MODELS SJ 6826RT SJ 6832RT

Service Manual
Compact Rough Terrain Scissors (ANSI/CSA)

Part No. 157951AA June 2011

 This manual is based on Serial Number(s):

SJ 68XXRT 37,002,788 & Above

Please refer to the website (www.skyjack.com) for older Serial Numbers.

Skyjack Service Center 3451 Swenson Ave. St. Charles, Illinois, 60174 USA
Phone: 630-262-0005
Toll Free: 1-800-275-9522
Fax: 630-262-0006
Email: service@skyjack.com

Parts (North America)

Toll Free: 1-800-965-4626
Toll Free Fax: 1-888-782-4825
Email: parts@skyjack.com

Parts & Service (Europe) Unit 1 Maes Y Clawdd, Maesbury Road Industrial Estate Oswestry, Shropshire SY10 8NN UK
Phone: +44-1691-676-235
Fax: +44-1691-676-238
Email: info@skyjackeurope.co.uk

Skyjack Asia Pacific Singapore

Phone: +65-6449-3710
Fax: +65-6449-7690
Email: skyjack@singnet.com.sg
 SERVICE AND MAINTENANCE

Table of Contents

Section 1 - Scheduled Maintenance

Table of Contents

Section 2 - Maintenance Tables

Table of Contents

Section 3 - Schematics
Table of Contents

Section 4 - Troubleshooting
Table of Contents

Section 5 - Procedures
Table of Contents

Rough Terrain Compact Series SKYJACK, Page 3

Engine Powered
157951
Service and Maintenance Operator’s Responsibility for Maintenance

The Safety Alert Symbol identifies important

safety messages on aerial platforms, safety This Safety Alert Symbol means attention!
signs in manuals or elsewhere. When you
see this symbol, be alert to the possibility of Become alert! Your safety is involved.
personal injury or death. Follow the instructions
in the safety message.

DANGER
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.

WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.

important
IMPORTANT indicates a procedure) essential for safe operation and which,
if not followed, may result in a malfunction or damage to the aerial platform.

SKYJACK, Page 4 Rough Terrain Compact Series

Engine Powered
157951
 1
Section 1
schedule maintenance
Table of Contents
Operator’s Responsibility for Maintenance
Aerial Platform Definition...............................................................................................................................................7
Purpose of Equipment..................................................................................................................................................7
Use of Equipment.........................................................................................................................................................7
Manuals.........................................................................................................................................................................7
Operator........................................................................................................................................................................7
Service Policy and Warranty.........................................................................................................................................7
Optional Accessories....................................................................................................................................................7
Scope of this Manual....................................................................................................................................................8
Operator Safety Reminders..........................................................................................................................................8
Electrocution Hazard....................................................................................................................................................9
Safety Precautions......................................................................................................................................................10
Maintenance and Inspection Schedule......................................................................................................................13
Owner’s Annual Inspection Record............................................................................................................................13
Replacement Parts......................................................................................................................................................13
Maintenance and Service Safety Tips........................................................................................................................13
Hydraulic System & Component Maintenance and Repair.......................................................................................14
Maintenance Hints......................................................................................................................................................14

Service and Maintenance

About this Section.......................................................................................................................................................15
Service Bulletins..........................................................................................................................................................15
Maintenance and Inspection......................................................................................................................................15
Maintenance Instructions............................................................................................................................................15

Schedule Maintenance Inspections

1.1 Scheduled Maintenance Inspections...............................................................................................................18
1.2 Function Tests..................................................................................................................................................27

Tables
1.1 Owner’s Annual Inspection Record.................................................................................................................16
1.2 Maintenance and Inspection Checklist............................................................................................................17

Rough Terrain Compact Series SKYJACK, Page 5

Engine Powered
157951
 Notes

SKYJACK, Page 6 Rough Terrain Compact Series

Engine Powered
157951
Operator’s Responsibility for Maintenance Service and Maintenance

SKYJACK is continuously improving and expanding product features on its equipment, therefore, specifications
and dimensions are subject to change without notice.

Aerial Platform Definition

A mobile device that has an adjustable position platform supported from ground level by a structure.

Purpose of Equipment
The SKYJACK Rough Terrain Compact Series aerial platforms are designed to transport and raise personnel, tools
and materials to overhead work areas.

Use of Equipment
The aerial platform is a highly maneuverable, mobile work station. Lifting and driving must be on a flat, level,
compacted surface. It can be driven over uneven terrain only when the platform is fully lowered.

Manuals
Operating
The operating manual is considered a fundamental part of the aerial platform. It is a very important way to
communicate necessary safety information to users and operators. A complete and legible copy of this manual
must be kept in the provided weather-resistant storage compartment on the aerial platform at all times.

Service & Maintenance

The purpose of this is to provide the customer with the servicing and maintenance procedures essential for
the promotion of proper machine operation for its intended purpose.

All information in this manual should be read and understood before any attempt is made to service the machine.
The updated copy of the manuals are found on the company’s website: www.skyjack.com.

Operator
The operator must read and completely understand both this operating manual and the safety panel label located on
the platform and all other warnings in this manual and on the aerial platform. Compare the labels on the aerial platform
with the labels found within this manual. If any labels are damaged or missing, replace them immediately.

Service Policy and Warranty

SKYJACK warrants each new SJRT Compact Series work platform to be free of defective parts and workmanship
for the first 24 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge
for parts or labor. Contact the SKYJACK Service Department for warranty statement extensions or exclusions.

Optional Accessories
The SKYJACK aerial platform is designed to accept a variety of optional accessories. These are listed under “Standard
and Optional Features” in Table 2.1 of the operating manual. Operating instructions for these options (if equipped)
are located in section 2 of the operating manual.

For non-standard components or systems, contact the SKYJACK Service Department at

North America:
( : 800 275-9522
 

7 : 630 262-0006

Include the model and serial number for each applicable aerial platform.

Rough Terrain Compact Series SKYJACK, Page 7

Engine Powered
157951
Service and Maintenance Operator’s Responsibility for Maintenance

Scope of this Manual

a. This manual applies to the ANSI/SIA, CSA versions of the SJRT Compact Series aerial platform models listed
on Table 2.1.

- Equipment identified with “ANSI” meets the ANSI SIA-A92.6-2006 standard.

- Equipment identified with “CSA” meets the CSA B354.2-01 standard.

b. CSA (Canada)
Operators are required to conform to national, territorial/provincial and local health and safety regulations
applicable to the operation of this aerial platform.

c. ANSI/SIA (United States)

Operators are required by the current ANSI/SIA A92.6 standards to read and understand their responsibilities
in the manual of responsibilities before they use or operate this aerial platform.

WARNING
Failure to comply with your required responsibilities in the use and operation of the aerial platform
could result in death or serious injury!

Operator Safety Reminders

A study conducted by St. Paul Travelers showed that most accidents are caused by the failure of the operator to
follow simple and fundamental safety rules and precautions.

You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this aerial platform
is mandatory. The following pages of this manual should be read and understood completely before operating the
aerial platform.

Common sense dictates the use of protective clothing when working on or near machinery. Use appropriate safety
devices to protect your eyes, ears, hands, feet and body.

Any modifications from the original design are strictly forbidden without written permission from SKYJACK.

SKYJACK, Page 8 Rough Terrain Compact Series

Engine Powered
157951
Operator’s Responsibility for Maintenance Service and Maintenance

Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from ener-
gized power lines and parts as listed below. The operator must allow for the platform to sway, rock or sag. This
aerial platform does not provide protection from contact with or proximity to an electrically charged conductor.

Per ANSI A92.6-2006 8.10(7)

“The operator shall perform only that work for which he or she is qualified, in compliance with all applicable safety
related work practices intended to prevent electric shock covered by the Code of Federal Regulations (CFR)
1910.333. The operator’s level of competence shall be established only by persons qualified to do so. Operators
shall maintain the appropriate minimum approach distance (MAD) from energized power lines and parts covered
by CFR 1910.333 (c).”

Unqualified persons must maintain a minimum approach distance of 10 feet from any energized power line up to
50 kV. Energized power lines over 50 kV require a greater minimum approach distance to be maintained. Refer to
CFR 1910.333.

As per CSA B354.2-01

“The operator shall maintain the minimum safe approach distance (MSAD) from energized conductors at all times
in accordance with the authority having jurisdiction.”

As per AS 2550.1-2002
Elevating Work Platforms must remain 6.4 m from electrical distribution lines up to 133 kV and 8 m from transmis-
sion lines greater than 133 kV. State regulations may take precedence over these approach distances.

DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS.

DANGER
Avoid Power Lines

Minimum Safe Approach Distance

ANSI/SIA A92.6-2006 & CSA B354.2-01 Requirements
Voltage Range Minimum Safe Approach Distance
(Phase to Phase) (Feet)
0 to 300V Avoid Contact
Over 300V to 50KV 10
Over 50KV to 200KV 15
Over 200KV to 350KV 20
Over 350KV to 500KV 25
Over 500KV to 750KV 35
Over 750KV to 1000KV 45
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
60023AD-ANSI

Rough Terrain Compact Series SKYJACK, Page 9

Engine Powered
157951
Service and Maintenance Operator’s Responsibility for Maintenance

Safety Precautions
Know and understand the safety precautions before going on to next section.

warning
Failure to heed the following safety • DO NOT increase the lateral
precautions could result in tip over, surface area of the platform.
falling, crushing, or other hazards leading Increasing the area exposed
to death or serious injury. to the wind will decrease aerial
platform stability.
• KNOW all national, state/provincial and local
rules which apply to your aerial platform and
jobsite. • DO NOT drive or elevate the
aerial platform if it is not on a
• TURN emergency main power disconnect firm level surface. Do not drive
switch “ ” off when leaving the aerial platform elevated near depressions
unattended. Remove the key to prevent or holes of any type, loading
unauthorized use of the aerial platform. docks, debris, drop-offs and
surfaces that may affect the
• WEAR all the protective clothing and personal stability of the aerial platform.
safety devices issued to you or called for by job
conditions.
• If operation in areas
• DO NOT wear loose clothing, with holes or drop-offs
dangling neckties, scarves, is absolutely necessary,
rings, wristwatches or other elevated driving shall not be
jewelry while operating this allowed. Position the aerial
aerial platform. platform horizontally only with






the platform fully lowered. After

ensuring that all 4 wheels or
outriggers (if equipped) have
contact with level firm surface,
• AVOID entanglement with the aerial platform can be
ropes, cords or hoses. elevated. After elevation, the
drive function must not be
activated.

• Elevated driving must

• AVOID falling. Stay within the only be done on a firm level
boundaries of the guardrails. surface.

• DO NOT ascend or descend

a grade when elevated. When
• DO NOT raise the aerial fully lowered, ascending or
platform in windy or gusty descending, only grades up
conditions. to rated maximum listed in
Table 2.1 are permissible.

SKYJACK, Page 10 Rough Terrain Compact Series

Engine Powered
157951
Operator’s Responsibility for Maintenance Service and Maintenance

Safety Precautions (Continued)

Know and understand the safety precautions before going on to next section.

• DO NOT operate on surfaces not capable of • DO NOT raise the aerial platform
holding the weight of the aerial platform including while the aerial platform is on a
the rated load, e.g. covers, drains, and trenches. truck, fork lift or other device or
vehicle.

• DO NOT operate an aerial

platform that has ladders,
scaffolding or other devices
mounted on it to increase • BE AWARE of crushing
its size or work height. It is hazards. Keep all body parts
prohibited. inside platform guardrail.

• DO NOT exert side forces on

aerial platform while elevated.
• DO NOT lower the platform
unless the area below is
clear of personnel and
obstructions.

• DO NOT use the aerial platform • ENSURE that there are no personnel or
as a crane. It is prohibited. obstructions in the path of travel, including blind
spots.

• DO NOT sit, stand or climb on

the guardrails. It is prohibited.

• BE AWARE of blind spots when operating the

aerial platform.

• DO NOT climb on scissor arm • STUNT driving and horseplay are prohibited.
assembly. It is prohibited.
• ENSURE ALL tires are in good condition and lug
nuts are properly tightened.

• DO NOT alter or disable limit switches or other

safety devices.
• BE AWARE of overhead
obstructions or other possible • DO NOT use the aerial platform without
hazards around the aerial guardrails, locking pins and the entry gate/chain/
platform when driving or lifting. bar in place.

Rough Terrain Compact Series SKYJACK, Page 11

Engine Powered
157951
Service and Maintenance Operator’s Responsibility for Maintenance

Safety Precautions (Continued)

Know and understand the safety precautions before going on to next section.

• DO NOT exceed the rated capacity of the aerial

WARNING
platform. Do make sure the load is evenly distrib-
uted on the platform. Entering and exiting the aerial platform
should only be done using the three
• DO NOT attempt to free a snagged platform with points of contact.
lower controls until personnel are removed from
the platform. • Use only equipped access openings.
• Enter and exit only when the aerial
• DO NOT position the aerial platform against an- platform is in the fully retracted position.
other object to steady the platform.
• Do use three points of contact to enter and exit
• DO NOT place materials on the guardrails or ma- the platform. Enter and exit the platform from
terials that exceed the confines of the guardrails the ground only. Face the aerial platform when
unless approved by Skyjack. entering or exiting the platform.

Fall Protection • Three points of contact means that two hands

As per the ANSI A92.6-2006 standard, “The guard- and one foot or one hand and two feet are in
rail system of the aerial platform provides fall pro- contact with the aerial platform or the ground at
tection. If occupant(s) of the platform are required all times during entering and exiting.
to wear personal fall protection equipment (PFPE),
occupants shall comply with instructions provided WARNING
by the aerial platform manufacturer (remanufac-
An operator should not use any aerial
turer) regarding anchorage(s).”
platform that:
If additional fall protection is required, by an em-
• does not appear to be working properly.
ployer or the authority having jurisdiction, Skyjack
• has been damaged or appears to have worn or
recommends the use of a fall restraint system to
missing parts.
keep an occupant within the confines of the plat-
• has alterations or modifications not approved by
form, and thus not expose the occupant to any
the manufacturer.
fall hazard requiring a fall arrest.
• has safety devices which have been altered or
disabled.
All personal fall protection equipment must com-
• has been tagged or blocked out for non-use or
ply with applicable governmental regulations and
repair.
must be inspected and used in accordance with
the manufacturer’s recommendations.
Failure to avoid these hazards could
result in death or serious injury.
All personal fall protection equipment must be at-
tached only to approved anchorage points within
the platform of the aerial platform. Jobsite Inspection
• Do not use in hazardous locations.
• Perform a thorough jobsite inspection prior to
operating the aerial platform, to identify potential
hazards in your work area.
• Be aware of moving equipment in the area. Take
appropriate actions to avoid collision.

SKYJACK, Page 12 Rough Terrain Compact Series

Engine Powered
157951
Operator’s Responsibility for Maintenance Service and Maintenance

Maintenance and Inspection Schedule Maintenance and Service Safety Tips

The actual operating environment of the work platform Maintenance and repair should only be performed by
governs the use of the maintenance schedule. The personnel who are trained and qualified to service this
inspection points covered in Table 1.2. Maintenance aerial platform.
and lnspection Checklist, indicates the areas of the
aerial platform to be maintained or inspected and at All maintenance and service procedures should be
what intervals the maintenance and inspections are to performed in a well lighted and well ventilated area.
be performed.
Anyone operating or servicing this aerial platform
Owner’s Annual Inspection Record must read and completely understand all operating
It is the responsibility of the owner to arrange quarterly instructions and safety hazards in this manual and
and annual inspections of the aerial platform. Table 1.1. operating manual.
Owner’s Annual lnspection Record is to be used for
recording the date of the inspection, owner’s name, All tools, supports and lifting equipment to be used
and the person responsible for the inspection of the must be of proper rated load and in good working order
work platform. before any service work begins. Work area should be
kept clean and free of debris to avoid contaminating
Replacement Parts components while servicing.
Use only original replacement parts. Parts such
as batteries, wheels, railings, etc. with weight and All service personnel must be familiar with employer
dimensions different from original parts will affect and governmental regulations that apply to servicing
stability of the work platform and must not be used this type of equipment.
without manufacturer’s consent.
Keep sparks and flames away from all flammable or
Use only original filled tires for models which must be combustible materials.
so equipped. Consult factory.
Properly dispose of all waste material such as
All replacement tires must be of the same size and load lubricants, rags, and old parts according to the relative
rating as original equipment to maintain safety and law provisions obtaining in the country.
stability of the work platform. Consult factory.
Before attempting any repair work, turn Battery
Disconnect Switch to the “OFF” position.
WARNING
Any unit that is damaged or not operat- Preventive maintenance is the easiest and least
ing properly must be immediately tagged expensive type of maintenance.
and removed from service until proper
repairs are completed.

Rough Terrain Compact Series SKYJACK, Page 13

Engine Powered
157951
Service and Maintenance Operator’s Responsibility for Maintenance

Hydraulic System & Component Oil change intervals will depend on the
Maintenance and Repair care used in keeping the oil clean, and the
The following points should be kept in mind when operating conditions. Dirt and/or moisture
working on the hydraulic system or any component: cotamination will dictate that the oil should
be changed more often. Under normal use
1. Any structure has limits of strength and durability. and operating conditions, the hydraulic oil
To prevent failure of structural parts of hydraulic should be changed every two years. Refer
components, relief valves which limit pressure to to Table 1.2 of this manual.
safe operating values are included in the hydraulic
circuits. 7. All hydraulic components must be disassembled
in spotlessly clean surroundings. During
2. Tolerance of working parts in the hydraulic system disassembly, pay particular attention to the
is very close. Even small amounts of dirt or identification of parts to assure proper reassembly.
foreign materials in the system can cause wear Clean all metal parts in a clean mineral oil solvent.
or damage to components, as well as general Be sure to thoroughly clean all internal passages.
faulty operation of the hydraulic system. Every After the parts have been dried thoroughly, lay
precaution must be taken to assure absolute them on a clean, lint-free surface for inspection.
cleanliness of the hydraulic oil.
8. Replace all O-rings and seals when overhauling
3. Whenever there is a hydraulic system failure any component. Lubricate all parts with clean
which gives reason to believe that there are metal hydraulic oil before reassembly. Use small
particles or foreign materials in the system, drain amounts of petroleum jelly to hold O-rings in
and flush the entire system and replace the filter place during assembly.
cartridges. A complete change of oil must be
made under these circumstances. 9. Be sure to replace any lost hydraulic oil when
completing the installation of the repaired
4. Whenever the hydraulic system is drained, check component, and bleed any air from the system
the magnets in the hydraulic reservoir for metal when required.
particles. If metal particles are present, flush the
entire system and add a new change of oil. The 10. All hydraulic connections must be kept tight. A
presence of metal particles also may indicate the loose connection in a pressure line will permit
possibility of imminent component failure. A very the oil to leak out or air to be drawn into the
small amount of fine particles is normal. system. Air in the system can cause damage
to the components and noisy or erratic system
5. All containers and funnels used in handling operation.
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic Maintenance Hints
oil reservoir, and fill the reservoir only through Three simple maintenance procedures have the
the filter opening. The use of cloth to strain the greatest effect on the hydraulic system performance,
oil should be avoided to prevent lint from getting efficiency and life. Yet, the very simplicity of them may
into the system. be the reason they are so often overlooked. What are
they? Simply these:
6. When removing any hydraulic component, be sure
to cap and tag all hydraulic lines involved. Also, 1. Change filters annually. The filters will need
plug the ports of the removed components. to be changed more often depending on
the operating conditions. Dirty, dusty, high
Note moisture environments may cause the
Samples of hydraulic oil should be drawn hydraulic system to be contaminated more
from the reservoir and tested annually. quickly.
These samples should be taken when the 2. Maintain a sufficient quantity of clean
oil is warmed through normal operation of hydraulic oil of the proper type and viscosity
the system. The sample should be analyzed in the hydraulic reservoir.
by a qualified lubrication specialist to 3. Keep all connections tight.
determine if it is suitable for continued use.

SKYJACK, Page 14 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Service and Maintenance Inspections

About this Section Maintenance Instructions

This section contains the maintenance and inspection This manual consists of four schedules to be done for
schedule that is to be performed. maintaining on an aerial platform. Inspection schedule
frequency is shown below:
References are made to the procedures in section 5
that outline detailed step-by-step instructions for checks Inspection Schedule
and replacements. Daily A
Frequently A+B
Service Bulletins Annually A+B+C
Before performing any scheduled maintenance Bi-annually A+B+C+D
inspection procedure, refer to service bulletins found
in our web site: www.skyjack.com for updates related • Make copies of the maintenance and inspection
to service and maintenance of this aerial platform. checklist to be used for each inspection.
• Check the schedule on the checklist for the type of
inspection to be performed.
Maintenance and Inspection • Place a check in the appropriate box after each
Death or injury can result if the aerial platform is not kept inspection procedure is completed.
in good working order. Inspection and maintenance • Use the maintenance and inspection checklist and
should be performed by competent personnel who step-by-step procedures in section 5 to perform
are trained and qualified on maintenance of this aerial these inspections.
platform. • If any inspection receives a fail, tag and remove the
aerial platform from service.
WARNING • If any aerial platform component(s) has been
repaired, an inspection must be performed again
Failure to perform each procedure as pre-
before removing the tag. Place a check in the repair
sented and scheduled may cause death,
column.
serious injury or substantial damage.

Note Legend
Preventive maintenance is the easiest and P = Pass
least expensive type of maintenance. F = Fail
R = Repaired
• Unless otherwise specified, perform each
maintenance procedure with the aerial platform in
the following configuration:
- Aerial platform parked on a flat and level
surface
- Disconnect the battery by turning the main
power disconnect switch to the “OFF” position.
• Repair any damaged or malfunction components
before operating aerial platform.
• Keep records on all inspections.

Rough Terrain Compact Series SKYJACK, Page 15

Engine Powered
157951
Service and Maintenance Inspections Section 1 - Scheduled Maintenance

Table 1.1 Owner’s Annual Inspection Record

Model Number: _________________ Serial Number:__________________

* 20__ 20__ 20__ 20__ 20__ 20__ 20__ 20__ 20__

**
1000AA

As described earlier in this section, this decal is located on the scissor assembly. It must be completed after an annual
inspection has been completed. Do not use the aerial platform if an inspection has not been recorded in the last 13
months.

Pictorial Description
Inspection Date

Inspector Signature

**

SKYJACK, Page 16 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Service and Maintenance Inspections

Table 1.2 MAINTENANCE AND INSPECTION CHECKLIST

Serial Number:
Model:
Hourmeter Reading: Name (Printed):
Date:
Time: Signature:
Each item shall be inspected using the the appropriate section of the Skyjack service manual.
As each item is inspected, write the apropriate grade in the box.
INSPECTION FREQUENCY Inspection Schedule
‰ DAILY Daily A
P - PASS ‰ FREQUENTLY Frequently*† A+B
F - FAIL ‰ ANNUALLY Annually† A+B+C
R - REPAIRED ‰ BI-ANNUALLY Bi-annually† A+B+C+D

Schedule P F R Schedule P F R
Schedule Maintenance Inspections Base
Labels A Base Weldment A, B
Limit Switches A, B Wheel/Tire Assembly A, B
Engine Compartment Steer Cylinder Assembly A, B
Main Power Disconnect Switch A, B Splitter Manifold A, B
Base Control Switches A, B Tie Rod A, B
Tilt Sensor A, B Emergency Lowering Access Rod A, B
Battery A, B Ladder A, B
Hydraulic Pump A, B, C Outriggers A, B
Radiator A, B, C Function Tests
Muffler and Exhaust A, B Test Main Power Discconect Switch A, B
Engine Pivot Tray A, B Base Control Console
Engine Oil Level A, B
Test Platform/Engine/Base Key Switch A, B
Fuel Shut-off Valve A, B
Engine Air Filter A, B Test Emergency Stop A, B
Fuel Leaks A, B Test Platform Raise/Lower Switch A, B
Hydraulic/Fuel Compartment Test Emergency Lowering A, B
Hydraulic Tank A, B, C Test Free-wheeling A, B
Hydraulic Oil A, B, C Platform Control Console
Hydraulic Return Filter A, B Test Emergency Stop A, B
Fuel Tank A, B Test Enable Trigger Switch A, B
Main Manifold A, B Test Platform Raising/Lowering A, B
Gear Type Flow Divider A, B Test Steering A, B
Engine Oil Level A, B Test Driving A, B
Platform Assembly Test Speed Limit A, B
Lanyard Attachment Anchors A Test Brake A, B
AC Outlet on Platform A, B Test Horn A, B
Manuals A, B Test Hydraulic Outriggers
A, B
Platform Control Console A, B (If Equipped)
Lift Mechanism 302AA

Maintenance Support A, B
Scissor Assembly A, B
Scissor Bumpers A, B
Rollers A, B
Lift Cylinder(s) A, B

A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2.3 and Section 2.4 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1.0 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1.0 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1.0 of this manual.
* Perform scheduled inspection every three months or 150 hours.
† Refer to Skyjack's webiste @ www.skyjack.com for latest service bulletins prior to performing quarterly or yearly inspection.
Note: Make a copy of this page or visit the Skyjack web site:www.skyjack.com for a printable copy.

Rough Terrain Compact Series SKYJACK, Page 17

Engine Powered
157951
Service and Maintenance Inspections Section 1 - Scheduled Maintenance

Platform Control
Console
Scissor Assembly
Platform Assembly

Limit Switch

Limit Switch
Outriggers

Outriggers
Base

1.1 Scheduled Maintenance Inspections Perform a visual inspection around the following
Begin the scheduled maintenance inspections by areas:
checking each item in sequence for the conditions listed
in this section. • hydraulic tank filter, fittings, hoses, emergency
power unit (if equipped) and base surfaces
WARNING • engine compartment fittings, hoses, main
pump, and filter
To avoid injury, do not operate an aerial • all hydraulic cylinders
platform until all malfunctions have been • all hydraulic manifolds
corrected. • the underside of the base
• ground area under the aerial platform
WARNING • outriggers
To avoid possible injury, ensure aerial
1.1-1 Labels
platform power is off during your visual
Refer to the labels section in this manual and determine
and daily maintenance inspections.
that all labels are in place and are legible.
Electrical
1.1-2 Limit Switches
Maintaining the electrical components is essential
Detecting limit switch malfunction is essential to safe
to good performance and service life of the aerial
aerial platform operation. Ensure limit switches are
platform.
properly secured with no signs of visible damage and
movement is not obstructed.
Inspect the following areas for chafed, corroded
and loose wires:
Visually inspect all limit switch located inside the
• base to platform cables and wiring harness
scissor arms and the outrigger assemblies for the
• engine compartment electrical panel
following:
• engine wiring harness
• broken or missing actuator arm
• hydraulic/electrical wiring harnesses
• missing fasteners
• loose wiring
Hydraulic
Maintaining the hydraulic components is essential
to good performance and service life of the aerial
platform.

SKYJACK, Page 18 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Service and Maintenance Inspections

Muffler and Exhaust Engine

Base Control
Console
Tilt Sensor

Engine Air Filter

Main Power
Disconnect Switch
Radiator
Hydraulic Pump

Fuel Shut-off
Valve
Battery

1.1-3 Engine Compartment

WARNING
-- Ensure compartment latch is secure and
in proper working order. Battery acid is extremely corrosive -
Wear proper eye and facial protection as
• Main Power Disconnect Switch well as appropriate protective clothing.
-- Turn main power disconnect switch to If contact occurs, immediately flush with
“ ” off position. cold water and seek medical attention.
-- Ensure all cables are secure and switch
is in proper working condition. 1. Check battery case for damage.

• Base Control Switches 2. Clean battery terminals and cable ends

-- Ensure there are no signs of visible thoroughly with a terminal cleaning tool or
damage and all switches are in their wire brush.
neutral positions.
3. Ensure all battery connections are tight.
• Tilt Sensor
-- Ensure tilt sensor is properly secure and
4. If applicable, check battery fluid level. If plates
there is no visible damage.
are not covered by at least 1/2” (13 mm)
• Battery of solution, add distilled or demineralized
Proper battery condition is essential to water.
good performance and operational safety.
Improper fluid levels or damaged cables and 5. Replace battery if damaged or incapable of
connections can result in component damage holding a lasting charge.
and hazardous conditions.
WARNING
WARNING Use original or manufacturer-approved
Explosion hazard. Keep flames and parts and components for the aerial
sparks away. Do not smoke near bat- platform.
teries.

Rough Terrain Compact Series SKYJACK, Page 19

Engine Powered
157951
Service and Maintenance Inspections Section 1 - Scheduled Maintenance

Muffler and Exhaust Engine

Base Control
Console
Tilt Sensor

Engine Air Filter

Main Power
Disconnect Switch
Radiator
Hydraulic Pump

Fuel Shut-off
Valve
Battery

• Hydraulic Pump
WARNING
-- Ensure there are no loose or missing
parts and there is no visible damage. Beware of hot engine components.
-- Ensure all bolts are properly tightened. Check oil level on dipstick
-- Ensure all fittings and hoses are properly -- Oil level should be in the “safe” zone. Add
tightened and there is no evidence of oil as needed.
hydraulic leakage. • Fuel Shut-off Valve
• Radiator -- Ensure there are no loose or missing
-- Ensure radiator is secure. parts and there is no visible damage.

-- Ensure there are no loose or missing • Engine Air Filter

parts and there is no visible damage. -- Ensure there are no loose or missing
parts and there is no visible damage.
-- Check coolant level and add as
needed.
• Muffler and Exhaust
-- Ensure muffler and exhaust system are
properly secured, with no evidence of
damage.
• Engine Pivot Tray
-- Ensure there are no loose or missing
parts and no visible damage to the engine
pivot tray. Ensure that both tray-securing
bolts are in place.
• Engine Oil Level
-- Maintaining the engine components
is essential to good performance and
service life of the aerial platform.

SKYJACK, Page 20 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Service and Maintenance Inspections

Muffler and Exhaust Engine

Base Control
Console
Tilt Sensor

Engine Air Filter

Main Power
Disconnect Switch
Radiator
Hydraulic Pump

Fuel Shut-off
Valve
Battery

• Fuel Leaks
Failure to detect and correct fuel leaks will
result in an unsafe condition. An explosion or
fuel fire may cause death or serious injury.

DANGER
Engine fuels are combustible. Inspect
the aerial platform in an open, well-ven-
tilated area away from heaters, sparks
and flames. Always have an approved
fire extinguisher within easy reach.

Perform a visual inspection around the following

areas:
• hoses and fittings
• fuel pump
• fuel filter

Rough Terrain Compact Series SKYJACK, Page 21

Engine Powered
157951
Service and Maintenance Inspections Section 1 - Scheduled Maintenance

Gear Type
Hydraulic
Flow Divider
Oil Filter

Oil Level
Gauge

Fuel Level
Main Gauge
Manifold

Hydraulic
Tank Fuel Tank

1.1-4 Hydraulic/Fuel Compartment • Fuel Leaks

-- Ensure compartment latch is secure and Failure to detect and correct fuel leaks will
in proper working order. result in an unsafe condition. An explosion or
fuel fire may cause death or serious injury.
• Hydraulic Tank
-- Ensure hydraulic filler cap is secure.
DANGER
-- Ensure tank shows no visible damage
Engine fuels are combustible. Inspect
and no evidence of hydraulic leakage.
the aerial platform in an open, well-ven-
• Hydraulic Oil tilated area away from heaters, sparks
-- Ensure platform is fully lowered, and then and flames. Always have an approved
visually inspect the sight gauge located fire extinguisher within easy reach.
on the side of the hydraulic oil tank.
Perform a visual inspection around the following
-- The hydraulic oil level should be at or areas:
slightly above the top mark of the sight • fuel tank
glass. • hoses and fittings
• Hydraulic Return Filter
-- Ensure filter element is secure. • Main Manifold
-- Ensure all fittings and hoses are properly
-- Ensure there are no signs of leakage or tightened and there is no evidence of
visible damage. hydraulic leakage.
• Fuel Tank -- Ensure there are no loose wires or
missing fasteners.
IMPORTANT
Before using your aerial platform ensure • Gear Type Flow Divider
there is enough fuel for expected use. -- Ensure there are no loose or missing
parts and there is no visible damage.
-- Ensure fuel filler cap is secure.
-- Ensure tank shows no visible damage
and no evidence of fuel leakage.

SKYJACK, Page 22 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Service and Maintenance Inspections

Manuals
Platform Control
Console

Platform
Railing
Platform
Assembly

1.1-5 Platform Assembly • Manuals

Ensure a copy of operating manual, manual
WARNING of responsibilities and ANSI/CSA certificate
are enclosed in manual storage box.
Ensure that you maintain three points of
contact to mount/dismount platform. -- Check to be sure manual storage box is
present and in good condition.
1. Use the ladder of aerial platform to platform.
-- Ensure manuals are legible and in good
2. Close the gate. condition.
-- Always return manuals to the manual
-- Ensure there are no loose or missing
storage box after use.
parts and there is no visible damage.
• Platform Control Console
-- Ensure all fasteners are securely in
-- Ensure all switches and controller are
place.
returned to neutral and are properly
-- Ensure all railings are properly positioned secured.
and secured.
-- Ensure there are no loose or missing
-- Ensure gate is in good working order. parts and there is no visible damage.

• Lanyard Attachment Anchors WARNING

-- Ensure attachment rings are secure and
no visible damage. Ensure that you maintain three points of
contact to mount/dismount platform.
• AC Outlet on Platform
-- Ensure outlet has no visible damage and 3. Use the ladder to dismount from platform.
free from dirt or obstructions.

Rough Terrain Compact Series SKYJACK, Page 23

Engine Powered
157951
Service and Maintenance Inspections Section 1 - Scheduled Maintenance

Lift Cylinder

Maintenance
Support

Scissor Assembly
Scissor Bumper

Roller

1.1-6 Lifting Mechanism • Rollers

-- Ensure rollers are secure and there is no
1. Raise the platform until there is adequate visible damage.
clearance to swing down the maintenance
support. -- Ensure rollers’ path of travel are free from
dirt and obstructions.
• Maintenance Support • Lift Cylinder(s)
-- Ensure maintenance support is properly -- Ensure each lift cylinder is properly
secured and shows no visible damage. secured, there are no loose or missing
• Scissor Assembly parts and there is no evidence of
-- Ensure scissor assembly shows no visible damage.
damage and no signs of deformation in -- Ensure all fittings and hoses are properly
weldments. tightened and there is no evidence of
-- Ensure all pins are properly secured. hydraulic leakage.

-- Ensure cables and wires are properly 2. Raise the platform until there is adequate
routed and shows no signs of wear and/ clearance to swing up the maintenance
or physical damage. support into storage bracket.

• Scissor Bumpers 3. Fully lower the platform.

-- Ensure bumpers are secure and shows
no sign of visible damage.

SKYJACK, Page 24 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Service and Maintenance Inspections

Overhead View

Steer Cylinder
Base Assembly
Weldment
Splitter Manifold

Wheel/Tire
Assembly
Tie Rod

Emergency Lowering
Access Rod

1.1-7 Base
WARNING
• Base Weldment An over-inflated tire can explode and
-- Ensure there are no visible cracks in may cause death or serious injury.
welds or structure and there are no signs
of deformation. -- Check all tire treads and sidewalls for
cuts, cracks, punctures and unusual
• Wheel/Tire Assembly wear.
The aerial platform is either equipped with
air tires or foam-filled tires. Tire and/or wheel -- Check each wheel for damage and
failure could result in an aerial platform cracked welds.
tipover. Component damage may also result
-- Check each lug nut for proper torque to
if problems are not discovered and repaired
ensure none are loose.
in a timely fashion.
-- Check wheel motor assembly for loose
WARNING or missing parts and signs of visible
damage.
Air filled tires are not permitted on some
models. Refer to Table 2.1. -- Ensure wheels are aligned and true
vertically and horizontally.

Rough Terrain Compact Series SKYJACK, Page 25

Engine Powered
157951
Service and Maintenance Inspections Section 1 - Scheduled Maintenance

Overhead View

Steer Cylinder
Base Assembly
Weldment
Splitter Manifold

Wheel/Tire
Assembly
Tie Rod

Emergency Lowering
Access Rod

To safeguard maximum stability, achieve optimum • Tie Rod

aerial platform handling and minimize tire wear, -- Ensure there are no loose or missing
it is essential to maintain proper pressure in all parts, tie rod end studs are locked and
air-filled tires. there is no visible damage.

-- Check each tire with an air pressure gauge • Emergency Lowering Access Rod
and add air as needed. -- Ensure rod is properly secured and there
is no visible damage.
Refer to Table 2.1 for wheel/tire specifications.
• Ladder
• Steer Cylinder Assembly -- Ensure there are no loose or missing
-- Ensure steer cylinder assembly is properly parts and there is no visible damage.
secured, there are no loose or missing • Outriggers
parts, all fittings and hoses are properly -- Ensure there are no loose or missing
tightened and there is no evidence of parts and there is no visible damage.
hydraulic leakage.
• Splitter Manifold
-- Ensure all fittings and hoses are properly
tightened and there is no evidence of
hydraulic leakage.

SKYJACK, Page 26 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Function Tests

Emergency Stop Button

Platform/Engine/Base
Key Switch
Emergency Main Power
Disconnect Switch

1.2 Function Tests 1.2-2 Base Control Console

Function tests are designed to discover any malfunctions
before aerial platform is put into service. The operator WARNING
must understand and follow step-by-step instructions
to test all aerial platform functions. Ensure that you maintain three points of
contact when using the ladder to mount/
dismount platform.
WARNING
Never use a malfunctioning aerial 1. Use the ladder of aerial platform to access
platform. If malfunctions are discovered, platform.
aerial platform must be tagged and
placed out of service. Repairs to aerial 2. Close the gate.
platform may only be made by a qualified
service technician. 3. On platform control console, pull out “ ”
emergency stop button.
After repairs are completed, operator must perform a
pre-operation inspection and a series of function tests
again before putting aerial platform into service. 4. Select low/high throttle switch to “ ” low
throttle position.
Prior to performing function tests, be sure to read and
understand the Start Operation section of the operating 5. Use the ladder to dismount from platform.
manual.
6. Turn emergency main power disconnect
1.2-1 Test Main Power Disconnect Switch switch to “ ”on position.

1. In engine compartment, turn emergency

main power disconnect switch to “ ” off
position.
Result: Aerial platform functions should not
operate.

Rough Terrain Compact Series SKYJACK, Page 27

Engine Powered
157951
Function Tests Section 1 - Scheduled Maintenance

Emergency Stop
Button

Free-wheeling
Valve
Platform/Engine/Base
Key Switch

Brake Hand
Pump Brake Auto
Emergency Reset Valve
Lowering
Base Control Console Valve
Emergency Main Power
Disconnect Switch
Main Manifold

• Test Platform/Engine/Base Key Switch • Test Platform Raise/Lower Switch

WARNING 1. Select platform/engine/base key switch to

Be aware of overhead obstructions or “ ” base position and raise or lower the

other possible hazards around the aerial platform with platform “ ” raise or “ ”
platform when lifting. lower switch.
Result: Platform raising and lowering
1. Pull out base “ ” emergency stop functions should operate.
button.
2. Insert key into platform/engine/base key • Test Emergency Lowering

switch, select “ ” engine position and 1. Raise the platform.

attempt to start engine.
Result: Engine should not start. 2. Locate holding valve manual override
3. With key inserted into platform/engine/ knob at the base of each lift cylinder.
base key switch, select “ ” base Depress and turn counterclockwise. If
position and attempt to start engine. necessary, use access rod that is located
Result: Engine should start. on the base of the aerial platform.

• Test Emergency Stop 3. On hydraulic/fuel compartment, pull out

and hold emergency lowering valve to
1. Push in base “ ” emergency stop fully lower the platform.
button. Result: The platform should lower.
Result: Engine should shut down and
aerial platform functions should not 4. To restore normal operation, depress and
operate. turn holding valve manual override knobs
clockwise.
2. Pull out base “ ” emergency stop
button and restart engine.

SKYJACK, Page 28 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Function Tests

Enable Trigger Low/High Throttle

Switch Switch
Drive/Lift/Steer
Controller Choke (Dual Fuel)/
Free-wheeling Glow Plug (Diesel)
Lift/Torque/Drive Pushbutton
Valve Switch
Brake Auto
Brake Hand Reset Valve
Pump

Emergency Engine Start

Lowering Pushbutton
Valve
Horn Pushbutton
Emergency Stop
Main Manifold Button

• Test Free-wheeling
WARNING
1. Ensure path of intended motion is clear. Ensure that you maintain three points of
contact when using the ladder to mount/
2. Release the brake manually. dismount platform.

3. Turn free-wheeling valve knob counterclockwise 4. Use the ladder of aerial platform to access
to a fully opened position and attempt to push/ platform.
pull the aerial platform.
Result: Aerial platform should move. 5. Close the gate.

4. Turn free-wheeling valve knob clockwise to a 6. On platform control console, pull out “ ”
fully closed position for normal operation. emergency stop button.

5. Reengage the brake. • Test Emergency Stop

1.2-3 Platform Control Console 1. Ensure engine is running.

1. Ensure base “ ” emergency stop button is 2. Push in “ ” emergency stop button.

pulled out. Result: Engine should shut down and aerial
platform functions should not operate.
2. Ensure emergency main power disconnect
switch is in “ ” on position. • Test Enable Trigger Switch

1. Ensure engine is running.

3. Select platform/engine/base key switch to “
” platform position and remove key.
2. Without activating “ ” enable trigger switch,
attempt to activate any platform function.
Result: All platform functions should not
operate.

Rough Terrain Compact Series SKYJACK, Page 29

Engine Powered
157951
Function Tests Section 1 - Scheduled Maintenance

Enable Trigger Rocker Switch

Switch
Low/High Throttle
Drive/Lift/Steer Switch
Controller
Choke (Dual Fuel)/
Glow Plug (Diesel)
Lift/Torque/Drive Pushbutton
Switch
Emergency Stop
Button
Engine Start
Pushbutton

Horn Pushbutton

• Test Platform Raising/Lowering • Test Steering

WARNING 1. Ensure engine is running.

Be aware of overhead obstructions 2. Press rocker switch on top of controller to

or other possible hazards around the
aerial platform when lifting. “ ” left and “ ” right.
Result: Steer wheels should turn left and
right.
1. Select lift/torque/drive switch to “ ” lift
position.

2. Activate and hold “ ” enable trigger

switch.

3. Push or pull controller handle until desired

height is reached.
Result: Platform raising and lowering
functions should operate.

SKYJACK, Page 30 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Function Tests

Enable Trigger Rocker Switch

Switch
Low/High Throttle
Drive/Lift/Steer Switch
Controller
Choke (Dual Fuel)/
Glow Plug (Diesel)
Lift/Torque/Drive Pushbutton
Switch

Emergency Stop
Button
Engine Start
Pushbutton

Horn Pushbutton

• Test Driving • Test Speed Limit

1. Ensure path of intended motion is clear. WARNING

2. On platform control console, select Be aware of overhead obstructions

or other possible hazards around the
lift/torque/drive switch to “ ” drive aerial platform when lifting.
position.
3. Activate and hold “ ”enable trigger 1. Ensure path of intended motion is clear.
switch.
2. Raise the platform until approximately a
4. Slowly move controller in “ ” forward or height of 7 feet (2 meters) is reached and
attempt to drive forward or reverse.
“ ” reverse direction until aerial platform Result: Aerial platform should move slower
begins to move, and then return handle to than when it is in stowed position.
center position.
Result: Aerial platform should move in
forward or reverse direction, and then
come to a stop.

Rough Terrain Compact Series SKYJACK, Page 31

Engine Powered
157951
Function Tests Section 1 - Scheduled Maintenance

Enable Trigger Rocker Switch

Switch
Low/High Throttle
Drive/Lift/Steer Switch
Controller
Choke (Dual Fuel)/
Glow Plug (Diesel)
Lift/Torque/Drive Pushbutton
Switch
Emergency Stop
Button
Engine Start
Pushbutton

Horn Pushbutton

• Test Brakes
4. Drive aerial platform “ ” forward. Test
WARNING brake again by releasing “ ” enable
Brakes will engage instantly when you trigger switch only.
release the controller handle, causing Result: Aerial platform should come to an
aerial platform to stop immediately. instant and abrupt stop. If aerial platform
does not stop immediately, or if aerial
1. Ensure path of intended motion is clear. platform pulls to one side while stopping,
do not operate aerial platform until brake
adjustments have been checked.
2. Activate and hold “ ” enable trigger
switch. • Test Horn
3. Drive aerial platform “ ” forward. Test
brake by releasing controller handle. 1. Push “ ” horn pushbutton.
Result: Aerial platform should come to Result: Horn should sound.
a stop. If aerial platform pulls to one side
while stopping, do not operate aerial
platform until brake adjustments have
been checked.

SKYJACK, Page 32 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Function Tests

Left-Rear Left-Front

Platform Control
Console

Right-Rear Right-Front

• Te s t H y d r a u l i c O u t r i g g e r s ( I f 7. Drive the aerial platform to maximum

Equipped) speed.
Result: Aerial platform drives at high
1. Ensure aerial platform is parked on a firm speed.
level surface and free from obstructions. WARNING

2. Ensure platform is fully lowered. Be aware of overhead obstructions or

other possible hazards around the aerial
3. Ensure outriggers are fully retracted. platform when lifting or driving.

4. Auto-level (If equipped): 8. Lift platform to 12 feet (measured from the

Use auto-level to extend outriggers. bottom of the tires to the platform surface)
Result: All four outriggers will extend from stowed position.
until they are supporting weight and bring Result: Lift function will operate.
machine to within level.
9. Drive aerial platform at raised height (12
5. Once auto-level is complete, attempt to lift feet).
platform 1 foot and then lower the platform Result: Aerial platform drives at slow
to stowed position. speed.
Result: Platform will lift and lower.
10. Attempt to operate outriggers at raised
6. With platform at stowed position, fully height (12 feet).
retract all outriggers using auto-level. -- Attempt to partially extend Left-Front
Result: All four outriggers will retract until Outrigger (approximately 4”).
they are in the stowed (up) position. Result: Outrigger will not extend.

-- Attempt to partially extend Right-Front

WARNING Outrigger (approximately 4”).
Ensure that there are no personnel or Result: Outrigger will not extend.
obstructions in the path of travel, includ-
ing blind spots.

Rough Terrain Compact Series SKYJACK, Page 33

Engine Powered
157951
Function Tests Section 1 - Scheduled Maintenance

Left-Rear Left-Front

Platform Control
Console

Right-Rear Right-Front

-- Attempt to partially extend Right-Rear -- With Right-Rear Outrigger partially

Outrigger (approximately 4”). extended, attempt to lift the platform.
Result: Outrigger will not extend. Result: Lift function will not operate.

-- Attempt to partially extend Left-Rear -- With Left-Rear Outrigger partially

Outrigger (approximately 4”). extended, attempt to lift the platform.
Result: Outrigger will not extend. Result: Lift function will not operate.

11. Lower the platform to stowed position. 14. Platform at stowed position.
Result: Lower function will operate. -- Extend each outrigger until it raises the
tires up approximately 2”.
12. Raise the platform 1 foot from stowed
position and partially extend Left-Front -- Retract the Left-Front Outrigger until the
Outrigger (approximately 4”). weight is resting on the corresponding
-- Attempt to lift the platform. tire.
Result: Lift function will not operate.
-- Extend the Right-Rear Outrigger until it
-- Attempt to drive the aerial platform. makes contact with ground.
R e s u l t : Drive function will not
operate. -- Attempt to lift the platform 1 foot.
Result: Lift function will not operate.
-- Attempt to lower the platform.
Result: Lower function will operate. 15. Platform at stowed position.
-- Extend each outrigger until it raises the
13. Platform at stowed position. tires up approximately 2”.
-- With Left-Front Outrigger partially
extended, attempt to lift the platform. -- Retract the Right-Front Outrigger
Result: Lift function will not operate. until the weight is resting on the
corresponding tire.
-- With Right-Front Outrigger partially
extended, attempt to lift the platform. -- Extend the Left-Rear Outrigger until it
Result: Lift function will not operate. makes contact with ground.

SKYJACK, Page 34 Rough Terrain Compact Series

Engine Powered
157951
Section 1 - Scheduled Maintenance Function Tests

Left-Rear Left-Front

Platform Control
Console

Right-Rear Right-Front

-- Attempt to lift the platform 1 foot. 18. Extend all four outriggers until all tires are
Result: Lift function will not operate. off the ground and the aerial platform is
levelled.
16. Platform at stowed position.
-- Extend each outrigger until it raises the -- Lift the platform to 12 feet.
tires up approximately 2”. Result: Lift function will operate.

-- Retract the Right-Rear Outrigger -- Lower the platform from raised height
until the weight is resting on the (12 feet).
corresponding tire. Result: Lower function will operate.

-- Extend the Left-Front Outrigger until it WARNING

makes contact with ground.
If any outrigger interlocks fail to oper-
-- Attempt to lift the platform 1 foot. ate in the expected manner, the aerial
Result: Lift function will not operate. platform should be tagged and removed
from operation immediately.
17. Platform at stowed position.
-- Extend each outrigger until it raises the WARNING
tires up approximately 2”.
Repairs to the aerial platform may only
be made by a qualified service techni-
-- Retract the Left-Rear Outrigger until the
cian.
weight is resting on the corresponding
tire.

-- Extend the Right-Front Outrigger until

it makes contact with ground.

-- Attempt to lift the platform 1 foot.

Result: Lift function will not operate.

Rough Terrain Compact Series SKYJACK, Page 35

Engine Powered
157951
 Notes

SKYJACK, Page 36 Rough Terrain Compact Series

Engine Powered
157951
 Section 2
maintenance tables and diagrams
Table of Contents

Tables
2.1 Specifications and Features - ANSI/CSA...........................................................................................................2
2.2 Floor Loading Pressure......................................................................................................................................4
2.3 Maximum Platform Capacities (Evenly Distributed)..........................................................................................5
2.4 Rough Terrain Scissor Fluids.............................................................................................................................6

2
2.5 Torque Specifications.........................................................................................................................................8

Rough Terrain Compact Series SKYJACK, Page 1

Engine Powered
157951
Service and Maintenance Section 2 - Maintenance Tables and Diagrams

Table 2.1 Specifications and Features

Compact RT’s
Model
6826 6832

No Outriggers 6400 lb. 2903 kg 7660 lb. 3475 kg

Weight*

With Outriggers 7500 lb. 3402 kg 8060 lb. 3656 kg

Width 68” 1.73 m 68” 1.73 m

No Outriggers 106.6” 2.71 m 106.6” 2.71 m

Length

With Outriggers 131.4” 3.34 m 131.4” 3.34 m

Platform Size 56” x 99” 1.4 m x 2.5 m 56” x 99” 1.4 m x 2.5 m

Working 32 ft. 9.8 m 38 ft. 11.7 m

Platform Elevated 26 ft. 8m 32 ft. 9.8 m

Height

Platform Lowered 7.8 ft. 2.37 m 8.25 ft. 2.52 m

Drive 26 ft. 7.95 m 32 ft. 9.8 m

Normal Drive 4 mph 6.3 km/h 4 mph 6.3 km/h

Elevated Drive 0.39 mph 0.63 km/h 0.39 mph 0.63 km/h
Speed

Lift (Rated Load) 36 sec 39 sec

Lower (Rated Load) 36 sec 36 sec

Kubota Diesel 3500 (High Throttle) / 2050 (Low Throttle)

Engine
(RPM)

Kubota Dual Fuel 3500 (High Throttle) / 2050 (Low Throttle)

Foam-filled OTR Outrigger - 26 x 12

Tires

Air-filled N/A

Sound Pressure 96 dB(A)

Gradeability (Torque Equivalent To) 50% 40%

RTC T4.2 - 133048AP

* Weights are approximate; refer to serial nameplate for specific weight.

SKYJACK, Page 2 Rough Terrain Compact Series

Engine Powered
157951
Section 2 - Maintenance Tables and Diagrams Service and Maintenance

Floor Loading Pressure

Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):

Foot Print Area = Length x Width Base Area = Length x Width

= πr2

Weight of Aerial Platform + Capacity Weight of Aerial Platform + Capacity

LCP = OUP =
Foot Print Area x 4 (Tires) Base Area

Minimum safe approach distance

(Feet) (Meters)

0 to 300V Avoid contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62

Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72

A 128742AA

Length

Width
Width

Length

Width

Diameter

Length

WARNING
Intermixing tires of different types or using tires of types other than those originally supplied with
this equipment can adversely affect stability. Therefore, replace tires only with the exact original
Skyjack-approved type. Failure to operate with matched approved tires in good condition may
result in death or serious injury.

Rough Terrain Compact Series SKYJACK, Page 3

Engine Powered
157951
Service and Maintenance Section 2 - Maintenance Tables and Diagrams

Table 2.2 Floor Loading Pressure

Total Aerial Platform Total Aerial Platform Load

MODEL Weight Wheel LCP** OUP**

lb. kg lb. kg psi kPa psf kg/m2

min* 6400 2903 2560 1161 152 1046 206 1007

6826
max* 8666 3931 3466 1572 168 1159 280 1364

6826 min* 7286 3305 2914 1322 37 256 235 1146

Outrigger Pads max* 3931 3466 1572 44 305 280 1364

8666
min* 7661 3475 3064 1390 162 1114 247 1205
6832
max* 9189 4168 3675 1667 171 1179 296 1446

6832 min* 8058 3655 3223 1462 41 283 260 1268

Outrigger Pads max* 9189 4168 3675 1667 47 323 296 1446
1014AA-ANSI

* min - Total aerial platform weight with no options

max - aerial platform weight + all options + full capacity
** LCP – Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact with
the floor. The floor covering (tile, carpet, etc.) must be able to withstand more than the indicated values above.
OUP – Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface directly
underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values

NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the
engineer or architect for that particular structure.

SKYJACK, Page 4 Rough Terrain Compact Series

Engine Powered
157951
Section 2 - Maintenance Tables and Diagrams Service and Maintenance

Table 2.3 Maximum Platform Capacities (Evenly Distributed)

Total Machine Weight Extension

MODEL Number of Number of
Capacity Capacity
Occupants Occupants
One Extension
6826 1250 lb. 567 kg 4 300 lb. 136 kg 1
Platform
One Extension
6832 1000 lb. 453.6 kg 4 300 lb. 136 kg 1
Platform
RTC T4.4 - 133048AP

NOTE:
Occupants and materials are not to exceed rated load.
Refer to capacity label for additional information and for models equipped with options.

Rough Terrain Compact Series SKYJACK, Page 5

Engine Powered
157951
Service and Maintenance Section 2 - Maintenance Tables and Diagrams

Table 2.4 Rough Terrain Scissor Fluids

AXLE OIL
*Qty. *Qty.
Axle Type Oil Type Recommended Equivalent Oil
(Liters) (Gallons)
Cushman Front
2.4 0.634 Gear Oil, 80W-90 GL5 -
Dana Front / Rear
Chevron Gear Lubricant Delo ESI 80W-90,
Caltex Gear Lubricant ESI 80W-90,
Cushman Rear 1 0.264 Gear Oil, ESI 80W-90
Caltex RPM Borate EP 80W-90,
Texaco Star Gear Lubricant 80W-90

*All fuel capacity quantities are in standard liter or US gallons (liquid).

**Use distilled water and 50/50 mix of anti-freeze/water.

CENTER DRIVE OIL

*Qty. *Qty.
Center Drive Type Oil Type Recommended Equivalent Oil
(Liters) (Gallons)
Center Drive 1 0.26 Gear Oil, 80W-90 GL5 -

*All fuel capacity quantities are in standard liter or US gallons (liquid).

**Use distilled water and 50/50 mix of anti-freeze/water.

HYDRAULIC OIL
*Qty. *Qty.
Model Oil Type
(Liters) (Gallons)
SJRT-68XX 86.88 22.95
SJRT-7127
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850
SJRT-8831 ATF Dexron III
SJRT-8841
75.71 20
SJRT-8831E
SJRT-8841E
SJRT-9241
67.38 17.8
SJRT-9250

*All fuel capacity quantities are in standard liter or US gallons (liquid).

**Use distilled water and 50/50 mix of anti-freeze/water.

SKYJACK, Page 6 Rough Terrain Compact Series

Engine Powered
157951
Section 2 - Maintenance Tables and Diagrams Service and Maintenance

Table 2.4 Rough Terrain Scissor Fluids (Continued)

ENGINE OIL
*Qty. *Qty. Recommended Equivalent Oil
Engine Type Oil Type, Viscosity
(Liters) (Gallons) (Viscosity - API Service Designation)
Kubota D902 3.9 1.03
Kubota D1105 5.1 1.35 10W30 - API Service Designation CG-4,
Kubota DF972 3.4 0.9 Engine Oil, SAE 10W-30 CF-4, CF, CD, SH.
Nissan A15
3.5 0.98
GM 1.6 10W30 - API Service Designation SF/CC.

*All fuel capacity quantities are in standard liter or US gallons (liquid).

**Use distilled water and 50/50 mix of anti-freeze/water.

ENGINE COOLANT
*Qty. *Qty.
Component Type **Coolant Type
(Liters) (Gallons)
Kubota D902
Kubota D1105 3.1 0.82
Anti-freeze / Water
Kubota DF972
Nissan A15
11.4 3.01
GM 1.6 Extended life anti-freeze / Water

*All fuel capacity quantities are in standard liter or US gallons (liquid).

**Use distilled water and 50/50 mix of anti-freeze/water.

ENGINE FUEL
Tank Diesel Gasoline / Liquid Propane
Model *Qty. *Qty.
Kubota D902 Kubtoa D1105 Kubota DF972 GM 1.6 Nissan A15
(Liters) (Gallons)
SJRT-68xx 86.88 22.95 3 N/A
SJRT-7127 3 N/A
SJRT-7135
80.48 21.26
SJRT-8243
SJRT-8850
N/A 3
SJRT-8831
49.21 13 N/A 3
SJRT-8841
SJRT-9241
64.35 17
SJRT-9250

*All fuel capacity quantities are in standard liter or US gallons (liquid).

**Use distilled water and 50/50 mix of anti-freeze/water.

Rough Terrain Compact Series SKYJACK, Page 7

Engine Powered
157951
Service and Maintenance Section 2 - Maintenance Tables and Diagrams

Table 2.5 Torque Specifications

Hydraulic drive motor castle nut 350 lbl/ft

Directional valve mounting bolts 28-32 lbf.in 3.16 - 3.61 Nm
Wheel mounting bolts 135-145 lbf.ft 183 – 196 Nm
Center drive sprocket mounting bolts 110-115 lbf.ft (242 LOCTITE) 149 – 156 Nm
Hydraulic drive motor mounting bolts 120 lbf.ft (242 LOCTITE) 162 Nm
Positive battery post cable/fuse nut 90 lb-in 10.2 Nm
Cartridge
Size
Torque
08 38 58 10 12 16
Lbf.ft (max) 20 25 35 50
Lbf.in (max) 240 300 420 600
Nm (max) 27.12 33.90 47.46 67.80
Coils
Size
Torque
All coils
Lbf.ft (max) 4 to 5
Lbf.in (max) 48 to 60
Nm (max) 5.42 to 6.78
SAE Plugs
Size
Torque
2 4 5 6 8 10 12 16
Lbf.ft (max) 3 10 15 25 30 35
Lbf.in (max) 36 120 180 300 360 420
Nm (max) 4.07 13.56 20.34 33.90 40.68 47.46
Newton-meter = Nm Pound-force foot = lbf.ft Pound-force inch = lbf.in
60022AD

SKYJACK, Page 8 Rough Terrain Compact Series

Engine Powered
157951
 Section 3
System component identification and schematics

Table of Contents
Charts
3.1. Hydraulic Symbol Chart................................................................................................................................. 3
3.2. Electrical Symbol Chart................................................................................................................................. 4

Parts List
3.3. Hydraulic Schematic Parts List...................................................................................................................... 5
3.4. Electrical Parts List ........................................................................................................................................ 7

Diagrams and Schematics

3.5. Hydraulic Schematic.................................................................................................................................... 13
3.6. Hydraulic Manifolds And Ports Identification............................................................................................... 14
3.7. Control Box Diagram (with All Options)....................................................................................................... 16
3.8. Outrigger/Hydraulic Generator Control Console Wiring Diagram.............................................................. 17
3.9. Scissor Arm Control Cable Wiring Diagram................................................................................................ 18

3
3.10. Main Manifold Harness Wiring Diagram...................................................................................................... 19
3.11. Kubota Engine Wiring Diagram (Dual Fuel System)................................................................................... 20
3.12. Kubota Engine Wiring Diagram (Diesel Fuel System)................................................................................. 21
3.13. Outrigger Harness Wiring Diagram............................................................................................................. 22
3.14. Hydraulic Generator Electrical Panel Assembly.......................................................................................... 23
3.15. Electrical Panel Wiring Diagram.................................................................................................................. 25
3.16. Electrical Schematic (No Option with Kubota Dual Fuel Engine)............................................................... 26
3.17. Electrical Schematic (All Option with Kubota Dual Fuel Engine)............................................................... 27
3.18. Electrical Schematic (All Option with Kubota Diesel Engine)..................................................................... 28

Rough Terrain Compact Series SKYJACK, Page 1

Engine Powered
157951
 Notes

SKYJACK, Page 2 Rough Terrain Compact Series

Engine Powered
157951
Section 3 - System Component Identification and Schematics Service and Maintenance

3.1. Hydraulic Symbol Chart

VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALV VELOCITY FUSE
PUMP

ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER

HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER

HYDRAULIC PRESSURE DOUBLE ACTING

FILTER WITH REDUCING PRESSURE
DOUBLE
BYPASS VALVE SWITCH
RODDED

ELECTRIC MOTION SPRING APPLIED

MOTOR FIXED ORIFICE CONTROL VALVE HYDRAULIC
RELEASED
BRAKE

ADJUSTABLE FLOW DIVIDER BRAKE

ENGINE FLOW CONTROL COMBINER CYLINDER

FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP

THREE POSITION BI DIRECTIONAL

FOUR WAY HYDRAULIC
OIL COOLER VALVE COIL
PROPORTIONAL MOTOR

SERIES TWO POSITION THREE POSITION

PARALLEL TWO WAY FOUR WAY
HYDRAULIC TWO POSITION CLOSED CENTER
NORMALLY
MOTOR THREE WAY OPEN PORT
CLOSED

TWO POSITION THREE POSITION THREE POSITION

TWO WAY TWO POSITION FOUR WAY FOUR WAY
NORMALLY THREE WAY CLOSED CENTER PROPORTIONAL
OPEN CLOSED PORT

VARIABLE
PRESSURE PILOT LINES D DISPLACEMENT
MAIN LINES S
TRANSDUCER HYDRAULIC MOTOR

UICK
SERVO DISCONNECT

Rough Terrain Compact Series SKYJACK, Page 3

Engine Powered
157951
Service and Maintenance Section 3 - System Component Identification and Schematics

3.2. Electrical Symbol Chart

ANGLE
WIRE CROSSING HOURMETER KEY SWITCH
TRANSDUCER

WIRES JOINED LIGHT FOOT SWITCH PRESSURE

TRANSDUCER

HYDRAULIC LIMIT SWITCH

BATTERY TOGGLE SWITCH
VALVE COIL N.O.

PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON N.O. HELD
VALVE COIL CLOSED

LIMIT SWITCH
ELECTRIC
FUSE ROTARY SWITCH N.C.
MOTOR

CIRCUIT LIMIT SWITCH

HORN LIMIT SWITCH
BREAKER N.C. HELD OPEN

BATTERY SILICON
EMERGENCY CAM OPERATED
CHARGE CONTROLLED
STOP BUTTON LIMIT SWITCH
INDICATOR RECTIFIER

PROXIMITY
CAPACITOR RESISTOR TILT SWITCH
SWITCH

SINGLE POLE
PNP
POTENTIOMETER LEVEL SENSOR SINGLE THROWN
TRANSISTOR
RELAY

SINGLE POLE DOUBLE POLE DOUBLE POLE

DOUBLE THROW NPN
DOUBLE THROW SINGLE THROW
RELAY TRANSISTOR
RELAY RELAY

TRIPLE POLE PRESSURE/

DOUBLE THROW DIODE TRANSISTOR VACUUM
RELAY SWITCH

TEMPERATURE
SWITCH

SKYJACK, Page 4 Rough Terrain Compact Series

Engine Powered
157951
Section 3 - System Component Identification and Schematics Service and Maintenance

3.3. Hydraulic Schematic Parts List

Index Skyjack
Qty. Description
No. Part No.

C1 120989 1 CYLINDER, Lift (Lower)

C2 120989 1 CYLINDER, Lift (Upper)
C7 135896 1 CYLINDER, Steer
C8 107752 1 CYLINDER, Cushion
C9 132694 1 CYLINDER, Outrigger (Front left)
C10 132694 1 CYLINDER, Outrigger (Front right)
C11 132694 1 CYLINDER, Outrigger (Rear right)
C12 132694 1 CYLINDER, Outrigger (Rear left)
CB1 137181 1 VALVE, Counterbalance (Main)
CB2 137181 1 VALVE, Counterbalance (Parallel)
CV1 104624 1 VALVE, Check
CV2 104624 1 VALVE, Check
CV3 104624 1 VALVE, Pilot check
CV4 104624 1 VALVE, Pilot check
CV5 104624 1 VALVE, Pilot check
CV6 104624 1 VALVE, Pilot check
CV7 104115 1 VALVE, Pilot check
CV8 104115 1 VALVE, Pilot check
CV9 104115 1 VALVE, Pilot check
CV10 104115 1 VALVE, Pilot check
F1 136405 1 FILTER ASSEMBLY
FD1 137185 1 VALVE, Flow divider
HP2 110652 1 PUMP, Brake hand
2H-13 103655 1 VALVE, Control (Lowering)
2H-13-1 107269 1 VALVE, Holding (Lower cylinder)
2H-13-2 107269 1 VALVE, Holding (Upper cylinder)
2H-17A 114365 1 VALVE, Control (Large pump dump)
2H-17C 103655 1 VALVE, Holding (Outrigger)
2H-18B 103656 1 VALVE, Control (Small pump dump)
2H-20B 111937 1 VALVE, Control (High speed)
2H-86D 103655 1 VALVE, Control (Hydraulic generator)
3H-14A 106273 1 VALVE, Control (Lift)
3H-30 103623 1 VALVE, Control (Brake)
4H-15A 139256 1 VALVE, Control (Reverse drive)
4H-15B 128318 1 VALVE, Control (Parallel reverse drive)
4H-16A 139256 1 VALVE, Control (Forward drive)
4H-16B 128318 1 VALVE, Control (Parallel forward drive)

Parts list continued on following page.

Rough Terrain Compact Series SKYJACK, Page 5

Engine Powered
157951
Service and Maintenance Section 3 - System Component Identification and Schematics

3.3. Hydraulic Schematic Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.

Parts list continued from previous page.

4H-20A 139351 1 VALVE, Control (Series/Parallel)

4H-23 153336 1 VALVE, Control (Right steer)
4H-24 153336 1 VALVE, Control (Left steer)
4H-71 153336 1 VALVE, Control (Front left outrigger retract)
4H-72 153336 1 VALVE, Control (Front right outrigger retract)
4H-73 153336 1 VALVE, Control (Rear right outrigger retract)
4H-74 153336 1 VALVE, Control (Rear left outrigger retract)
4H-75 153336 1 VALVE, Control (Front left outrigger extend)
4H-76 153336 1 VALVE, Control (Extend outrigger right front)
4H-77 153336 1 VALVE, Control (Extend outrigger right rear)
4H-78 153336 1 VALVE, Control (Extend outrigger left rear)
MI 137479 1 MOTOR (Front left)
M2 137479 1 MOTOR (Front right)
M3 137480 1 MOTOR (Rear right)
M4 137480 1 MOTOR (Rear left)
MB1 137125 1 BLOCK, Manifold (Main)
MB2 139450 1 BLOCK, Manifold (Splitter)
MB3 106688 BLOCK, Manifold (Lower holding valve)
MB4 108778 1 BLOCK, Manifold (Upper holding valve)
MB5 139830 1 BLOCK, Manifold (Sandwich)
MB6 139450 1 BLOCK, Manifold (Splitter)
MB8 111970 1 BLOCK, Manifold (Outrigger)
MB9 146109 1 BLOCK, Manifold (Hydraulic generator)
O1 105281 1 ORIFICE (0.067” diameter)
O2 137510 AR ORIFICE, Lowering (0.106” diameter) (Model 6826RT)
137509 AR ORIFICE, Lowering (0.089” diameter) (Model 6832RT)
O3 137510 AR ORIFICE, Lowering (0.106” diameter) (Model 6826RT)
137509 AR ORIFICE, Lowering (0.089” diameter) (Model 6832RT)
O4 137508 2 ORIFICE, Brake (0.028” diameter)
P1 114201 1 PUMP, Dual hydraulic (0.671/ 0.366)
R1 104534 1 VALVE, Relief (System)
R2 104534 1 VALVE, Relief (Lift)
R3 106557 1 VALVE, Relief (Lift cylinder)
R4 106557 1 VALVE, Relief (Lift cylinder)
R5 104534 1 VALVE, Relief (Drive)
V1 107271 1 VALVE, Emergency lowering
V2 137182 1 VALVE, Freewheel
V6 113752 1 VALVE, Brake auto reset

SKYJACK, Page 6 Rough Terrain Compact Series

Engine Powered
157951
Section 3 - System Component Identification and Schematics Service and Maintenance

3.4. Electrical Parts List

SUPPLY (B+) (Common)

CONTROL (B+) GROUND (B-)

NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT

Index Skyjack
Qty. Description
No. Part No.

8CCR 127035 1 ENABLE RELAY

9CR2 127131 1 RELAY, 12 Volt (Outrigger enable)
9CR3 127131 1 RELAY, 12 Volt (Outrigger enable proof)
10BCR 127035 1 RELAY, 12 Volt (40 Amp) (main power)
10CR1 127035 1 RELAY, 12 Volt (40 Amp)
10CR2 127035 1 RELAY, 12 Volt (40 Amp)
15CR 127035 1 RELAY, 12 Volt (40 Amp) (Reverse drive)
16CR 127035 1 RELAY, 12 Volt (40 Amp) (Forward drive)
17CR 127035 1 RELAY, 12 Volt (40 Amp) (Small pump)
17DCR 127131 1 RELAY, 12 Volt (Outrigger lift disable)
19CR 127035 1 RELAY, 12 Volt (40 Amp) (Large pump)
20CR 127035 1 RELAY, 12 Volt (40 Amp) (Series/Parallel drive)
20ACR1 127035 1 RELAY, 12 Volt (40 Amp) (Series/Parallel)
20ACR2 127035 1 RELAY, 12 Volt (40 Amp) (Series/Parallel)
28ACR1 127035 1 RELAY, 12 Volt (40 Amp) (Small pump dump enable)
28ACR2 127035 1 RELAY, 12 Volt (40 Amp) (Large pump dump enable)
31CR 127035 1 RELAY, 12 Volt (40 Amp) (Glow plug)
32ACR 127035 1 CONTACTOR, Engine start
32CR1 127035 1 RELAY, 12 Volt (40 Amp)
32CR2 127035 1 RELAY, 12 Volt (40 Amp) (Engine start)

Parts list continued on the following page.

Rough Terrain Compact Series SKYJACK, Page 7

Engine Powered
157951
Service and Maintenance Section 3 - System Component Identification and Schematics

3.4. Electrical Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.

Parts list continued from the previous page.

33CR 127035 1 RELAY, Power on-demand

34ACR 127035 1 RELAY, 12 Volt 40 Amp (Throttle)
35ACR 127035 1 RELAY, 12 Volt 40 Amp (Throttle enable)
35CR 127035 1 RELAY, 12 Volt 40 Amp (Elevation/High speed cutout)
61CR 127131 1 RELAY, 12 Volt 40 Amp (Outrigger drive enable)
65CR 127131 1 RELAY, 12 Volt (Outrigger lift enable)
86ACR 127035 1 RELAY, 12 Volt 40 Amp (Hydraulic generator stop)
86BCR 127035 1 RELAY, 12 Volt 40 Amp (Hydraulic generator latching)
86CCR 127035 1 RELAY, 12 Volt 40 Amp (Hydraulic generator)
2G-11 (Ref.) 1 SOLENOID, Gas shutoff (Kubota Dual Fuel Engine)
B1 103295 1 BATTERY, 12 Volt (Wet)
BP-29 103056 1 BEEPER (7.5 - 16 VDC)
CB1 137919 1 CIRCUIT BREAKER (25 Amp)
CB3 137919 1 CIRCUIT BREAKER (25 Amp)
CPS1 136172 1 SENSOR, Cranshaft position
CRD1 137355 1 CONTROL CABLE ASSEMBLY (Control console)
CRD2 137356 1 CONTROL CABLE ASSEMBLY (Scissor arm) (Model 6826RT)
137363 1 CONTROL CABLE ASSEMBLY (Scissor arm) (Model 6832RT)
CRD3 137354 1 CONTROL CABLE ASSEMBLY (Electrical panel)
CS-31A 103007 1 Solenoid, Choke
DXX 102921 AR DIODE
EGP1 KUBOTA 1 PLUG, Engine glow
F1 128595 1 FUSE (300 Amp)
F4 138091 1 FUSE (125 Amp) (Electrical inverter option)
FL-22 121476 1 FLASHING LIGHT
FL-29 103743 1 FLASHER
FP 136119 1 PUMP, Electric fuel
GPL1 133133 1 LIGHT, Glow plug indicator
GPT1 137868 1 TIMER, Glow plug
H1 146652 1 HORN, 12 Volt
HTS-34C 103007 1 Solenoid, High throttle
ICM1 136121 1 MODULE, Igniter control
IG 137857 1 ALTERNATOR (Kubota DF902)
136101 1 ALTERNATOR (Kubota DF972)
IGC1 136106 1 COIL, Ignition
IGC2 136106 1 COIL, Ignition
LED-1 137785 1 LIGHT, Power on
LED-2 137785 1 LIGHT, Power on (Base controls)
LS5 122010 1 LIMIT SWITCH (High drive cutout/tilt override)
LS61 138060 1 LIMIT SWITCH (Front left outrigger up)

Parts list continued on the following page.

SKYJACK, Page 8 Rough Terrain Compact Series

Engine Powered
157951
Section 3 - System Component Identification and Schematics Service and Maintenance

3.4. Electrical Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.

Parts list continued from the previous page.

LS62 138060 1 LIMIT SWITCH (Front right outrigger retracted)
LS63 138060 1 LIMIT SWITCH (Rear right outrigger retracted)
LS64 138060 1 LIMIT SWITCH (Rear left outrigger retracted)
LS65 138059 1 LIMIT SWITCH (Front left outrigger extended)
LS66 138059 1 LIMIT SWITCH (Front right outrigger extended)
LS67 138059 1 LIMIT SWITCH (Rear right outrigger extended)
LS68 138059 1 LIMIT SWITCH (Rear left outrigger extended)
OCM1 132804 1 MODULE, Outrigger auto-level control
OPS1 102838 1 SWITCH, Oil pressure
S1 119726 1 SWITCH, Main power disconnect
S2 102853 1 BLOCK, N.O. contact (Up/down)
S3 - 1 SWITCH ASSEMBLY (Lift/Drive low/Drive)
137793 1 • HEAD, Switch selector (3-Way)
137788 1 • SWITCH ASSEMBLY (Base)
137783 3 • • BLOCK, N.C. Contact
137782 4 • • BLOCK, N.O. Contact
137781 1 • • LATCH
S4 - 1 SWITCH ASSEMBLY (Emergency stop)
137795 1 • SWITCH HEAD, Emergency Stop (Red)
137791 1 • SWITCH ASSEMBLY (Base)
137785 1 • • SWITCH, LED block (Red)
137783 2 • • BLOCK, N.C. Contact
137781 1 • • LATCH
S6 137790 1 SWITCH BASE ASSEMBLY (NC/LED, Red) (Base controls)
137795 1 SWITCH ASSEMBLY (Emergency stop)
S7 132537 1 CONTROLLER ASSEMBLY (Drive/steer )
S7-1 122869 1 • SWITCH W/ACTUATOR, 2nd Speed
S7-2 122877 1 • SWITCH, Right steer
S7-3 122877 1 • SWITCH, Left steer
S7-4 122869 1 • SWITCH W/ACTUATOR, Reverse drive
S7-5 122869 1 • SWITCH W/ACTUATOR, Forward drive
S7-6 122869 1 • SWITCH W/ACTUATOR, 3rd Speed
S7-7 122872 1 • SWITCH, Joystick enable
S8 - 1 SWITCH ASSEMBLY (Horn)
137792 1 • SWITCH HEAD, Pushbutton (Black)
137786 1 • SWITCH ASSEMBLY (Base)
137782 1 • • BLOCK, N.O. Spring contact
137781 1 • • LATCH
S9A 102853 1 SWITCH, Outrigger Enable
S9B 127132 1 SWITCH, Outrigger enable
S10 133762 1 BLOCK, N.O. Contact (Platform/Idle/Base) (Base controls)

Parts list continued on the following page.

Rough Terrain Compact Series SKYJACK, Page 9

Engine Powered
157951
Service and Maintenance Section 3 - System Component Identification and Schematics

3.4. Electrical Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.

Parts list continued from the previous page.

S14 - 1 SWITCH ASSEMBLY (Low/High throttle select)
137794 1 • HEAD, Switch Selector (2-Way)
137786 1 • SWITCH ASSEMBLY (Base)
137782 1 • • BLOCK, N.O. Spring contact
137781 1 • • LATCH
S15 - 1 SWITCH ASSEMBLY (Start)
137792 1 • SWITCH HEAD, Pushbutton (Black)
137786 1 • SWITCH ASSEMBLY (Base)
137782 1 • • BLOCK, N.O. Spring contact
137781 1 • • LATCH
S20 102853 1 SWITCH, Toggle (Front left outrigger up/down)
S20A 127132 1 SWITCH, Front left outrigger rocker
S21 102853 1 SWITCH, Toggle (Front right outrigger up/down)
S21A 127132 1 SWITCH, Front right outrigger rocker
S22 102853 1 SWITCH, Toggle (Rear right outrigger up/down)
S22A 127132 1 SWITCH, Rear right outrigger rocker
S23 102853 1 SWITCH, Toggle (Rear left outrigger up/down)
S23A 127132 1 SWITCH, Rear left outrigger rocker
S24 102853 1 SWITCH, Auto-level outrigger
S31 102692 1 SWITCH, Engine glow plug
S32 102692 1 SWITCH, Engine start pushbutton
S33 115747 1 SWITCH, Fuel select
TPS1 113400 1 SWITCH, Engine temperature
TS1 146661 1 TILT SWITCH
TT 103336 1 HOUR METER
2H-13 103613 1 COIL, 12 Volt (Lowering valve)
2H-13-1 103613 1 COIL, 12 Volt (Lower lift cylinder holding valve)
2H-13-2 103613 1 COIL, 12 Volt (Upper lift cylinder holding valve)
2H-17A 106272 1 COIL, 12 Volt (Large pump dump valve)
2H-17C 106272 1 COIL, 12 Volt (Holding outrigger valve)
2H-18B 103613 1 COIL, 12 Volt (Small pump dump valve)
2H-86D 103613 1 COIL, 12 Volt (Hydraulic generator)
2P-50-1 125793 1 SOLENOID, Propane lockoff valve, vaporizer (Kubota Dual Fuel Engine)
3H-14A 106272 1 COIL, 12 Volt (Lift valve)
3H-30 103613 1 COIL, 12 Volt (Brake valve)
4H-15A 128321 1 COIL, 12 Volt (Reverse drive valve)
4H-15B 128321 1 COIL, 12 Volt (Parallel reverse drive valve)
4H-16A 128321 1 COIL, 12 Volt (Forward drive valve)
4H-16B 128321 1 COIL, 12 Volt (Parallel forward drive valve)
4H-20A 137513 1 COIL, 12 Volt (Series/Parallel drive)
4H-23 128321 1 COIL, 12 Volt (Right steer valve)

Parts list continued on the following page.

SKYJACK, Page 10 Rough Terrain Compact Series

Engine Powered
157951
Section 3 - System Component Identification and Schematics Service and Maintenance

3.4. Electrical Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.

Parts list continued from the previous page.

4H-24 128321 1 COIL, 12 Volt (Left steer valve)
4H-71 128321 1 COIL, 12 Volt (Front left outrigger retract)
4H-72 128321 1 COIL, 12 Volt (Front right outrigger retract)
4H-73 128321 1 COIL, 12 Volt (Rear right outrigger retract)
4H-74 128321 1 COIL, 12 Volt (Rear left outrigger retract)
4H-75 128321 1 COIL, 12 Volt (Front left outrigger extend)
4H-76 128321 1 COIL, 12 Volt (Front right outrigger extend)
4H-77 128321 1 COIL, 12 Volt (Rear right outrigger extend)
4H-78 128321 1 COIL, 12 Volt (Rear left outrigger extend)

Rough Terrain Compact Series SKYJACK, Page 11

Engine Powered
157951
 Notes

SKYJACK, Page 12 Rough Terrain Compact Series

Engine Powered
157951
 3.5. Hydraulic Schematic
A B C D E F G H

M2
FRONT
RIGHT

V
WHEELMOTOR
CASE DRAIN
C2 M3
UPPER REAR
LIFT RIGHT
CYLINDER WHEELMOTOR
6826/6832
M1
O1 FRONT
Ø0.067 LEFT CASE DRAIN
WHEELMOTOR M4
REAR
R4 2H-13-2 (ANSI/CSA) LEFT
PT1 RELIEF 2H-13B-2 (CE) WHEELMOTOR
PRESSURE VALVE HOLDING
OVERLOAD VALVE SPLITTER
CV6
TRANSDUCER MANIFOLD
OPTION (ANSI/CSA) MANIFOLD BLOCK MB6
C1
STANDARD (CE) MB4
LOWER
CV5
LIFT
CYLINDER R5
6826/6832 DRIVE
CV4 RELIEF
O1
Ø0.067 VALVE
CHECK
CV3 VALVES

R3
2H-13-1 (ANSI/CSA)
2H-13B-1 (CE) W
RELIEF HOLDING C7
VALVE VALVE STEER CYLINDER CYLINDER CYLINDER CYLINDER
CYLINDER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
04 LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
MANIFOLD BLOCK STEERING C9 C10 C11 C12
MB3 ORIFICE
Ø0.055 FD1 VALVE VALVE VALVE VALVE
FLOW CUSHION CHECK CHECK CHECK CHECK
DIVIDER CYLINDER CV7 CV8 CV9 CV10
03 C8
P-A LOWERING
HYDRAULIC ORIFICE
DISCONNECT Ø0.106 6826RT
LIFT STEER-A STEER-B P-C BRAKE FD-A FD-B FD-C M-A M-B M-C M-D
Ø0.089 6832RT

P-B
AUXILIARY
PRESSURE PORT
V1
MB9 HYD 2H-86D EMERGENCY S5
HP2
HAND V2
GENERATOR HYDRAULIC LOWERING 4H-24 PUMP FREEWHEEL
PULL LEFT STEER SANDWICH
MANIFOLD GENERATOR VALVE
VALVE
MANIFOLD
A B VALVE
BLOCK VALVE S10

HYDRAULIC
MB5
2H-20B
HIGH SPEED
VALVE
EXTEND
VALVE
EXTEND
VALVE
EXTEND
VALVE
EXTEND
X
S5
GENERATOR 4H-23
P T VALVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
GM1 GENERATOR OPTION S3 RIGHT STEER S9
LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
2H-13 (ANSI/CSA) 4H-75 4H-76 4H-77 4H-78
MOTOR WITH 2H-13B (CE)
VALVE
V6
4H-16B P A P A P A P A
R2 A B A B PARALLEL
ADJUSTABLE LIFT
LOWERING AUTO
FORWARD T B T B T B T B
VALVE RESET
FLOW CONTROL RELIEF VALVE
DRIVE
VALVE VALVE
P T S9 P T
S8 S8
4H-15B
4H-16A 4H-15A
PARALLEL VALVE VALVE VALVE VALVE
FORWARD REVERSE VALVE
REVERSE RETRACT RETRACT RETRACT RETRACT
DRIVE DRIVE HOLDING
S1 DRIVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
S4 VALVE VALVE OUTRIGGER
2H-17A (ANSI/CSA) VALVE LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR
3H-14A 2H-17C
2H-17B (CE) 4H-71 4H-72 4H-73 4H-74
LIFT S6
LARGE
CV2 VALVE 3H-30
PUMP DUMP
VALVE CHECK BRAKE
VALVE VALVE
S7 CB2
CV1 4H-20A PARALLEL
02 COUNTERBALANCE
CHECK R1 SERIES/PARALLEL
LOWERING VALVE
VALVE SYSTEM VALVE
ORIFICE 04
RELIEF Ø0.106 6826RT BRAKE
VALVE Ø0.089 6832RT ORIFICE
Ø0.028
CB1
MAIN T-A Y
COUNTERBALANCE
S2 VALVE MB8 OUTRIGGER MANIFOLD BLOCK
2H-18B (ANSI/CSA)
2H-18C (CE)
SMALL
PUMP DUMP
VALVE
T-B
AUXILIARY
TANK PORT

LRG SM TANK DRAIN MB1 68XXRT MAIN MANIFOLD

PUMP PUMP

F1
LARGE SMALL
FILTER
PUMP PUMP
ENGINE

Z
P1
PUMP

RESERVOIR

M137360AI

Rough Terrain Compact Series SKYJACK, Page 13

Engine Powered
157951
 3.6. Hydraulic Manifolds And Ports Identification
A B C D E F G H

CB1 S9
MAIN 4H-15B
COUNTERBALANCE PARALLEL
VALVE REVERSE V
DRIVE
S7 VALVE
4H-20A
SERIES/PARALLEL
VALVE

S8 S8
4H-16A 4H-15A
FORWARD REVERSE CB2
PARALLEL S9
DRIVE DRIVE
VALVE VALVE COUNTERBALANCE 4H-16B W
VALVE PARALLEL
FORWARD
TO DRIVE
BRAKE VALVE
O4
BRAKE S10
S6 ORIFICE 2H-20B
3H-30D HIGH
BRAKE SPEED
VALVE VALVE
TO
LARGE S3
PUMP 2H-13(ANSI/CSA)
2H13B(CE) X
S5 LOWERING
4H-24 S1
V2 VALVE
LEFTSTEER 2H-17A (ANSI/CSA)
FREEWHEEL
VALVE 2H17B (CE)
VALVE
LARGE
CV2 PUMP DUMP
HP2 CHECK VALVE
HAND VALVE
PUMP
R2
TO TO TO LIFT
V6 SMALL STEER LIFT RELIEF
S2
AUTO PUMP CYLINDER CYLINDER VALVE
2H-18B (ANSI/CSA)
RESET 2H18C (CE)
VALVE SMALL Y
PUMP DUMP
VALVE

TO TO
TANK DRAIN
CV1
V1 R1 S4
S5 CHECK
EMERGENCY SYSTEM 3H-14A
4H-23 VALVE
LOWERING RELIEF LIFT
RIGHT STEER
PULL VALVE VALVE Z
VALVE
VALVE
MAIN MANIFOLD

M138189AE_3

SKYJACK, Page 14 Rough Terrain Compact Series

Engine Powered
157951
 3.6. Hydraulic Manifolds And Ports Identification (Continued)
A B C D E F G H

4H-74A
4H-71A
OUTRIGGER
OUTRIGGER
LEFT REAR
4H-72A LEFT FRONT
OUTRIGGER RETRACT
RETRACT V
RIGHT FRONT
RETRACT
4H-78A
R5 OUTRIGGER
DRIVE LEFT REAR
RELIEF EXTEND
DRIVE

CV3 4H-73A W
CHECK
OUTRIGGER
VALVE
RIGHT REAR
RETRACT 4H-75A
OUTRIGGER
LEFT FRONT
EXTEND 2H-17C
OUTRIGGER
4H-76A HOLDING
CV5
4H-77A OUTRIGGER VALVE
CHECK
VALVE OUTRIGGER RIGHT FRONT
RIGHT REAR EXTEND X
EXTEND

CV4
CHECK
VALVE

CV6
CHECK
VALVE

SPLITTER MANIFOLD Z
OUTRIGGER
OUTRIGGER MANIFOLD CYLINDER

M138075AB_1 M138045AB_1

Rough Terrain Compact Series SKYJACK, Page 15

Engine Powered
157951
 3.7. Control Box Diagram (with All Options)
A B C D E F G H

S3 - LIFT/DRIVE SELECTOR
BOTTOM SECTION S15 - START S8 - HORN
08
20

NO
S3 - LIFT/DRIVE SELECTOR 08
3 4 V
MIDDLE SECTION 8B 8A
8A

NC
A 8B
15 1 2

NC
1 2 08 08 08
08

NO

NO

NO
09 08 32 08
13 3 4 3 4 49 3 4

NO
A
3 4

S3 - LIFT/DRIVE SELECTOR
TOP SECTION
16 B S14 - THROTTLE S13 - CHOKE/GLOW S4 - EMERGENCY STOP
07 08
W

NC
1 2 08

NC
07
1 2
14 02

NO
B
3 4 60 LED-1 02

X2
X1
08 08 05 10
34 08

NO

NO

NC
31 08 05 10
3 4 3 4 1 2

X
00
RST1

BACK VIEW
MALE

(15) BLUE RED BLACK WHITE

12
CONTROL BOX HARNESS PIN # - FUNCTION JOYSTICK HARNESS

24
(14) BLACK ORANGE GREEN (60)

11

23
24 BLUE/BLACK PIN 1 - LEFT 24 WHITE/RED (13) ORANGE GREEN (49)
Y

10

22
08 BLUE PIN 2 - JOYSTICK VS+ 08 WHITE/BLACK (10) BLUE RED GREEN WHITE (34)

21
9
(10) BLUE WHITE GREEN BLACK (32)

20
8
23 BLACK/WHITE PIN 3 - RIGHT 23 WHITE (09) ORANGE RED RED WHITE (31)

19
7
B RED PIN 4 - FORWARD/UP B YELLOW (08) BLACK RED BLUE BLACK (24)

18
6
(07) RED GREEN BLACK WHITE (23)
08B BROWN/RED PIN 5 - STEERING VS+ 08B WHITE/GREEN

17
5
(07) RED BLACK WHITE RED (20)

16
4
A PURPLE/WHITE PIN 6 - REVERSE/DOWN A GREY (05) WHITE BLACK RED ORANGE BLACK (19)

15
3
02

8B
8A

19 ORANGE/BLACK PIN 7 - 2nd SPEED 19 BROWN (05) WHITE RED RED BLACK (18)

14
2
(02) WHITE WHITE BLACK (16)
8A BLUE PIN 8 - ENABLE VS+ 8A WHITE/BLUE

13
1
02

8B
8A

18 RED/BLACK PIN 9 - 3rd SPEED 18 RED/BLACK GROUND - GREEN BLACK WHITE

JOYSTICK HARNESS REFERENCE

MALE QDC - 2nd/3rd SPD V+ 8B PURPLE CRD1
FEMALE QDC - ENABLE VS+ 8A WHITE/BLUE Z
MALE QDC - GROUND 02 WHITE

M137799AD

SKYJACK, Page 16 Rough Terrain Compact Series

Engine Powered
157951
 3.8. Outrigger/Hydraulic Generator Control Console Wiring Diagram
A B C D E F G H

09
86

85
1
2
3
TO HYDRAULIC GENERATOR SWITCH
PIN 1 - 86 WHITE
PIN 2 - 09 BLACK W
TO AUTO OUTRIGGER SWITCH
PIN 3 - 85 GREEN
PIN 1 - 79 GREEN
PIN 2 - 35D PURPLE/WHITE

35D
79
70
PIN 3 - 70 GREEN/BLACK

1
3
2
35D

35C
TO OUTRIGGER ENABLE SWITCH 35D 70A

1
3
2
PIN 1 - 35D PURPLE/WHITE

35C
35D

35D
02
PIN 2 - 35C x 3 (WHITE/BLACK, TO OUTRIGGER LIGHT
BLUE/WHITE & GREEN/WHITE) 70A RED/WHITE
PIN 3 - 35D PURPLE/WHITE 02 WHITE X

TO ELECTRIC PANEL
86 WHITE
HYDRAULIC GENERATOR CONTROL CABLE 09 BLACK
85 GREEN

1 2 3

4 5 6

7 8 9

10 11 12

13 14 15

OUTRIGGER CONTROL CABLE

TO ELECTRIC PANEL
PIN 1 - 02 WHITE PIN 9 - 75 ORANGE/BLACK
Z
PIN 2 - 35C WHITE/BLACK PIN 10 - 76 RED/BLACK
PIN 3 - 70 GREEN/BLACK PIN 11 - 77 BLUE/BLACK
PIN 4 - 70A RED/WHITE PIN 12 - 78 BLACK/WHITE
PIN 5 - 71 ORANGE PIN 13 - 79 GREEN
PIN 6 - 72 RED PIN 14 - 35C BLUE/WHITE M129301AB

PIN 7 - 73 BLUE PIN 15 - 35C GREEN/WHITE

Rough Terrain Compact Series PIN 8 - 74 BLACK SKYJACK, Page 17
Engine Powered
157951
 3.9. Scissor Arm Control Cable Wiring Diagram
A B C D E F G H

BACK VIEW V

(15) BLUE RED BLACK WHITE

12

24
(14) BLACK ORANGE GREEN (60)

11

23
(13) ORANGE GREEN (49)

10

22
(10) BLUE RED GREEN WHITE (34)

21
9
(10) BLUE WHITE GREEN BLACK (32)

20
8
(09) ORANGE RED RED WHITE (31)

19
7
(08) BLACK RED BLUE BLACK (24)

18
6
(07) RED GREEN BLACK WHITE (23) W

17
5
(07) RED BLACK WHITE RED (20)

16
4
(05) WHITE BLACK RED ORANGE BLACK (19)

15
3
(05) WHITE RED RED BLACK (18)

14
2
(02) WHITE WHITE BLACK (16)

13
1
GROUND - GREEN BLACK WHITE

MALE

X
BACK VIEW

WHITE/BLACK (16) (02) WHITE

13

1
RED/BLACK (18) (05) WHITE/RED

14

2
ORANGE/BLACK (19) (05) WHITE/BLACK/RED

15

3
BLACK/WHITE/RED (20) (07) RED

16

4
BLACK/WHITE (23) (07) RED GREEN

17

5
BLUE/BLACK (24) (08) BLACK/RED

18

6
RED/WHITE (31) (09) ORANGE/RED Y

19

7
GREEN/BLACK (32) (10) BLUE/WHITE

20

8
GREEN/WHITE (34) (10) BLUE/RED

21

9
GREEN (49) (13) ORANGE

22

10
ORANGE/GREEN (60) (14) BLACK

23

11
RED/BLACK/WHITE (NOT USED) (15) BLUE

24

12
(GROUND) GRN/BLK/WHT TO (00)

FEMALE

M137356AB

SKYJACK, Page 18 Rough Terrain Compact Series

Engine Powered
157951
 3.10. Main Manifold Harness Wiring Diagram
A B C D E F G H

SMALL PUMP DUMP VALVE

18B - RED/BLACK
02 - WHITE
V

18B
02
LEFT STEER VALVE
GREY HIRSHMAN
PIN 1 - 24 BLUE/BLACK
PIN 2 - 02 WHITE

24
GREY
02
INSERT ORIENTATION
RIGHT STEER VALVE BOTTOM VIEW
W
BLACK HIRSHMAN

02
PIN 1 - 23 BLACK/WHITE

BLACK
23
PIN 2 - 02 WHITE
HIGH SPEED VALVE HYDRAULIC GENERATOR
20B - BLACK/RED/WHITE 86D - ORANGE/BLACK/WHITE
02 - WHITE PARALLEL FORWARD VALVE 02 - WHITE
02 BLACK HIRSHMAN
PIN 1 - 16B WHITE/RED

20B

02
INSERT ORIENTATION
14A LOWERING VALVE PIN 2 - 02 WHITE 86D
BOTTOM VIEW
LIFT VALVE 13 - ORANGE 16B 02
14A - BLACK 02 - WHITE 02 PARALLEL REVERSE VALVE
02 - WHITE GREY HIRSHMAN
BLAC PIN 1 - 15B BLUE/YELLOW

02
13
K PIN 2 - 02 WHITE
X

15B
PARALLEL REVERSE VALVE
GREY HIRSHMAN

02
GRE
PIN 1 - 15B BLUE/YELLOW

Y
LARGE PUMP DUMP VALVE PIN 2 - 02 WHITE
BRAKE FEED VALVE
TO ELECTRIC PANEL - 14 WIRES 17A - BLUE/RED 30 - BROWN
02 - WHITE 17A - BLUE/RED (ANSI/CSA), 17B - BLUE/RED (CE) 02 - WHITE 02 - WHITE

30
13 - ORANGE (ANSI/CSA), 13B - ORANGE 18B- RED/BLACK (ANSI/CSA), 18C - RED/BLACK (CE)

02

20A
17A

02
(CE) 20A - BLACK/WHITE/RED FORWARD VALVE

(SPLICE 1)

02
14A - BLACK 23 - BLACK/WHITE BLACK HIRSHMAN

02

13

02
15A - BLUE 24 - BLUE/BLACK PIN 1 - 16A WHITE/BLACK
15B - BLUE/YELLOW 30 - BROWN SERIES/PARALLEL VALVE PIN 2 - 02 WHITE
16A - WHITE/BLACK 86D - ORANGE/BLACK/WHITE 20A - BLACK/RED/WHITE
16B - WHITE/RED

BLACK

16A
02 - WHITE

02
02 INSERT ORIENTATION Y
BOTTOM VIEW

02 15A
GREY
HOLDING VALVE
13 - ORANGE
02 - WHITE
REVERSE VALVE
GREY HIRSHMAN
PIN 1 - 15A BLUE
HOLDING VALVE (UPPER) PIN 2 - 02 WHITE
HOLDING VALVE (LOWER) PIN 1 - 13 BLACK

1
13 - BLACK 13 PIN 1 - 13 BLACK PIN 2 - 02 WHITE
PIN 2 - 02 WHITE

1
02 - WHITE 02

2
Z

M139827AB

Rough Terrain Compact Series SKYJACK, Page 19

Engine Powered
157951
 3.11. Kubota Engine Wiring Diagram (Dual Fuel System)
A B C D E F G H

FLASHER
FL-29

V
3 1
2

2A
10
3 2 1

22

29
FUEL SELECT SWITCH S33
PIN 1 - 50 ORANGE
05 10
A 3A A
00
PIN 2 - 37 BLUE/WHITE 1
X1
PIN 3 - 11 BLUE 2 X2
3A 02 03 B B 02

FUEL SELECT SWITCH S33 TEMPERATURE SWITCH (TPS1)

KEYWAY TO THE RIGHT 2B - WHITE

32
31

10B

10B
A B

2B
A B

37
50
11

10B

32
31
13

A B C D E F
10E

10E 10 05 07 14E

103 103 PROPANE LOCKOFF SOLENOID

6

AT CARBURETOR
ALTERNATOR MAIN ENGINE STARTER CONTACTOR

00 - WHITE (10 GA)

GAS LOCKOFF SOLENOID BACK VIEW

ENGINE GROUND
AT CARBURATOR STARTER SOLENOID X
1 8
ELECTRIC PANEL 32A - GREEN/BLACK

DEUTSCH
2
3
7
6 PIN 1 - N/U
4 5
PIN 2 - 34C GREEN/WHITE STARTER MOTOR
PRESSURE SWITCH (OPS1)
PIN 3 - 02 WHITE 57 - BLACK/WHITE

00
2A - BLACK/RED

11

50
PROPANE LOCKOFF SOLENOID AT PIN 4 - 32A GREEN/BLACK
2B - WHITE

00
PROPANE REGULATOR/VAPORIZOR PIN 5 - 2A BLACK/RED
PROPANE VALVE SOLENOID (2P-50-1) 2B 32A

50
11

00
PIN 6 - 37 BLUE/WHITE
50 - ORANGE BACK VIEW
PIN 7 - 3A BLUE 2A 57
00 - WHITE
PIN 8 - 31 RED/WHITE 37
GAS SOLENOID (2G-11) IGNITION COIL
3 2 1
11 - BLUE 37 BLUE/WHITE
00 - WHITE 00-WHITE

ALTERNATOR TRIGGER
00

50

PIN 1 - N/U

57
31CR
FUEL PUMP PIN 2 - 37 BLUE/WHITE
Y
00

50

POS - BLACK 87
PIN 3 - N/U
BACK VIEW

86

PROPANE VALVE SOLENOID (2P-50-2) NEG - WHITE/BLACK 87a

85
30
50 - ORANGE HIGH THROTTLE SOLENOID (HTS-34C)

57
FUEL PUMP
00 - WHITE 34C - GREEN/WHITE 37 00 11 - BLUE
02 - WHITE 00 - WHITE CHOKE RELAY (31CR) D57
D57

31A
31
3A
02
+
11 - PIN 87 - 31A RED/WHITE
CHOKE SOLENOID (CS-31A) PIN 86 - 02 WHITE

37
34C PIN 30 - 3A BLUE
31A - RED/WHITE 00
02 - WHITE PIN 85 - 31 RED/WHITE
02
PIN 87a - NOT USED

37
31A

00 02 37
02

00 02 37
M137528AC

SKYJACK, Page 20 Rough Terrain Compact Series

Engine Powered
157951
 3.12. Kubota Engine Wiring Diagram (Diesel Fuel System)
A B C D E F G H

DIESEL VALVE SOLENOID

(2D37)
V
00 BLACK (COMMON)
37 RED (HOLD)
57A WHITE (PULL)
BACK VIEW

57A
37

00
321
DIESEL VALVE SOLENOID ENGINE STARTER

57A
37

00
57 - BLACK/WHITE
00 WHITE 103 - RED (10 GA)
37 BLUE/WHITE ALTERNATOR TRIGGER
PIN 1 - N/U
57A BLACK/WHITE PIN 2 - 37 BLUE/WHITE (18 GA)
PIN 3 - N/U

32A
ENGINE STARTER
CONTACTOR

103

57
32A - GREEN/BLACK

PRESSURE SWITCH
(OPS1)
ENGINE

2C
2B
GLOW PLUG 91A
2B - BLACK/RED
2C - WHITE
(EGP1)
91A - RED (10 GA)

103 103 TEMPERATURE SWITCH

2

(TPS1)
ALTERNATOR MAIN MAIN ENGINE STARTER FRAME GROUND 2C - WHITE
-ATTACH AT BELL HOUSING/AIR FILTER BRKT
00 -WHITE 2C
00

HIGH 34C
THROTTLE SOLENOID
(HTS-34C)
02 -WHITE
02
X
34C - GREEN/WHITE

FLASHER
FL-29 GLOW PLUG RELAY
GLOW PLUG TIMER (31CR)
PIN 30 - 103 RED (10 GA)
(GPT1) PIN 87 - 91A RED (10 GA)
6 5 4 PIN 85 - 31 RED/WHITE
PIN 1 - N/U 3 2 1 PIN 86 - 02 WHITE
2A
10

PIN 2 - N/U PIN 87a - N/U

PIN 3 - 02 WHITE
87
PIN 4 - 91A RED 86
22

29

PIN 5 - 32A GREEN/BLACK 87a

PIN 6 - 90 RED
ELECTRIC PANEL
85
30

PIN 1 - N/U

90

02
32A

91A
05 10
A A PIN 2 - 34C GREEN/WHITE

91A
3A

103
00
1

31
02
X1
PIN 3 - 02 WHITE
2 X2
GLOW PLUG LIGHT
3A 02 03 B B 02 PIN 4
PIN 5
- 32A GREEN/BLACK
- 2A BLACK/RED
91A 02
GLOW PLUG
(GPL1)
90 - RED
LIGHT GPL1 PIN 6 - 37 BLUE/WHITE
DIESEL VALVE
Y
32

PIN 7 - 3A BLUE
31

10B

10B

91A
91A - RED A B
A B PIN 8 - 31 RED/WHITE PULL-IN RELAY
90 (3ACR)
10B

32
31

PIN 30 - 57 BLACK/WHITE
PIN 87a - 57A BLACK/WHITE
BACK VIEW PIN 85 - 3A BLUE
PIN 86 - 2B BLACK/RED
13 31 PIN 87 - N/U
1 8
91A 02 32A 37
DEUTSCH

D32A
31 32A 37 57 02 57A

D57

D02
A B C D E F
10E 2 7
3 6 32A
10E 10 05 07 14E 4 5
87
86
57
87a
85
57A 30

3A

2B

31
31
D32A
32A 32A 37 37 57 02 57A

D57

D02
32A Z

M137884AH

Rough Terrain Compact Series SKYJACK, Page 21

Engine Powered
157951
 3.13. Outrigger Harness Wiring Diagram
A B C D E F G H
CN14

86A

36A
10A

01

61
09

02
02

36
04

44
17
D17B-2
CN21

D73
17B
D17B-1

71
02
78
73
77

75
72
76
74

REAR RIGHT
REAR LEFT

D74
CN20

D77
35C

71
78
73
77

75
72
76
74
OUTRIGGER ELECTRIC PANEL

D78
9CR3 9CR2
V

FRONT RIGHT
FRONT LEFT

D72
PIN 1 - 28A GREEN/WHITE

D71
PIN 2 - 17A BLUE/BLACK (ANSI/CSA)

D76
17B BLUE/BLACK (CE) 61CR 17DCR 65CR

J17D

D75
PIN 3 - 86A ORANGE/BLACK/WHITE ENABLE

J17E
PIN 4 - 10A BLUE/WHITE

10A
10A
10A
10A
10A
61
62
62
63
63

65
64
64
PIN 5 - 09 ORANGE (2x)

-
-

D36
CN22
PIN 6 - 44 RED
UP RELAY - 14CR JUMP J17E
PIN 7 - 28 GREEN/BLACK
PIN 30 - 36A YELLOW PIN 8 - 02 WHITE (2x)
PIN 85 - 14 BLACK PIN 9 - 02 WHITE/BLACK OUTRIGGER CONTROL BOX OUTRIGGER MANIFOLD LEFT REAR OUTR DOWN LEFT FRONT OUTR DOWN RIGHT FRONT OUTR DOWN RIGHT REAR OUTR DOWN
PIN 86 - 02 WHITE PIN 10 - 36A YELLOW OUTRIGGER LIMIT SWITCHES PIN 1 - 35C WHITE/BLACK (x2) PIN 1 - 17C WHITE/BLACK
PIN 87 - 14A BLK/WHT PIN 11 - 61 GREEN PIN 1 - 61 OUTR CTRL BOX - CN20 PIN 2 - 78 BLACK/WHITE (x2)
OUTR MANIFOLD - CN21 PIN 2 - 02 WHITE PIN 1 - 78 BLACK/WHITE PIN 1 - 75 ORANGE/BLACK PIN 1 - 76 RED/BLACK PIN 1 - 77 BLUE/BLACK
PIN 87a - N/U PIN 12 - 36 YELLOW PIN 2 - 62 GREEN OUTRIGGER LIMIT SWITCHES - CN22 PIN 3 - 73 BLUE (x2) PIN 3 - 78 BLACK/WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10

PIN 3 - 62 RED PIN 4 - 77 BLUE/BLACK (x2) PIN 4 - 73 BLUE

ELECTRIC PANEL - CN14 PIN 4 - 63 GREEN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PIN 5 - 77 BLUE/BLACK
W

02

78

02

75

02

76

02

77
14CR

36A
PIN 5 - 74 BLACK (x2)
PIN 5 - 63 RED PIN 6 - 71 ORANGE (x2) PIN 6 - 74 BLACK
02

1 2 3 4 5 6 7 8 9 10 11 12
14

14A PIN 6 - 64 GREEN PIN 7 - 75 ORANGE/BLACK (x2) PIN 7 - 71 ORANGE

PIN 7 - 64 RED PIN 8 - 72 RED (x2) PIN 8 - 75 ORANGE/BLACK
PIN 8 - N/U PIN 9 - 76 RED/BLACK (x2) PIN 9 - 72 RED
36A
14A

D36-1
02
14

PIN 9 - 10A BLACK (2x) PIN 10 - 76 RED/BLACK

PIN 10 - 10A BLACK (2x)
36

4
1
6

35C
PIN 11 - 10A BLACK (2x)

5
5

6
3
4

1
PIN 12 - 10A BLACK (2x) 02
BACK VIEW BACK VIEW 02
PIN 13 - 10A GREEN
PIN 14 - N/U TO CONTROL MODULE TO LIMIT SWITCHES
PIN 15 - N/U PIN 1 - 65 GREEN/BLACK PIN 1 - 65 GREEN/BLACK
17C
PIN 16 - 65 GREEN/BLACK PIN 2 - 65A WHITE PIN 2 - 65A GREEN/WHITE
36

PIN 3 - 66A WHITE PIN 3 - 66A BLUE/WHITE 02

36

PIN 4 - 67A WHITE PIN 4 - 67A RED/WHITE 17C - WHITE/BLACK X

PIN 5 - 68A WHITE PIN 5 - 68A WHITE 02 - WHITE
HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG TO OUTRIGGER
PIN 6 - N/U PIN 6 - N/U 7 8 9 10 11 12 4

86D PIN 1 - EMPTY PIN 7 - 14 BLACK (2x) CONTROL BOX

4

1
5

2
6

3
7

4
8

5
9

6
3

PIN 2 - EMPTY PIN 8 - 17 BLUE CONTROL CABLE

1 2 3 1

74

02

02

72

02

73

02
71
PIN 3 - EMPTY PIN 9 - 43 RED/BLACK PIN 1 - 74 BLACK PIN 1 - 71 ORANGE PIN 1 - 72 RED PIN 1 - 73 BLUE
PIN 4 - 02 WHITE (2x) PIN 10 - 43A RED/WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE
PIN 5 - 2A ORANGE/BLACK PIN 11 - 86A ORANGE/BLACK/WHITE
PIN 6 - 09 ORANGE PIN 12 - 86D ORANGE/BLACK/WHITE LEFT REAR OUTR UP LEFT FRONT OUTR UP RIGHT FRONT OUTR UP RIGHT REAR OUTR UP

P2
P4
TILT SWITCH
PIN 1 - 10A BLACK
PIN 2 - 28 GREEN
PIN 3 - 02 WHITE
Y
TO OUTRIGGER LIMIT SWITCHES PIN 4 - 44 RED
2
1

BACK VIEW
DEUTSCH

4 1 DEUTSCH

OUTR CONTROL BOX CONTROL MODULE - P4 CONTROL MODULE - P2

3 2

LEFT FRONT OUTRIGGER: PIN 1 - 02 WHITE PIN 1 - 78 BLACK/WHITE PIN 1 - 68A WHITE
4
3

PIN 1 - BLACK (10A) PIN 2 - WHITE (65A)

PIN 3 - GREEN (62) PIN 4 - RED (36) TO ELECTRIC PANEL PIN 2 - 35C WHITE/BLACK PIN 2 - 77 BLUE/BLACK PIN 2 - 67A RED/WHITE
TILT SWITCH CONNECTOR PIN 3 - 70 GREEN/BLACK PIN 3 - 76 RED/BLACK PIN 3 - 66A BLUE/WHITE
PIN 4 - 70A RED/WHITE PIN 4 - 75 ORANGE/BLACK PIN 4 - 65A GREEN/WHITE
DEUTSCH

4 1
3 2

RIGHT FRONT OUTRIGGER: PIN 5 - 71 ORANGE PIN 5 - 74 BLACK PIN 5 - 70 GREEN/BLACK

PIN 1 - BLACK (10A) PIN 2 - WHITE (66A) PIN 6 - 72 RED PIN 6 - 73 BLUE PIN 6 - 79 GREEN
PIN 3 - GREEN (63) PIN 4 - RED (62) PIN 7 - 73 BLUE PIN 7 - 72 RED PIN 7 - 70A RED/WHITE
PIN 8 - 74 BLACK PIN 8 - 71 ORANGE PIN 8 - 65 GREEN/BLACK
DEUTSCH

4 1

PIN 9 - 75 ORANGE/BLACK PIN 9 - 35C WHITE/BLACK PIN 9 - 28 GREEN

3 2

RIGHT REAR OUTRIGGER: PIN 10 - 76 RED/BLACK PIN 10 - 44 RED Z

PIN 1 - BLACK (10A) PIN 2 - WHITE (67A)
PIN 3 - GREEN (64) PIN 4 - RED (63)
PIN 11 - 77 BLUE/BLACK PIN 11 - 02 WHITE (2x)
PIN 12 - 78 BLACK/WHITE PIN 12 - 10A BLACK
PIN 13 - 79 GREEN
DEUTSCH

4 1
3 2

LEFT REAR OUTRIGGER: PIN 14 - 35C WHITE

PIN 1 - BLACK (10A) PIN 2 - WHITE (68A) PIN 15 - 35C GREEN
PIN 3 - GREEN (10A) PIN 4 - RED (64) M146126AC

SKYJACK, Page 22 Rough Terrain Compact Series

Engine Powered
157951
 3.14. Hydraulic Generator Electrical Panel Assembly
A B C D E F G H

V
86ACR 86BCR 86CCR 14CR

OUTRIGGER OPTION

WIRE# 86ACR - HYDRAULIC GENERATOR STOP RELAY

W3 PIN 85 - 86A ORANGE/BLACK/WHITE
W4 PIN 86 - 02 WHITE
W2 PIN 30 - 85 ORANGE/BLACK/WHITE W
W9 PIN 87a - 86B ORANGE/BLACK/WHITE 86ACR 86BCR 86CCR
- PIN 87 - N/U 85 09 43

86B 43A
WIRE# 86BCR - HYDRAULIC GENERATOR LATCHING RELAY

86C
86B
86A

2A
02

02
86C 86D
W9 PIN 85 - 86B ORANGE/BLACK/WHITE
W5 PIN 86 - 2A ORANGE/BLACK D86 D86C D86D
W1 PIN 30 - 09 ORANGE
- PIN 87a - N/U
W2 PIN 87 - 86C ORANGE/BLACK/WHITE

WIRE# 86ACR - HYDRAULIC GENERATOR RELAY

W2 PIN 85 - 86C ORANGE/BLACK/WHITE X
W4 PIN 86 - 02 WHITE
W7 PIN 30 - 43 RED/BLACK D14

W8 PIN 87a - 43A RED/WHITE

36A
14A

02
14

36
W6 PIN 87 - 86D ORANGE/BLACK/WHITE

WIRE# HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG

W1 PIN 1 - 09 ORANGE FROM HYDRAULIC GENERATOR
W2 PIN 2 - 85 ORANGE/BLACK/WHITE CONTROL CABLE
W3 PIN 3 - 86 ORANGE/BLACK/WHITE PIN 1 - 09 BLACK
W4 PIN 4 - 02 WHITE
W5 PIN 5 - 2A ORANGE/BLACK PIN 2 - 85 GREEN
W1 PIN 6 - 09 ORANGE PIN 3 - 86 WHITE Y
W3 PIN 7 - 14 (DIODE)
W6 PIN 8 - 17A/B BLUE/BLACK 86D - ORG/BLK/WHT, FROM MAIN MANIFOLD HARNESS
W7 PIN 9 - 43 RED/BLACK
W8 PIN 10 - 43A RED/WHITE
W3 PIN 11 - 86A ORANGE/BLACK/WHITE
W6 PIN 12 - 86D ORANGE/BLACK/WHITE

OUTRIGGER/HYDRAULIC GENERATOR HARNESS

86 FROM HYDRAULIC Z
85 GENERATOR
09 CONTROL BOX

M146108AC

Rough Terrain Compact Series SKYJACK, Page 23

Engine Powered
157951
 Notes

SKYJACK, Page 24 Rough Terrain Compact Series

Engine Powered
157951
 3.15. Electrical Panel Wiring Diagram
A B C D E F G H I J K L M N O

R
37 2A 15 16 19 20 20A 16B

10CR1 10CR2 10BCR 15CR 16CR 17CR 19CR 20CR 20ACR1 FLASHER HOURMETER
37 42 10A 15A 16A 17 20A FL-29 TT

10B
10 2A 10 2A 02 15 02 16 02 17 02 19 02 20 02 02

20A
41 18A 16B

3A 02 3A 10A 10A 21 44 44 16A

CIRCUIT BREAKER
43 43A
20ACR2 28ACR1 34ACR 35CR 35ACR
CB1

2A
10
28ACR2 32CR1 32CR2 33CR

15A 18A 17 41 43A 34

S
3A 34B 10A

15B 28C 28B 43

EMERGENCY STOP

28A

28A
20A
41 02 42

35A
02

34A
02 02 32 41 32 33 35 02 02

22

29
18B 17A 32A 02 34C 34B 44 34A
S6
2A
LEGEND: 15B 32A 34C
35 34 CIRCUIT BREAKER
CB3 POWER ON
MAIN MANIFOLD HARNESS LED-2
05 10
A 3A A
00
1
ENGINE HARNESS 10E 10E
X1
2 X2 GLOW PLUG
PLATFORM CONTROL BOX 3A 02 03 B B 02
LIGHT GPL1
T
29

OUTR/GEN HARNESS 10
10 START SWITCH OR
10A 02 02 3A 31
S32 FUEL SELECT

32
31

10B

10B
TILT SWITCH A B SWITCH S33

D14E-1
D14A-3

D23
A B
D0
A-2

D17A
9

HIGH SPEED LIMIT SWITCH

D15

D14A-1

D15A-1
D44-1

D24

10B

32
31
D13
05 3A

34A
35A

28A
18B

10B
17A

14E
14A
14A

18A

10E

15A
15A
16A
16A

10A
21
21
29

09

29

49
05

33

08

07

28

30

23

02
02
02
44
44

24

60
13

10

10
14
05 31 32

GLOW PLUG OR U
13
CHOKE SWITCH S31

D14E-2
10E

D08

D16A-2
A B C D E F

D1

0E

-2
8B

D16
D44
D1

A-1
10E 10 05 07 14E
D28B D14A-2 D18 D28C KEY SWITCH
10A
14E 07
10E 13
S10
32 10B
3A 29
10 29
13 17A 18B 14A 30 15A 16A 23 24 02 22 05
02
2A
TO HORN 05 13 08 07 09 14 10 23 24 49 60 02
UP/DOWN
02 - WHITE V
SWITCH S2
H1 49
49 - BLACK 17A 14A 61 18 09 14 44 28 28A
TILT SWITCH
ENGINE HARNESS
OUTR/GEN HARNESS
MAIN MANIFOLD HARNESS

28 10A 02
PLATFORM CONTROL BOX

44 02
HIGH SPEED LIMIT SW

LS5
02

HIGH SPEED LIMIT SWITCH

10A - BLUE
35 - BROWN
OUTRIGGER 12 PIN CONNECTOR PLUG UP RELAY - 14CR HYDRAULIC GENERATOR 12 PIN CONNECTOR PLUG 00 WHITE - 14GA

NO
BROWN

BLUE
PIN 1 - 28A GREEN/WHITE 02 WHITE PIN 1 - EMPTY PIN 7 - 14 BLACK (2x)

10A
35
14 BLACK

00
PIN 2 - 17A BLUE/BLACK PIN 2 - EMPTY PIN 8 - 17A BLUE/BLACK 00
PIN 3 - 86A ORANGE/BLACK/WHITE 14A BLK/WHT PIN 3 - EMPTY PIN 9 - 43 RED/BLACK W
PIN 4 - 10A BLUE/WHITE 36A YELLOW PIN 4 - 02 WHITE (2x) PIN 10 - 43A RED/WHITE
2

FL-22 TO FLASHING LIGHT PIN 5 - 09 ORANGE (2x) PIN 5 - 2A ORANGE/BLACK PIN 11 - 86A ORANGE/BLACK/WHITE F1 FUSE
& BEEPER

100
02 - WHITE
PIN 6 - 44 RED PIN 6 - 09 ORANGE PIN 12 - 86D ORANGE/BLACK/WHITE 300 AMP
PIN 7 - 28 GREEN/BLACK
FLASHING LIGHT 22 - GREEN
29 - BLACK PIN 8 - 02 WHITE (2x)
02 - WHITE
22 - GREEN
PIN 9 - 02 WHITE/BLACK MAIN BATTERY
PIN 10 - 36A YELLOW
22 22
MAIN MANIFOLD HARNESS
PIN 11 - 61 GREEN B1
02 - WHITE 17A - BLUE/RED
PIN 12 - 36 YELLOW
13 - ORANGE 18B - RED/BLACK 03 BLUE - 14GA
02 14A - BLACK 20A - BLACK/WHITE/RED
02 86D TO ENGINE HARNESS X
02 15A - BLUE 23 - BLACK/WHITE PIN 1 - N/U
00

2
BP-29 15B - BLUE/YELLOW 24 - BLUE/BLACK PIN 2 - 34C GREEN/WHITE

100
29 29 16A - WHITE/BLACK 30 - BROWN PIN 3 - 02 WHITE TO ENGINE

03
36

16B - WHITE/RED 86D - ORANGE/BLACK/WHITE PIN 4 - 32A GREEN/BLACK MAIN

36A

14A

1
2
3
4
2

02

14
PIN 5 - 2A BLACK/RED DISCONNECT 103 103
36

BEEPER

2
BACK VIEW PIN 6 - 37 BLUE/WHITE
SWITCH S1

103
DEUTSCH
02 - BLACK PIN 7 - 3A BLUE
FEMALE
9 10 11 12 8 7 6 5 4 3 2 1 9 10 11 12 8 7 6 5 4 3 2 1

103
29 - RED
OUTRIGGER PIN 8 - 31 RED/WHITE

8
7
6
5
LIMIT SWITCHES BACK VIEW

1
2
WHITE/BLACK (16) (02) WHITE
13

9 10 11 12 8 7 6 5 4 3 2 1 9 10 11 12 8 7 6 5 4 3 2 1
Y
1

RED/BLACK (18) (05) WHITE/RED DEUTSCH

14

ORANGE/BLACK (19) (05) WHITE/BLACK/RED

15

14A
14

3
BLACK/WHITE/RED (20) (07) RED

4
16

BACK VIEW
36

BLACK/WHITE (23) (07) RED GREEN

17

BLUE/BLACK (24) (08) BLACK/RED

18

TILT SWITCH OR
RED/WHITE (31) (09) ORANGE/RED
19

D36-1 OUTR CTRL MODULE

7

GREEN/BLACK (32) (10) BLUE/WHITE PIN 1 - 10A BLACK

20

CRD3
8

GREEN/WHITE (34) (10) BLUE/RED NO OUTRIGGER JUMPER PLUG UP RELAY JUMPER NO HYDR GEN JUMPER PLUG PIN 2 - 28 GREEN
21

GREEN (49) (13) ORANGE PIN 3 - 02 WHITE

22

10

PIN 1 & 7 - GRN/RED (28-28A) BLACK (14-14A) PIN 9 & 10 - RED (43-43A) PIN 4 - 44 RED
ORANGE/GREEN (60) (14) BLACK
23

11

Z
RED/BLACK/WHITE (NOT USED) (15) BLUE
24

12

(GROUND) GREEN/BLACK/WHITE TO (00)

M146124AB

Rough Terrain Compact Series SECTION 3, Page 25

Engine Powered
157951
157951
A

Engine Powered
Rough Terrain Compact Series
B
C

S10
PLTF/IDLE/BASE S6
KEY SWITCH EMERGENCY
S4 BASE (IN IDLE POSITION) STOP
CONTROL BOX KUBOTA DUAL FUEL ENGINE
EMERGENCY S2
STOP UP/DOWN NEGATIV
SWITCH SWITCH
07
08 07 RED 07 05 05 3A
D

13 ICM1 IGNITION
07 RED/GREEN 07 10E 10 10 02 37 00 CONTROL MODULE
14E 10E 2
LED-2 CPS1
POWER ON CRANKSHAFT IGNITION COILS
D10E LIGHT 1 2 3 3
POSITION
SENSOR
10 05 WHITE/RED 05 00
4
IGC1 IGC2 IGC3
CHOKE
05 WHITE/BLACK/RED 05 3A 3A 31A CS-31A SOLENOID
5
D02-16
HIGH THROTTLE
3A 43 43A 34B 34C 34C 34C HTS-34C SOLENOID
6
HYDR GEN D02-17
10 BLUE/WHITE 10 JUMPER 11 00 FUEL PUMP
FP 7
32ACR
ENGINE STARTER
10 BLUE/RED 10 3A 32A 32A 32A 32A 00 CONTACTOR
8
S33 FUEL
HOURMETER SELECT SW 2G-11 GAS VALVE
10 11 00 SOLENOID
E

TT OIL GAS 9
PRESSURE 37
PROPANE VALVE
SWITCH 50 00
PROP SOLENOID
10
ENGINE 10CR1 TPS1
2P-50-1 TEMPERATURE
GLOW PLUG 10 10 2A 2A 2A 2B 00
/CHOKE SW SWITCH
11
OPS1 2P-50-2 PROPANE VALVE
31 10B 3A 3A 37 37 37 37 50 00 SOLENOID
S13 12
GLOW PLUG/ S31
D57
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 02 CHOKE RELAY
13
10CR2 31CR
ENGINE 10 10 2A 02 02 02
START SW 14

ENGINE STARTER
32 10B 57 EL. MOTOR
M 15
S32 MAIN POWER
IG
32 41 DISCONNECT
ALTERNATOR
G 16
S1 F1
32CR1 FUSE B1
103 100 12V 12V BATTERY
F

17
300 AMP
103 03
18
CB1 CB3
3A 3A 03 00 02 25 A BREAKER
19
25A BREAKER
08 BLACK/RED 08 D08
20

41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41 START RELAY
22
S14 32CR2
LOW/HIGH THROTTLE 08 34 GREEN/WHITE 34 34 34A 42 THROTTLE RELAY
23

RST1 D14E-2 34ACR POWER ON-

LED-1 33
2.7K OHMS DEMAND RELAY
POWER ON 24
LIGHT 10BCR 33CR
00 02 02 60 60 ORANGE/GREEN 60 08 10B MAIN POWER RELAY
G

25
CONTROL BOX
HOLDING VALVE
LIGHT JUMPER 3A 10A 2H-13-2
SOLENOID
26
D02-1
HOLDING VALVE
CRD1 CRD2 CRD3 2H-13-1
SOLENOID
27
D02-2
S8 MAIN LOWERING
13 2H-13
HORN VALVE SOLENOID
28
D02-3
08 49 GREEN 49 49 HORN
29
H1
D13 30
S3 17CR
LIFT/DRV LOW/DRV HI 17 SMALL PUMP RELAY
(IN LIFT POSITION) 31

D28B
13 13 ORANGE 13 17 28B
A 32
NOHC D14A-1 D28C
18A 28C 29 29 BEEPER
H

D14E-1 33
BP-29
LIFT VALVE
14 14 BLACK 14 14A 14A 3H-14A
SOLENOID
B 34
NO OUTRIGGER D02-4
NOHC
JUMPER 1
35
D09 THROTTLE ENABLE
09 09 ORANGE/RED 09 35A RELAY
08 36
NOHC 35ACR D44-2 20ACR1 SERIES/PARELLEL
20A RELAY
37
TILT OVERRIDE/ 20ACR2 SERIES/PARELLEL
HIGH DRIVE CUTOUT 44 20A 20A RELAY
LIMIT SWITCH 38
NORMALLY OPEN 35CR
HELD CLOSED ELEVATION/HI SPD
10A 35 35 CUTOUT RELAY
39
08 LS5 SERIES/PARELLEL
20 20 BLACK/WHITE/RED 20 20 RELAY
NO 40

20CR SERIES/PARALLEL
10A 10A 44 4H-20A
I

VALVE SOLENOID
41
D02-6
LARGE PUMP DUMP
44 17 17 17 17A 17A 2H-17A
VALVE SOLENOID
S7-1 42
2ND SPEED D02-7
19 19 ORANGE/BLACK 19 19 LARGE PUMP RELAY
43

the “Table Of Contents” found at the beginning of this section.

JOYSTICK ENABLE
3.16. Electrical Schematic (No Option with Kubota Dual Fuel Engine)

ENABLE RELAY 19CR D17A HIGH SPEED

33 20B 2H-20B
VALVE SOLENOID
44
8CCR D02-5
08 8C 02 02 WHITE 02
45
S7-2 RIGHT D16B D15B RIGHT STEERING
23 23 BLACK/WHITE 23 23 4H-23 VALVE SOLENOID
46
S7-3 LEFT D02-8
LEFT STEERING
24 24 BLUE/BLACK 24 24 4H-24 VALVE SOLENOID
47
D02-9
D23 D15A-1 D15A-2 PARALLEL REVERSE
4H-15B

NOTE: To determine the correct electrical schematic that resembles your machine, refer to
08 8A 8A 8B 15A 15B VALVE SOLENOID
48
NCHO D02-10
REVERSE
10A 15A 15A 4H-15A
VALVE SOLENOID
J

49
S7-4 REV D02-11
A A 15 15 BLUE 15 15 REVERSE RELAY
50
NCHO
15CR D24 D16A-1 D16A-2 BRAKE
30 3H-30 VALVE SOLENOID
51
D02-12
FORWARD
10A 16A 16A 4H-16A
VALVE SOLENOID
52
S7-5 FWD D02-13
B B 16 16 WHITE/BLACK 16 16 FORWARD RELAY
53
NCHO
16CR PARALLEL FORWARD
21 18A 16A 16B 4H-16B
VALVE SOLENOID
S7-6 54
S7
3RD SPEED D02-14
JOYSTICK D18 SMALL PUMP DUMP
18 18 RED/BLACK 18 18A 18B 2H-18B
CONTROLLER VALVE SOLENOID
55
D02-15
33 D18B
56

SMALL PUMP DUMP

TS1 28A ENABLE RELAY
K

TILT D44-1 57
SWITCH 28ACR1 LARGE PUMP DUMP
10A 28 28A ENABLE RELAY
58
NO OUTRIGGER
28ACR2
JUMPER 2
02
59
L
M
N
O

M137324AG
Z
T

Y
X
S
R

SECTION 3, Page 26
157951
A

Engine Powered
Rough Terrain Compact Series
S10
PLTF/IDLE/BASE S6
KEY SWITCH EMERGENCY
S4 CONTROL BOX BASE (IN IDLE POSITION) STOP
EMERGENCY S2 KUBOTA DUAL FUEL ENGINE
STOP UP/DOWN NEGATIV
SWITCH SWITCH -
07
08 07 RED 07 05 05 3A
1
13 ICM1 IGNITION
07 RED/GREEN 07 10E 10 10 02 37 00
14E 10E 2 CONTROL MODULE
B

LED-2 CPS1
POWER ON CRANKSHAFT IGNITION COILS
D10E LIGHT 1 2 3 3
POSITION
SENSOR
10 05 WHITE/RED 05 00
4
IGC1 IGC2 IGC3
CHOKE
05 WHITE/BLACK/RED 05 3A 3A 31A CS-31A
5 SOLENOID
D02-26
3A HIGH THROTTLE
43 43A 34B 34C 34C 34C HTS-34C SOLENOID
6
D02-27
10 BLUE/WHITE 10 11 00 FUEL PUMP
FP 7
32ACR
3A ENGINE STARTER
10 BLUE/RED 10 32A 32A 32A 32A 00
8 CONTACTOR
S33 FUEL
HOURMETER SELECT SW 2G-11 GAS VALVE
10 11 00
TT 9 SOLENOID
OIL GAS
PRESSURE 37
SWITCH PROPANE VALVE
PROP 50 00 SOLENOID
10
C

ENGINE 10CR1 TPS1 2P-50-1 TEMPERATURE

GLOW PLUG 10 10 2A 2A 2A 2B 00
/CHOKE SW 11 SWITCH
OPS1 2P-50-2 PROPANE VALVE
31 10B 3A 3A 37 37 37 37 50 00 SOLENOID
S13 12
GLOW PLUG/ S31
D57
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 02 CHOKE RELAY
13
10CR2 31CR
ENGINE 10 10 2A 02 02 02
START SW 14
ENGINE STARTER
32 10B 57 EL. MOTOR
M 15
S32 MAIN POWER
DISCONNECT IG
32 41 ALTERNATOR
G 16
S1 F1
32CR1 FUSE B1
103 100 12V 12V BATTERY
17
300 AMP
103 03
18
D

CB1 CB3
3A 3A 03 00 02 25 A BREAKER
19
25A BREAKER

20

41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41 START RELAY
22
S14 32CR2
LOW/HIGH THROTTLE 08 34 GREEN/WHITE 34 34 34A 42 THROTTLE RELAY
23

D14E-2 34ACR POWER ON-

33
24 DEMAND RELAY
10BCR 33CR
08 BLACK/RED 08 D08 10B
25 MAIN POWER RELAY
F4
RST1 LED-1 3A 10A FUSE INV1
2.7K OHMS 26 INVERTER OPTION
POWER ON
LIGHT 125 AMP
HOLDING VALVE
E

00 02 02 60 60 ORANGE/GREEN 60 08 10 2H-13-2
27 SOLENOID
CONTROL BOX D02-1
LIGHT JUMPER HOLDING VALVE
CRD1 CRD2 CRD3 2H-13-1
28 SOLENOID
D02-2
S8 MAIN LOWERING
13 2H-13
HORN 29 VALVE SOLENOID
D02-3
08 49 GREEN 49 49 HORN
30
S3 H1 FLASHER FLASHING LIGHT
LIFT/DRV LOW/DRV HI D13
29 29 22 OPTION
(IN LIFT POSITION) 31
FL-22
17CR FL-29
13 13 ORANGE 13 17 SMALL PUMP RELAY
A 32
NOHC D28B ALL MOTION ALARM
17 28B OPTION
D14E-1 D30 D14A-3 33

14 BLACK 14 D28C
14 18A 28C 29 29 BEEPER
B 34
BP-29
NOHC LIFT VALVE
14A 3H-14A
F

35 SOLENOID
D02-4
D09 THROTTLE ENABLE
09 09 ORANGE/RED 09 35A
08 36 RELAY

NOHC 35ACR D44-2 D14A-1 20ACR1 SERIES/PARELLEL

20A RELAY
37
TILT OVERRIDE/ 20ACR2 SERIES/PARELLEL
HIGH DRIVE CUTOUT 44 20A 20A RELAY
LIMIT SWITCH 38
NORMALLY OPEN 35CR
HELD CLOSED ELEVATION/HI SPD
10A 35 35
39 CUTOUT RELAY

08 LS5 SERIES/PARELLEL
20 20 BLACK/WHITE/RED 20 20 RELAY
NO 40

20CR SERIES/PARALLEL
10A 10A 44 4H-20A
41 VALVE SOLENOID
D02-5
LARGE PUMP DUMP
44 17 17 17 17A 17A 2H-17A
S7-1 42 VALVE SOLENOID
2ND SPEED D02-6
19 19 ORANGE/BLACK 19 19 LARGE PUMP RELAY
G

JOYSTICK ENABLE 43
ENABLE RELAY D23 19CR D17A HIGH SPEED
33 20B 2H-20B
44 VALVE SOLENOID
8CCR D02-7
D16B
08 8C 02 02 WHITE 02
45
S7-2 RIGHT D15B RIGHT STEERING
23 23 BLACK/WHITE 23 23 4H-23
46 VALVE SOLENOID
S7-3 LEFT D02-8
LEFT STEERING
24 24 BLUE/BLACK 24 24 4H-24
47 VALVE SOLENOID
D02-9
D24 D15A-1 D15A-2 4H-15B PARALLEL REVERSE
08 8A 8A 8B 15A 15B VALVE SOLENOID
48
NCHO D02-10
4H-15A REVERSE
10A 15A 15A
49 VALVE SOLENOID
S7-4 REV D02-11
A A 15 15 BLUE 15 15 REVERSE RELAY
50
NCHO
15CR D16A-1 D16A-2 BRAKE
30 3H-30 VALVE SOLENOID
51
H

D02-12
4H-16A FORWARD
10A 16A 16A
52 VALVE SOLENOID
S7-5 FWD D02-13
B B 16 16 WHITE/BLACK 16 16 FORWARD RELAY
53
NCHO
16CR PARALLEL FORWARD
21 18A 16A 16B 4H-16B
S7-6 54 VALVE SOLENOID
S7 D02-14
3RD SPEED D18
JOYSTICK SMALL PUMP DUMP
18 18 RED/BLACK 18 18A 18B 2H-18B
CONTROLLER 55 VALVE SOLENOID
D02-15
33 D18B
56
SMALL PUMP DUMP
44 14A 28A ENABLE RELAY
57
28ACR1 LARGE PUMP DUMP
HYDRAULIC GENERATOR OPTION 28A ENABLE RELAY
D44-1 D14A-2 58

28ACR2 D86D
59
I

09 D86C 2H-86D
43 86D HYDR. GENERATOR
60
S12 D02-16 SOLENOID
HYDRAULIC 09 09 86C
GENERATOR 61 HYDR. GENERATOR
SWITCH RELAY

the “Table Of Contents” found at the beginning of this section.

86CCR
3.17. Electrical Schematic (All Option with Kubota Dual Fuel Engine)

85 85 86B 2A
62 HYDR. GENERATOR
ON LATCHING RELAY
09
86 D86 86BCR
86A HYDR. GENERATOR
OFF 63
STOP RELAY
D14 86ACR
64

65
FF EE CC HH MM GG BB PP II,JJ

D17C-1 D17C-2 66

NOTE: To determine the correct electrical schematic that resembles your machine, refer to
2H-17C OUTRIGGER
28 28 28A 10A 17E 17C
67 HOLDING SOLENOID
J17E D02-17
J

10A 10A 36A 14A

68
OUTRIGGER UP LIMIT SWITCHES KK
NORMALLY OPEN HELD CLOSED OUTRIGGER LIFT
65 ENABLE RELAY
69
LS64 LS63 LS62 LS61 D36 65CR OUTRIGGER DRIVE
10A 10A D36-1
64 63 62 36 61 ENABLE RELAY
70
NN
LEFT RIGHT RIGHT LEFT 61CR
REAR REAR FRONT FRONT
71
OUTRIGGERS SHOWN IN
14 RETRACTED POSITION 14
72 UP RELAY
9CR3
14CR OUTRIGGER
09 PROOF RELAY
73
9CR2
OUTRIGGER
09 ENABLE RELAY
74
S20A S21A S22A S23A
FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT OUTRIGGER
44 35B 35C 35C 35E 17D LIFT DISABLE RELAY
75

S9B UP UP UP UP 17DCR OUTRIGGER

K

OUTRIGGER 76 CONTROL MODULE

ENABLE DN DN DN DN CUT J17D
D71 OCM1
71
71 = P4-8 77 LEFT FRONT UP

D72
72
72 = P4-7 78 RIGHT FRONT UP

D73
73
73 = P4-6 79 RIGHT REAR UP

D74
74
74 = P4-5 80 LEFT REAR UP

D75
75
75 = P4-4 81 LEFT FRONT DOWN

D76
76
76 = P4-3 82 RIGHT FRONT DOWN

D77
77
77 = P4-2 83 RIGHT REAR DOWN

D78
78
L

78 = P4-1 84 LEFT REAR DOWN

44 TILT OVERRIDE/
44 = P2-10 85 HIGH DRIVE CUTOUT

28
28 = P2-9 86 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 87 LIFT ENABLE

LS68
10A 10A 68A
68A = P2-1 88 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A RIGHT REAR DOWN
OUTRIGGER OPTION 67A = P2-2 89
WITH AUTO LEVELLING RIGHT REAR
LS66
10A 66A RIGHT FRONT DOWN
66A = P2-3 90
RIGHT FRONT
LS65
35C GREEN/WHITE 35C 10A 65A LEFT FRONT DOWN
65A = P2-4 91
S9A LEFT FRONT
OUTRIGGER 35C BLUE/WHITE 35C 10A
ENABLE 10A = P2-12 92 POWER
M

OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 93 OUTRIGGER ENABLE

S24
AUTO 79 GREEN 79 AUTO RETRACT
ALL UP 79 = P2-6 94
MODE 35D
70 GREEN/BLACK 70 AUTO LEVEL
LEVEL 70 = P2-5 95

02 70A RED/WHITE 70A OUTRIGGER LIGHT

OL1 70A = P2-7 96
OUTRIGGER
LIGHT GROUND
02 = P2-11 97

02 WHITE 02
98
S20 LEFT FRONT UP
71 ORANGE 71 71 4H-71
FRONT 99 OUTRIGGER SOLENOID
LEFT UP
35D D02-18
75 4H-75 LEFT FRONT DOWN
75 ORANGE/BLACK 75
DN 100 OUTRIGGER SOLENOID
N

D02-19
S21 RIGHT FRONT UP
72 RED 72 72 4H-72
FRONT 101 OUTRIGGER SOLENOID
RIGHT UP
35D D02-20
76 4H-76 RIGHT FRONT DOWN
76 RED/BLACK 76
DN 102 OUTRIGGER SOLENOID
D02-21
S22 RIGHT REAR UP
73 BLUE 73 73 4H-73
REAR 103 OUTRIGGER SOLENOID
RIGHT UP
35D D02-22
77 4H-77 RIGHT REAR DOWN
77 BLUE/BLACK 77
DN 104 OUTRIGGER SOLENOID
D02-23
S23 LEFT REAR UP
74 BLACK 74 74 4H-74
REAR 105 OUTRIGGER SOLENOID
LEFT UP
35D D02-24
78 4H-78 LEFT REAR DOWN
78 BLACK/WHITE 78
DN 106 OUTRIGGER SOLENOID
D02-25
O

M137325AL
Z
T

Y
X
S
R

SECTION 3, Page 27
157951
A

Engine Powered
S10
PLTF/IDLE/BASE S6
KEY SWITCH EMERGENCY

Rough Terrain Compact Series

S4 CONTROL BOX BASE (IN IDLE POSITION) STOP
EMERGENCY S2
STOP UP/DOWN NEGATIV
SWITCH SWITCH -
07 KUBOTA DIESEL ENGINE
08 07 RED 07 05 05 3A
1
13 GPT1
07 RED/GREEN 07 10E 10 10 02 32A 02 GLOW PLUG
14E 10E 2
TIMER
LED-2 90
POWER ON GLOW PLUG
B

D10E LIGHT GPL1 3

INDICATOR
WHITE/RED EGP1
10 05 05 103 91A 00 ENGINE
4
GLOW PLUGS
05 WHITE/BLACK/RED 05 34C 34C HTS-34C HIGH THROTTLE
5
D02-26 SOLENOID
3A 43 43A 34B 34C 3A 3A
6
3ACR
10 BLUE/WHITE 10 2B 3A DIESEL VALVE
7
PULL-IN RELAY
10 BLUE/RED 10 3A 32A 32A 32A 37 2D37 00 DIESEL VALVE
8
SOLENOID
HOURMETER D57
10 57 57A
TT OIL 9
PRESSURE 32ACR D02-27
SWITCH 32A 00 ENGINE STARTER
10
CONTACTOR
ENGINE 10CR1 TPS1
GLOW PLUG 10 10 2A 2A 2A D2A 2B 2C 2C 00 TEMPERATURE
C

/CHOKE SW 11
SWITCH
OPS1
31 10B 3A 3A 37 37 37
S13 12
GLOW PLUG/ S31
D32A
CHOKE SWITCH 08 31 RED/WHITE 31 31 31 31 02 GLOW PLUG
13
RELAY
10CR2 31CR
ENGINE 10 10 2A 02 02 02
START SW 14

32 10B 57 ENGINE STARTER

M 15
S32 EL. MOTOR
MAIN POWER
DISCONNECT IG
32 41
G 16 ALTERNATOR
S1 F1
32CR1 FUSE B1
103 100 12V
17 12V BATTERY
300 AMP
103 03
18
CB1 CB3
D

3A 3A 03 00 02
19 25 A BREAKER
25A BREAKER

20

41
21
S15
ENGINE START 08 32 GREEN/BLACK 32 32 41
22 START RELAY
S14 32CR2
LOW/HIGH THROTTLE 08 34 GREEN/WHITE 34 34 34A 42
23 THROTTLE RELAY

D14E-2 34ACR
33 POWER ON-
24
DEMAND RELAY
10BCR 33CR
08 BLACK/RED 08 D08 10B
25 MAIN POWER RELAY
F4
LED-1 3A 10A FUSE INV1
RST1 POWER ON 26 INVERTER OPTION
2.7K OHMS LIGHT 125 AMP
E

00 02 02 60 60 ORANGE/GREEN 60 08 10 2H-13-2 HOLDING VALVE

27
D02-1 SOLENOID
CONTROL BOX
CRD1 CRD2 CRD3 LIGHT JUMPER 2H-13-1 HOLDING VALVE
28
D02-2 SOLENOID
S8 13 2H-13
HORN MAIN LOWERING
29
D02-3 VALVE SOLENOID
08 49 GREEN 49 49
30 HORN
S3 H1 FLASHER
LIFT/DRV LOW/DRV HI D13
29 29 22 FLASHING LIGHT
(IN LIFT POSITION) 31
FL-22 OPTION
17CR FL-29
13 13 ORANGE 13 17
A 32 SMALL PUMP RELAY
NOHC D28B
17 28B ALL MOTION ALARM
D14E-1 D30 D14A-3 33
OPTION
14 BLACK 14 D28C
14 18A 28C 29 29
B 34 BEEPER
BP-29
F

NOHC
14A 3H-14A LIFT VALVE
35
D02-4 SOLENOID
D09
09 09 ORANGE/RED 09 35A THROTTLE ENABLE
08 36
RELAY
NOHC 35ACR D44-2 D14A-1 20ACR1
20A SERIES/PARELLEL
37
RELAY
TILT OVERRIDE/ 20ACR2
HIGH DRIVE CUTOUT 44 20A 20A SERIES/PARELLEL
LIMIT SWITCH 38
NORMALLY OPEN RELAY
35CR
HELD CLOSED 10A 35 35 ELEVATION/HI SPD
39
CUTOUT RELAY
08 LS5
20 20 BLACK/WHITE/RED 20 20 SERIES/PARELLEL
NO 40
RELAY
10A 44 20CR 4H-20A
10A SERIES/PARALLEL
41
D02-5 VALVE SOLENOID
44 17 17 17 17A 17A 2H-17A LARGE PUMP DUMP
S7-1 42
G

D02-6 VALVE SOLENOID

2ND SPEED
19 19 ORANGE/BLACK 19 19
JOYSTICK ENABLE 43 LARGE PUMP RELAY
ENABLE RELAY 19CR D17A
33 20B 2H-20B HIGH SPEED
44
D02-7 VALVE SOLENOID
8CCR D16B
08 8C 02 02 WHITE 02
45
S7-2 RIGHT D15B
23 23 BLACK/WHITE 23 23 4H-23 RIGHT STEERING
46
D02-8 VALVE SOLENOID
S7-3 LEFT
24 24 BLUE/BLACK 24 24 4H-24 LEFT STEERING
47
D02-9 VALVE SOLENOID
D23 D15A-1 D15A-2 4H-15B
08 8A 8A 8B 15A 15B PARALLEL REVERSE
48
NCHO D02-10 VALVE SOLENOID
10A 15A 15A 4H-15A REVERSE
49
D02-11 VALVE SOLENOID
S7-4 REV
A A 15 15 BLUE 15 15
H

50 REVERSE RELAY
NCHO
15CR D24 D16A-1 D16A-2
30 3H-30 BRAKE
51
D02-12 VALVE SOLENOID
10A 16A 16A 4H-16A FORWARD
52
D02-13 VALVE SOLENOID
S7-5 FWD
B B 16 16 WHITE/BLACK 16 16
53 FORWARD RELAY
NCHO
16CR
21 18A 16A 16B 4H-16B PARALLEL FORWARD
S7-6 54
S7 D02-14 VALVE SOLENOID
3RD SPEED D18
JOYSTICK
18 18 RED/BLACK 18 18A 18B 2H-18B SMALL PUMP DUMP
CONTROLLER 55
D02-15 VALVE SOLENOID
33 D18B
56

44 14A 28A SMALL PUMP DUMP

57
ENABLE RELAY
28ACR1
I

HYDRAULIC GENERATOR OPTION 28A LARGE PUMP DUMP

D44-1 D14A-2 58
ENABLE RELAY
28ACR2 D86D
59
3.18. Electrical Schematic (All Option with Kubota Diesel Engine)

09 D86C 2H-86D
43 86D

the “Table Of Contents” found at the beginning of this section.

60 HYDR. GENERATOR
S12 D02-16 SOLENOID
HYDRAULIC 09 09 86C
GENERATOR 61 HYDR. GENERATOR
SWITCH RELAY
86CCR
85 85 86B 2A
62 HYDR. GENERATOR
ON LATCHING RELAY
09
86 D86 86BCR
86A
OFF 63 HYDR. GENERATOR
STOP RELAY
D14 86ACR
64

NOTE: To determine the correct electrical schematic that resembles your machine, refer to
65
FF EE CC HH MM GG BB PP II,JJ
J

D17C-1 D17C-2 66

28 28 28A 10A 17E 17C 2H-17C OUTRIGGER

67
J17E D02-17 HOLDING SOLENOID
10A 10A 36A 14A
68
OUTRIGGER UP LIMIT SWITCHES KK
NORMALLY OPEN HELD CLOSED
65 OUTRIGGER LIFT
69
ENABLE RELAY
LS64 LS63 LS62 LS61 D36 65CR
10A 10A D36-1
64 63 62 36 61 OUTRIGGER DRIVE
70
NN ENABLE RELAY
LEFT RIGHT RIGHT LEFT 61CR
REAR REAR FRONT FRONT
71
OUTRIGGERS SHOWN IN CUT J36
14 RETRACTED POSITION 14
72 UP RELAY
9CR3
14CR
09 OUTRIGGER
73
PROOF RELAY
9CR2
K

09 OUTRIGGER
74
ENABLE RELAY
S20A S21A S22A S23A
44 35B 35C 35C 35E FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT 17D OUTRIGGER
75
LIFT DISABLE RELAY
S9B UP UP UP UP 17DCR
OUTRIGGER
OUTRIGGER 76
CUT J17D CONTROL MODULE
ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 77 LEFT FRONT UP
D72
72
72 = P4-7 78 RIGHT FRONT UP
D73
73
73 = P4-6 79 RIGHT REAR UP
D74
74
74 = P4-5 80 LEFT REAR UP
D75
75
75 = P4-4 81 LEFT FRONT DOWN
L

D76
76
76 = P4-3 82 RIGHT FRONT DOWN
D77
77
77 = P4-2 83 RIGHT REAR DOWN
D78
78
78 = P4-1 84 LEFT REAR DOWN

44 TILT OVERRIDE/
44 = P2-10 85
HIGH DRIVE CUTOUT
28
28 = P2-9 86 TILT
OUTRIGGER DOWN LIMIT SWITCHES
65 NORMALLY CLOSED HELD OPEN
65 = P2-8 87 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 88 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
OUTRIGGER OPTION 67A = P2-2 89 RIGHT REAR DOWN
M

WITH AUTO LEVELLING RIGHT REAR

LS66
10A 66A
66A = P2-3 90 RIGHT FRONT DOWN
RIGHT FRONT
LS65
35C GREEN/WHITE 35C 10A 65A
65A = P2-4 91 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER 35C BLUE/WHITE 35C 10A
ENABLE 10A = P2-12 92 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 93 OUTRIGGER ENABLE
S24
79 GREEN 79
AUTO 79 = P2-6 94 AUTO RETRACT
MODE ALL UP
35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 95 AUTO LEVEL

02 70A RED/WHITE 70A

70A = P2-7 96 OUTRIGGER LIGHT
OL1
OUTRIGGER
N

02 = P2-11 97 GROUND
LIGHT
02 WHITE 02
98
S20
71 ORANGE 71 71 4H-71 LEFT FRONT UP
FRONT 99
LEFT UP OUTRIGGER SOLENOID
35D D02-18
75 ORANGE/BLACK 75 75 4H-75 LEFT FRONT DOWN
DN 100
D02-19 OUTRIGGER SOLENOID
S21
72 RED 72 72 4H-72 RIGHT FRONT UP
FRONT 101
RIGHT UP OUTRIGGER SOLENOID
35D D02-20
76 RED/BLACK 76 76 4H-76 RIGHT FRONT DOWN
DN 102
D02-21 OUTRIGGER SOLENOID
S22
73 BLUE 73 73 4H-73 RIGHT REAR UP
REAR 103
RIGHT UP OUTRIGGER SOLENOID
35D D02-22
77 BLUE/BLACK 77 77 4H-77 RIGHT REAR DOWN
DN 104
D02-23 OUTRIGGER SOLENOID
S23
74 74 4H-74
O

REAR 74 BLACK LEFT REAR UP

105
LEFT UP OUTRIGGER SOLENOID
35D D02-24
78 BLACK/WHITE 78 78 4H-78 LEFT REAR DOWN
DN 106
D02-25 OUTRIGGER SOLENOID
M137326AN
Z
T

Y
X
S
R

SECTION 3, Page 28
AB
 Section 4
Troubleshooting Information

Table of Contents
Introduction...................................................................................................................................................................4

Electrical System
4.1-1 All Controls Inoperative....................................................................................................................................5
4.1-2 No Power To Platform......................................................................................................................................5
4.1-3 All Functions Inoperative (Machines Equipped with Load Sensing System) (CE)..........................................6
4.1-4 All Functions Inoperative from The Platform...................................................................................................6
4.1-5 Engine Will Not Crank from Platform or Base Control Console.....................................................................6
4.1-6 Engine Cranks But Will Not Start - Kubota Diesel...........................................................................................7
4.1-7 Engine Cranks But Will Not Start - Kubota Dual Fuel.....................................................................................7
4.1-8 Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models)...................................................8
4.1-9 Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel).....................................................9
4.1-10 High Throttle Inoperative.................................................................................................................................9
4.1-11 High Throttle On Demand Inoperative (Kubota Dual Fuel)...........................................................................10
4.1-12 Drive and Steer Inoperative (Machines without outriggers option)..............................................................10
4.1-13 Drive and Steer Inoperative (Machines with outriggers option)...................................................................11
4.1-14 Brakes Will Not Release................................................................................................................................12
4.1-15 Steer Right Inoperative..................................................................................................................................12
4.1-16 Steer Left Inoperative.....................................................................................................................................12
4.1-17 Reverse Drive Inoperative..............................................................................................................................13
4.1-18 Forward Drive Inoperative..............................................................................................................................13
4.1-19 First Drive Speed and Steering Inoperative..................................................................................................14

4
4.1-20 Second Drive Speed Inoperative...................................................................................................................14
4.1-21 Third Drive Speed Inoperative.......................................................................................................................16
4.1-22 High Drive Speed Inoperative........................................................................................................................16
4.1-23 Up Circuit Inoperative from Platform.............................................................................................................17
4.1-24 Up Circuit Inoperative from Base Control Console.......................................................................................17
4.1-25 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers)..................................17
4.1-26 Platform will Not Lift from Platform or Base Control Console with Outriggers Retracted
(Lift Operates Correctly with Outriggers Extended)......................................................................................17
4.1-27 Platform will Not Lift from Platform or Base Control Console with Outriggers Extended.............................18
4.1-28 Platform will Not Lift from Platform or Base Control Console with Outriggers Extended or Retracted........19
4.1-29 Down Circuit Inoperative from Platform........................................................................................................19
4.1-30 Down Circuit Inoperative from Base..............................................................................................................20
4.1-31 No Down Function (Additional for machines with Load Sensing System) (CE)..........................................20
4.1-32 Hydraulic Generator Inoperative...................................................................................................................21
4.1-33 Hydraulic Generator will not Shut Off from Generator Switch......................................................................21
4.1-34 All Outriggers Inoperative (Auto-Level and Manual).....................................................................................22
4.1-35 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)..............................................22
4.1-36 All Outriggers Inoperative (Base Controls only)............................................................................................23
4.1-37 All Outriggers Inoperative (Auto Level only)
A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not On (Constant)..............................23
4.1-38 All Outriggers Inoperative (Auto Level only)
B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing..............................................24
4.1-39 Left Front Outrigger Inoperative Manually.....................................................................................................25
4.1-40 Right Front Outrigger Inoperative Manually..................................................................................................25

Rough Terrain Compact Series SKYJACK, Page 1

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Table of Contents (Continued)

4.1-41 Right Rear Outriggers Inoperative Manually.................................................................................................25

4.1-42 Left Rear Outriggers Inoperative Manually....................................................................................................25
4.1-43 Individual Outrigger Functions Inoperative (Auto-Level) .............................................................................26
4.1-44 Auto-Level Inoperative...................................................................................................................................26
4.1-45 Auto All Up Inoperative (Retract)...................................................................................................................26

Hydraulic System
4.2-1 All Functions Inoperative ..............................................................................................................................27
4.2-2 Steering Inoperative.......................................................................................................................................27
4.2-3 Lift, Steer and First Drive Speed Inoperative.................................................................................................27
4.2-4 Second Drive Speed Inoperative...................................................................................................................27
4.2-5 Drive Inoperative............................................................................................................................................27
4.2-6 Drive Sluggish................................................................................................................................................28
4.2-7 Reverse Drive Inoperative..............................................................................................................................28
4.2-8 Forward Drive Inoperative..............................................................................................................................28
4.2-9 Drive Inoperative When in Low Drive............................................................................................................28
4.2-10 Drive Inoperative When in High Drive............................................................................................................28
4.2-11 Brakes Will Not Release................................................................................................................................28
4.2-12 Up Circuit Inoperative....................................................................................................................................28
4.2-13 Down Circuit Inoperative...............................................................................................................................29
4.2-14 Hydraulic Generator Inoperative...................................................................................................................29
4.2-15 All Outriggers Inoperative..............................................................................................................................29
4.2-16 Left Front Outriggers Inoperative...................................................................................................................29
4.2-17 Right Front Outriggers Inoperative................................................................................................................29
4.2-18 Right Rear Outriggers Inoperative.................................................................................................................29
4.2-19 Left Rear Outriggers Inoperative...................................................................................................................29
4.2-20 Outriggers Drift In..........................................................................................................................................30

SKYJACK, Page 2 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Introduction

The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble
which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting Information
will localize the trouble more quickly than any other method. This manual cannot cover all possible troubles and
deficiencies that may occur. If a specific trouble is not listed, isolate the major component in which the trouble oc-
curs, isolate whether the problem is electrical or hydraulic, and then isolate and correct the specific problem.

The content of this section is separated into “probable cause” and “remedy.” The information preceded by a num-
ber represents the “probable cause.” The following line, noted by a dash represents the “remedy” to the “probable
cause” directly above it. See example below for clarification.

1. Probable Cause
-- Remedy

Rough Terrain Compact Series SKYJACK, Page 3

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System

4.1-1 All Controls Inoperative

1. Battery disconnected or discharged.
-- Reconnect battery. Recharge if discharged.
2. Loose or dirty battery cables.
-- Clean and tighten battery cables.
3. Defective main fuse F1 (300Amp).
-- Check fuse. Replace if defective.
4. Open or defective main power disconnect switch S1.
-- Close switch. Replace if defective.
5. Loose or broken wire #03 from main power disconnect switch S1 to circuit breaker CB1.
-- Check continuity. Replace if defective.
6. Tripped or defective circuit breaker CB1.
-- Reset breaker. Check for defective wiring. Replace breaker if defective.
7. Loose or broken wire #3A from breaker CB1 to base terminal block TB-1.
-- Check continuity. Replace if defective.
8. Loose or broken wire #3A from base terminal block TB-1 to base emergency stop switch S6.
-- Check continuity. Replace if defective.
9. Defective base emergency stop switch S6.
-- Check switch. Replace if defective.
10. Loose or broken wire #5 from base emergency stop switch S6 to base terminal block TB-1.
-- Check continuity. Replace if defective.
11. Loose or broken wire #5 from base terminal block TB-1 to key switch S10.
-- Check continuity. Replace if defective.
12. Defective key switch S10.
-- Check switch. Replace if defective.
13. Loose or broken wire #7 from key switch S10 to base terminal block TB-1.
-- Check continuity. Replace if defective.
14. Loose or broken wire #7 from base terminal block TB-1 to platform emergency stop switch S4.
-- Check continuity. Replace if defective.
15. Defective platform emergency stop switch S4.
-- Check switch. Replace if defective.
16. Loose or broken wire #10 from platform emergency stop switch S4 to base terminal block TB-1.
-- Check continuity. Replace if defective.
17. Loose or broken wire #10 from base terminal block TB-1 to key switch S10.
-- Check continuity. Replace if defective.
18. Defective key switch S10.
-- Check switch. Replace if defective.

4.1-2 No Power To Platform

1. Open or defective key switch S10.
-- Check switch. Replace if defective.
2. Loose or broken wire #07 from key switch S10 to base terminal block TB-1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #07 from base terminal block TB-1 to platform emergency stop switch S4.
-- Check continuity. Replace if defective.
4. Open or defective platform emergency stop switch S4.
-- Check switch. Replace if defective.

SKYJACK, Page 4 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

4.1-3 All Functions Inoperative (Machines Equipped with Load Sensing System) (CE)
1. Loose or broken wire #10A from base terminal block TB1 to control module CM1 at pin #P2-12.
-- Check for 12 Volts at P2-12. If no voltage present, check wire continuity. Replace if defective.
2. Loose or broken wire #02 from control module CM1 at pin #P2-11 to base terminal block TB1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #28E from control module CM1 at pin #P3-6 to 28ECR1 small pump dump
auxiliary enable relay and 28ECR2 large pump dump auxiliary enable relay and 28ECR3 auxiliary down
enable relay.
-- Check for 12 Volts at P3-6. If voltage present, check for 12 Volts at wire #28E at 28ECR1, 28ECR2
and 28ECR3 relays. If voltage present, check operation of relays. If no voltage present, check
wire continuity. Replace if defective.
4. Defective pressure transducer PT1 or angle transducer AT1 or related wiring.
-- Refer to transducer troubleshooting charts.

4.1-4 All Functions Inoperative from The Platform

1. Open or defective emergency stop switch S4.
-- Check switch. Replace if defective.
2. Loose or broken wire #08 from platform emergency stop switch S4 to base terminal block TB-1.
-- Check continuity. Replace if defective.
3. Open diode D08 at base terminal block TB-1.
-- Check diode. Replace if defective.

4.1-5 Engine Will Not Crank from Platform or Base Control Console
1. Loose or broken wire #8 from horn switch S8 to start switch S15 (Platform only).
-- Check continuity. Replace if defective.
2. Defective start switch S15 (Platform only).
-- Check switch. Replace if defective.
3. Loose or broken wire #32 from start switch S15 to base start switch S32 (Platform only).
-- Check continuity. Replace if defective.
4. Loose or broken wire #10E from key switch S10 to base terminal block TB-1 (Base only).
-- Check continuity. Replace if defective.
5. Defective key switch S10 (Base only).
-- Check switch. Replace if defective.
6. Open or defective diode D10E (Base only).
-- Check diode. Replace if defective.
7. Loose or broken wire #10B from base terminal block TB-1 to base choke/ glow plug switch S31(Base
only).
-- Check continuity. Replace if defective.
8. Loose or broken wire #10B from base choke/ glow plug switch S31 to base start switch S32 (Base
only).
-- Check continuity. Replace if defective.
9. Defective base start switch S32 (Base only).
-- Check switch. Replace if defective.
10. Loose or broken wire #32 from base start switch S32 to relay 32CR2.
-- Check continuity. Replace if defective.
11. Defective relay 32CR2.
-- Check relay. Replace if defective.
12. Loose or broken jumper wire #41 on relay 32CR2.
-- Check continuity. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 5

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

13. Loose or broken wire #02 from relay 32CR2 to base terminal block TB-1.
-- Check continuity. Replace if defective.
14. Ground not getting through N/C set of contacts on relay 10CR2 to relay 32CR2.
-- Check continuity through contacts. Replace if defective.
15. Loose or broken wire #3A from relay 10BC2 to relay 32CR1.
-- Check continuity. Replace if defective.
16. Loose or broken wire #32A from relay 32CR1 to engine harness.
-- Check continuity. Replace if defective.
17. Loose or broken wire #32 from relay 32CR2 to relay 32CR1.
-- Check continuity. Replace if defective.
18. Loose or broken wire #41 from relay 32CR2 to relay 32CR1.
-- Check continuity. Replace if defective.
19. Defective relay 32CR1.
-- Check relay. Replace if defective.
20. Loose or broken wire #32A from engine harness to starter contactor 32ACR.
-- Check continuity. Replace if defective.
21. Defective starter contactor 32ACR.
-- Check contactor. Replace if defective.
22. Loose or broken wire #00 from starter contactor 32ACR to base terminal block TB-1.
-- Check continuity. Replace if defective.
23. Loose or broken wire #103 from main power disconnect S1 to starter contactor 32ACR.
-- Check continuity. Replace if defective.
24. Loose or broken wire #57 from starter contactor 32ACR to starter motor.
-- Check continuity. Replace if defective.
25. Defective starter motor.
-- Check motor. Repair or replace if defective.

4.1-6 Engine Cranks But Will Not Start - Kubota Diesel

1. Open diode D32A from engine start switch S32 to glow plug switch S31. (Diode located in Engine
harness. Refer to Engine wiring diagram- Diesel Fuel System)
-- Check diode. Replace if defective.
2. Loose or broken wire #37 from engine harness to diesel valve solenoid 2D37.
-- Check continuity. Replace if defective.
3. Loose or broken wire #57 from starter contactor 32ACR to diesel valve solenoid 2D37.
-- Check continuity. Replace if defective.
4. Defective fuel valve solenoid 2D37.
-- Check solenoid. Replace if defective.
5. Defective glow plugs.
-- Check glow plugs. Repair if necessary.
6. Defective glow plug timer GPT1.
-- Check timer. Replace if defective.
7. Defective glow plug relay 31CR.
-- Check relay. Replace if defective.

4.1-7 Engine Cranks But Will Not Start - Kubota Dual Fuel
1. Open or defective diode D57. (Diode located in Engine harness. Refer to Engine wiring diagram- Dual
Fuel System)
-- Check diode. Replace if defective.
2. Loose or broken wire #37 from engine harness plug to coil pack 2 wire connector.
-- Check continuity. Replace if defective.

SKYJACK, Page 6 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

3. Loose or broken wire #00 from coil pack 2 wire connector to engine ground.
-- Check continuity. Replace if defective.
4. Loose or broken wire #00 from engine ground to crank position sensor.
-- Check continuity. Replace if defective.
5. Loose or broken wire #37 from ignition control module ICM1 to crank position sensor CPS1.
-- Check continuity. Replace if defective.
6. Defective ignition control module ICM1.
-- Refer to section 5 of this manual for Ohm specifications. Replace if defective.
7. Defective crank position sensor CPS1.
-- Refer to section 5 of this manual for Ohm specifications. Replace if defective.
8. Loose or broken wire #37 from engine harness plug to fuel select switch S33.
-- Check continuity. Replace if defective.
9. Defective fuel switch S33.
-- Check switch. Replace if defective.
10. While in gasoline, loose or broken wire #11 from fuel select switch S33 to fuel pump FP11 or gas valve
2G-11.
-- Check continuity. Replace if defective.
11. While in propane, loose or broken wire #50 from fuel select switch S33 to fuel lockoff 2P-50-1 or propane
lockoff 2P-50-2.
-- Check continuity. Replace if defective.
12. Loose or broken wire #00 from engine ground to propane lockoff 2P-50-1 or 2P-50-2 (propane) or to
gasoline 2G-11 or fuel pump FP11 (gasoline).
-- Check continuity. Replace if defective.
13. Defective propane lockoff 2P-50-1 or 2P-50-2 (propane) or gas valve 2G-11 or fuel pump FP11
(gasoline).
-- Check lockoffs, valve or pump. Replace if defective.

4.1-8 Glow Plugs Inoperative from Engine Controls or Platform (Diesel Models)
1. Loose or broken wire #8 from start switch S15 to glow plug switch S13 (Platform only).
-- Check continuity. Replace if defective.
2. Defective glow plug switch S13 (Platform only).
-- Check switch. Replace if defective.
3. Loose or broken wire #31 from glow plug switch S13 to base glow plug switch S31 (Platform only).
-- Check continuity. Replace if defective.
4. Loose or broken wire #10B from base terminal block TB-1 to base glow plug switch S31 (Base only).
-- Check continuity. Replace if defective.
5. Defective base glow plug switch S31 (Base only).
-- Check switch. Replace if defective.
6. Loose or broken wire #31 from glow plug switch S31 to glow plug relay 31CR.
-- Check continuity. Replace if defective.
7. Loose or broken wire #02 from glow plug relay 31CR to base terminal block TB1.
-- Check continuity. Replace if defective.
8. Loose or broken wire #103 from engine starter to relay 31CR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #91A from relay 31CR to engine glow plugs EGP1.
-- Check continuity. Replace if defective.
10. Defective glow plug relay 31CR.
-- Check relay. Replace if defective.
11. Defective glow plugs.
-- Check glow plugs. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 7

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

4.1-9 Choke Inoperative from Engine Controls or Platform (Kubota Dual Fuel)
1. Loose or broken wire #8 from start switch S15 to choke switch S13 (Platform only).
-- Check continuity. Replace if defective.
2. Defective choke switch S13 (Platform only).
-- Check switch. Replace if defective.
3. Loose or broken wire #31 from choke switch S13 to base choke switch S31 (Platform only).
-- Check continuity. Replace if defective.
4. Loose or broken wire #10B from base terminal block TB-1 to base choke switch S31 (Base only).
-- Check continuity. Replace if defective.
5. Defective base choke switch S31 (Base only).
-- Check switch. Replace if defective.
6. Loose or broken wire #31 from base choke switch S31 to engine harness.
-- Check continuity. Replace if defective.
7. Loose or broken wire #31 from engine harness to relay 31CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #02 from engine harness to relay 31CR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #3A from engine harness to relay 31CR.
-- Check continuity. Replace if defective.
10. Defective relay 31CR.
-- Check relay. Replace if defective.
11. Loose or broken wire #31A from relay 31CR to choke solenoid CS-31A.
-- Check continuity. Replace if defective.
12. Loose or broken wire #02 from engine harness to choke solenoid CS-31A.
-- Check continuity. Replace if defective.
13. Defective choke solenoid CS-31A.
-- Check solenoid. Replace if defective.

4.1-10 High Throttle Inoperative

NOTE
If machine is in drive mode and is elevated above high speed limit
switch, high throttle is inoperative.

1. Loose or broken wire #08 from lift/drive select switch S3 to low/high throttle switch S14.
-- Check continuity. Replace if defective.
2. Defective low/high throttle switch S14.
-- Check switch. Replace if defective.
3. Loose or broken wire #34 from low/high throttle switch S14 to relay 35ACR.
-- Check continuity. Replace if defective.
4. Open diode D09 (when in lift only).
-- Check diode. Replace if defective.
5. Open diode D44-2 (when in drive only).
-- Check diode. Replace if defective.
6. Loose or broken wire #35A from base terminal block TB-1 to relay 35ACR.
-- Check continuity. Replace if defective.
7. Defective relay 35ACR.
-- Check relay. Replace if defective.
8. Loose or broken wire #02 from relay 35ACR to terminal block TB1.
-- Check continuity. Replace if defective.

SKYJACK, Page 8 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

9. Loose or broken wire #34A from relay 35ACR to relay 34ACR.

-- Check continuity. Replace if defective.
10. Defective relay 34ACR.
-- Check relay. Replace if defective.
11. Loose or broken wire #42 from relay 34ACR to relay 10CR2.
-- Check continuity. Replace if defective.
12. Defective relay 10CR2.
-- Check relay. Replace if defective.
13. Loose or broken wire #2A from relay 10CR2 to relay 10CR1.
-- Check continuity. Replace if defective.
14. Loose or broken wire #3A from base terminal block TB1 to relay 32CR1.
-- Check continuity. Replace if defective.
15. Defective relay 32CR1.
-- Check relay. Replace if defective.
16. Loose or broken wire #43 from relay 32CR1 to relay 34ACR.
-- Check continuity. Replace if defective.
17. Loose or broken wire #34B from relay 34ACR to relay 33CR.
-- Check continuity. Replace if defective.

4.1-11 High Throttle On Demand Inoperative (Kubota Dual Fuel)

NOTE
If machine is in drive mode and is elevated above high speed limit
switch, high throttle is inoperative.

1. Throttle switch S14 in low throttle position.

-- Select high throttle position on switch.
2. Open or defective diode D17A or D18B.
-- Check diodes. Replace if defective.
3. Loose or broken wire #33 from terminal block TB1 to power on demand relay 33CR.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from terminal block TB1 to power on demand relay 33CR.
-- Check continuity. Replace if defective.
5. Defective power on demand relay 33CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #34C from power on demand relay 33CR to high throttle solenoid HTS-34C.
-- Check continuity. Replace if defective.
7. Defective high throttle solenoid HTS-34C.
-- Check solenoid. Replace if defective.

NOTE
If the above does not repair the high throttle on demand, refer to high
throttle inoperative in this section.

4.1-12 Drive and Steer Inoperative (Machines without outriggers option)

1. Lift/Drive select switch S3 in lift position.
-- Turn switch to Drive position.
2. Defective contacts on lift/drive select switch between wire #8A and wire #8B.
-- Check continuity through contact. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 9

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

3. Loose or broken wire #08 from Lift/Drive select switch S3 to controller enable switch S7-7.
-- Check continuity. Replace if defective.
4. Defective controller enable switch S7-7.
-- Check switch. Replace if defective.
5. Loose or broken wire #8A from controller enable relay 8CCR to speed, steer and direction switches
S7-1 to S7-6.
-- Check continuity. Replace if defective.
6. Loose or broken wire #8C from controller enable switch S7-7 to controller enable relay 8CCR.
-- Check continuity. Replace if defective.
7. Defective controller enable relay 8CCR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #02 from controller enable relay 8CCR to controller harness.
-- Check continuity. Replace if defective.
9. Loose or broken wire #10A from base terminal block to tilt switch TS1.
-- Check continuity. Replace if defective.
10. Defective tilt switch TS1.
-- Check tilt switch. Replace if defective.
11. Loose or broken wire #28 from tilt switch TS1 to terminal block TB1.
-- Check continuity. Replace if defective.
12. Loose or broken wire #28 from base terminal TB1 to outrigger connector CN14 at pin #7.
-- Check continuity. Replace if defective.
13. Loose or broken jumper wire from #28 to # 28A on outrigger connector CN14 between pin #1 and pin
#7.
-- Check continuity. Replace if defective.
14. Loose or broken wire #28A from outrigger connector CN14 at pin #1 to base terminal block TB1.
-- Check continuity. Replace if defective.

4.1-13 Drive and Steer Inoperative (Machines with outriggers option)

1. Outriggers not fully retracted
-- Fully retract outrigger cylinders
2. Lift/Drive select switch S3 in lift position.
-- Turn switch to Drive position.
3. Defective contacts on lift/drive select switch between wire #8A and wire #8B.
-- Check continuity through contact. Replace if defective.
4. Loose or broken wire #08 from lift/drive select switch S3 to controller enable switch S7-7.
-- Check continuity. Replace if defective.
5. Defective controller enable switch S7-7.
-- Check switch. Replace if defective.
6. Loose or broken wire #8A from controller enable relay 8CCR to speed, steer and direction switches
S7-1 to S7-6.
-- Check continuity. Replace if defective.
7. Loose or broken wire #8C from controller enable switch S7-7 to controller enable relay 8CCR.
-- Check continuity. Replace if defective.
8. Defective controller enable relay 8CCR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from controller enable relay 8CCR to controller harness.
-- Check continuity. Replace if defective.

SKYJACK, Page 10 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

10. Loose or broken wire #10A from base terminal block TB1 to outrigger control module OCM1 at pin
#p2-12.
-- Check continuity. Replace if defective.
11. Loose or broken wire #28 from outrigger control module OCM1 at pin #P2-9 to outrigger connector
CN14 at pin #7.
-- Check continuity. Replace if defective.
12. Left rear outrigger limit switch LS64 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
13. Right rear outrigger limit switch LS63 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
14. Right front outrigger limit switch LS62 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
15. Left front outrigger limit switch LS61 is out of adjustment or defective.
-- Check continuity through switch. Adjust switch if out of adjustment. Replace if defective.
16. Defective drive enable relay 61CR.
-- Check relay. Replace if defective.
17. Loose or broken wire #28A from pin #1 on connector CN14 at the outrigger board to terminal block
TB1.
-- Check continuity. Replace if defective.

4.1-14 Brakes Will Not Release

1. Loose or broken wire #30 from base terminal block TB1 to brake valve coil 3H-30.
-- Check continuity. Replace if defective.
2. Defective brake valve coil 3H-30.
-- Check continuity through coil. Replace if defective.
3. Loose or broken wire #02 from brake valve 3H-30 to base terminal block TB1.
-- Check continuity. Replace if defective.

4.1-15 Steer Right Inoperative

1. Defective steer right switch S7-2 in controller S7.
-- Check switch. Replace if defective.
2. Loose or broken wire #23 from steer right switch S7-2 to base terminal block TB1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #23 from base terminal block TB1 to steer right valve coil 4H-23.
-- Check continuity. Replace if defective.
4. Defective steer right valve coil 4H-23.
-- Check coil. Replace if defective.
5. Loose or broken wire #02 from steer right valve coil 4H-23 to base terminal block TB1.
-- Check continuity. Replace if defective.
6. Open diode D23.
-- Check diode. Replace if defective.

4.1-16 Steer Left Inoperative

1. Defective steer left switch S7-3 in controller S7.
-- Check switch. Replace if defective.
2. Loose or broken wire #24 from steer left switch S7-3 to base terminal block TB1.
-- Check continuity. Replace if defective.
3. Loose or broken wire #24 from base terminal block TB1 to steer left valve coil 4H-24.
-- Check continuity. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 11

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

4. Defective steer left valve coil 4H-24.

-- Check coil. Replace if defective.
5. Loose or broken wire #02 from steer left valve coil 4H-24 to base terminal block TB1.
-- Check continuity. Replace if defective.
6. Open diode D24.
-- Check diode. Replace if defective.

4.1-17 Reverse Drive Inoperative

1. Defective reverse switch S7-4 in controller S7.
-- Check switch. Replace if defective.
2. Defective controller S7.
-- Check controller. Replace if defective.
3. Loose or broken wire #A from reverse switch S7-4 to contacts on Lift/Drive select switch between wire
#A and wire #15.
-- Check continuity. Replace if defective.
4. Loose or broken wire #15 from Lift/Drive select switch to relay 15CR.
-- Check continuity. Replace if defective.
5. Defective relay 15CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #02 from relay 15CR to base terminal block.
-- Check continuity. Replace if defective.
7. Loose or broken wire #10A from base terminal block to relay 15CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #15A from relay 15CR to reverse valve coil 4H-15A.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from reverse valve coil to base terminal block TB1.
-- Check continuity. Replace if defective.
10. Loose or broken wire #15A from base terminal block TB1 to relay 20ACR2 (In parallel drive only).
-- Check continuity. Replace if defective.
11. Defective relay 20ACR2 (in parallel drive only).
-- Check relay. Replace if defective.
12. Loose or broken wire #15B from relay 20ACR2 to parallel reverse valve coil 4H-15B (in parallel drive
only).
-- Check continuity. Replace if defective.
13. Loose or broken wire #02 from base terminal block TB1 to parallel reverse valve coil 4H-15B (in parallel
drive only).
-- Check continuity. Replace if defective.
14. Defective parallel reverse valve coil 4H-15B (in parallel drive only).
-- Check coil. Replace if defective.
15. Open diode D15A-1 or D15A-2.
-- Check diodes. Replace if defective.

4.1-18 Forward Drive Inoperative

1. Defective forward switch S7-5 in controller S7.
-- Check switch. Replace if defective.
2. Defective controller S7.
-- Check controller. Replace if defective.
3. Loose or broken wire #B from forward switch S7-5 to contacts on lift/drive select switch between wire
#B and wire #16.
-- Check continuity. Replace if defective.

SKYJACK, Page 12 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

4. Loose or broken wire #16 from lift/drive select switch to relay 16CR.
-- Check continuity. Replace if defective.
5. Defective relay 16CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #02 from relay 16CR to base terminal block.
-- Check continuity. Replace if defective.
7. Loose or broken wire #10A from base terminal block to relay 16CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #16A from relay 16CR to forward valve coil 4H-16A.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from forward valve coil to base terminal block TB1.
-- Check continuity. Replace if defective.
10. Loose or broken wire #16A from base terminal block TB1 to relay 20ACR1 (in parallel drive only).
-- Check continuity. Replace if defective.
11. Defective relay 20ACR1 (in parallel drive only).
-- Check relay. Replace if defective.
12. Loose or broken wire #16B from relay 20ACR1 to parallel forward valve coil 4H-16B (in parallel drive
only).
-- Check continuity. Replace if defective.
13. Loose or broken wire #02 from base terminal block TB1 to parallel forward valve coil 4H-16B (in parallel
drive only).
-- Check continuity. Replace if defective.
14. Defective parallel forward valve coil 4H-16B (in parallel drive only).
-- Check coil. Replace if defective.
15. Open diode D16A-1 or D16A-2.
-- Check diodes. Replace if defective.

4.1-19 First Drive Speed and Steering Inoperative

1. Loose or broken wire #21 from base terminal block TB1 to relay 17CR.
-- Check continuity. Replace if defective.
2. Defective relay 17CR.
-- Check relay. Replace if defective.
3. Loose or broken wire #18A from relay 17CR to base terminal block TB1.
-- Check continuity. Replace if defective.
4. Loose or broken wire #18A from base terminal block TB1 to relay 28ACR1.
-- Check continuity. Replace if defective.
5. Defective relay 28ACR1.
-- Check relay. Replace if defective.
6. Loose or broken wire #18B from relay 28ACR1 to base terminal block TB1.
-- Check continuity. Replace if defective.
7. Loose or broken wire #18B from base terminal block TB1 to small pump dump valve coil 2H-18B.
-- Check continuity. Replace if defective.
8. Defective small pump dump valve coil 2H-18B.
-- Check coil. Replace if defective.
9. Loose or broken wire #02 from small pump dump coil 2H-18B to base terminal block TB1.
-- Check continuity. Replace if defective.

4.1-20 Second Drive Speed Inoperative

1. Defective second speed switch S7-1 in controller S7.
-- Check switch. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 13

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

2. Defective controller S7.

-- Check controller. Replace if defective.
3. Loose or broken wire #19 from controller S7-1 to relay 19CR.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from platform terminal block TB1 to relay 19CR.
-- Check continuity. Replace if defective.
5. Defective relay 19CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #10A from base terminal block to high drive/tilt override limit switch LS5.
-- Check continuity. Replace if defective.
7. Misadjusted or defective high drive/tilt override limit switch LS5.
-- Adjust switch. Replace if defective.
8. Loose or broken wire #35 from high drive/tilt override limit switch LS5 to relay 35CR.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from relay 35CR to base terminal block.
-- Check continuity. Replace if defective.
10. Defective relay 35CR.
-- Check relay. Replace if defective.
11. Loose or broken wire #10A from base terminal block TB1 to relay 35CR.
-- Check continuity. Replace if defective.
12. Loose or broken wire #44 from relay 35CR to base terminal block TB1.
-- Check continuity. Replace if defective.
13. Loose or broken wire #44 from base terminal block TB1 to relay 19CR.
-- Check continuity. Replace if defective.
14. Loose or broken wire #17 from relay 19CR to relay 17CR.
-- Check continuity. Replace if defective.
15. Defective relay 17CR.
-- Check relay. Replace if defective.
16. Loose or broken wire #02 from relay 17CR to base terminal block TB1.
-- Check continuity. Replace if defective.
17. Loose or broken wire #17 from relay 17CR to relay 28ACR2.
-- Check continuity. Replace if defective.
18. Loose or broken wire #17A from relay 28ACR2 to base terminal block TB1. (ANSI/CSA)
-- Check continuity. Replace if defective.
19. Defective relay 28ACR2.
-- Check relay. Replace if defective.
20. Loose or broken wire #17A from relay 28ACR2 to relay 28ECR2. (CE)
-- Check continuity. Replace if defective.
21. Defective relay 28ECR2. (CE)
-- Check relay. Replace if defective.
22. Loose or broken wire #17B from relay 28ECR2 to base terminal block TB1. (CE)
-- Check continuity. Replace if defective.
23. Loose or broken wire #17A from base terminal block TB1 to large pump dump valve coil 2H-17A. (ANSI/
CSA)
-- Check continuity. Replace if defective.
24. Loose or broken wire #17B from base terminal block TB1 to large pump dump valve coil 2H-17B.
(CE)
-- Check continuity. Replace if defective.

SKYJACK, Page 14 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

25. Loose or broken wire #02 from large pump dump valve coil 2H-17A (ANSI/CSA) or 2H-17B (CE) to
base terminal block TB1.
-- Check continuity. Replace if defective.
26. Defective large pump dump valve coil 2H-17A (ANSI/CSA) or 2H-17B (CE).
-- Check coil. Replace if defective.

4.1-21 Third Drive Speed Inoperative

1. Defective third speed switch S7-6 in controller S7.
-- Check switch. Replace if defective.
2. Defective controller S7.
-- Check controller. Replace if defective.
3. Loose or broken wire #18 from third speed switch S7-6 to diode D18 at base terminal block TB1.
-- Check continuity. Replace if defective.
4. Defective diode D18.
-- Check diode. Replace if defective.

4.1-22 High Drive Speed Inoperative

1. Lift/Drive select switch S3 in low drive position.
-- Select high drive position on lift/drive select switch.
2. Defective contacts on lift/drive select switch S3 between wire #08 and wire #20.
-- Check continuity through contact. Replace if defective.
3. Loose or broken wire #20 from lift/drive select switch S3 to relay 20CR.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from relay 20CR to base terminal block TB1.
-- Check continuity. Replace if defective.
5. Defective relay 20CR.
-- Check relay. Replace if defective.
6. Loose or broken wire #44 from base terminal block TB1 to relay 20CR.
-- Check continuity. Replace if defective.
7. Loose or broken wire #20A from relay 20CR to relay 20ACR1.
-- Check continuity. Replace if defective.
8. Loose or broken wire #20A from relay 20ACR1 to series/parallel valve coil 4H-20A.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from series/parallel valve coil 4H-20A to base terminal block TB1.
-- Check continuity. Replace if defective.
10 Defective series/parallel valve coil 4H-20A.
-- Check coil. Replace if defective.
11. Loose or broken wire #02 from relay 20ACR1 to base terminal block TB1 (forward drive only).
-- Check continuity. Replace if defective.
12. Defective relay 20ACR1 (forward drive only).
-- Check relay. Replace if defective.
13. Loose or broken wire #20A from relay 20CR to relay 20ACR2 (reverse drive only).
-- Check continuity. Replace if defective.
14. Loose or broken wire #02 from relay 20ACR2 to base terminal block TB1 (reverse drive only).
-- Check continuity. Replace if defective.
15. Defective relay 20ACR2 (reverse drive only).
-- Check relay. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 15

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

4.1-23 Up Circuit Inoperative from Platform

1. Lift/Drive select switch S3 in drive position.
-- Select lift on lift/drive select switch.
2. Defective contact on lift/drive select switch S3 between wire #B and wire #14.
-- Check continuity through contact. Replace if defective.
3. Defective forward switch S7-5 on controller S7.
-- Check switch. Replace if defective.
4. Loose or broken wire #B from forward switch S7-5 to contact on lift/drive select switch S3.
-- Check continuity. Replace if defective.
5. Loose or broken wire #14 from contact on lift/drive select switch S3 to base terminal block TB1.
-- Check continuity. Replace if defective.

4.1-24 Up Circuit Inoperative from Base Control Console

1. Loose or broken wire #10E from base terminal block TB1 to base/up/down switch S2.
-- Check continuity. Replace if defective.
2. Loose or broken wire #14E from base/up/down switch S2 to base terminal block TB1.
-- Check continuity. Replace if defective.
3. Defective base/up/down switch S2.
-- Check switch. Replace if defective.
4. Open diode D14E-1.
-- Check diode. Replace if defective.
5. Loose or broken wire #10E from base terminal block to control module CM1 at pin #P2-2. (CE)
-- Check continuity. Replace if defective.

4.1-25 Up Circuit Inoperative from Platform or Base Control Console (without Outriggers)
1. Loose or broken wire #14 from base terminal block TB1 to up relay jumper between wire #14 and
#14A.
-- Check continuity. Replace if defective.
2. Loose or broken up relay jumper wire between wires #14 and #14A.
-- Check continuity. Replace if defective.
3. Loose or broken wire #14A from up relay jumper to base terminal block TB1.
-- Check continuity. Replace if defective.
4. Loose or broken wire #14 from base terminal block to control module CM1 at pin #P2-3 (CE).
-- Check continuity. Replace if defective.
5. Loose or broken wire #14A from base terminal block TB1 to lift valve coil 3H-14A.
-- Check continuity. Replace if defective.
6. Loose or broken wire #02 from lift valve coil 3H-14A to base terminal block TB1.
-- Check continuity. Replace if defective.
7. Defective lift valve coil 3H-14A.
-- Check coil. Replace if defective.
8. Defective diode D14A-1.
-- Check diode. Replace if defective.

4.1-26 Platform will Not Lift from Platform or Base Control Console with Outriggers
Retracted (Lift Operates Correctly with Outriggers Extended)
1. Outriggers not fully retracted.
-- Fully retract outrigger cylinders.
2. Loose or broken wire #10A from base terminal block TB1 to pin #4 on connector CN14 at the outrigger
board.
-- Check continuity. Replace if defective.

SKYJACK, Page 16 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

3. Loose or broken wire #10A from outrigger board to outrigger limit switch LS64.
-- Check continuity. Replace if defective.
4. Defective outrigger limit switch LS64.
-- Check switch. Replace if defective.
5. Loose or broken wire #64 from outrigger limit switch LS64 to outrigger board.
-- Check continuity. Replace if defective.
6. Loose or broken wire #64 from outrigger board to outrigger limit switch LS63.
-- Check continuity. Replace if defective.
7. Defective outrigger limit switch LS63.
-- Check continuity. Replace if defective.
8. Loose or broken wire #63 from outrigger limit switch LS63 to outrigger board.
-- Check continuity. Replace if defective.
9. Loose or broken wire #63 from outrigger board to outrigger limit switch LS62.
-- Check continuity. Replace if defective.
10. Defective Limit Switch LS62.
-- Check switch. Replace if defective.
11. Loose or broken wire #62 from outrigger limit switch LS62 to outrigger board.
-- Check continuity. Replace if defective.
12. Loose or broken wire #62 from outrigger board to outrigger limit switch LS61.
-- Check continuity. Replace if defective.
13. Defective outrigger limit switch LS61.
-- Check switch. Replace if defective.
14. Loose or broken wire #61 from outrigger limit switch LS61 to outrigger board.
-- Check continuity. Replace if defective.
15. Open diode D36 on outrigger board.
-- Check diode. Replace if defective.
16. Open diode D36-1 at pin #1 on CN22 on outrigger board.
-- Check diode. Replace if defective.

4.1-27 Platform will Not Lift from Platform or Base Control Console with Outriggers
Extended
1. Outriggers not extended enough.
-- Extend outriggers to take weight off tires (refer to operator section).
2. Loose or broken wire #10A from base terminal block TB1 to pin #4 on connector CN14 at the outrigger
board.
-- Check continuity. Replace if defective.
3. Loose or broken wire #10A from outrigger board to outrigger limit switch LS68.
-- Check continuity. Replace if defective.
4. Defective outrigger limit switch LS68.
-- Check switch. Replace if defective.
5. Loose or broken wire #68A from outrigger limit switch LS68 to outrigger board.
-- Check continuity. Replace if defective.
6. Loose or broken wire #10A from outrigger board to outrigger limit switch LS67.
-- Check continuity. Replace if defective.
7. Defective outrigger limit switch LS67.
-- Check switch. Replace if defective.
8. Loose or broken wire #67A from outrigger limit switch LS67 to outrigger board.
-- Check continuity. Replace if defective.
9. Loose or broken wire #10A from outrigger board to outrigger limit switch LS66.
-- Check continuity. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 17

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

10. Defective outrigger limit switch LS66.

-- Check switch. Replace if defective.
11. Loose or broken wire #66A from outrigger limit switch LS66 to outrigger board.
-- Check continuity. Replace if defective.
12. Loose or broken wire #10A from outrigger board to outrigger limit switch LS65.
-- Check continuity. Replace if defective.
13. Defective outrigger limit switch LS65.
-- Check switch. Replace if defective.
14. Loose or broken wire #65A from outrigger limit switch LS65 to outrigger board.
-- Check continuity. Replace if defective.
15. Check for power on wire #65 at outrigger control module at pin P2-8.
-- If no voltage present, proceed to outrigger control module troubleshooting.
16. Loose or broken wire #65 from outrigger control module at pin P2-8 to outrigger board.
-- Check continuity. Replace if defective.
17. Open diode D14A-2 at base terminal block TB1.
-- Check diode. Replace if defective.

4.1-28 Platform will Not Lift from Platform or Base Control Console with Outriggers
Extended or Retracted
1. Defective lift enable relay 65CR.
-- Check relay. Replace if defective.
2. Defective lift disable relay 17DCR.
-- Check relay. Replace if defective.
3. Loose or broken wire #14 from base terminal block TB1 to outrigger/ generator harness connector.
-- Check continuity. Replace if defective.
4. Loose or broken wire #02 from base terminal block TB1 to outrigger/ generator harness connector.
-- Check continuity. Replace if defective.
5. Loose or broken wire #14 from base terminal block to control module CM1 at pin #P2-3 (CE).
-- Check continuity. Replace if defective.
6. Defective up relay 14CR.
-- Check relay. Replace if defective.
7. Loose or broken wire #36A from pin#10 on connector CN14 to up relay 14CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #14A from up relay 14CR to base terminal block TB1.
-- Check continuity. Replace if defective.

4.1-29 Down Circuit Inoperative from Platform

1. Lift/Drive select switch S3 in drive position.
-- Select lift on lift/drive select switch.
2. Defective reverse switch S7-4 on controller S7.
-- Check continuity through switch. Replace if defective.
3. Loose or broken wire #A from reverse switch S7-4 to contact on lift/drive select switch S3.
-- Check continuity. Replace if defective.
4. Defective contact on lift/drive select switch S3 between wire #A and wire #13.
-- Check continuity through contact. Replace if defective.
5. Loose or broken wire #13 from lift/drive select switch S3 to base terminal block TB1.
-- Check continuity. Replace if defective.
6. Loose or broken wire #13 from base terminal block TB1 to lowering valve 2H-13 or holding valve 2H-
13-1 and 2H-13-2.
-- Check continuity. Replace if defective.

SKYJACK, Page 18 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

7. Loose or broken wire #02 from base terminal block TB1 to lowering valve 2H-13 or holding valve 2H-
13-1 and 2H-13-2.
-- Check continuity. Replace if defective.
8. Defective lowering valve coil 2H-13 or holding valve 2H-13-1 and 2H-13-2.
-- Check Coil. Replace if defective.

4.1-30 Down Circuit Inoperative from Base

1. Loose or broken wire #10E from base terminal block TB1 to base up/down switch S2.
-- Check continuity. Replace if defective.
2. Loose or broken wire #13 from base up/down switch S2 to base terminal block TB1.
-- Check continuity. Replace if defective.
3. Defective base up/down switch S2.
-- Check switch. Replace if defective.
4. Loose or broken wire #13 from base terminal block TB1 to lowering valve 2H-13 or holding valve 2H-
13-1 and 2H-13-2. (ANSI/CSA)
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from base terminal block TB1 to lowering valve 2H-13 or holding valve 2H-
13-1 and 2H-13-2. (ANSI/CSA)
-- Check continuity. Replace if defective.
6. Defective lowering valve coil 2H-13 or holding valve 2H-13-1 and 2H-13-2. (ANSI/CSA)
-- Check Coil. Replace if defective.

4.1-31 No Down Function (Additional for machines with Load Sensing System) (CE)
1. Loose or broken wire #02 from base terminal strip TB1 to down enable relay 28CR or auxiliary down
enable relay 28ECR3.
-- Check continuity. Replace if defective.
2. Defective down enable relay 28CR or auxiliary down enable relay 28ECR3.
-- Check relay. Replace if defective.
3. Loose or broken wire #28 from control module CM1 at pin #P3-4 to down enable relay 28CR.
-- Check continuity. Replace if defective.
4. Loose or broken wire #28E from control module CM1 at pin #P3-6 to auxiliary down enable relay
28ECR3.
-- Check continuity. Replace if defective.
5. Loose or broken wire #13 from base terminal block to down enable relay 28CR.
-- Check continuity. Replace if defective.
6. Loose or broken wire #13 from base terminal block to control module CM1 at pin #P2-4.
-- Check continuity. Replace if defective.
7. Loose or broken wire #13A from auxiliary down enable relay 28ECR3 to down enable relay 28CR.
-- Check continuity. Replace if defective.
8. Loose or broken wire #13B from auxiliary down enable relay 28CR3 to lowering valve 2H-13B or holding
valve 2H-13B-1 and 2H-13B-2.
-- Check continuity. Replace if defective.
9. Loose or broken wire #02 from base terminal block TB1 to lowering valve 2H-13B or holding valve
2H-13B-1 and 2H-13B-2.
-- Check continuity. Replace if defective.
10. Defective lowering valve coil 2H-13B or holding valve 2H-13B-1 and 2H-13B-2.
-- Check Coil. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 19

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

4.1-32 Hydraulic Generator Inoperative

1. Key switch S3 in drive position.

-- Turn switch to lift position.
2. Loose or broken wire #9 from base terminal block TB1 to generator relay 86BCR.
-- Check continuity. Replace if defective.
3. Loose or broken wire #9 from generator relay 86BCR to generator switch S12.
-- Check continuity. Replace if defective.
4. Defective generator switch S12.
-- Check switch. Replace if defective.
5. Loose or broken wire #85 from generator switch S12 to generator relay 86ACR.
-- Check continuity. Replace if defective.
6. Loose or broken wire #86B from generator relay 86ACR to generator relay 86BCR.
-- Check continuity. Replace if defective.
7. Defective relay 86ACR.
-- Check relay. Replace if defective.
8. Defective relay 86BCR.
-- Check relay. Replace if defective.
9. Loose or broken wire #2A from hour meter to relay 86BCR.
-- Check continuity. Replace if defective.
10. Loose or broken wire #86C from generator relay 86BCR to generator relay 86CCR.
-- Check continuity. Replace if defective.
11. Open diode D86C.
-- Check diode. Replace if defective.
12. Loose or broken wire #85 from diode D86C to relay 86ACR.
-- Check continuity. Replace if defective.
13. Loose or broken wire #02 from base terminal block TB1 to relay 86CCR.
-- Check continuity. Replace if defective.
14. Defective relay 86CCR.
-- Check relay. Replace if defective.
15. Loose or broken wire #43 from relay 32CR1 to relay 86CCR.
-- Check continuity. Replace if defective.
16. Loose or broken wire #86D from relay 86CCR to generator valve coil 2H-86D.
-- Check continuity. Replace if defective.
17. Loose or broken wire #02 from base terminal block to generator valve coil 2H-86D.
-- Check continuity. Replace if defective.
18. Defective generator valve coil 2H-86D.
-- Check coil. Replace if defective.
19. Open diode D86D.
-- Check diode. Replace if defective.
20. Loose or broken wire #17A from diode D86D to base terminal block TB1.
-- Check continuity. Replace if defective.

4.1-33 Hydraulic Generator will not Shut Off from Generator Switch

1. Defective generator switch S12.

-- Check switch. Replace if defective.
2. Loose or broken wire #86 from generator switch S12 to diode D86.
-- Check continuity. Replace if defective.

SKYJACK, Page 20 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

3. Open diode D86.

-- Check diode. Replace if defective.
4. Defective relay 86ACR.
-- Check relay. Replace if defective.
5. Loose or broken wire #02 from base terminal block to relay 86ACR.
-- Check continuity. Replace if defective.

4.1-34 All Outriggers Inoperative (Auto-Level and Manual)

WARNING
Scissors lift must be below high speed limit switch for outriggers to
function.

NOTE
For the outriggers to function the upper control box must be in the lift
position and the scissor stack stowed or fully retracted.

1. Loose or broken wire # 44 from base terminal block TB1 to pin #6 on connector CN14 on outrigger
board.
-- Check for continuity. Replace if defective.
2. No power at wire #9 at pin #5 on connector CN14 on outrigger board.
-- If no power is present check for continuity on wire #9 back to the main terminal block TB1.
Replace if defective.
3. Defective relay 9CR2 or 9CR3 on outrigger board.
-- Check relays. Replace if defective.
4. Open diode D17C-1 on outrigger board.
-- Check diode. Replace if defective.
5. Defective relay 17DCR on outrigger board.
-- Check relay. Replace if defective.
6. Open or defective fuse jumper J17E on outrigger board.
-- Check fuse. Replace if defective.
7. Loose or broken wire # 17A from pin #2 on connector CN14 on outrigger board to terminal block
TB1.
-- Check for continuity. Replace if defective.
8. Loose or broken wire #17C at pin #1 or wire #02 at pin #2 on connector CN21 on outrigger board to
outrigger holding valve coil 2H-17C.
-- Check for continuity. Replace if defective.
9. Defective outrigger holding valve coil 2H-17C.
-- Check coil. Replace if defective.

4.1-35 All Outriggers Inoperative (Auto-Level and Manual from Platform Controls)

1. Loose or broken wires #35C at pin #1 on connector CN20 on outrigger board through outrigger cables
and plugs to the outrigger enable switch S9A in the control box.
-- Check for continuity. Replace if defective.
2. Loose or broken wire #35D from outrigger enable switch S9A to pin #5 on the outrigger control console
plug.
-- Check for continuity. Replace if defective.
3. Defective outrigger enable switch S9A.
-- Check switch. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 21

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

4.1-36 All Outriggers Inoperative (Base Controls only)

1. Defective outrigger enable switch S9B.

-- Check switch. Replace if defective.

4.1-37 All Outriggers Inoperative (Auto Level only)

A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not On (Constant)
1. Loose or broken wire #10A at pin #1 of the tilt switch connector to pin P2-12 on the outrigger
control module OCM1.
-- Check for continuity. Replace if defective.
2. Loose or broken wire #10A at pin #1 of the tilt switch connector to base terminal block TB1.
-- Check for continuity. Replace if defective.
3. Loose or broken wire # 02 at pin #3 of the tilt switch connector to pin P2-11 on the outrigger
control module OCM1.
-- Check for continuity. Replace if defective.
4. Loose or broken wire #02 at pin #3 of the tilt switch connector to base terminal block TB1.
-- Check for continuity. Replace if defective.
5. Defective outrigger control module OCM1.
-- Replace.

SKYJACK, Page 22 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

4.1-38 All Outriggers Inoperative (Auto Level only)

B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing

Flash Code Probable Cause Remedy

1. Outriggers are all up and machine is 1. Level the machine.
1/1
tilted.
1. Machine is elevated. 1. Lower the scissor stack below high speed limit switch.
1/2 2. Loose or broken wire # 35. 2. Check for input voltage on wire #35 at pin P2-10 of the outrigger
control module (OCM1). Replace if defective.
1. At least one outrigger is not fully 1. Fully retract all outriggers.
retracted.
2. Defective outrigger rod limit switch 2. Replace defective or damaged switch(es) or wiring.
2/2
(LS61, LS62, LS63, LS64) or wiring.
3. Defective diode (D36) on outrigger 3. Check for continuity. Replace if defective.
board.
1. Outriggers are all down and the machine 1. Move machine to less sloped terrain if it will not lift.
2/1
is not fully level.
1. Power on wire #70 or #79 at power on. 1. Check for power on wire #70 or #79 at pin P2-5 or P2-6 of the
outrigger control module. Replace defective component.
5/5 2. Power on wire #70 or #79 when 2. Check for power on wire #70 or #79 while manually operating an
manually operating outriggers. outrigger.
1. Low or no voltage on wire #35c. 1. Check battery and charging system to ensure minimum 9 volts.
5/2 2. Loose or broken wire on #35c. 2. Check for input voltage on wire #35c at pin P4-9 of outrigger
control module (OCM1).
1. Excessive vibration. 1. Outrigger control module cannot read tilt sensor.
7/1
2. Defective outrigger control module. 2. Replace.
1. Outriggers are being manually 1. Indicates function activated. No repair necessary.
6/6
controlled.
1. Error occured while self diagnosing the 1. Turn off power to reset the outrigger control module. Turn power
7/8 hardware fail safe. back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Low input voltage to outrigger control 1. Check for minimum 9 volts between wire #02 at pin P2-11 and wire
5/1 module. #10A at pin P2-12 at outrigger control module.
1. Startup error occurred while self 1. Turn off power to reset the outrigger control module. Turn power
7/7 diagnosing. back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
7/5 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
7/2 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
8/1 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
8/2 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
8/3 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
8/4 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
8/5 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
1. Internal failure of OCM1. 1. Turn off power to reset the outrigger control module. Turn power
7/6 back on and see if the code has cleared. If problem persists,
replace outrigger control module.
60416AB

Rough Terrain Compact Series SKYJACK, Page 23

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Electrical System (Continued)

4.1-39 Left Front Outrigger Inoperative Manually
1. Defective left front outrigger switch S20 at platform control console or S20A at base control console.
-- Check switch. Replace if defective.
2. Loose or broken wire #71(up) from outrigger control console to pin #6 (up) on connector CN20 at outrigger
board, or wire #75 (down) to pin #7 (down).
-- Check continuity. Replace if defective.
3. Open diode D71 (up) or D75 (down) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #71(up) at pin #7 (up) or pin #75 (down) at pin #8 (down) on connector CN21 at outrigger
board to valve coil 4H-71 (up) or 4H-75 (down).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-71 (up) or 4H-75 (down) to pin #2 on connector CN21 at the
outrigger board.
-- Check continuity. Replace if defective.

4.1-40 Right Front Outrigger Inoperative Manually

1. Defective right front outrigger switch S21 at platform control console or S21A at base control console.
-- Check switch. Replace if defective.
2. Loose or broken wire #72 (up) from outrigger control console to pin #8 (up) on connector CN20 at outrigger
board, or wire #76 (down) to pin #9 (down).
-- Check continuity. Replace if defective.
3. Open diode D72 (up) or D76 (down) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #72 (up) at pin #9 (up) or wire #76 (down) at pin #10 (down) on connector CN21 at
outrigger board to valve coil 4H-72 (up) or 4H-76 (down).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-72 (up) or 4H-76 (down) to pin #2 on connector CN21 at the
outrigger board.
-- Check continuity. Replace if defective.

4.1-41 Right Rear Outriggers Inoperative Manually

1. Defective right rear outrigger switch S22 at platform control console or S22A at base control console.
-- Check switch. Replace if defective.
2. Loose or broken wire #73(up) from outrigger control console to pin #3 (up) on connector CN20 at outrigger
board, or wire #77 (down) to pin #4 (down).
-- Check continuity. Replace if defective.
3. Open diode D73 (up) or D77 (down) on outrigger board.
-- Check diode. Replace if defective.
4. Loose or broken wire #73(up) at pin #4 (up) or wire #77 (down) at pin #5 (down) on connector CN21 at
outrigger board to valve coil 4H-73 (up) or 4H-77 (down).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-73 (up) or 4H-77 (down) to pin #2 on connector CN21 at the
outrigger board.
-- Check continuity. Replace if defective.

4.1-42 Left Rear Outriggers Inoperative Manually

1. Defective left rear outrigger switch S23 at platform control console or S23A at base control console.
-- Check switch. Replace if defective.
2. Loose or broken wire #74 (up) from outrigger control console to pin #5 (up) on connector CN20 at outrigger
board, or #78 (down) from pin #2 (down).
-- Check continuity. Replace if defective.
3. Open diode D74 (up) or D78 (down) on outrigger board.
-- Check diode. Replace if defective.

SKYJACK, Page 24 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Electrical System (Continued)

4. Loose or broken wire #74(up) at pin #6 (up) or wire #78 (down) at pin #3 (down) on connector CN21 at
outrigger board to valve coil 4H-74 (up) or 4H-78 (down).
-- Check continuity. Replace if defective.
5. Loose or broken wire #02 from valve coil 4H-74 (up) or 4H-78 (down) to pin #2 on connector CN21 at the
outrigger board.
-- Check continuity. Replace if defective.

4.1-43 Individual Outrigger Functions Inoperative (Auto-Level)

1. Loose or broken wire #71- #75 (depending on function not working) at outrigger control module plug P4 pins
1-8.
-- Check connections of outrigger functions not working (refer to Section 5 for pin reference chart).
Replace if defective.
2. No output from outrigger control module OCM1 at plug P4 pins 1-8.
-- Turn off power to reset the outrigger control module. Turn power back on and retest. If problem persists,
replace outrigger control module.

4.1-44 Auto-Level Inoperative

1. Loose or broken wire #35D from outrigger enable switch S9A to auto mode outrigger switch S24.
-- Check continuity. Replace if defective.
2. Defective auto mode outrigger switch S24.
-- Check switch. Replace if defective.
3. Loose or broken wire #10A at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-12. If no voltage present, check continuity of wire. Replace if defective.
4. Loose or broken wire #44 at pin #P2-10 on outrigger control module OCM1.
-- Check for power at P2-10. If no voltage present, check continuity of wire. Replace if defective.
5. Loose or broken wire #02 at pin #P2-11 on outrigger control module OCM1.
-- Check for ground at P2-11. If no ground present, check continuity of wire. Replace if defective.
6. Loose or broken wire #70 from auto mode outrigger switch S24 to pin #P2-5 on outrigger control module
OCM1.
-- Check continuity. Replace if defective.
7. For additional information, refer to sections 4 & 5 “Outrigger Control Module - Troubleshooting.”

4.1-45 Auto All Up Inoperative (Retract)

1. Loose or broken wire #35D from outrigger enable switch S9A to auto mode outrigger switch S24.
-- Check continuity. Replace if defective.
2. Defective auto mode outrigger switch S24.
-- Check switch. Replace if defective.
3. Loose or broken wire #10A at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-12. If no voltage present, check continuity of wire. Replace if defective.
4. Loose or broken wire #44 at pin #P2-12 on outrigger control module OCM1.
-- Check for power at P2-10. If no voltage present, check continuity of wire. Replace if defective.
5. Loose or broken wire #02 at pin #P2-11 on outrigger control module OCM1.
-- Check for ground at P2-11. If no ground present, check continuity of wire. Replace if defective.
6. Loose or broken wire #79 from auto mode outrigger switch S24 to pin #P2-6 on outrigger control module
OCM1.
-- Check continuity. Replace if defective.
7. For additional information, refer to section 5 “Outrigger Control Module.”

Rough Terrain Compact Series SKYJACK, Page 25

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Hydraulic System

4.2-1 All Functions Inoperative

1. Hydraulic oil level low.
-- Refill tank to proper level.
2. Defective pump P1.
-- Check pump. Repair or replace if defective.
3. Broken engine to pump coupler.
-- Check coupler. Replace if defective.
4. Relief valve R1 open.
-- Check valve. Replace if defective.

4.2-2 Steering Inoperative

1. Stuck or defective steer right valve 4H-23A or steer left valve 4H-24A.
-- Check valves. Replace if defective.
2. Steer cylinder C7 damaged or bypassing internally.
-- Check cylinder. Repair or replace if defective.

4.2-3 Lift, Steer and First Drive Speed Inoperative

1. Small pump dump valve 2H-18B stuck open.
-- Check valve. Repair or replace if defective.
2. Worn or defective small pump section of pump P1.
-- Check pump. Repair or replace if defective.
3. Check valve CV1 or CV2 stuck.
-- Check valves. Clean or replace if defective.

4.2-4 Second Drive Speed Inoperative

1. Large pump dump valve 2H-17A stuck open.
-- Check valve. Repair or replace if defective.
2. Worn or defective large pump section of pump P1.
-- Check pump. Repair or replace if defective.
3. Check valve CV1 or CV2 stuck.
-- Check valves. Clean or replace if defective.

4.2-5 Drive Inoperative

1. Stuck or defective drive reverse valve 4H-15A or drive forward valve 4H-16A.
-- Check valves. Repair or replace if defective.
2. Defective drive relief valve R5.
-- Check valve. Replace if defective.
3. Stuck or defective main counterbalance valve CB1.
-- Check valve. Repair or replace if defective.
4. Defective drive motor M1, M2, M3 or M4.
-- Check motor. Repair or replace if defective.
5. Free wheeling valve V2 open or defective.
-- Close valve. Repair or replace if defective.
6. Stuck or defective high speed valve 2H-20B.
-- Check valve. Repair or replace if defective.
7. Cushion cylinder C8 bypassing internally.
-- Check cylinder. Repair or replace if defective.

SKYJACK, Page 26 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Hydraulic System (Continued)

4.2-6 Drive Sluggish

1. Stuck open or defective valve CV3, CV4, CV5, or CV6.
-- Check valve. Replace if defective.
2. Drive relief valve R5 set too low.
-- Refer to Section 5 of this manual for setup procedure.
3. Defective flow divider FD1.
-- Check flow divider. Replace if defective.

4.2-7 Reverse Drive Inoperative

1. Stuck or defective drive valve 4H-15A.
-- Check valve. Repair or replace if defective.

4.2-8 Forward Drive Inoperative

1. Stuck or defective drive valve 4H-16A.
-- Check valve. Repair or replace if defective.

4.2-9 Drive Inoperative When in Low Drive

1. Stuck or defective parallel counterbalance valve CB2.
-- Check valve. Replace if defective.
2. Stuck or defective parallel forward drive valve 4H-16B or parallel reverse valve 4H-15B.
-- Check valve. Replace if defective.

4.2-10 Drive Inoperative When in High Drive

1. Stuck or defective series/parallel valve 4H-20A.
-- Check valve. Replace if defective.
2. Stuck or defective main counterbalance valve CB1.
-- Check valve. Replace if defective.

4.2-11 Brakes Will Not Release

1. Stuck or defective brake valve 3H-30.
-- Check valve. Repair or replace if defective.
2. Stuck or defective auto reset valve V6.
-- Check valve. Repair or replace if defective.

4.2-12 Up Circuit Inoperative

1. Stuck or defective lift valve 3H-14A.
-- Check valve. Repair or replace if defective.
2. Misadjusted or defective lift relief valve R2.
-- Adjust valve. Replace if defective.
3. Stuck or defective lowering valve 2H-13.
-- Check valve. Repair or replace if defective.
4. Stuck or defective manual lowering valve V1.
-- Check valve. Repair or replace if defective.
5. Open manual override on holding valve 2H13-1 or 2H13-2.
-- Depress and turn manual override clockwise to close. Replace if defective.
6. Stuck holding valve 2H13-1 or 2H13-2.
-- Check valves. Repair or replace if defective.

Rough Terrain Compact Series SKYJACK, Page 27

Engine Powered
157951
Service and Maintenance Section 4 - Troubleshooting Information

Hydraulic System (Continued)

4.2-13 Down Circuit Inoperative

1. Stuck or defective lowering valve 2H-13.
-- Check valve. Repair or replace if defective.
2. Stuck holding valve 2H13-1 or 2H13-2.
-- Check valves. Repair or replace if defective.
3. Plugged lowering orifice O1.
-- Clean or replace orifice.

4.2-14 Hydraulic Generator Inoperative

1. Stuck or defective hydraulic generator valve 2H-86D.
-- Check valve. Repair or replace if defective.
2. Misadjusted or defective flow control valve FC1.
-- Adjust valve. Replace if defective.
3. Stuck or defective large pump dump valve 2H-17A.
-- Check valve. Repair or replace if defective.
4. Defective hydraulic generator hydraulic motor GM1.
-- Check motor. Repair or replace if defective.

4.2-15 All Outriggers Inoperative

1. Stuck or defective outrigger holding valve 2H-17C.
-- Check valve. Repair or replace if defective.

4.2-16 Left Front Outriggers Inoperative

1. Stuck or defective retract valve 4H-71 or extend valve 4H-75.
-- Clean valve. Replace if defective.
2. Stuck or defective check valve CV7.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C9.
-- Repack cylinder. Replace if defective.

4.2-17 Right Front Outriggers Inoperative

1. Stuck or defective retract valve 4H-72 or extend valve 4H-76.
-- Clean valve. Replace if defective.
2. Stuck or defective check valve CV8.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C10.
-- Repack cylinder. Replace if defective

4.2-18 Right Rear Outriggers Inoperative

1. Stuck or defective retract valve 4H-73 or extend valve 4H-77.
-- Clean valve. Replace if defective.
2. Stuck or defective check valve CV9.
-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C11.
-- Repack cylinder. Replace if defective.

4.2-19 Left Rear Outriggers Inoperative

1. Stuck or defective retract valve 4H-74 or extend valve 4H-78.
-- Clean valve. Replace if defective.

SKYJACK, Page 28 Rough Terrain Compact Series

Engine Powered
157951
Section 4 - Troubleshooting Information Service and Maintenance

Hydraulic System (Continued)

2. Stuck or defective check valve CV10.

-- Check valve. Replace if defective.
3. Bypassing outrigger cylinder C12.
-- Repack cylinder. Replace if defective

4.2-20 Outriggers Drift In

1. Defective check valve left front CV7, right front CV8, right rear CV9 or left rear CV10.
-- Clean valve. Replace if defective.
2. Outriggers cylinder bypassing left front C9, right front C10, right rear C11 or left rear C12.
-- Repack cylinder. Replace if defective.

Rough Terrain Compact Series SKYJACK, Page 29

Engine Powered
157951
 Notes

SKYJACK, Page 30 Rough Terrain Compact Series

Engine Powered
157951
 Section 5
Procedures

Table of Contents
General..........................................................................................................................................................................3
Safety and Workmanship..............................................................................................................................................3

Base
5.1-1 System Lift and Pressure Adjustment................................................................................................................3
5.1-2 Winching and Towing Procedures and Parking Brake System . ......................................................................4
5.1-3 Wheel Bolt/Nut Inspection and Torquing Procedure.........................................................................................5
5.1-4 Wheel Reinstallation and Torquing Procedure..................................................................................................5

Engine
5.2-1 Kubota Dual Fuel (DF972) Resistance Checks..................................................................................................6

Options
5.3-1 Auto-Leveling Outrigger PC Board Layout........................................................................................................8
5.3-2 Outrigger Mechanical Limit Switch Wiring Diagram..........................................................................................9
5.3-3 Auto-Leveling Outrigger Settings and Error Codes.........................................................................................10
5.3-4 Auto-Leveling Outrigger Error Code Breakdown.............................................................................................11
5.3-5 Hand Held Calibration/Diagnostic Tool Key Functions....................................................................................12
5.3-6 Outrigger Control Module Instructions............................................................................................................13
5.3-7 Auto-Leveling Outrigger Control Module Pin Reference Chart.......................................................................16

Rough Terrain Compact Series SKYJACK, Page 1

Engine Powered
157951
 Notes

SKYJACK, Page 2 Rough Terrain Compact Series

Engine Powered
157951
Section 5 - Procedures Service and Maintenance

General 10. Release steer switch and retighten locknut on

The following information is provided to assist you in system relief valve (R1).
the use and application of servicing and maintenance
procedures contained in this chapter. 11. Remove gauge from steer line.
Safety and Workmanship Lift Pressure Adjustment
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment.
Always be conscious of weight. Never attempt to move WARNING
heavy parts without the aid of a mechanical device. Do Fully lower the platform.
not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that 1. Locate the lift line coming out of the main manifold.
adequate support is provided. (Refer to Hydraulic Manifold Component and Port
Identification found in Section 3 for location.)
Base
5.1-1 System Lift and Pressure Adjustment 2. Open manual lowering valve with platform fully
All adjustments must be made with a calibrated lowered. Remove lift line from main manifold.
hydraulic gauge. Refer to the serial number
nameplate located on the rear of the machine for 3. Install a 3000 psi gauge into the lift line port fitting
system and lift pressure values. on the main manifold. Plug the lift line going to the
lift cylinders.
System Relief Pressure Adjustment 4. Loosen locknut on lift relief valve (R2). (Refer
1. Locate right steer hydraulic line at main manifold. to Hydraulic Manifold Component and Port
(Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location.)
Identification found in Section 3 for location.)
5. Close the manual lowering valve.
2. Tee in a calibrated 3000 psi gauge into the right
steer line. 6. At base controls in hydraulic/electric cabinet,
depress and hold the up pushbutton.
3. Remove operator’s control box from guardrail and
disconnect it from scissors control cable. 7. Observe reading on pressure gauge. Adjust lift
relief valve (R2) to the pressure listed on the serial
4. Locate electrical panel cable plug in the hydraulic/ number nameplate.
electric cabinet.
NOTE
5. Disconnect scissors control cable and connect Turning the stem on the relief valve
operator’s control box cable. clockwise increases pressure. Turning
6. At main manifold, loosen locknut on system the stem counter-clockwise decreases
relief valve (R1). (Refer to Hydraulic Manifold pressure.
Component and Port Identification found in
Section 3 for location.) 8. Release the up pushbutton and retighten locknut
on lift relief valve (R2).
7. Select drive position with lift/drive select switch on
platform control console. 9. Remove gauge from lift line port fitting and reinstall
the lift line.
8. Engage steer right with rocker switch of the
controller handle and hold.
WARNING
9. Observe reading on pressure gauge. Adjust Ensure machine does not lift more than
system relief valve R1 to the pressure listed on rated load.
the serial number nameplate.

NOTE
Turning the stem on the relief valve
clockwise increases pressure. Turning
the stem counter-clockwise decreases
pressure.

Rough Terrain Compact Series SKYJACK, Page 3

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

5.1-2 Winching and Towing Procedures and To Release the Parking Brakes Manually
Parking Brake System
This section provides the operator with procedures WARNING
about towing and winching and on how to manually
Do not manually disengage the park-
release the parking brake.
ing brakes if the aerial platform is on a
slope.
WARNING
Ensure platform is fully lowered before
winching or towing. Sudden motion could
cause the aerial platform to become
unstable. Death or serious injury could
result.

WARNING
Diagram 5.1-2. Disc Brakes System
In emergency situations where machine
functions are not available and lowering is Parking Brakes - The brakes must be manually disen-
impeded by an obstacle, the utmost care gaged for pushing, towing or winching.
must be taken to move the machine far
enough to clear the obstacle. In such cas-
1. Make sure that the aerial platform is on level
es operation must be extremely smooth
ground. Chock or block the wheels to keep aerial
with no sudden movements and must not
platform from rolling.
exceed a speed of 2”/sec.When pushing,
towing or winching, do not exceed 2 mph
2. Turn emergency main power disconnect switch
(3.2 km/h).
to off position.
Do not push, tow or winch vehicle on to a
slope, or brake the towing vehicle rapidly.
3. Locate brake hand pump and brake auto reset
Do not pull the aerial platform down an
valve at main manifold in hydraulic/fuel cabinet.
incline towards a winch.
4. Push in brake auto reset valve (item 1).
To Release the Free-Wheeling Valve
1. Make sure that the aerial platform is on level
5. Grasp the red hand pump (item 2) and rapidly
ground. Chock or block the wheels to keep aerial
depress until firm resistance is felt. The brakes
platform from rolling.
are now released.

6. Remove the wheel chocks or blocks, then push,

tow or winch the aerial platform to the desired
location.

WARNING
Diagram 5.1-1. Free-Wheeling Valve The parking brake MUST be re-engaged
immediately after reaching the desired
2. Free-Wheeling Valve - Turning the valve knob location.
counterclockwise (item 1) to a fully opened
position allows fluid to flow through the wheel 7. Position the machine on a firm and level surface.
motors, thus providing “free-wheeling”.
8. Chock or block the wheels to prevent the aerial
WARNING platform from rolling.
The free-wheeling valve must be closed
9. Re-engage the parking brakes by pulling out the
tightly (clockwise) for normal operation.
black brake valve plunger.

SKYJACK, Page 4 Rough Terrain Compact Series

Engine Powered
157951
Section 5 - Procedures Service and Maintenance

5.1-3 Wheel Bolt/Nut Inspection and Torquing 5.1-4 Wheel Reinstallation and Torquing
Procedure Procedure
It is necessary to check the torque on all wheel nuts and When a Wheel/Tire Assembly has been removed or
wheel bolts at pre-delivery, after 8 hours of operation and replaced, it will be necessary to follow the procedure
at weekly intervals using the following procedure: below to ensure proper installation:

1. Confirm that each wheel fastener is torqued to 1. Inspect wheel fastener threads for damage and
80±5 ft-Ib. All fasteners must be torqued using defects. Replace if defective.
the tightening sequence below.
2. Clean the mounting surfaces of hub and the wheel
rim of debris, rust, excess paint, etc.
1
3. Mount wheel on the hub, centering mounting holes
3 6 on the wheel studs or bolt holes. Use appropriate
lifting device as required.

5 4 4. Install wheel nuts or wheel bolts and hand tighten

to center the rim.
2
5. Tighten nuts or bolts to approximately 50 ft-lb torque
Diagram 5.1-3. Wheel Torque Sequence using the tightening sequence in procedure 5.1-3.

2. Again, confirm that each wheel fastener is torqued 6. Tighten to 80 ft-Ib using the same sequence.
to the specified tolerance. Re-torque as necessary
until all fasteners are properly torqued. 7. Repeat the torque sequence to confirm that none
have changed from 80 ft-lb. If any are found below
80 ft-lb, repeat complete sequence until there is
no change in torque values. If possible, drive the
machine prior to checking torques.

8. Check torque values after 8 hours of operation

and then at weekly intervals.

Rough Terrain Compact Series SKYJACK, Page 5

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

Engine
5.2-1 Kubota Dual Fuel (DF972) Resistance Checks

Resistance of Pick-Up Sensor

A B
1. Disconnect the connector.
2. Measure the resistance with the ohmmeter.
3. If the resistance is not within the factory
specifications, replace it.
Resistance Factory Spec. A - B 1.85 to 2.45kΩ at 20°C

Resistance of Ignition Coil

1. Disconnect the connector. B C

2. Measure the resistance with an ohmmeter.
A
3. If the resistance is not within the factory
specifications, replace it.

A - B 1.87 to 2.53Ω at 20°C

Resistance Factory Spec.
A - C 10.4 to 15.6Ω at 20°C

A: Terminal (+) C: High Tension Cord

B: Terminal (-)

Resistance of Ignitor

1. Disconnect the connector. A B

2. Measure the resistance with an ohmmeter. C D
3. If the resistance is not within the factory E F
G H
specifications, replace it.
(1)
Important:
To replace the ignitor with a service part, make sure
the ignitor has the same part cord No / ID mark as
the old one. (See the information label (1).)
Ignitor Check Chart
Negative
A B C D E F G H
Positive
A 10 to 40 kΩ 10 to 40 kΩ 11 to 47 kΩ infinity infinity infinity infinity
0.33 to 1.3 1.8 to 7.3
B 10 to 40 kΩ infinity infinity infinity infinity
kΩ kΩ
0.33 to 1.3 1.5 to 6.0
C 10 to 40 kΩ infinity infinity infinity infinity
kΩ kΩ
1.8 to 7.3 1.5 to 6.0
D 11 to 47 kΩ infinity infinity infinity infinity
kΩ kΩ
E infinity infinity infinity infinity infinity infinity infinity
2 megohm 2 megohm 2 megohm 2 megohm
F infinity infinity infinity
(minimum) (minimum) (minimum) (minimum)
2 megohm 2 megohm 2 megohm 2 megohm
G infinity infinity infinity
(minimum) (minimum) (minimum) (minimum)
2 megohm 2 megohm 2 megohm 2 megohm
H infinity infinity infinity
(minimum) (minimum) (minimum) (minimum)
60434AA

SKYJACK, Page 6 Rough Terrain Compact Series

Engine Powered
157951
 Notes

Rough Terrain Compact Series SKYJACK, Page 7

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

Options
5.3-1 Auto-Leveling Outrigger PC Board Layout

CN14

17A/B
28A
86A

36A
10A

28

61
09

02
02

36
44
D17B-2 CN21

D73
17C
D17B-1

71
02
78
73
77

75
72
76
74

REAR RIGHT
REAR LEFT

D74
CN20

D77
35C

71
78
73
77

75
72
76
74

D78
9CR3 9CR2

FRONT RIGHT
FRONT LEFT

D72
D71
D76
61CR 17DCR 65CR
J17D

D75
J17E
ENABLE
10A
10A
10A
10A
10A
N/U

N/U
N/U
61
62
62
63
63

65
64
64

D36

CN22

SKYJACK, Page 8 Rough Terrain Compact Series

Engine Powered
157951
Section 5 - Procedures Service and Maintenance

5.3-2 Outrigger Mechanical Limit Switch Wiring Diagram

O.R. UP SWITCH (NO) - BLUE & BROWN O.R. UP SWITCH (NO) - BLUE & BROWN

PIN 1 - BLACK
PIN 1 - BLACK PIN 2 - BLACK / WHITE
PIN 2 - BLACK / WHITE PIN 3 - BLUE
PIN 3 - BLUE PIN 4 - BROWN
PIN 4 - BROWN
BACK VIEW - MALE BACK VIEW - MALE

3 2 3 2

4 1 4 1
RIGHT FRONT OUTRIGGER
PIN 1 - BLACK (10A)
PIN 2 - WHITE (66A)
BACK VIEW - FEMALE PIN 3 - GREEN (63)
PIN 4 - RED (62) BACK VIEW - FEMALE
LEFT FRONT OUTRIGGER
2 3 2 3
PIN 1 - BLACK (10A)
PIN 2 - WHITE (65A)
PIN 3 - GREEN (62) 1 4
1 4
PIN 4 - RED (36)

O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE

LEFT FRONT OUTRIGGER SECTION VIEW RIGHT FRONT OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE) (SHOWN IN THE RETRACTED STATE)

SIXTEEN PIN CONNECTOR PLUG LEFT FRONT

OUTRIGGER PCB ON ELECTRICAL PANEL
PIN 1 - 61 PIN 9 - 10A BLACK (2x)
RIGHT FRONT
PIN 2 - 62 GREEN PIN 10 - 10A BLACK (2x)
PIN 3 - 62 RED PIN 11 - 10A BLACK (2x)
PIN 4 - 63 GREEN PIN 12 - 10A BLACK (2x)
PIN 5 - 63 RED PIN 13 - 10A GREEN
PIN 6 - 64 GREEN PIN 14 - N/U RIGHT REAR
PIN 7 - 64 RED PIN 15 - N/U
PIN 8 - N/U PIN 16 - 65 GREEN/BLACK
LEFT REAR
TO CONTROL MODULE O.R. UP SWITCH (NO) - BLUE & BROWN
PIN 1 - 65 GREEN / BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE PIN 1 - BLACK
PIN 5 - 68A WHITE PIN 2 - BLACK / WHITE
PIN 6 - (N/U) PIN 3 - BLUE
O.R. UP SWITCH (NO) - BLUE & BROWN PIN 4 - BROWN
BACK VIEW - MALE
BACK VIEW - MALE
3 2
3 2 PIN 1 - BLACK
PIN 2 - BLACK / WHITE 4 1
4 1 PIN 3 - BLUE
PIN 4 - BROWN RIGHT REAR OUTRIGGER
PIN 1 - BLACK (10A)
BACK VIEW - FEMALE PIN 2 - WHITE (67A) BACK VIEW - FEMALE
LEFT REAR OUTRIGGER
PIN 3 - GREEN (64)
2 3 PIN 1 - BLACK (10A) 2 3
PIN 4 - RED (63)
PIN 2 - WHITE (68A)
PIN 3 - GREEN (10A)
1 4 1 4
PIN 4 - RED (64)

O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE O.R. DOWN SWITCH (NC) - BLACK & BLACK / WHITE

LEFT REAR OUTRIGGER SECTION VIEW RIGHT REAR OUTRIGGER SECTION VIEW
(SHOWN IN THE RETRACTED STATE) (SHOWN IN THE RETRACTED STATE)

Rough Terrain Compact Series SKYJACK, Page 9

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

5.3-3 Auto-Leveling Outrigger Settings and Error Codes

Reading the Codes:

In order to read the fault codes, a sequence of pauses and flashes can be seen on the LED mounted on the outrigger
control module. The codes are continuously displayed by the LED until the fault is cleared, the outrigger control
module is reset and no longer detects the fault, or idle timeout becomes active.
The sequence is as follows:

1. Half second flashes followed by half second pauses indicate the first digit.
2. A 2.5 second pause.
3. Half second flashes followed by half second pauses indicate the second digit
4. A 5 second pause.

Repeat steps 1-4

Since the outrigger control module only reports one error, only one code can be read from the LED per instance.
If the error is cleared and another error is present, it will then be presented.

LED ERROR CODES

EVERYTHING OK ON
VEHICLE TILTED 1/1
OUTRIGGERS CANNOT BE MOVED ! 1/2
OUTRIGGERS NOT HOME 2/2
NOT FULLY LEVEL 2/1
RELEASE OUTRIGGER DEMAND ! 5/5
CHECK OUTRIGGER SUPPLY (P4-9) 5/2
CANNOT LEVEL : BAD TILT SENSOR 7/1
OUTRIGGERS MANUALLY CONTROLLED ! 6/6
TESTING HWFS 7/8
B+ SUPPLY TOO LOW 5/1
STARTUP ! 7/7
FAULT : BAD SLAVE MICRO 7/5
FAULT : BAD TILT SENSOR 7/1
FAULT : BAD HWFS 7/2
FAULT : P2-5 FAULTY 8/1
FAULT : P2-6 FAULTY 8/2
FAULT : P2-8 STUCK ON 8/3
FAULT : P2-8 ALWAYS ON 8/4
FAULT : P2-8 ALWAYS OFF 8/5
FAULT : HWFS STALLED ! 7/6

60402AA

SKYJACK, Page 10 Rough Terrain Compact Series

Engine Powered
157951
Section 5 - Procedures Service and Maintenance

5.3-4 Auto-Leveling Outrigger Error Code Breakdown

RELEASE OUTRIGGER DEMAND! 5/5

Check inputs on P2 pins 5 & 6 - the “auto-level” or “auto-retract” input is active at power-on or
when it is not allowed to carry out the function.

OUTRIGGERS CANNOT BE MOVED! 1/2

Check input on P2 pin 10 – “auto-level” or “auto-retract” has been requested but the platform is
elevated.

NOT FULLY LEVEL 2/1

The outrigger legs are all down (touching the ground) but the platform is not fully level.

OUTRIGGERS NOT HOME 2/2

The outrigger legs are not all down (touching the ground) and also are not all home (fully
retracted).

B+ SUPPLY TOO LOW 5/1

CHECK OUTRIGGER SUPPLY (P4-9) 5/2
Check that the battery voltage is not too low.
VEHICLE TILTED 1/1
These is not a true fault – move the vehicle to level ground!

TESTING HWFS 7/8

STARTUP! 7/7
These are not true faults unless they do not clear – the start-up tests should only occur for a
short time.

OUTRIGGERS MANUALLY CONTROLLED! 6/6

This is not a true fault – the outriggers are being manually operated (one or more outrigger legs
on P4 pins 1-8 is high, when the outrigger control module is not active.

CANNOT LEVEL (BAD TILT SENSOR) 7/1

FAULT: BAD TILT SENSOR 7/1
FAULT: BAD HWFS 7/2
FAULT: BAD SLAVE MICRO 7/5
FAULT: HWFS STALLED! 7/6
FAULT: P2-5 FAULTY 8/1
FAULT: P2-6 FAULTY 8/2
FAULT: P2-8 STUCK ON 8/3
FAULT: P2-8 ALWAYS ON 8/4
FAULT: P2-8 ALWAYS OFF 8/5
60412AB
These are internal faults. If the fault persists after the power has been reset, the outrigger control module may need
to be replaced.

Rough Terrain Compact Series SKYJACK, Page 11

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

5.3-5 Hand Held Calibration/Diagnostic Tool Key Functions

WARNING
Only trained and authorized personnel shall be permitted to service an aerial platform.

WARNING
Read all instructions closely before attempting each phase of this procedure.

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONS
To move back and forth between menu and sub-menu

LEFT/RIGHT BUTTONS
Select menus and setting to be adjusted

UP/DOWN BUTTONS
Adjust setting values

Outrigger Settings
SJIIIB SJIIIB
Model 7027 7127 7135 8243 8831 8831E 8841 8841E 8850 9241 9250
6826E 6832E
O.R. Settings 4 4 5 4 4 4 5 5 5 5 4 8 8

SKYJACK, Page 12 Rough Terrain Compact Series

Engine Powered
157951
Section 5 - Procedures Service and Maintenance

5.3-6 Outrigger Control Module Instructions

When EZcal hand-held device is connected to the OCM1 control module, a two line displays shows various menus
and settings. At any time the top line of the display describes the currently selected menu and the bottom line shows
the currently selected item in that menu.

Six buttons on EZcal allow easy navigation through the menus:

 and  change the selected item (the bottom line display)
ENTER enters the selected new menu when available (top line display changes)
 and  adjusts the selected item when available
ESC exits the current menu back to the previous menu

TOP LEVEL MENU OPTIONS

HELP Select this menu to see a description of current OCM1 status
DIAGNOSTICS Select this menu to see switch input status & logged data
ACCESS LEVEL Select this menu & enter correct code to enable adjustments and calibrations
ADJUSTMENTS Select this menu to see and adjust OCM1 settings
NOTE: this menu provides for adjustments which might be needed for different work
activities
SETUPS Select this menu to carry out initial set-up of the OCM1
NOTE: this menu provides for set-ups which are needed to configure the OCM1 for a
particular vehicle

HELP MENU OPTIONS

(help message) A message displays current OCM1 status, indicating if everything is OK or if there is an
error code (see LED Error Codes - Table 5.3)

DIAGNOSTIC MENU OPTIONS

SYSTEM Select this menu to see general OCM1 system information
SWITCHES Select this menu to see switch input status
OUTPUTS Select this menu to see OCM1 output status
LOG Select this menu to see logged information

DIAGNOSTIC / SYSTEM MENU OPTIONS

OUTRIGGERS Displays various status during the auto-level function
TILT Displays vehicle tilt in “X” and “Y” orientations measured by integral sensor
TILTED Displays whether vehicle is tilted (YES or NO)
BATTERY Displays battery supply voltage (on P2-12)

DIAGNOSTIC / SWITCHES MENU OPTIONS

LR/P2-1 High when the left rear outrigger is in contact with the ground
RR/P2-2 High when the right rear outrigger is in contact with the ground
RF/P2-3 High when the right front outrigger is in contact with the ground
LF/P2-4 High when the left front outrigger is in contact with the ground
EXTEND/P2-5 High to activate the auto-level function
RETRACT/P2-6 High to activate the auto-retract function
ELEV/P2-10 High when the scissor stack is stowed (“elevated” input indicates that the vehicle is
stowed).

Rough Terrain Compact Series SKYJACK, Page 13

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

DIAGNOSTIC / OUTPUTS MENU OPTIONS

LAMP/P2-7 Displays state of outrigger control box light
STABLE/P2-8 Displays state of stable (all legs touching the ground) output
TILT/P2-9 Displays state of tilt
LRe/P4-1 Displays state of left rear outrigger extend valve
RRe/P4-2 Displays state of right rear outrigger extend valve
RFe/P4-3 Displays state of right front outrigger extend valve
LFe/P4-4 Displays state of left front outrigger extend valve
LRr/P4-5 Displays state of left rear outrigger retract valve
RRr/P4-6 Displays state of right rear outrigger retract valve
RFr/P4-7 Displays state of right front outrigger retract valve
LFr/P4-8 Displays state of left front outrigger retract valve
P4-9 MON Displays the voltage to the outrigger valve (can only be seen when operating in
auto-level or retract)

DIAGNOSTIC / LOG MENU OPTIONS

MAX.BATTERY Displays maximum recorded battery supply voltage
OCM1 version Displays part number and software version of GP106
EZcal version Displays software version of EZcal

ACCESS LEVEL MENU OPTIONS

CODE xxxx “ACCESS LEVEL” 3 (allows viewing only)
“ACCESS LEVEL” 2 (allows setup on OCM1)

ADJUSTMENTS MENU OPTIONS (factory set - not adjustable)

Xtilt TRIP Displays the tilt trip point in the “X” orientation
Ytilt TRIP Displays the tilt trip point in the “Y” orientation
TILT ENTRY Displays the tilt delay time
TILT EXIT Displays the tilt delay time
Xlevel TRIP Displays the tilt trip point in the “X” orientation during the auto-level function
Ylevel TRIP Displays the tilt trip point in the “Y” orientation which applies during the auto-level function

MACHINE SETUP MENU OPTIONS (factory set - not adjustable)

DEFAULTS Allows all adjustments & machine settings to be set to defaults
WARNING: all GP106 settings will be changed; use with caution!
CALIBRATE LEVEL Allows levelling of the integral tilt sensor of the GP106, when the vehicle is
positioned on level ground (see Appendix Four)
TILT MODE Allows configuration of the GP106 tilt output (P2-9):
1 – output turns on to light lamp when tilted
2 – output turns off to cutout functions when tilted
3 – output turns off to cutout functions when tilted AND elevated
TILT FILTER Displays the filter applied to the tilt measurements during the auto-level function
(used to minimize the effect of vehicle vibrations on the tilt measurement)
Xlevel TARGET Displays the tilt in the “X” orientation at which the auto-level function will complete.
Ylevel TARGET Displays the tilt in the “Y” orientation at which the auto-level function will complete.
tilt SLACK Displays the amount of vehicle tilt exceeding the Xtilt TARGET and/or Ytilt TARGET in
which the auto-level function will not attempt to level
EXAMPLE:
Xtilt TARGET=0.3°, Ytilt TARGET=0.7°, tilt SLACK=0.5°
If machine is tilted to 1.0° in the X and Y orientations, the auto-level function will attempt
to level the X orientation (0.3+0.5<1.0) but will not attempt to level the Y orientation
(0.7+0.5>1.0)
RANGE: 0.0° to 1.0°, default 0.3°

SKYJACK, Page 14 Rough Terrain Compact Series

Engine Powered
157951
Section 5 - Procedures Service and Maintenance

IMPORTANT
Each phase must be completed before the next phase can be carried out.
All phases must be completed before the aerial platform can be operated.
Always follow the instructions of the Calibration instrument.

1. Ensure aerial platform is parked on a firm and level surface.

2. Elevate the scissors high enough to lay a level accross the base tubes. Ensure there is no debris on the base
and the level sits flat. Do not elevate aerial platform higher than the high speed/tilt override limit switch.

3. Manually operate the outriggers and level the machine in 4 places: left side, right side, front and rear. All 4
outriggers must be firmly placed and all 4 tires are off the ground.

4. Double check that the aerial platform is level at all 4 points.

5. Connect the EZcal tool to the P1 connector on the CONTROL MODULE.

6. The display will show “Help: Press Enter”.

By using Left/Right buttons, select the “Access Level (3 )” from the menu and press the ENTER button.

7. The display will show “Access Level: Code (0000)”.

By using the Up/Down buttons, enter the Access Level Code (1 1  2  2) followed by pressing the ENTER
button.

8. The display will show “Access Level 2”.

By using Left/Right buttons, select the “Setups” from the menu and press the ENTER button.

9. The display will show “Setups: Change Defaults”.

Select the “Change Defaults” from the menu and press the ENTER button.

10. The display will show “Defaults, 0 = Custom”.

By using Up/Down buttons, select the “Defaults: Code Setting for your Model (For Default Code Refer to Table
5-3)” from the menu and press the ENTER button and followed by ESCAPE button.

11. The display will show “Setups Change Defaults”.

By using Left/Right buttons, select the “Calibrate Level” from the menu and press the ENTER.

12. The display will show “Calibrate Level: Yes: Enter, No: ESC”.
Select the “Yes” from the menu by press the ENTER button.

13. The display will show “Calibrate Level: Tilt 0.0’ , 0.0’”.
Select the “ESCAPE” from the menu once.

14. The display will show “Setups Calibrate Level”.

Select the “ESCAPE” from the menu once again.

15. The Calibration procedure is complete, unplug and remove the EZ-Cal.

16. Close the hydraulic/electric cabinet.

Rough Terrain Compact Series SKYJACK, Page 15

Engine Powered
157951
Service and Maintenance Section 5 - Procedures

5.3-7 Auto-Leveling Outrigger Control Module Pin Reference Chart

LED

GP106 Control Module

WIRE #
PIN
PLUG AND WIRE FUNCTION
#
COLOUR
P1 The Calibration Connection
P2 1 68A White Input indicating that the LEFT REAR outrigger is in contact with the ground
P2 2 67A Red/White Input indicating that the RIGHT REAR outrigger is in contact with the ground
P2 3 66A Blue/White Input indicating that the RIGHT FRONT outrigger is in contact with the ground
P2 4 65A Green/White Input indicating that the LEFT FRONT outrigger is in contact with the ground
P2 5 70 Green/Black Input for AUTO-LEVEL function to extend the outriggers to level the machine
P2 6 79 Green Input for AUTO-RETRACT function to retract the outriggers until the switch is released
P2 7 70A Red/White Outrigger Light on Outrigger Control Box
P2 8 65 Green/Black STABLE output to indicate that all outriggers are in contact with the ground
P2 9 28 Green TILT output to indicate that the machine is level (ANSI/CSA only)
P2 10 44 Green Tilt override / High Drive Cutout
P2 11 02 White Negative Input
P2 12 10A Black Main Power Input
P4 1 78 Black/White Output used to extend the LEFT REAR outrigger
P4 2 77 Blue/Black Output used to extend the RIGHT REAR outrigger
P4 3 76 Red/Black Output used to extend the RIGHT FRONT outrigger
P4 4 75 Orange/Black Output used to extend the LEFT FRONT outrigger
P4 5 74 Black Output used to retract the LEFT REAR outrigger
P4 6 73 Blue Output used to retract the RIGHT REAR outrigger
P4 7 72 Red Output used to retract the RIGHT FRONT outrigger
P4 8 71 Orange Output used to retract the LEFT FRONT outrigger
P4 9 35C White/Black Power input for outriggers
60401AC

SKYJACK, Page 16 Rough Terrain Compact Series

Engine Powered
157951
Notes
Reliable lift solutions by people who care.

www.skyjack.com