238274aea 20

SERVICE
MANUAL
SJ45 AJ+
ARTICULATING BOOMS
238274AEA
January 25 2024
ANSI/CSA, CE, AS
This manual is for MEWPs with serial numbers:
SJ45 AJ+: A301 100 001 - A301 199 999
SJ45 AJ+: B301 100 001 - B301 199 999
Please refer to the website (www.skyjack.com) for contact

information, other serial numbers, the most recent technical
manuals, animations, and USB software.
The original instructions are in English.

THIS SAFETY ALERT SYMBOL MEANS ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED.
The Safety Alert Symbol identifies important safety

messages on MEWPs, safety signs in manuals or
elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
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 MEWP.
SJ45 AJ+ 238274AEA

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Notes
238274AEA SJ45 AJ+

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Table of Contents
Section 1 – Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Read and Heed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-1 Mobile Elevating Work Platform (MEWP) definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-2 Purpose of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-3 Use of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-4 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-5 Ownership of MEWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-6 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-1 Owner’s annual inspection record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-2 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-3 Maintenance and service safety tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-4 Hydraulic system & component maintenance and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2-5 Hydraulic oil maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2-6 Hydraulic maintenance tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2-7 Railing maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2-8 Multi-conduction control cable repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Scheduled maintenance and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3-1 Service bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3-2 Maintenance and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3-3 Schedule and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3-4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3-5 Pre-delivery/maintenance inspection checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3-6 Inspection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3-7 Function tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.1 Standard Hose Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Torque Specifications for Fasteners (US Imperial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5 MEWP Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6 Axle Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.7 Axle Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.8 Hydraulic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9 MEWP Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.10 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.11 Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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2.12 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.13 Reach Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 39

3.1 Electrical Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Hydraulic Symbol Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Wire Number and Colour Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4 Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.5 Electrical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.6 Brake Manifold Components and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.7 Drive and System Pump Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.8 Drive Motor Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.9 Jib Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10 Main Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.11 Main Manifold Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.12 Main Manifold Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.13 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.14 Main Harness and Fuel Level Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.15 Engine Harness - D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.16 Engine Harness Wiring Diagram - D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.17 Engine Harness - WG972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.18 Engine Harness Wiring Diagram - WG972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.19 Jib and Platform Rotate Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.20 Limit Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.21 SGE Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.22 Moba Load Cell Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.23 Footswitch Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.24 CANbus Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.25 Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.26 All Motion Alarm Connections - CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.27 Flashing Amber Light Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.28 Positive Air Shut-off Harness - Kubota D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.29 Drive Pump Harness - Hengli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.30 Hydraulic Schematic - for MEWPs with Eaton drive pumps and motors . . . . . . . . . . . . . . . . . . . . . . 73
3.31 Hydraulic Schematic - for MEWPs with Hengli drive pumps and motors . . . . . . . . . . . . . . . . . . . . . 74
3.32 Platform Control Box Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.33 Base Control Box Wiring - ANSI/CSA & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.34 Base Control Box Wiring - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.35 Electrical Schematic - ANSI/CSA & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.36 Electrical Schematic - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.37 Engine Schematic - Kubota D1305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.38 Engine Schematic - Kubota WG972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2-1 All Controls are Inoperative from the Base or Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2-2 All Controls are Inoperative from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2-3 The Engine will not Crank from the Base or Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2-4 The Engine will not Crank from the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-5 The Engine will not Crank from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-6 The Boom Controls are Inoperative (Drive Operates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-7 No Boom Up from the Base or Platform Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2-8 No Boom Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2-9 No Boom Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2-10 No Boom Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2-11 No Boom Down from the Base Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-12 No Boom Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-13 No Turret Rotate Right from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-14 No Turret Rotate Right from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-15 No Turret Rotate Right from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-16 No Turret Rotate Left from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-17 No Turret Rotate Left from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-18 No Turret Rotate Left from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-19 No Riser Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-20 No Riser Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-21 No Riser Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-22 No Riser Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-23 No Riser Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-24 No Riser Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-25 No Telescope Out from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-26 No Telescope Out from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-27 No Telescope Out from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-28 No Telescope In from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-29 No Telescope In from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-30 No Telescope In from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-31 No Platform Level Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-32 No Platform Level Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-33 No Platform Level Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-34 No Platform Level Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-35 No Platform Level Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-36 No Platform Level Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . 95
4.2-38 No Platform Rotate Right from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-39 No Platform Rotate Right from the Base Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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4.2-40 No Platform Rotate Right from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-41 No Platform Rotate Left from the Base or Platform Consoles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-42 No Platform Rotate Left from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-43 No Platform Rotate Left from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-44 No Jib Up from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-45 No Jib Up from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-46 No Jib Up from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-47 No Jib Down from the Base or Platform Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-48 No Jib Down from the Base Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-49 No Jib Down from the Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-50 No Drive or Steer Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-51 No Forward or Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-52 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-53 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-54 The Brake will not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-55 No Left Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-56 No Right Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-57 The Directon Sensing is Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform Empty or Below
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-59 The Overload Indicator Light does not Turn On when the Platform is Overloaded . . . . . . . . . . . 102
4.2-60 The Audible Alarm does not Turn On with the Platform Overloaded . . . . . . . . . . . . . . . . . . . . . . 102
4.3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.3-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.3-2 All Boom Functions Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.3-3 No Main Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.3-4 No Main Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3-5 No Riser Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3-6 No Riser Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3-7 Riser Boom Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3-8 No Turret Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3-9 No Turret Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3-10 No Boom Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3-11 No Boom Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3-12 No Jib Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.3-13 No Jib Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3-14 No Platform Rotation Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3-15 No Platform Rotation Left 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.3-16 Platform will not Level Down Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.3-17 Platform will not Level Up Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.3-18 Brake will not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.3-19 Brake will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3-20 Differential Lock will not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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4.3-21 No Drive Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3-22 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3-23 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-24 No High Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-25 No Right Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-26 No Left Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-27 Axle Will Not Oscillate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3-28 Axle Will Not Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.2 System Control Module (SCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.2-1 User Interface Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.2-2 SCM Character Functions Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.2-3 SCM Function Channel Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.2-4 SCM Pin Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.2-5 SCM Recommended Settings - Kubota WG972 Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . 124
5.2-6 Default Recommended Settings - Kubota D1305 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.2-7 Unlock and Modify the SCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2-8 SCM Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.2-9 Check I/O Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2-10 SCM Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2-11 SCM Calibration Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2-12 CAN Bus Communication Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.3 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3-1 Fly Boom Switch Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3-2 Platform Controller Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.3-3 Replace the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.4 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4-1 Check Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4-2 Shim Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4-3 Cable Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4-4 Rotary Actuator Bolt Torque Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4-5 Master Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.4-6 Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.5 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.5-1 Check and Replace the High Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.5-2 Turret Rotation Gear Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.5-3 Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.5-4 Tilt Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.5-5 Set Up a New Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.5-6 Reprogram an Existing Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.6 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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5.6-1 Replace Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.6-2 Replace the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.6-3 Replace the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.6-4 Check the Engine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.6-5 Kubota D1305 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.6-6 Kubota D1305 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.6-7 Kubota WG972 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.7 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.7-1 Tension the Generator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.8 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.8-1 Hydraulic Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.8-2 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.9 Manifold and Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.9-1 Hydraulic Brake Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.9-2 Hydraulic System Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.9-3 Riser Down Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.9-4 Turret Rotate Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.9-5 Platform Level Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.9-6 Test Charge Pump Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.9-7 Test Forward Drive Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.9-8 Test Reverse Drive Pressure on Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.10 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.10-1 Change the Oil in the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.10-2 Check the Oil Level in the Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.10-3 Change the Oil in the Torque Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.10-4 Check the Oil Level in the Axle Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.10-5 Change the Oil in the Axle Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.10-6 Oscillating Cylinder Mount Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.10-7 Oscillating Cylinder Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.10-8 Oscillating Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.10-9 Bleed the Oscillating Axle Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.10-10 Test the Oscillating Axle Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.10-11 Pin Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.10-12 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.10-13 Axle U-Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.11 Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.11-1 Grease the Turret Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.11-2 Grease the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.11-3 Grease the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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Section 1 – Maintenance
1.1 Read and Heed 1.1-6 Optional equipment
This MEWP accepts a variety of optional equipment.
Skyjack is continuously improving and expanding
Refer to the operation manual for a list of the optional
product features on its equipment; therefore,
accessories. Operating instructions for these options
specifications and dimensions are subject to change
are in the operation manual.
without notice.
For components or systems that are not standard,
1.1-1 Mobile Elevating Work Platform speak to the Skyjack service department. Give the
model and serial number for each applicable MEWP.
(MEWP) definition
A MEWP is a mobile machine intended for moving
persons, tools, and material to working positions. It
consists of a work platform with controls, an extending
structure, and a chassis.
1.1-2 Purpose of equipment

The Skyjack Articulating Boom Series MEWPs are
designed to move personnel, tools, and materials to
working positions.
1.1-3 Use of equipment

The MEWP is a highly maneuverable, mobile work
station. Only elevate the platform, or drive while
elevated on a firm, level surface.
1.1-4 Service Policy and Warranty

Skyjack warrants each new product to be free of
defective parts and workmanship for the first 2 years
or 3000 hours, whichever occurs first. Your local
Skyjack dealer will replace or repair any defective
part, with no charge for parts or labour. In addition, all
products have a 5-year structural warranty. Contact
the Skyjack service department for warranty statement
extensions or exclusions.
1.1-5 Ownership of MEWP

Notify Skyjack of MEWP ownership. If you sell or
transfer the ownership of a MEWP, promptly notify
Skyjack of the new owner’s contact information.
Skyjack needs this information to inform the owner of
any updates or additional activities that are necessary
to keep the machine in proper working condition.
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Section 1 – Maintenance General information
1.2 General information

WARNING
1.2-1 Owner’s annual inspection record A unit that is damaged or not operating correctly
must be immediately tagged and removed from
The owner is responsible for the maintenance
service until repairs are completed.
inspections and repairs. Keep a record of the annual
inspection on the label on the control side cowling.
1.2-3 Maintenance and service safety tips
Inspection 1. Maintenance and repair should only be done
date by personnel who are trained and qualified to
service this MEWP.
2. Do the maintenance and service procedures in a
well-lit and well-ventilated area.
3. Anyone operating or servicing this MEWP
must read and fully understand all operating
instructions and safety hazards in both this
manual and the operation manual.
4. Make sure all tools, supports, and lifting
equipment are of the correct rated load and in
good working condition.
5. Keep the work area clean and free of debris to
avoid component contamination.
Inspector’s 6. Make sure personnel are not below unsupported
signature
components or systems that are at risk of
movement during maintenance.
7. All service personnel must be familiar with the
employer and governmental regulations for
servicing this type of equipment.
1.2-2 Replacement parts
8. Keep sparks and flames away from flammable or
Use only original replacement parts. Parts such
combustible materials.
as batteries, wheels, railings, etc. with weights and
dimensions different from the original parts will affect 9. Correctly dispose of waste material such as
the stability of the MEWP. They must not be used lubricants, rags, and old parts in accordance
without the manufacturer’s consent. with national, state/provincial/territorial, and local
regulations.
All replacement tires must be of the same size and
load rating as the originally supplied tires to maintain 10. Before you do any repair work, disconnect the
the safety and stability of the MEWP. main power connectors.
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General information Section 1 – Maintenance
1.2-4 Hydraulic system & component 10. Keep all hydraulic connections tight. A loose
maintenance and repair connection in a pressure line allows the oil
to leak or draw air into the system. Air in the
system can damage components and cause
WARNING
noisy or erratic system operation.
The fluid which escapes from a high-pressure 11. Preventive maintenance is the easiest and least
hydraulic leak can damage your eyes, penetrate expensive type of maintenance.
your skin, and cause serious injury. Wear the
correct personal protective equipment at all times.
1. The hydraulic circuits include relief valves 1.2-5 Hydraulic oil maintenance
which limit pressure to safe operation values. Draw samples of hydraulic oil from the reservior
They help to prevent the failure of hydraulic or annually and test them.
structural components.
▪ Take these samples when the oil is warmed
2. Make sure the hydraulic oil is completely through normal operation of the system.
clean. Even small amounts of dirt or
▪ Have the sample analyzed by a qualified
unwanted materials in the system can damage
lubrication specialist to determine if it is suitable
components and cause unsatisfactory operation
for continued use.
of the hydraulic system.
Oil change intervals depend on the care used to keep
3. Drain and flush the entire system and replace
the oil clean, and the operating conditions.
the filter cartridges if you have any reason to
believe there is contamination of the hydraulic ▪ Oil must be changed more often when there is
system, or hydraulic system failure. dirt or moisture contamination.
4. When you drain the hydraulic system, check ▪ Under normal use and operating conditions, you
the magnets in the hydraulic tank for metal should change the hydraulic oil every two years.
particles. Metal particles can indicate imminent
component failure. If metal particles are present,
flush the entire system and change the hydraulic 1.2-6 Hydraulic maintenance tips
oil.
1. Change the filters annually. Dirty, dusty, and
5. All containers and funnels used in handling the high-moisture environments can cause the
hydraulic oil must be completely clean. Use a hydraulic system to be contaminated more
funnel when necessary and fill the reservoir only quickly. You may need to change the filters
through the filter opening. Do not use a cloth to more often.
strain the oil, as lint could get into the system.
2. Keep a sufficient quantity of clean hydraulic oil
6. When you remove a hydraulic component, cap of the correct type and viscosity in the hydraulic
and tag all of the hydraulic lines involved. Plug tank.
the ports of the removed components.
3. Keep all hydraulic connections tight.
7. Disassemble hydraulic components in clean
surroundings. Carefully identify the parts to
make sure you reassemble them correctly. Clean
all metal parts in a clean mineral oil solvent. Be
sure to clean all internal passages fully. After
the parts are dry, lay them on a clean, lint-free
surface for inspection.
8. Replace all O-rings and seals when you overhaul
a component. Lubricate all parts with clean
hydraulic oil before you reassemble them. Use a
small amount of petroleum jelly to hold O-rings
in place during assembly.
9. Be sure to replace lost hydraulic oil after you
install the repaired component. Bleed air from
the system when required.
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Section 1 – Maintenance Scheduled maintenance and inspections
1.2-7 Railing maintenance and repair 1.3 Scheduled maintenance

Skyjack MEWPs have been designed to ensure
compliance with the relevant design standards and inspections
applicable for that particular unit at the time of
manufacture. As such, any repairs made to the
guardrail or basket structure need to ensure this 1.3-1 Service bulletins
compliance is not compromised and must return the
structure to its original condition. Before performing any scheduled maintenance
inspection procedure, refer to the service bulletins
Any damage must be repaired by returning the railing found on our website: www.skyjack.com for updates
assembly to its undamaged state. Damage includes, related to the service and maintenance of this MEWP.
but is not limited to, the items listed below:
▪ bent/deformed guardrail sections 1.3-2 Maintenance and inspections
▪ cracks or broken welds in railing sections Death or injury can result if the MEWP is not kept in
▪ damaged pin connections good working order. Inspection and maintenance
should be done by competent personnel who are
▪ missing pins or broken pin lanyards
trained and qualified on maintenance of this MEWP.
▪ missing railing hardware
▪ loose or missing parts WARNING
▪ additional holes in guardrail sections other than
Failure to perform each procedure as presented
those approved by Skyjack
and scheduled may cause death, serious injury, or
Additionally, the guardrails must be properly substantial damage.
positioned and secured, and the entry gate must be
in good working order.
The strength of the guardrail system, and therefore NOTE
its ability to provide fall protection for platform Preventive maintenance is the easiest and least
occupants, depends upon the design being secure expensive type of maintenance.
and undamaged.
▪ Unless otherwise specified, do each
Skyjack railings are designed for modular maintenance procedure with the MEWP in the
replacement, and Skyjack recommends replacement following configuration:
of any damaged railing section. Skyjack-approved ▪ Park the MEWP on a flat and level surface
replacement parts will meet this requirement.
▪ Disconnect the batteries by disconnecting the
main power connectors.
▪ Repair damaged or malfunctioning components
1.2-8 Multi-conduction control cable before operating the MEWP.
repair ▪ Keep records of all inspections.
If damage occurs to the outer casing of a multi-
conductor control cable, you may use heat shrink
tubing to case and protect the control cable casing.
Before you install the heat shrink, make sure there is
no damage to the individual wires contained in the
control cable, or to their insulation.
The heat shrink tubing selected and used should seal
the electrical circuit from water intrusion, be suitable
for the machine operating temperature range, and be
suitably flexible to allow the required bending radius
of the cable in its application.
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Scheduled maintenance and inspections Section 1 – Maintenance
1.3-3 Schedule and instructions 1.3-4 Repairs

The actual operating environment of the MEWP may When repairs are made to a MEWP, the service
affect the maintenance schedule. technician must complete the full pre-operation
The inspection points covered in the 1.3-5 inspection and function tests before putting the MEWP
Pre-delivery/maintenance inspection checklist indicate into service.
the areas of the MEWP to be maintained or inspected,
IMPORTANT
and at what intervals the maintenance and inspections
Never use a malfunctioning MEWP. If malfunctions are
are to be done.
discovered, tag the MEWP and remove it from service.
Inspection schedule frequency:
PDI/Frequent/ B Do a PDI before each
Periodic delivery, or a Frequent
Inspection every 200 days
or 200 hours.
Annual C Do a Scheduled
Maintenance Inspection
every year.
Additional * Do this at time-sensitive
maintenance intervals.
▪ Make copies of the maintenance and inspection

checklist to be used for each inspection.
▪ Check the schedule on the checklist for the type
of inspection to be done.
▪ Place a check mark in the appropriate box after
each inspection procedure is done.
▪ Use the maintenance and inspection checklist
and the step-by-step procedures in 1.3-6
Inspection points.
▪ If an inspection receives a fail, tag and remove
the MEWP from service.
▪ If a MEWP components has been repaired, do
an inspection again before you remove the tag.
Place a check mark in the repair column.
Legend
Pass P
Not applicable N/A
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1.3-5 Pre-delivery/maintenance inspection checklist
Frequent/Periodic/Annual/PDI Checklist
Articulating Booms and Telescopic Booms
Serial Number: Starting with serial number A000 000 000 or B000 000 000 and above Product Owner:
Product User:
Model: Date/Time:
Hourmeter Reading: Inspection Type (Choose one): Pre-delivery Frequent Periodic Annual
Use this table for pre-delivery inspections (PDI) before each rental, lease or sale and as an instruction for all frequent inspections and annual inspections.
Refer to the operation and service manuals for inspection instructions (for example, visual inspection and function tests, torque specs, engine oil, chain
inspection intervals, and more).
B - Do the pre-delivery inspection before the machine is sent out or during the frequent inspections at 200 days or 200 hour P - Pass
Inspection Type Schedule
intervals. For more instructions, refer to the operation and service manuals. N/A - Not Applicable
PDI/Frequent/Periodic B
C - Do the scheduled maintenance Inspections each year. For more instructions, refer to the service manual.
Annual B+C
Put a check mark in the “Pass” column as you meet the requirements of the inspection for each item. Add a comment if the item does not pass inspection.
Items for Inspection P N/A Items for Inspection P N/A
Service Bulletins. Make sure there are no open service bulletins. B Axles. Correctly attached and no missing components. Tight fittings and hoses
B
and no leaks. Make sure the axles and drive shaft are lubricated.
Annual Inspection. Make sure you complete it within 13 months. B
Axles. Do a check of the brakes. Lubricate the axles and drive shaft. C
Labels. In place, correctly attached and you can read them. B
Oscillating Cylinders. Correctly attached and no missing components. Tight
Limit Switches. Correctly installed and no obstructions or damage. B B
fittings and hoses and no leaks.
ENGINE COMPARTMENT Oscillating Cylinders. Correctly attached and no missing components. Tight
C
Main Power Disconnect Switch. Cables and switch tight and in working order. B fittings and hoses and no leaks. Do a check of the mounting bolts torque seal.
Battery. No damage, tight connections and sufficient fluid levels. Clean Steer Cylinder. Correctly attached and no missing components. Tight fittings
B B
terminals and cable ends. and hoses and no leaks.
Swing Drive. Tight fittings, hoses and bolts. No damage, missing components Steer Linkage. No damage/wear or missing components. B
B
or leaks. Wheel/Tire Assembly. Do a check of all tires for damage, wear and
B
Hydraulic Pump and Motor. Tight fittings, hoses and bolts. No damage, correctly aligned.
B
missing components or leaks. Wheel/Tire Assembly. No loose bolts. Wheel nuts torqued as recommended. C
Engine and Components. Do a check of the engine and components for any PLATFORM
loose, missing, damaged, or failed items. Do a check of the oil and coolant
B
levels. Make sure you do not exceed the recommended oil and coolant change Raillings and Gates. Correctly attached and no damage or missing
B
intervals. components.
Air Filter. Do a check of the filter. Replace the air filter if necessary. C Platform Floor. Correctly attached and no damage or missing components. B
Fuel Filter. Do a check of the filter. Replace the fuel filter if necessary. C Footswitch. Correctly attached. Operates correctly with no modifications. B
Radiator. Do a check of the coolant condition and replace if necessary. C Fall-Protection Anchorage. Anchorages are correctly attached and no damage. B
CONTROL COMPARTMENT AC Power Socket. No obstructions, dirt, or damage. B
Turret Transportation Lock. Unlocked and no damage or missing Platform Control Console. Operate the switches and make sure they all
B B
components. operate correctly. No damage or missing components.
Base Control Console. Operate the switches and make sure they all operate Manual Storage Box. Manuals and documents are in storage box, in good
B B
correctly. No damage or missing components. condition, and you can read them.
Hydraulic Tank. Filler cap closed tightly and no damage or leaks. B BOOM
Hydraulic Oil. Level between min. and max. marks. B Rotary Actuator. No damage or missing components. Tight fittings, hoses and
B
bolts and no leaks.
Hydraulic Oil. Do a check and replace oil and filters if necessary. C
Jib. No damage or missing components. Tight hoses and bolts and no leaks. B
Hydraulic Return Filter. Correctly attached and no damage, missing
B
components or leaks. Boom. No damage or missing components. No deformation or cracks in welds.
B
Tight fittings, hoses, bolts, and pins. No leaks.
Hydraulic Return Filter. Do a check of the filter. Replace the filter if necessary. C
Cable Track. No damage or missing components. B
Manifolds. Tight fittings and hoses and no damage or leaks. Tight wire
B
connections, no missing components and correctly working valves. Wear Pads. No damage, wear or missing components. Fasteners tight. B
High-pressure Filter. Do a check of the filter. Replace the filter if necessary. Riser. No damage or missing components. No deformation or cracks in welds.
B
Tight fittings, hoses, bolts, and pins. No leaks.
Emergency Power Unit. Tight fittings and hoses. No leaks. Tight wire
B
connections and no damage or missing components. Cylinders. No damage or missing components. Tight fittings and hoses and no
B
leaks. Pins and bushing are tight and correctly installed.
Fuel Tank and Lines. Filler cap, tank, fittings and hoses are closed tightly and
B
no damage or leaks. Control Cables and Hoses. No damage or missing components. No leaks. B
BASE Wire Ropes. No damage or missing components. Tight jam nuts. No spring
B
gaps. Do not exceed the inspection interval.
Base Weldment. No deformation or cracks. B
OPTIONAL EQUIPMENT
Rotary Manifold. Tight fittings and hoses, and no leaks. B
Special Options and Approved Attachments. Correctly attached and no
Turret Rotation Motor/Gear. Tight fittings, hoses and bolts. No damage, B
B damage or missing components.
missing components or leaks. Make sure the gears are lubricated.
Function Tests. Refer to the operating manual for your serial number for PASS
Turret Rotation Motor/Gear. Lubricate the gears. C
information on how to run these tests. FAIL
199342AB
Comments:
The undersigned has made sure that all areas in the list have received an inspection.
The undersigned has told the machine owner of all inconsistencies in the inspection and corrected them before machine operation.
Owner: Print Name Signature Date (DD/MM/YY)
User: Print Name Signature Date (DD/MM/YY)
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1.3-6 Inspection points Use the 1.3-5 Pre-delivery/maintenance inspection

Refer to 1.3 Scheduled maintenance and inspections checklist and do the inspections that follow:
for more information and the inspection schedule. Labels
▪ Refer to the operation manual. Make sure all
labels are present and in the correct location,
WARNING in good condition, and are legible. B
Environmental hazard. Immediately remove
gasoline, diesel fuel, engine oil, and hydraulic Electrical components
fluid spills and leaks with rags. Discard these
rags in accordance with national, state/provincial/
▪ Do a check of all electrical components and
harnesses for chafed, corroded, loose, or
territorial, and local regulations. Spilled fluids can
damaged wires and connectors. Make sure
damage the environment. When spilled fluids go
the connections are tight.
into the water (for example, a sewage system,
streams, rivers, or other surface water), they can ▪ Make sure all switches and buttons rotate or
kill aquatic life. move to all positions, are in good condition,
and return to the neutral position. Make sure
the switches haven’t been tampered with or
disabled.
▪ Make sure the limit switches do not have
Legend broken or missing actuator arms. B
Refer to 5.4-6 Limit Switch Locations.
Visual inspection
Fluids and Filters
Action required
▪ Make sure all fittings and hoses are correctly
tightened.
▪ Make sure the hydraulic tank cap, fuel tank
cap, and radiator cap are tightly closed.
Filters
▪ Make sure the air, hydraulic oil, fuel, and
engine oil filter housings are tight.
▪ If the filters have service indicators on them,
Fluids replace the filter element if indicated.
▪ Look for hydraulic oil, engine oil, fuel, and
coolant leaks.
Grease
▪ Do a check of the fuel, engine oil, coolant,
and hydraulic oil levels. Add more fluid if
necessary. Refer to 2.11 Fluids.
B C Inspection frequency
All components
Procedure available in Section 5 ▪ Make sure there are no loose or missing parts.
▪ Make sure there is no visible damage,
including cracks or deformities in welded
parts.
Return to the PDI form
▪ Make sure all hardware is present and the
fasteners are tight.
▪ Make sure all pins are present and the
fasteners are tight.
▪ Additional inspection items are listed on the
following pages.
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Main power Hydraulic pump and motor

disconnect switch
B
B
Battery B Engine tray
1. Do an inspection of the battery case for damage.

2. Clean the battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
brush.
3. Make sure all the battery connections are tight.
4. If applicable, check the battery fluid level.
▪ If the plates do not have a minimum 13 mm
(1/2 inch) of solution above them, add distilled
or demineralized water.
▪ Replace the battery if it is damaged or cannot
hold a lasting charge.
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Air filter
B C
Muffler and exhaust
Radiator and coolant B

B
C
▪ Check the coolant strength.
High pressure filter Engine oil filter Engine fuel filter

B B B
C C C
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Hydraulic return filter Hydraulic tank and lines Base control console
B
B C B C
Manifolds Turret transportation lock

B B
Fuel tank and lines
Emergency power unit
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Base weldment
Steer linkages
B
B
Brake cylinder
Steer cylinder
B
Axles
Turret rotation B
motor and gear
C
B C
Wheels/tires ▪ Do a check on all tire treads and Oscillating Cylinders

sidewalls for cuts, cracks, holes, ▪ Do a check of the heads of the
and unusual wear. oscillating cylinder mounting
▪ Do a check on each wheel for bolts to make sure the torque
B C damage, and cracked welds. B seal is visible and undamaged. If
the torque seal is damaged or is
▪ Do a check on each lug nut for C missing, remove and replace the
the correct torque to make sure
affected bolts.
they are not loose.
▪ Make sure the wheels are
correctly aligned vertically and
horizontally.
WARNING
Do not use tires other than those that Skyjack
specifies for this MEWP. Do not mix different sizes
or types of tires, or use tires that are not in good
condition. Only replace the tires with the same
types that are approved by Skyjack. The use of
other tires can make the MEWP less stable. If you
do not obey, there is a risk of death or serious
injury.
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Platform control console AC power socket
Railings
Fall-protection
anchorages
Floor
Footswitch
Gates
▪ Make sure the gates or drop

bars operate correctly.
Load Cell B
Manual storage box
▪ Make sure there is no debris lodged between
B the platform and the boom adaptor.
▪ Make sure the operation manual and other

important documents are in the manual
storage box.
▪ Make sure the documents are in good
condition, and are legible.
▪ Always put the manuals and other
documents back in the storage box after
use.
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Wear pads
Boom
B
Riser
B
Jib
B
Rotary actuator
Cable track Control cables Wear pads

and hoses
B B
B
Cylinders
B
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Optional equipment Cold or arctic Welder

weather package
B
B
Generator
Flashing light
B
Tool tray
Glazier Pipe rack
B B
1.3-7 Function tests

Do the function tests after you complete the inspections.
Refer to the “Inspections before operation” section of the operation manual for detailed instructions on how to do
the function tests.
238274AEA SJ45 AJ+

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Section 2 – Maintenance Tables and
Diagrams
2.1 Standard Hose Numbering System
H1104 0081 2
FITTING LENGTH IN FRACTIONS

ARRANGEMENT LENGTH OF HOSE IN (1/4" INCREMENTS)
(See Schedule Below) WHOLE INCHES 1=1/4"
HOSE SIZE
2=1/2"
(See Chart Below)
3=3/4"
Using the number above as an example,

H1104 0081 2, this hose requires a 37° JIC female NOTE
swivel fitting on one end, and a medium length 90° JIC Hose ends and hose must be from same
female swivel fitting for the other end. The hose must manufacturer per S.A.E. J1273 Nov. ‘91, Sections
meet or exceed the S.A.E. 100R13 hose specification, 3.10 and 4.2. Hose ends and hose must be of the
and be a total of 81-1/2" long. same size i.e. #4 size fittings must be used with
#4 size hose.
Hose Size Chart
Size 03 04 06 08 10 12 16 20 24 32 40 48 56 64
ID 3/16" 1/4" 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 3-1/2" 4"
Fitting Arrangement Schedule

S.A.E.
Hose Prefix Hose End Fitting Hose End Fitting
Hose Specification
H01 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H03 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R17
H05 FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R17
H06 FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17
H07 LONG 90°, FEMALE, 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R17
H10 FEMALE, 37° JIC, SWIVEL MALE PIPE THREAD FITTING 100R17
H11 FEMALE, 37° JIC, SWIVEL MEDIUM 90°, FEMALE, 37° JIC, SWIVEL 100R13
H12 SHORT 90°, FEMALE, 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R17
H13 FEMALE, 37° JIC, SWIVEL REUSABLE MALE PIPE THREAD FITTING 300 PSI
H14 REUSABLE MALE PIPE THREAD FITTING NO FITTING 300 PSI
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Section 2 – Maintenance Tables and Diagrams Standard Hose Numbering System
Hose S.A.E. Hose

Hose End Fitting Hose End Fitting
Prefix Specification
H15 REUSABLE FEMALE, 37° JIC, SWIVEL REUSABLE FEMALE, 37° JIC, SWIVEL 300 PSI
H16 NO FITTING NO FITTING 100R4
H17 NO FITTING NO FITTING 300 PSI
H18 REUSABLE, FEMALE, 37° JIC, SWIVEL NO FITTING 300 PSI
H19 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R13
H20 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R4
H21 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R2AT
H22 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R2AT
H23 FEMALE, LONG 37° JIC, SWIVEL LONG 90°, FEMALE, 37° JIC, SWIVEL 100R2AT
H24 FEMALE, SHORT 37° JIC, SWIVEL SHORT 90°, FEMALE, 37° JIC, SWIVEL 100R13
H30 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H32 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H57 SHORT 45°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H58 FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H59 MEDIUM 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R13
H66 FEMALE, 37° JIC, SWIVEL NO FITTING 100R4
H71 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15
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Torque Specifications for Fasteners (Metric) Section 2 – Maintenance Tables and Diagrams
2.2 Torque Specifications for Fasteners (Metric)

When specific torque values are not provided within this manual for a task, use the torque values given in the table
below.
Torque 8.8 10.9

Size
Type Dry Lubed Dry Lubed
(in-lb) (54) (41) (78) (59)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7
(in-lb) (92) (69) (133) (99)
M6 x 1.00
Nm 10.4 7.8 15 11.2
(in-lb) (156) (116) (222) (167)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9
(in-lb) (225) (169) (333) (242)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3
ft-lb 37 28 53 40
M10 x 1.50
Nm 50 38 72 54
ft-lb 65 49 93 69
M12 x 1.75
Nm 88 66 126 94
ft-lb 104 78 148 111
M14 x 2.00
Nm 141 106 201 150
ft-lb 161 121 230 172
M16 x 2.00
Nm 218 164 312 233
ft-lb 222 167 318 238
M18 x 2.50
Nm 301 226 431 323
ft-lb 314 235 449 337
M20 x 2.50
Nm 426 319 609 457
ft-lb 428 321 613 460
M22 x 2.50
Nm 580 435 831 624
ft-lb 543 407 776 582
M24 x 3.00
Nm 736 552 1052 789
ft-lb 796 597 1139 854
M27 x 3.00
Nm 1079 809 1544 1158
ft-lb 1079 809 1543 1158
M30 x 3.50
Nm 1463 1097 2092 1570
ft-lb 1468 1101 2101 1576
M33 x 3.50
Nm 1990 1493 2849 2137
ft-lb 1886 1415 2699 2024
M36 x 4.00
Nm 2557 1918 3659 2744
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. 1375AC
Refer to the specific thread locker manufacturer’s instructions for specific torque adjustments.
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Section 2 – Maintenance Tables and Diagrams Torque Specifications for Fasteners (US Imperial)
2.3 Torque Specifications for Fasteners (US Imperial)

When specific torque values are not provided within this manual for a task, use the torque values given in the table
below.
Torque SAE 2 SAE 5 SAE 8 Torque SAE 2 SAE 5 SAE 8

Size Size
Type Dry Lubed Dry Lubed Dry Lubed Type Dry Lubed Dry Lubed Dry Lubed
(in-lb) (5) (4) (8) (6) (12) (9) ft-lb 70 55 110 80 150 110
4-40 9/16-12
Nm 0.6 0.5 0.9 0.7 1.4 1.0 Nm 95 75 149 108 203 149
(in-lb) (6) (5) (9) (7) (13) (10) ft-lb 80 60 120 90 170 130
4-48 9/16-18
Nm 0.7 0.6 1.0 0.8 1.5 1.1 Nm 108 81 163 122 230 176
(in-lb) (10) (8) (16) (12) (23) (17) ft-lb 100 75 150 110 220 170
6-32 5/8-11
Nm 1.1 0.9 1.8 1.4 2.6 1.9 Nm 136 102 203 149 298 230
(in-lb) (12) (9) (18) (13) (25) (19) ft-lb 110 85 180 130 240 180
6-40 5/8-18
Nm 1.4 1.0 2.0 1.5 2.8 2.1 Nm 149 115 244 176 325 244
(in-lb) (19) (14) (30) (22) (41) (31) ft-lb 175 130 260 200 380 280
8-32 3/4-10
Nm 2.1 1.6 3.4 2.5 4.6 3.5 Nm 237 176 353 271 515 380
(in-lb) (20) (15) (31) (23) (43) (32) ft-lb 200 150 300 220 420 320
8-36 3/4-16
Nm 2.3 1.7 3.5 2.6 4.9 3.6 Nm 271 203 407 298 569 434
ft-lb 170 125 430 320 600 460
(in-lb) (27) (21) (43) (32) (60) (45) 7/8-9
10-24 Nm 230 169 583 434 813 624
Nm 3.1 2.4 4.9 3.6 6.8 5.1
ft-lb 180 140 470 360 660 500
(in-lb) (31) (23) (49) (36) (68) (51) 7/8-14
10-32 Nm 244 190 637 488 895 678
Nm 3.5 2.6 5.5 4.1 7.7 5.8
ft-lb 250 190 640 480 900 680
(in-lb) ft-lb (66) (50) 8 (75) 12 9 1-8
1/4-20 Nm 339 258 868 651 1220 922
Nm 7.5 5.6 11 8.5 16 12
ft-lb 270 210 710 530 1000 740
(in-lb) ft-lb (76) (56) 10 (86) 14 10 1-12
1/4-28 Nm 366 285 963 719 1356 1003
Nm 8.6 6.3 14 9.7 19 14
ft-lb 280 210 730 540 1020 760
ft-lb 11 8 17 13 25 18 1-14
5/16-18 Nm 380 285 990 732 1383 1030
Nm 15 11 23 18 34 24
ft-lb 350 270 800 600 1280 960
ft-lb 12 9 19 14 25 20 1 1/8-7
5/16-24 Nm 475 366 1085 813 1735 1302
Nm 16 12 26 19 34 27
ft-lb 400 300 880 660 1440 1080
ft-lb 20 15 30 23 45 35 1 1/8-12
3/8-16 Nm 542 407 1193 895 1952 1464
Nm 27 20 41 31 61 47
ft-lb 500 380 1120 840 1820 1360
ft-lb 23 17 35 25 50 35 1 1/4-7
3/8-24 Nm 678 515 1519 1139 2468 1844
Nm 31 23 47 34 68 47
ft-lb 550 420 1240 920 2000 1500
ft-lb 32 24 50 35 70 55 1 1/4-12
7/16-14 Nm 746 569 1681 1247 2712 2034
Nm 43 33 68 47 95 75
ft-lb 670 490 1460 1100 2380 1780
ft-lb 36 27 55 40 80 60 1 3/8-6
7/16-20 Nm 908 664 1979 1491 3227 2413
Nm 49 37 75 54 108 81 ft-lb 750 560 1680 1260 2720 2040
ft-lb 50 35 75 55 110 80 1 3/8-12
1/2-13 Nm 1017 759 2278 1708 3688 2766
Nm 68 47 102 75 149 108 ft-lb 870 650 1940 1460 3160 2360
1 1/2-6
ft-lb 55 40 90 65 120 90 Nm 1180 881 2630 1979 4284 3200
1/2-20
Nm 75 54 122 88 163 122 ft-lb 980 730 2200 1640 3560 2660
1 1/2-12
Nm 1329 990 2983 2224 4827 3606
NOTE: Lubed includes lubricants such as lubrizing, oil, grease, and some uncured thread lockers. Refer to the specific 1374AB
thread locker manufacturer’s instructions for specific torque adjustments.
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Torque Specifications for Hydraulic Couplings & Hoses Section 2 – Maintenance Tables and Diagrams
2.4 Torque Specifications for Hydraulic Couplings & Hoses

Hydraulic Coupling Torque Chart
O-Ring Port Connectors
Steel Ports Non-ferrous Ports
SAE Size
ft-lb Nm ft-lb Nm
4 14-16 20-22 9-10 12-13
6 24-26 33-35 15-16 20-21
8 50-60 68-78 30-36 41-47
10 72-80 98-110 43-48 60-66
12 125-135 170-183 75-81 102-110
16 200-220 270-300 120-132 162-180
20 210-280 285-380 126-168 171-228
24 270-360 370-490 162-216 222-294
32 - - - -
Hose End Torque Chart Hose End Torque Chart

for JIC for Flat-Face O-Ring Seal (Steel)
Size Steel Brass Size Torque Specification
ft-lb Nm ft-lb Nm ft-lb Nm
Dash Frac. Dash Frac.
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
-4 1/4" 10 11 13 15 5 6 6.75 9 -4 1/4" 10 12 14 16
-6 3/8" 17 19 23 26 12 15 17 20 -6 3/8" 18 20 24 27
-8 1/2" 34 38 47 52 20 24 27.66 33 -8 1/2" 32 40 43 54
-10 5/8" 50 56 69 76 34 40 46.33 55 -10 5/8" 46 56 60 75
-12 3/4" 70 78 96 106 53 60 72.33 82 -12 3/4" 65 80 90 110
-16 1" 94 104 127 141 74 82 100.5 111 -14 1" 65 80 90 110
-20 1 1/4" 124 138 169 188 75 83 101.5 113 -16 1 1/4" 92 105 125 240
-24 1 1/2 156 173 212 235 79 87 107 118 -20 1 1/2 125 140 170 190
-32 2" 219 243 296 329 158 175 214 237 -24 2" 150 180 200 245
1276AA
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Section 2 – Maintenance Tables and Diagrams MEWP Torque Specifications
2.5 MEWP Torque Specifications

Location Description Torque (ft-lb) Torque (Nm)
Base
Trunnion Mount BOLT, Hex head (3/4"-10 x 5" G8) 210 285
Rear Axle Mount ** NUT, Torque lock (3/4"-10 GC) 210 285
Axle Lock BOLT, Hex head (1/2"-13 x 2-1/4" G8) 80 108
Rotation Gear ** BOLT, Hex head (5/8"-11 x 4-1/2" G8) 170 230
Hydraulic Drive Motor BOLT, Hex head (M14 x 2 x 30mm CL8.8) 80 108
Wheel Nut NUT, Wheel 247-302 335-410
Turret
Rotation Gear ** BOLT, Hex head (5/8"-11 x 2-3/4" G8) 170 230
BOLT, Hex head, patch (3/8”-16 x 3/4” G5)
Diesel Fuel Tank Mount 25 34
BOLT, Hex head, patch (3/8”-16 x 2-1/4” G5)
Engine
BOLT, Hex head (M10 x 1.25 x 25 CL8.8) 30 40
Engine Mounts
Flywheel BOLT, Hex head (M8 x 1.25 x 16 CL10.9) 20 27
Drive Pump BOLT, Hex head (1/2"-13 x 1-1/2" G5) 55 75
System Pump BOLT, Socket (3/8"-16 x 1 G5) 26 35
Cylinders
ROD NUT 425 576
Lift
GLAND 400 542
Extension ROD NUT 150 203
GLAND 450-500 610-678
Master
ROD NUT 350 475
Slave GLAND & ROD NUT 350 475
GLAND 350 475
Axle Lock
BOLT, Hex head (1/2"-13 x 2-1/4" G8) 80 108
Jib BOLT, Hex head (5/16”-18 x 2-3/4" G5) 15 20
Riser ROD NUT & GLAND 350 475
Platform
BOLT, Hex head patch (3/8"-16 x 7/8" G8)* 35 48
Rotary Mount
BOLT, Hex head (1"-8 x 10-1/2" G8) 480 569
Rotary Actuator ** BOLT, Hex head (3/4"-10 x 3" G8) 210 285
BOLT, Hex head patch (M16 x 1.5 x 45 CL10.9)* 200 271
Load Cell
BOLT, Hex head (1/2"-13 x 2-1/2" G8) 80 108
Generator
Generator Upper Pulley BOLT, Hex head (M10 x 1.25 x 35 CL10.9) 40 54
Generator Lower Pulley
*Loctite 243 on standard bolts may be used in place of patch bolts.
**Torque procedure available in Section 5. 2215AC
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Axle Torque Specifications Section 2 – Maintenance Tables and Diagrams
2.6 Axle Torque Specifications

Type of Bolt
8.8 10.9 12.9
Size of Bolt Normali Normali Normali
Loctite 270 Loctite 270 Loctite 270
Loctite 242 Loctite 242 Loctite 242
(Nm) (Nm) (Nm)
(Nm) (Nm) (Nm)
M6 x 1 9.5-10.5 10.5-11.5 14.3-15.7 15.2-16.8 16.2-17.8 18.1-20.0
M8 x 1.25 23.8-26.2 25.6-28.4 34.2-37.8 36.7-40.5 39.0-43.0 43.7-48.3
M10 x 1.5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1.75 82-91 90-100 116-128 126-139 139-153 152-168
Coarse Pitch
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263

M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2.5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2.5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2.5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3.5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8 x 1 25.7-28.3 27.5-30.5 36.2-39.8 40.0-44.0 42.8-47.2 47.5-52.5
M10 x 1.25 49.4-54.6 55.2-61.0 71.5-78.5 78.0-86.0 86.0-94.0 93.0-103.0
M12 x 1.25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1.5 86-95 94-104 120-132 133-147 143-158 159-175
M14 x 1.5 143-158 157-173 200-222 219-242 238-263 261-289
Fine Pitch
M16 x 1.5 214-236 233-257 302-334 333-368 361-399 394-436

M18 x 1.5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1.5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1.5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
1373AA
Note: 1 Nm = 0.7376 ft-lb
Screw-locking, Sealing and Lubricating Materials
Loctite 242
▪ Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength
locking. Before using it, completely remove any lubricant by using the specific activator.
Loctite 270
▪ Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength
locking. Before using it, completely remove any lubricant by using the specific activator. To remove parts,
it may be necessary to heat them at 80˚C approx.
SJ45 AJ+ 238274AEA

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Section 2 – Maintenance Tables and Diagrams Axle Maintenance Intervals
2.7 Axle Maintenance Intervals
Operation Component Frequency Lubricants

Differential monthly
Check Levels Planetary reduction every 200 hours SAE 80W-90 API GL-5
Gear box monthly
Differential every 800 hours *
Planetary reduction every 1000 hours *
Oil Change Self-locking differential gear every 700 hours * & SAE 80W-90 API GL-5
once at 50 hours after every
Gear box
1000 hours
Gear box screws/bolts every 200 hours
Tighten N/A
Wheel Nuts every 200 hours
Operation Member Conditions Frequency Lubricants

Normal work monthly
Grease Articulations MOLIKOTE
Awkward work weekly
Gear Oil Gear Box Central Housing Hubs (each)

5.5 L (5.8 qt) front
Maximum Oil Capacities 2.4 L (2.5 qt) 0.9 L (0.9 qt)
7.5 L (7.9 qt) rear
*Initially after 100 working hours 2238AA-2

& when it starts sounding noisy
NOTE
1 Nm = 0.7376 ft-lb
238274AEA SJ45 AJ+

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Hydraulic Specifications Section 2 – Maintenance Tables and Diagrams
2.8 Hydraulic Specifications

Description Metric US
Pumps
Displacement - 2000 rpm 46 CC 2.8 CIR 24.3 gpm @ 2000 rpm
Drive Pump Pressure 345 bar 5000 psi

Drive Pump
Charge Pump Displacement 13.9 CC 0.85 CIR
Charge Pump Pressure 22 bar 313 psi
Displacement - Static 11 CC 0.67 CIR / 5.8 gpm @ 2000 rpm

System Pump
System Pump Pressure 207 bar 3000 psi
Filters
Charge Pump Filter Max. Operating Pressure 9 µm/35 50 psi
High Pressure Filter Max. Operating Pressure 10 µm/25 87 psi
Return Filter Max. Operating Pressure 10 µm/40 22 psi

Motors
Displacement - Low 21 CC 1.55 CIR

Drive Motor
Displacement - High 38 CC 2.32 CIR
Motor Displacement 65.56 CC 4 CIR

Swing Motor
Maximum Swing Pressure 121 bar 1750 psi
Cylinders
Bore 5.1 cm 2 in.
Rod Diameter 3.2 cm 1.25 in.

Extension Cylinder
Stroke 1.7 m 67 in.
Maximum Boom Pressure 207 bar 3000 psi
Bore 10.2 cm 4 in.

Main Lift Cylinder
Stroke 64.6 cm 25.44 in.
Maximum Lift Pressure 207 bar 3000 psi
Bore 6.4 cm 2.5 in.
Riser Cylinder Stroke 92 cm 36.21 in.
Maximum Lift Pressure 207 bar 3000 psi
Maximum Lower Pressure 190 bar 2750 psi
Steering Cylinder Maximum Steering Pressure 207 bar 3000 psi
2039AB
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Section 2 – Maintenance Tables and Diagrams MEWP Specifications
2.9 MEWP Specifications
Working Height - maximum 15.54 m 51 ft 0 in

Platform Height - maximum 13.72 m 45 ft 0 in
Horizontal Reach - maximum 6.93 m 22 ft 9 in
Height & Horizontal Reach - at maximum height 2.98 m 9 ft 10 in

Reach Horizontal Reach - fly boom retracted 5.23 m 17 ft 2 in
Tailswing 0.61 m 2 ft 0 in
Up and Over Clearance - at platform 7.53 m 24 ft 8.75 in
Up and Over Clearance - at main boom 7.45 m 24 ft 5.25 in
0.76 x 1.52 m 30 x 60 in
Platform Size
0.76 x 1.83 m 30 x 72 in
Platform Rotation 175°
Platform Platform rotation radius 1.14 m 45 in
Platform height - stowed 0.28 m 11 in
Overall railing height 1.35 m 53 in
Platform railing height 1.11 m 44 in
Jib Length 1.42 m 55.75 in
Jib vertical Range of Motion 2.7 m 106.5 in
Jib
Jib Range of Motion - down 70°
Jib Range of Motion - up 75°
Height - stowed min. 2.06 m 6 ft 9 in
Stowed length @ min. height 6m 19 ft 8 in
Stowed length - min. 4.75 m 15 ft 7 in
Width 2.29 m 7 ft 6 in
Wheelbase 2.03 m 6 ft 8 in
Dimensional
Ground Clearance - chassis 0.39 m 15.25 in
Data
Ground Clearance - front axle 0.33 m 13 in
Axle Oscillation 0.09 m 3.7 in
Turning Radius - inside 1.5 m 4 ft 11.25 in
Turning Radius - outside 4.34 m 14 ft 3 in
Turret Rotation 360°
114
2148AA
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Platform Capacities Section 2 – Maintenance Tables and Diagrams
2.9 MEWP Specifications (continued)
Gradeability - maximum 40%
Drive Speed - stowed / low torque 4 km/h 2.5 mph
Drive Speed - stowed / high torque 1.9 km/h 1.2 mph
Drive Speed - elevated / low torque 0.6 km/h 0.36 mph
Drive Speed - elevated / high torque 0.6 km/h 0.36 mph

70 - 90 s (ANSI/CSA & AS)
Turret Rotation Time - stowed
90 - 110 s (CE)
Platform Rotation Time 5-9s
Boom Up Time 29 - 32 s
Performance
& Speeds Boom Down Time 27 - 30 s
Boom Extend Time 10 - 16 s
Boom Retract Time 24 - 27 s
Riser Up 24 - 30 s
Riser Down 24 - 30 s
Jib Up Time 18 - 24 s
Jib Down Time 10 - 16 s
Steer Left Time 5-9s
Steer Right Time 5-9s
System Voltage 12 V DC
Electrical
Battery Type Lead / Acid
2148AA-2
2.10 Platform Capacities
Regular Platform Capacity Derated Platform Capacity*

Capacity 300 kg 660 lb 272 kg 600 lb
Maximum number of people 3 3 1 1
Manual side force 400 N 90 lbf 200 N 45 lbf
Wind rating - 12.5 m/s (28 mph) 12.5 m/s (28 mph)
Tilt cutout setting side-to-side x front-to-back 5 degrees x 5 degrees 5 degrees x 5 degrees
2150AA
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Section 2 – Maintenance Tables and Diagrams Fluids
2.11 Fluids
Fluid Temperature Range Recommended Type
Petro-Canada ATF D3M,
Standard / Cold -26°C to 38°C (-15°F to 100°F) Shell ATF Donax TG,
Shell Tellus T46
Hydraulic Oil
Biodegradable -29°C to 32°C (-20°F to 90°F) Shell Naturelle HF-E 46
Arctic -40°C to 38°C (-40°F to 100°F) Esso Univis HVI 26
Standard / Cold -29°C to 45°C (-20°F to 115°F) 80W-90 API GL5
Gear Oil
Arctic -40°C to 45°C (-40°F to 115°F) Shell Spirax S4 TXM 10W-30
Petro-Canada Duron-E 10W-30,
Standard / Cold -18°C to 45°C (0°F to 115°F)
Esso XD-3 Extra Premium Heavy Duty 10W-30
Engine Oil
Petro-Canada Duron-E synthetic 0W-40,
Arctic -40°C to 45°C (-40°F to 115°F)
Esso XD-3 Extra 0W-40
Standard / Cold -40°C to 45°C (-40°F to 115°F) Recochem 50/50 Premix (green)
Coolant *Recochem 50/50 Premix (green) mixed with
Arctic -40°C to 45°C (-40°F to 115°F)
Recochem Extended Life Predilute 60/40 concentrate
*Add the concentrate antifreeze to the 50/50 mix to obtain a 60/40 concentration. 2146AB
2.12 Engines
RPM Settings 1400 Idle / 1700 Mid / 2600 High

Kubota D1305
Horsepower @ 2000 rpm (intermittent) 18.4 kW / 25 hp

Fuel Type Diesel
Fuel Tank Capacity 45 gal (170.3 L)
Lube Oil Sump Capacity 2.38 gal (9 L)
Coolant Capacity 3.0 gal (11.4 L)
RPM Settings 1400 Idle /2100 Mid / 3000 High
Kubota WG972
Horsepower @ 2300 rpm (intermittent) 18.4 kW / 25 hp

Fuel Type Diesel
Fuel Tank Capacity 15 gal (60 L)
Coolant Capacity 2.75 gal (10.4 L)
Lube Oil Sump Capacity 2.11 gal (8.0 L)
2144AB
238274AEA SJ45 AJ+

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Reach Diagram Section 2 – Maintenance Tables and Diagrams
2.13 Reach Diagram
16.76
(55)
15.24
(50)
13.72
(45)
12.19
(40)
10.67
(35)
9.14
(30)
7.62
(25)
6.10
(20)
4.57
(15)
3.05
(10)
1.52
(5)
-1.52
(-5)
-3.05
(-10)
-3.05 -1.52 0 1.52 3.05 4.57 6.10 7.62 9.14 10.67
(-10) (-5) (5) (10) (15) (20) (25) (30) (35)
SJ45 AJ+ 238274AEA

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Notes
238274AEA SJ45 AJ+

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Section 3 – System Component
Identification and Schematics
SJ45 AJ+ 238274AEA

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Section 3 – System Component Identification and Schematics Electrical Symbol Chart
Table 3.1 Electrical Symbol Chart
CIRCUITS CROSSING
NO CONNECTION TT HOURMETER KEY SWITCH LIMIT SWITCH
CIRCUITS CAM OPERATED

LIGHT FOOT SWITCH
CONNECTED LIMIT SWITCH
HYDRAULIC LIMIT SWITCH

BATTERY TOGGLE SWITCH
VALVE COIL N.O
PROPORTIONAL ANGLE LIMIT SWITCH

GROUND HYDRAULIC TRANSDUCER N.O HELD
VALVE COIL & TILT SWITCH CLOSED
ELECTRIC TEMPERATURE LIMIT SWITCH

FUSE M MOTOR SWITCH N.C.
CIRCUIT SINGLE POLE LIMIT SWITCH

BREAKER HORN SINGLE THROW N.C HELD OPEN
RELAY
SINGLE POLE
VOLT METER
V PUSH BUTTON DOUBLE THROW BEEPER
RELAY
DOUBLE POLE
CAPACITOR ROTARY SWITCH DOUBLE THROW DIODE
RELAY
DOUBLE POLE
EMERGENCY SINGLE THROW
POTENTIOMETER STOP BUTTON RELAY
TRIPLE POLE
RESISTOR DOUBLE THROW
RHEOSTAT
RELAY
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Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics
Table 3.2 Hydraulic Symbol Chart
THREE POSITION
FIXED
FOUR WAY
LINE CROSSING
A B
SHUTTLE VALVE
PT
DISPLACEMENT
CLOSED CENTER
PUMP
OPEN PORT
VARIABLE CUSHION
LINE JOINED DISPLACEMENT PRESSURE
SWITCH CYLINDER
PUMP
MAIN LINES MOTION DOUBLE ACTING

HAND PUMP CYLINDER
Solid CONTROL VALVE
DOUBLE ACTING
PILOT LINES OIL COOLER FLOW DIVIDER DOUBLE
Dashed COMBINER RODDED
CYLINDER
HYDRAULIC COUNTER BRAKE

VELOCITY FUSE
TANK BALANCE VALVE CYLINDER
SPRING APPLIED
HYDRAULIC
VALVE COIL HYDRAULIC
FILTER WITH RELIEF VALVE RELEASED
BYPASS
BRAKE
TWO POSITION
ELECTRIC PRESSURE TWO WAY ROTARY
M MOTOR REDUCING NORMALLY ACTUATOR
VALVE OPEN VALVE
TWO POSITION
PRESSURE TWO WAY
ENGINE
TRANSDUCER NORMALLY SERVO
CLOSED VALVE
BI DIRECTIONAL
TWO POSITION
HYDRAULIC FIXED ORIFICE THREE WAY VALVE
MOTOR
VARIABLE
DISPLACEMENT ADJUSTABLE TWO POSITION
HYDRAULIC MOTOR FLOW CONTROL THREE WAY VALVE
SERIES PARALLEL THREE POSITION

FOUR WAY
B
HYDRAULIC CHECK VALVE

A B
PT
MOTOR CLOSED CENTER

A
CLOSED PORT
SJ45 AJ+ 238274AEA

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Section 3 – System Component Identification and Schematics Wire Number and Colour Chart
3.3 Wire Number and Colour Chart

Wire No. Wire Colour Wire No. Wire Colour
B+ GREEN/PURPLE 34 ORANGE/BLACK
0 WHITE 35 ORANGE/WHITE
1 PURPLE/BLACK 36 RED/PURPLE
2 WHITE 37 WHITE/RED/BLACK
3 GREEN/PURPLE 38 ORANGE/RED
4 RED/YELLOW 39 BLACK/RED
5 PURPLE 40 BLUE/RED
7 RED 41 BLUE/PURPLE
9 YELLOW 42 PINK
10 BLUE/WHITE 45 YELLOW/ORANGE
11 WHITE/ORANGE 49 GREEN/RED
12 RED/BLACK/YELLOW 55 YELLOW/PURPLE
13 ORANGE 57 BROWN/GREEN
14 BLACK 59 YELLOW/BLUE
15 BLUE 65 YELLOW/PINK
16 WHITE/BLACK 68 GREY
17 BLUE/GREEN 74 GREEN/GREY
20 ORANGE/BLUE 76 BROWN/BLUE
21 WHITE/RED 77 BROWN/GREY
23 BLACK/WHITE 85 GREY/BLUE
24 BLUE/BLACK 108 YELLOW/BROWN
26 BLUE/YELLOW 118 PURPLE/PINK
28 GREEN 119 PURPLE/YELLOW
29 GREY/ORANGE(BLACK) 120 GREY/BROWN
30 RED/GREEN 121 GREY/RED
31 RED/WHITE 122 GREY/YELLOW
32 GREEN/BLACK 128 BLACK/YELLOW
33 GREEN/WHITE 165 PINK/BLACK
This table is a wire number/colour reference for all electrical drawings and schematics. 2178AB
All wire numbers retain their original colour coding; for example if wire 7 is red, wires 7A,
7B, and 7C are also red.
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Hydraulic Parts List Section 3 – System Component Identification and Schematics
3.4 Hydraulic Parts List

Index Skyjack
Description
No. Part No.
2H-21A 166039 VALVE (Dump)
2H-42 231438 VALVE, Proportional
3H-21 195036 VALVE, Control (Load Circuit)
3H-26 159827 VALVE, Control (Brake Release)
3H-38 166037 VALVE, Control (Boom Retract)
3H-39 166037 VALVE, Control (Boom Extend)
3H-45A 159827 VALVE, Control (2 Speed Motor)
3H-65 159827 VALVE, Control (Axle Lockout)
3H-85 168448 VALVE, Generator Bypass (3.5kW Generator)
4H-13 166041 VALVE, Control (Main Boom Lift Down)
4H-14 166041 VALVE, Control (Main Boom Lift Up)
4H-23A 158186 VALVE, Control (Steering Left)
4H-24A 158186 VALVE, Control (Steering Right)
4H-30 166041 VALVE, Control (Riser Down)
4H-31 166041 VALVE, Control (Riser Up)
4H-32 166041 VALVE, Control (Turret Rotate Left)
4H-33 166041 VALVE, Control (Turret Rotate Right)
4H-34 166036 VALVE, Control (Jib Down)
4H-35 166036 VALVE, Control (Jib Up)
4H-36 166036 VALVE, Control (Platform Rotate Left)
4H-37 166036 VALVE, Control (Platform Rotate Right)
4H-40 166036 VALVE, Control (Platform Level Down)
4H-41 166036 VALVE, Control (Platform Level Up)
C1 218750 CYLINDER (Jib)
C2 148712 CYLINDER (Fly Boom)
C3 238369 CYLINDER (Main Boom Lift)
C4 148715 CYLINDER (Platform Level, Master)
C5 148716 CYLINDER (Platform Level, Slave)
C6 148710 CYLINDER (Riser Lift)
C7 148710 CYLINDER (Riser Lift)
C9 212871 RAM (Axle Lockout)
C10 212871 RAM (Axle Lockout)
CB1 212872 VALVE, Counterbalance (Axle Lockout)
CB2 212872 VALVE, Counterbalance (Axle Lockout)
CB3 220533 VALVE, Counterbalance (Swing Drive)
CB4 220533 VALVE, Counterbalance (Swing Drive)
CB5 149488 VALVE, Counterbalance (Riser Down)
CB6 149488 VALVE, Counterbalance (Riser Down)
CB7 149228 VALVE, Counterbalance (Platform Level, Slave)
CB8 149228 VALVE, Counterbalance (Platform Level, Slave)
CB9 152326 VALVE, Counterbalance (Boom Lift)
CB10 149228 VALVE, Counterbalance (Fly Boom Extend)
CB11 141453 VALVE, Counterbalance (Fly Boom Retract)
CB12 149372 VALVE, Counterbalance (Jib)
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Section 3 – System Component Identification and Schematics Hydraulic Parts List

Index Skyjack
Description
No. Part No.
CB13 149372 VALVE, Counterbalance (Jib)
CB14 141399 VALVE, Counterbalance (Rotary Actuator)
CB15 141399 VALVE, Counterbalance (Rotary Actuator)
CP1 231437 PLUG, Cavity
CV2 171413 VALVE, Check (Brake Manifold)
CV3 166064 VALVE, Check (Main Control)
CV4 159817 VALVE, Check (Double, Piloted, Platform Level)
CV5 163183 VALVE, Check (Riser)
CV6 163182 VALVE, Check (Riser)
CV7 166067 VALVE, Check (LS)
DSV1 166059 VALVE, System Load Sense (Differential Sensing Valves)
DSV2 166062 VALVE, Differential Sensing (Boom Rotate)
DSV3 166063 VALVE, Differential Sensing (Riser)
DSV4 166063 VALVE, Differential Sensing (Main Lift)
DSV5 166062 VALVE, Differential Sensing (Jib/Platform Rotate)
EPU 160923 PUMP, Emergency Power Unit
F1 161932 FILTER, High Pressure
F2 161934 FILTER, Return
M1 161964 MOTOR, Drive - Eaton
M1 243285 MOTOR, Drive - Hengli
MB1 218327 MANIFOLD, Main
MB2 168642 MANIFOLD, Brake
MB3 231501 MANIFOLD, Jib
OR1 167353 ORIFICE, Main Control (Platform Rotate)
OR2 167352 ORIFICE, Main Control (Jib)
OR3 166056 ORIFICE, Main Control (Boom Extend)
OR4 166057 ORIFICE, Main Control (Platform Level)
OR5 171420 ORIFICE, Brake Manifold (Loop Flush)
OR6 163710 ORIFICE, Riser Down (0.067”)
OR7 195033 VALVE, Needle (Load Circuit)
P1 170599 PUMP, Hydrostatic - Eaton
P1 243280 PUMP, Hydrostatic - Hengli
P1A 170599 PUMP, Charge
P2 161963 PUMP, System
PFC1 166055 CONTROL, Priority Flow (Steer)
PFC2 169407 CONTROL, Priority Flow (Generator 3.5kW)
PR1 168754 VALVE, Pressure Reducing
QD1 122420 DISCONNECT, Quick
RA1 144710 ACTUATOR, Platform
RA2 216673 WORM GEAR, Slew drive
RV6 166043 VALVE, Relief (Main Control)
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Hydraulic Parts List Section 3 – System Component Identification and Schematics

Index Skyjack
Description
No. Part No.
RV7 238568 VALVE, Relief (Boom Rotate)
RV8 166044 VALVE, Relief (Riser Down)
RV9 238569 VALVE, Relief (Platform Level)
RV10 195600 VALVE, Relief (3.5 kW Generator Option)
RV11 238571 VALVE, Relief (12 kW Generator Option)
RV12 195596 VALVE, Relief (3.5 kW Generator Option)
RV13 195035 VALVE, Relief (Load Circuit)
RV15 238570 VALVE, Relief (Load Circuit)
RV16 238571 VALVE, Relief (12 kW Generator Option)
SV1 141414 SHUTTLE VALVE, Brake Manifold (LS)
SV2 166054 SHUTTLE VALVE, Brake Manifold (M1 / M2)
SV4 166054 SHUTTLE VALVE, Main Manifold (Swing)
SV5 166054 SHUTTLE VALVE, Main Manifold (Riser)
SV6 166054 SHUTTLE VALVE, Main Manifold (Boom Lift)
SV7 166054 SHUTTLE VALVE, Main Manifold (Platform Level)
SV8 166054 SHUTTLE VALVE, Main Manifold (Platform Level)
V1 141436 VALVE, Control (Brake Release Override)
V2 166053 VALVE, Control (Loop Flush)
V3 159831 HAND PUMP (Brake Release)
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Section 3 – System Component Identification and Schematics Electrical Parts List
3.5 Electrical Parts List

Relay diagrams SUPPLY (B+) (Common)
Control (B+) CONTROL (B+)
1
Normally GROUND (B-)
Supply (B+)
3 5 4 Closed
(Common)
Contact
2
Normally Open Contact Ground (B-)
NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT
Index Skyjack
Description
No. Part No.
01ACR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console)
04ACR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console)
07CR 127131 RELAY, 12 Volt 40 Amp (Base control console - E-pump/Enable)
08CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Footswitch/Starter interlock)
09CR 127131 RELAY, 12 Volt 40 Amp (Engine power on)
21CR 127131 RELAY, 12 Volt 40 Amp (Base control console - Dump valve)
27CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Tilt alarm)
45CR1 127131 RELAY, 12 Volt 40 Amp (Base control console - 2-SPD motor)
45CR2 127131 RELAY, 12 Volt 40 Amp (Base control console - 2-SPD motor controller)
49CR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console)
57ACR 127131 RELAY, 12 Volt 40 Amp (Base control console - Engine Start)
57DCR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console)
60CR 127131 RELAY, 12 Volt 40 Amp (Base control console - System power)
78CR 127131 RELAY, 12 Volt 40 Amp (Base control console - High idle)
79CR 127131 RELAY, 12 Volt 40 Amp (Base control console - Low idle)
82CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Load sensing alarm)
165CR 127131 RELAY, 12 Volt 40 Amp (Platform control console - Differential lock)
403ACR 931298 RELAY, Micro 12 V DC, 30 amp (Base control console - Positive air shut-off option)
2H-21A 159819 COIL, 12 Volt (Dump valve)
2H-34A 159821 COIL, 12 Volt (Jib enble valve)
2H-36A 159821 COIL, 12 Volt (Platform rotate enble valve)
3H-26 159827 COIL, 12 Volt (Brake valve)
3H-45 159827 COIL, 12 Volt (Motor 2-speed valve)
3H-65 159827 COIL, 12 Volt (Axle lock valve)
3H-165 159827 COIL, 12 Volt (Differential lock valve)
4H-13 159819 COIL, 12 Volt (Boom down valve)
4H-14 159819 COIL, 12 Volt (Boom up valve)
4H-23A 159819 COIL, 12 Volt (Right steer valve)
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Electrical Parts List Section 3 – System Component Identification and Schematics

Index Skyjack
Description
No. Part No.
4H-24A 159819 COIL, 12 Volt (Left steer valve)
4H-30 159819 COIL, 12 Volt (Riser down valve)
4H-31 159819 COIL, 12 Volt (Riser up valve)
4H-32 159819 COIL, 12 Volt (Left turret rotate valve)
4H-33 159819 COIL, 12 Volt (Right turret rotate valve)
4H-34 159821 COIL, 12 Volt (Jib down valve)
4H-35 159821 COIL, 12 Volt (Jib up valve)
4H-36 159821 COIL, 12 Volt (Platform left rotate valve)
4H-37 159821 COIL, 12 Volt (Platform right rotate valve)
4H-38 159821 COIL, 12 Volt (Boom retract valve)
4H-39 159821 COIL, 12 Volt (Boom extend valve)
4H-40 159821 COIL, 12 Volt (Platform level down valve)
4H-41 159821 COIL, 12 Volt (Platform level up valve)
A1 138224 JOYSTICK (Fly boom/Turret)
A2 138225 JOYSTICK (Drive/Steer)
A3 148707 JOYSTICK (Riser boom)
AT1 149426 ANGLE TRANSDUCER
B1 144676 BATTERY, 12V (Wet)
BP1 103057 BEEPER, 4-28 VDC Slow pulsing (Platform control console)
BP2 103056 BEEPER, 7.5-16 VDC (Base control console)
BP3 144387 ALARM, Overload
C1 231427 CAPACITOR, 22 kuF
CB1 117325 CIRCUIT BREAKER (15 Amp)
CI 152323 INDICATOR, Charge
DXX 102921 DIODE
FU1 138848 FUSE, 50 Amp
FS1 138230 SWITCH, Low fuel
H1 146652 HORN, 12 Volt
LS1 122007 SWITCH, Limit (Direction sensing)
LS2 111356 SWITCH, Limit (Riser down)
LS3 161582 SWITCH, Limit (Boom down)
LS4 160018 SWITCH, Limit (Fly in)
M1 706921 PUMP, Emergency
PL1 148971 LIGHT, Pilot (Engine fault)
PL2 148972 LIGHT, Pilot (Glow plug)
PL3 147229 LED BLOCK, Red (12 volts) (Base control console)
PL4 147229 LED BLOCK, Red (12 volts) (Platform control console)
PL5 138229 MODULE, Upper indicating
PL6 148971 LIGHT, Pilot (Platform control console)
QD1 122420 QUICK DISCONNECT
R1 110999 RESISTOR, 5 ohm 25 W
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Section 3 – System Component Identification and Schematics Electrical Parts List
Index Skyjack
Description
No. Part No.
R3 163021 RESISTOR, 120 ohm 1/2 W
R4 164859 RESISTOR, 2.2k ohm 1/2 W
R6 164857 RESISTOR, 3.9k ohm 1/2 W
S1 119725 SWITCH, Main power disconnect
S2 218354 KEYSWITCH, Base/Off/Platform (Base control) - ANSI/CSA & AS
218920 KEYSWITCH, Base/Off/Platform (Base control) - CE
S3 147053 N.C. CONTACT, Emergency stop (Base control console)
S4 147053 N.C. CONTACT, Emergency stop (Platform control console)
S5 138278 SWITCH, Ignition/emergency pump toggle (Base control console)
S6 138278 SWITCH, Ignition/emergency toggle (Platform control console)
S8 102853 SWITCH, Diagnose toggle (Base control console) (Deutz engine)
S9 124446 SWITCH, Ignition (Platform control console)
S10 115574 SWITCH, Throttle toggle (Platform control console)
S11 138721 ASSEMBLY, Footswitch
S12 138278 SWITCH, Boom up/down toggle (Base control console)
S13 102853 SWITCH, Turret rotate toggle (Base control console)
S14 102853 SWITCH, Telescope in/out toggle (Base control console)
S15 102853 SWITCH, Platform leveling toggle (Base control console)
S16 102853 SWITCH, Platform rotate toggle (Base control console)
S17 102853 SWITCH, Jib up/down toggle (Base control console)
S18 138278 SWITCH, Telescope in/out toggle (Platform control console)
S19 138278 SWITCH, Platform leveling toggle (Platform control console)
S20 138278 SWITCH, Platform rotate toggle (Platform control console)
S21 138278 SWITCH, Jib up/down toggle (Platform control console)
S23 147054 N.O. CONTACT, Horn (Platform control console)
S25 138278 SWITCH, Riser boom up/down toggle (Base control console)
S26 115574 SWITCH, Fuel select (Platform control console) (GM engine)
S28 148998 SWITCH, Differential (Platform control console)
S48 115747 SWITCH, Drive torque toggle (Platform control console)
SMB1-105 238028 MODULE, Master
SMB1-106 218382 MODULE, Slave
TT1 103336 HOUR METER
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Brake Manifold Components and Ports Section 3 – System Component Identification and Schematics
3.6 Brake Manifold Components and Ports
3H-65
Counterweight Axle Lockout Valve
end of MEWP 3H-45A
3H-26 2 Speed Valve
Brake Valve 3H-165
BR Differential Lock Valve
Pressure Gauge
SV1
BRG Shuttle Valve
To Rotary Manifold
Fro
nt
D
V3 To Rotary
Brake Valve Top Manifold
i g ht 2SPD
R To Rotary
Manifold
PR1
Pressure Reducing
Valve SV2
Shuttle T
Valve To Hydraulic Tank
V1 V8 M2
Brake Release Loop Flush To Drive Pump
Override Valve M1
OR6 To Drive Pump
Orifice
CV13 LS
Check Valve To Main Manifold
AL
To Rotary Manifold
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Section 3 – System Component Identification and Schematics Drive and System Pump Ports
3.7 Drive and System Pump Ports
D2 M2
To hydraulic tank To brake manifold
A
To hydraulic tank
C1
To rotary manifold
A
To rotary manifold
B
To rotary manifold
B
To high pressure filter S
To hydraulic tank
M1
To brake manifold
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Drive Motor Ports Section 3 – System Component Identification and Schematics
3.8 Drive Motor Ports
B
L1 To rotary manifold
To rotary manifold
A
To rotary manifold
X1
To rotary manifold
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Section 3 – System Component Identification and Schematics Jib Valve Ports
3.9 Jib Valve Ports
4H-37 4H-34
Platform right Jib down
4H-36 4H-35
Platform left Jib up
1B 2B
To rotary actuator To jib cylinder
1A 2A
To rotary actuator To jib cylinder
Top
T P1
To main manifold To main manifold
Platform end
of MEWP
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3.10 Main Manifold Ports
A B C D E F G H
GP1
Test port 1 P
GP2 To brake manifold
Test port 2 To high pressure filter V
LA
To lift cylinder AUX
To emergency power unit
LB
To lift cylinder
PLA
To master cylinder T1
To return filter
om
Bott
W
nt
Fro
B
RS
RSB
To riser cylinder
LB
EA SB
To extension cylinder X
LA
t A
e igh RS
w
ter EWP EA RA SA
un
Co of M T A SB
end PL To steer cylinder
T RB SA
To jib lift/platform To steer cylinder
P LB
rotate valve
Y
RB
PP PP To ring gear
EB
To jib lift/platform RA
rotate valve To ring gear
RSA
EB To riser cylinder
To extension cylinder PLB
To master cylinder
Z
M218327AB-2
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3.11 Main Manifold Electrical Components
A B C D E F G H
4H-32
Turret rotate left
4H-40
3H-38 Platform V
Boom retract 4H-33
level down
Turret rotate right
4H-24A
4H-41 Steer left
Count Platform
erw
end of eight level up
MEWP
4H-23A
Steer right W
X
2H-42
Platform rotate
Top
Front Y
2H-21A
3H-39 Dump
Boom extend
4H-14
Boom up Z
4H-13
Boom down 4H-30 4H-31
Riser down Riser up
M218327AB-3
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3.12 Main Manifold Hydraulic Components
A B C D E F G H
CP1 OR3 OR4 V

Cavity plug Orifice CV4 Orifice
Check valve SV4
Shuttle valve CV8
DSV4
CV9 Compensator Check valve
Check valve valve RV6
Relief valve
PFC1
Flow control o t tom W
B
valve
X
nt
Fro
DSV2
Front Compensator
Top
valve
DSV5 RV7
Compensator DSV1 Relief valve Y
valve SV7 Compensator CV7
Shuttle valve valve Check valve
RV8 CV12 CV10
Relief valve Check valve SV6 Check valve
SV5
DSV3 SV8 Shuttle valve
Shuttle valve
CV3
Compensator RV9 Shuttle valve
Coun Check valve CV11
ter valve Relief valve
end o weight Check valve Z
f MEW
P
M218327AB-4
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3.13 Major Components
A B C D E F G H
Upper SCM controller SMB1-106

(inside the control box) Platform control box
Serial plate W
Engine display
(if equipped) Elevate keypad
(if equipped)
Elevate GPS
(if equipped)
Y
Main disconnect switch
(in front of the battery)
ECU
(on the turret side
of the engine)
Lower SCM controller SCM1-108
Emergency power Z
(inside the control box)
unit
Load cell
Base control box (under the platform)
M68931AA
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3.14 Main Harness and Fuel Level Switch Harness
A B C D E F G H
PIN 24 THIS CORNER PIN 1 - 13 - ORANGE PIN 13 - 38 - ORANGE/RED

PIN 2 - 14 - BLACK PIN 14 - 39 - BLACK/RED
PIN 3 - 21A - WHITE/RED PIN 15 - 40 - BLUE/RED
PIN 4 - 23A - BLACK/WHITE PIN 16 - 41 - BLUE/PURPLE Fuel Level Switch Harness V
PIN 5 - 24A - BLUE/BLACK PIN 17 - 45A - YELLOW/ORANGE
PIN 6 - 26 - BLUE/YELLOW PIN 18 - 49A - GREEN/RED
1
PIN 7 - 30 - RED/GREEN PIN 19 - 65 - YELLOW/PINK
PIN 8 - 31 - RED/WHITE PIN 20 - 108 - YELLOW/BROWN [14 GA.]
PIN 9 - 32 - GREEN/BLACK PIN 21 - 165 - PINK/BLACK SOCKET 1 - BLACK
PIN 10 - 33 - GREEN/WHITE PIN 22 - 02 - WHITE (SPLICE #1) [14 GA.] SOCKET 2 - WHITE
PIN 11 - N/U PIN 23 - 02 - WHITE (SPLICE #2) [14 GA.]
PIN 12 - 42 - PINK PIN 24 - 02 - WHITE (SPLICE #3) [14 GA.]
HORN
W
49
A
49A - GREEN/RED
02 - WHITE (SPLICE #1)
02
DIFFERENTIAL LOCK VALVE
PIN 1 - 165 PINK/BLACK
PIN 2 - 02 WHITE
1
AXLE LOCK VALVE
PIN 1 - 65 YELLOW/PINK
PIN 2 - 02 WHITE
1
108 EMERGENCY PUMP
108 - YELLOW/BROWN
BRAKE VALVE 14 GA.
1
PIN 1 - 26 BLUE/YELLOW
PIN 2 - 02 WHITE X
STEER LEFT DUMP VALVE
1
PIN 1 - 24A BLUE/BLACK PIN 1 - 21A WHITE/RED MOTOR TORQUE
1
PIN 1 - 45A YELLOW/ORANGE
1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE (SPLICE #2)
PIN 2 - 02 WHITE
STEER RIGHT
PIN 23A
1 - BLACK/WHITE
1
PIN 2 - 02 WHITE
TURRET ROTATE LEFT RISER UP

PIN 1 - 32 GREEN/BLACK
1
PIN 1 - 31 RED/WHITE
1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE

TURRET ROTATE RIGHT RISER DOWN
PIN 1 - 33 GREEN/WHITE
1
PIN 1 - 30 RED/GREEN
1

Y
PLATFORM LEVEL UP BOOM UP
PIN 1 - 41 BLUE/PURPLE
1
PIN 1 - 14 BLACK
1

PLATFORM LEVEL DOWN BOOM DOWN
PIN 1 - 40 BLUE/RED
1
PIN 1 - 13 ORANGE
1
TELESCOPE IN
PIN 1 - 39 BLACK/RED
1
PIN 2 - 02 WHITE
TELESCOPE OUT FLOW ENABLE Z
PIN 1 - 38 ORANGE/RED PIN 1 - 42
1
M149012AA_S3
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3.15 Engine Harness - D1305
A B C D E F G H
V
POSI AIR OPTION
J4
BACK VIEW
1105
J4 - TO MACHINE CONTROLLER HARNESS
PIN 1 - 57A - BRN/GRN -16
PIN 2 - 74- GRN/GY -16
J3 PIN 3 - 68 -GREY-16
PIN 4 - 76-BRN/BLU-16
BACK VIEW
PIN 5 - CANL - GREEN
PIN 6 - CANH - YELLOW
1 2 3
J3 - TO SPEED SENSOR PIN 7 - 77-BRN/GRY-16
PIN 1 - 1104 - BLUE PIN 8 - PLUGGED
PIN 2 - 1105 - WHITE PIN 9 - PLUGGED
PIN 3 - 1106 - BROWN PIN 10 - PLUGGED
PIN 11 -PLUGGED
PIN 12- PLUGGED
TO MAIN BATTERY DISCONNECT J5
103 - RED BACK VIEW
PIN A - 68 - GREY
PIN B - 00 - WHITE
PIN C - CANH - YELLOW D
PIN D - CANL - GREEN C J5 - TO TEMP. SENSOR
CAP A B P66 2 1
PIN 1 - 105 - BLUE/BLACK
BACK VIEW
S68 SCANL SCANH

PIN 2 - 106 - BLUE/WHITE
P66
103
S1105
TO GLOW PLUG
74-GREEN/GREY-12
74
J2
BACK VIEW J6
BACK VIEW
2
S00 S74 S68B

2
1
J6 - TO ALTERNATOR IGNITION
J2 - TO ACTUATOR SOLENOID PIN 1 - 68B-GREY-18
PIN 1 - 286 - WHITE PIN 2 - 2005 - BLUE
PIN 2 - 86 - PURPLE/BLUE
X
J1 - TO ENGINE CONTROL UNIT

PIN 1 - 105 - BLUE/BLACK
PIN 2 - 1105 - WHITE
PIN 3 - N/U
PIN 4 - N/U
PIN 5 - N/U
PIN 6 - 106 - BLUE/WHITE
PIN 7 - N/U
PIN 8 - 2005 - BLUE
PIN 9 - N/U
PIN 10 - N/U ENGINE FUSEBLOCK
PIN 11 - N/U BACK VIEW
PIN 12 - N/U
PIN 13 - 76 BROWN/BLUE
PIN 14 - N/U
PIN 15 - 2A - WHITE
PIN 16 - 00 - WHITE
PIN 17 - 00 - WHITE
PIN 18 - 00 - WHITE
2A
68B 103C
PIN 19 - 00 - WHITE
103A
TO STARTER 57ACR 74BCR 68A "F6" "F4"
PIN 20 - 1104 - BLUE TO B+ ON ALTERNATOR
103A
PIN 21 - 57F-BRN/GRN-16 RELAY "68CR"
103A - RED TO S00-1 00
PIN 22 - 103C - RED S103 103
1/4" RING 57E-BROWN/GREEN-12 68
57E
PIN 23 - CANH - YELLOW TO STARTER
57F "F2" TO OIL PRESSURE SWITCH
PIN 24 - CANL - GREEN B+ POST "F3"
PIN 25 - N/U 68A 2A - WHITE
5/16" RING
PIN 26 - N/U
PIN 27 - N/U J1 F3 F2 S103B
PIN 28 - N/U 68CR 103B
BACK VIEW 103B 103B
PIN 29 - N/U TO S00-1
PIN 30 - N/U 57A
00
PIN 31 - N/U
232 74B
PIN 32 - N/U F6 F4
PIN 33 - N/U 57A
57E 74
PIN 34 - N/U
PIN 35 - N/U "57ACR" "74BCR"
PIN 37 - N/U
PIN 38 - 77- BRN/GRY-16
PIN 39 - 74B-GRN/GY-18 ENGINE FUSEBOX
PIN 41 - 86 - PURPLE/BLUE
PIN 42 - N/U
PIN 43 - 1106 - BROWN
PIN 44 - 68B-GREY-16
00
TO ENGINE GROUND
00 - WHITE
M236167AJ-2
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3.16 Engine Harness Wiring Diagram - D1305
A B C D E F G H
J2 J3 TO STARTER TO STARTER J6 J5
TO ACTUATOR SOLENOID POSI AIR OPTION TO SPEED SENSOR RELAY B+ POST TO OIL PRESSURE SW. TO B+ ON ALTERNATOR TO ENGINE GROUND TO ALTERNATOR IGNITION TO TEMP. SENSOR TO GLOW PLUG
1 2 1 2 3 1 2 1 2
74-GRN/GY-12
103A-FLK-12
57E-BRN/GRN-12
103A-FLK-12
2A-WH-18
00-WH-12
106-BU/WH-18
105-BU/BK-18
86-PU/BU-16
2005-BU-18
286-WH-16
1105-WH-18
1105-WH-18
1104-BU-18
1106-BN-18
68B-GREY-18
S00 V
L = 661mm/26 "
105-BU/BK-18
1
1105-WH-18 S1105
2
5
106-BU/WH-18
6
7
2005-BU-18
8
10
11
12
W
76-BRN/BLU - 16
13
14
2A-WH-18
15
00-WH-18
16
00-WH-18
17
00-WH-18
18
00-WH-18
19
1104-BU-18
20
57F-BRN/GRN-16
21 68-GREY-16
A
103C-RD-16
J1 22
CANH-YL-18 SCANL CANL-GN-18 P66
TO ENGINE ECU 23 D
CANH-YL-18
CAP DIAGNOSTIC CONN.
CANL-GN-18 SCANH
24 C
25 00-WH-18
B
26
27 X
28
29
30
31
S68B
32
33
34
35
S74
286-WH-16
36
37
77- BRN/GRY-16
38
74B-GRN/GY-18
39
232-WH-18
40
86-PU/BU-16
41
42
S68
43 1106-BN-18
Y
(GLOW PLUG ON)
68B-GREY-16
44
S00-1
57A-BRN/GRN-16
76- BRN/BLU - 16
77- BRN/GRY-16
74 GRN/GY-16
68- GREY- 16
CANL-GN-18
CANH-YL-18
57E--BRN/GRN-12
57A-BRN/GRN-16
57F-BRN/GRN-16
103C-RD-16
232-WH-18
103-RD-10
103-RD-10
00-WH-18
74B-GRN/GY-18
74-GRN/GY-12
68B-GREY-16
68-GREY- 16
00-WH-18
68A-GREY-16
CANH
CANL
1 2 3 4 5 6 7 8 9 10 11 12 F6
TO MAIN BATTERY
DISCONNECT
10A
68CR
J4
TO BASE CONTROL BOX
74BCR 57ACR
103B-RD-12
103B-RD-16
F3
57A-BN/GN-18
103B-RD-12
F4
5A
Z
103-RD-14
S103B
S103 10A
F2
103-RD-12
103B-RD-12 30A
ENGINE FUSEBOX
M236167AJ-3
SJ45 AJ+ 238274AEA

59
3.17 Engine Harness - WG972
A B C D E F G H
TO
LPG
C/O
11B
00
W
BACK VIEW
00,00,57E,11,11A,77,1002,
TO ALTERNATOR 76,1005,1008,1009,1017, A
D
C
B
1030,1044,1054,1060,
1060,3002,CANH,CANL
CAP
103
P66
P1
68,
CANH,
CANL,
00
103 X
57C S57A S1070 S1060-2 S68-1 S00 S1060-1 S68-2 SCANL SCANH
TO STARTER
J2 J1 P3 1060,3002 P2
68
1060, 1009, 1005, 1060, 57A,68,76,

68, 1060, 1008, 57A,
1002,1030,
11A, 1070, 1060 1017
CANL,CANH,
1054,1060 77,11
11B 1070 1060 57C
TO PRE O2 57A,
SENSOR J9 J8 J7 J6 57E P4 1070
00,00
F2 00
68,
1044
F3
1070CR
1060CR
11ACR
57ACR
Y
M238014AC-2
238274AEA SJ45 AJ+

60
3.18 Engine Harness Wiring Diagram - WG972
A B C D E F G H
GND ON DIAGNOSTIC
TO TO FUEL TO CTRL PNL TO BATT. TO ENGINE HARNESS
ENGINE CONN.
LPG PUMP
BLOCK
C/O
P3 P66 P2 P4 P1
1 2 CAP
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
B D C A V
11B-WHITE/ORG-18
00-WHT-18
CANL-GRN-18
68-GREY-14
11-WHITE/ORG-18
11A-WHITE/ORG-18
1017-BRN/WHT-18
1009-BRN/GRN-18
CANH-YEL/BLU-18
11-WHITE/ORG-18
CANH-YEL/BLU-18
57E-BRN/GRN-18
CANH-YEL/BLU-18
1054-PUR/RED-18
1044-RD/WHT-18
57A-BRN/GRN-16
1008-RD/BLK-18
76-BRN/BLU -18
1030-YL/BLU-18
1005-BLU/YL-18
77-BRN/GRY-16
1060-BLK-18
77-BRN/GRY-16
3002-WHT-18
76-BRN/BLU -18
3002-WHT-18
CANL-GRN-18
CANL-GRN-18
1002-WHT-18
1060-BLK-16
1060-BLK-16
00-WHT-18
00-WHT-16
1070-RD-12
68-GREY-14
00-WHT-16
00-WHT-16
00-WHT-16
S68-2
S00 S1060-1
W
SCANH
J1 SCANL
1054-PUR/RED-18
A
1030-YL/BLU-18
PRE O2 B
1060-BLK-18
SENSOR C
1002-WHT-18 J3 F3
D
B
1044-RD/WHT-18
S68-1
5A
68-GREY-18
A
J4 F2
B
57E-BRN/GRN-18
5A
57A-BRN/GRN-14
X
A
1060-BLK-12
J2
1
ALTERNATOR 68-GREY-18
IG 2
3
S57A
J6
1060-BLK-14
B+
103 FLK-12
30
86
57A-BRN/GRN-14
57ACR
STARTER
85
87A
1017-BRN/WHT-18 RELAY
87
57C-BRN/GRN-14
J7 Y
30
1005-BLU/YEL-18
86
B+ 1060-BLK-18
STARTER 103 FLK-12 1060CR
1008-RD/BLK-18 ETV
85
87A
RELAY
87
ST 57C-BRN/GRN-14 S1060-2 1060-BLK-18
J8
S1070
30
1070-RD-12
86
1070-RD-18
1070CR
1009-BRN/GRN-18 POWER
85
87A
RELAY
87
1060-BLK-12
J9
Z
1060-BLK-18
30
86
68-GREY-18
11ACR
11A-WHITE/ORG-18 LPG
85
87A
RELAY
87
11B-WHITE/ORG-18
M238014AC-3
SJ45 AJ+ 238274AEA

61
3.19 Jib and Platform Rotate Harness
A B C D E F G H
A W
CAVITY WIRE NO. COLOUR DESCRIPTION

1 34 ORANGE/BLK JIB DOWN
2 02 WHITE (SPLICE 2) GROUND X

1 35 ORANGE/WHITE JIB UP
2 02 WHITE (SPLICE 2) GROUND

1 36 RED/PURPLE ROTATE CW
2 02 WHITE (SPLICE 1) GROUND Y

1 37 WHITE/RED/BLK ROTATE CCW
2 02 WHITE (SPLICE 1) GROUND
M167698AB
238274AEA SJ45 AJ+

62
3.20 Limit Switch Connections
A B C D E F G H
121
122
29A
09
09
09
09
09
17
29
59
Base Control Box
Terminal Strip
Black (09) Black/White (17) Black (09) Black/White (29A) Black (09) Black/White (59) Black (29) Black/White (29A)
LS1 - Direction Sensing LS2 - Fly Stowed Limit LS3 - Main Boom LS6 - Riser Stowed
Limit Switch Switch Limit Switch Limit Switch
M68651AA
SJ45 AJ+ 238274AEA

63
3.21 SGE Connections
A B C D E F G H
LEGEND VIEW V
04- BLACK SECTION A
61- WHITE
04- BLACK
W
61- WHITE
A
X
PLATFORM
Y
M231422AA_SGE
238274AEA SJ45 AJ+

64
3.22 Moba Load Cell Connections
A B C D E F G H
LEGEND
02- BLACK & BLUE V
04- RED & YELLOW VIEW
CANH- PUR & WHITE SECTION A
CANL- BROWN & GREEN
BLACK
W
BLUE
RED
YELLOW
PURPLE A
WHITE BROWN
GREEN
PLATFORM
M231422AA_Moba
SJ45 AJ+ 238274AEA

65
3.23 Footswitch Connections
A B C D E F G H
VIEW V
SECTION A
LEGEND
04- BLACK
08A- WHITE
04- BLACK
08A- WHITE
X
A
PLATFORM Y
M231422AA_FS
238274AEA SJ45 AJ+

66
3.24 CANbus Cable Connections
A B C D E F G H
VIEW
SECTION B
CANL - WHITE WIRE

W
A
CANH - BROWN WIRE
PLATFORM
VIEW
SECTION A X
BASE
B
Y
Z
CAN2H - BROWN WIRE
CAN2L - WHITE WIRE
M231421AA_CAN
SJ45 AJ+ 238274AEA

67
3.25 Power Cable Connections
A B C D E F G H
V
02- WHITE
04- RED
07A- BLK
VIEW
SECTION B
49- GREEN
A
PLATFORM
BASE
B
VIEW Y
SECTION A
Z
07A- BLK
49- GRN
04- RED
02- WHITE
M231421AA_PWR
238274AEA SJ45 AJ+

68
3.26 All Motion Alarm Connections - CE & AS
A B C D E F G H
ALARM
PASS WIRES THROUGH
TOP-MOST STRAIN RELIEF
(LOOSEN GLAND FIRST)
W
02-WHITE
20-ORANGE/BLUE X
20
02
02
02
02
02
Y
-WIRE INSTALLATION-
M152361AA_S3
SJ45 AJ+ 238274AEA

69
3.27 Flashing Amber Light Connections
A B C D E F G H
20
02
BLACK - 20 WHITE-02
CONTROL COMPARTMENT BASE CONTROL BOX LAYOUT Y
TO LAMP
1
CONNECTOR
M148528AA_S3
238274AEA SJ45 AJ+

70
3.28 Positive Air Shut-off Harness - Kubota D1305
A B C D E F G H
03-GN/PU-14 V
03
00-WH
403
402
00
J1
BACK VIEW 403A J2
S00 BACK VIEW
1
00
A BC
6
7 2 W
8
S403A
J1 3
4
9
PIN 1 - 401 - BLACK 10 5
PIN 2 - PLUG
PIN 3 - 403A - WHITE 410
PIN 4 - 402 - GREEN J2
PIN 5 - PLUG PIN A - 408 - GREEN
PIN 6 - 403 - BLUE PIN B - 403A - WHITE
PIN 7 - 00 - WHITE PIN C - 401 - BLACK
PIN 8 - 408 - GREEN
PIN 9 - PLUG
PIN 10 - 410 - YELLOW
X
03-GN/PU-14
TO CB TO B+
J1 P1
401-BK-14 401-BK-14
1 C
S403A 403A-WH-14 Y
2 B
403A-WH-14 408-GN-14
3 A
402-GN-16 402-GN-16
4 TO SW.
00-WH-16
5 TO SW.
403-BU-14 403-BU-14
6 + TO CB
00-WH-14 S02 00-WH-14
7 - TO BATT.
408-GN-14 403A-RD-16
8 TO LAMP+
00-WH-16
9 TO LAMP- Z
410-YL-16 410-YL-16
10 TO SPD. SENS.
WIRING SCHEMATIC
M238641AB-1
SJ45 AJ+ 238274AEA

71
3.29 Drive Pump Harness - Hengli
A B C D E F G H
V
1 2
2
REV
PIN 1 - 15 - BLUE
PIN 2 - 02 WHITE
1 4
DEUTSCH
2 3
W
PIN 1 - 15 - BLUE
PIN 2 - 02 WHITE
2
PIN 3 - 02 WHITE 1 2
PIN 4 - 16 WHITE/BLACK
FWD X
15-18 BU
PIN 1 - 16 - WHITE/BLACK
1
REV PIN 2 - 02 - WHITE
02-18 WH
2
Y
15-18 BU
1
02-18 WH
2
02-18 WH
3
16-18 WH/BK 16-18 WH/BK
4 1
FWD
02-18 WH
2
M244394AA-2
238274AEA SJ45 AJ+

72
3.30 Hydraulic Schematic - for MEWPs with Eaton drive pumps and motors
A B C D E F G H I J K L M N O
C7 C6
RISER RISER
CYLINDER CYLINDER
SAE 04
C5 C1
PLATFORM LEVELING JIB LIFT
RA2 SLAVE CYLINDER CYLINDER
BOOM ROTATE
SWING DRIVE 2.5 2.5 C4
MASTER
C3
MAIN BOOM LIFT C2/C11 R
1.75 1.75 FLY BOOM EXTENSION
36.2 36.2 CYLINDER CYLINDER
CYLINDER
RA1
CV1 M2 PLATFORM ROTARY
ACTUATOR
RV9
RELIEF VALVE 3.25 2.5
2500 PSI 1.5 1.6
11.63 29.5
CB4 CB3 4.0 2.5 CB14
500 PSI 500 PSI 3.75 3 1.5 CB15
1.5 60 175 3300 PSI 3300 PSI
12.06 CB8 CB7 3:1 3:1 CB13 CB12
CB5 3000 PSI 3000 PSI 3000 PSI 3000 PSI
CB6 3500 PSI 4.5:1 4.5:1 1.5:1 1.5:1
EPU 3500 PSI 1.5:1
1.5:1 SAE 06 CB11 CB10
EMERGENCY 1000 PSI 3000 PSI
POWER UNIT 3:1 4.5:1
SAE 06
SAE 06
12VDC
MOTOR M SV3
SAE 04
SAE 04
CB9
SAE 04
SAE 04
SAE 04
SAE 04
4000 PSI
OR6 3:1
S
SAE 08
CV5
BULKHEAD #1 TOP OF FLYBOOM - AT TIP
CV6
SAE 06
1A 1B 2A 2B
T3 4H-37 4H-36 4H-35 4H-34
RIGHT LEFT UP DOWN
SAE 04
SAE 04
SAE 06
SAE 06
SAE 04
SAE 04
SAE 04
SAE 04
SAE 04
SAE 06
SA SB RA RB RSA RSB PLA PLB LA LB EA EB P T
P1
SV8
PROVISIOIN T
PROVISIOIN FOR
FOR ORIFICE MB3 JIB LIFT & PLATFORM ROTATE
ORIFICE PLUG MANIFOLD
RV8 RV9 PLUG 1/16-27
POWER TRACK CARRIER ASSEMBLY

SV4 2750 SV5 2750 SV6 1/16-27 NPTF
MB2 BRAKE MANIFOLD NPTF
PSI PSI 3H-38
CV4
BOOM
RET
T
SV2 CP1
M1 M2
SV7
V2
LOOP FLUSH
3H-39
BOOM 2H-42
VALVE EXT PLATFORM
4H-33 4H-32 4H-31 4H-30 4H-14 4H-13
RIGHT LEFT UP DOWN UP DOWN
4H-23A 4H-24A
RIGHT LEFT
SAE 04
SAE 04
SAE 04
SAE 04
PR1 PFC1 4H-41 4H-40
UP DOWN
n 0.073"
PRESS.
OR3
OR5 REDUCING DSV2 DSV3 DSV4 DSV5
VALVE AUX
500 PSI OR4
RV7
1750
CV2
QD1
GP1 PSI
U
CE ONLY
P
CV3
TEST4 CV7 CV8
CV9 CV10
CV11 CV12
DSV1
2H-21A RV6
DUMP 3100
T1 PSI
3H-165 3H-65
D AXLE AL
DIFF LOCK SV1
VALVE LOCKOUT
VALVE LS T2
T3 TEST3 GP2 LS MB1 MAIN MANIFOLD
3H-26 SAE 12 SAE 04

3H-45A
BRAKE
2SPD
2 SPEED
VALVE
VALVE ?
?
4.7
V
C8
FRONT AXLE
V1 STEERING CYLINDER
BRAKE SAE 08 SAE 04
RELEASE
V3 OVERRIDE
BRAKE BRG
HAND
PUMP SAE 04
?
?
?
BR
C13
REAR AXLE
DIFF. LOCK
T
SAE 04
2
1.25
2.75
C12
SAE 06
REAR AXLE SAHR

BRAKE CYLINDER
CB1
SAE 04 4800PSI
12:1 W
SAE 04
SAE 06
4.25
3.5
T4
SAE 04
C9/C10
AXLE LOCK-OUT
CYLINDERS
SAE 06
4.25
3.5
CB2
SAE 08 SAE 04 4800 PSI
12:1
M1
DRIVE MOTOR
(17.5 CC/1.07 CIR) A
(40.6 CC/2.48 CIR)
SAE 04
T6
S1 D2 X
B
SAE 12
SAE 12
PUMP DISPL FILTER F1

CONTROL
SAE 04
4H-15 = REVERSE
4H-16 = FORWARD
a b
SAE 10
TP TP
Mb C2 C1 B
V4
BYPASS
Y
VALVE
DIESEL OR
DUAL FUEL RV2
ENGINE 5000 PSI
T6
P1A P2
CHARGE T5
PUMP SYSTEM PUMP
SAE 12
(13.8 CC/
0.84 CIR) (10.8 CC/0.66CIR)
P1
DRIVE PUMP RV3 RV1 (7.43 GPM @ 2600 RPM) T4
(40.6 CC/ 2.48 CIR) 313 PSI 5000 PSI
(27.91 GPM @ 2600 RPM) (8.57 GPM @ 3000 RPM)
(32.21 GPM @ 3000 RPM)
T3
D1 D2 Ma S A T1
TP
T2
SAE 04
F2
RETURN FILTER VIEW OF TANK PORT PHYSICAL LOCATION Z
SAE 16
SAE 12
SAE 16
3.30 Hydraulic Schematic - for MEWPs with

M218470AD T5 T2 T1 Eaton drive pumps and motors
SJ45 AJ+ 238274AEA

73
3.31 Hydraulic Schematic - for MEWPs with Hengli drive pumps and motors
C7 C6
RISER RISER
CYLINDER CYLINDER
SAE 04
C5 C1
PLATFORM LEVELING JIB LIFT
RA2 AC SLAVE CYLINDER CYLINDER
BOOM ROTATE
SWING DRIVE 2.5 2.5 C4 C3
C2/C11
R
1.75 1.75 MASTER MAIN BOOM LIFT
CYLINDER CYLINDER FLY BOOM EXTENSION
36.2 36.2 CYLINDER
RA1
CV1 M2 PLATFORM ROTARY
ACTUATOR
RV9
RELIEF VALVE 3.25 2.5
2500 PSI 1.5 1.6
11.63 29.5
CB4 CB3 4.0 2.5 CB14
500 PSI 500 PSI 3.75 3 1.5 CB15
1.5 60 175 3300 PSI 3300 PSI
12.06 CB8 CB7 3:1 3:1 CB13 CB12
CB5 3000 PSI 3000 PSI 3000 PSI 3000 PSI
CB6 3500 PSI 4.5:1 4.5:1 1.5:1 1.5:1
EPU 3500 PSI 1.5:1
1.5:1 SAE 06 CB11 CB10
EMERGENCY 1000 PSI 3000 PSI
POWER UNIT 3:1 4.5:1
SAE 06
SAE 06
12VDC
MOTOR M SV3
SAE 04
SAE 04
CB9
SAE 04
SAE 04
SAE 04
SAE 04
4000 PSI
OR6 3:1 S
SAE 08
CV5
BULKHEAD #1 TOP OF FLYBOOM - AT TIP
CV6
SAE 06
1A 1B 2A 2B
T3 4H-37 4H-36 4H-35 4H-34
RIGHT LEFT UP DOWN
SAE 04
SAE 04
SAE 06
SAE 06
SAE 04
SAE 04
SAE 04
SAE 04
SAE 04
SAE 06
SA SB RA RB RSA RSB PLA PLB LA LB EA EB P T
P1
SV8
PROVISIOIN T
PROVISIOIN FOR
FOR ORIFICE MB3 JIB LIFT & PLATFORM ROTATE
ORIFICE PLUG MANIFOLD
RV8 RV9 PLUG 1/16-27
POWER TRACK CARRIER ASSEMBLY

SV4 2750 SV5 2750 SV6 1/16-27 NPTF
MB2 BRAKE MANIFOLD NPTF
PSI PSI
CV4 3H-38
BOOM
RET
T
SV2 CP1
M1 M2
SV7
V2
LOOP FLUSH
3H-39
BOOM 2H-42
VALVE EXT PLATFORM
4H-33 4H-32 4H-31 4H-30 4H-14 4H-13
RIGHT LEFT UP DOWN UP DOWN
4H-23A 4H-24A
RIGHT LEFT
SAE 04
SAE 04
SAE 04
SAE 04
PR1 PFC1 4H-41 4H-40
UP DOWN
n 0.073"
PRESS.
REDUCING OR3
OR5 DSV2 DSV3 DSV4 DSV5
VALVE AUX
500 PSI OR4
RV7
1750
CV2
QD1
GP1 PSI
U
CE ONLY
P
CV3
TEST4 CV7 CV8
CV9 CV10
CV11 CV12
DSV1
2H-21A RV6
DUMP 3100
T1 PSI
3H-165 3H-65
D AXLE AL
DIFF LOCK SV1
VALVE LOCKOUT
VALVE LS T2
T3 TEST3 GP2 LS MB1 MAIN MANIFOLD
3H-26 SAE 12
3H-45A
BRAKE
2 SPEED
2SPD
VALVE
VALVE ?
?
4.7
V
C8
FRONT AXLE
V1 STEERING CYLINDER
BRAKE SAE 08
RELEASE
V3 OVERRIDE
BRAKE BRG PORT #1
HAND SAE 04 STEER SAE 04
PUMP RIGHT
?
?
?
BR
PORT #5 C13
SAE 04
STEER LEFT
SAE 04 REAR AXLE
DIFF. LOCK
T
PORT #10
SAE 04 SAE 04
2
1.25
2.75
DIFF.LOCK
C12
SAE 06
REAR AXLE SAHR

SAE 04
PORT #2
SAE 04 BRAKE CYLINDER
AXLE LOCK
PORT #6 CB1
SAE 04
2-SPD
SAE 04 SAE 04 4800PSI
12:1
W
SAE 04
PORT #4 SAE 04 SAE 06
4.25
3.5
BRAKE
T4
PORT #3
TP SAE 04
AXLE PRESS.
SAE 04
C9/C10
AXLE LOCK-OUT
CYLINDERS
PORT #7
50 SAE 12 DRIVE SAE 12
psi REVERSE
PORT #8
SAE 12 DRIVE SAE 12 SAE 06
4.25
3.5
F3 FORWARD
CHARGE FILTER
PORT #9 CB2
SAE 08 MOTOR SAE 08 SAE 04 4800 PSI
DRAIN 12:1
M1
DRIVE MOTOR
(17.5 CC/1.07 CIR) B
(40.6 CC/2.48 CIR)
T6
S1 D2 X
A
SAE 08
SAE 08
FILTER F1
TP
E D
PUMP DISPL
SAE 04
CONTROL
4H-15 = REVERSE M3
4H-16 = FORWARD Ma
SAE 10
M4 A
RV2
5000 PSI
M5
Y
DIESEL OR V4
DUAL FUEL BYPASS
ENGINE VALVE
flow out B T6
CW RV1 P2
5000 PSI T5
SYSTEM PUMP
L2
SAE 12
B
P1 (10.8 CC/0.66CIR)
DRIVE PUMP (HENGLI) P1A RV3 (7.43 GPM @ 2600 RPM) T4
CHARGE 363 PSI
(40.6 CC/ 2.48 CIR) PUMP (8.57 GPM @ 3000 RPM)
(27.91 GPM@2600 RPM) (13.9 CC/
0.84 CIR)
(32.21 GPM@3000 RPM) T3
L1 s Mb
SAE 20
SAE 04
T1
TP
T2
F2
RETURN FILTER VIEW OF TANK PORT PHYSICAL LOCATION Z
SAE 16
SAE 12
T5 T2 T1
3.31 Hydraulic Schematic - for MEWPs with
M246240AA Eaton drive pumps and motors
SJ45 AJ+ 238274AEA

74
3.32 Platform Control Box Wiring
Wire Number and Colour Chart

A3 JOYSTICK A2 JOYSTICK
R
A1 P11
GLAZIER
JOYSTICK ACTIVE
04(RED) POWER RED
04 (RED/YELLOW) POWER RED 02 (WHITE) GROUND BLK
02 (WHITE) GROUND BLK BLACK D-SIGNAL YEL
R(RED/GREEN) R-SIGNAL YL 24A (BLUE/BLACK) LEFT WHT/RED
233A
02
23A (BLACK/WHITE) RIGHT WHT/YEL
NOTE: ZIP TIE

DUAL FUEL READY
S20-PLTF S19-LEVEL S18-TELE S21-JIB
LOOSE END
NEAR DUAL FUEL ROTATE S
RED (+)
WHT (X)
BLU (Y)
BLK (-)
SWITCH LOCATION
04
11
HEAT SHRINK ON RING
165A
04 S28-DIFF.
41A 38A 35A
Y-SIGNAL
GROUND
POWER
X-SIGNAL
165A
04 04 04
37A
36A
04
40A 39A 34A
04 (RED/YELLOW)
PL6
BLUE
02 (WHITE)
RED
02 165B TO J13 ON CONTROLLER PIN 18 - N/U
GRN PIN 1 N/U PIN 19 - R SIG RED/GRN
PIN 2 - 55 YLW/PUR PIN 20 - N/U
GENERATOR READY PIN 3 - 577 PIN 21 - N/U
NOTE:
PIN 4 - 27A RED/BLK/WHT PIN 22 - N/U
ZIP TIE
LOOSE END
PIN 5 - N/U
T
04
85
NEAR GENERATOR
SWITCH LOCATION ECO START NOTE:
PIN 23 - 76 BRN/BLU
HEAT SHRINK ON RING
PL23 LED SHOWN FOR
REFERENCE
GLOW
S48- S10- PIN 6 - 63 GRAY/YEL PIN 24 - N/U
02
FOOTSWITCH TILT OVERLOAD MIL FUEL PIN 7 - 82 BRN/WHT PIN 25 - 08 PUR/WHT
S30-SGE 577
NOTE:
ZIP TIE LOOSE ENDS
PL9 PL8 PL10 PL7 PL6
PLUG
PL5 S6-EPUMP TORQ THROT PIN 8 - 118 PUR/PINK PIN 26 - 40A BLU/RED
S4-E STOP PIN 9 - 74A GRN/GRY PIN 27 - N/U
01 78
S23-HORN PIN 10 - 119 PIN 28 - 37A WHT/RED/BLK
04 04 04 PIN 11 - 120A
63
62 04A 57B 49 07A
PIN 29 - 36A RED/PUR
07A 04
01 45 PIN 12 - 120
04 04 PIN 30 - 165A PINK/BLK
02
02
02
27
82
02
08
02
02
76
55
74
PIN 13 - 27 RED/BLK/WHT
02
04 PIN 31 - 85A GRAY/BLU
04
02
PIN 14 - D BLK
12
10 PIN 15 - Y BLU PIN 32 - 61 GRAY/BRN
PIN 16 - X RED PIN 33 - 62 GRAY/RED
PIN 34 - N/U
S9-IGN PIN 17 - N/U
PIN 35 - 165B PINK/BLK
U
TO J11 ON CONTROLLER
PIN 1 - 04 RED/YEL
PIN 2 - 04 RED/YEL
PIN 3 - 04 RED/YEL
PIN 4 - 04 RED/YEL
PIN 5 - N/U
PIN 6 - SPARE
PIN 7 - SPARE V
PIN 8 - CANH BLK
PIN 9 - CANL WHT
PIN 10 - 02 WHT
PIN 11 - 02 WHT
PIN 12 - 02 WHT
PIN 13 - 02 WHT
PIN 14 - SPARE
J13
12 35
23
11 34
22
10 33
9
21
20
32
02 W
8 31
02
19
7 30
18
6 29
5
17
16
28
02 PIN 18 - 01A PUR/BLK
4 27 TO J12 ON CONTROLLER
3
15
14
26 02 PIN 1 - 37 WHT/RED/BLOK PIN 19 - 04A
2 25
J11 1
13
24 04 PIN 2 - 36 RED/PUR PIN 20 - N/U
04 PIN 3 - N/U PIN 21 - 38A ORG/RED
5 14
PIN 4 - N/U PIN 22 - 41A BLU/PUR
04
9
4 13
3
8
12 PIN 5 - N/U PIN 23 - N/U
2
7
6
11 63(La) La 04 PIN 6 - N/U PIN 24 - 34 ORG/BLK
1 10
02(N)
N
07A PIN 7 - N/U PIN 25 - 233 BLU/BRN
BP4 PIN 26 - 34A ORG/BLK
Lb
08A PIN 8 - N/U
X
J12 PIN 9 - N/U PIN 27 - N/U
12 35
34 PIN 10 -N/U PIN 28 - 35A ORG/WHT
11
10
23
22
34
33
35 PIN 11 -N/U PIN 29 - 78 RED/BLU
9
21
20
32 36 PIN 12 - N/U PIN 30 - 57B BRN/GRN
8 31
PIN 31 - N/U
7
19
18
30 37 PIN 13 - 35 ORG/WHT
PIN 32 - 11 WHT/ORG
PIN 14 - 08A PUR/WHT
6
5
17
29
28
61 PIN 15 - 24A BLU/BLK PIN 33 - 39A BLK/RED
16
4
15
27
CANH PIN 16 - 23A BLK/WHT PIN 34 - N/U
3 26
14
2 25
CANH PIN 17 - 45 YEL/ORG PIN 35 - N/U
120ohm
13
1 24
CANL
CANL
Y
233
233A
04
TOP
27A
118
02
02
SCREW
Z
S30
GLAZIER
BP1 TILT ALARM SWITCH BP3 OVERLOAD ALARM
M218376AG 3.32 Platform Control Box Wiring
SJ45 AJ+ 238274AEA

75
3.33 Base Control Box Wiring - ANSI/CSA & AS
Wire Number and Colour Chart Relay diagrams
BP2
_
+
_
12 35
TT1 23
T
11 34
22
10 33
21
9 32
20
8 31
19
7 30
18
6 29
17
5 28
16
4 27
CB1 3
15
14
26
2 25
13
1 24
(31) (4)
_ 12 35
23
11 34
+
22
10 33
8
21
20
32
31
U
19
7 30
18
6 29
17
5 28
16
4 27
15
3 26
14
2 25
13
1 24
CB2
S13-TUR
S16-ROT
S17 S15- 1 13
-JIB LEVEL 2
3
14
15
07A
CANH
CANH
CANL
09
CANL
09
17
CAN2H
09
09
09
CAN2L
02
02
02
04
02
4 16
5 17
6 18
7 19
8 20
W
9 21
10 22
11 23
12 24
24P-FEMALE
+
_ _ _
J6 BACK VIEW
12 1
11 2
10 3
9
8
4
5 Y
7 6
J4 BACK VIEW
7 6
8 5
9 4
10 3
11 2
12 1
3.33 Base Control Box Wiring - ANSI/CSA

M238013AD & AS
SJ45 AJ+ 238274AEA

76
3.34 Base Control Box Wiring - CE
Wire Number and Colour Chart Relay diagrams
CONNECTOR J1 - TO ENGINE DISPLAY

SOCKET 1 - 02
09-YL-18 SOCKET 2 - 09
02-WH-18 SOCKET 3 - CANH
CANH-BK-18 SOCKET 4 - CANL
CANL-WH-18 SOCKET 5 - N/A
SOCKET 6 - N/A
BACK
J1 VIEW
J3 WHITE
77
03-GN/PU-12
165
TT1
12 35
11 23
11 34
26
20-OR/BU-18 20
57C
10
9
22
21
33
32
122
121
T
128 20
68 8 31 31B
85-GY/BU-18 85 7
19
30
30B
18 36B
03 65
6
17
29
37B
121-GY/RD-18
5 28
77-BN/GY-18
122-GY/YL-18
165-PK/BK-18
118A-PU/PK-18 16
77 02 118A 4 27
CB1 01-PU/BK-18
23
01
3
2
15
14
26
25
40B
45A
15A J1
1
13
24
21A
BLANK
02-WH-18
5 14
CAN2L-GN-18
77-BN/GY-18
9 24
05 4
8
13
CAN2H-YL-18
3 12
CANL-WH-18 118A-PU/PK-18
D57D 09-YL-12 2
7
11
57D-BN/GN-18 6
1 10
57D 57A 57C 02
CANH-BK-18
04ACR 57DCR
57C-BN/GN-18
J2 GREY
02-WH-12
05-PU-14
09
02 _ 42 12 35 40
02 07
09 04A 22kµF 23
11 34
+
39
22 41B
10 33 39B
04A
38 9
21
32
38B
12
33B U
00-WH-12
20
8 31 10
02 29 19
49A 09 41 7 30 57
10A 18
13
49CR
6 29 59
14 5
17
28
32B
35B
BATTERY (B+)
16 13B 03 - BLACK 12 GAUGE Ă5/16"
49 30 4 27 28
15 14B CONNECT TO E-PUMP POWER STUD
31 3 26 34B
02 55 14
108 09 15 2 25 17
01ACR
32 13
00 1 24
03 03
37B-WH/RD/BK-18
16 33
108-YL/BN-18 00
36B-RD/PU-18
01
33B-GN/WH-18
32B-GN/BK-18
04A-RD/YL-18
15
CB2 02
S16-ROT
S13-TUR
02
15A D04
04-RD/YL-18
16
D12 00
02 02-WH-18
09-YL-18 (TYPICAL)
D10-1 BATTERY (B-)
36B
37B
32B
33B
00 - WHITE12 GAUGE Ă5/16"
D10A1
CONNECT TO E-PUMP HOUSING (REAR)
10A
10A
10A
11-WH/OR-18
V
49-GN/RD-18
17-BU/GN-18
85-GY/BU-18
29-GY/OR-18
20-OR/BU-18
59-YL/BU-18
55-YL/PU-18
02-WH-18
68-GY-18
09-YL-12
02-WH-14
10A-BU/WH-18 (TYPICAL)
S17 S15-
40B-BU/RD-18
34B-OR/BK-18
1 13 38-OR/RD-18
13-OR-18
-JIB LEVEL 2 14 39-BK/RD-18

14-BK-18 120ohm 120ohm
40-BU/RD-18
35B-OR/WH-18
3 15
34B 40B
07A
29A
121
CANH
CANH
CANL
165
CANL
09
59
21A-WH/RD-18
09
CAN2H
CAN2L
09
122
09
09
17
02
02
02
04
02
68
11
85
49
29
20
55
41-BU/PU-18
1
2
4 16
10A 10A 23-BK/WH-18
5 17 45A-YL/OR-18
10A-BU/WH-18
10B-BU/WH-18
57-BN/GN-18
35B 41B
24-BU/BK-18
J2
10-BU/WH-18
DEUTSCH
6 18 49A-GN/RD-18
26-BU/YL-18 CONNECTOR J2 - TO DRIVE PUMP VALVE
7 19 65-YL/PK-18 PIN 1 - 15 RED
PL20
41B-BU/PU-18 30-RD/GN-18
3
4
8 20 108-YL/BN-18 PIN 2 - 02 WHITE
PIN 3 - 02 GREEN
S12 S25 OVERLOAD 9 21
31-RD/WH-18
165-PK/BK-18
32-GN/BK-18
BACK VIEW PIN 4 - 16 BLACK W
30B-RD/GN-18
_
+
10 22 02-WH-14
13B-OR-18
S14-TEL BOOM RISER 33-GN/WH-18

10A
10B
02-WH-14 02-WH-12
57
11 23
77 02
CANH-BK-18
CANL-WH-18
07A
31B-RD/WH-18
118A
02
38B-OR/RD-18 02-WH-14
13B 30B
12 24
38B 42-PK-18
14B-BK-18
10A 10A 10A

02
10A
39B-BK/RD-18 14B 31B S5 59-YL/BU-18
SUPP
118A-PU/PK-18
39B 04
12-RD/BK/YL-18
07-RD-18
02-WH-18
IGN. MAIN
77-BN/GY-18
D10A
CANH
CANL
10A-BU/WH-18 (TYPICAL) HARNESS
05-PU-14 10A
24P-FEMALE
07-RD-14 07-RD-14
05
09
(AMBER)
(AMBER)
(AMBER)
(AMBER)
POSIAIR
SPARE
SPARE
GLOW
P224
FUEL
Pl16
PL18
PL3
WIF
MIL
+
+
E-STOP
_ _ _
S2-
NOEM 3 NCLB 1 NC 3
KSW
09
55
02
76
74
02
S3
4 2 4
09-YL-18
X
07
02
07A-RD-18
07A-RD-14
07A-RD-18
02-WH-18
07-RD-14
09-YL-18
02-WH-18
55-YL/PU-18
B+
CONNECTOR J6
B+-GN/PU-18
SOCKET 1 - PLUG J6 BACK VIEW
77 SOCKET 2 - 07A
SOCKET 3 - B+
SOCKET 4 - 00
12 1
SOCKET 5 - PLUG
11 2
07A-RD-18 SOCKET 6 - PLUG
00-WH-18
CANH-BK-18
J6 SOCKET 7 - CAN H
10
9
3
4
Y
SOCKET 8 - CAN L 8 5
CANL-BK-18
SOCKET 9 - 57D 7 6
57D-BN/GN-18
SOCKET 10 - PLUG
SOCKET 11 - PLUG
SOCKET 12 - PLUG
57A-BN/GN-18 CONNECTOR J4
74-GN/GY-18 SOCKET 1 - 57A J4 BACK VIEW
68-GY-18 SOCKET 2 - 74
09-YL-18 76-BN/BU-18 J4 SOCKET 3 - 68
CANL-WH-18 SOCKET 4 - 76
AT1
28-GN-18 6
CANH-BK-18 SOCKET 5 - CANL 7
02-WH-18
SOCKET 6 - CANH 8 5
128-BK/YL-18
ANGLE 11-WH/OR-18 SOCKET 7 - PLUGGED
SOCKET 8 - 11
9
10
4
3
AT1 SENSOR CONNECTION
TRANS. PIN 1 - 09 YELLOW
SOCKET 9 - PLUGGED
SOCKET 10 -PLUGGED
11
12
2
1
SOCKET 11 -PLUGGED
PIN 2 - 28 GREEN SOCKET 12 -PLUGGED
PIN 3 - 02 WHITE
PIN 4 - 128 BLACK/YELLOW Z
M238425AB 3.34 Base Control Box Wiring - CE
SJ45 AJ+ 238274AEA

77
SJ45 AJ+
M238035AD
A
Relay diagrams
OPTION - TELEMATICS
FU1
B+ 1 AMP
CAN L
8 3 IEC 9.1
CAN H 7 TRACK UNIT 00

4
07A(KEY) 2
9
JMPR
S2 REMOVE WHEN
S4 KEY SWITCH
EMERGENCY BOOM S3 OPTION
57D
OFF/BASE/PLATFORM EMERGENCY INSTALLED
STOP CABLE
(IN OFF POSITION) S1
TRACK STOP DISCONNECT 1
CB1 15 AMP SWITCH
04 07A 07A BLACK 07A 07 05 05 03 + - 00 2 BATTERY
PL12 02 NCHO CB2 15 AMP
PL21 09 C1=22kuF 00 00 3
B
04ACR 108CR 4
04 RED 04 D04 04A 02 03
M1 5
108 EMERGENCY PUMP
D10A D10
02 02 WHITE 02 6
S23
HORN SWITCH 7
49CR
49 49 GREEN 49 49 02 02
8
H1
HORN 9
02
07 09 49A
PLATFORM LOAD SENSOR-CAN 10
11
04 YL BU 02 02 09
3.35 Electrical Schematic - ANSI/CSA & AS
SMB1-108 12
04 RD AD BK 02 02
C
13
J1.1 09
VIO CAN1+ 14
J1.2 09
BN CAN1- 03 00 15
J1.3 09
WH CAN2+ 07A BASE 10 J2.31 TO ENGINE TO ENGINE
STARTER POST GROUND 16
J1.4 09 01ACR
NC 108
GN CAN2-
17
07A J3.2 01A 02
PLATFORM 12 J2.20
NO 18
D57D ENGINE DETAIL ON SHEET 2 & 3
19
SMB1-106 57DCR
S5 09 57D
IGNITION/ENABLE 20
S30 SWITCH
GLAZIER J3.9 57C 57C 57A 57A 21 ENGINE START
57 ENGINE START 57 J2.30
1
SWITCH 233 J12.25 GLAZIER ON 10 PL18

10A 10A J2.18 02 PREHEAT 74 22 PREHEAT/GLOW PLUG INDICATOR
2
04 PL11
D
233A 233A 02
+
ENABLE or J3.8 68 -
68
RUN ENABLE
3
E-PUMP 23
R3= 120 MIL
04 J11.1 J11.10 02 ohm 09 PL3 76
4
MIL
+
- 24
04 CAN SHLD CAN L
J11.2 J11.11 02
5
25 J1939 COMMUNICATION
J1.6 CAN H CAN H
6
04 J11.3 J11.12 02
J1.7 CAN L P4 26
7
04 J11.4 J11.13 02
J3.23 27
11 11
8
S49
04 DUAL FUEL 28
9
LPG 11A J12.32

29
S6
10
E-PUMP J3.12 02
04 01 J12.18 R1= 120 R2= 120 77
TT 30 HOURMETER
11
ohm ohm
S9
IGNITION
12
PL22 31
4 START 57B J12.30 J11.8 CAN 2H CAN 2H J1.8 J2.14 55 LOW FUEL 02
BROWN
E
04 5 32 FUEL INDICATOR
FS1 LOW + -
6 J11.9 CAN 2L WHITE CAN 2L J1.9 FUEL SWITCH
1 RUN 04A J12.19 55 33
04 09
2
CAN SHLD
S48 34
3
DRIVE TORQUE
SWITCH BP4
ECO START OVERLOAD ALARM 35
04 J13.3 577 PL23 02
LOW TORQUE 45 J12.17 118A
36 OVERLOAD ALARM
AS REGION ONLY J3.4 118A
S10 OVERLOAD 37
OVERLOAD ALARM 118A PL20
THROTTLE 02
BP3
SWITCH J13.8 118 38
04
2600RPM/3000RPM 78 J12.29 OVERLOAD 39
J13.7 82 PL10 02
S11 40
FOOT BP1
SWITCH J13.4 TILT ALARM 41
04 08A J12.14 27A
F
LS6 LS2 42
FOOTSWITCH
RISER STOWED FLY STOWED
J13.25 08 PL9 02 43
NORMALLY NORMALLY
S22 CLOSED CLOSED
ELECTRICAL 44
TILT J2.19 09
GENERATOR 29 29A
J13.13 27 PL8 02 S12 45
04 LS3
85 J13.31 MAIN LIFT MAIN BOOM
UP/DOWN 46
S28 J2.15 NORMALLY
UP 14B
DIFF LOCK CLOSED
10A J2.29 47
SWITCH DN 13B J2.16 59 09
BOOM TURRET LIMIT SWITCHES
ENGINE FAULT (MIL) S14 48
04 165A J13.30
J13.23 76P PL7 TELESCOPE 02 02
02 49
RET/EXT SUPPR.
IN 38B J2.21
10A J3.25 45A 45A 3H-45A 50
J12.21 LOW FUEL
IN 38A OUT 39B J2.33 MOTOR 2-SPEED VALVE
S18 J13.2 55 PL6 02 SUPPR.
04 S13 (COIL ON = HIGH SPEED)
G
TELESCOPE 51
39A J12.33 TURRET
IN/OUT OUT ROTATE SUPPR. 52
GLOW PLUG 02
LT 32B J2.17
J13.9 74 PL5 02 10B
10A J3.24 2H-21A 53
RT 33B J2.32 21A 21A 02 DUMP VALVE
41A J12.22
UP LOW CAPACITY 54
S19 04 OPTION - GENERATOR
PLATFORM 40A J13.26 J13.12 120 PL4 02 60AJ S15 55
LEVEL DN ONLY PLATFORM EXCITE RELAY - INSIDE GENERATOR
LEVELING J3.7 85 85 02 OPTIONAL GENERATOR
HI CAPACITY UP 41B J2.22 56
PL3
10A
J13.11 120A 02 40B J3.26 OPTION - BEACON
DN 57
LT 36A J13.29
S16 20 02
S20 04
LOAD ZONE BORD. PLATFORM 58 OPTIONAL STROBE LIGHT
PLATFORM 37A J13.28 LB2
ROTATE RT PL2
ROTATE
J13.10 119 02 36B J3.29 J3.10
LT 20 20 02 59
10A ALL MOTION ALARM
DIFF LOCK ON RT 37B J3.28 BP2 60
H
S21 J12.28 J13.35 165B PL11

UP 35A 02 J3.35 165 165 3H-165
JIB 04
61 DIFFERENTIAL LOCK
UP/DOWN AT1 - CHASSIS
34A J12.26 SUPPR.
DN 62
ANGLE TRANSDUCER
S17 N.C. HELD OPEN LS1 & TILT SWITCH
DIRECTION BP5 63
JIB UP/DOWN WITH ENGINE OVER 20 02
UP 35B J2.28 J2.25 STEERING AXLE SENSING 09 OPTION
BOOM/TUR 17 64
04 X J13.16 10A WHITE NOISE ALARM
Vbat Xaxis 34B J2.26 128
DN J3.20 02
A1 Y J13.15 128 65
BOOM/TURRET Yaxis
JOYSTICK J2.27 28 28 66
02
Gnd
LS4
121 NC HELD OPEN 67
J3.32 LS4 09
BOOM DOWN
A2 04 DRIVE 24A S25 68
J12.15
DRIVE/STEER Vbat Left RISER UP/DOWN J3.33 122 LS5 09
JOYSTICK 4H-36 UP 31B J3.31 69
23A J12.16 J12.2 36 LS5
Right PLATFORM LEFT 10A NC
I
D J13.14 J12.1 4H-37 DN 30B J3.30 FLY OUT

70
37 60AJ ONLY
Output PLATFORM RIGHT 3H-16
J2.1 16 16 71 FORWARD DRIVE VALVE
02 3H-15
Gnd
J2.2 15 15 72 REVERSE DRIVE VALVE
J12.13 35 4H-35 J3.34 3H-26
26 26 02 73 BRAKE VALVE
JIB UP
A3 04 RISER R J13.19 J12.24 4H-34
34 SUPPR. 02
RISER Vbat Output JIB DOWN 74
JOYSTICK J3.5 3H-65
02 65 65 02
R 75
SUPPR. 02 AXLE LOCK VALVE
76 (COIL ON = FLOATING AXLE)
J3.13 24 24 4H-24
02 77
SUPPR. 02
78 LEFT STEER VALVE
J3.3 23 23 4H-23 02
79
J
SUPPR. 02
80 RIGHT STEER VALVE
SENSOR BAR 4H-14
J2.5 14 14
J13.32 81 BOOM UP VALVE
04 61
J2.6 13 13 4H-13
82 BOOM DOWN VALVE
BP6
S30 83
J13.33 J13.6 SIREN 4H-38
62 63 J2.9 38 38 84 TELESCOPE IN VALVE
63 J2.10 39 39 4H-39
BEACON 85 TELESCOPE OUT VALVE
SGE 86
RESET J2.13 32 32 4H-32
87 TURRET ROTATE LEFT VALVE
J2.24 33 33 4H-33
88 TURRET ROTATE RIGHT VALVE
K
89
J2.7 41 4H-41
41 90 PLATFORM LEVEL UP
J2.35 40 40 4H-40
91 PLATFORM LEVEL DOWN
J2.12 42 42 2H-42
92 PROPORTIONAL FLOW ENABLE
J2.3 31 31 4H-31
93 RISER UP VALVE
J2.4 30 30 4H-30
94 RISER DOWN VALVE
95
J2.8 13A 13A 2H-13A
96 BOOM DOWN THROTTLE VALVE
60AJ 97
LOW CAP ONLY
J3.6 120 PL15 02
120 98 LOW CAP INDICATOR
L
HIGH CAP 99
J3.11 120A PL14 02
120A
100 HIGH CAP INDICATOR
LOAD ZONE BORDER
J3.1 119 PL13 02 101
119
BORDER ZONE INDICATOR
J1.10 02 102
02
J1.11 02 02 103
J1.12 02 02 104
J1.13 02 02 105
106
107
M
108 110V PLATFORM POWER

BELT-DRIVEN
3.5KW/7.5kW GENERATOR 109
OPTIONAL GENERATOR
OPTION 110
110A WHITE 110A 110A
110A
110B 110B 110B CB6 15 AMP

BLACK 110B 110C
M F
GND GREEN GND
NOTE: WITH BELT-DRIVEN GENERATOR OPTION
MALE AND FEMALE PLUGS ARE CONNECTED
CB5 30 AMP WELDER

WHITE WHITE
GENERATOR
RED RED 3Ø
N
F OPTION
BLACK BLACK
GREEN GREEN
110A
CB6 15 AMP
110B 110C
F
NOTE: WITH WELDER GENERATOR OPTION

O
3.35 Electrical Schematic - ANSI/CSA & AS

Z
T
Y
X
S
R
238274AEA
78
SJ45 AJ+
M238036AD
A
Relay diagrams
OPTION - TELEMATICS
FU1
B+ 1 AMP
CAN L 8 3 IEC 9.1
CAN H 7
00
TRACK UNIT 4
07A(KEY) 2
9
JMPR
S2 REMOVE WHEN
S4 KEY SWITCH
EMERGENCY BOOM S3 OPTION
57D
CABLE OFF/BASE/PLATFORM EMERGENCY INSTALLED + V -
STOP S1
B
TRACK (IN OFF POSITION) STOP DISCONNECT CHARGE INDICATOR 1

CB1 15 AMP SWITCH
04 07A 07A BLACK 07A 07 05 05 03 + - 00
3.36 Electrical Schematic - CE
2 BATTERY
PL12 02 NCHO CB2 15 AMP
PL21 09 C1=22kuF 00 00 3
04ACR 108CR 4
04 RED 04 D04 04A 02 03
M1 5
108 EMERGENCY PUMP
D10A D10
02 02 WHITE 02 6
S23
HORN SWITCH 7
49CR
49 49 GREEN 49 49 02 02
8
H1
HORN 9
02
07 09 49A
PLATFORM LOAD SENSOR-CAN 10
C
11
04 YL BU 02 02 09
SMB1-108 12
04 RD AD BK 02 02
13
J1.1 09
VIO CAN1+ 14
J1.2 09
BN CAN1- 03 00 15
J1.3 09
WH CAN2+ 07A BASE 10 J2.31 TO ENGINE TO ENGINE
STARTER POST GROUND 16
J1.4 09 01ACR
NC 108
GN CAN2-
17
07A J3.2 01A 02
PLATFORM 12 J2.20
NO 18
D57D ENGINE DETAIL ON SHEET 2 & 3
D10-1 D12
10B 19
SMB1-106 57DCR
D
S5 09 57D
IGNITION/ENABLE 20
S30 SWITCH
GLAZIER J3.9 57C 57C 57A 57A 21 ENGINE START
57 ENGINE START 57 J2.30
1
SWITCH 233 J12.25 GLAZIER ON 10B PL18

10A 10A J2.18 02 PREHEAT 74 22 PREHEAT/GLOW PLUG INDICATOR
2
04 233A PL11 02
233A
+
ENABLE or J3.8 68 -
68
RUN ENABLE
3
E-PUMP 23
R3= 120 MIL
04 J11.1 J11.10 02 ohm 09 PL3 76
4
MIL
+
- 24
04 CAN SHLD CAN L
J11.2 J11.11 02
5
25 J1939 COMMUNICATION
J1.6 CAN H CAN H
6
04 J11.3 J11.12 02
J1.7 CAN L P4 26
7
04 J11.4 J11.13 02
J3.23 27
11 11
8
28
9
S6 29
E
10
E-PUMP J3.12 77 02
04 01 J12.18 R1= 120 R2= 120 TT 30 HOURMETER
11
ohm ohm
S9
IGNITION
12
PL22 31
4 START 57B J12.30 J11.8 CAN 2H CAN 2H J1.8 J2.14 55 LOW FUEL 02
04 BROWN
5 32 FUEL INDICATOR
FS1 LOW + -
6 J11.9 CAN 2L WHITE CAN 2L J1.9 FUEL SWITCH
1 RUN 04A J12.19 55 33
04 09
2
CAN SHLD BP4
S48 34
3 OVERLOAD ALARM
DRIVE TORQUE
SWITCH ECO START 118A 35 OVERLOAD ALARM
04 J13.3 577 PL23 02
LOW TORQUE 45 J12.17 J3.4 118A
OVERLOAD 36
OPTION - CE 118A PL20 02
S10 OVERLOAD ALARM 37
THROTTLE
BP3
SWITCH J13.8 118 38
04
F
2600RPM/3000RPM 78 J12.29 OVERLOAD 39

J13.7 82 PL10 02
S11 40
FOOT BP1
SWITCH J13.4 TILT ALARM 41
04 08A J12.14 27A
LS6 LS2 42
FOOTSWITCH
RISER STOWED FLY STOWED
J13.25 08 PL9 02 43
NORMALLY NORMALLY
S22 CLOSED CLOSED
ELECTRICAL 44
TILT J2.19 09
GENERATOR 29 29A
J13.13 27 PL8 02 S12 45
04 LS3
85 J13.31 MAIN LIFT MAIN BOOM
UP/DOWN 46
S28 14B J2.15 NORMALLY
UP CLOSED
DIFF LOCK 10A
SWITCH DN J2.29 59 09 47
13B J2.16
BOOM TURRET LIMIT SWITCHES
48
G
04 ENGINE FAULT (MIL) S14

165A J13.30 TELESCOPE 02 02
J13.23 76P PL7 02
RET/EXT 49
IN 38B J2.21 SUPPR.
10A J3.25 45A 45A 3H-45A 50
J12.21 LOW FUEL
IN 38A OUT 39B J2.33 MOTOR 2-SPEED VALVE
S18 J13.2 55 PL6 02 SUPPR.
04 S13 51 (COIL ON = HIGH SPEED)
TELESCOPE
39A J12.33 TURRET
IN/OUT OUT ROTATE SUPPR. 52
GLOW PLUG 02
LT 32B J2.17
J13.9 74 PL5 02 10B
10A J3.24 2H-21A 53
RT 33B J2.32 21A 21A 02 DUMP VALVE
41A J12.22
UP LOW CAPACITY 54
S19 04 OPTION - GENERATOR
PLATFORM 40A J13.26 J13.12 120 PL4 02 60AJ S15 55
LEVEL DN ONLY PLATFORM EXCITE RELAY - INSIDE GENERATOR
LEVELING J3.7 85 85 02 OPTIONAL GENERATOR
HI CAPACITY UP 41B J2.22 56
PL3
10A
J13.11 120A 02 40B J3.26 OPTION - BEACON
DN 57
LT 36A J13.29
H
S16 20 02
S20 04
LOAD ZONE BORD. PLATFORM 58 OPTIONAL STROBE LIGHT
PLATFORM 37A J13.28 LB2
ROTATE RT PL2
ROTATE
J13.10 119 02 36B J3.29 J3.10
LT 20 20 02 59
10A ALL MOTION ALARM
DIFF LOCK ON RT 37B J3.28 BP2 60
OPTION-CE
S21 J12.28 J13.35 165B PL11
UP 35A 02 J3.35 165 165 3H-165
JIB 04
61 DIFFERENTIAL LOCK
UP/DOWN AT1 - CHASSIS
34A J12.26 SUPPR.
DN 62
ANGLE TRANSDUCER
S17 N.C. HELD OPEN LS1 & TILT SWITCH BP5
JIB UP/DOWN WITH ENGINE OVER DIRECTION 20 02 63 WHITE NOISE ALARM
UP 35B J2.28 J2.25 STEERING AXLE SENSING 09 OPTION
BOOM/TUR 17 64
04 X J13.16 10A WHITE NOISE ALARM
Vbat Xaxis 34B J2.26 128
DN J3.20 02
A1 Y J13.15 128 65
BOOM/TURRET Yaxis
JOYSTICK J2.27 28 28 66
02
Gnd
LS4
I
121 NC HELD OPEN 67

J3.32 LS4 09
BOOM DOWN
A2 04 DRIVE 24A S25 68
J12.15
DRIVE/STEER Vbat Left RISER UP/DOWN J3.33 122 LS5 09
JOYSTICK 4H-36 UP 31B J3.31 69
23A J12.16 J12.2 36 LS5
Right PLATFORM LEFT 10A NC
D J13.14 J12.1 4H-37 DN 30B J3.30 FLY OUT
70
37 60AJ ONLY
Output PLATFORM RIGHT 3H-16
J2.1 16 16 71 FORWARD DRIVE VALVE
02 3H-15
Gnd
J2.2 15 15 72 REVERSE DRIVE VALVE
J12.13 35 4H-35 J3.34 3H-26
26 26 02 73 BRAKE VALVE
JIB UP
A3 04 RISER R J13.19 J12.24 4H-34
34 SUPPR. 02
RISER Vbat Output JIB DOWN 74
JOYSTICK J3.5 3H-65
02 65 65 02
R 75
SUPPR. 02 AXLE LOCK VALVE
76 (COIL ON = FLOATING AXLE)
J
J3.13 24 24 4H-24
02 77
SUPPR. 02
78 LEFT STEER VALVE
J3.3 23 23 4H-23 02
79
SUPPR. 02
80 RIGHT STEER VALVE
SENSOR BAR 4H-14
J2.5 14 14
J13.32 81 BOOM UP VALVE
04 61
J2.6 13 13 4H-13
82 BOOM DOWN VALVE
BP6
S30 83
J13.33 J13.6 SIREN 4H-38
62 63 J2.9 38 38 84 TELESCOPE IN VALVE
63 J2.10 39 39 4H-39
BEACON 85 TELESCOPE OUT VALVE
K
SGE 86
RESET J2.13 32 32 4H-32
87 TURRET ROTATE LEFT VALVE
J2.24 33 33 4H-33
88 TURRET ROTATE RIGHT VALVE
89
J2.7 41 4H-41
41 90 PLATFORM LEVEL UP
J2.35 40 40 4H-40
91 PLATFORM LEVEL DOWN
J2.12 42 42 2H-42
92 PROPORTIONAL FLOW ENABLE
J2.3 31 31 4H-31
93 RISER UP VALVE
J2.4 30 30 4H-30
94 RISER DOWN VALVE
95
L
J2.8 13A 13A 2H-13A

96 BOOM DOWN THROTTLE VALVE
60AJ 97
LOW CAP ONLY
J3.6 120 PL15 02
120 98 LOW CAP INDICATOR
HIGH CAP 99
J3.11 120A PL14 02
120A
100 HIGH CAP INDICATOR
LOAD ZONE BORDER
J3.1 119 PL13 02 101
119
BORDER ZONE INDICATOR
J1.10 02 102
02
J1.11 02 02 103
J1.12 02 02 104
M
J1.13 02 02 105
106
107
108 110V PLATFORM POWER

BELT-DRIVEN
3.5KW GENERATOR 109
OPTIONAL GENERATOR
OPTION 110
110A WHITE 110A 110A
110A
110B 110B 110B CB6 15 AMP

BLACK 110B 110C
M F
GND GREEN GND
NOTE: WITH BELT-DRIVEN GENERATOR OPTION
N
O
3.36 Electrical Schematic - CE

Z
T
Y
X
S
R
238274AEA
79
3.37 Engine Schematic - Kubota D1305
57E-BN/GN-12
DIESEL ENGINE STARTER

RELAY
R
TO MAIN TO BATTERY
DISCONNECT B- POST
POSI AIR OPTION STARTER
ACTUATOR SOLENOID SPEED SENSOR SOLENOID TEMP. SENSOR GLOW PLUG
OIL PRESSURE SW.
03
401 STARTER
00
C 1
105-BU/BK-18
AUTOMATIC REV. CB40
106-BU/WH-18
SHUT OFF
A 408 8 LIMITER 20A M
U SOLENOID
74-GN/GY-12
2A-WH-18
403 03
00-WH-18
403A
86-PU/BU-16
286-WH-16
n B 3 6
7 10 4
1 2 3
2005-BU-18
403A
410
1105-WH-18
1106-BN-18
402
1104-BU-18
FLK
00
G 2 1
3
+
103-RD-10
FUSE LINK ALTERNATOR
PL40 S40 U
1105-WH-18
68B-GY-18
SHUT-OFF t
AIR S.O.
TEST S
-
SWITCH COOLANT
00
00
TEMPERATURE
SENSOR
105-BU/BK-18
1
1105-WH-18
2
5
106-BU/WH-18
6
7 T
2005-BU-18
8
10
11
12
76-BN/BU - 16
13
14
2A-WH-18
15
00-WH-18
16
00-WH-18 U
17
00-WH-18
18
00-WH-18
19
1104-BU-18
20
57F-BN/GN-16
21
103C-RD-16
J1 22
TO ENGINE ECU CANH-YL-18
23
CANL-GN-18
24
25
26
V
27
28
29
30
31
32
33
34
35
286-WH-16
36 W
37
38
74B-GN/GY-18
39
232-WH-18
40
86-PU/BU-16
41
42
43 1106-BN-18
(GLOW PLUG ON)
68B-GY-16
44
X
76- BN/BU - 16
57A-BN/GN-16
74 GN/GY-16
CANL-GN-18
CANH-YL-18
57E--BN/GN-12
57A-BN/GN-16
57F-BN/GN-16
103C-RD-16
232-WH-18
103-RD-10
00-WH-18
74B-GN/GY-18
74-GN/GY-12
68B-GY-16
68-GY- 16
00-WH-18
68- GY- 16
CANH
CANL
1 2 3 4 5 6 7 8 9 10 11 12
F6
10A
74BCR 57ACR
J4 68CR
TO BASE CONTROL BOX
Y
103B-RD-12
103B-RD-12
103B-RD-16 68A-GY-16
57A-BN/GN-18 F3
5A
103-RD-14 F4
10A
103-RD-12 F2
30A
103B-RD-12
ENGINE FUSEBOX
Z
TO
ENGINE
GROUND
M238035AA-2 3.37 Engine Schematic - Kubota D1305
SJ45 AJ+ 238274AEA

80
3.38 Engine Schematic - Kubota WG972
DUAL FUEL ENGINE LPG

CUT-OFF
FUEL
PUMP
P2
TO BASE CONTROL BOX TO BATT. B+ TO ECU
R
P1
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
30A
F1
FP
CANH-YL/BU-18
76- BN/BU - 16
57A-BN/GN-16
11-WH/OR-18
CANL-GN-18
11B-WH/OR-18
1044-RD/WH-18
CANH-YL/BU-18
1017-BN/WH-18
1009-BN/GN-18
68- GY- 16
1054-PU/RD-18
1008-RD/BK-18
1030-YL/BU-18
11A-WH/OR-18
2 3
1005-BU/YL-18
1
57E-BN/GN-18
1 S
11-WH/OR-18
P3
76-BN/BU-18
P4
3002-WH-18
CANL-GN-18
1060-BK-16
1060-BK-16
1002-WH-18
00-WH-18
00-WH-16
00-WH-16
00-WH-16
00-WH-16
1060-BK-16
3002-WH-18
1070-RD-12
GND ON
ENGINE
BLOCK
J1
1054-PU/RD-18
A
1030-YL/BU-18
PRE O2 B
SENSOR 1060-BK-18
C
1002-WH-18
D
1044-RD/WH-18
U
5A
F3
68-GY-18
57E-BN/GN-18
5A
F2
57A-BN/GN-14
V
1060-BK-12
57C-BN/GN-14
STARTER
RELAY 1017-BN/WH-18 W
57A-BN/GN-14
STARTER
57ACR
SOLENOID STARTER
TO BATTERY RELAY
TO MAIN 1060-BK-14
DISCONNECT B- POST
103 00
STARTER 57C-BN/GN-14
M
68-GY-16 1008-RD/BK-18
1060-BK-18
FLK B+ G 1060CR X
FUSE LINK
3
ALTERNATOR
ELECTRONIC
THROTTLE VALVE
1005-BU/YL-18 RELAY
1060-BK-18
1009-BN/GN-18
1070-RD-18
1070CR
POWER
RELAY
1070-RD-12 Y
1060-BK-12
11A-WH/OR-18
68-GY-18
11ACR
LPG
RELAY
1060-BK-18
11B-WH/OR-18 Z
M238035AA-3 3.38 Engine Schematic - Kubota WG972
SJ45 AJ+ 238274AEA

81
Notes
238274AEA SJ45 AJ+

82
Section 4 – Troubleshooting Information
4.1 Introduction
The following pages contain a table of
Troubleshooting for locating and correcting most
service trouble which can develop. Careful and
accurate analysis of the systems listed in the table
of Troubleshooting will localize the trouble more
quickly than any other method. 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 occurs, 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 in the left-
hand column, preceded by a number, represents the
“probable cause.” The information in the right-hand
column, in bold text, represents the “remedy” to the
“probable cause” directly beside it. See the example
below for clarification.
1. Probable cause Remedy
SJ45 AJ+ 238274AEA

83
Section 4 – Troubleshooting Information Electrical System
4.2 Electrical System
4.2-1 All Controls are Inoperative from the Base or Platform Console
NOTE
Functions may be disabled by the dual load zone system or the overload system. Please first
make sure the boom is at or below level and fully retracted, the platform is level and free of added
weight, and there are no faults in the dual load or overload systems.
1. Battery cables loose/disconnected Tighten or connect battery cables

2. Battery Discharged or Defective Charge battery or replace if defective
3. Loose or broken B+ cable from batteries to Check continuity. Replace if defective.
battery disconnect switch S1
4. Open or defective battery disconnect switch S1 Close switch. Replace if defective
5. Loose or broken wire #03 from battery Check continuity. Replace if defective
disconnect switch S1 to circuit breaker CB1
6. Circuit breaker CB1 tripped or defective. Reset breaker, check for defective wiring. Replace
if defective.
7. Loose or broken wire #05 from circuit breaker Check continuity. Replace if defective.
CB1 to base emergency stop switch S3.
8. Open or defective base emergency stop switch Close switch. Replace if defective.
S3.
9. Loose or broken wire #07 from base emergency Check continuity. Replace if defective.
stop switch S3 to base key switch S2.
10. Loose or broken #07A wires between base key Check continuity. Replace if defective.
switch S2 terminals
11. Open or defective key select switch S2 Close switch. Replace if defective
12. Loose or broken wire #04A from base terminal Check continuity. Replace if defective.
block to relay 04ACR.
13. Loose or broken wire #07 from base emergency Check continuity. Replace if defective.
stop switch S3 to relay 04ACR.
14. Loose or broken wire #02 from relay 04ACR to Check continuity. Replace if defective.
base terminal block.
15. Defective relay 04ACR. Check relay. Replace if defective.
16. Loose or broken wire #09 from relay 04ACR to Check continuity. Replace if defective.
base terminal block.
238274AEA SJ45 AJ+

84
Electrical System Section 4 – Troubleshooting Information
17. Loose or broken wire #09 from base terminal Check continuity. Replace if defective.
block to base control module connector J1 pins
1, 2, 3, and/or 4.
18. Loose or broken wire #02 from base control Check continuity. Replace if defective.
module connector J1 pins 10, 11, 12, and/or 13
to base terminal block.
19. Loose or broken wire #02 from base terminal Check continuity. Replace if defective.
block to circuit breaker CB2.
20. Circuit breaker CB2 tripped or defective. Reset breaker, check for defective wiring. Replace
if defective.
21. Loose or broken wire #00 from circuit breaker Check continuity. Replace if defective.
CB2 to battery negative.
22. Loose or broken wire #07A from base key Check continuity. Replace if defective.
switch S2 to base terminal block.
23. Loose or broken wire #07A from base terminal Check continuity. Replace if defective.
block to platform terminal block.
24. Loose or broken wire #07A from platform Check continuity. Replace if defective.
terminal block to platform emergency stop switch
S4.
25. Open or defective platform emergency stop Close switch. Replace if defective.
switch S4.
26. Loose or broken wire #04 from platform Check continuity. Replace if defective.
emergency stop switch S4 to platform terminal
block.
27. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block platform control module connector J11
pins 1, 2, 3, and/or 4.
28. Loose or broken CAN H wire from platform Check continuity. Replace if defective.
control module connector J11 pin 8 to platform
terminal block
29. Loose or broken CAN H wire from platform Check continuity. Replace if defective.
terminal block to base terminal block.
30. Loose or broken CAN H wire from base terminal Check continuity. Replace if defective.
block to base control module connector J1 pin 8.
31. Loose or broken CAN L wire from platform Check continuity. Replace if defective.
control module connector J11 pin 9 to platform
terminal block
32. Loose or broken CAN L wire from platform Check continuity. Replace if defective.
terminal block to base terminal block.
33. Loose or broken CAN L wire from base terminal Check continuity. Replace if defective.
block to base control module connector J1 pin 9.
SJ45 AJ+ 238274AEA

85
34. Loose, broken, or defective 120 ohm CAN Check that resistance between CAN H and CAN L
termination resistor(s) between CAN H and is appoximately 60 ohms (2 x 120 ohm in parallel).
CAN L teminals in platform and/or base terminal Check connections. Repair connections or replace
block(s). if defective.
35. Loose or broken wire #02 from platform control Check continuity. Replace if defective.
module connector J11 pins 10, 11, 12, and/or 13
to platform terminal block.
36. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to base terminal block.
37. Defective base (master) control module SMB1- Replace if Defective
105
38. Defective platform (slave) control module SMB1- Replace if Defective
106
4.2-2 All Controls are Inoperative from the Base Console
1. loose or defective wire #10 from keyswitch S2 to Check continuity. Replace if defective
ignition/enable switch S5
2. Defective ignition/enable switch S5 Check continuity through switch when activated.
Replace if defective
3. Loose or broken wire #10A from ignition/enable Check continuity. Replace if defective
switch S5 to base control module connector J2
pin 18.
4. Loose or broken wire #10A from ignition/enable Check continuity. Replace if defective
switch S5 to base boom control toggle switches.
4.2-3 The Engine will not Crank from the Base or Platform
1. Loose or broken wire #57C from base control Check continuity. Replace if defective
module connector J3 pin 9 to 57DCR relay pin
30.
2. Loose or broken wire #09 from base terminal Check continuity. Replace if defective
block to 57DCR relay pin 85
3. Loose or broken wire #57D from 57DCR relay Check continuity. Replace if defective
pin 86 to telematics connector J6 pin 9
4. Loose or broken junper wire from J6 pin 9 to J6 Check continuity of jumper. Check telematics if
pin 4, or if equipped with telematics then either equipped. Repair or replace as required.
start interlock is engaged or telematics are
inoperative
5. Loose or broken wire#00 from J6 pin 4 to Check continuity. Replace if defective
ground.
6. Loose or broken wire #57A from relay 57DCR pin Check continuity. Replace if defective
87 to connector J4 pin 8.
238274AEA SJ45 AJ+

86
7. Defective relay 57DCR. Check relay. Replace if defective.

8. Loose or broken 57A wire from connector P4 Check schematic applicable to the engine equipped
pin 8 to start input on ECU or 57ACR relay if on the machine to determine ECU pin # or relay if
equipped. equipped.
NOTE
For other engine-related problems, consult the engine manufacturer’s manual.
4.2-4 The Engine will not Crank from the Base
1. Loose or broken wire #10 from base keyswitch Check continuity. Replace if defective
S2 to base start switch S5
2. Loose or broken wire #57 from base start switch Check continuity. Replace if defective
S5 to base control module connector J2 pin 30.
3. Defective start/enable switch S5 Check continuity through switch. Replace if
defective
4.2-5 The Engine will not Crank from the Platform
NOTE
The engine will not crank from the platform with the footswitch pressed.
1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective
block to start switch S9.
2. Loose or broken wire #57B from start switch S9 Check continuity. Replace if defective
to platform control module connector J12 pin 30
3. Defective start switch S9 Check continuity through switch. Replace if
defective
4.2-6 The Boom Controls are Inoperative (Drive Operates)
1. Loose or broken wire #21A from base control Check continuity. Replace if defective
module connector J3 pin 24 to main harness 24
pin connector pin 3
2. Loose or broken wire #21A from main harness Check continuity. Replace if defective
plug pin #3 to dump valve 2H-21A
3. Loose or broken wire #02 from dump valve Check continuity. Replace if defective
2H-21A to main harness plug
4. Defective dump valve coil 2H-21A Check continuity and resistance through coil.
SJ45 AJ+ 238274AEA

87
4.2-7 No Boom Up from the Base or Platform Controls
1. Loose or broken wire #14 from base control Check continuity. Replace if defective
module connector J2 pin 5 base terminal block to
turret harness plug pin #2
2. Loose or broken wire #14 from turret harness Check continuity. Replace if defective
plug pin #2 to boom up valve 4H-14
plug to boom up valve 4H-14
4. Defective boom up coil 4H-14 Check continuity and resistance through coil.
4.2-8 No Boom Up from the Base Console
1. Loose or broken wire #10A from IGN switch S5 Check continuity. Replace if defective
to boom switch S12
2. Defective boom switch S12 Check continuity through switch while activating
boom up function between wires #10A and #14B.
Replace switch if no continuity
3. Loose or broken wire #14B from boom switch Check continuity. Replace if defective
S12 to base control module connector J2 pin 15
4.2-9 No Boom Up from the Platform Console
block to joystick controller A1
3. No output on y-axis of joystick controller A1 Refer to joystick test procedure in section 5
4. Loose or broken wire “Y” from joystick controller Check continuity. Replace if defective
to J13 pin #16 of platform control module
4.2-10 No Boom Down from the Base or Platform Consoles
module connector J2 pin 6 base terminal block to
turret harness plug pin #1
plug pin #1 to boom down valve 4H-13
plug to boom down valve 4H-13
4. Defective boom down coil 4H-13 Check continuity and resistance through coil.
238274AEA SJ45 AJ+

88
4.2-11 No Boom Down from the Base Console
to boom switch S12
boom down function between wires #10A and
#13B. Replace switch if no continuity
4.2-12 No Boom Down from the Platform Console
4.2-13 No Turret Rotate Right from the Base or Platform Consoles
module connector J2 pin 24 base terminal block
to turret harness plug pin #10
plug pin #10 to boom up valve 4H-33
4. Defective boom up coil 4H-33 Check continuity and resistance through coil.
4.2-14 No Turret Rotate Right from the Base Console
to turret rotate switch S13
2. Defective turret rotate switch S13 Check continuity through switch while activating
turret rotate right function between wires #10A and
SJ45 AJ+ 238274AEA

89
4.2-15 No Turret Rotate Right from the Platform Console
3. No output on X-axis of joystick controller A1 Refer to joystick test procedure in section 5
4. Loose or broken wire “x” from joystick controller Check continuity. Replace if defective
4.2-16 No Turret Rotate Left from the Base or Platform Consoles
module connector J2 pin 13 to turret harness
plug pin #9
plug pin #9 to turret rotate left valve 4H-32
plug to turret rotate left valve 4H-32
4. Defective turret rotate left coil 4H-32 Check continuity and resistance through coil.
4.2-17 No Turret Rotate Left from the Base Console
to turret rotate switch S13
2. Defective turret rotate switch S13 Check continuity through switch while activating
down function between wires #10A and #32B.
3. Loose or broken wire #32B from turret rotate Check continuity. Replace if defective
pin 17
4.2-18 No Turret Rotate Left from the Platform Console
238274AEA SJ45 AJ+

90
4.2-19 No Riser Up from the Base or Platform Consoles
module connector J2 pin 3 to turret harness plug
pin #8
plug pin #8 to riser up valve 4H-31
plug to riser up valve 4H-31
4. Defective rise up coil 4H-31 Check continuity and resistance through coil.
4.2-20 No Riser Up from the Base Console
to boom switch S25
2. Defective riser switch S25 Check continuity through switch while activating
riser up function between wires #10A and #31B.
3. Loose or broken wire #31B from riser switch S25 Check continuity. Replace if defective
to base control module connector J3 pin 31
4.2-21 No Riser Up from the Platform Console
3. No output on "R" of joystick controller A3 Refer to joystick test procedure in section 5
4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective
4.2-22 No Riser Down from the Base or Platform Consoles
pin #7
plug pin #7 to riser down valve 4H-30
plug to riser down valve 4H-30
4. Defective rise down coil 4H-30 Check continuity and resistance through coil.
SJ45 AJ+ 238274AEA

91
4.2-23 No Riser Down from the Base Console
to boom switch S25
2. Defective riser switch S25 Check continuity through switch while activating
riser down function between wires #10A and #30B.
3. Loose or broken wire #30B from riser switch S25 Check continuity. Replace if defective
to base control module connector J3 pin 30
4.2-24 No Riser Down from the Platform Console
3. No output on "R" of joystick controller A3 Refer to joystick test procedure in section 5
4. Loose or broken wire “R” from joystick controller Check continuity. Replace if defective
4.2-25 No Telescope Out from the Base or Platform Consoles
plug pin #14
plug pin #14 to telescope out valve 4H-39
4. Defective telescope out coil 4H-39 Check continuity and resistance through coil.
4.2-26 No Telescope Out from the Base Console
to telescope switch S13
telescope out function between wires #10A and
3. Loose or broken wire #39B from telescope Check continuity. Replace if defective
pin 33
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4.2-27 No Telescope Out from the Platform Console
block totelescope switch S18
telescope out function between wires #04 and
#39A. Replace switch if no continuity
3. Loose or broken wire #39A from telescope Check continuity. Replace if defective
switch S18 to platform control module connector
J12 pin 33
4.2-28 No Telescope In from the Base or Platform Consoles
pin #13
plug pin #13 to telescope in valve 4H-38
plug to telescope in valve 4H-38
4. Defective telescope in coil 4H-38 Check continuity and resistance through coil.
4.2-29 No Telescope In from the Base Console
to telescope switch S14
2. Defective telescope switch S14 Check continuity through switch while activating
telescope in function between wires #10A and
4.2-30 No Telescope In from the Platform Console
block to telescope switch S18
2. Defective telescope switch S18 Check continuity through switch while activating
down function between wires #04 and #38A.
3. Loose or broken wire #38A from boom switch Check continuity. Replace if defective
S18 to platform control module connector J12
pin 21
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4.2-31 No Platform Level Up from the Base or Platform Consoles
module connector J2 pin #7 to turret harness
plug pin #16
plug pin #16 to platform level up valve 4H-41
plug to platform level up valve 4H-41
4. Defective platform level up coil 4H-41 Check continuity and resistance through coil.
4.2-32 No Platform Level Up from the Base Console
to platform level switch S15
2. Defective platform level switch S15 Check continuity through switch while activating up
function between wires #10A and #41B. Replace
switch if no continuity
3. Loose or broken wire #41B from platform level Check continuity. Replace if defective
pin 22
4.2-33 No Platform Level Up from the Platform Console
block to platform level switch S19
2. Defective platform level switch S19 Check continuity through switch while activating
platform level up function between wires #04 and
3. Loose or broken wire #41A from platform level Check continuity. Replace if defective
switch S19 to platfrom control module connector
J12 pin 22
4.2-34 No Platform Level Down from the Base or Platform Consoles
plug pin #15
plug pin #15 to platform level down valve 4H-40
plug to platform level down valve 4H-40
4. Defective platform level down coil 4H-40 Check continuity and resistance through coil.
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4.2-35 No Platform Level Down from the Base Console
2. Defective platfrom level switch S16 Check continuity through switch while activating
platfrom level down function between wires #10A
and #40B. Replace switch if no continuity
pin 26
4.2-36 No Platform Level Down from the Platform Console
block to platform level switch S19
platfrom level down function between wires #04
and #40A. Replace switch if no continuity
3. Loose or broken wire #40A from platform level Check continuity. Replace if defective
switch S19 to platform control module connector
J13 pin 26
4.2-37 No Platform Rotate or Jib Functions from the Base or Platform Consoles
plug pin #20
plug pin #20 to platform flow enable valve 2H-
42
plug to platform flow enable valve 2H-42
4. Defective platform flow enable coil 2H-42 Check continuity and resistance through coil.
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4.2-38 No Platform Rotate Right from the Base or Platform Consoles
1. Loose or broken wire #37 from platform control Check continuity. Replace if defective
module connector J12 pin #1 to platform
terminal strip
strip to platform platform rotate right valve 4H-37
strip to platform rotate right valve 4H-37
4. Defective platform rotate right coil 4H-37 Check continuity and resistance through coil.
4.2-39 No Platform Rotate Right from the Base Console
to platform rotate switch S16
2. Defective platform rotate switch S16 Check continuity through switch while activating
platform rotate right function between wires #10A
3. Loose or broken wire #37B from platform rotate Check continuity. Replace if defective
pin 28
4.2-40 No Platform Rotate Right from the Platform Console
block to platform rotate switch S20
platform rotate right function between wires #04
and #37A. Replace switch if no continuity
3. Loose or broken wire #37A from platform rotate Check continuity. Replace if defective
J13 pin 28
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4.2-41 No Platform Rotate Left from the Base or Platform Consoles
terminal strip
strip to platform platform rotate left valve 4H-36
strip to platform rotate left valve 4H-36
4. Defective platform rotate left coil 4H-36 Check continuity and resistance through coil.
4.2-42 No Platform Rotate Left from the Base Console
platfrom level down function between wires #10A
pin 29
4.2-43 No Platform Rotate Left from the Platform Console
block to platform rotate switch S20
platform rotate left function between wires #04 and
3. Loose or broken wire #37A from platform rotate Check continuity. Replace if defective
J13 pin 28
4.2-44 No Jib Up from the Base or Platform Consoles
terminal strip
strip to jib up valve 4H-35
strip to jib up valve 4H-35
4. Defective jib up coil 4H-35 Check continuity and resistance through coil.
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4.2-45 No Jib Up from the Base Console
to jib switch S17
2. Defective jib switch S17 Check continuity through switch while activating
jib up function between wires #10A and #35B.
3. Loose or broken wire #35B from jib switch S17 to Check continuity. Replace if defective
base control module connector J2 pin 28
4.2-46 No Jib Up from the Platform Console
block to jib switch S21
2. Defective jib switch S21 Check continuity through switch while activating jib
up function between wires #04 and #35A. Replace
switch if no continuity
3. Loose or broken wire #35A from jib switch S21 to Check continuity. Replace if defective
platfrom control module connector J12 pin 28
4.2-47 No Jib Down from the Base or Platform Consoles
terminal strip
strip to jib down valve 4H-34
strip to jib down valve 4H-34
4. Defective jib down coil 4H-34 Check continuity and resistance through coil.
4.2-48 No Jib Down from the Base Console
to jib switch S17
jib down function between wires #10A and #34B.
3. Loose or broken wire #34B from jib switch S17 to Check continuity. Replace if defective
base control module connector J2 pin 26
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4.2-49 No Jib Down from the Platform Console
block to jib switch S21
jib down function between wires #04 and #34A.
3. Loose or broken wire #34A from jib switch S21 to Check continuity. Replace if defective
platfrom control module connector J12 pin 26
4.2-50 No Drive or Steer Functions
block to drive joystick A2
block to drive joystick A2
3. Defective drive joystickA2 See drive joystick test procedure in section 5
4.2-51 No Forward or Reverse Drive
1. No output on “D” when forward is selected on See drive joystick test procedure in section 5
drive joystick A2
2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective
joystick A2 to platform control module connector
J13 pin #14
4.2-52 No Forward Drive
1. No output from base control module at connector Check for correct output voltage.
J2 pin #1 to wire #16
2. Loose or broken wire 16 from base control Check continuity. Replace if defective
module connector J2 pin #1 to turret connector
pin 21
3. Loose or broken wire #16 from turret plug pin 21 Check continuity. Replace if defective
to drive pump valve connector pin #4
4. Loose or broken wire #16 from drive pump valve Check continuity. Replace if defective
connector pin #4 to 3H-16 Forward coil
5. Loose or broken wire #02 wire from 3H-16 Check continuity. Replace if defective
Forward coil to ground
6. Defective forward coil 3H-16 Check continuity and resistance through coil.
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4.2-53 No Reverse Drive
1. No output from base control module at connector Check for correct output voltage.
module connector J2 pin #2 to turret connector
pin 20
3. Loose or broken wire #15 from turret plug pin 20 Check continuity. Replace if defective
to drive pump valve connector pin #1
4. Loose or broken wire #15 from drive pump valve Check continuity. Replace if defective
connector pin #1 to 3H-15 Forward coil
5. Loose or broken wire #02 wire from 3H-15 Check continuity. Replace if defective
Reverse coil to ground
6. Defective reverse coil 3H-15 Check continuity and resistance through coil.
4.2-54 The Brake will not Release
1. No output from base control module coneector Check for correct output voltage
connector pin #8
connector pin #8 to 3H-26 Brake coil
4. Loose or broken wire #02 wire from 3H-26 Brake Check continuity. Replace if defective
coil to ground
5. Defective brake coil 3H-26 Check continuity and resistance through coil.
4.2-55 No Left Steer
1. Loose or broken wire #24P from drive joystick Check continuity. Replace if defective
A2 to platform control module connector J12 pin
#15
2. No output from base control module on Check pin #13 for 12 volts. If no voltage present
connector J3 pin #13 with foot on footswitch and activating steer function
check section 5 for OCM pin voltage reference
connector pin #7
plug pin #7 to left steer valve 4H-24
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plug to left steer valve 4H-24
6. Defective left steer valve coil 4H-24 Check continuity and resistance through coil.
4.2-56 No Right Steer
1. Loose or broken wire #23P from drive joystick Check continuity. Replace if defective
A2 to platform control module connector J12 pin
#16
2. No output from base control module on Check pin #13 for 12 volts. If no voltage present
connector J3 pin #3 with foot on footswitch and activating steer function
check section 5 for OCM pin voltage reference
connector pin #6
plug pin #6 to right steer valve 4H-23
plug to right steer valve 4H-23
6. Defective right steer valve coil 4H-23 Check continuity and resistance through coil.
4.2-57 The Directon Sensing is Inoperative
block to limit switch LS1
2. Open or defective limit switch LS1 Adjust limit switch if required. Check continuity
through switch. Replace if defective
3. Loose or broken wire #17 from limit switch LS1 Check continuity. Replace if defective
to base terminal block
block to base control module connector J2 pin
#25
5. Defective base control module channel input for Replace if Defective
direction sense enable
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4.2-58 The Load Sense Indicates Overload or Overload Warning with the Platform
Empty or Below Weight
1. Load sense mis-calibration Refer to calibration procedure for recalibration of

load cell
2. Load cell circuit not operating Check wiring from load cell to platform control
module. Check CAN termination resistors. Check
load cell. Repair or replace as required
4.2-59 The Overload Indicator Light does not Turn On when the Platform is Overloaded
1. Defective lamp Check lamp. Replace if defective

2. Load cell circuit not operating Check wiring from load cell to platform control
module. Check CAN termination resistors. Check
load cell. Repair or replace as required
3. Load sense out of calibration Refer to calibration procedure for recalibration of
load cell
4. No output control module Check Voltage at platform control module
connectpr J3 pin #7 for 12V when platform is
loaded with 110% of rated capacity. (Boom fully
retracted and 12” (30cm) off the ground.)
5. Loose or broken wire #82 from the platform Check continuity. Replace if defective
control module connector J13 pin 7 to overload
lamp PL10.
6. Loose or broken wire #02 from overload lamp to Check continuity. Replace if defective
platform terminal strip
4.2-60 The Audible Alarm does not Turn On with the Platform Overloaded
1. Defective alarm BP3 Check alarm. Replace if defective

module connector J13 pin 8 to alarm BP3
3. Loose or broken wire #02 from alarm BP3 to Check continuity. Replace if defective
platform terminal block
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Hydraulic System Section 4 – Troubleshooting Information
4.3 Hydraulic System
4.3-1 All Controls Inoperative
1. Broken or defective drive pump shaft or coupling. Check pump shaft and coupling. Replace if
defective.
2. Hydraulic oil level low. Check oil level. Fill to proper level.
4.3-2 All Boom Functions Inoperative
1. Open or defective dump valve 2H-21A. Clean valve. Check O-rings on valve. Check
operation of valve. Repair or replace valve as
required.
2. Stuck or defective relief valve RV6. Set valve to specifications. Check O-rings and
clean valve. Repair or replace valve as required.
3. Stuck or defective Inlet Compensator/ differential Check O-rings and clean valve. Check operation of
sensing valve DSV1. valve. Repair or replace valve as required.
4. System pump P2 defective. Test pump with flow meter. Replace if defective.
5. Plugged or defective high pressure filter F1. Check filter. Replace if plugged or defective.
4.3-3 No Main Boom Up
1. Stuck or defective lift up valve 4H-14. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective shuttle valve SV6. Clean valve. Check O-rings on valve. Check
required.
3. Stuck or defective check valve CV10. Clean valve. Check operation of valve. Repair or
4. Stuck or defective differential sensing valve Clean valve. Check O-rings on valve. Check
DSV4. operation of valve. Repair or replace valve as
required.
5. Stuck or defective counterbalance valve CB9. Clean valve. Check O-rings on valve. Repair or
6. Defective lift cylinder C3. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.
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Section 4 – Troubleshooting Information Hydraulic System
4.3-4 No Main Boom Down
1. Stuck or defective lift down valve 4H-13. Clean valve. Check operation of valve. Repair or
required.
4. Stuck or defective differential sensing valve Clean valve. Check O-rings on valve. Check
DSV4. operation of valve. Repair or replace valve as
required.
6. Defective lift cylinder C3. Check seals on cylinder. Replace as necessary.
4.3-5 No Riser Boom Up

1. Stuck or defective riser up valve 4H-31. Clean valve. Check operation of valve. Repair or
required.
3. Stuck or defective check valve CV5. Clean valve. Check O-rings on valve. Check
required.
5. Stuck or defective differential pressure sensing Clean valve. Check O-rings on valve. Check
valve DSV3. operation of valve. Repair or replace valve as
required.
6. Stuck or defective counterbalance valve CB5 or Clean valve. Check O-rings on valve. Repair or
CB6. replace valve as required.
7. Defective riser cylinder C6 or C7. Check seals on cylinder. Replace as necessary.
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4.3-6 No Riser Boom Down

1. Stuck or defective riser down valve 4H-30. Clean valve. Check operation of valve. Repair or
required.
3. Plugged or defective orifice OR6. Check orifice. Replace if plugged or defective.
required.
required.
8. Stuck or defective counterbalance valve CB5 or Clean valve. Check O-rings on valve. Repair or
CB6. replace valve as required.
9. Defective riser cylinder C6 or C7. Check seals on cylinder. Replace as necessary.
4.3-7 Riser Boom Down Jerky

1. Stuck open or defective check valve CV5. Clean valve. Check operation of valve. Repair or
2. Stuck or incorrectly set counterbalance valve CB5 Clean valve. Check O-rings on valve. Check
or CB6. operation of valve. Repair or replace valve as
required.
4.3-8 No Turret Rotate Left

1. Stuck or defective rotate left valve 4H-32. Clean valve. Check operation of valve. Repair or
required.
3. Stuck or defective relief valve RV7. Set valve to specifications. Check o-rings and
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required.
required.
8. Turret rotate brake BR2 not releasing. Inspect brake for worn seals or broken
components. Repair and replace as necessary.
9. Worn or defective swing drive motor RA2. Check motor. Repair or replace if defective.
4.3-9 No Turret Rotate Right

1. Stuck or defective rotate right valve 4H-33. Clean valve. Check operation of valve. Repair or
required.
3. Stuck or defective relief valve RV7. Set valve to specifications. Check o-rings and
required.
required.
8. Turret rotate brake BR2 not releasing. Inspect brake for worn seals or broken
components. Repair and replace as necessary.
9. Worn or defective swing drive motor RA2. Check motor. Repair or replace if defective.
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4.3-10 No Boom Extend

1. Stuck or defective boom extend valve 3H-39. Clean valve. Check operation of valve. Repair or
2. Plugged, incorrectly adjusted or defective orifice Check orifice. Replace if plugged or defective.
OR3.
3. Stuck in the shifted position or defective boom Clean valve. Check operation of valve. Repair or
retract valve 3H-38. replace valve as required.
6. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary.
4.3-11 No Boom Retract

1. Stuck or defective boom retract valve 3H-38. Clean valve. Check operation of valve. Repair or
OR3.
5. Defective extension cylinder C2. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective
4.3-12 No Jib Up
1. Stuck or defective jib enable valve 2H-42. Clean valve. Check O-rings on valve. Check
required.
required.
4. Stuck or defective jib up valve 4H-35. Clean valve. Check operation of valve. Repair or
6. Defective jib cylinder C1. Check seals on cylinder. Replace as necessary.
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4.3-13 No Jib Down

1. Stuck or defective jib enable valve 2H-42. Clean valve. Check O-rings on valve. Check
required.
required.
4. Stuck or defective jib down valve 4H-34. Clean valve. Check operation of valve. Repair or
6. Defective jib cylinder C1. Check seals on cylinder. Replace as necessary.
4.3-14 No Platform Rotation Right

1. Stuck or defective platform rotate enable valve Clean valve. Check O-rings on valve. Check
2H-42. operation of valve. Repair or replace valve as
required.
required.
4. Stuck or defective platform rotate right valve 4H- Clean valve. Check operation of valve. Repair or
37. replace valve as required.
6. Defective rotary actuator RA1. Check actuator. Repair or replace as necessary.
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4.3-15 No Platform Rotation Left 4

1. Stuck or defective platform rotate enable valve Clean valve. Check O-rings on valve. Check
2H-42. operation of valve. Repair or replace valve as
required.
required.
4. Stuck or defective platform rotate right valve 4H- Clean valve. Check operation of valve. Repair or
6. Defective rotary actuator RA1. Check actuator. Repair or replace as necessary.
4.3-16 Platform will not Level Down Manually

OR4.
2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or
required.
required.
required.
9. Defective leveling cylinder C4 or slave cylinder Check seals on cylinder. Replace as necessary.
C5. Replace cylinder if defective.
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4.3-17 Platform will not Level Up Manually

OR4.
2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or
required.
required.
required.
9. Defective leveling cylinder C4 or slave cylinder Check seals on cylinder. Replace as necessary.
4.3-18 Brake will not Release

required.
2. Defective or misadjusted pressure reducing valve Set valve to specifications. Check O-rings and
PR1. clean valve. Repair or replace valve as required.
3. Stuck or defective brake valve 3H-26. Clean valve. Check O-rings on valve. Check
required.
required.
5. Defective or misadjusted relief valve RV4. Set valve to specifications. Check O-rings and
6. Stuck or defective brake release override valve Clean valve. Check O-rings on valve. Repair or
V1. replace valve as required.
7. Bypassing or defective brake hand pump V3. Clean valve. Check O-rings on valve. Repair or
8. Bypassing or defective brake cylinder C12. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective
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4.3-19 Brake will not Engage

1. Brake cylinder defective. Check cylinders. Repair or replace as necessary.
2. Brake valve 3H-26 stuck in shifted position. Check valve. Replace if defective.
3. Brake inside axle out of adjustment. See section 5 for brake adjustment procedure.
4.3-20 Differential Lock will not Engage

required.
2. Defective or misadjusted pressure reducing valve Set valve to specifications. Check O-rings and
PR1. clean valve. Repair or replace valve as required.
3. Stuck or defective differential lock valve 3H-165. Clean valve. Check O-rings on valve. Check
required.
4. Bypassing or defective differential lock cylinder Check seals on cylinder. Replace as necessary.
C13. Replace cylinder if defective
4.3-21 No Drive Forward or Reverse

1. Brake not releasing. See “brake will not release” in this section.
2. Defective or misadjusted charge pump relief Set valve to specifications. Check O-rings and
valve RV3. clean valve. Repair or replace valve as required.
3. Plugged or defective charge pump filter F1. Check filter. Replace if plugged or defective.
4. Worn charge pump P1A. Check pump. Replace if defective.
5. Defective pump displacement control 4H-15 and Check control. Replace if defective.
4H-16.
6. Open bypass valve V4. Close bypass valve.
7. Worn drive pump P1. Check pump. Replace if defective.
8. Worn or defective drive motor M1. Check motor. Replace if defective.
4.3-22 No Forward Drive

1. Defective pump displacement control 4H-16. Check control. Replace if defective.
2. Defective or misadjusted drive relief valve RV1. See section 5 for drive pump set up procedures.
3. Drive pump servo stuck or not shifting. Check pump. Replace if defective.
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4.3-23 No Reverse Drive

1. Defective pump displacement control 4H-15. Check control. Replace if defective.
2. Defective or misadjusted drive relief valve RV2. See section 5 for drive pump set up procedures.
3. Drive pump servo stuck or not shifting. Check pump. Replace if defective.
4.3-24 No High Speed Drive

1. Stuck or defective 2 speed valve 3H-45. Clean valve. Check O-rings on valve. Check
required.
2. Defective shift spool in drive motor M1. Check motor. Repair or replace if necessary.
4.3-25 No Right Steer

1. Plugged, incorrectly adjusted or defective priority Check operation. Set flow rate to 1.25 GPM @ 2000
flow control PFC1. psi. Replace if plugged or defective.
2. Stuck or defective right steer valve 4H-23A. Clean valve. Check operation of valve. Repair or
3. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary.
4.3-26 No Left Steer
1. Plugged, incorrectly adjusted or defective priority Check operation. Set flow rate to 1.25 GPM @ 2000
flow control PFC1. psi. Replace if plugged or defective.
2. Stuck or defective left steer valve 4H-24A. Clean valve. Check operation of valve. Repair or
3. Defective steer cylinder C8. Check seals on cylinder. Replace as necessary.
4.3-27 Axle Will Not Oscillate
NOTE
Axle will only oscillate when boom is fully retracted and is horizontal or below.
1. Stuck or defective axle lockout valve 3H-65. Clean valve. Check O-rings on valve. Repair or
2. One or more counterbalance valves (CB1 or CB2) Clean valve. Check O-rings on valve. Repair or
failed to shift or is defective. replace valve as required.
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4.3-28 Axle Will Not Lock
NOTE
Axle is in constant float if boom is fully retracted and is horizontal or below.
1. Axle lockout valve 3H-65 is stuck in shifted Clean valve. Check O-rings on valve. Check
position or is defective. operation of valve. Repair or replace valve as
required.
2. Bypassing or defective axle lock cylinders C9 and Check seals on cylinder. Replace as necessary.
3. Counterbalance valves (CB1 or CB2) out of Clean valve. Check O-rings on valve. Repair or
adjustment or are defective. replace valve as required.
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Notes
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114
Section 5 – Procedures
NOTE
The illustrations in this manual are for instructional
WARNING
purposes only. The models and components shown Fall hazard. Use the three points of contact
may appear somewhat different from those on your principle when you use the MEWP to enter or exit
actual MEWP. the platform. If you do not obey, there is a risk of
death or serious injury.
5.1 Safety and Workmanship

Your safety, and that of others, is the first WARNING
consideration when doing maintenance on Do not operate the platform controls without the
equipment. Always be conscious of weight. Never correct fall protection attached to the designated
attempt to move heavy parts without the aid of a location in the platform. Failure to do so could
mechanical device. Do not allow heavy objects to rest result in death or serious injury!
in an unstable position. When you raise a part of the
equipment, make sure it has sufficient support.
WARNING
Before you do routine maintenance underneath the
riser, support it using a suitably rated lifting device Make sure there are no people or obstructions in
(refer to Figure 01), or cylinder chocks on both riser the test area, and there is sufficient space for the
cylinders. Contact Skyjack Parts to order chocks. boom and drive functions required for the given
procedures.
WARNING
Remove all material and personnel from the
platform while using the maintenance support(s).
1. Park the MEWP on a firm, level surface.

2. Retract and lower the boom, riser, and platform
until the MEWP is in the stowed position.
3. Turn the engine off.
4. Push in the emergency stop buttons on the base
controls and on the platform controls.
5. Turn the battery disconnect switch to the off
position. 13 345 N
After you complete a procedure which involves 3,000 lbf
the modification, adjustment, or replacement of
a hydraulic or electrical component, do all of the
function tests given in your unit’s Operation Manual. Figure 01 Support location
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Section 5 – Procedures System Control Module (SCM)
5.2 System Control Module

(SCM)
CONTROLS INC.
Maintaining proper calibration is essential for good

7
performance of the MEWP.
MENU SAVE
Open the base control box to access the lower main SELECT EXIT
controller, or the platform control box to access the

upper secondary controller.
The SCM has an integrated multi segment, two
line display with membrane keys that allow it to be
used as the main interface to system controls and 1 2 3 4 5
adjustments. The SCM serves as your window into the
application software to allow you to monitor or adjust
6
the following information:
▪ Active function in use

▪ Part number and serial number
▪ Restore the factory default settings
5 Connector P1/P11
▪ Output calibrations (Thresh, Max, Ramp.etc)
▪ I-O status
6 Connector P2/P12
▪ CANBus status 7 Connector P3/P13
5.2-1 User Interface Keys
MENU MENU Enters a new menu screen and/or

1
SELECT SELECT Selects the flashing item.
DOWN Selects the previous item in the current menu’s list.

2
MINUS Decreases an adjustable parameter such as ramp time.
UP Selects the next item in the current menu’s list.

3
PLUS Increases an adjustable parameter.
SAVE SAVE Saves the new data to EEPROM (permanent memory storage).
4
EXIT EXIT Exit to the previous screen.
2 3 Press UP and DOWN together to reset the SCM to the menu screen.
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System Control Module (SCM) Section 5 – Procedures
5.2-2 SCM Character Functions Charts
SCM Keypad Function Attribute

Keys Short Form THRESH Threshold
Menu/Select (M/S) RAMPDN Ramp Down
/- (-) RAMPUP Ramp Up
/+ (+) LOWRNG Low Range
Save/Exit (S/E) MAXOUT Maximum Output
1345AA
5.2-3 SCM Function Channel Names
SCM Function (Channel) Names

DRIVE REV Fn01A Drive Reverse (Flat)
DRIVE FWD Fn01B Drive Forward (Flat)
CHAN 2A Fn02A Drive Off Confirmation
CHAN 2B Fn02B Drive On Confirmation
BOOM DOWN Fn03A Main Boom Down
BOOM UP Fn03B Main Boom Up
ROTATE L Fn04A Turret Rotate Left
ROTATE R Fn04B Turret Rotate Right
RISER DN Fn05A Riser Down
RISER UP Fn05B Riser Up
LR REV Fn06A Drive Reverse (Hill)
LR FWD Fn06B Drive Forward (Hill)
1346AB
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5.2-4 SCM Pin Reference
P3/P13
WHITE
12 35
23
11 34
22
10 33
21
9 32
20
8 31
19
7 30
18
6 29
17
5 28
16
4 27
15
3 26
14
P1/P11 2
1
13
25
24
BLACK
5 14
9
4 13
8
3 12
7
2
1
6
11
10 P2/P12
GREY
12 35
23
11 34
22
10 33
21
9 32
20
8 31
19
7 30
18
6 29
17
5 28
16
4 27
15
3 26
14
2 25
13
1 24
P1 (Black) Lower Main Controller: SMB1-105

Pin Wire Function Input/Output Type I/O Test I/O Error
1 09 Power VS1
2 09 Power VS2
3 09 Power VS3
4 09 Power VS4
5 Not used Vreg 5v
6 CAN H CANH to Engine ECU & Telematics J1939 CAN
7 CAN L CANL to Engine ECU & Telematics J1939 CAN
8 CAN 2H CANH to PLTF SMB1-106 CANopen
9 CAN 2L CANL to PLTF SMB1-106 CANopen
10 02 Ground GND1
11 02 Ground GND2
12 02 Ground GND3
13 02 Ground GND4
14 Not used --
2056AC
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P2 (Grey) Lower Main Controller: SMB1-105

1 16 Drive Forward Analog Output PWM02 PE2
2 15 Drive Reverse Analog Output PWM01 PE1
3 31 Riser Up Analog Output PWM08 PE8
4 30 Riser Down Analog Output PWM07 PE7
5 14 Boom Up Analog Output PWM06 PE6
6 13 Boom Down Analog Output PWM05 PE5
7 41 Platform Level Up Analog Output PWM12 PE12
13A SJ63 AJ Boom Down Throttle
8 Analog Output PWM11 PE11
85B SJ46 AJ 2nd Generator O/P
9 38 Fly Boom In Analog Output PWM10 PE10
10 39 Fly Boom Out Analog Output PWM09 PE9
11 Not Used -- --
12 42 Proportional Flow Analog Output PWM15 PE15
13 32 Turret Rotate Left Analog Output PWM03 PE3
14 55 Fuel level float sw Digital Input DI2 IE2
15 14B Main Boom Up Digital Input DI4 IE4
16 13B Main Boom Dn Digital Input DI6 IE6
17 32B Turret Rotate L Digital Input DI8 IE8
18 10A Emergency Pump / Enable Digital Input DI10 IE10
19 29 Fly Boom In LS (Hi Speed Drive) Digital Input DI12 IE12
20 12 Platform key position Digital Input DI14 IE14
21 38B Telescope Retract Digital Input DI16 IE16
22 41B Platform Level Up Digital Input DI18 IE18
23 Not Used -- --
24 33 Turret Rotate Right Analog Output PWM04 PE4
25 17 Direction Sensing Digital Input DI1 IE1
26 34B Jib Down Digital Input DI3 IE3
27 28 Tilt Switch Active Digital Input DI5 IE5
28 35B Jib Up Digital Input DI7 IE7
29 59 Main Boom Cradled LS (Hi Speed Drive) Digital Input DI9 IE9
30 57 Engine Start Request Digital Input DI11 IE11
31 10 Base key position Digital Input DI13 IE13
32 33B Turret Rotate R Digital Input DI15 IE15
33 39B Telescope Extend Digital Input DI17 IE17
34 Not Used -- --
35 40 Platform Level Down Analog Output PWM13 PE13
2057AC
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P3 (White) Lower Main Controller: SMB1-105

1 119 Load Zone Border Lamp Digital Output DO1 OE1
2 01A Emergency Pump Relay Digital Output DO8 OE8
3 23 Steer Right Digital Output DO7 OE7
4 118A Overload Alarm/lamp Digital Output DO6 OE6
5 65 Axle Lock Digital Output DO5 OE5
6 120 Low capacity zone lamp Digital Output DO12 OE12
7 85 Generator Solenoid Digital Output DO11 OE11
8 68 Engine Run Enable Digital Output DO10 OE10
9 57A Engine Start Digital Output DO9 OE9
10 20 All-Motion Alarm Digital Output DO16 OE16
11 120A High capacity zone lamp Digital Output DO15 OE15
12 Not Used Digital Output DO14 OE14
13 24 Steer Left Digital Output DO2 OE2
14 Not Used Analog Input AI1 AE1
20 128 Angle Sensor - Chassis Analog Input AI7 AE7
Propane Run (Dual Fuel)
23 11 Digital Output DO13 OE13
Load Kit Option (ANSI/CSA D2.9L)
24 21A Dump Valve Digital Output DO3 OE3
25 45A Motor 2 Speed Digital Output DO4 OE4
26 40B Platform Level Down Digital Input DI19 IE19
27 Main Boom Creep (used on 86) Digital Input DI20 IE20
28 37B Platform Rotate Right Digital Input DI21 IE21
29 36B Platform Rotate Left Digital Input DI22 IE22
30 Riser Down Digital Input DI23 IE23
31 Riser Up Digital Input DI24 IE24
32 121 load zone safety limit (Main) Digital Input DI25 IE25
33 122 load zone safety limit (Fly) Digital Output DI26 IE26
34 26 Holding Brake Off Digital Output DO17 OE17
35 165 Diff Lock Digital Output DO18 OE18
2058AD
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P11 (Black) Upper Secondary Controller: SMB1-106

1 04 Power VS1
2 04 Power VS2
3 04 Power VS3
4 04 Power VS4
5 L Speed control supply (T Booms) Vreg 5v
6 Not Used J1939 CAN
7 Not Used J1939 CAN
8 CAN 2H CANH To PLTF SMB1-106 CANopen
9 CAN 2L CANL To PLTF SMB1-106 CANopen
10 02 Ground GND1
11 02 Ground GND2
12 02 Ground GND3
13 02 Ground GND4
14 Not used --
2059AC
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P12 (Grey) Upper Secondary Controller: SMB1-106

1 37 Platform Rotation Right PWM17 PE17
2 36 Platform Rotation Left PWM16 PE16
3 Not Used PWM18 PE18
4 Not Used -- --
7 Not Used -- --
8 Not Used -- --
9 Not Used -- --
10 Not Used -- --
11 Not Used -- --
12 Not Used -- --
13 35 Jib Up PWM18 PE18
14 08A Footswitch Actuated Y DI28 IE28
15 24P Steer Left Y DI30 IE30
16 23P Steer Right Y DI32 IE32
17 45 High Torque Drive Mode Selected Y DI34 IE34
18 01 Emergency Pump Request Y DI36 IE36
19 04A Engine Run/Enable DI38 IE38
20 MPS2 = KC O/H (Korea) Y DI40 IE40
21 38A Fly Boom In Y DI42 IE42
22 41A Platform Level Up Y DI44 IE44
23 Not Used -- --
24 34 Jib Down PWM19 PE19
25 233 Glazier Load Restrict DI27 IE27
26 34A Jib Down Y DI29 IE29
27 Not Used Y DI31 IE31
28 35A Jib Up Y DI33 IE33
29 78 High Throttle Selected Y DI35 IE35
30 57B Engine Start Request Y DI37 IE37
31 MPS1 = KC O/H (Korea) Y DI39 IE39
Propane Fuel Select (Dual Fuel)
32 11A DI41 IE41
Load Kit Option (ANSI/CSA TD2.9L)
33 39A Fly Boom Out Y DI43 IE43
34 Not Used -- --
35 Not Used -- --
2060AC
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P13 (White) Upper Secondary Controller: SMB1-106

1 Not Used Y DO19 OE19
2 55 Low Fuel Indicator Lamp Y DO26 OE26
3 577 EcoStart Indicator Light DO25 OE25
4 27A Tilt Audible Indicator Y DO24 OE24
5 231 Regen Lamp (EU Stage 5 engine) DO23 OE23
6 63 SGE Alarm DO30 OE30
7 82 O/L Lamp DO29 OE29
8 118 O/L Alarm DO28 OE28
9 74 Glow Plug Indicator Lamp Y DO27 OE27
10 119 Load Zone Border Lamp DO34 OE34
11 120A High capacity zone lamp DO33 OE33
12 120 Low capacity zone lamp DO32 OE32
13 27 5 Degree Tilt LED Indicator DO20 OE20
14 D Drive Controller Y AI10 AE10
15 Y Main Boom Elevation Controller Y AI11 AE11
16 X Turret controller Y AI12 AE12
17 Not Used Y AI13 AE13
19 R Riser Controller (AJ Booms) AI15 AE15
22 C Speed control knob (T booms) Y AI18 AE18
23 76P MIL DO31 OE31
24 Not Used DO21 OE21
25 08 Footswitch Indicator Y DO22 OE22
26 40A Platform Level Down Y DI45 IE45
27 232 Regen Temp. Override (EU Stage 5 engine) DI46 IE46
28 35A Platform Rotate Right Y DI47 IE47
29 36A Platform Rotate Left Y DI48 IE48
30 165A Diff Lock Y DI49 IE49
31 85 Generator On/Off Y DI50 IE50
32 61 SGE - Bar In Y DI51 IE51
33 62 Reset SGE Y DI52 IE52
34 Not Used -- --
35 165B Diff Lock Indicator DO36 OE36
2061AC
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5.2-5 SCM Recommended Settings - Kubota WG972 Dual Fuel Engine

Function Thresh (mA) Maxout (mA) Low Rng (mA) Ramp Up (sec) Ramp Dn (sec)
Drive REV 400 750 580  3 0.2
Drive FWD 400 710 520  3 0.2
Rotate L ANSI (CE) 400 1350 (820) 900 (700)  1 1
Rotate R ANSI (CE) 400 1000 (750) 880 (750)  1 1
Boom DN 450 630 520  1 1
Boom UP 470 720 630  2 1
Fly IN 470 1200 920  1 0.2
Fly OUT 470 1200 920  1 0.2
Riser UP 470 960 510  1 0.7
Riser DN 470 1080 600  1 0.7
Jib UP 420 900 900  0 0
Jib DN 420 900 900  0 0
Platform R 350 900 900  0 0
Platform L 340 900 900  0 0
Level UP 400 1200 N/A 0 0
Level DN 400 1200 N/A 0 0
JIB FL UP 450 700 630  1 0.7
JIB FL DN 450 670 500  1 0.7
Platform Flow 340 640 520  1 0.7
Function Fwd Rev
Low Range B 714 760
Drive Threshold 530 530
LRNG Pmax  940  930 
LRNG Pmin  530  530 
B Boundary Default Default
Drive Timer Default Default
Function Up Dn
Boom Creep N/A N/A
Ramp Time N/A
PID Setting KP KI KD
Antistall 23 10 30
DF Setting RPM Torque
Antistall 99 75%
Steer Settings T1 T2
AntiStall 1900 1800
 This is the maximum value allowed.

 Do not modify this setting. 2168AA
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5.2-6 Default Recommended Settings - Kubota D1305 Diesel Engine

Function Thresh (mA) Maxout (mA) Low Rng (mA) Ramp Up (sec) Ramp Dn (sec)
Drive REV 400 850 610  3 0.2
Drive FWD 400 850 610  3 0.2
Rotate L ANSI (CE) 400 1318 (820) 980 (820)  1 1
Rotate R ANSI (CE) 400 1000 (790) 880 (790)  1 1
Boom DN 450 780 680  1 1.5 
Boom UP 470 840 700  2 1
Fly IN 470 1200 920  1 0.2
Fly OUT 470 1200 930  1 0.2
Riser UP 470 990 800  1 0.7
Riser DN 470 700 600  1 0.7
Jib UP 420 900 900  0 0
Jib DN 420 900 900  0 0
Platform R 340 870 870  0 0
Platform L 340 870 870  0 0
Level UP 400 1200 680  0 0
Level DN 400 1200 680  0 0
JIB FL UP 450 770 700  1 0.7
JIB FL DN 450 750 610  1 0.7
Platform Flow 340 670 600  1 0.7
Function Fwd Rev
Low Range B 864 868
Drive Threshold 530 530
LRNG Pmax  940  930 
LRNG Pmin  600  580 
B Boundary Default Default
Drive Timer Default Default
Function Up Dn
Boom Creep
Ramp Time
PID Setting KP KI KD
Antistall 23 10 30
Diesel Setting RPMinitial RPMexit %initial %more %less
Antistall 600 400 70% 20% 10%
Steer Settings T1 T2
AntiStall 1600 1500
 This is the maximum value allowed.

 Do not modify this setting.
2169AA
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5.2-7 Unlock and Modify the SCM
MODEL: XXXX  SMB1-XXXX UNLOCK SETUP? MENU

FUNCTIONS OFF + SN XXXXXXXXXX PRESS SELECT SELECT
ENTER PASSWORD  MENU ENTER PASSWORD  MENU

0** +
x7 SELECT 70* +
x5 SELECT
ENTER PASSWORD  ENTER PASSWORD MENU SETUP UNLOCKED

750 +
x5 755 SELECT PRESS - OR +
 SET DRIVE TIMER SAVE MODEL: XXXX MENU ADJUST CANBUS

+ EXIT FUNCTIONS OFF SELECT IO TEST MAIN
MENU   DRIVE REV

DRIVE REV THRESH DRIVE FWD THRESH
DRIVE FWD
SELECT Fn1 XXXmA + Fn1 XXXmA + ROTATE L
ROTATE R
BOOM DOWN
 BOOM UP
MAXOUT FLY OUT
MENU DRIVE REV THRESH + LOWRNG MENU
FLY IN
SELECT Fn1 XXXmA  RAMPUP SELECT RISER DN
RAMPDN RISER UP
-
JIB DOWN
JIB UP
JIB FL DN
JIB FL UP
 PLAT LFT
+ INCREASE OR SAVE PLAT RGT
DECREASE VALUES EXIT
PLT FLOW

PLEV DOWN
- PLEV UP
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5.2-8 SCM Model Select
START SCREEN BASE SMB1-105** (SOFTWARE

REV)
MODE: NO CONFIG
FUNCTIONS OFF SMB1-106** (SOFTWARE
REV)
PLATFORM
7X
MENU
UNLOCK SETUP? ENTER PASSWORD
PRESS SELECT SELECT 0**
5X
MENU
ENTER PASSWORD ENTER PASSWORD
7** SELECT 70*
5X
MENU ENTER PASSWORD
ENTER PASSWORD
SELECT 750
75*
ENTER PASSWORD MENU SETUP UNLOCKED
755 SELECT PRESS - OR +
SET DRIVE TIMER SET B BOUNDRY

PRESS SELECT
SET LRNG B&C&THR *OVERLOAD COUNTER

VALUE =
*Available on CE MEWPs only Continued on

the next page
SJ45 AJ+ 238274AEA

127
Continued from the previous page
*CLR OVL COUNTER WEIGHT CALIB?

PRESS SELECT
*Available on CE MEWPs only
SET A-STALL PID? ANTI-STALL CHG?

PRESS SELECT PRESS SELECT
AE=XXX=5 W=X CURRENT ENGINE

P1=XXX P2=XXXX
GEN SELECT MODEL SELECT MENU

3.5 kW 50Hz
PRESS SELECT SELECT
45T SAVE SELECT MULTIFNCT

45AJ
EXIT ANSI CE AS
60AJ
40T
SAVE SELECT ENGINE SAVE MODEL:XXXX

D1305 WG972
EXIT EXIT FUNCTIONS OFF
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5.2-9 Check I/O Error
If a fault is detected, the engine shuts off and the SCM displays “Check I/O Err? Press select”.
Press Menu/Select.
This check helps to determine which channel has the fault.
PE=PWM error
OE=Digital output error
IE=Digital input error
AE=Analog error
Scroll through to the end of the first set of channels, then use Menu/Select to enter into the next channel menu.
Make sure to repeat through all four channel menus.
Use the 5.2-4 SCM Pin Reference chart to determine which function each channel is related to. A properly
working channel is indicated by a “0”. A fault is indicated by a “1”.
Check IO Err? MENU

PRESS SELECT SELECT
PE 1 2 3 4 5
0 0 0 0 0
PE 6 7 8 9 10
0 0 0 0 0 
+
PE 11 12 13 14 15
0 0 0 0 0
This is an example. The

MEWP may have more
channels than shown here.
Make sure to scroll
through all of the channels
in each menu using the
+ key.
OE 1 2 3 4 5
Example:
0 0 0 0 0
MENU
SELECT PE 6 7 8 9 10
IE 1 2 3 4 5 0 1 0 0 0
0 0 0 0 0
This example indicates a
SAVE PWM (PE) error (1) in
AE 1 2 3 4 5
channel 7.
0 0 0 0 0 EXIT
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5.2-10 SCM Calibration 4. Do the calibration procedure from the SCM 3

Tare weight calibration sets the unladen weight of the in the base control box. Follow the flowchart on
platform. It is the weight of an empty platform that the the next page.
SCM subtracts from the gross weight reading of the
load cell, giving a new zero (net) weight to start from 3
when measuring the contents of the platform.
Net weight = Gross weight - Tare weight
Net weight: the weight of the platform.
Gross weight: the total weight as measured by the CONTROLS INC.
load cell.
Tare weight: the weight of the empty platform as set
by the tare weight calibration.
1. Make sure the platform is level.

2. Remove all items from the platform, including
optional attachments.
3. Make sure the capacity derate switch 1 is
in the full capacity position, and the capacity
derate light 2 is not on.
TM
TM
1
+ +
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5.2-11 SCM Calibration Flowchart

Password 755
MODEL: XXXX SMB1-XXXX UNLOCK SETUP? MENU
FUNCTIONS OFF + SN XXXXXXXXXX PRESS SELECT SELECT
MENU MENU
ENTER PASSWORD
0** +
x7 SELECT
ENTER PASSWORD
70* +
x5 SELECT
ENTER PASSWORD
750 +
x5 ENTER PASSWORD
755
MENU
SELECT
SETUP UNLOCKED
PRESS - OR + +
Before going to the next step, make

sure the platform is: MENU
WEIGHT CALIB? OPTION(S)
• Horizontal to the ground
PRESS SELECT • Not touching the ground SELECT ADD or SET ? +
• Completely empty
OPTION(S) OPTION(S)
ADD or SET ? ADD or SET ?
(ADD flashing) (SET flashing)
MENU MENU
If the platform has options installed,
SELECT SELECT
identify and add up the weights of the
options from the table
Option Weight (lb) TARE CAL= 0 lb VALUE= 0 lb
Glazier SJ45 AJ+ 38 VALUE= 262 lbs TARE CAL= 0 lb
Glazier all other models 58
Pipe Rack 6
Tool Caddy 11
MENU
Wire Mesh (36” x 96”) 54 Enter the weight.
Wire Mesh (36” x 72”) 49 SELECT + Press SELECT after
Wire Mesh (30“ x 72”) 47 each digit.
Wire Mesh (30” x 60”) 44
SGM 51 TARE CAL= 262 lb
-
Control Box Cover 10 VALUE= 262 lbs
External Railing (36” x 96”) 22
MENU
External Railing (30” x 72”) 17
Welder ready 23 If no options are installed on the SELECT
platform, calibration is complete
SAVE
EXIT
SAVE CALIB: SUCCESS! SAVE
EXIT EXIT or SELECT EXIT
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5.2-12 CAN Bus Communication Check
MODEL: XXXX MENU ADJUST CAN BUS  ADJUST CAN BUS MENU
FUNCTIONS OFF SELECT IO TEST MAIN + IO TEST MAIN SELECT
SCMB1-105 Brain  SCMB1-106 Slave 1  MRW-1 Slave 4 

ID 1 OPERATING + ID 8 OPERATING + ID 11 OPERATING +
MRW-2 Slave 5  ENGINE J1939

ID 12 OPERATING + ID 0 OPERATING
All channels must be “OPERATING”.

If a channel is not reading correctly (OPERATING), “NO DATA” is shown.
Look at each channel for several seconds to confirm that it is not switching
from “OPERATING” to “NO DATA”.
SCMB1-105 Brain is the lower controller

SCMB1-106 Slave is the upper controller
MRW-1 Slave 4 ID 11 is CAN from the load cell. If it is not operating,
“LOAD CELL 1 LOST” appears on the screen when powered on.
MRW-2 Slave 5 ID 12 is CAN from the load cell. If it is not operating,
“LOAD CELL 2 LOST” appears on the screen when powered on.
ENGINE J1939 is CAN from the engine.
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Platform Section 5 – Procedures
5.3 Platform
5.3-1 Fly Boom Switch Voltage References
TELESCOPE SWITCH WORKSHEET

VOLTAGE DIVIDER CIRCUIT
R9
250 OHMS
250 OHMS R10

TELESCOPE IN
WIRE
L
PIN WIRE#38A +
32
4.83V
> >> P1-32 FLY TOGGLE SWITCH
7.25V
-
GND
TELESCOPE OUT O2
250 OHMS
R11
R8
250 OHMS
R9
250 OHMS
250 OHMS R10

TELESCOPE IN
WIRE
L
PIN WIRE#38A +
32
2.41V
> >> P1-32
FLY TOGGLE SWITCH 7.25V
-
GND
TELESCOPE OUT O2
250 OHMS
R11
R8
250 OHMS
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Section 5 – Procedures Platform
5.3-2 Platform Controller Voltage References

Boom/Turret (A1) Controller
Boom Up
12 Volts
Y
RED (+) POWER 04 RED/YEL
Neutral BLK(-) GROUND 02 WHT
Turret Rotate Left Position Turret Rotate Right WHT(X) X-SIGNAL RED
X 4.2 - 4.8 Pin 28
Volts
BLU(Y) Y-SIGNAL BLU
Pin 29
OCM
Reference
Analog Input
Boom Down AI 3
Reference
Analog Input Turret Rotation (X axis) Boom Elevation (Y axis)
AI 2
Neutral Position = 4.2 - 4.9 Volts Neutral Position = 4.2 - 4.8 Volts
Right = 4.9 - 8.5 Volts @ full stroke Up = 4.9 - 8.5 Volts @ full stroke
Left = 4.1 - 0.5 Volts @ full stroke Down = 4.1 - 0.5 Volts @ full stroke
Drive (A2) Controller

12 Volts
Drive Forward
04 YEL POWER RED
02 WHT GROUND BLK

Neutral
BLK D-SIGNAL YEL Position
Pin 27
4.2 - 4.8
24 BLU/BLK LEFT WHT/RED Volts
Pin 17
23 BLK/WHT RIGHT WHT/YEL
Pin 18
OCM
Drive Reverse
Reference
Analog Input
AI 1
12 Volts 12 Volts Neutral Position = 4.2 - 4.8 Volts

Left Steer Right Steer Forward = 4.9 - 8.5 Volts @ full stroke
Selected Selected Reverse = 4.1 - 0.5 Volts @ full stroke
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134
5.3-3 Replace the load cell Remove the old load cell
1. Remove the four outer bolts, washers, and
spacers that secure the rotary actuator bracket
Disconnect the old load cell to the platform. Set aside the hardware.
1. Lower the jib and boom until the platform rests
in a stable position at a comfortable working
height on support stands or a similar device.
Make sure you have easy access to the load cell
hardware under the platform.
2. Remove the platform control box from its
brackets and set it on the floor of the platform.
3. If needed, cut the cable ties which secure the
cables to the upright platform railing.
both sides
2. Remove the four bolts and washers from the

load cell on the underside of the platform.
4. Find the load cell cable and follow it into the

platform control box. Make note of the wire
connections, then disconnect it. Note: wire
colours can vary and may not be the same as
the legend below.
5. Loosen the strain relief connector and pull the
load cell cable out of the platform control box.
Cut cable ties as needed to free it.
black
blue
red
yellow
purple
white brown
green
Legend
02 - black
02 - blue
04 - red
04 - yellow
CANH - purple
CANH - white
CANL - brown
CANL - green
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135
3. Separate the platform from the jib/boom until the Install the new load cell
load cell is fully visible. 1. Take the new load cell and use a small flat
4. Remove the remaining four sets of hardware screwdriver to turn both dials on the side from 0
from the load cell. Set the hardware aside. to 2.
5
34 6
789A
F012
BC E
D
5
34 6
789A
F012
BC E
D
3456
F0 1 2
789A
5. Pull the load cell cable out of the rotary actuator
bracket.
6. Remove the load cell.
E
BCD
2. Feed the load cell cable through the hole in the

rotary actuator bracket.
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136
3. With the side marked “TOP” facing up, secure 8. Install the four outer bolts, washers, spacers,
the load cell to the rotary actuator bracket with safety washers, and nuts.
the hardware removed earlier. Hand-tighten the 9. Torque the bolts to 108 Nm (80 ft-lb).
bolts.
4. Then use the sequence below to torque the
bolts to 271 Nm (200 ft-lb).
1 4
both sides
3 2
5. Move the platform and the rotary actuator

bracket together and line up the holes.
6. Install the four bolts and washers on the load
cell, under the platform. Hand-tighten the bolts.
7. Torque the bolts to 271 Nm (200 ft-lb). 10. Mount the platform control box on its brackets.
1 4
3 2
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137
11. Feed the load cell cable into the platform control
box.
12. Connect the load cell wires to the terminal
blocks.
13. Tighten the strain relief connector.
black
blue
red
yellow
purple
white brown
green
Legend
02 - black
02 - blue
04 - red
04 - yellow
CANH - purple
CANH - white
CANL - brown
CANL - green
14. Replace any cable ties that were cut inside and
outside of the control box.
15. Follow 5.2-8 SCM Calibration and 5.2-11 SCM

Calibration Flowchart to calibrate the load cell.
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138
Boom Section 5 – Procedures
5.4 Boom 5.4-3 Cable Carrier Repair

To repair the cable carrier, simply use a screwdriver.
5.4-1 Check Wear Pads Snap each crossbar off from either side of the chain,
either by hand or by using the screwdriver as a lever.
1. Ensure the MEWP is on a firm level surface and Install new crossbars by snapping the links together.
is in the stowed position.
2. Start the engine from the base control console.
3. Raise the main boom to a comfortable working
Female Side
height (chest high), and then extend fly boom
approximately 30 cm (1 ft).
4. Measure the thickness of each wear pad, and
replace wear pad if it is less than 11 mm (7/16").
5. If the wear pad is within the specified thickness,
shim it as necessary.
Male Side
5.4-2 Shim Wear Pads Crossbar
1. Ensure the MEWP is on a firm level surface and

is in the stowed position.
2. Raise the main boom to a comfortable working
height (chest high) and extend the fly boom until 5.4-4 Rotary Actuator Bolt Torque
the wear pads are accessible. Procedure
3. Loosen the wear pad fasteners.
4. Shim the wear pads as necessary to obtain zero WARNING
to 1/32”(0.8 mm) clearance and zero drag. Maintaining proper torque is essential to safe
MEWP operation. Improper bolt torque could result
Fly Boom in an unsafe operating condition and component
damage.
1. Set the torque wrench to 25 Nm (17 ft-Ib) and

tighten the mounting bolts in a cross pattern
sequence.
1/32” Feeler
Gauge 1
8 5
Shim
Wear Pad
4 3
5. Extend and retract the fly boom through the
entire range of motion and observe for loose
points.
6 7
NOTE
Always maintain squareness between the boom’s
2
outer and inner tubes. 2. Set the torque wrench to 47 Nm (35 ft-Ib) and
tighten mounting bolts with the same sequence.
3. Torque the center bolt to 650 Nm (480 ft-lb).
SJ45 AJ+ 238274AEA
139
Section 5 – Procedures Boom
5.4-5 Master Cylinder Replacement 5. Secure the master cylinder with straps. See below
for an example.
1. Ensure the MEWP is parked on a firm and level
surface.
WARNING
Ensure that there is sufficient room for boom to
swing and elevate.
WARNING
Be aware of overhead obstructions or other
possible hazards around the machine when lifting.
2. By using the base controls, position the machine

as below to allow for easy work access to the CAUTION
basket/jib boom and the master cylinder.
Label all electrical cables and hydraulic hoses
before removal
CAUTION
To prevent hydraulic system contaminations, cap
all hydraulic hoses and fittings after removal.
6. Remove the hydraulic hoses and fittings on the

master cylinder. Replace any worn or damaged
components.
7. Disconnect the master cylinder from the main
boom by removing the connecting pin, see
below. Set all parts aside for reuse.
3. Turn the main disconnect switch to the off position

. Lock the switch to prevent unauthorized
use during this procedure.
NOTE
Ensure all components are secured before lifting
or removing them.
4. Using straps, secure the main boom on suitable

lifting equipment such as a crane.
8. Install the new master by installing the cylinder

pins as shown above. Secure the keeper pin and
the bolt with Loctile 242 (Blue) or equivalent.
9. Install the hydraulic hoses and fittings on the
master cylinder.
238274AEA SJ45 AJ+

140
Boom Section 5 – Procedures
5.4-6 Limit Switch Locations
4 2 3
1 Limit Switch LS1 - Direction Sensing

2 Limit Switch LS2 - Fly Stowed (high speed cut-out)
3 Limit Switch LS3 - Main Boom (high speed cut-out)
4 Limit Switch LS6 - Riser Stowed
SJ45 AJ+ 238274AEA

141
Section 5 – Procedures Turret
5.5 Turret 5.5-2 Turret Rotation Gear Bolt Torque

Sequence
5.5-1 Check and Replace the High WARNING

Pressure Filter Maintaining proper torque is essential to safe
MEWP operation. Improper bolt torque could result
1. Start the engine from the base control console. in an unsafe operating condition and component
damage.
2. Inspect the filter restriction indicator gauge 1 .
The filter should operate with the gauge pointing
to the green area. If it is in the red area, the filter
1. Set the torque wrench to 115 Nm (85 ft-lb)
needs to be replaced.
and tighten the mounting bolts in a criss-cross
3. To replace the filter, turn the engine off. pattern sequence.
4. Place a suitable container under the filter.
1 5
16
12 9
5
8 11 12 17
4 18 10 22
17 23
16
4 6 1 13
5 2
4 3 3
18
21 13
3 20 14
19 9 15
14 8 7 7
10 11
6 15
2
2
2. Set the torque wrench to 230 Nm (170 ft-Ib)
and tighten the mounting bolts with the same
5. Using a 30 mm box wrench on the filter housing
sequence.
nut 2 , loosen the filter housing 3 and remove
it from the filter head 4 .
6. Remove the filter element 5 from the filter head
and install a new high pressure filter element.
7. Apply hydraulic oil to the o-ring on the high
pressure filter housing.
8. Reinstall the housing, screwing it in fully, then
backing it off by one quarter turn.
238274AEA SJ45 AJ+

142
Turret Section 5 – Procedures
5.5-3 Battery Replacement 5.5-4 Tilt Switch Operation
1. Turn the main power disconnect switch to the off The following describes the LED’s and what they
position. indicate.
Light Indicators
2
1
R
Gre ed LE
en D
LE
D
4
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.
2. Remove the positive and negative connectors
Illuminated whenever tilt on
from the batteries. one or more axes is more than
Red LED
3. Remove the battery retainer bracket nuts, the specified degrees out from
washers, and j-hooks 1 . the zero/ home position.
4. Remove the bracket 2 . On together, no blinking when
Green & Red LED
fault detected.
5. Remove the batteries 3 .
6. Replace the battery pad 4 if needed.
7. Replace the batteries and secure them with the
bracket, j-hooks, washers and nuts.
8. Clean the terminal posts and clamps of the
batteries, and apply acid-free and acid-resistant
grease.
9. Re-connect the batteries with the positive and
negative connector cables (ensure the clamps
make good contact).
SJ45 AJ+ 238274AEA

143
Section 5 – Procedures Turret
5.5-5 Set Up a New Tilt Switch 8. Verify the switch is powered (red or green LED
will be solid).
Red LED Red LED

Y AXIS
Green LED Green LED
X AXIS
9. Program the tilt switch:

a. Press and release the set to zero button 3
times. Observe LED flash codes as shown
below.
b. Only the red LED will
blink for 4 seconds.
Red LED
Green LED
c. Both LEDs will flash for

NOTE 1 second.
To reprogram an existing tilt switch, go to 5.5-6 Results: The switch is Red LED
Reprogram an Existing Tilt Switch. learning the new zero Green LED
1. Park the MEWP on a firm level surface. position.

2. Disconnect the tilt switch from the 4 pin d. Both LEDs will turn on
connector. solid for 1 second.
Results: The new Red LED
NOTE
zero position has been Green LED
Make sure the part number of the old tilt switch and
learned.
new tilt switch are the same.
3. Remove the old tilt switch from the mount.

e. The green LED will flash and then the
red LED will turn on solid for 2 seconds.
Results: The switch is verifying the new zero
position.
Red LED Red LED

Green LED Green LED
4. Install the new switch on the mount and connect f. Only the red LED will
the switch plug to the 4 pin connector. blink for 4 seconds.
NOTE Red LED
Green LED
The tilt circuit is only powered when the controls are
powered up.
10. Turn the main power disconnect switch to the off
5. Turn the main disconnect switch to the ON position.
position.
11. Push in the emergency stop buttons.
6. Turn the base/off/platform key switch to the base
position.
7. Pull out both emergency stop buttons.
238274AEA SJ45 AJ+

144
Turret Section 5 – Procedures
5.5-6 Reprogram an Existing Tilt Switch

IMPORTANT
Step “c” must be completed within a 5 second
The set to zero button is located period, or the switch will automatically exit
Light Indicators on this face next to the harness
program mode and return to normal operation
using the previously stored data.
c. Press and release the set to zero button 3

times.
R
Gre ed LE
en
LE
D
D d. If the 5 second period has expired prior to
completion, repeat steps “a”, “b” and “c”.
e. Observe program
delay / stabilization
time (only the red Red LED
LED will blink for 4 Green LED
seconds).
NOTE f. Both LEDs will flash for
The tilt circuit is only powered when the controls 1 second.
are powered up. Results: The switch is Red LED
1. Turn the main disconnect switch to the ON learning the new zero Green LED
position. position.
2. Turn the base/off/platform key switch to the base g. Both LEDs will turn on
position. solid for 1 second.
3. Pull out both emergency stop buttons. Results: The new Red LED
zero position has been Green LED
4. Verify switch is powered (red or green LED will
learned.
be solid).
h. The green LED will flash and then the red
LED will turn on solid for 2 seconds.
Results: The switch is verifying the new zero
Red LED Red LED position.
Green LED Green LED
Red LED Red LED

Green LED Green LED
5. Reprogram the Tilt Switch
i. The green LED will turn
a. Press and hold the on solid.
set to zero button for Results: The switch Red LED
5 seconds. Red LED is ready for normal Green LED
Results: Both LEDs Green LED operation.

will be OFF. 6. Turn the main power disconnect switch to the off
position.
b. Both LEDs will flash. 7. Push in the emergency stop buttons.
Red LED
Green LED
8. Refer to 5.5-4 Tilt Switch Operation.
SJ45 AJ+ 238274AEA

145
Section 5 – Procedures Engines
5.6 Engines 5.6-2 Replace the Fuel Filter

1. Close the fuel shut-off valve.
2. Place a suitable container under the fuel filter.
Maintaining the engine components is essential to
3. Remove the fuel filter and catch any escaping
good performance and service life of the MEWP.
fuel.
5.6-1 Replace Engine Oil and Filter

WARNING
Periodic replacement of the engine oil and filter is
essential to good engine performance. Dispose of fuel in accordance with local and
federal regulations.
NOTE
Warm the engine to normal operating temperature
4. Clean any dirt from the filter carrier sealing
before starting this procedure.
surface.
5. Apply a thin layer of oil or diesel fuel to the
CAUTION rubber gasket of the new fuel filter.
Beware of hot engine components and hot oil. 6. Install the fuel filter and tighten it by hand, then
Contact with hot components may cause severe tighten the filter cartridge with a final half-turn.
burns. 7. Clean up any fuel that may have spilled during
this procedure.
1. Turn the engine off.
8. Open the fuel shut-off valve.
2. Place a suitable container under the engine oil
9. Check for fuel leakage.
drain.
10. Swing the engine tray back to its original
3. Remove the oil drain plug and allow all engine
position.
oil to drain into the container.
11. Reinstall the engine tray bolt.
WARNING
Dispose of oil in accordance with local and federal
regulations.
4. Install the oil drain plug with a new seal ring and
tighten it firmly.
5. Remove the oil filter and catch any escaping oil.
6. Clean inside the filter head.
7. Add clean engine oil to the oil filter.
8. Apply a thin layer of engine oil to the new oil
filter gasket.
9. Install the filter and tighten it by hand.
10. Clean up any oil that may have spilled during
this procedure.
11. Refill the engine with new oil. Refer to 2.11
Fluids.
12. Start the engine from the base control console
and allow the engine to run for 30 seconds, then
shut off the engine.
13. Check for oil leakage.
14. Check the engine oil level on the dipstick and
add oil if needed.
238274AEA SJ45 AJ+

146
Engines Section 5 – Procedures
5.6-3 Replace the Air Filter 5.6-4 Check the Engine Belt
Engine specifications require that this procedure be
performed more often if dusty conditions exist. Refer The MEWP will not operate properly with a loose
to the engine manual.
or defective belt. Continuous usage may cause
component damage.
CAUTION
Perform this procedure with the engine off. WARNING
Do not inspect the fan belt while the engine is
1. Remove the mounting fasteners from the air filter
running. Remove the key to prevent accidental
canister, and remove the end cap.
operation.
2. Remove the filter from inside of the canister.
3. Clean the inside of the canister and gasket with 1. Inspect the engine belt for:
a dry cloth. ▪ cracking
4. Insert a new filter into the canister. ▪ glazing
5. Reinstall the end cap. ▪ separation
▪ breaks
2. For correct tension of the engine belt, refer to
the engine manual.
5.6-5 Kubota D1305 Fuse Box
SJ45 AJ+ 238274AEA

147
J1939-73 Limp
148
Lamp Home Recovery
Time/
DTC SPN Name Detected Item DTC Set Parameter Blinking Action by from
238274AEA
No.*
FMI
SPN
Pattern Engine Error
ECU
Engine oil Despite rpm, oil pressure Long 1 Key switch
Oil pressure error 100 1 Oil pressure switch ≥ 1 sec
pressure switch is ON Short 2 turn OFF
Engine coolant Overheat of engine water Engine water temperature Long 1 Key switch
Engine overheat 110 0 ≥ 1 sec
temperature temperature ≥115 °C (239 °F) Short 6 turn OFF
Voltage of coolant
Water temperature Engine coolant Open circuit of sensor/ Long 2 Key switch
110 3 temperature sensor is 4.9 ≥ 1 sec
sensor: high temperature harness, B+ short circuit Short 4 turn OFF
V or above
Voltage of coolant
Water temperature Engine coolant Ground short circuit of Long 2 Key switch
110 4 temperature sensor is 0.1 ≥ 1 sec
sensor: low temperature sensor/harness Short 5 turn OFF
V or less
5.6-6 Kubota D1305 Error Codes
Open circuit, short circuit,

Battery voltage: Battery potential ECU recognition of battery Long 2 Key switch
158 3 or damage of harness. ≥ 1 sec Engine stop
high (voltage) switched voltage is above 18 V Short 7 turn OFF
Failure of battery.
Engine speeds exceeds Engine speed >2990 min- Long 1 Key switch
Engine overrun 190 0 Engined speed ≥ 1 sec Engine stop
threshold speed 1 (rpm) Short 1 turn OFF
Sensor supply Sensor supply Voltage to sensor is below Long 2 Key switch
3509 4 Sensor supply voltage 1 ≥ 1 sec Engine stop
voltage 1: low voltage 1 4V Short 8 turn OFF
Open circuit, short circuit, Actuator current >3.0 A or Long 2 Key switch
Actuator abnormal 523771 2 Proprietary ≥ 1 sec Engine stop
or damage of harness <80 mA Short 2 turn OFF
Engine speed = 0 min-1
Engine speed Open circuit, short circuit, Long 2 Key switch
523772 2 Proprietary (rpm) after starter signal ≥ 30 sec Engine stop
sensor abnormal or damage of harness Short 1 turn OFF
into ECU
Starter running time Starter running time is Long 1 Key switch
Starter error 523736 2 Proprietary ≥ 12 sec Engine stop
exceed threshold time above 12 sec Short 7 turn OFF
Alternator L terminal has
Alternator L Open circuit, short circuit, Long 2 Key switch
523737 2 Proprietary voltage while 0 rpm (after ≥ 1 sec
terminal abnormal or damage of harness Short 6 turn OFF
key on)
Open circuit, short circuit, Alternator L terminal is 0 V Long 1 Key switch
Chargin failure 523738 2 Proprietary ≥ 1 sec
or damage of harness while engine is running Short 3 turn OFF
CAN
Long 3 Key switch
communication 523774 2 Proprietary CAN Bus CAN Bus OFF ≥ 0.2 sec
Short 3 turn OFF
abnormal
Emergency stop CAN Long 1 Key switch
Emergency stop - - - Emergency stop switch ≥ 0.1 sec Engine stop
signal into ECO Short 5 turn OFF
SJ45 AJ+
Engines
J1939
Time/
Name DTC DTC Name Detected Item DTC Set Preconditions DTC Set Conditions System Action
Engines
Occ* MIL
Lamp
SJ45 AJ+
Enable
FMI
SPN
• Simulate intake
manifold pressure from
Intake manifold • Sensor/wiring • Intake manifold engine speed and
• Key on or engine
P0238 102 3 pressure harness short to power pressure sensor 1.0 sec throttle position O2F/B • •
running
voltage high • Sensor malfunction voltage >= 4.9 V adaptive learn stop
speed limit 2050rpm
throttle limit 30%
• Simulate intake
manifold pressure from
• Sensor/wiring
Intake manifold • Intake manifold engine speed and
harness open/short/ • Key on or engine
P0237 102 4 pressure pressure sensor 1.0 sec throttle position O2F/B • •
damage running
voltage low voltage <= 0.1 V adaptive learn stop
• Sensor malfunction
Tmap speed limit 2050rpm
throttle limit 30%
5.6-7 Kubota WG972 Error Codes
sensor
• Simulate intake
manifold temperature 30
Intake manifold • Sensor/wiring • Intake manifold
• Key on or engine °C (86 °F)
P0113 105 3 temperature harness short to power temperature sensor 1.0 sec • •
running • O2F/B adaptive learn
voltage high • Sensor malfunction voltage >= 4.6 V
stop
throttle limit 30%
• Simulate intake
• Sensor/wiring manifold temperature 30
Intake manifold • Intake manifold
harness open/short/ • Key on or engine °C (86 °F)
P0112 105 4 temperature temperature sensor 1.0 sec • •
damage running • O2F/B adaptive learn
voltage low voltage <= 0.1 V
• Sensor malfunction stop
throttle limit 30%
• Simulate engine
coolant temperature 70
Engine coolant • Engine coolant
• Sensor/wiring • Key on or engine °C (158 °F)
P0118 110 3 sensor voltage sensor voltage >= 1.0 sec • •
harness short to power running • O2F/B adaptive learn
high 4.9 V
• Sensor malfunction stop
Engine
• Throttle limit 30%
coolant
• Simulate engine
sensor
coolant temperature 70
Engine coolant • Sensor/wiring • Engine coolant
• Key on or engine °C (158 °F)
P0117 110 4 sensor voltage harness open/short/ sensor voltage <= 1.0 sec • •
running • O2F/B adaptive learn
low damage 0.1 V
stop
• Sensor malfunction
• TPS circuit in the running
TPS1 signal • TPS1 voltage >=
P0123 51 3 harness short to power • Motor power supply 0.5 sec • Engine stop (fuel cut) • •
voltage high 4.8 V
• TPS malfunction is normal or TPS power
149
238274AEA
supply is normal
J1939
150
Time/
Occ* MIL
Lamp
Enable
238274AEA
FMI
SPN
running
• Partial pressure terminal
• Motor power supply
TPS main i/f of TPS >= 4.8 V or partial
P1618 523717 2 • TPS malfunction is normal or TPS power 0.45 sec • Engine stop (fuel cut) • •
circuit error pressure terminal of TPS
supply is normal
<= 0.2 V
• TPS1 is normal
• TPS2 is normal
TPS
TPS power running • TPS power supply
P1619 523718 1 • TPS malfunction 0.5 sec • Engine stop (fuel cut) • •
supply error • Motor power supply is voltage <= 4.1 V
normal
• Engine speed > 1000

• Exhaust leaks upstream
rpm
or near the HEGO sensor
• Engine coolant
• Fuel pressure
temperature > 50 °C
abnormality
PreO2 sensor (122 °F) • Judgment is rich or 120 sec
P0130 3217 2 • An injector that is stuck • O2F/B stop • •
stay at one side • Engine coolant sensor judgment is lean or more
closed
is normal
• Wiring harness open/
• Intake manifold pressure
Heated short/damage
is normal
O2 • Sensor malfunction
• O2 F/B operative
sensor
• Open feed circuit to O2 • Engine coolant
heater temperature > 50 °C
• Open heater ground (122 °F)
PreO2 sensor circuit • Engine coolant sensor
P0134 3217 5 • O2 sensor is non active 70.0 sec • None • •
non activity • Open or shorted to is normal
ground O2 signal wire • Intake manifold pressure
• Open sensor ground is normal
• Inoperative sensor • Not idle
• Loss of sensor feed • No recognition of crank

• Open sensor ground • Engine cranking 2.0 sec • Engine stop (fuel cut) • •
Crank Crank sensor sensor pulse
P0335 636 2 • Open or shorted to
sensor error
ground signal wire • Pulse count per rotation
• Sensor malfunction • Engine running 16 times • Engine stop (fuel cut) • •
is error
• Loss of feed voltage to
Cam sensor
• Loss of sensor feed
Cam • Pulse count per rotation
P0341 723 2 Cam sensor error • Open sensor ground • Engine running 24 times • Engine stop (fuel cut) • •
SJ45 AJ+
Engines
sensor is error
• Open or shorted to
J1939
Time/
Engines
Occ* MIL
Lamp
SJ45 AJ+
Enable
FMI
SPN
• O2 heater running
Heated • Wiring harness open/ current <= 170 ma or
O2 P0135 523719 2 O2 heater error short/damage current >= 10.5 A 1.0 sec • O2F/B adaptive learn stop • •
running
sensor O2 heater malfunction • O2 heater stop
• Voltage <= 3.0 V
• The difference of
TargetTPS and ActualTPS
>= 0.6 V and TargetTPS
running
P1601 523710 2 F/B error1 • ETV malfunction < 1.5 V 1.3 Sec • Engine stop (fuel cut) • •
• Battery voltage is normal
• Or the difference of
• TPS is normal
TargetTPS and ActualTPS
>= 1.0 V
F/B error2 (valve running
P1602 523710 0 • ETV malfunction ActualTPS and TargetTPS 0.5 Sec • Engine stop (fuel cut) • •
open) • Battery voltage is normal
>= 0.5 V
• TPS is normal
F/B error2 (ISC running
P1603 523710 1 • ETV malfunction ActualTPS and TargetTPS 10.0 Sec • Engine stop (fuel cut) • •
close) • Battery voltage is normal
>= 0.05 V
• TPS adaptive completed
• Short to power
running
P1604 523711 2 Motor error • ETV malfunction short to gnd 0.3 Sec • Engine stop (fuel cut) • •
• ETV power supply
ETV temperature abnormality
voltage is normal
running
• ETV drive duty >=
P1605 523712 2 F/B error3 • ETV malfunction • BAttery voltage is normal 0.7 Sec • Engine stop (fuel cut) • •
100 %
• Motor drive circuit is
normal
Motor current • Motor power supply
P1606 523712 1 • ETV malfunction running 0.35 Sec • Engine stop (fuel cut) • •
open error voltage <= 6.0 V
battery voltage is normal
Return spring • Key on or engine • Middle valve adaptive

P1607 523712 7 • ETV malfunction 0 Sec • Speed limit 1600 rpm • •
breakage running value >= 3.8 V
• Filling-up efficiency >=

• TPS is abnormality
50 %
P1608 523713 0 DBW open stuck • ETV malfunction (except power supply 0.35 Sec • Engine stop (fuel cut) • •
engine speed >= 4000
error)
rpm
• Exhaust leaks upstream
or near the HEGO sensor
• Compensation value of
• Fuel pressure
O2 F/B and adaptive value
abnormality
Fuel of O2 F/B > 35%
P1617 523716 2 Fuel system error • An injector that is stuck • Engine running 0 Sec • O2F/B stop • •
System • Compensation value of
closed
O2 F/B and adaptive value
151
238274AEA
of O2 F/B < -35%
short/damage
J1939
152
Time/
Occ* MIL
Lamp
Enable
238274AEA
FMI
SPN
Fuel
Fuel shutoff short/damage • Lock off valve voltage
shutoff P1625 523725 2 • Key on N/A • None • •
solenoid error • Fuel shutoff solenoid is low
solenoid
malfunction

Fuel • Key on
P0627 1347 2 Fuel pump error short/damage • Fuel pump voltage is low 1 sec • None • •
pump • Un-driving
• Fuel pump malfunction
Power
P0687 1485 3 Power relay error • Power relay malfunction • Key off • ECU is alive 30 sec • None • •
relay
Sensor • Wiring harness open/

Sensor power • Key on or engine • Sensor power source < • Throttle limit 30%
power P0642 3509 4 short/damage 1.0 sec • •
source error running 4.1 Volts O2F/B adaptive learn stop
source • ECU malfunction
• CAN_TSC1 frame time

• Wiring harness open/ • Idle
Can • Key on or engine out error
U1001 695 9 CAN frame error short/damage 200 ms throttle limit 15% • •
frame running 5 sec passed since ECU
• CAN system malfunction O2F/B adaptive learn stop
is on.
EEPROM P0605 523721 2 EEPROM error • EEPROM malfunction • Unique ID is incorrect N/A • None • •
running
• Run time wait for ECT

Engine coolant • Engine coolant • Engine running faults = 30 sec
P0217 110 0 temperature temperature abnormality • Engine coolant sensor • Engine coolant 1.0 sec • Engine stop (fuel cut) • •
exceeds stage2 (high side stage 2) is normal temperature >= 115 °C
Engine (240 °F)
over heat • Run time wait for ECT
Engine coolant • Engine coolant • Engine running faults = 30 sec
P0116 110 15 temperature temperature abnormality • Engine coolant sensor • Engine coolant 1.0 sec • •
• O2F/B adaptive learn stop
exceeds stage1 (high side stage 1) is normal temperature >= 110 °C
(230 °F)
Intake manifold • Intake air temperature running • Intake manifold
P0127 105 0 temperature abnormality • Intake manifold temperature >= 77 °C 1.0 sec • Engine stop (fuel cut) • •
exceeds stage2 (high side stage 2) temperature sensor is (170 °F)
Intake normal
manifold
temp • Key on or engine
Intake manifold • Intake air temperature running • Intake manifold
P0111 105 15 temperature abnormality • Intake manifold temperature >= 77 °C 1.0 sec • Engine stop (fuel cut) • •
exceeds stage1 (high side stage 1) temperature sensor is (170 °F)
normal
SJ45 AJ+
Engines
Generator Section 5 – Procedures
5.7 Generator 3. If the deflection is more than 8 mm (5/16"),

adjust the belt tensioner bolts on the generator
tray to tighten the belt.
5.7-1 Tension the Generator Belt
1. Place a straight edge along the side of the belt,

from the generator pulley to the engine pulley.
2. With a belt tension meter, measure the deflection
of the belt while adding 22 N (5 lb) of force.
Radiator removed
for clarity.
4. Continue to measure and adjust until the belt

deflection is between 6 mm (1/4") and 5 mm
(3/16").
22 N (5 lb)
5 mm-6 mm
(3/16”-1/4”)
IMPORTANT
If the belt still slips or squeaks after it is correctly
tensioned, replace the belt.
IMPORTANT
Do not over-tension the belt! You can damage
components if you do.
SJ45 AJ+ 238274AEA

153
Section 5 – Procedures Hydraulic Tank
5.8 Hydraulic Tank 5.8-2 Hydraulic Filter Replacement
1. Turn the MEWP off.

Maintaining the hydraulic components and hydraulic
oil at the proper level are essential to the good 2. Place a suitable container under the filter.
performance and service life of the MEWP.
5.8-1 Hydraulic Oil Replacement
1. Turn the engine on and allow the hydraulic oil to

warm up.
2. Shut the engine off.
3. Place a suitable container under the hydraulic
tank.
4. Remove the oil drain plug and allow all of the
hydraulic oil to drain into the container.
5. Reinstall the drain plug with a new seal ring and
tighten the plug firmly.
6. Refill the hydraulic tank with new oil. Refer to 3. Use a filter wrench to remove the filter from the
2.11 Fluids. head. Throw out the filter.
7. Check for leakage. 4. Apply hydraulic oil to the o-ring on the new filter,
8. Clean up any oil that may have spilled during and screw the filter into place.
this procedure. 5. Tighten the filter with the filter wrench.
9. Check the hydraulic oil level. The hydraulic oil
level should be at or slightly above the fill line on
the tank. NOTE
Refer to your national/local regulations on how to
dispose of used filters and oil.
NOTE
Refer to your national/local regulations on how to
dispose of the used filter and oil.
NOTE
Samples of hydraulic oil should be drawn from
the reservoir and tested annually. These samples
should be taken when the oil is warmed through
normal operation of the system. The sample should
be analyzed by a qualified lubrication specialist to
determine if it is suitable for continued use. Oil change
intervals will depend on the care used in keeping the
oil clean, and the operating conditions. Dirt and/or
moisture cotamination dictate that the oil should be
changed more often. Under normal use and operating
conditions, the hydraulic oil should be changed every
two years. For oil specifications, refer to 2.11 Fluids.
238274AEA SJ45 AJ+

154
Manifold and Hydraulic Pumps Section 5 – Procedures
5.9 Manifold and Hydraulic

WARNING
Pumps Make sure there are no personnel or obstructions
in the test area and there is sufficient room for
5.9-1 Hydraulic Brake Pressure forward or reverse travel.
Adjustment
5. Start the engine from the platform control
Maintaining accurate hydraulic brake pressure is console and extend the boom slightly to achieve
elevates speed drive.
important when it comes to safe MEWP operation.
6. Drive the MEWP forward or reverse. The
1. Make sure the MEWP is on a firm level surface pressure gauge reading should be 34 bar
and is in the stowed position. (500 psi). Stop the MEWP. Follow the next steps
2. Locate the BRG port 1 on the side of the brake for adjusting the relief valve pressure, if needed.
manifold and remove the cap. If no adjustment is required continue to step 10.
3. Connect a pressure gauge (70 bar/1000 psi) to 7. Turn the adjusting stem on the pressure relief
the BRG port. valve 2 ¼ of a turn at a time clockwise to
increase pressure or counterclockwise to
decrease pressure. Drive the MEWP forward or
reverse, note the pressure and stop the MEWP.
8. Repeat step 9 until brake pressure is achieved
(34 bar/500 psi) then tighten the lock nut on
brake system pressure relief valve PR1 2 .
1 9. Reconnect the wiring in the same position it was
removed from in step 4.
10. Test the brake and two-speed functions.
4. Remove the wiring from three valves: differential

lock valve wire numbers 165 and 02, axle
lockout valve wires 65 and 02, as well as two
speed valve wires 45A and 02. Mark the valves
to ensure you put the wiring back in the correct
positions later.
CAUTION
Failure to remove the wiring may cause damage to
components downstream.
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Section 5 – Procedures Manifold and Hydraulic Pumps
5.9-2 Hydraulic System Relief Valve 5.9-3 Riser Down Relief Valve Adjustment
Adjustment
1. Locate the GP2 port 3 on the main manifold.
1. Locate the GP1 port 1 on the main manifold. Remove the cap.
Remove the cap. 2. Connect a pressure gauge (345 bar/5000 psi) to
2. Connect a pressure gauge (345 bar/5000 psi) to GP2 3 .
GP1 1 .
2
4
3
1

and let it run for 2-5 minutes.
3. Start the engine from the base control console 4. Raise the main boom to make sure the platform
and let it run for 2-5 minutes. will not contact the ground.
4. Extend or retract the jib fully and then check 5. Fully lower the riser and check the reading on
the reading on the gauge. The pressure should the gauge. The pressure should be 190 bar
be 214 bar (3100 psi). Follow the next steps for (2750 psi). Follow the next steps for adjusting
adjusting the pressure, if needed. the pressure, if needed.
5. Locate system relief valve RV6 2 . 6. Locate riser down relief valve RV8 4 .
6. Loosen the lock nut on system relief valve 7. Loosen the lock nut on system relief valve
RV6 2 . Turn the adjusting stem clockwise to RV8 4 . Turn the adjusting stem clockwise to
increase the pressure, and counterclockwise to increase the pressure, and counterclockwise to
decrease the pressure. decrease the pressure.
7. Tighten the lock nut on system relief valve RV6 8. Tighten the lock nut on system relief valve RV8
2 once 214 bar (3100 psi) is observed on 2 once 190 bar (2750 psi) is observed on the
the gauge. Note: You must steer fully in one gauge. Note: You must fully lower the riser to
direction to activate the pressure reading on the activate the pressure reading on the gauge.
gauge.
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5.9-4 Turret Rotate Relief Valve 5.9-5 Platform Level Relief Valve
Adjustment Adjustment
1. Locate the GP2 port 1 on the main manifold. 1. Locate the GP2 port 1 on the main manifold.
2. Connect a pressure gauge (345 bar / 5000 psi) 2. Connect a pressure gauge (345 bar / 5000 psi)
to GP2. to GP2.
1 1
2 3

3. Start the engine from the base control console and let it run for 2-5 minutes.
and let it run for 2-5 minutes. 4. Raise the main boom to make sure the platform
4. Raise the main boom to make sure the platform will not contact the ground.
will not contact the ground. 5. Fully raise or lower the platform level and check
5. Engage the turret transport lock. the reading on the gauge. The pressure should
6. Attempt to rotate the turret. The pressure should be 190 bar (2750 psi). Follow the next steps for
be 120 bar (1750 psi). Follow the next steps for adjusting the pressure, if needed.
adjusting the pressure, if needed. 6. Locate the platform leveling relief valve RV9 3 .
7. Locate the turret rotate relief valve RV7 2 . 7. Loosen the lock nut on the platform level relief
8. Loosen the lock nut on the turret rotate relief valve RV9 3 . Turn the adjusting stem clockwise
valve RV7 2 . Turn the adjusting stem clockwise to increase the pressure, and counterclockwise
to increase the pressure, and counterclockwise to decrease the pressure.
to decrease the pressure. 8. Tighten the lock nut on the platform level
9. Tighten the lock nut on the turret rotate relief relief valve RV9 3 once 190 bar (2750 psi) is
valve RV7 2 once 86 bar 120 bar (1750 psi) is observed on the gauge. You must fully raise or
observed on the gauge. You must activate the lower the platform level to activate a pressure
turret rotate to obtain a pressure reading on the reading on the gauge.
gauge.
10. Disengage the turret transport lock.
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5.9-6 Test Charge Pump Pressure on 5.9-7 Test Forward Drive Pressure on
Drive Pump Drive Pump
1. Locate test port TP3 1 on the drive pump. NOTE

2. Connect a pressure gauge 41.5 bar (600 psi) to Make sure the charge pump pressure test is
the test port. completed first.
1. Locate test port TP1 2 on the drive pump.

2. Connect a pressure gauge (690 bar / 10 000 psi)
to test port TP1.
3. Start the engine from the base control console.
WARNING 3. Start the engine from the platform control

console.
To protect the gauge, do not activate any controls
during this procedure. 4. Unplug the brake solenoid power cable (26) on
the brake valve.
4. Check the reading on the gauge. Standard 5. Activate the drive function slowly forward with
pressure should be 21.5 ±2 bar (313 ±31 psi). the engine at high speed. The wheels should not
5. Replace the charge pump relief valve RV3 2 if turn.
the standard pressure is not achieved.
6. Repeat steps 2, 3, and 4 after the charge pump
NOTE
Activating the drive function too quickly will stall
relief valve is replaced.
the engine.
7. If the pressure is still not in range, repair or
replace the pump as necessary. 6. Check the reading on the gauge. The standard
pressure should be 345 bar (5000 psi).
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7. If the correct pressure is not achieved, turn the 12. Start the engine.
engine off and remove the hose from the tee 13. Activate the drive function slowly forward with
fitting 3 connected to TP1. Cap the fitting and the engine at high speed. The wheels should not
plug the hose. turn.
3 NOTE
the engine.
14. Check the reading on the gauge. The standard

15. Replace the pump if the pressure is not
achieved.
16. Remove the pressure gauge. Connect the
hoses to their original locations. Connect the
brake solenoid power cable.
8. Start the engine.

9. Activate the drive function slowly forward with
the engine at high speed. The wheels should not
turn.
NOTE
the engine.

11. If the pressure is not achieved, turn the engine
off. Remove the hose from the smaller fitting
4 on the system pump as seen below. Cap the
fitting on the pump and plug the hose.
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5.9-8 Test Reverse Drive Pressure on 7. If the correct pressure is not achieved, turn the
Drive Pump engine off and remove the hose from the tee
fitting 2 connected to TP1. Cap the fitting and
plug the hose.
NOTE
Make sure the charge pump pressure test is
2
completed first.
1. Locate test port TP2 1 on the drive pump.

9. Activate the drive function slowly in reverse with
1
turn.
2. Connect a pressure gauge (690 bar / 10 000 psi) NOTE

to test port TP2. Activating the drive function too quickly will stall
the engine.
WARNING
To protect the gauge, do not activate any controls pressure should be 345 bar (5000 psi).
during this procedure.
11. If the pressure is not achieved, turn the engine
off and remove the hose from the lower fitting
3 on the system pump as seen below. Cap the
3. Start the engine from the platform control
console. fitting on the pump and plug the hose.
4. Unplug the brake solenoid power cable (26) on
the brake valve.
turn.
NOTE
the engine.
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turn.
NOTE
the engine.

15. Replace the pump if the pressure is not
achieved.
16. Remove the pressure gauge. Connect the
hoses to their original locations. Connect the
brake solenoid power cable.
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Section 5 – Procedures Axles
5.10 Axles 5.10-2 Check the Oil Level in the Torque

Hubs
5.10-1 Change the Oil in the Axles
1. Drive the MEWP to rotate the hub until the plug
1. Place a suitable container under the axle. is in the 3 or 9 o’clock position. Shut off the
engine.
2. Remove the fill plug.
2. Remove the plug and check the oil level. The oil
3. Remove all three drain plugs to allow the oil to level should be even with the bottom of the plug
drain into the container. hole. Add oil if needed. Refer to 2.11 Fluids. for
oil specifications.
Fill Level Check
Drain Fill
Drain
Front Axle
Fill Level Check 5.10-3 Change the Oil in the Torque Hubs
1. Start the engine and drive the boom until the fill/
drain port of one of the hubs is in the 6 o’clock
position. Shut off the engine. Place a container
under the fill/drain port.
2. Remove the plug and allow all of the oil to drain,
watching carefully to avoid spills.
Drain 3. Restart the engine and drive the boom until the
Rear Axle drain plug is in the 3 or 9 o’clock position. Shut
off the engine.
4. Refill the hub with new oil as per specifications.
4. Reinstall all of the drain plugs. Refer to 2.11 Fluids.
5. Remove the check plug. 5. Repeat the above steps with the other three
wheel hubs.
NOTE
The axle is full when oil is leaking from the check
port.
6. Refill the axle with new oil as per specifications

Refer to 2.11 Fluids.
7. Reinstall both of the fill and check plugs.
Drain Fill
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Axles Section 5 – Procedures
5.10-4 Check the Oil Level in the Axle 5.10-5 Change the Oil in the Axle Gearbox
Gearbox
1. Place a suitable container under the gearbox.
1. Remove the fill plug 1 from the gear box. 2. Remove the fill plug.
2. Check the oil level. It should be even with the 3. Remove the drain plug to allow oil to drain into
bottom of the fill plug hole. Add oil if needed. the container.
Refer to 2.11 Fluids. for oil specifications.
1 Fill/Check Port Drain Port
4. Reinstall the drain plug.
NOTE
The gearbox is full when oil is leaking from the
check port.
5. Refill the gearbox with new oil as per
specifications. Refer to 2.11 Fluids.
6. Reinstall the fill plug.
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5.10-6 Oscillating Cylinder Mount 5.10-7 Oscillating Cylinder Bolt

Inspection Replacement
1. Look at the areas where the oscillating axle
cylinder and the cylinder mount plate meet. If on inspection you find the oscillating cylinder bolts
Inspect for the following: have missing or damaged torque seal, you must
▪ Gaps between the cylinder and the mounting replace the affected bolts. If you replace more than
plate mating surfaces. one bolt, do so one at a time to prevent the cylinder
▪ Damage, distortion, or movement of the from shifting.
mounting surface of the cylinder. 1. Remove the affected bolt.
▪ Loose or missing mounting bolts. 2. Clean the cylinder’s corresponding internal
threaded hole thoroughly.
3. Replace the removed bolt with either a new
1/2”-13 x 1-3/4” grade 8 bolt with liquid blue
Loctite 242 or 243 applied to the bottom half of
the bolt, or a new 1/2”-13 x 1-3/4” grade 8 patch
bolt, along with a new 1/2” hardened washer.
4. Hand-tighten the bolt.
No gaps
5. Torque the new bolt to 108 Nm (80 ft-lb) for a
standard bolt with blue Loctite applied, or to 129
Nm (95 ft-lb) for a patch bolt.
6. Apply a line of torque seal to each new bolt
extending from the bolt head over the washer
and to the chassis wall.
No damage
Contact the Skyjack service department for

instructions if you find:
▪ gaps between the mating surfaces, or
▪ damage or distortion of the mounting plate, or
▪ distortion or movement of the cylinder.
If there is damage to the cylinder but no evidence
of the other conditions listed above, go to 5.10-8
Oscillating Cylinder Replacement
If there are loose or missing bolts but no evidence
of the other conditions listed above, go to 5.10-7
Oscillating Cylinder Bolt Replacement.
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5.10-8 Oscillating Cylinder Replacement 3. With a rag in hand to catch oil leaks, slowly
loosen the bleeder screw to release trapped air
within the cylinder, then tighten it again.
CAUTION 4. Slowly loosen the oscillating axle cylinder hoses
to release the pressure, then disconnect them
The oscillating axle cylinder weighs approximately fully. Be sure to plug the hose ends.
19.5 kg (43 lbs), so a second person to help with 5. Remove and set aside the cylinder fittings.
the removal and replacement would be helpful. Make sure they stay clean.
1. Wedge a block of wood between the front

axle and the chassis, to prevent the axle from
oscillating during the procedure.
6. Remove and throw away the bolts and washers

that hold the cylinder to the chassis. Lift the
cylinder away.
7. Lift a new cylinder into place.
8. Install either new 1/2”-13 x 1-3/4” grade 8 bolts
2. Remove and set aside the base cover from the with liquid blue Loctite 242 or 243 applied to
oscillating axle end of the chassis. the bottom half of the bolts, or new 1/2”-13 x
1-3/4” grade 8 patch bolts, along with new 1/2"
hardened washers.
9. Hand-tighten the bolts.
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10. Adjust the oscillating cylinder position until 13. Install the cylinder fittings. Torque the larger one
there is continuous contact between the cylinder to 33 Nm [24 ft-lbs] and the smaller one to 20
mounting surface and the mounting plate, and Nm [15 ft-lbs].
between the mounting plate and the cylinder 14. Remove the plugs and reconnect the hoses to
shoulder, with no gaps. the cylinder fittings. Torque the larger hose end
11. Torque the bolts to 108 Nm (80 ft-lb) for a to 28 Nm [21 ft-lbs] and the smaller hose end to
standard bolt with blue Loctite applied, or to 129 16 Nm [12 ft-lbs].
Nm (95 ft-lb) for a patch bolt. 15. Install the base cover.
16. Remove the block of wood between the axle and
the chassis.
17. Turn the engine on and let it run for a few
minutes to pressurize the cylinder, then turn it off
again.
18. Look at the hydraulic oil level on the hydraulic
tank sight gauge. Add more hydraulic oil if
necessary.
19. Bleed the cylinder. Refer to 5.10-9 Bleed the
No gaps Oscillating Axle Cylinders.
12. Apply a line of torque seal to each bolt extending

from the bolt head over the washer and to the
chassis wall.
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5.10-9 Bleed the Oscillating Axle Cylinders 5.10-10 Test the Oscillating Axle Cylinders
1. Extend the fly boom 30 cm (1 ft) while on a firm,

WARNING level surface.
If the axle oscillation system does not ▪ Result: The steer axle locks.
operate correctly, the stability of the MEWP is 2. Drive one of the steer tires up onto a 15 cm (6”)
compromised and it may tip over. block or curb.
▪ Result: An appropriate tilt of the MEWP
chassis occurs.
Items you need before you start:
▪ a container for oil
▪ a hose that reaches from the bleeders to the
container
1. Locate a bleeder on either side of the oscillating

axle cylinder.
2. Connect a hose to the bleeder nipple.
4. Slowly open the bleeder to allow the oil to flow in
a continuous stream.
5. Close the bleeder.
6. Repeat the procedure with the other oscillating
axle cylinder.
3. Retract the fly boom while in the tilted position.
4. Drive the MEWP forward.
▪ Result: The steer axle unlocks and the chassis
levels itself with the ground.
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167
5.10-11 Pin Brake Adjustments 4. Tighten the Jam nut. Repeat this procedure for
the other side.
1. To manually release the brake give a light blow

to the external ring of the check unit.
2. To adjust the idle elimination loosen jam nut and

back out adjustment stem a few turns. 5. On the Cylinder side ensure that there is some
clearance between the cylinder and the lever “A”
with the lever against the stop.
3. Apply a 2lb. force (1Kg) in the direction of brake

application and turn adjusting stem so that it
touches the stop. 6. Introduce pressure into the cylinder and ensure
that the check unit engages.
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168
7. Release the pressure from the cylinder and 5.10-12 Brake Inspection
check that the rod returns and stops in a
position where it projects out from the cylinder
head by 5 mm (3/16"). 1. Remove the oil level plug from one of the
braking axle arms, as shown below.
2. Insert a 4.5 mm feeler gauge into the drain port.
8. If adjustment is needed loosen the jam nut,

pressurize the cylinder and turn the adjustment
stem. Repeat step 7 and tighten jam nut when
correct adjustment is obtained.
3. Use the gauge to check the gap between the

disks (A). The minimum distance allowed is
4.5 mm. Reinstall the oil level plug.
9.
4. Repeat the inspection on the other axle arm. If

the gap is smaller than 4.5 mm between the
disks of either arm (i.e. the gauge doesn’t fit),
the brake disks must be replaced on both arms.
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5.10-13 Axle U-Bolt Torque 4. Gradually tighten the nuts evenly so the same
amount of bolt thread shows above all 4 nuts.
Use the sequence shown below.
Replace the u-bolts and nuts every time you replace
5. Use the same sequence to torque the nuts to
or remove an axle, or when a u-bolt has been
290 Nm (214 ft-lb).
loosened for any reason.
Refer to the parts manual for the u-bolt, flat washer,
and nut part numbers.
1. If applicable, set the axle in place under the
chassis.
2. Put a new u-bolt through the holes in the =
mounting bracket. Place flat washers over the
bolts. Install two new nuts on the ends of the
bolt. Finger-tighten the nuts.
3. Repeat with the other three u-bolts and nuts.
1 5 7 3
2 6 8 4
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Grease Points Section 5 – Procedures
5.11 Grease Points
Maintaining proper lubrication is essential for good performance and service life of the MEWP. If the
bearing and gear of the MEWP are improperly greased, it could result in component damage.
5.11-1 Grease the Turret Ring Gear

1. Open the control side cowling, and locate the turret ring gear grease fitting 1 under the bottom right corner
of the base control box.
2. Pump grease into the fitting, and continue pumping until new lube appears continuously around the grease
seal lip of the ring gear.
3. Rotate the turret in increments of 10 to 13 cm (4 to 5 inches) at a time, and repeat step 2 until the entire
bearing has been greased.
4. Pump grease into the three grease fittings on the outside of the worm gear motor 2 .
2 1
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Section 5 – Procedures Grease Points
5.11-2 Grease the Axles

1. Open the axle cover plates and locate the grease fittings.
2. Pump grease into the grease fittings.
5.11-3 Grease the Drive Shaft

1. Locate the grease fittings on the drive shaft u-joints, and pump grease into the fittings.
238274AEA SJ45 AJ+

172
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SERVICE

Please refer to the website (www.skyjack.com) for contact

The original instructions are in English.

BECOME ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

SJ45 AJ+ 238274AEA

238274AEA SJ45 AJ+

Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SJ45 AJ+ 238274AEA

Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 39

238274AEA SJ45 AJ+

SJ45 AJ+ 238274AEA

238274AEA SJ45 AJ+

Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

SJ45 AJ+ 238274AEA

238274AEA SJ45 AJ+

1.1-2 Purpose of equipment

1.1-3 Use of equipment

1.1-4 Service Policy and Warranty

1.1-5 Ownership of MEWP

SJ45 AJ+ 238274AEA

1.2 General information

238274AEA SJ45 AJ+

SJ45 AJ+ 238274AEA

1.2-7 Railing maintenance and repair 1.3 Scheduled maintenance

238274AEA SJ45 AJ+

1.3-3 Schedule and instructions 1.3-4 Repairs

▪ Make copies of the maintenance and inspection

SJ45 AJ+ 238274AEA

1.3-5 Pre-delivery/maintenance inspection checklist

User: Print Name Signature Date (DD/MM/YY)

238274AEA SJ45 AJ+

1.3-6 Inspection points Use the 1.3-5 Pre-delivery/maintenance inspection

SJ45 AJ+ 238274AEA

Main power Hydraulic pump and motor

Battery B Engine tray

1. Do an inspection of the battery case for damage.

238274AEA SJ45 AJ+

Muffler and exhaust

Radiator and coolant B

High pressure filter Engine oil filter Engine fuel filter

SJ45 AJ+ 238274AEA

Manifolds Turret transportation lock

Emergency power unit

238274AEA SJ45 AJ+

Wheels/tires ▪ Do a check on all tire treads and Oscillating Cylinders

SJ45 AJ+ 238274AEA

Platform control console AC power socket

▪ Make sure the gates or drop

▪ Make sure the operation manual and other

238274AEA SJ45 AJ+

Cable track Control cables Wear pads

SJ45 AJ+ 238274AEA

Optional equipment Cold or arctic Welder

Glazier Pipe rack

1.3-7 Function tests

238274AEA SJ45 AJ+

FITTING LENGTH IN FRACTIONS

Using the number above as an example,