 4 – Troubleshooting Information 11. Loose or broken wire #10 from base terminal Check continuity. Replace if defective block to Ignition/E-pump (enable) switch S5. 12. Open or defective Ignition/E-pump (enable) Check switch. Replace if defective switch S5.
  • Page 137 Section 4 – Troubleshooting Information Electrical System - CE & AS 2. Loose or broken wire #57A from 12 pin Check continuity. Replace if defective. connector (P1) pin 8 to 94 pin ECU connector, pin 35. 3. Loose or broken B+ wire from battery B+ to ECU Check continuity.
  • Page 138 Electrical System - CE & AS Section 4 – Troubleshooting Information 13. Loose or broken wire #54A from base terminal Check continuity. Replace if defective. block to relay 57BCR1. 14. Defective contacts in relay 57BCR1. Check continuity between wires #54A and #57C when cranking.
  • Page 139 Section 4 – Troubleshooting Information Electrical System - CE & AS 15. Loose or broken red/tan wire from fuse F12 to Check continuity. Replace if defective. relay 57ACR. 16. Loose or broken white wire from relay 57ACR to Check continuity. Replace if defective. start solenoid 32BCR.

  • Page 140: Engine Cranks But Will Not Start

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-4 Engine Cranks but Will Not Start Deutz Diesel D2.9L 1. Loose or broken wire #54 from 94 pin ECU Check continuity. Replace if defective. connector, pin90 to 12 pin connector (P2), pin 9. 2.
  • Page 141 Section 4 – Troubleshooting Information Electrical System - CE & AS 4. Defective relay 57BCR. Check relay. Replace if defective. 5. Glow plug circuit not operating. See “Glow Plug Circuit Inoperative” in this section. 6. No fuel in fuel tank or fuel line obstructions. Check fuel level and flow through lines.
  • Page 142 Electrical System - CE & AS Section 4 – Troubleshooting Information 16. Loose or broken tan/orange wire from ECU Check continuity. Replace if defective. connector pin #83 to throttle actuator RA1. 17. Loose or broken light green/red wire from ECU Check continuity.

  • Page 143: Glow Plug Circuit Inoperative - Deutz D2011 Diesel Engine

    Section 4 – Troubleshooting Information Electrical System - CE & AS 31. Loose or broken wire #60 from platform terminal Check continuity. Replace if defective. block to fuel select switch S26. 32. Defective fuel select switch S26. Check switch. Replace if defective. 33.

  • Page 144: All Base Control Console Inoperative

    Electrical System - CE & AS Section 4 – Troubleshooting Information 5. Loose or broken wire #54A from base terminal Check continuity. Replace if defective. strip to relay 54ACR. 6. Loose or broken wire #11 from base terminal Check continuity. Replace if defective. block to relay 54ACR.

  • Page 145: No Movement From Base Control Console

    Section 4 – Troubleshooting Information Electrical System - CE & AS NOTE For further CE troubleshooting refer to Load Sensing System. 14. Defective relay 21CR. Check relay. Replace if defective. 15. Loose or broken wire #21A from relay 21CR to Check continuity.
  • Page 146 Electrical System - CE & AS Section 4 – Troubleshooting Information No Boom Down 1. Loose or broken wire #10B 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 #10B and #13.
  • Page 147 Section 4 – Troubleshooting Information Electrical System - CE & AS 4. Loose or broken wire #30 from base terminal Check continuity. Replace if defective. block to main harness plug pin #7. 5. Loose or broken wire #30 from main harness Check continuity.
  • Page 148 Electrical System - CE & AS Section 4 – Troubleshooting Information No Telescope Retract From Base Control Console 1. Loose or broken wire #10A from ignition/ pump Check continuity. Replace if defective. switch S5 to telescope switch S14. 2. Defective telescope switch S14. Check continuity through switch while activating retract function between wires #10A and #38.
  • Page 149 Section 4 – Troubleshooting Information Electrical System - CE & AS 4. Loose or broken wire #36A from diode D36 to Check continuity. Replace if defective. main harness plug pin #12. 5. Loose or broken wire #36A from main harness Check continuity.
  • Page 150 Electrical System - CE & AS Section 4 – Troubleshooting Information 9. Loose or broken wire #37 in boom cable A or its Check for continuity between pins #19 on cable A. connectors. Check for loose or corroded connections on cable connectors.
  • Page 151 Section 4 – Troubleshooting Information Electrical System - CE & AS No Jib Down 1. Loose or broken wire #10A from ignition/ pump Check continuity. Replace if defective switch S5 to jib switch S17. 2. Defective jib down switch S17. Check continuity through switch while activating jib down function between wires #10A and #34.

  • Page 152: All Controls Inoperative From Platform Control Console

    Electrical System - CE & AS Section 4 – Troubleshooting Information 6. Loose or broken wire #02 from turret harness pin Check continuity. Replace if defective plug platform level up valve 4H-41. 7. Defective platform level up valve coil 4H-41. Check continuity and resistance through coil.
  • Page 153 Section 4 – Troubleshooting Information Electrical System - CE & AS 8. Loose or broken wire #04A from platform Check continuity. Replace if defective. terminal block to footswitch S11. 9. Open or defective footswitch S11. Check continuity through switch while activating footswitch function between wires #04A and #08A.
  • Page 154 Electrical System - CE & AS Section 4 – Troubleshooting Information 7. Loose or broken wire #14 from valve driver pin Check continuity. Replace if defective. #22 to plug A pin #7 in platform control console. 8. Loose or broken wire #14 in boom cable A or its Check for continuity between pins #7 on cable A.
  • Page 155 Section 4 – Troubleshooting Information Electrical System - CE & AS 12. Loose or broken wire #02 from turret harness Check continuity. Replace if defective. plug to boom down valve 4H-13. 13. Defective boom down valve coil 4H-13. Check continuity and resistance through coil. Replace if defective.
  • Page 156 Electrical System - CE & AS Section 4 – Troubleshooting Information 4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective. A3 to valve driver pin #30. 5. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts.
  • Page 157 Section 4 – Troubleshooting Information Electrical System - CE & AS 8. Loose or broken wire #32 in boom cable A or its Check for continuity between pins #14 on cable A. connectors. Check for loose or corroded connections on cable connectors.
  • Page 158 Electrical System - CE & AS Section 4 – Troubleshooting Information 13. Defective turret right valve coil 4H-33. Check continuity and resistance through coil. Replace if defective. No Toggle Switch Functions from Platform Control Console 1. Loose or broken wire #8 from platform terminal Check continuity.
  • Page 159 Section 4 – Troubleshooting Information Electrical System - CE & AS 3. Loose or broken wire #20A from telescope Check continuity. Replace if defective. switch S18 to valve driver pin #33. 4. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts.
  • Page 160 Electrical System - CE & AS Section 4 – Troubleshooting Information 9. Loose or broken wire #36 in boom cable A or its Check for continuity between pins #18 on cable A. connectors. Check for loose or corroded connections on cable connectors.
  • Page 161 Section 4 – Troubleshooting Information Electrical System - CE & AS 10. Loose or broken wire #37 from base connector Check continuity. Replace if defective. plug A pin #19 to base platform rotate switch S16. 11. Defective base platform rotate switch S16. Check continuity through switch while activating rotate left function between wires #10A and #36.
  • Page 162 Electrical System - CE & AS Section 4 – Troubleshooting Information 11. Defective base jib up switch S17. Check continuity through switch while activating jib up function between wires #10A and #35. If no continuity found, replace switch. 12. Open or defective diode D35. Check continuity.
  • Page 163 Section 4 – Troubleshooting Information Electrical System - CE & AS 13. Loose or broken wire #34A from diode D34 to Check continuity. Replace if defective. main harness plug pin #11. 14. Loose or broken wire #34A from main harness Check continuity.

  • Page 164: Throttle Inoperative, Mid And High - Deutz D2.9L

    Electrical System - CE & AS Section 4 – Troubleshooting Information 3. Loose or broken wire #20A from platform leveling Check continuity. Replace if defective. switch S19 to valve driver pin #33. 4. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts.

  • Page 165: 10 Mid Throttle Inoperative

    Section 4 – Troubleshooting Information Electrical System - CE & AS 4.3-10 Mid Throttle Inoperative 1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective. block to throttle switch S10. 2. Defective throttle switch S10. Check continuity through switch while activating mid throttle function between wires #08 and #79.

  • Page 166: 11 High Throttle Inoperative

    Electrical System - CE & AS Section 4 – Troubleshooting Information With the following conditions: Kubota Dual Fuel ▪ 16. Loose or broken wire #79 from base plug B pin Check continuity. Replace if defective. #20 to engine harness plug. 17.

  • Page 167: 12 Brake Will Not Release

    Section 4 – Troubleshooting Information Electrical System - CE & AS With the following conditions: Deutz D2011 Diesel ▪ 10. Loose or broken wire #78 from base plug B pin Check continuity. Replace if defective. #17 to relay 78CR. 11. Loose or broken wire #02 from base terminal Check continuity.

  • Page 168: 13 Differential Lock Will Not Engage

    Electrical System - CE & AS Section 4 – Troubleshooting Information 4.3-13 Differential Lock will not Engage NOTE Differential Lock cannot be engaged if a drive function has been selected. 1. No output on pin #19 from valve driver to wire Check pin #19 for 12 volts when drive in neutral #26A.

  • Page 169: 15 No Drive And Steer

    Section 4 – Troubleshooting Information Electrical System - CE & AS 8. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective. block to diode D08-1. 9. Open or defective diode D08-1. Check diode. Replace if defective. 10.
  • Page 170 Electrical System - CE & AS Section 4 – Troubleshooting Information 6. Loose or broken wire #16 from base plug B pin Check continuity. Replace if defective. #5 to turret harness plug pin #21. 7. Loose or broken wire #16 or #02 from turret Check continuity.

  • Page 171: 16 No High Speed Drive

    Section 4 – Troubleshooting Information Electrical System - CE & AS 5. Loose or broken wire #24A from base plug A pin Check continuity. Replace if defective. #10 to main harness plug pin #5. 6. Loose or broken wire #24A or #02 from main Check continuity.
  • Page 172 Electrical System - CE & AS Section 4 – Troubleshooting Information 4. Loose or broken wire #29 from base terminal Check continuity. Replace if defective. block to limit switch LS3. 5. Open or defective limit switch LS3. Ensure boom is fully retracted and horizontal or below.

  • Page 173: 17 No Elevated Drive

    Section 4 – Troubleshooting Information Electrical System - CE & AS 22. Defective relay 45CR1. Check relay. Replace if defective. 23. Loose or broken wire #45A from relay 45CR1 to Check continuity. Replace if defective. main harness plug pin #17. 24.
  • Page 174 Electrical System - CE & AS Section 4 – Troubleshooting Information 5. Loose or broken wire #17 in boom cable B or its Check for continuity between pins #6 on cable B. connectors. Check for loose or corroded connections on cable connectors.

  • Page 175: Load Sensing System - Ce & As

    Section 4 – Troubleshooting Information Load Sensing System - CE & AS 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 176: Boom And Drive Functions Are Enabled (With Boom Extended)

    Load Sensing System - CE & AS Section 4 – Troubleshooting Information 4.4-7 Boom and Drive Functions are Enabled (with boom extended) 1. “Fly IN” limit switch LS3 is not operating properly. Check for voltage (0V) between wires #59 and #02 from platform terminal block.

  • Page 177: Hydraulic System

    Section 4 – Troubleshooting Information Hydraulic System 4.5 Hydraulic System 4.5-1 All Controls 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. Fill to proper level. 4.5-2 All Boom Functions Inoperative 1.

  • Page 178: No Main Boom Down

    Hydraulic System Section 4 – Troubleshooting Information 4.5-4 No Main Boom Down 1. Stuck or defective lift down valve 4H-13. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV6. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 179: No Riser Boom Down

    Section 4 – Troubleshooting Information Hydraulic System 4.5-6 No Riser Boom Down 1. Stuck or defective riser down valve 4H-30. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Stuck or defective shuttle valve SV5. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 180: No Turret Rotate Right

    Hydraulic System Section 4 – Troubleshooting Information 4. Stuck or defective differential pressure sensing Clean valve. Check O-rings on valve. Check valve DSV2. operation of valve. Repair or replace valve as required. 5. Stuck or defective shuttle valve SV3. Clean valve. Check O-rings on valve. Check operation of valve.

  • Page 181: 10 No Boom Extend

    Section 4 – Troubleshooting Information Hydraulic System 4.5-10 No Boom Extend 1. Stuck or defective boom extend valve 3H-39. Clean valve. Check operation of valve. Repair or replace valve as required. 2. Plugged, incorrectly adjusted or defective orifice Check orifice. Replace if plugged or defective. OR3.

  • Page 182: 13 No Jib Up - Ce & As

    Hydraulic System Section 4 – Troubleshooting Information 4.5-13 No Jib Up - CE & AS 1. Stuck or defective jib enable valve 2H-34A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice.

  • Page 183: 15 No Jib Down - Ce & As

    Section 4 – Troubleshooting Information Hydraulic System 4.5-15 No Jib Down - CE & AS 1. Stuck or defective jib enable valve 2H-34A. Clean valve. Check O-rings on valve. Check operation of valve. Repair or replace valve as required. 2. Plugged or defective orifice OR2. Check orifice.

  • Page 184: 17 No Platform Rotation Right - Ce & As

    Hydraulic System Section 4 – Troubleshooting Information 4.5-17 No Platform Rotation Right - CE & AS 1. Stuck or defective platform rotate enable valve Clean valve. Check O-rings on valve. Check 2H-36A. operation of valve. Repair or replace valve as required.

  • Page 185: 19 No Platform Rotation Left - Ce & As

    Section 4 – Troubleshooting Information Hydraulic System 4.5-19 No Platform Rotation Left - CE & AS 1. Stuck or defective platform rotate enable valve Clean valve. Check O-rings on valve. Check 2H-36A. operation of valve. Repair or replace valve as required.

  • Page 186: 21 Platform Will Not Level Up Manually

    Hydraulic System Section 4 – Troubleshooting Information 4.5-21 Platform will not Level Up Manually 1. Plugged, incorrectly adjusted or defective orifice Check orifice. Replace if plugged or defective. OR4. 2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or replace valve as required.

  • Page 187: 23 Brake Will Not Engage

    Section 4 – Troubleshooting Information Hydraulic System 4.5-23 Brake will not Engage 1. Brake cylinder defective. Check cylinders. Repair or replace as necessary. 2. Brake valve 3H-26 stuck in shifted position. Check valve. Replace if defective. 3. Brake inside axle out of adjustment. See section 5 for brake adjustment procedure.

  • Page 188: 27 No Reverse Drive

    Hydraulic System Section 4 – Troubleshooting Information 4.5-27 No Reverse Drive 1. Defective pump displacement control 4H-15. Check control. Replace if defective. 2. Defective or misadjusted drive relief valve RV2. See section 5 for drive pump set up procedures. 3. Drive pump servo stuck or not shifting. Check pump.

  • Page 189: 32 Axle Will Not Lock

    Section 4 – Troubleshooting Information Hydraulic System 4.5-32 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. Check O-rings on valve. Check position or is defective.

  • Page 190: 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 191: Platform

    Section 5 – Procedures Platform 5.2 Platform 5.2-1 Human Machine Interface (HMI) - CE & AS Maintaining proper calibration is essential for 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 192: 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 SCM Function (Channel) Names DRIVE REV Fn01A Drive Reverse...

  • Page 193: 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 194: How To Select Ocm Functionality - Ce & As

    Platform Section 5 – Procedures 5.2-6 How to Select OCM 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 195: 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 196: 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 197: Ocm Pin Reference

    Section 5 – Procedures Platform 5.2-9 OCM Pin Reference 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 198 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 199 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 200 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 201 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 202 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 203: 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 204 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 205 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 206: 11 Scm Calibration - Ansi/Csa

    Platform Section 5 – Procedures 5.2-11 SCM Calibration - ANSI/CSA 4. Do the calibration procedure from the SCM in the base control box. Follow the flowchart on the next two pages. Tare weight calibration sets the unladen weight of the platform.

  • Page 207: 12 Scm Calibration Flowchart - Ansi/Csa

    Section 5 – Procedures Platform 5.2-12 SCM Calibration Flowchart - ANSI/CSA START SCREEN BASE PLATFORM Press the + or - button until you see the weight calibration screen. Continued on the next page 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...
  • Page 208 Do not reset Set Points 1 or 2 unless directed to do so by Skyjack. Value = Net weight: the weight Calibration Save/Exit screen. currently on the platform. Press the Save exit button to...

  • Page 209: 13 Fly Boom Switch Voltage References

    Section 5 – Procedures Platform 5.2-13 Fly Boom Switch Voltage References TELESCOPE SWITCH WORKSHEET VOLTAGE DIVIDER CIRCUIT 250 OHMS 250 OHMS TELESCOPE IN WIRE WIRE#38A > >> 7.25V 4.83V P1-32 FLY TOGGLE SWITCH TELESCOPE OUT 250 OHMS 250 OHMS 250 OHMS 250 OHMS TELESCOPE IN WIRE...

  • Page 210: 14 Platform Controller Voltage References

    Platform Section 5 – Procedures 5.2-14 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: Load Sensing System - Ce & As

    5.3-1 Load Sensing System 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 212: Verify Proper Operation Of The Load Sensing System

    Load Sensing System - CE & AS Section 5 – Procedures 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 213: Calibration Of Load Sensing System (With "Teach In" Handset)

    Section 5 – Procedures Load Sensing System - CE & AS 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 214: Boom

    Boom Section 5 – Procedures 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 215: Master Cylinder Replacement

    Section 5 – Procedures Boom 5.4-5 Master Cylinder Replacement 5. Secure the master cylinder with straps. See below for an example. 1. Ensure the MEWP is parked on a firm and level surface. WARNING Ensure that there is sufficient room for boom to swing and elevate.

  • Page 216: Limit Switch Locations - Sj46 Aj+ Ansi/Csa

    Boom Section 5 – Procedures 5.4-6 Limit Switch Locations - SJ46 AJ+ ANSI/CSA Limit Switch LS1 - Direction Sensing Limit Switch LS2 - Fly Stowed (high speed cut-out) Limit Switch LS3 - Main Boom (high speed cut-out) Limit Switch LS6 - Riser Stowed SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 217: Limit Switch Locations - Sj46 Aj & Sj51 Aj Ce & As

    Section 5 – Procedures Boom 5.4-7 Limit Switch Locations - SJ46 AJ & SJ51 AJ CE & AS Limit Switch LS1 - Direction Sensing Limit Switch LS2 - Riser Down Limit Switch LS3 - Boom Down (high speed cut-out) Limit Switch LS4 - Fly In (high speed cut-out) 229042ABA SJ46 AJ+, SJ46 AJ, SJ51 AJ...

  • Page 218: Turret

    Turret Section 5 – Procedures 5.5 Turret 5.5-2 Adjust the Turret Rotation Gear Backlash 5.5-1 Check and Replace the High The swing drive is located near the center of the turret, underneath the riser/main boom. Pressure Filter NOTE 1. Start the engine from the base control console. The adjustment of the backlash must be 2.

  • Page 219: Swing Drive Removal

    Section 5 – Procedures Turret 5.5-3 Swing Drive Removal 5. Loosen the mounting fasteners on the swing drive. The swing drive is located near the center of the turret, 6. Push the swing drive towards the rotation gear underneath the riser/main boom. as close as possible (this will push the swing drive gear into the rotation gear...

  • Page 220: Swing Drive Replacement

    Turret Section 5 – Procedures 5.5-4 Swing Drive Replacement 5.5-6 Change the Swing Drive Oil 1. Refer to procedure . 2. Use a lifting device to position the new swing NOTE drive onto the turret and loosely bolt the swing The oil change must be performed on a flat, level drive to the turret.

  • Page 221: Check Rotation Bearing For Axial Wear

    Section 5 – Procedures Turret 5.5-7 Check Rotation Bearing for Axial 5.5-8 Turret Rotation Gear Bolt Torque Wear Sequence 1. Position the boom so that it is centered over the WARNING front drive and steer axle and is horizontal with the ground.

  • Page 222: Electronic Tilt Switch Setup Procedure

    Section 5 – Procedures Turret 5.5-9 Electronic Tilt Switch Setup 7. Pull out both emergency stop buttons Procedure 8. Verify the switch is powered (red or green LED will be continually blinking). Tilt Switch Replacement Red LED Red LED Y AXIS Green LED Green LED X AXIS...
  • Page 223 Section 5 – Procedures Turret Reprogramming the Existing Tilt Switch IMPORTANT Step “c” must be completed within a 5 second The set to zero button is located period, or the switch will automatically exit Light Indicators on this face next to the harness program mode and return to normal operation using the previously stored data.

  • Page 224: 10 Battery Replacement

    Turret Section 5 – Procedures Verify Tilt Circuit 5.5-10 Battery Replacement 1. Turn the main power disconnect switch to the off Light Indicators 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 2.

  • Page 225: Deutz Diesel Engines

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

  • Page 226: Replace The Fuel Filter

    Deutz Diesel Engines 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 turret. The MEWP will not operate properly with a loose 2. Pull the locking pin down and swing the engine or defective belt.

  • Page 227: Deutz D2.9L Fault Codes

    Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 228 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 229 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 230 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 231 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 232 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 233 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 234 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 235 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 236 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 237 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 238 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 239 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 240 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 241 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 242 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 243 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 244 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 245 Section 5 – Procedures Deutz Diesel Engines 5.6-6 Deutz D2.9L 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 246 Deutz Diesel Engines Section 5 – Procedures 5.6-6 Deutz D2.9L 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 247: Hydraulic Tank

    Section 5 – Procedures Hydraulic Tank 5.7 Hydraulic Tank 5.7-2 Hydraulic Filter Replacement 1. Turn the MEWP off. Maintaining the hydraulic components and hydraulic 2. Place a suitable container under the filter. oil at the proper level are essential to the good performance and service life of the MEWP .

  • Page 248: Kubota Wg2503 Dual Fuel Engine

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.8 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 249: Kubota Wg2503 Diagnostic Trouble Codes

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.8-2 Kubota WG2503 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...
  • Page 250 Kubota WG2503 Dual Fuel Engine Section 5 – Procedures Kubota WG2503 Diagnostic Trouble Codes (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...
  • Page 251 Section 5 – Procedures Kubota WG2503 Dual Fuel Engine Kubota WG2503 Diagnostic Trouble Codes (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...
  • Page 252 Kubota WG2503 Dual Fuel Engine Section 5 – Procedures Kubota WG2503 Diagnostic Trouble Codes (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...
  • Page 253 Section 5 – Procedures Kubota WG2503 Dual Fuel Engine Kubota WG2503 Diagnostic Trouble Codes (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...

  • Page 254: Ecu Pin Reference Chart (Kubota Wg2503)

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.8-3 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 255: Fuse Box (Kubota Wg2503)

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.8-4 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 256: Map Sensor (Kubota Wg2503)

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.8-5 MAP Sensor (Kubota WG2503) TAMP Sensor 5V ext 1 MAP Signal 5V rtn 1 5.8-6 IAT Sensor (Kubota WG2503) TAMP Sensor 5V rtn 1 Thermistor SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 257: Ect (Kubota Wg2503)

    Section 5 – Procedures Kubota WG2503 Dual Fuel Engine 5.8-7 ECT (Kubota WG2503) ECT Sensor 5V rtn 1 Thermistor 5.8-8 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 258: Fuel Temperature Sensor (Kubota Wg2503)

    Kubota WG2503 Dual Fuel Engine Section 5 – Procedures 5.8-9 Fuel Temperature Sensor (Kubota WG2503) FP/FT Sensor 5V ext 1 FRP Signal 5V rtn 1 FRP Signal 5.8-10 Oil Pressure Sensor (Kubota WG2503) Oil Pressure Switch + 5 V Pressure Voltage SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 259: Manifold And Hydraulic Pumps

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9 Manifold and Hydraulic WARNING Pumps Ensure there are no personnel or obstructions in test area and there is sufficient room for forward or 5.9-1 Hydraulic Brake Pressure reverse travel. Adjustment 6. Start the engine from the platform control console and extend the boom slightly to achieve Maintaining accurate hydraulic brake pressure is low speed drive.

  • Page 260: Hydraulic System Relief Valve Adjustment

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.9-2 Hydraulic System Relief Valve 5.9-3 Riser Down Relief Valve Adjustment Adjustment 1. Locate Test Port 5 on the main manifold. 1. Locate Test Port 1 on the main manifold. 2. Connect a pressure gauge (345 bar 5000 psi) to Remove the cap.

  • Page 261: Turret Rotate Relief Valve Adjustment

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9-4 Turret Rotate Relief Valve 5.9-5 Platform Level Relief Valve Adjustment Adjustment 1. Locate Test Port 5 on the main manifold. 1. Locate the Test 5 Port on the main manifold. 2. Connect a pressure gauge (345 bar / 5000 psi) 2.

  • Page 262: Test Charge Pump Pressure On Drive Pump

    Manifold and Hydraulic Pumps Section 5 – Procedures 5.9-6 Test Charge Pump Pressure on 5.9-7 Test Forward Drive Pressure on Drive Pump Drive Pump 1. Locate test port TP3 on the drive pump. NOTE 2. Connect a pressure gauge 41.5 bar (600 psi) to Make sure the charge pump pressure test is the test port.

  • Page 263: Test Reverse Drive Pressure On Drive Pump

    Section 5 – Procedures Manifold and Hydraulic Pumps 5.9-8 Test Reverse Drive Pressure on Drive Pump NOTE Make sure the charge pump pressure test is completed first. 1. Locate test port TP2 on the drive pump. 2. Connect a pressure gauge (690 bar / 10 000 psi) to test port TP2.

  • Page 264: 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 265: 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 266: 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 267 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 268: Bleed The Oscillating Axle Cylinders

    Axles Section 5 – Procedures 9. Reinstall the cylinder fittings, torquing the larger 5.10-9 Test the Oscillating Axle Cylinders one to 33 Nm (24 ft-lb) and the smaller one to 20 Nm (15 ft-lb). 10. Remove the plugs and reconnect the hoses to 1.

  • Page 269: 10 Pin Brake Adjustments

    Section 5 – Procedures Axles 5.10-10 Pin Brake Adjustments 4. Tighten the Jam nut. Repeat this procedure for the other side. 1. To manually release the brake give a light blow to the external ring of the check unit. 2. To adjust the idle elimination loosen jam nut and back out adjustment stem a few turns.

  • Page 270: 11 Brake Inspection

    Axles Section 5 – Procedures 7. Release the pressure from the cylinder and 5.10-11 Brake Inspection check that the rod returns and stops in a position where it projects out from the cylinder 1. Remove the oil level plug from one of the head by 5 mm (3/16").

  • Page 271: Grease Points

    Section 5 – Procedures Grease Points 5.11 Grease Points Maintaining proper lubrication is essential for 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 272: 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. SJ46 AJ+, SJ46 AJ, SJ51 AJ 229042ABA...

  • Page 273: 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 274: 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 275 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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