Service Manual: SJIII Conventional Series (ANSI/CSA)

MODELS SJ 3220 SJ 3226 SJ 4620 SJ 4626 SJ 4632
Service Manual
SJIII Conventional Series (ANSI/CSA)
Part No. 157928AA February 2011

This manual is based on Serial Number(s):
SJIII 3320 60,002,259 & Above

SJIII 3226 27,006,432 & Above
SJIII 46xx 70,007,139 & 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 Inspections

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
SJIII Series SKYJACK, Page 3

Operator’s Responsibility for Maintenance Section 1 - Scheduled 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 SJIII Series

1
Section 1
schedule maintenance inspections
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..........................................................................................................................................9
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
Scheduled Maintenance
1.1 Scheduled Maintenance Inspections...............................................................................................................18
1.2 Function Tests..................................................................................................................................................25
Tables
1.1 Owner’s Annual Inspection Record.................................................................................................................16
1.2 Maintenance and Inspection Checklist............................................................................................................17

Section 1 - Scheduled Maintenance Operator’s Responsibility for 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 SJIII Compact and Conventional series aerial platforms are designed to transport and raise person-
nel, 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 SJIII 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 & Asia: Europe:

( : 800 275-9522
( : 44 1691-676-235
7 : 630 262-0006 7 : 44 1691-676-239
Include the model and serial number for each applicable aerial platform.

Scope of this Manual

a. This manual applies to the ANSI/SIA, CSA and CE versions of the SJIII 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.
- Equipment identified with “CE” meets the requirements for the European countries, i.e., Machinery
Directive 98/37/EC and EMC Directive 89/336/EEC and the corresponding EN standards.
b. CSA (Canada) and CE (Europe)

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 Inc.
Electrocution Hazard
This aerial platform is not electrically insulated. Maintain a Minimum Safe Approach Distance (MSAD) from energized
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.
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 CE Guidance Note
and CSA B354.2-01 Requirements “Avoidance of danger from overhead lines”
Voltage Range Minimum Safe Approach Distance
(Phase to Phase) (Feet)
0 to 300V Avoid Contact
Over 300V to 50KV 10
Adhere strictly to the governmental rulings
Over 50KV to 200KV 15
and regulations applicable in your country.
FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY!
60023AD

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 or territorial/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 switch firm level surface. Do not drive
“ ” off when leaving the aerial platform unat- elevated near depressions
tended. Remove the key to prevent unauthorized or holes of any type, loading
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 with
• DO NOT wear loose clothing, holes or drop-offs is abso-
dangling neckties, scarves, lutely necessary, elevated
rings, wristwatches or other driving shall not be allowed.
jewelry while operating this Position the aerial platform
lift. 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 el-
ropes, cords or hoses. evated. After elevation, the
drive function must not be ac-
tivated.
• Elevated driving must only

• AVOID falling. Stay within the be done on a firm level sur-
boundaries of the guardrails. face.
• DO NOT ascend or descend

a grade when elevated. When
• DO NOT raise the aerial plat- fully lowered, ascending or
form in windy or gusty condi- descending, only grades up
tions. to rated maximum listed in
Tables 2-3 are permissible.

Safety Precautions (Continued)

• DO NOT operate on surfaces not capable

of holding the weight of the aerial platform • DO NOT raise the aerial platform
including the rated load, e.g., covers, drains, and while the aerial platform is on a
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 its size • BE AWARE of crushing hazards.
or work height. It is prohibited. Keep all body parts 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

as a crane. It is prohibited. • ENSURE that there are no personnel or 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.
• B E A W A R E o f o v e r h e a d
obstructions or other possible • DO NOT use the aerial platform without guardrails,
hazards around the aerial locking pins and the entry gate in place.
platform when driving or lifting.

Safety Precautions (Continued)

• DO NOT exceed the rated capacity of the

WARNING
aerial platform. Do make sure the load is evenly
distributed 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 platform is in the fully retracted position.
another object to steady the platform.
• Do use three points of contact to enter and exit
• DO NOT place materials on the guardrails or the platform. Enter and exit the platform from
materials 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 guardrail and one foot or one hand and two feet are in
system of the aerial platform provides fall protection. contact with the aerial platform or the ground at
If occupant(s) of the platform are required to wear all times during entering and exiting.
personal fall protection equipment (PFPE), occupants
shall comply with instructions provided by the aerial WARNING
platform manufacturer (remanufacturer) regarding
An operator should not use any aerial
anchorage(s).”
platform that:
• does not appear to be working properly.
If additional fall protection is required, by an employer or
• has been damaged or appears to have worn or
the authority having jurisdiction, Skyjack recommends
missing parts.
the use of a fall restraint system to keep an occupant
• has alterations or modifications not approved by
within the confines of the platform, and thus not expose
the manufacturer.
the occupant to any fall hazard requiring a fall arrest.
• has safety devices which have been altered or
disabled.
All personal fall protection equipment must comply
• has been tagged or blocked out for non-use or
with applicable governmental regulations and must
repair.
be inspected and used in accordance with the
manufacturer’s recommendations.
Failure to avoid these hazards could re-
sult in death or serious injury.
All personal fall protection equipment must be attached
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.

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 aerial platform and must not be used this type of equipment.
without manufacturer’s consent.
Keep sparks and flames away from all flammable or
All replacement tires must be of the same size and load combustible materials.
rating as originally supplied tires; to maintain safety and
stability of aerial platform. Properly dispose of all waste material such as lubricants,
rags, and old parts according to the relative law
Consult SKYJACK’s Service Department for optional provisions obtaining in the country.
tires specifications and installation.
Before attempting any repair work, turn Battery
Disconnect Switch to the “OFF” position.
WARNING
Any unit that is damaged or not operating Preventive maintenance is the easiest and least
properly must be immediately tagged and expensive type of maintenance.
removed from service until proper repairs
are completed.

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 dis-assembled
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 foreign identification of parts to assure proper reassembly.
materials in the system can cause wear or damage Clean all metal parts in a clean mineral oil solvent.
to components, as well as general faulty operation Be sure to thoroughly clean all internal passages.
of the hydraulic system. Every precaution must After the parts have been dried thoroughly, lay
be taken to assure absolute cleanliness of the them on a clean, lint-free surface for inspection.
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 place
and flush the entire system and replace the filter 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 oil Maintenance Hints
reservoir, and fill the reservoir only through the Three simple maintenance procedures have the
filter opening. The use of cloth to strain the oil greatest effect on the hydraulic system performance,
should be avoided to prevent lint from getting into efficiency and life. Yet, the very simplicity of them may
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 hydraulic
oil is warmed through normal operation of oil of the proper type and viscosity in the
the system. The sample should be analyzed hydraulic reservoir.
by a qualified lubrication specialist to 3. Keep all connections tight.
determine if it is suitable for continued use.

Section 1 - Scheduled Maintenance Service and Maintenance
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.skyjackinc.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 mantenance 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
Failure to perform each procedure as pre- repaired, an inspection must be performed again
sented and scheduled may cause death, before removing the tag. Place a check in the repair
serious injury or substantial damage. column.
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.

Service and Maintenance Section 1 - Scheduled Maintenance
Table 1.1 Owner’s Annual Inspection Record
Model Number: ____________________________ Serial Number: ____________________________
Recording
Date
Recording
1 2 3 4 5 6 7 8 9
Year #
Owner’s
Name
Inspected
By
60564AA
As described earlier in this section, this decal is located on the control compartment cowling. 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.

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 operating 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 Platform Assembly
Labels A Lanyard Attachment Anchors A, B
Limit Switches A, B AC Outlet on Platform A, B
Entrance Side Platform Control Console A, B
Main Power Disconnect Switch A, B Manuals A, B
Base Control Switches A, B Powered Extension Control Console
A, B
Free-wheeling Valve Knob (If Equipped)
A, B
(Compacts - Front Side) Lift Mechanism
Brakes A, B, C Maintenance Support A, B
AC Outlet Receptacle A, B Scissor Assembly A, B
Ladder A, B Scissor Bumpers A, B
Battery Tray Side Rollers A, B
Pothole Protection Device A, B Lift Cylinder(s) A, B
Battery Tray A, B Function Tests
Battery Charger A, B Test Main Power Discconect Switch A, B
Battery A, B Base Control Console
Steer Cylinder Assembly A, B Test Base Emergency Stop A, B
Wheel/Tire Assembly A, B Test Off/Platform/Base A, B
Tie Rod (Conventionals) A, B Test Lower/Neutral/Raise Switch A, B
Greasing Points A, B, C Test Emergency Lowering A, B
Hydraulic/Electric Tray Side Test Free-wheeling A, B
Pothole Protection Device A, B Platform Control Console
Hydraulic Tank A, B, C Test Platform Emergency Stop A, B
Hydraulic Oil A, B, C Test Enable Trigger Switch A, B
Hydraulic Pump and Motor A, B Test Steering A, B
Electrical Panel A, B Test Driving A, B
Proportional and Main Manifolds A, B Test Brakes A, B
Tilt Sensor A, B Test Platform Raising/Lowering A, B
Emergency Lowering Access Rod Test Horn A, B
A, B
(If Equipped) Test Pothole Sensor A, B
Test Elevated Drive Speed A, B
Test Tilt Sensor A, B
1002AA
A - Perform Visual and Daily Maintenance Inspections & Functions Test. Refer to Section 2 of the Operating Manual.
B - Perform Scheduled Maintenance Inspection every three months or 150 hrs. Refer to Section 1 of this manual.
C - Perform Scheduled Maintenance Inspection every year. Refer to Section 1 of this manual.
D - Perform Scheduled Maintenance Inspection every 2 years. Refer to Section 1 of this manual.
* Perform scheduled inspection every three months or 150 hours.
† - Refer to Skyjack's website @ www.skyjack.com for latest service bulletins porior 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.

High Speed
Limit Switch
High Speed
Limit Switch
Pothole Protection
Limit Switch
CONVENTIONALS COMPACTS
1.1 Scheduled Maintenance Inspections Hydraulic
Begin the scheduled maintenance inspections by Maintaining the hydraulic components is essential
checking each item in sequence for the conditions listed to good performance and service life of the aerial
in this section. platform.
WARNING Perform a visual inspection around the following

areas:
To avoid injury, do not operate an aerial • hoses and fittings
platform until all malfunctions have been • all hydraulic cylinders
corrected. • all hydraulic manifolds
• the underside of the base
WARNING • ground area under the aerial platform
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 and movement is not obstructed.
Inspect the following areas for chafed, corroded and
Visually inspect all limit switch located inside the scissor
loose wires:
arms and the outrigger assemblies for the following:
• base to platform cables and wiring harness
• broken or missing actuator arm
• battery tray wiring harnesses
• missing fasteners
• hydraulic/electrical wiring harnesses
• loose wiring

Compact Ladder Conventional

(Back View)
110V Outlet
Receptacle
Free-wheeling
Valve
Emergency Main
Brakes Power
Ladder Disconnect
Base Switch
Control Console
110V Outlet
Receptacle
Free-wheeling
Valve
Compact
Brakes (Back View)
1.1-3 Entrance Side • AC Outlet Receptacle

-- Ensure receptacle is free from dirt and
• Main Power Disconnect Switch obstructions.
-- Turn emergency main power disconnect
switch to “ ” off position. • Ladder
-- Ensure there are no loose or missing
-- Ensure all cables are secure and switch parts and there is no visible damage.
is in proper working condition.
• Base Control Switches
-- Ensure there are no signs of visible
damage and all switches are in their
neutral positions.
• Free-wheeling Valve Knob
(Compacts - Front Side)
parts and there is no visible damage.
• Brakes
-- Ensure tabs are not locked.

Conventional Compact
Battery
Battery
Charger Battery
Charger
Hydraulic/Electric
Battery Tray Battery Fuse Box Tray Pothole Protection Device Battery Tray
1.1-4 Battery Tray Side

WARNING
• Pothole Protection Device Battery acid is extremely corrosive
-- Ensure mechanisms have no sign of - Wear proper eye and facial protec-
visible damage and are free from dirt and tion as well as appropriate protective
obstructions. clothing. If contact occurs, immedi-
ately flush with cold water and seek
• Battery Tray medical attention.
-- Ensure tray latch is secure and in proper
working order. 1. Check battery case for damage.
• Battery Charger
(Compacts - Entrance Side) 2. Clean battery terminals and cable ends
-- Ensure charger is secure and shows no thoroughly with a terminal cleaning tool
visible damage. or wire brush.
• Battery 3. Ensure all battery connections are tight.

Proper battery condition is essential to
good performance and operational safety. 4. If applicable, check battery fluid level. If
Improper fluid levels or damaged cables and plates are not covered by at least 1/2”
connections can result in component damage (13 mm) of solution, add distilled or
and hazardous conditions. demineralized water.
WARNING 5. Replace battery if damaged or incapable

of holding a lasting charge.
Explosion hazard. Keep flames
and sparks away. Do not smoke
near batteries. WARNING
Use original or manufacturer-approved
parts and components for the aerial
platform.

Conventional
Wheel/Tire
Steer Cylinder
Wheel/Tire
Greasing Point
Wheel Motor Tie Rod
• Steer Cylinder Assembly • Tie Rod (Conventionals)

-- Ensure steer cylinder assembly is -- Ensure there are no loose or missing
properly secured and there are no loose parts, tie rod end studs are locked and
or missing parts. there is no visible damage.
• Wheel/Tire Assembly • Greasing Points
The aerial platform is either equipped with -- Ensure greasing points have no sign of
solid rubber tires or foam-filled tires. Tire visible damage and are free from dirt and
and/or wheel failure could result in an aerial obstructions.
platform tip-over. Component damage may
also result if problems are not discovered and B - Frequent Inspection
repaired in a timely fashion. -- Locate grease fittings and pump grease
as needed.
-- Check all tire treads and sidewalls for
cuts, cracks, punctures and unusual
wear.
-- Check each wheel for damage and
cracked welds.
-- Check each lug nut for proper torque to
ensure none are loose.
-- Check wheel motor assembly for loose
or missing parts and signs of visible
damage.
-- Ensure wheels are aligned and true
vertically and horizontally.

Compact Tilt Sensor

Emergency Lowering Greasing Point
Access Rod
Electrical Panel
Hydraulic/Electric
Tray
Main Manifold
Greasing Point
Hydraulic Tank
1.1-5 Hydraulic/Electric Tray Side • Electrical Panel

-- Ensure tray latch is secure and in proper -- Ensure panel is properly secured and
working order. there is no visible damage.
• Pothole Protection Device -- Ensure there are no loose wires or
-- Ensure mechanisms have no sign of missing fasteners.
visible damage and are free from dirt and
obstructions. • Proportional and Main Manifolds
-- Ensure all fittings and hoses are properly
• Hydraulic Tank tightened and there is no evidence of
-- Ensure hydraulic filler cap is secure. hydraulic leakage.
-- Ensure tank shows no visible damage -- Ensure there are no loose wires or
and no evidence of hydraulic leakage. missing fasteners.
• Hydraulic Oil • Tilt Sensor
-- Ensure platform is fully lowered, and then -- Ensure tilt sensor is properly secured and
visually inspect the sight gauge located there is no visible damage.
on the side of the hydraulic oil tank.
• Emergency Lowering Access Rod
-- The hydraulic oil level should be at or (If Equipped)
slightly above the top mark of the sight -- Ensure rod is properly secured and there
glass. is no visible damage.
C - Annual Inspection
-- For hydraulic oil replacement procedure,
refer to section 5.
• Hydraulic Pump and Motor

Powered Extension
Platform Control Console
Control Console
Platform
Railing
Manual Storage
Box Lanyard
Attachment
Platform Anchor
Assembly
1.1-6 Platform Assembly • Platform Control Console

-- Ensure all switches and controller are
WARNING returned to neutral and are properly
secured.
Ensure that you maintain three points of
contact to mount/dismount platform. -- Ensure there are no loose or missing
1. Use the ladder of aerial platform to access
• Manuals
platform.
Ensure a copy of operating manual and other
important documents are enclosed in manual
2. Close the gate.
storage box.
-- Check to be sure manual storage box is
present and in good condition.
-- Ensure all fasteners are securely in
-- Ensure manuals are legible and in good
place.
condition.
-- Ensure all railings are properly positioned
-- Always return manuals to the manual
and secured.
storage box after use.
-- Ensure gate is in good working order.
• Lanyard Attachment Anchors
-- Ensure attachment rings are secure and
no visible damage.
• AC Outlet on Platform
-- Ensure outlet has no visible damage and
free from dirt or obstructions.

Maintenance
Support
Lift Cylinder
Scissor Bumper
Scissor Assembly
Roller
• Powered Extension Control Console • Scissor Bumpers

(If Equipped) -- Ensure bumpers are secure and shows
-- Ensure all switches are returned to no sign of visible damage.
neutral and are properly secured.
• Rollers
-- Ensure there are no loose or missing -- Ensure rollers are secure and there is no
parts and there is no visible damage. visible damage.
-- Ensure rollers’ path of travel are free from
WARNING dirt and obstructions.
Ensure that you maintain three points of
• Lift Cylinder(s)
contact to mount/dismount platform.
-- Ensure each lift cylinder is properly
secured, there are no loose or missing
3. Use the ladder to dismount from platform.
parts and there is no evidence of
damage.
1.1-7 Lifting Mechanism
-- Ensure all fittings and hoses are properly
1. Raise the platform until there is adequate clearance tightened and there is no evidence of
to swing down the maintenance support. hydraulic leakage.
• Maintenance Support 2. Raise the platform until there is adequate clearance

-- Ensure maintenance support is properly to swing up the maintenance support.
secured and shows no visible damage.
3. Swing up maintenance support into storage
• Scissor Assembly bracket.
-- Ensure scissor assembly shows no visible
damage and no signs of deformation in 4. Fully lower the platform.
weldments.
-- Ensure all pins are properly secured.
-- Ensure cables and wires are properly
routed and shows no signs of wear and/
or physical damage.

Section 1 - Scheduled Maintenance Function Tests
(Back View) (Back View)
Free-wheeling
Valve
Lower/ Lower/
Neutral/Raise Neutral/Raise
Switch Switch
Emergency Stop Platform/Off/Base Emergency Stop

Button Key Switch Button
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 4. Use the ladder to dismount from platform.
again before putting aerial platform into service.
5. Turn main power disconnect switch to “ ” on
Prior to performing function tests, be sure to read position.
and understand Section 2.10 - Start Operation of the
operating manual.
1.2-1 Test Main Power Disconnect Switch
1. At rear of the base, turn main power disconnect

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

Function Tests Section 1 - Scheduled Maintenance
Free-wheeling
Valve
Platform Platform
Raise/Lower Raise/Lower
Switch Switch

• Test Base Emergency Stop 3. Select and hold off/platform/base key

switch to “ ” base position. Attempt
1. Push in “ ” emergency stop button and to raise or lower the platform.
attempt to raise or lower the platform. Result: Platform raising and lowering
Result: Platform raising and lowering functions should operate.
functions should not operate.
• Test Lower/Neutral/Raise Switch
2. Pull out base “ ” emergency stop
button. 1. Select and hold off/platform/base key
switch to “ ” base position and
• Test Off/Platform/Base Switch
“ ” raise the platform with lower/neutral/
raise switch.
WARNING Result: Platform should rise.
Be aware of overhead obstructions
or other possible hazards around the 2. Select and hold off/platform/base key
aerial platform when lifting. switch to “ ” base position and
“ ” lower the platform with lower/
1. Select off/platform/base key switch neutral/raise switch.
“ ” off position. Attempt to raise or lower Result: Platform should lower.
the platform.
Result: Platform raising and lowering
2. Select off/platform/base key switch to “ ”

platform position. Attempt to raise or lower
the platform.
Result: Platform raising and lowering

Free-wheeling
Valve
Lower/ Lower/
Neutral/Raise Neutral/Raise
Switch Switch

• Test Emergency Lowering • Test Free-wheeling
1. Raise the platform. 1. Ensure path of intended motion is clear.
2. Locate holding valve manual override 2. Release the brake manually.

knob at the base of each lift cylinder.
Depress and turn counterclockwise. If 3. Tu r n f r e e - w h e e l i n g v a l v e k n o b
necessary, use access rod that is located counterclockwise to a fully opened
on the base of the aerial platform. position and attempt to push/pull the aerial
platform.
3. On hydraulic/electric tray, pull out and Result: Platform should move.
hold emergency lowering valve to fully
lower the platform. 4. Turn free-wheeling valve knob clockwise
Result: The platform should lower. to a fully closed position for normal
operation.
4. To restore normal operation, depress and
turn holding valve manual override knobs 5. Reengage the brake.
clockwise.

Lift/Drive/Steer Enable
Trigger Switch Rocker Switch
Controller
Inclined Drive/Level Drive Emergency Stop Button/

Switch Operation Light
Horn Pushbutton
Lift/Off/Drive Switch
1.2-3 Platform Control Console • Test Platform Emergency Stop
1. Ensure base “ ” emergency stop button is 1. Push in “ ” emergency stop button

pulled out. and attempt to activate any platform
function.
Result: All selected platform functions
2. Select off/platform/base key switch to “ ” should not operate.
platform position.
• Test Enable Trigger Switch
3. Ensure main power disconnect switch is in “ ” on
position.
1. Without activating “ ” enable trigger
WARNING switch, attempt to activate any platform
Ensure that you maintain three points of function.
contact when using the ladder to mount/ Result: All platform functions should not
dismount platform. operate.
.
4. Use the ladder of aerial platform to access
platform.
5. Close the gate.
6. On platform control console, pull out “

”emergency stop button.

Controller

Horn Pushbutton
• Test Steering • Test Driving

NOTE
Inclined drive (low speed/high torque) is 1. Ensure path of intended motion is clear.
not available on 3215 and 3219 models.
2. Activate and hold “ ”enable trigger
1. Select lift/off/drive switch to “ ” drive switch.
position.
3. Slowly move controller handle in
2. Activate and hold “ ” enable trigger
“ ” forward direction until aerial platform
switch.
begins to move, and then return handle to
center position.
3. Press rocker switch on top of controller
Result: Aerial platform should move in
handle to “ ” left and “ ” forward direction, and then come to a
right. stop.
Result: Steer wheels should turn left and
right.
4. Slowly move controller handle in “ ”
reverse direction until aerial platform begins
to move, and then return handle to center
position.
Result: Aerial platform should move in
reverse direction, and then come to a
stop.

Controller

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

controller handle.
Result: Aerial platform should come to
a stop. If aerial platform pulls to one side
while stopping, do not operate aerial
platform until brake adjustments have
been checked.

Pothole Protection
Pothole Protection
Device
Device
• Test Platform Raising/Lowering • Test Pothole Sensor
WARNING WARNING
Be aware of overhead obstructions Ensure that you maintain three points
or other possible hazards around the of contact to mount/dismount plat-
aerial platform when lifting. form.
1. Use the ladder to dismount from platform

1. Select lift/off/drive switch to “ ” lift
and place a block, approximately
position.
1.5” (3.75 cm), under the hydraulic/electric
tray.
2. Activate and hold “ ” enable trigger
switch. 2. Use the ladder of aerial platform to access
platform.
3. Push controller handle and raise the
platform to an approximate height of 3. Close the gate.
1 ft. (30.5 cm).
Result: Platform should rise. 4. Raise the platform until approximately a
height of 7 feet (2 meters) is reached and
4. Pull controller handle and lower the attempt to drive forward or reverse.
platform fully. Result: Aerial platform should not move
Result: Platform should lower. forward or backward.
• Test Horn 5. Repeat the steps above with block placed

under battery tray.
1. Push “ ” horn pushbutton. Result: Aerial platform should not move
Result: Horn should sound. forward or backward.

Pothole Protection
Pothole Protection
Device
Device
• Test Elevated Drive Speed 2. Use the ladder to dismount from
WARNING platform.
Be aware of overhead obstructions 3. On base control console, slowly raise the

or other possible hazards around the platform.
aerial platform when lifting. Result: When platform reaches an
appropriate height, a warning signal
1. Ensure path of intended motion is clear. should sound and platform stop raising
as lift and drive controls should be
2. Raise the platform until approximately a disabled.
height of 7 feet (2 meters) is reached and
attempt to drive forward or reverse.
Result: Aerial platform should move slower
than when it was in stowed position.
• Test Tilt Sensor
WARNING
Be aware of overhead obstructions
or other possible hazards around the
aerial platform when lifting.
WARNING
Ensure that there are no personnel
or obstructions in the path of travel,
including blind spots.
1. Move the aerial platform on to a slope not

greater than 4.5°.

Section 2
maintenance tables and diagrams
Table of Contents
Tables
2.1 Specifications and Features...............................................................................................................................2
2.2 Floor Loading Pressure......................................................................................................................................5
2.3 Maximum Platform Capacities (Evenly Distributed)..........................................................................................6
2.4 Torque Specifications.........................................................................................................................................7

Service and Maintenance Section 2 - Maintenance Tables and Diagrams
Table 2.1 Specifications and Features
MODEL 3215 3219 3220 3226

2400 lb. 2580 lb. 3510 lb. 4135 lb.
Weight *
1089 kg 1170 kg 1592 kg 1876 kg
32" 32"
Overall width
0.81 m 0.81 m
70.0” 91"
Overall length
1.78 m 2.3 m
26” x 64” 28” x 83”
Platform Size (inside)
0.66 m x 1.63 m 0.71 x 2.1 m
Height
21’ 25’ 26’ 32’
Working Height
6.4 m 7.6 m 8.1 m 9.9 m
15' 19’ 20’ 26’
Platform Elevated Height
4.6 m 5.8 m 6.1 m 7.9 m
34.5” 39" 38" 45"
Stowed Platform Height
0.88 m 0.99 m 0.97 m 1.1 m
74” 78.5" 82" 89"
Stowed Height (Railings Up)
1.88 m 1.99 m 2.1 m 2.3 m
Drive Height FULL
Standard Operating Time

Lift Time (No Load) 18 s 20 s 27 s 47 s
Lower Time (No Load) 32 s 39 s 41 s 63 s
Lift Time (Rated Load) 23 s 25 s 33 s 51 s
Lower Time (Rated Load) 24 s 29 s 29 s 46 s
Chassis
2 mph 1.9 mph 2.4 mph
Normal Drive Speed
3.2 km/h 3.0 km/h 3.8 km/h
0.65 mph 0.64 mph 0.64 mph
Elevated Drive Speed
1.05 km/h 1.0 km/h 1.0 km/h
0.95 mph 1.2 mph
High Torque Drive Speed N/A
1.5 km/h 1.9 km/h
Gradeability (Ramp Angle) 23% 25%
12 x 4 x 8 16 x 5 x 12
Tires
Solid Rubber Solid Rubber
Hydraulic Oil
Type ATF Dexron III ATF Dexron III
2.9 gal. 7.93 gal.
Tank Capacity
10.9 L 30 L
162AB
* Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform.
Refer to nameplate for aerial platforms with 5' (1.5 m) or 6' (1.8 m) extension platform.

Section 2 - Maintenance Tables and Diagrams Service and Maintenance
Table 2.1 Specifications and Features (Continued)

MODEL 4620 4626 4632
4100 lb. 4700 lb. 5075 lb.
Weight *
1860 kg 2132 kg 2302 kg
46"
Overall width
1.17 m
91"
Overall length
2.31 m
42" x 84"
Platform Size (inside)
1.07 m x 2.13 m
Height
26' 32' 38'
Working Height
7.92 m 9.75 m 11.6 m
20' 26' 32'
Platform Elevated Height
6.1 m 7.9 m 9.8 m
38" 45" 48.5"
Stowed Platform Height
0.97 m 1.14 m 1.23 m
77.25" 84.5" 88"
Stowed Height Railings Up
1.96 m 2.15 m 2.24 m
Drive Height FULL
Standard Operating Time

Lift Time (No Load) 24 s 48 s 50 s
Lower Time (No Load) 48 s 45 s 62 s
Lift Time (Rated Load) 32 s 54 s 59 s
Lower Time (Rated Load) 32 s 32 s 49 s
Chassis
2.0 mph
Normal Drive Speed
3.2 km/h
0.56 mph
Elevated Drive Speed
0.90 km/h
1.0 mph
High Torque Drive Speed
1.6 km/h
Gradeability 25%
16 x 5 x 12
Tires
Solid Rubber
Hydraulic Oil
Type ATF Dexron III
7.93 gal.
Tank Capacity
30 L
163AC
* Weight with standard 3' (0.9 m) or 4' (1.2 m) extension platform.
Refer to serial nameplate for specific applications.
1
Fill hardness: 55 Durometer

Floor Loading Pressure
Locally Concentrated Pressure (LCP): Overall Uniform Pressure (OUP):
Foot Print Area = Length x Width Base Area = Length x Width
Weight of Aerial Platform + Capacity Weight of Aerial Platform + Capacity

LCP = 0.4 X OUP =
Foot Print Area Base Area
Width Width
Length
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.

Table 2.2 Floor Loading Pressure
Total Aerial Total Aerial Platform Load

Platform Weight Wheel LCP** OUP**
MODEL
KPa KPa
lb. kg lb. kg psi psf
(kN/m2) (kN/m2)
min* 2400 1089 960 435 100 689.48 160 7.66
3215
max* 3000 1361 1200 544 110 758.42 200 9.58
min* 2580 1170 1032 468 100 689.48 170 8.14
3219
max* 3130 1420 1252 568 110 758.42 210 10.05
min* 3400 1542 1396 633 110 758.42 175 8.38
3220
max* 4299 1950 1936 878 130 896.32 245 11.73
min* 4100 1860 1644 746 120 827.37 210 10.05
3226
max* 4610 2091 1844 836 130 896.32 235 11.25
min* 4100 1860 1640 744 191 1316.90 146 6.99
4620
max* 5620 2549 2250 1021 222 1530.64 199 9.53
min* 4700 2132 1880 853 206 1420.32 168 8.04
4626
max* 5920 2685 2370 1075 224 1544.43 210 10.05
min* 5075 2302 2030 921 208 1434.11 180 8.62
4632
max* 5775 2620 2310 1048 223 1537.53 205 9.82
60354AF-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 that 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 above.
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.

Table 2.3 Maximum Platform Capacities (Evenly Distributed)
Manual Extension Platform Powered Extension Platform Maximum Tilt

MODEL Wind Cutout
Total Capacity Extension Capacity Total Capacity Extension Capacity Speed Setting
600 lb. 250 lb. 28 mph
3215 2 Persons 1 Person N/A 1.5 x 3.5
272 kg 113 kg 12.5 m/s
550 lb. 250 lb. 28 mph

249 kg 113 kg 12.5 m/s
900 lb. 300 lb. 800 lb. 300 lb. 28 mph

3220 2 Persons 1 Person 2 Persons 1 Person 1.5 x 3.5
408 kg 136 kg 363 kg 136 kg 12.5 m/s
500 lb. 250 lb. 28 mph

227 kg 113 kg 12.5 m/s
1300 lb. 300 lb. 1300 lb. 300 lb. 28 mph

590 kg 136 kg 590 kg 136 kg 12.5 m/s
1000 lb. 300 lb. 1000 lb. 300 lb. 28 mph

454 kg 136 kg 454 kg 136 kg 12.5 m/s
700 lb. 250 lb. 28 mph

318 kg 113 kg 12.5 m/s
165AB
NOTE: Overall Capacity - Occupants and materials not to exceed rated load.

Table 2.4 Torque Specifications
Directional valve mounting bolts 28-32 lbf.in 2.2 – 3.6 Nm

Wheel mounting bolts 70 lbf.ft 94.9 Nm
Wheel motor castle nut (Models 32xx & 46xx) 280 lbf.ft 379.6 Nm
Wheel motor castle nut (Model 68xx) 350 lbf.ft 474.5 Nm
Parking brake cylinder rod nut 35 lbf.ft 47.5 Nm
Cartridge
Size
Torque 08 38 58 10 12 16
Lbf.ft (max) 20 20 20 25 35 50
Lbf.in (max) 240 240 240 300 420 600
Nm (max) 27.12 27.12 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 15 25 25 30 35
Lbf.in (max) 36 120 180 180 300 300 360 420
Nm (max) 4.07 13.56 20.34 20.34 33.90 33.90 40.68 47.46
Newton-meter = Nm Pound-force foot = lbf.ft Pound-force inch = lbf.in
60056AD

Section 3
System component idenification and schematics
Table of Contents
Charts
3.1 Electrical Symbol Chart...................................................................................................................................3
3.2 Hydraulic Symbol Chart...................................................................................................................................4
3.3 Wire Number and Color Code.........................................................................................................................5
Parts List
3.4 Hydraulic Schematic Parts List........................................................................................................................7
3.5 Electrical Components Parts List.....................................................................................................................9
Diagrams and Schematics

3.6 Hydraulic Manifold and Port Identifications...................................................................................................12
3.7 Platform Control Console Diagram...............................................................................................................13
3.8 Platform Control Console - Powered Extension Platform Modification Diagram.........................................14
3.9 Powered Extension Platform Control Console and Harness........................................................................15
3.10 Base Control Console Diagram.....................................................................................................................16
3
3.11 Scissor Arm Control Cable Diagram.............................................................................................................17
3.12 Hydraulic Schematic (Models 322x).............................................................................................................19
3.13 Hydraulic Schematic (Models 46xx)..............................................................................................................20
3.14 Main Manifold Harness and Holding Valve Harness.....................................................................................21
3.15 Electrical Panel Diagram................................................................................................................................22
3.16 Electrical Panel Diagram (EE Rated).............................................................................................................23
3.17 Harnesses Diagram.......................................................................................................................................24
3.18 Limit Switch Assemblies Diagram.................................................................................................................25
3.19 Horn/Tilt Switch/Flashing Light Diagram.......................................................................................................26
3.20 Electrical Schematic (Equipped with no options).........................................................................................27
3.21 Electrical Schematic (Equipped with all options)..........................................................................................28
3.22 Electrical Schematic (EE Rated - Equipped with no options).......................................................................29
3.23 Electrical Schematic (EE Rated - Equipped with all options).......................................................................30
SJIII Conventional Series SKYJACK, Page 1

157928
Section 3 - System Component Identification and Schematics Service and Maintenance
3.1 Electrical Symbol Chart
CIRCUITS CROSSING LIMIT SWITCH

NO CONNECTION HOURMETER KEY SWITCH
LIMIT SWITCH
CIRCUITS LIGHT FOOT SWITCH
CONNECTED CLOSED
LIMIT SWITCH
HYDRAULIC
BATTERY TOGGLE SWITCH
VALVE COIL
PROPORTIONAL LIMIT SWITCH

GROUND HYDRAULIC PUSH BUTTON
VALVE COIL
SILICON
ELECTRIC CONTROLLED
FUSE ROTARY SWITCH
MOTOR RECTIFIER
CIRCUIT PROXIMITY
HORN LIMIT SWITCH
BREAKER SWITCH
EMERGENCY CAM OPERATED PNP

VOLT METER STOP BUTTON LIMIT SWITCH TRANSISTOR
CAPACITOR RESISTOR NPN

TILT SWITCH
TRANSISTOR
SINGLE POLE
POTENTIOMETER LEVEL SENSOR SINGLE THROWN VACUUM
RELAY SWITCH
SINGLE POLE DOUBLE POLE DOUBLE POLE TEMPERATURE

DOUBLE THROW SINGLE THROW DOUBLE THROW SWITCH
RELAY RELAY RELAY
TRIPLE POLE
DOUBLE THROW DIODE RHEOSTAT
RELAY

157928
Service and Maintenance Section 3 - System Component Identification and Schematics
3.2 Hydraulic Symbol Chart
VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALVE VELOCITY FUSE
PUMP
ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER
HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER
DOUBLE ACTING
HYDRAULIC PRESSURE
PRESSURE DOUBLE
FILTER WITH REDUCING
SWITCH RODDED
BYPASS VALVE
CYLINDER
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
VARIABLE BI DIRECTIONAL
FOUR WAY
DISPLACEMENT HYDRAULIC
OIL COOLER VALVE COIL
PROPORTIONAL
HYDRAULIC MOTOR MOTOR
SERIES TWO POSITION THREE POSITION

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

TWO WAY TWO POSITION FOUR WAY FOUR WAY
NORMALLY THREE WAY VALVE CLOSED CENTER PROPORTIONAL
OPEN VALVE CLOSED PORT
PRESSURE PILOT LINES Dashed

MAIN LINES Solid
TRANSDUCER
SERVO
SKYJACK, Page 4 SJIII Conventional Series

157928
3.3 Wire Number and Color Code
WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE

WIRE COLOR
NO. COLOR NO. NO. COLOR NO. COLOR NO. COLOR
00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD
000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD
B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY
01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY
02 WHT 25 BRN/BLK 48 YEL/GREY 71 RED/ORG 97 ORG/GREY
03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD
04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD
GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR
07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG
08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN
09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK
10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

GREY/
11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 108 YEL/BRN
RED/YEL/
12 35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL
BLK
13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU
WHT/RED/
14 BLK 37 60 WHT/BLU 83 BLU/GREY 110B BRN
BLK
WHT/BLK/
15 BLU 38 ORG/RED 61 GREY/BRN 84 111 GREY/GRN
PUR
16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG
17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN
18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED
19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR
22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK
This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.

157928
3.4 Hydraulic Schematic Parts List

Index Skyjack
Qty. Description
No. Part No.
2H-13 103655 1 VALVE, Control (Lowering) (ANSI/CSA)

2H-13-1 107269 1 VALVE, Control (Holding) (ANSI/CSA)
2H-13-2 107269 1 VALVE, Control (Holding) (ANSI/CSA)
2H-18A 104132 1 VALVE, Control (Differential)
2H-59B 132749 1 VALVE, Control (Proportional)
3H-14 106273 1 VALVE, Control (Lift)
3H-17A 103623 1 VALVE, Control (Brake)
3H-18A-1 103623 1 VALVE, Control (Speed A)
3H-18A-2 103623 1 VALVE, Control (Speed B)
4H-15 153334 1 VALVE, Control (Reverse drive) (Hytos) (includes 4H-16)
4H-16 - 1 VALVE, Control (Forward drive) (Hytos)
4H-23 153334 1 VALVE, Control (Right steer) (Hytos) (includes 4H-24)
4H-24 1 VALVE, Control (Left steer) (Hytos)
4H-26 113953 1 VALVE, Powered platform extend (includes 4H-27) (Models 3220/4620/4626)
4H-27 113953 1 VALVE, Powered platform retract (includes 4H-26) (Models 3220/4620/4626)
C1 124291 1 CYLINDER (Cushion)
C2 120989 1 CYLINDER (Lift) (Models 3220/4620)
120989 2 CYLINDER (Lift) (Models 3226/4626/4632)
C3 120236 1 CYLINDER (Steer)
C4 120220 2 CYLINDER (Brake) (Models 322x)
C5 127100 1 CYLINDER (Powered extension platform) (Models 3220/4620)
127100 2 CYLINDER (Powered extension platform) (Model 4626)
CB1 147889 1 VALVE, Counterbalance
CRV1 115299 1 VALVE, Cross-Over Relief (Option)
F1 109568 1 FILTER ASSEMBLY, Return
FD1 103354 1 VALVE, Flow divider/combiner
M1 103129 1 MOTOR, Hydraulic Wheel (Left hand) (Models 322x)
M2 103129 1 MOTOR, Hydraulic Wheel (Right hand) (Models 322x)
M3 134573 1 MOTOR, Hydraulic Wheel (Left hand) (Models 46xx)
M4 134573 1 MOTOR, Hydraulic Wheel (Right hand) (Models 46xx)
MB1 107354 1 BLOCK, Manifold (Main)
MB2 107493 1 BLOCK, Manifold (Emergency lowering)
MB3 111314 1 BLOCK, Manifold (Holding valve) (Models 3220/4620 ANSI/CSA)
111320 1 BLOCK, Manifold (Upper holding valve) (Models xx26/4632 ANSI/CSA)
111316 1 BLOCK, Manifold (Lower holding valve) (Models xx26/4632 ANSI/CSA)
MB4 108195 1 BLOCK, Manifold (Rear drive)
MB5 -- 1 BLOCK, Manifold (Powered extension platform - part of cylinder weldment)
MB7 146563 1 MANIFOLD BLOCK (Brake release) (Models 46xx)
MB9 132748 1 MANIFOLD BLOCK (Proportional control)
O2 105530 1 ORIFICE (0.081” diameter) (Lowering) (Model 4632)
122213 1 ORIFICE (0.073” diameter) (Lowering) (Model 4620)
O3 105811 1 ORIFICE (0.040” diameter) (Steer)
O4 105281 1 ORIFICE (0.067” diameter) (Emergency lowering) (Models 3220/4620)
105281 2 ORIFICE (0.067” diameter) (Emergency lowering) (Models 3226/4626/4632)
O6 104434 1 ORIFICE (0.040” diameter) (Differential)
O7 104434 1 ORIFICE (0.040” diameter) (Brake) (Models 322x)
137127 1 ORIFICE (0.020” diameter) (Brake) (Models 46xx)
Parts list continued on the following page.

157928
3.4 Hydraulic Schematic Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
Parts list continued from the following page.
P1 106577 1 PUMP, Hydraulic (Model 4620, except EE rated)

106587 1 PUMP, Hydraulic (Models 4626/4632, except EE rated)
129961 1 PUMP, Hydraulic (ANSI/CSA EE rated)
129965 1 PUMP, Hydraulic (EE rated)
310567 1 PUMP, Hydraulic (Standard)
P2 146560 1 PUMP, Handle (Brake release) (Models 46xx)
PS1 102863 1 SWITCH, Pressure (Option)
113799 1 • BLOCK, Manifold
R1 104534 1 VALVE, Relief (System)
R2 104534 1 VALVE, Relief (Lift)
R3 106557 2 VALVE, Relief (Holding valve) (Models 3226/4626/4632)
V1 107271 1 VALVE (Emergency lowering)
V2 103136 1 VALVE (Free-wheeling)
V3 146562 1 VALVE (Auto reset - brake release) (Models 46xx)

157928
3.5 Electrical Components Parts List
SUPPLY (B+) (Common)
CONTROL (B+) GROUND (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Qty. Description
No. Part No.
17CR 108589 1 RELAY, 24 Volt (Transfer)

21CCR 108589 1 RELAY, 24 Volt (Proportional) (ANSI/CSA & EE rated)
28CR 108589 1 RELAY, 24 Volt (Tilt switch) (ANSI/CSA & EE rated)
2H-13 103605 1 COIL, 24 Volt (Lowering valve) (ANSI/CSA)
2H-13-1 104493 1 COIL, 24 Volt (Holding valve) (ANSI/CSA)
2H-13-2 104493 1 COIL, 24 Volt (Holding valve) (ANSI/CSA)
2H-18A 103605 1 COIL, 24 Volt (Differential valve)
2H-59 115370 1 COIL, 24 Volt (Proportional valve)
3H-14A 105610 1 COIL, 24 Volt (Lift valve) (ANSI/CSA)
3H-17A 103605 1 COIL, 24 Volt (Brake valve)
3H-18A-1 103605 1 COIL, 24 Volt (Speed A)
3H-18A-2 103605 1 COIL, 24 Volt (Speed B)
4H-15 153335 1 COIL, 24 Volt (Reverse drive spool valve) (Hytos)
4H-16 153335 1 COIL, 24 Volt (Forward drive spool valve) (Hytos)
4H-23 153335 1 COIL, 24 Volt (Right steer spool valve) (Hytos)
4H-24 153335 1 COIL, 24 Volt (Left steer spool valve) (Hytos)
4H-26 103605 1 COIL, 24 Volt (Power extension platform extend) (option)
4H-27 103605 1 COIL, 24 Volt (Power extension platform retract) (option)
AT1 130440 1 TRANSDUCER, Angle
B1-B4 103480 4 BATTERY, 6 Volt (U2200)
B1-B4 106552 4 BATTERY, 6 Volt (U2500)
B1-B4 $ 4 BATTERY, 6 Volt (T2200)

157928
3.5 Electrical Component Parts List

Index Skyjack
Qty. Description
No. Part No.
BC 128537 1 CHARGER, 24VDC Battery (superior universal)

BCI 122093 1 BATTERY CHARGE INDICATOR
BP-29 103057 1 BEEPER, 24 VDC
C1 146475 1 CONTACTOR, Motor (24 Volt)
CAP1 110699 1 CAPACITOR (.47UF 50 Volts)
CB1 117325 2 BREAKER, Circuit (15 Amp)
CB2 117325 2 BREAKER, Circuit (15 Amp)
D02-X 129258 AR DIODE
D19A - ALARM OPTION
DA1 119758 1 DIODE PACK
DA2 119520 1 DIODE ASSEMBLY
DA3 119624 1 DIODE ASSEMBLY
DCM1 147664 1 MOTOR (24 VDC)
123477 1 MOTOR (24 VDC) (EE rated)
DXX 102921 AR DIODE
F1 310517 1 FUSE (300 Amp in-line fuse)
FL-22 121477 1 FLASHING LIGHT, 24VDC (Option)
FL-29 103743 1 FLASHER (Option)
H1 146649 1 HORN, Operator (Low tone)
LED-1 147061 1 POWER INDICATOR LIGHT (Platform control console)
LED-2 147061 1 POWER INDICATOR LIGHT (Base control console)
LS1A 121975 1 LIMIT SWITCH (High speed)
LS1B 121975 1 LIMIT SWITCH (High speed)
LS3 122014 1 LIMIT SWITCH (End of stroke - option)
LS4 125887 1 LIMIT SWITCH, Pothole protection (Battery tray)
LS4 126051 1 LIMIT SWITCH, Pothole protection (Battery tray) (EE rated)
LS5 125885 1 LIMIT SWITCH, Pothole protection (Hydraulic tray)
LS5 126060 1 LIMIT SWITCH, Pothole protection (Hydraulic tray) (EE rated)
LS6 121975 1 LIMIT SWITCH (Drive override)
RST1 119629 1 RESISTOR (2.7K ohm)
RST2 146644 1 RESISTOR (25W-30 ohm)
RST3 116505 1 RESISTOR, Low voltage protection

157928
3.5 Electrical Component Parts List (Continued)

Index Skyjack
Qty. Description
No. Part No.
S1 119725 1 SWITCH, Main power disconnect

S2 147054 2 N.O. CONTACT (Raise/Lower)
S3 147053 3 N.C. CONTACT (Lift/Drive)
147054 3 N.O. CONTACT (Lift/Drive) (without power extension platform)
4 N.O. CONTACT (Lift/Drive) (with power extension platform)
S4 147053 2 N.C. CONTACT (Emergency stop) (Platform control console)
S7 123994 1 CONTROLLER ASSEMBLY, Proportional
S7-1 122869 1 SWITCH (Neutral)
S7-2 122877 1 SWITCH (Right steer)
S7-3 122877 1 SWITCH (Left steer)
S7-6 122872 1 SWITCH, Pushbutton (Enable)
S8 147054 1 N.O. CONTACT (Horn)
S10 147053 2 N.C. CONTACT (Off/Platform)
147054 1 N.O. CONTACT (Base)
S11 102853 1 SWITCH (Powered extension platform extend/retract)
S12 102853 1 SWITCH (Powered extension platform enable)
S28 147053 1 N.C. CONTACT (Emergency stop) (Base control console)
TS1 146658 1 TILT SWITCH (Model 32xx)
146661 1 TILT SWITCH (Model 46xx)
TT 103336 1 HOURMETER

157928
3.6 Hydraulic Manifold and Port Identifications
2H-18A 2H-59B
If equipped Proportional Valve
Differential Valve
(Internal Compensator Valve) To Main Manifold
3H-18A-2
Speed Valve B
To Main Manifold
FD1
Flow Divier/Combiner
Valve
To Pump
V2 V3
Free-wheeling Valve Auto Reset Valve
Hydraulic Fitting
P2
3H-18A-1 Hand Pump
Speed Valve A 3H-14
Lift Valve
CB1
Counterbalance
Valve
02
Lowering Orifice R4
(Model 4620 & 4632 Only) Relief Valve
3H-17A
Brake Valve
Quick Disconnect
4H-16
(If equipped)
Forward Valve
R2
Lift Relief Valve
R5 2H-13
Relief Valve Lowering Valve
4H-23
4H-15 Right Steer Valve
Reverse Drive Valve
4H-24 R1 Quick Disconnect
Left Steer Valve System Relief Valve (If equipped)
M138117AA_S3

157928
3.7 Platform Control Console Diagram
15 16 12B
S8 - HORN
S27 - TORQUE
12B
B
18 A 8A
12B 08
08
49
13 14
S3 - LIFT/OFF/DRIVE
00
S4 - EMERGENCY STOP
RST1
8C 08
02
60/7A LED-1 02
X2
X1
08 07 7A
21B GREEN/BLACK - TIED BACK
MALE
(7A) GREEN 8 16 RED WHITE (60/7A)

(49) GREEN WHITE 7 15 BLACK WHITE (23)
9 PIN CONNECTOR SUB-ASSEMBLY (8C) BLUE WHITE 6 14 BLUE BLACK (24)
(07) RED 5 13 GREEN BLACK (21B) (OPT)
(14) BLACK 4 12 ORANGE BLACK (59)
(13) ORANGE 3 11 RED BLACK (18)
(15) BLUE 2 10 WHITE BLACK (16)
(02) WHITE 1 9 (NOT USED)
CTRL BOX
HARNESS
BACK VIEW
JOYSTICK HARNESS PIN # - FUNCTION CTRL BOX HARNESS JOYSTICK HARNESS

PIN 1 - LEFT 24 BLUE/BLACK WHITE/RED
PIN 2 - STEERING VS+ 12B BROWN/RED WHITE/GREEN
PIN 3 - RIGHT 23 BLACK/WHITE WHITE
PIN 4 - FWD/UP B RED YELLOW
PIN 5 - JOYSTICK VS+ 08 BLUE WHITE/BLACK CRD1
PIN 6 - REV/DOWN A PURPLE/WHITE GREY
PIN 7 - PWM 59 ORANGE/BLACK BLUE
PIN 8 - GND 02 WHITE BLACK
PIN 9 - ENABLE VS+ 8A BLUE WHITE/ BLUE
M156881AA

157928
3.8 Platform Control Console - Powered Extension Platform Modification Diagram
S3 - LIFT/OFF/DRIVE
S8 - HORN
S27 - TORQUE
08
09
S4 - EMERGENCY STOP
08 02
LED-1
X2
X1
21B
D26 D27
MALE
21B
02 26 27 09 (7A) GREEN 8 16 RED WHITE (60/7A)
(49) GREEN WHITE 7 15 BLACK WHITE (23)
(8C) BLUE WHITE 6 14 BLUE BLACK (24)
(07) RED 5 13 GREEN BLACK (21B) (OPT)
(13) ORANGE 3 11 RED BLACK (18)
(02) WHITE 1 9 (NOT USED)
BACK VIEW
TO PWR DECK
SOLENOID VALVES
PIN 1 - 27 BLACK
PIN 2 - 02 WHITE
PIN 3 - 26 GREEN
PIN 4 - N / U
PIN 5 - N / U
TO PWR DECK
CONTROL BOX
PIN 1 - 27 BLACK
PIN 2 - 09 WHITE
PIN 3 - 26 GREEN
PIN 4 - N / U
PIN 5 - N / U
M156955AA1

157928
3.9 Powered Extension Platform Control Console and Harness
EXTENSION PLATFORM CONTROL CONSOLE
BOX
WHITE BLACK
1 GREEN
1
2
2
3
TO POWER CONTROL CONSOLE BACK VIEW W/ALL FUNCTION CUTOUT

MALE 1 BLACK (27)
3 2
2 WHITE (08)
3 GREEN (26)
4 1 4 (N/U)
TO POWER CONTROL CONSOLE BACK VIEW

EXTENSION PLATFORM CYLINDER HARNESS MALE
3
1 BLACK (27)
2
2 WHITE (02)
3 GREEN (26)
27 4 1 4 (N/U)
26
02
02
M115592AI1_S3

157928
3.10 Base Control Console Diagram
S10 - IDLE SW S2 - UP SWITCH

N.C. CONTACT N.O. CONTACT
PIN 1 - 5A PURPLE/WHITE PIN 3 - 10E WHITE/BLACK (X2)
PIN 2 - 07 RED (X2) PIN 4 - 14E BLACK
S2 - DOWN SWITCH
S10 - BASE SW N.O. CONTACT
N.O. CONTACT
PIN 3 - 10E WHITE/BLACK
PIN 3 - 10E WHITE/BLACK (X2) PIN 4 - 13 ORANGE
PIN 4 - 7A RED/BLACK
S10 - PLATFORM SWITCH

N.C. CONTACT S28 - EMERGENCY STOP
PIN 1 - 8C BLUE N.C. CONTACT
PIN 2 - 07 RED PIN 1 - 5A PURPLE/WHITE
PIN 2 - 05 ORANGE/BLACK
LED 2 - POWER ON/LSS LIGHT

PIN X1 - 02 WHITE
PIN X2 - 7A RED/BLACK (X2)
TO ELECTRIC PANEL
PIN 1 - 07 (RED)
PIN 2 - 05 (ORANGE/BLACK)
PIN 3 - 13 (ORANGE)
PIN 4 - 14E (BLACK)
PIN 5 - 10E (WHITE/BLACK) (CE)
PIN 6 - 8C (BLUE)
PIN 7 - 7A (RED/BLACK)
PIN 8 - 02 (WHITE)
BACK VIEW
5 4
DEUTSCH
6 3
7 2
8 1
M149553AA_S3

157928
3.11 Scissor Arm Control Cable Diagram
CONTROL CABLE OPTIONS

EUROPE N.A
WIRE COLOUR WIRE NUMBER WIRE NUMBER
GREEN/BLACK 21B 21B
RED/WHITE 60 7A
BACK VIEW FRONT VIEW TO ELECTRIC PANEL

CONTROL CABLE
MALE
(7A) GREEN 8 16 RED WHITE (OPT) 16 8
(49) GREEN WHITE 7 15 BLACK WHITE (23) 15 7
(8C) BLUE WHITE 6 14 BLUE BLACK (24) 14 6
(07) RED 5 13 GREEN BLACK (OPT) 13 5

12 4
(13) ORANGE 3 11 RED BLACK (18) 11 3
10 2
(02) WHITE 1 9 (NOT USED) 9 1
TO PLATFORM CONTROL CONSOLE FRONT VIEW BACK VIEW

CONTROL CABLE
FEMALE
8 16 (OPT) RED WHITE 16 8 GREEN (7A)

7 15 (23) BLACK WHITE 15 7 GREEN WHITE (49)
6 14 (24) BLUE BLACK 14 6 BLUE WHITE (8C)
5 13 (OPT) GREEN BLACK 13 5 RED (07)
4 12 (59) ORANGE BLACK 12 4 BLACK (14)
3 11 (18) RED BLACK 11 3 ORANGE (13)
2 10 (16) WHITE BLACK 10 2 BLUE (15)
1 9 (NOT USED) 9 1 WHITE (02)
M146650AB_S3

157928
3.12 Hydraulic Schematic (Models 322x)
A B C D E F G H
C4 BRAKE C4 BRAKE
CYLINDER O7 CYLINDER M4
BRAKE RIGHT DRIVE 04
MOTOR C2
ORIFICE Ø.040 EMERGENCY
UPPER LIFT
CYLINDER LOWERING
ORIFICE
2H-18A
3226
Ø.067
V
DIFFERENTIAL MB4
VALVE REAR DRIVE
MANIFOLD BLOCK
O6
4H-27 C5 P.DECK R3 2H-13-2
DIFFERENTIAL
RETRACT CYLINDER PT1 RELIEF VALVE HOLDING VALVE PT1
ORIFICE Ø.040
PLATFORM FD1 PRESSURE PRESSURE
VALVE C1
FLOW DIVIDER OVERLOAD OVERLOAD
CUSHION
3H-18A-2 COMBINER TRANSDUCER TRANSDUCER
CYLINDER
SPEED VALVE B OPTION C2 04 OPTION C2 04
OPTIONAL POWERED T A LOWER LIFT EMERGENCY LOWER LIFT EMERGENCY
EXTENSION DECK SJ3D 3220 CYLINDER LOWERING CYLINDER LOWERING
P B
V2 3226 ORIFICE 3220 ORIFICE
3H-18A-1 Ø.067 Ø.067
SPEED VALVE A FREE-WHEELING W
VALVE 2H-13-1 (ANSI/CSA)
4H-26 MB3 MB3 2H-13B-1 (CE)
MB5 P. DECK EXTEND HOLDING VALVE HOLDING VALVE HOLDING VALVE
MANIFOLD BLOCK PLATFORM MANIFOLD BLOCK MANIFOLD BLOCK
R3 2H-13-1
VALVE RELIEF VALVE HOLDING VALVE
M3
LEFT DRIVE PS1
MOTOR C3 STEERING OPTIONAL
CYLINDER PRESSURE
SWITCH
O3
STEER ORIFICE
Ø.040 REFERENCE TABLE
X
SJ3D ORIFICE
MB9 4H-23
PR0PORTIONAL 4H-15 RIGHT STEER MODEL LOWERING LIFT
REVERSE DRIVE 2H-13 (ANSI/CSA) ORIFICE ORIFICE

MANIFOLD VALVE
VALVE 3H-14 2H-13B (CE)
BLOCK SJ3 3220 NONE
LIFT VALVE LOWERING VALVE
3H-17A P A P A SJ3 3226 NONE
0.067
BRAKE VALVE B
T B T SJ3 4620 0.073" DIA
2H-59 CRV1 CROSS-OVER
4H-16
PRESSURE- RELIEF VALVE OPTION
SJ3 4626 NONE
FORWARD DRIVE 4H-24
COMPENSATED R2 LIFT
R1 VALVE LEFT STEER O2 SJ3 4632
PROPORTIONAL RELIEF
0.081" DIA
VALVE SYSTEM RELIEF VALVE LOWERING ORIFICE
CB1 VALVE
VALVE SEE REFERENCE TABLE
COUNTERBALANCE VALVE
Y
DCM1
DC MOTOR MB1
P1 MAIN MANIFOLD BLOCK MB2 V1 EMERGENCY
M HYDRAULIC LOWERING LOWERING
PUMP VALVE VALVE
BLOCK (MANUAL)
F1
RETURN
FILTER Z
RESERVOIR
M132308AD1

157928
3.13 Hydraulic Schematic (Models 46xx)
A B C D E F G H
M4
V3
RIGHT DRIVE C2
AUTO RESET 04
MOTOR/BRAKE UPPER LIFT
VALVE CASE DRAIN EMERGENCY
CYLINDER
LOWERING
P2 3226/4626/4632 V
MB4 ORIFICE
HAND PUMP REAR DRIVE Ø.067
O6 2H-18A
DIFFERENTIAL DIFFERENTIAL MANIFOLD BLOCK 2H-13-2 (ANSI/CSA)
MB7 MB3 2H-13B-2 (CE)
ORIFICE Ø.040 VALVE
BRAKE RELEASE HOLDING VALVE HOLDING VALVE
MANIFOLD BLOCK MANIFOLD BLOCK
O7 R3
BRAKE ONE-WAY FD1 PT1 RELIEF VALVE PT1
ORIFICE Ø.020 FLOW DIVIDER PRESSURE PRESSURE
COMBINER OVERLOAD OVERLOAD
3H-18A-2 TRANSDUCER C2 TRANSDUCER C2
SPEED VALVE B OPTION LOWER LIFT 04 OPTION 04
LOWER LIFT
CYLINDER EMERGENCY CYLINDER EMERGENCY
C1 LOWERING LOWERING
V2 CUSHION 3226/4626/4632 3220/4620 W
ORIFICE ORIFICE
3H-18A-1 FREE-WHEELING CYLINDER Ø.067 Ø.067
SPEED VALVE A VALVE
C5 P.DECK C5 P.DECK MB3 MB3
CYLINDER CYLINDER HOLDING VALVE HOLDING VALVE
CASE DRAIN M3 MANIFOLD BLOCK R3 MANIFOLD BLOCK
2H-13-1 2H-13-1
LEFT DRIVE RELIEF VALVE HOLDING VALVE HOLDING VALVE
4H-27 4H-26
EXTENSION DECK (SJ3D 4626)
MOTOR/BRAKE C3 STEERING
RETRACT EXTEND
B
A
CYLINDER PS1 OPTIONAL

PLATFORM PLATFORM
OPTIONAL POWERED
PRESSURE
VALVE VALVE
T
P
O3 SWITCH
STEER ORIFICE
Ø.040 REFERENCE TABLE
MB5 P. DECK
X
MANIFOLD BLOCK SJ3D ORIFICE
MB9 LOWERING LIFT
4H-15 MODEL ORIFICE ORIFICE
PR0PORTIONAL 4H-23
REVERSE DRIVE 2H-13 (ANSI/CSA)
C5 P.DECK MANIFOLD RIGHT STEER SJ3 3220
VALVE 3H-14 2H-13B (CE) NONE
CYLINDER BLOCK VALVE LIFT VALVE LOWERING VALVE
3H-17A SJ3 3226 NONE
P A
EXTENSION DECK (SJ3D 3220/4620)
BRAKE VALVE
A
0.067
B P SJ3 4620 0.073" DIA
4H-27 4H-26 T
RETRACT EXTEND
B
A
T B
PLATFORM PLATFORM 4H-16 CRV1 CROSS-OVER SJ3 4626 NONE
OPTIONAL POWERED
VALVE VALVE FORWARD DRIVE RELIEF VALVE OPTION

T
P
VALVE 4H-24 O2 R2 LIFT SJ3 4632 0.081" DIA

R1 LEFT STEER LOWERING ORIFICE RELIEF
2H-59 SYSTEM RELIEF CB1 SEE REFERENCE TABLE VALVE Y
VALVE
MB5 P. DECK PRESSURE- VALVE COUNTERBALANCE VALVE
MANIFOLD BLOCK COMPENSATED
PROPORTIONAL
VALVE
MB1
MAIN MANIFOLD BLOCK MB2 V1
LOWERING EMERGENCY LOWERING
VALVE VALVE
DCM1
DC MOTOR BLOCK (MANUAL)
P1
M HYDRAULIC
F1
PUMP
RETURN
FILTER Z
RESERVOIR
M137018AD1

157928
3.14 Main Manifold Harness and Holding Valve Harness
A B C D E F G H
V
HOLDING VALVE HARNESS - MODEL XX20
HOLDING VALVE
1
13 - BLACK
13
PIN 1 - 13 BLACK
PIN 2 - 02 WHITE
2
02 - WHITE 02
INSERT ORIENTATION
BOTTOM VIEW
FORWARD VALVE RIGHT STEER VALVE
HOLDING VALVE HARNESS - MODEL XX26 / XX32 REVERSE PIN 1 - 16 WHITE/BLACK PIN 1 - 23 BLACK/WHITE
15
HOLDING VALVE (LOWER) 02 PIN 2 - 02 WHITE PIN 2 - 02 WHITE
LEFT
PIN 1 - 13 BLACK
1
13 - BLACK 13
PIN 2 - 02 WHITE HOLDING VALVE (UPPER) 24 CLE FORWARD REVERSE VALVE LEFT STEER VALVE
02 - WHITE AR
16
PIN 1 - 13 BLACK 02
2
02
PIN 1 - 15 BLUE PIN 1 - 24 BLUE/BLACK W
PIN 2 - 02 WHITE
1
02
2
PIN 2 - 02 WHITE PIN 2 - 02 WHITE

CLE
CLE
AR
AR
RIGHT
23
02
CLE
AR
X
TO ELECTRIC PANEL - 9 WIRES

02 - WHITE 02
13 - ORANGE
14 - BLACK 02 02 LOWERING VALVE
15 - BLUE 13 - ORANGE
16 - WHITE/BLACK 13 13 02 - WHITE Y
17A - BLUE/RED
23 - BLACK/WHITE HOLDING VALVE
24 - BLUE/BLACK 13 - ORANGE PROPORTIONAL VALVE
02 - WHITE LIFT VALVE
59 - ORANGE/BLACK 02 59 - ORANGE/BLACK
14 - BLACK
02 - WHITE
02 02 - WHITE
02 02 02
59
14 BRAKE VALVE
17A 17A - BLUE/RED
02 - WHITE Z
M146669AA_S3

157928
3.15 Electrical Panel Diagram
A B C D E F G H
LEGEND: TO BASE CONTROLS V

TO JOYSTICK BOX TO BASE CONTROLS
8 1
PIN 1 - 07 (RED) PIN 5 - N/U
DEUTSCH
7 2 PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE)
TO TERMINAL BLOCK TO TILT SWITCH 6 3
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN) POWER DECK OPTION (Models 3220 / 4620 / 4626)
5 4
TO ENGINE TO BATTERY BLUE PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE)
TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH 21B 59 21A
TO REAR MANIFOLD TO POWER DECK YEL

R
D21B-1 D21B-2
02 8 1
PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U
TO OUTRIGGER
DEUTSCH
TO END OF STROKE 02 02 02 7 2 PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
SOLENOID CABLES
6 3
PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
TO FLASHER TO HORN/FLASHING LIGHT 5 4
PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (WHITE/BLACK) PLATFORM CONTROL BOX
18A 18A 18A 21B - GREEN/BLACK
TO REAR MANIFOLD
18A 18A - RED/BLACK TO HIGH SPEED LIMIT
02 - WHITE TO POTHOLE LIMIT
W
29 29
BEEPER
02 02
19A 02
+
02
03
FROM MAIN DISCONNECT
19A
TO FLASHER IF EQUIPPED
OTHERWISE TIE BACK
TO (+) AT MOTOR X
4
29 22
TO (-) AT MOTOR 00 03 02
+ TILT SWITCH RELAY BRAKE/STEERING RELAY
PIN 30 - 19 PIN 30 - 17B
D17C-1 D17C 02 PIN 85 - 28 PIN 85 - 17
30 30 PIN 86 - 02 TILT BRAKE/ PIN 86 - 02
3A 00 86
PIN 87 - 19A PIN 87 - 17A
D14E-1 87a 87a
SWITCH STEERING
D14E
D21-1
D17-1
D13 D15 D16 D21A D23 D24 PIN 87a - 28A PIN 87a - 17C
D14
R R
85 87 86 85 87 RELAY RELAY
3A - BLACK
END VIEW
TO CHARGER 7A 8C 49 02 02 05 07 13 14 14E 18 72 19 21 19A 29 21B 59 71 17 15 16 14 21A 17B 23 24
PROP. CONTROL RELAY
05 - WHITE PIN 30 - 59A
W R W W
86 87 PROPORTIONAL PIN 85 - 02
CONTROL
D19A
CONTROL CABLE OPTIONS D21 D17 87a PIN 86 - 21C
EUROPE N.A 30
85
59A RELAY PIN 87 - N/U
WIRE COLOUR WIRE NUMBER WIRE NUMBER D28A
PIN 87a - 59
GREEN/BLACK 21B 21B
RED/WHITE 60 7A
Y
BACK VIEW FRONT VIEW BATTERY TRAY
72 - BLACK/WHITE
FEMALE 71 - BLACK
(OPT) RED WHITE 16 8 GREEN (7A) 8 16
(23) BLACK WHITE 15 7 GREEN WHITE (49) 7 15
(24) BLUE BLACK 14 6 BLUE WHITE (8C) 6 14

HYDRAULIC TRAY
RED (07)
72 - BLACK/WHITE
(OPT) GREEN BLACK 13 5 5 13
19 - BLACK
(59) ORANGE BLACK 12 4 BLACK (14) 4 12
(18) RED BLACK 11 3 ORANGE (13) 3 11
(16) WHITE BLACK 10 2 BLUE (15) 2 10

MAIN MANIFOLD
(NOT USED) 9 1 WHITE (02) 1 9
PLATFORM CONTROL BOX

REAR HARNESS
TILT SWITCH
HORN/FLASHING LIGHT Z
M149583AA

157928
3.16 Electrical Panel Diagram (EE Rated)
A B C D E F G H
BACK VIEW
1 2 3 4 1 2 3 4
PIN 1 - 07 (RED) PIN 5 - N/U PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U
PIN 2 - 05 (GREEN/BLACK) PIN 6 - 8C (BLUE/WHITE) PIN 2 - 21 (ORANGE/BLACK) PIN 6 - N/U
DEUTSCH DEUTSCH
PIN 3 - 13 (ORANGE) PIN 7 - 7A (GREEN) PIN 3 - 18 (RED/BLACK) PIN 7 - 19 (BLUE)
PIN 4 - 14E (BLACK) PIN 8 - 02 (WHITE) PIN 4 - 18A (RED/BLACK) PIN 8 - 71 (BLACK/WHITE)
8 7 6 5 8 7 6 5
V
LEGEND: TO BASE CONTROLS TO HIGH SPEED LIMIT
TO JOYSTICK BOX TO LOWER KEYSWITCH BOX
TO POTHOLE LIMIT TILT SWITCH RELAY BRAKE/STEERING RELAY PROP. CONTROL RELAY
PIN 30 - 19 PIN 30 - 17B PIN 30 - 59A
TO TERMINAL BLOCK TO TILT SWITCH
PIN 85 - 28 PIN 85 - 17 PIN 85 - 21C
TO ENGINE TO BATTERY
TO BATTERIES TO MOTOR PIN 86 - 02 PIN 86 - 02 PIN 86 - 02
TO REAR MANIFOLD
PIN 87 - 19A PIN 87 - 17A PIN 87 - N/U
BLUE
YEL
TO MAIN MANIFOLD TO HIGH SPEED LIMIT SWITCH 18A - RED/BLACK
TO REAR MANIFOLD TO POWER DECK

02 - WHITE PIN 87a - 28A PIN 87a - 17C PIN 87a - 59
BATTERY
TO OUTRIGGER TO END OF STROKE CONNECTOR
SOLENOID CABLES
TO FLASHER HORN
(03 BLUE - 14 AWG)
(00 WHITE - 14 AWG)
29
W
18A
02
BEEPER
19A
02
02
00
22
18A
02
05
03
02
00
29
00
+
TO FLASHER IF EQUIPPED
18A
02
MAIN DISCONNECT
TILT BRAKE/ PROPORTIONAL X

CONTROL CABLE OPTIONS SWITCH STEERING CONTROL
EUROPE N.A
02 19A RELAY RELAY RELAY
18A
02
WIRE COLOUR WIRE NUMBER WIRE NUMBER
+
GREEN/BLACK 21B 21B
RED/WHITE 60 7A
02 19A 28 02 17A 17 02 21C

BACK VIEW FRONT VIEW
28A 17C 59 02
REAR HARNESS
FEMALE 19 17B 59A
(7A) RED WHITE 16 8 GREEN (7A) 8 16
(23) BLACK WHITE 15 7 GREEN WHITE (49) 7 15 MAIN MANIFOLD HARNESS 03

(24) BLUE BLACK 14 6 BLUE WHITE (8C) 6 14
(OPT) GREEN BLACK RED (07)

PLATFORM CONTROL BOX
+
13 5 5 13
(59) ORANGE BLACK BLACK (14)

(18) RED BLACK
12
11
4
3 ORANGE (13)
4
3
12
11
59A
(16) WHITE BLACK 10 2 BLUE (15) 2 10
(NOT USED) 9 1 WHITE (02) 1 9
D17-1 D14E D21A D17 Y

TO TILT SWITCH
PIN 1 - 19 (BLACK) D28A
D14E-1
D13 D17C-1 D17C D15 D16 D14 D23 D24
PIN 2 - 28 (GREEN) BATTERY TRAY
PIN 3 - 02 (WHITE) 72 - BROWN
PIN 4 - N/U 71 - BLUE 02 05 13 18 72 19 19A 21 29 14E 59 71 17 15 16 14 21A 23 24 07 7A 8C
D21-1 D21 D19A

HYDRAULIC TRAY
72 - BROWN
TO FLASHING LIGHT 22 19 - BLUE
02 - WHITE
22 - GREEN 02
MAIN MANIFOLD Z
TO HORN 02 PLATFORM CONTROL BOX
02 - WHITE REAR HARNESS
49 - BLACK 49
TILT SWITCH
HORN/FLASHING LIGHT 49 49
M147790AA_S3

157928
3.17 Harnesses Diagram
A B C D E F G H
CONTROL MODULE HARNESSES

HORN/FLASHING LIGHT HARNESS
TO FLASHING LIGHT 22
02 - WHITE
22 - GREEN 02 FROM ELECTRIC PANEL TO CONTROL MODULE - P3
28 BLACK PIN 3 - 60 GREEN
28E WHITE PIN 4 - 28 BLACK
TO HORN
60 GREEN PIN 6 - 28E WHITE W
02
02 - WHITE TO ELECTRIC PANEL BACK VIEW
49 - BLACK 22 - GREEN
49 02 - WHITE 3 2 1
6 5 4
49 - BLACK 9 8 7
12 11 10
FROM ELECTRIC PANEL CONTROL MODULE - P2

02 - WHITE PIN 1 - N/U
7A - RED PIN 2 - 10E BLACK/WHITE
10E - BLACK/WHITE PIN 3 - 14 BLACK
HORN HARNESS 13 - ORANGE PIN 4 - 13 ORANGE
14 - BLACK PIN 5 - N/U
15 - BLUE PIN 6 - N/U X
TO HORN 02
16 - WHITE/BLACK PIN 7 - 16 WHITE/BLACK
02 - WHITE
49 - BLACK 49 18B - RED/BLACK PIN 8 - 15 BLUE
TO ELECTRIC PANEL N/U - BLUE/BLACK PIN 9 - N/U
02 - WHITE N/U - ORANGE/BLACK PIN 10 - 18B RED/BLACK
49 - BLACK
PIN 11 - 02 WHITE
PIN 12 - 7A RED
TILT SWITCH HARNESS

DEUTSCH
4 1
3 2
CHARGER CUTOUT HARNESS
BACK VIEW
Y
TO TILT SWITCH TO ELECTRIC PANEL
PIN 1 - 19 (BLACK) 19 - BLACK
PIN 2 - 28 (GREEN) 28 - GREEN 2 1
PIN 3 - 02 (WHITE) 02 - WHITE
PIN 4 - N/U TO ELECTRIC PANEL
3A - BLACK PIN 1 - 3A BLACK
05 - WHITE PIN 2 - 05 WHITE
(OPT) - GREEN
M146588AA_S3

157928
3.18 Limit Switch Assemblies Diagram
A B C D E F G H
PIN 1 - 19 (BLACK)
PIN 2 - 28 (GREEN)
PIN 3 - 02 (WHITE)
BROWN BLACK
PIN 4 - N/U
19 BROWN BLACK
LS6 NO NC
18A
71 LS1A NO NC
W
DEUTSCH
4 1
BLUE BLACK/WHITE 18 3 2
BLUE BLACK/WHITE
BROWN BLACK
BROWN BLACK 21
18A PIN 1 - 71 (BLACK/WHITE) PIN 5 - N/U LS1B NO NC
PIN 2 - 21 (BLACK) PIN 6 - N/U)

LS1B
NO NC
71
18 PIN 3 - 18 (BLACK/WHITE) PIN 7 - 19 (BLACK) BLUE BLACK/WHITE 1 8
DEUTSCH
BLUE BLACK/WHITE PIN 4 - 18A (BLACK) PIN 8 - 71 (BLACK/WHITE) 2 7
3 6
4 5
1 8
DEUTSCH
BROWN BLACK
2 7
21 3 6 PIN 1 - 71 (BLACK/WHITE) PIN 5 - 02 (WHITE) X
NO NC 4 5
LS1A BROWN BLACK PIN 2 - 21 (BLACK) PIN 6 - 19 (BLACK)
71 19 PIN 3 - 18 (BLACK/WHITE) PIN 7 - 28 (GREEN)
BLUE BLACK/WHITE
LS6 NO NC PIN 4 - 18A (BLACK) PIN 8 - N/U
71
BLUE BLACK/WHITE
MODEL 32xx/46xx ANSI/CSA & EE RATED

EXCEPT MODEL 4632 EE RATED 2 1
1
PIN 1 - 19 (BLACK)
PIN 2 - 71 (BLACK/WHITE)
Y
MODEL 4632 EE RATED
M133664AB1

157928
3.19 Horn/Tilt Switch/Flashing Light Diagram
A B C D E F G H
1
2
V
DEUTSCH
BLACK - 22
WHITE - 02
3
4
02
PIN 1 - 19 (BLACK) 22
PIN 2 - 28 (GREEN)
PIN 3 - 02 (WHITE) BLACK - 22
PIN 4 - N/U WHITE - 02
02
W
22
DUAL FLASHING LIGHT HARNESS

X
TS1
TILT SWITCH (ANSI/CSA) 22
02
FL-22 BLACK - 22 02
22
FLASHING LIGHT
24V
02 WHITE - 02 (ANSI - FEM. TERM.)
WHITE - 02 (CE - RING TERM.)
22
02
22
02
02 - WHITE HORN/FLASHING LIGHT HARNESS

H1 02 FROM ELEC. PANEL
22 - GREEN
HORN 49
M146648AA_S3B

157928
3.20 Electrical Schematic (Equipped with no options)
A B C D E F G H
110 VAC
LINE VOLTAGE
BC 24V CHARGER
L1CR
CHARGER V
CUTOUT RELAY
1 CHARGER
B4 6V F1 B3 6V B2 6V B1 6V
2
BATTERY 300A BATTERY BATTERY BATTERY
S10 24V FUSE
CONTROL BOX BASE 00 BATTERY
S4 IDLE/PLTF/BASE 3
PACK
EMERGENCY KEY SWITCH
S1 MAIN
STOP (IN IDLE POSITION) DISCONNECT C1
MOTOR 4
CONTACTOR DCM1
08 8C 8C BLUE/WHITE 8C 8C 07 S28
M 5 PUMP MOTOR
NCHO EMERGENCY
STOP
SWITCH 15A CIRCUIT
6
BREAKER
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02
7
15A CIRCUIT
NCHO
7A GREEN 7A BREAKER 00 02
8 W
02 60 60 RED/WHITE 7A 7A 02
9 POWER ON LED
S8 LED-1 LED-2
HORN POWER ON/LSS 10E 7A POWER ON LIGHT
SWITCH LIGHT 10
NO
H1
08 49 49 GREEN/WHITE 49 HORN 49
11 HORN
2H-13
12 DOWN SOLENOID
13 ORANGE 13 13 13 2H-13-1 HOLDING VALVE

13
SINGLE CYLINDER
DO2-1
2H-13-2 HOLDING VALVE
D13 14
DO2-2 TWO CYLINDERS
14 BLACK 14 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN D28A
BATTERY CHARGE
INDICATOR
SWITCH D14E D14
19 28A 29 29
BP-29
16 BEEPER X
13
08 02 10E
V D19A 17 0.47uF CAPACITOR
14E CAP1
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
POTHOLE PROTECTION D14E-1 D21A
LIMIT SWITCHES N.C.H.O. 19A 02
RST1 TT 19 HOURMETER
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
LIMIT SWITCH N.C. TS1
02 02 WHITE 02
22
S3
3H-18A-1
LIFT/ 23 SPEED A SOLENOID
OFF/ S27 HIGH SPEED
DRIVE TORQUE LIMIT SWITCHES N.C. D21-1
19A 2H-18A
SWITCH SWITCH LS1B 24 DIFF. SOLENOID
Y
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2
25 SPEED B SOLENOID
JOYSTICK
21CCR
D21 RST3
71 21 21A 21C 02 PROPORTIONAL
26
JOYSTICK PCB RELAY
LOW VOLTAGE
ORANGE/BLACK LS1A PROTECTION RST2
08 PWM 59 59 59 59 59 59A
OUTPUT 27
D17C-1
02 2H-59 PROPORTIONAL
28
13 SOLENOID
A A D17-1 D17C
REV/DN 15 BLUE 15 4H-15
29 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
30 TRANSFER RELAY
14
B B D16
FWD/UP 16 WHITE/BLACK 16 4H-16
31 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 8A 8A 17B 17C
ENABLE
12B
32
Z
23 23 BLACK/WHITE 23 4H-23
33 RIGHT SOLENOID
S7-2 D23 DO2-5
RIGHT 12B 17A 3H-17A
17B
34 BRAKE SOLENOID
S7-3
LEFT D24
24 24 BLUE/BLACK 24 4H-24
35 LEFT SOLENOID
DO2-6
M146647AC1

157928
3.21 Electrical Schematic (Equipped with all options)
A B C D E F G H
110 VAC
LINE VOLTAGE
CONTROL BOX BASE
POWERED PLATFORM OPTION
BC 24V CHARGER
EXTEND/
EXTEND SOLENOID ENABLE
RETRACT L1CR
SWITCH
SWITCH CHARGER
4H-26 EXT
26
9A 09
CUTOUT RELAY V
1 CHARGER
RET
27
S11 S12
4H-27 B4 6V F1 B3 6V B2 6V B1 6V
2
RETRACT SOLENOID 21B 21B GREEN/BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY
24V FUSE
D26 D27 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
S4 IDLE/PLTF/BASE MOTOR
EMERGENCY KEY SWITCH CONTACTOR DCM1
STOP (IN IDLE POSITION)
M 5 PUMP MOTOR
F2
6 INVERTER OPTION
NCHO EMERGENCY
(UNAVAILABLE ON EE
STOP 50A FUSE RATED MACHINES)
SWITCH
7
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 3A 03 00 02 15A CIRCUIT
8
BREAKER
15A CIRCUIT
NCHO 85
7A GREEN 7A BREAKER 7A
TIMER
02
9 INVERTER TIMER W
02 60 60 RED/WHITE 7A 7A 02 19A
10 POWER ON LED
S8 LED-1 LED-2
HORN POWER ON/LSS 10E 7A POWER ON LIGHT 00 02
SWITCH LIGHT 11
NO
H1
12 HORN
FLASHER FL-22
29 22 FLASHING LIGHT
13
OPTION
FL-29
BCI 2H-13
BATTERY CHARGE 14 DOWN SOLENOID
INDICATOR
S3
08 02 LIFT/ 13 ORANGE 13 13 13 2H-13-1 HOLDING VALVE
V 15
OFF/ SINGLE CYLINDER
DO2-1
DRIVE D13
02 END OF STROKE 2H-13-2 HOLDING VALVE
SWITCH 16
LIMIT SWITCH N.C. DO2-2 TWO CYLINDERS
LS3
14 BLACK 14 14 14A 3H-14A
17 UP SOLENOID
09
S2
UP/DOWN 19 28A D28A
X
29 29
08 08 SWITCH D14E D14A 18 BEEPER
BP-29
13
10E
D19A 19 0.47uF CAPACITOR
14E CAP1
CRD1 CRD2 CRD3 19 19A 19A 02
20 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
22 TILT RELAY
LS6
28CR
71 19 19 02
23 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
24
3H-18A-1
25 SPEED A SOLENOID
S27 HIGH SPEED
D21B-2 LIMIT SWITCHES N.C. D21-1
Y
TORQUE 2H-18A
19A
SWITCH LS1B 26 DIFF. SOLENOID
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2

27 SPEED B SOLENOID
JOYSTICK
21CCR
D21 RST3
28
JOYSTICK PCB RELAY
D21B-1 LOW VOLTAGE
08 PWM 59 59 59 59 59 59A
OUTPUT 29
D17C-1
30
13 SOLENOID
A A D17-1 D17C
31 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
32 TRANSFER RELAY
14
B B D16
33 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 34
23
12B
23 BLACK/WHITE 23 4H-23
Z
35 RIGHT SOLENOID
S7-2 D23 DO2-5
17B
36 BRAKE SOLENOID
S7-3
LEFT D24
37 LEFT SOLENOID
DO2-6
M146624AE1

157928
3.22 Electrical Schematic (EE Rated - Equipped with no options)
A B C D E F G H
110 VAC
LINE VOLTAGE
24V CHARGER
110 VAC
BC 1 CHARGER
V
B4 6V F1 B3 6V B2 6V B1 6V
2
BATTERY 300A BATTERY BATTERY BATTERY
TO BATTERIES FUSE
S10 24V 00 BATTERY
CONTROL BOX BASE IDLE/PLTF/BASE 3
S4 PACK
EMERGENCY KEY SWITCH
S1 MAIN
STOP (IN IDLE POSITION) DISCONNECT C1
MOTOR 4
CONTACTOR DCM1
M 5 PUMP MOTOR
NCHO EMERGENCY
STOP
SWITCH 15A CIRCUIT
6
BREAKER
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 05 03 00 02
7
15A CIRCUIT
NCHO BREAKER
7A GREEN 7A 00 02
8
02 60 60 RED/WHITE 7A 7A 02
S8 LED-1 LED-2
9 POWER ON LED
W
HORN POWER ON/LSS 10E 7A POWER ON LIGHT
SWITCH LIGHT 10
NO
H1
11 HORN
2H-13
12 DOWN SOLENOID
13 ORANGE 13 13 13 2H-13-1 HOLDING VALVE

13
SINGLE CYLINDER
DO2-1
D13 14
DO2-2 TWO CYLINDERS
14 BLACK 14 14 3H-14
15 UP SOLENOID
S2
BCI UP/DOWN 19 28A D28A 29 29
BATTERY CHARGE SWITCH D14E D14 16 BEEPER
INDICATOR BP-29
13
08
V
02 10E
D19A 17 0.47uF CAPACITOR X
14E CAP1
02 CRD1 CRD2 CRD3 19 19A 19A 02
18 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
20 TILT RELAY
LS6
28CR
71 19 19 02
21 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
22
S3
3H-18A-1
LIFT/ 23 SPEED A SOLENOID
OFF/ S27 HIGH SPEED
DRIVE TORQUE LIMIT SWITCHES N.C. D21-1
19A 2H-18A
SWITCH SWITCH LS1B 24 DIFF. SOLENOID
S7
JOYSTICK
12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2
25 SPEED B SOLENOID Y
21CCR
D21 RST3
26
JOYSTICK PCB RELAY
LOW VOLTAGE
08 PWM 59 59 59 59 59 59A
OUTPUT 27
D17C-1
28
13 SOLENOID
A A D17-1 D17C
29 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
30 TRANSFER RELAY
14
B B D16
31 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE 32
23
12B
23 BLACK/WHITE 23 4H-23
33 RIGHT SOLENOID
Z
S7-2 D23 DO2-5
17B
34 BRAKE SOLENOID
S7-3
LEFT D24
35 LEFT SOLENOID
DO2-6
M150851AB-1

157928
3.23 Electrical Schematic (EE Rated - Equipped with all options)
A B C D E F G H
CONTROL BOX BASE

110 VAC
POWERED PLATFORM OPTION LINE VOLTAGE
EXTEND/ 24V CHARGER

EXTEND SOLENOID ENABLE
RETRACT
SWITCH
SWITCH
110 VAC
26
4H-26 EXT 9A 09
BC 1 CHARGER V
RET
27
S11 S12
4H-27 B4 6V F1 B3 6V B2 6V B1 6V
2
RETRACT SOLENOID 21B 21B GREEN/BLACK 21B BATTERY 300A BATTERY BATTERY BATTERY
TO BATTERIES FUSE
D26 D27 24V 00 BATTERY
3
PACK
S1 MAIN
S10 C1
DISCONNECT 4
S4 IDLE/PLTF/BASE MOTOR
EMERGENCY KEY SWITCH CONTACTOR DCM1
STOP (IN IDLE POSITION)
M 5 PUMP MOTOR
6
NCHO EMERGENCY
STOP
SWITCH 15A CIRCUIT
7
BREAKER
CB2 CB1
7A 07 07 RED 07 07 5A 5A 05 05 03 00 02
8
15A CIRCUIT
NCHO BREAKER
7A GREEN 7A
9
W
02 60 60 RED/WHITE 7A 7A 02
10 POWER ON LED
S8 LED-1 LED-2
HORN POWER ON/LSS 10E 7A POWER ON LIGHT 00 02
SWITCH LIGHT 11
NO
H1
12 HORN
FLASHER FL-22
29 22 FLASHING LIGHT
13
OPTION
FL-29
BCI 2H-13
BATTERY CHARGE 14 DOWN SOLENOID
INDICATOR
S3
08 02 LIFT/ 13 ORANGE 13 13 13 2H-13-1 HOLDING VALVE
V 15
OFF/ SINGLE CYLINDER
DO2-1
DRIVE D13
02 SWITCH
16
DO2-2 TWO CYLINDERS
14 BLACK 14 14 3H-14
17 UP SOLENOID
09
S2
UP/DOWN 19 28A D28A 29 29
X
08 08 SWITCH D14E D14 18 BEEPER
BP-29
13
10E
D19A 19 0.47uF CAPACITOR
14E CAP1
CRD1 CRD2 CRD3 19 19A 19A 02
20 MOTOR CONTACTOR
2.7K OHMS LS4 LS5
02 00 71 72 19 28 02
22 TILT RELAY
LS6
28CR
71 19 19 02
23 TILT SWITCH
DRIVE OVERRIDE
02 02 WHITE 02
24
3H-18A-1
25 SPEED A SOLENOID
S27 HIGH SPEED
D21B-2
Y
TORQUE LIMIT SWITCHES N.C. D21-1 2H-18A
19A
SWITCH LS1B 26 DIFF. SOLENOID
S7 12B 18 RED/BLACK 18 18 18A 18A 3H-18A-2

27 SPEED B SOLENOID
JOYSTICK
21CCR
D21 RST3
28
JOYSTICK PCB RELAY
D21B-1 LOW VOLTAGE
08 PWM 59 59 59 59 59 59A
OUTPUT 29
D17C-1
30
13 SOLENOID
A A D17-1 D17C
31 REVERSE SOLENOID
S7-1 15 DO2-3
D15 17CR
NUETRAL 17 17 02
32 TRANSFER RELAY
14
B B D16
33 FORWARD SOLENOID
S7-6 16 DO2-4
D17
ENABLE
12B
34
Z
23 23 BLACK/WHITE 23 4H-23
35 RIGHT SOLENOID
S7-2 D23 DO2-5
17B
36 BRAKE SOLENOID
S7-3
LEFT D24
37 LEFT SOLENOID
DO2-6
M147978AB-1

157928
Section 4
Troubleshooting Information
Table of Contents
Introduction...................................................................................................................................................................3
Electrical System
4.1-1 All Controls Inoperative....................................................................................................................................4
4.1-2 All Controls Except for Down Function Inoperative .......................................................................................4
4.1-3 All Controls Inoperative From Base Control Console.....................................................................................5
4.1-4 All Controls Inoperative From Platform Control Console................................................................................5
4.1-5 No Drive or Up Function from Platform or Base Controls (CE only)..............................................................6
4.1-6 No Down or Reverse Only Function from Platform Controls..........................................................................6
4.1-7 No Up or Forward Only Function from Platform Control Console..................................................................6
4.1-8 No Up Function from Platform or Base Control Console................................................................................6
4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA only)...............................................7
4.1-10 No Down Function from Platform or Base Control Console (CE only)...........................................................7
4.1-11 No Up Function from Base Control Console...................................................................................................8
4.1-12 No Down Function from Base Control Console..............................................................................................8
4.1-13 Steer Only Inoperative.....................................................................................................................................8
4.1-14 Drive Only Inoperative.....................................................................................................................................8
4.1-15 No Drive or Steer when Platform Fully Lowered.............................................................................................8
4.1-16 No Drive or Steer when Platform Elevated......................................................................................................9
4.1-17 Elevated Drive Speed Does not Activate.........................................................................................................9
4.1-18 Work Platform Drives in Slow Speed Only......................................................................................................9
4.1-19 Forward Drive Function Inoperative..............................................................................................................10
4
4.1-20 Reverse Drive Function Inoperative...............................................................................................................10
4.1-21 Brake will not Release...................................................................................................................................10
4.1-22 High/Low Torque Inoperative.........................................................................................................................10
4.1-23 Right Steer Inoperative .................................................................................................................................11
4.1-24 Left Steer Inoperative . ..................................................................................................................................11
4.1-25 Power Extension Platform will not Extend or Retract....................................................................................12
4.1-26 Power Extension Platform will not Extend.....................................................................................................12
4.1-27 Power Extension Platform will not Retract.....................................................................................................12
4.1-28 Two or more Functions at one time...............................................................................................................12
Hydraulic System
4.2-1 All Function Inoperative.................................................................................................................................13
4.2-2 Platform Drifts Down......................................................................................................................................13
4.2-3 Platform Lifts Slowly.......................................................................................................................................13
4.2-4 Platform does not Lift.....................................................................................................................................13
4.2-5 Platform will not Lower...................................................................................................................................13
4.2-6 Platform Drives Slow......................................................................................................................................14
4.2-7 Platform will not Drive in Forward or Reverse...............................................................................................14
4.2-8 Brake(s) will not Release...............................................................................................................................14
4.2-9 Brake(s) will not Release (Additional for machines with Integral Brakes)....................................................14
4.2-10 Aerial Platform will not hold on a Grade (Machines with Integrals Brakes)..................................................15
4.2-11 Platform does not Steer.................................................................................................................................15
4.2-12 All System sluggish.......................................................................................................................................15
4.2-13 Power Extension Platform will not Extend or Retract....................................................................................15
4.2-14 High/Low Torque Inoperative.........................................................................................................................15
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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

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Service and Maintenance Section 4 - Troubleshooting Information
Electrical System
4.1-1 All Controls Inoperative

1. Battery Charger plugged into external power source.
-- Disconnect charger cord.
2. Batteries disconnected.
-- Connect batteries.
3. Dirty or loose battery terminals.
-- Clean and tighten connections.
4. Battery charge low.
-- Check each cell with hydrometer. Reading should be 1.275 (fully charged). Recharge if low
reading. Replace if reading difference between cells is 0.050.
5. Main battery cables open or defective.
-- Check continuity. Replace if defective.
6. Fuse F1 defective.
-- Replace fuse.
7. Main battery disconnect switch S1 open or defective.
-- Close switch. Check continuity. Replace if defective.
8. Loose or broken wire #3 from motor contactor C1 to circuit breaker CB2.
9. Loose or broken wire #3A from circuit breaker CB2 to charger relay L1CR.
10. Defective battery charger relay L1CR.
-- Check relay. Replace if defective.
11. Defective or tripped circuit breaker CB2.
-- Reset circuit breaker. Replace if defective.
12. Loose or broken wire #5 from charger relay L1CR to base terminal block TB-1.
13. Loose or broken wire #5 from base terminal block TB-1 to base emergency stop switch S28.
14. Open or defective base emergency stop switch S28.
-- Close switch. Check switch. Replace if defective.
15. Loose or broken wire #5A from base emergency stop switch S28 to base key switch S10.
16. Open or defective base key switch S10.
-- Select function with switch. Check switch. Replace if defective.
17. Loose or broken wire #00 from pump motor DCM1 to circuit breaker CB1.
18. Defective or tripped circuit breaker CB1.
-- Reset circuit breaker. Replace if defective.
19. Loose or broken wire #2 from circuit breaker CB1 to base terminal block TB-1.
20. Loose or broken wire #7A from base terminal block to CM1 control module pin P2-12. (CE)
21. Loose or broken wire #02 from base terminal block to CM1 control module pin P2-11. (CE)
4.1-2 All Controls Except for Down Function Inoperative

1. Loose or broken wire #19A (ANSI/CSA) or wire #19B (CE) from base terminal block TB-1 to contactor
C1.

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Electrical System (Continued)
2. Contactor C1 defective.
-- Check contactor. Replace if defective.
3. Defective pump motor DCM1.
-- Check motor. Replace if defective.
4. Loose or broken wire #59 from relay 21CCR (ANSI/CSA) or relay 21ACR (CE) to proportional valve
coil 2H-59.
5. Loose or broken wire #02 from proportional valve coil 2H-59 to base terminal block TB-1.
6. Defective proportional valve coil 2H-59.
-- Check continuity through coil. Reading should be 19ohms. Replace if defective.
4.1-3 All Controls Inoperative From Base Control Console

1. Loose or broken wire #07 from base terminal block to platform emergency stop switch S4.
2. Open or defective platform emergency stop switch S4.
-- Close switch. Replace if defective.
3. Loose or broken wire #7A from platform emergency stop switch S4 to base terminal block.
4. Loose or broken wire #7A from base terminal block to base key switch S10.
5. Open or defective base key switch S10.
6. Loose or broken wire #10E from base key switch S10 to base up/down switch S2.
7. Loose or broken wire #10E from base terminal block TB-1 to CM1 control module pin P2-2. (CE)
4.1-4 All Controls Inoperative From Platform Control Console

1. Loose or broken wire #8C from base key switch S10 to base terminal block.
2. Loose or broken wire #8C or wire #02 from base terminal block to platform emergency stop switch
S4.
3. Open or defective platform emergency stop switch S4.
4. Loose or broken wire #8 or wire #02 from emergency stop switch S4 to battery charge indicator
BCI.
5. Loose or broken wire #8 or wire #02 from battery charge indicator BC1 to joystick S7.
6. Defective joystick enable switch S7-6.
-- Check switch. Replace if defective.
7. Defective joystick neutral switch S7-1.
8. Defective joystick S7.
-- Check joystick. Replace if defective.

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4.1-5 No Drive or Up Function from Platform or Base Controls (CE only)

1. Defective tilt relay 28CR1 or Aux. tilt relay 28ECR1.
2. Loose or broken wire #02 from base terminal block to tilt relay 28CR1 or Aux. tilt relay 28ECR1.
3. Loose or broken wire #28 from CM1 control module pin P3-4 to tilt relay 28CR1.
4. Loose or broken wire #28E from CM1 control module pin P3-6 to Aux. tilt relay 28ECR1.
5. Loose or broken wire #19 from base terminal block to Aux. tilt relay 28ECR1.
6. Loose or broken wire #19A from Aux. tilt relay 28ECR1 to tilt relay 28CR1.
7. Loose or broken wire #19B from tilt relay 28CR1 to base terminal block.
8. Loose or broken wire #19B from base terminal block to motor contactor C1.
4.1-6 No Down or Reverse Only Function from Platform Controls

1. Loose or broken wire “A” from proportional controller S7 to lift/drive switch S3.
2. Lift/Drive switch S3 defective.
3. Defective PWM card on joystick S7.
-- Check joystick card. Replace if defective.
4. Loose or broken wire #13 down or #15 reverse from lift/drive switch S3 to base terminal block.
4.1-7 No Up or Forward Only Function from Platform Control Console

1. Loose or broken wire “B” from proportional controller S7 to lift/drive switch S3.
2. Lift/Drive switch S3 defective.
3. Defective PWM card on joystick S7.
-- Check joystick card. Replace if defective.
4. Loose or broken wire #14 up or #16 forward from lift/drive switch S3 to base terminal block.
4.1-8 No Up Function from Platform or Base Control Console

1. Loose or broken wire #14 from base terminal block to up valve coil 3H-14.
2. Defective up valve coil 3H-14.
-- Check continuity through coil. Replace if defective.
3. Open diode D14.
-- Check diode. Replace if defective.
4. Open diode D21A (ANSI/CSA) or D21 (CE).
5. Machine not level. (Above high speed limit switch)
-- Use on level surface.

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6. Loose or broken wire #19 from base terminal block to tilt switch TS1 (ANSI/CSA).
7. Defective tilt switch TS1 (ANSI/CSA).
-- Test tilt switch. Replace if defective.
8. Loose or broken wire #28 from tilt switch TS1 to tilt relay 28CR (ANSI/CSA).
9. Loose or broken wire #02 from tilt switch TS1 to base terminal strip (ANSI/CSA).
10. Defective tilt relay 28CR (ANSI/CSA).
11. Loose or broken wire #19A from tilt relay 28CR to pump motor contactor (ANSI/CSA).
12. See 4.1-5 of this section for more troubleshooting information for (CE).
4.1-9 No Down Function from Platform or Base Control Console (ANSI/CSA)
NOTE
Down function is not proportionally controlled.
1. Loose or broken wire #13 from base terminal block to down valve 2H-13 or holding valve 2H-13-1 or
holding valve 2H-13-2.
2. Loose or broken wire #02 from base terminal block to down valve 2H-13 or holding valve 2H-13-1 or
holding valve 2H-13-2.
3. Defective down valve 2H-13.
4. Defective lift cylinder holding valve 2H-13-1 or holding valve 2H-13-2.
4.1-10 No Down Function from Platform or Base Control Console (CE)
NOTE
1. Loose or broken wire #13 from base terminal block to CM1 control module pin P2-4.
2. Defective down relay 28CR2 or Aux. down relay 28ECR2.
3. Loose or broken wire #02 from base terminal block to down relay 28CR2 or Aux. down relay
28ECR2.
4. Loose or broken wire #13 from base terminal block to Aux. down relay 28ECR2.
5. Loose or broken wire #13A from Aux. down relay 28ECR2 to down relay 28CR2.
6. Loose or broken wire # 13B from down relay 28CR2 to down valve 2H-13B or holding valve 2H-13B-1
or holding valve 2H-13B-2.

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7. Defective down valve 2H-13B.

8. Defective lift cylinder holding valve 2H-13B-1 or holding valve 2H-13B-2.
9. Loose or broken wire #02 from holding valve 2H-13B-1 or holding valve 2H-13B-2 or down valve 2H-13B
to base terminal block.
4.1-11 No Up Function from Base Control Console

1. Defective up/down switch S2.
2. Loose or broken wire #14E from up/down switch S2 to base terminal switch.
3. Open diode D14E-1.
4. Open diode D14E (ANSI/CSA) or diode D14E-2 (CE).
4.1-12 No Down Function from Base Control Console

1. Defective up/down switch S2.
2. Loose or broken wire #13 from up/down switch S2 to base terminal block.
4.1-13 Steer Only Inoperative

1. Defective relay 17CR.
2. Loose or broken wire #17B from diodes D23 and D24 to base terminal block TB1.
3. Loose or broken wire #17B from 17CR steer relay to base terminal block TB1.
4. Loose or broken wire #17C from 17CR steer relay to diodes D17C and D17C-1.
5. Open or defective diode D17C or diode D17C-1.
4.1-14 Drive Only Inoperative

1. Open or defective diode D17-1.
4.1-15 No Drive or Steer when Platform Fully Lowered

1. Loose or broken wire #71 from base terminal block to drive override limit switch LS6.
2. Defective drive override switch LS6.
3. Loose or broken wire #19 from drive override limit switch LS6 to base terminal block.

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4.1-16 No Drive or Steer when Platform Elevated

1. Pothole protection bars not fully lowered.
-- Clear obstructions. Repair as needed.
2. Loose or broken wire #71 from base terminal block to pothole protection limit switch LS4.
3. Defective pothole protection limit switch LS4.
4. Loose or broken wire #72 from pothole protection limit switch LS4 to base terminal block.
5. Loose or broken wire #72 from base terminal block to pothole protection limit switch LS5.
6. Defective pothole protection limit switch LS5.
7. Loose or broken wire #19 from pothole protection limit switch LS5 to base terminal block.
4.1-17 Elevated Drive Speed Does not Activate

1. Loose or broken wire #59 from base terminal strip proportional relay 21CCR (ANSI/CSA) or 21ACR
(CE).
1. Loose or broken wire #59A from proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) to resistor
RST2.
2. Resistor RST2 open.
-- Check resistor ohms, it should be 30 ohms. Replace if defective.
3. Loose or broken wire #02 from resistor RST2 to base terminal block.
4. Proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) defective.
-- Check relay, replace if defective.
4.1-18 Work Platform Drives in Slow Speed Only

1. Loose or broken wire #71 from base terminal block to high speed limit switch LS1A.
2. Open or defective high speed limit switch LS1A.
3. Loose or broken wire #21 from high speed limit switch LS1A to low voltage protection resistor RST3.
4. Defective low voltage protection resistor RST3.
-- Check resistor. Replace if defective.
5. Loose or broken wire #21C (ANSI/CSA) or #21A (CE) from low voltage protection resistor RST3 to
proportional relay 21CCR (ANSI/CSA) or 21ACR (CE).
6. Proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) defective.
-- Check relay, replace if defective.
7. Loose or broken wire #02 from proportional relay 21CCR (ANSI/CSA) or 21ACR (CE) to base terminal
block.
8. Proportional controller S7 out of adjustment.
-- Adjust controller. Refer to Section 5, Joystick Adjusting Procedure.

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4.1-19 Forward Drive Function Inoperative

1. Loose or broken wire #16 from lift/drive switch S3 to base terminal block.
2. Loose or broken wire #16 from base terminal block to forward drive valve coil 4H-16.
3. Forward drive valve coil 4H-16 defective.
4. Loose or broken wire #02 from forward drive valve coil 4H-16 to base terminal block.
5. Open diode D16.
4.1-20 Reverse Drive Function Inoperative

1. Loose or broken wire #15 from lift/drive switch S3 to base terminal block.
2. Loose or broken wire #15 from base terminal block to reverse drive valve coil 4H-15.
3. Reverse drive valve coil 4H-15 defective.
4. Loose or broken wire #02 from reverse drive valve coil 4H-15 to base terminal block.
5. Open diode D15.
4.1-21 Brake will not Release

1. Diode D-16 forward or D-15 reverse is shorted or open.
2. Loose or broken wire #17 from base terminal strip to transfer relay 17CR.
3. Loose or broken wire #02 from base terminal strip to transfer relay 17CR.
4. Defective transfer relay 17CR.
5. Open or defective diode D17.
6. Loose or broken wire #17B from base terminal strip to transfer relay 17CR.
7. Loose or broken wire #17A from transfer relay 17CR to brake coil 3H-17A.
8. Brake valve coil 3H-17A defective.
9. Loose or broken wire #02 from brake valve coil 3H-17A to base terminal block.
4.1-22 High/Low Torque Inoperative

1. Open diode D15-1 (reverse) or D16-1 (forward).
2. Loose or broken wire #7B from diodes D15-1 and D16-1 to lift/drive switch S3.

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3. Defective lift/drive switch S3.

4. Loose or broken wire #18 from lift/drive switch S3 to base terminal block TB-1.
5. Loose or broken wire #18 from base terminal block TB-1 to high speed limit switch LS1-B.
6. Defective high speed limit switch LS1-B.
7. Loose or broken wire #18A from high speed limit switch LS1-B to rear drive manifold.
8. Defective speed valve coil 3H-18A-1 or 3H-18A-2.
9. Loose or broken wire #02 from rear drive manifold to base terminal block TB-1.
4.1-23 Right Steer Inoperative

1. Loose or broken wire #12B from lift/drive switch S3 to right steer switch S7-2.
2. Defective right steer switch S7-2.
3. Loose or broken wire #23 from right steer switch S7-2 to base terminal block TB-1.
4. Loose or broken wire #23 from base terminal block TB-1 to steer right valve coil 4H-23.
5. Defective steer right valve coil 4H-23.
6. Loose or broken wire #02 from steer right valve coil 4H-23 to base terminal block TB-1.
7. Open diode D23.
4.1-24 Left Steer Inoperative

1. Loose or broken wire #12B from lift/drive switch S3 to left steer switch S7-3.
2. Defective left steer switch S7-3.
3. Loose or broken wire #24 from left steer switch S7-3 to base terminal block TB-1.
4. Loose or broken wire #24 from base terminal block TB-1 to steer left valve coil 4H-24.
5. Defective steer left valve coil 4H-24.
6. Loose or broken wire #02 from steer left valve coil 4H-24 to base terminal block TB-1.
7. Open diode D24.

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4.1-25 Power Extension Platform will not Extend or Retract

1. Lift/Drive switch S3 not in lift position.
-- Move switch to lift position.
2. Loose or broken wire #09 from lift/drive switch S3 to power extension platform enable switch S12.
3. Power extension platform enable switch S12 defective.
4. Loose or broken wire #09A from power extension platform enable switch S12 to platform extend/retract
switch S11.
5. Loose or broken wire #21B from platform control box to base terminal block TB-1.
6. Open diode D21B-1.
7. Open diode D21B-2.
8. Loose or broken wire #02 from extend valve coil 4H-26 to retract valve coil 4H-27 to platform control
box.
4.1-26 Power Extension Platform will not Extend

1. Powered extension platform extend/retract switch S11 defective.
2. Loose or broken wire #26 from power extension platform extend/retract switch S11 to extend valve coil
4H-26.
3. Extend valve coil 4H-26 defective.
-- Check continuity through coil, replace if defective.
4. Open diode D26.
5. Loose or broken wire #02 from extend valve coil 4H-26 to platform control box.
4.1-27 Power Extension Platform will not Retract

1. Powered Platform extend/retract switch S11 defective.
2. Loose or broken wire #27 from power extension platform extend/retract switch S11 to retract valve coil
4H-27.
3. Retract valve coil 4H-27 defective.
-- Check continuity through coil, replace if defective.
4. Open diode D27.
5. Loose or broken wire #02 from retract valve coil 4H-27 to platform control box.
4.1-28 Two or more Functions at one time

1. Shorted Diode.
-- Check continuity of all diodes. Replace if defective.

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Hydraulic System
4.2-1 All Function Inoperative

1. Proportional valve 2H-59 defective or is sticking.
-- Check valve. Replace if defective.
2. Pump P1 defective.
-- Check pump. Replace if defective.
4.2-2 Platform Drifts Down

1. Defective lift cylinder seals at the gland or holding valve manifold.
-- Replace if damaged. Note: There are no piston seals, just wear rings.
2. Combination of defective holding valves 2H-13-1 and 2H-13-2, and either defective lowering valve 2H-
13 or relief valve R2 or manual lowering valve V1. (ANSI/CSA)
-- Check valves. Replace if defective.
Combination of defective holding valves 2H-13B-1 and 2H-13B-2, and either defective lowering valve
2H-13B or relief valve R2 or manual lowering valve V1. (CE)
-- Check valves. Replace if defective.
4.2-3 Platform Lifts Slowly

1. Open or leaking manual lowering valve V1.
-- Close valve. Replace if defective.
2. Lift relief valve R2 defective.
3. Open manual override on holding valve 2H-13-1 or 2H-13-2. (ANSI/CSA)
-- Depress and turn manual override clockwise to close. Replace if defective.
Open manual override on holding valve 2H-13B-1 or 2H-13B-2. (CE)
-- Depress and turn manual override clockwise to close. Replace if defective.
4.2-4 Platform does not Lift

1. Open manual lowering valve V1.
2. Hydraulic oil level too low.
-- Fully lower the platform. Fill hydraulic tank until fluid is at or slightly above the top mark on the
sight glass.
3. Platform weight excessive.
-- Reduce platform load to maximum capacity.
4. Up valve 3H-14 or 3H-14A (Machines with end of stroke limit switch LS3 only) defective or is sticking.
4.2-5 Platform will not Lower
NOTE
ANSI/CSA Machines only

1. Lowering valve 2H-13 defective or is sticking.
-- Clean valve. Replace if defective.
2. Defective holding valve 2H-13-1 or 2H-13-2.

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Hydraulic System (Continued)
CE Machines only
3. Lowering valve 2H-13 defective or is sticking.
4. Defective holding valve 2H-13B-1 or 2H-13B-2.
4.2-6 Platform Drives Slow

1. Free-wheeling valve V2 open or defective.
2. Flow divider/combiner FD1 defective or is plugged.
3. Drive motor M1 or M2 defective.
-- Check motors. Replace if defective.
4. Cushion cylinder C1 defective.
-- Check cylinder. Replace if defective.
4.2-7 Platform will not Drive in Forward or Reverse

1. Open free-wheeling valve V2.
-- Close Valve. Replace if defective.
2. Forward drive valve 4H-16 or reverse drive valve 4H-15 defective or is sticking.
3. Flow/Divider/Combiner valve FD1 defective or is plugged.
4. Counterbalance valve CB1 defective or is plugged.
4.2-8 Brake(s) will not Release

1. Brake valve 3H-17A defective or is sticking.
2. Brake orifice(s) 07 plugged.
-- Remove orifice(s). Clean and reinstall.
3. Brake cylinder(s) C4 defective.
-- Rebuild cylinder(s). Replace if damaged.
4.2-9 Brake(s) will not Release (Additional for machines with Integral Brakes)
1. Stuck or defective auto reset value V3.
-- Check valve operation. Clean valve. Replace if defective.
2. Stuck or defective hand pump P2.
-- Check pump operation. Clean pump. Replace if defective.
3. Defective internal brake piston seals.
-- Check brake pack will maintain pressure. If pressure is not maintained replace seals.
4. Plugged or defective brake orifice 07.
-- Clear obstruction. Replace if defective.
5. Damaged integral brake in wheel motor.
-- Inspect wheel motor assembly. Repair and replace as necessary.

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Hydraulic System (Continued)
4.2-10 Aerial Platform will not hold on a Grade (Machines with Integrals Brakes)
1. Worn or damaged brake discs.
-- Inspect brake discs for wear. Replace if worn or damaged.
2. Broken or damaged brake compression springs.
-- Check springs. Replace if defective.
4.2-11 Platform does not Steer

1. Right steer valve 4H-23 or left steer valve 4H-24 defective or sticking.
2. Steer cylinder C3 seals leaking.
-- Rebuild cylinder(s). Replace if damaged.
3. Mechanical binding in king pins.
-- Check for binding. Repair as needed.
4. Orifices 03 plugged.
-- Clean orifices, and reinstall.
4.2-12 All System sluggish

1. System Relief Valve defective or not adjusted properly.
-- Adjust valve. Replace if defective.
2. Hydraulic pump P1 worn.
-- Check pump. Replace if defective.
3. Proportional valve 2H-59 contaminated or defective.
-- Clean. Replace if defective.
4.2-13 Power Extension Platform will not Extend or Retract

1. Platform extend valve 4H-26 or platform retract valve 4H-27 defective or is sticking.
2. Powered platform cylinder C5 seals defective.
-- Rebuild cylinder. Replace if damaged.
3. Mechanical binding in power extension platform mechanism.
-- Check for binding. Repair as needed.
4.2-14 High/Low Torque Inoperative

1. Stuck speed valve 3H-18A-1.
2. Stuck speed valve 3H-18A-2.

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Section 5
Procedures
Table of Contents
Service and Maintenance
General..........................................................................................................................................................................3
Safety and Workmanship..............................................................................................................................................3
Platform
5.1-1 OEM Controller Electronics Information............................................................................................................3
5.1-2 OEM Controller Troubleshooting.......................................................................................................................4
5.1-3 OEM Controller switch wiring.............................................................................................................................5
Base
5.2-1 System Relief Pressure Adjustment...................................................................................................................6
5.2-2 Lift Pressure Adjustment....................................................................................................................................6
5.2-3 Electronic Tilt Switch Setup Procedure..............................................................................................................7
Tilt Switch Replacement.....................................................................................................................................7
Reprogramming Existing Tilt Switch..................................................................................................................9
Test and Verify Tilt Circuit.................................................................................................................................10

Section 5 - Procedures Service and Maintenance
General “Threshold” Adjustments

The following information is provided to assist you in Adjusts the initial current flow or duty cycle, affecting
the use and application of servicing and maintenance the function response or speed when the handle is first
procedures contained in this chapter. moved from the off position. Deflect the handle slowly
to the position where the controller first turns on. Adjust
Safety and Workmanship the threshold trimpot screw to the point where the con-
Your safety, and that of others, is the first consideration trolled function just starts to move, then turn the trimpot
when engaging in the maintenance of equipment. Al- screw one, full turn in the counterclockwise direction.
ways be conscious of weight. Never attempt to move This adjustment should be done first.
heavy parts without the aid of a mechanical device. Do
not allow heavy objects to rest in an unstable position. “Maxout” Adjustments
When raising a portion of the equipment, ensure that Adjusts the full stroke current or duty cycle affecting the
adequate support is provided. maximum function response, or speed when the handle
is deflected to its full travel. Fully deflect the handle,
and adjust the maxout trimpot for maximum desired
Platform
function response or speed. To obtain proportional
5.1-1 OEM Controller Electronics Information
resolution, it is important that the function starts to slow
down as soon as the handle is moved back from the
Flow Control
fully deflected position.
Single coil or solenoid for single direction. The coil has
two connections; one is wired to the P.C. Board (A) ter-
minal and the other is wired to (-), or the negative side The ideal adjustment occurs when the function just
of the supply voltage. Switches to control directional begins to move when the handle is deflected, and the
valves may be provided on the controller. output increases until it reaches its maximum desired
response or speed at the end of handle travel.
Adjustment Procedures
Adjustments are made by turning a trimpot adjustment
screw. The trimpots are multi-turn, end to end-devices. It
may be necessary to turn the adjustment screw several
turns to observe a change in output.
Clockwise (CW) adjustment of the trimpot increases

the output.
Counter-clockwise (CCW) adjustment of the trimpot

decreases the output.
Adjustments affect output current, voltage or per-

centage of duty cycle to the coil. The minimum and
maximum output is preset at the factory. However, for
optimum performance, they must be adjusted while the
equipment is operating.
Although the following adjustments affect the current/

voltage or percentage of duty cycle, the best way to
adjust the function is to observe the response or speed
of the function. The following adjustments affect func-
tion response, or speed. There may be some interaction
between adjustments, making it necessary to repeat the
adjustment in order to achieve the desired response.

Service and Maintenance Section 5 - Procedures
5.1-2 OEM Controller Troubleshooting IRS Option

1. Function speed reacts too slowly or too quickly
Problem in relation to handle deflection.
1. The function will not operate when the handle is A. Check “IRS” (Ramp) trimpot adjustment.
moved. The LEDs do not light “CW ” increases ramp time, “CCW ”
A. Check that voltage is present at the positive decreases ramp time.
(+)input terminal.
B. Check that ground is connected to the Integrated Ramp System (IRS)
negative (-) terminal. Provides smooth function response ,when reacting
C. If there is an in-line fuse, check to see if it is to an abrupt change in handle deflection. “CW” rota-
good. tion of the trimpot increases ramp time and slows the
D. Check the controller on/off switch and the response time. “CCW” decreases ramp time and in-
connectors. Voltage should be present at creases the response time. To increase the ramp time,
the (X) terminal when the controller is turned turn the adjusting screw “CW” a few turns, then move
on. the controller handle abruptly. Continue to adjust until
a smooth response is observed. Most controllers have
E. Check that valve wiring is not shorted to on/off contacts which remove power from the P.C. Board
ground. The LEDs will not light. when the handle is returned to the off position. When
F. Check that valve wiring is not open. The the handle is abruptly returned to neutral, the output
LEDs will light, but the intensity will not will not ramp down, and the function will stop.
vary.
G. Check trimpot settings. Fully “CCW” turns Ramp Thru Off
output off, “CW” turns output fully on. The P.C. Board should be adjusted as outlined in the
2. The function jumps or lurches when turned on. IRS adjustment procedure. If the handle is abruptly
A. P e r f o r m “ T h r e s h o l d ” a d j u s t m e n t returned to neutral (OFF) the output will ramp down
procedures. to off. Ramp time is factory set to 2 seconds, unless
otherwise specified.
3. The function reaches maximum speed before the
handle is fully deflected,
Note
A. Perform “Maxout” adjustment procedures.
Trimpots should be sealed with nail polish
4. The function speed remains constant regardless or enamel based paint.
of the degree of handle deflection.
A. Perform “Maxout” adjustment procedures.
WARNING
Do not use RTV silicone.

5.1-3 OEM Controller switch wiring
WIRE CHART
COLOR FROM TO
WHT/RED STEER LEFT PIN #1
WHT/GRN STEER COMMON PIN #2
WHT STEER RIGHT PIN #3
YEL FORWARD/UP PIN #4
WHT/BLK +24V INPUT PIN #5
GRY REVERSE/DOWN PIN #6
BLU PWM OUT (A) PIN #7
BLK GROUND (-) PIN #8
WHT/BLU ENABLE OUT PIN #9
DOUBLE DOT
(STEER RIGHT)
STEER COMMON WHT/GRN SINGLE DOT

(STEER LEFT)
STEER RIGHT WHT
STEER LEFT WHT/RED
ENABLE OUT WHT/BLU
+24V INPUT WHT/BLK

ENABLE
15589 PCB
H1
H2 (+24V INPUT) WHT/BLK

BLU PWD OUT (A) (ENABLE) WHT/YEL
H10 H3
BLK GROUND (-)
H7 H4
YEL FORWARD/UP H9
GRY REVERSE/DOWN H8
H6 S1
H5
RED NO
BLK
CONNECTOR

Base 5.2-2 Lift Pressure Adjustment

5.2-1 System Relief Pressure Adjustment
1. Locate the system pressure quick disconnect port Note
on the main manifold. Adequate area to raise the platform to full
2. Install a calibrated 5000 psi gauge to the system height is required for the following steps.
pressure quick disconnect port.
3. Remove the platform control console the guardrail 1. Locate the lift pressure test port on the main
and disconnect from the main control cable. manifold.
4. Locate the main control cable plug at the rear of 2. Install a calibrated 3000 psi gauge to the lift
the aerial platform. pressure quick disconnect port.
5. Disconnect the main cable and connect the 3. At the main manifold, loosen the locknut on the
platform control console into the plug. lift relief valve R2.
6. At the main manifold, loosen the locknut on the 4. Close the manual lowering valve. Use the lift
system relief valve R1. switch at the base control console to raise the
7. Select drive with the lift/drive select switch on the platform to full height and hold the lift up switch
platform control console. on.
8. Engaged steer right and hold. 5. Observe the reading on the gauge. Adjust the
9. Observe reading on gauge. Adjust the R1 system R2 relief valve to the value listed on the serial
relief value listed on the serial number plate. number plate. Turning the stem of the relief valve
Turning the stem on the relief valve clockwise clockwise will increases pressure. Turning the
will increases pressure. Turning the stem stem counterclockwise will decreases pressure.
counterclockwise will decreases pressure. 6. Remove the gauge from lift pressure test port.
10. Release steer switch and tighten the locknut.
11. Remove the gauge from system pressure test Note
port. Pressure setting may vary as aerial platform
components wear. The lift pressure should
be set for rated load only.

5.2-3 Electronic Tilt Switch Setup Procedure 9. Disconnect all wires #02 from motor contactor.
The following information is supplied for replacement
or reprogramming of the electronic tilt switch. Also 10. Install jumper wire between #7 and #19 to
included are test and verification instructions. Follow terminal strip.
the appropriate procedures below.
11. Turn main disconnect switch to “ ” ON position.
Tilt Switch Replacement 12. Verify switch is powered. (Red or green LED will
be continually blinking)
Y AXIS
X AXIS
Red LED Red LED
Green LED Green LED
13. Program the Tilt Switch

a. Press and release the set up button 3
times.
b. Observe program delay

/ stabilization time. Red LED
1. Ensure aerial platform is parked on a firm level (Only the red LED will Green LED
surface. blink for 4 seconds)
2. Chock or block wheels to keep the aerial platform c. Both LEDs will
from rolling forward or backward. flash for 1 second.
3. Lower/Raise the platform and secure the scissors Results: The switch is Red LED
using the maintenance bar. (Refer to Operating learning the new zero Green LED
manual for Maintenance Support Procedure) position.
d. Both LEDs will turn

4. Push in “ ” emergency stop buttons and turn on solid for 1 second.
main disconnect switch to “ ” off position. Results: The new zero Red LED
position has been Green LED

5. Remove any covers to locate and view the tilt
learned.
switch.
e. The green LED will flash and then the
6. Disconnect tilt switch from 4 pin connector.
red LED will turn on solid for 2 seconds.
7. Remove old tilt switch from mount.
Note
Red LED Red LED
Ensure part number of old and new tilt Green LED Green LED
switch are the same.
8. Install new switch to mount (in the same orientation Results: The switch is verifying the new
as the old switch) and connect switch plug to 4 zero position.
pin connector.
f. The green LED
will turn on solid.
NOTE
Results: The switch Red LED
The tilt circuit is only powered when Green LED
is ready for normal
activating a function.
operation.

17. Reinstall any covers that was removed.

14. Turn main disconnect switch to “ ” off
position. 18. Remove chock or wheel blocks.
15. Remove jumper wire between #7 and #19 from 19. Proceed to Test and Verify Tilt Circuit.
terminal block.
16. Reattach all wires #02 to motor contactor.

Reprogramming Existing Tilt Switch 9. Reprogram the Tilt Switch

a. Press and hold the set
Set up button is located on this up button for 3 seconds.
Light Indicators face next to harness Results: Both LEDs will Red LED
Green LED
be OFF.
R
b. Both LEDs will flash.
Gre ed LE Red LED
en D
LE
D Green LED
IMPORTANT
Step “c” must be completed within
a 5 second period, or the switch will
automatically exit program mode and
return to normal operation using previously
1. Ensure aerial platform is parked on a firm level stored data.
surface.
2. Chock or block wheels to keep the aerial platform c. Press and release set up button 3 times.
from rolling forward or backward.
d. If 5 second period has expired prior
3. Lower/Raise the platform and secure the scissors completion, repeat Step “a”, “b” and “c”.
using the maintenance bar. (Refer to Operating
e. Observe program delay
manual for Maintenance Support Procedure)
/ stabilization time. Red LED
Note (Only the red LED will Green LED
The tilt circuit is only powered when blink for 4 seconds)
activating a function.
f. Both LEDs will
flash for 1 second.
4. Remove any covers to locate and view the tilt
Results: The switch is Red LED
switch. Green LED
learning the new zero
5. Disconnect all wires #02 from motor contactor. position.
6. Install jumper wire between #7 and #19 to g. Both LEDs will turn
terminal strip. on solid for 1 second.
Results: The new Red LED
Green LED
7. Turn main disconnect switch to “ ” ON position. zero position has been
learned.
8. Verify switch is powered. (Red or green LED will
be continually blinking) h. The green LED will flash and then the
red LED will turn on solid for 2 seconds.
Red LED Red LED

Green LED Green LED Red LED Red LED
Green LED Green LED
Results: The switch is verifying the new

zero position.

i. The green LED Test and Verify Tilt Circuit

will turn on solid.
Results: The switch Red LED Set up button is located on this
Light Indicators face next to harness
is ready for normal Green LED
operation.
10. Turn main disconnect switch to “ ” off

position. R
Gre ed LE
en D
LE
D
11. Remove jumper wire between #7 and #19 from
terminal block.
12. Reattach all wires #02 to motor contactor.
13. Reinstall any covers that was removed.
14. Remove chock or wheel blocks.

Operations of Tilt Switch
15. Proceed to Test and Verify Tilt Circuit.
The following describes the LED’s and what they
indicate.
Illuminated whenever both tilt

axes are within the specified
degrees of the zero/ home
learned position.
Green LED
Flashes when transitioning in
or out of tilt angle limits, but
built in time delay has not fully
occurred.
Illuminated whenever tilt on one
or more axes is more than the
Red LED
specified degrees out from the
zero/ home position.
On together, no blinking when
Green & Red LED
fault detected.
Tilt Circuit Test
1. Refer to section 2 for test tilt sensor procedure.

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Service Manual: SJIII Conventional Series (ANSI/CSA)

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What does the manual cover?

What does the manual cover?

What safety symbols are used in the manual?

What safety symbols are used in the manual?

MODELS SJ 3220 SJ 3226 SJ 4620 SJ 4626 SJ 4632

Part No. 157928AA February 2011

SJIII 3320 60,002,259 & Above

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

Parts (North America)

Skyjack Asia Pacific Singapore

Section 1 - Scheduled Maintenance Inspections

Section 2 - Maintenance Tables

SJIII Series SKYJACK, Page 3

The Safety Alert Symbol identifies important

SKYJACK, Page 4 SJIII Series

Service and Maintenance

SJIII Series SKYJACK, Page 5

Aerial Platform Definition

Service & Maintenance

Service Policy and Warranty

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

North America & Asia: Europe:

SJIII Series SKYJACK, Page 7

Scope of this Manual

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

b. CSA (Canada) and CE (Europe)

c. ANSI/SIA (United States)

SKYJACK, Page 8 SJIII Series

Operator Safety Reminders

DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING.

Minimum Safe Approach Distance

SJIII Series SKYJACK, Page 9

platform fully lowered. After

• Elevated driving must only

• DO NOT ascend or descend

SKYJACK, Page 10 SJIII Series

Safety Precautions (Continued)

• DO NOT operate on surfaces not capable

• DO NOT operate an aerial

• DO NOT exert side forces on

• DO NOT use the aerial platform

• DO NOT sit, stand or climb on

• BE AWARE of blind spots when operating the

• DO NOT alter or disable limit switches or other

SJIII Series SKYJACK, Page 11

Safety Precautions (Continued)

• DO NOT exceed the rated capacity of the

Fall Protection • Three points of contact means that two hands

SKYJACK, Page 12 SJIII Series

Maintenance and Inspection Schedule Maintenance and Service Safety Tips

SJIII Series SKYJACK, Page 13

SKYJACK, Page 14 SJIII Series

About this Section Maintenance Instructions

- Aerial platform parked on a flat and level

• Repair any damaged or malfunction components

SJIII Series SKYJACK, Page 15

Table 1.1 Owner’s Annual Inspection Record

Model Number: ____________________________ Serial Number: ____________________________

SKYJACK, Page 16 SJIII Series

Model Number: Serial Number: