SERVICE

MANUAL
SJ30AJE, SJ30ARJE
ARTICULATING BOOM

196274AF
November 2018
ANSI/CSA, CE, AS, KC
 This manual is based on Serial Numbers:
SJ30AJE& SJ30ARJE: 90 000 001 to 90 999 999

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

for contact information, other Serial Numbers,
the most recent Technical Manuals, and USB
software.

Original instructions 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.

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 Notes

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Table of Contents
Section 1 – Scheduled 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 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-5 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-6 Operator Safety Reminders, Warnings and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-1 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-2 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-3 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-4 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-5 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2-6 Hydraulic Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2-7 Railing Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3-1 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3-2 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Pre-Delivery/Maintenance Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6-1 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6-2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6-3 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6-4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6-5 Control Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6-6 Motor/Hydraulic Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-7 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6-10 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.6-11 Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6-12 Optional Equipment/Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.1 Standard Hose Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 MEWP Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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2.3 Torque Specifications for Fasteners (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Torque Specifications for Fasteners (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Torque Specifications for Hydraulic Couplings & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Maximum Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Floor Loading Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Hydraulic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.10 Specifications and Features - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.11 Specifications and Features - CE, AS & KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.12 Reach Diagram - SJ30AJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.13 Dimesion Diagram - SJ30AJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.14 Reach Diagram - SJ30ARJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.15 Dimension Diagram - SJ30ARJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Section 3 – System Component Identification and Schematics . . . . . . . . . . . . . . . . . . . . 45

3.1 Electrical Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Hydraulic Symbol Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Wire Number and Color Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5 Electrical Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6 Jib Valves and Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.7 Main Manifold Hose Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.8 Main Manifold Electrical Component Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.9 Main Manifold Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.10 Main Manifold Harness - ANSI/CSA, CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.11 Main Manifold Harness - KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.12 Control Cables & Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13 Platform Limit Switch Harness - KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.14 Emergency Pump Base Controls Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.15 Direction Sensing Limit Switch Base Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.16 High Speed Cut - Out Limit Switches Base Controls Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.17 Overload Sensor Platform Controls Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.18 Footswitch Platform Controls Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.19 SGE Platform Controls Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.20 Hydraulic Schematic - SJ30AJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.21 Hydraulic Schematic - SJ30ARJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.22 Platform Controls Schematic - SJ30AJE ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.23 Platform Controls Schematic - SJ30ARJE ANSI/CSA, CE & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.24 Platform Controls Schematic - SJ30ARJE KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.25 Base Controls Schematic - SJ30AJE ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.26 Base Controls Schematic - SJ30ARJE ANSI/CSA & AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.27 Base Controls Schematic - SJ30ARJE CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.28 Base Controls Schematic - SJ30ARJE KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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3.29 Electrical Schematic - ANSI/CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.30 Electrical Schematic - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.31 Electrical Schematic - AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.32 Electrical Schematic - KC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.33 Motor Controller Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2-2 All Controls Inoperative If Equipped with Elevate/Trackunit Telematics . . . . . . . . . . . . . . . . . . . . . 86
4.2-3 No Power To Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-4 All Functions Inoperative from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-5 No Boom Up from Base Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2-6 No Boom Down from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-7 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-8 No Riser Down from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-9 No Turret Rotate Left from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-10 No Turret Rotate Right from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-11 No Telescope Retract from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-12 No Telescope Extend from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-13 No Platform Rotate Left from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2-14 No Platform Rotate Right from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2-15 No Jib Up from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-16 No Jib Down from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-17 No Jib Rotate Right from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2-18 No Jib Rotate Left from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2-19 No Manual Platform Level Up from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2-20 No Manual Platform Level Down from Base Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2-21 All Controls Inoperative from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2-22 No Boom Up from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2-23 No Boom Down from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2-24 No Riser Up from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2-25 No Riser Down from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2-26 No Turret Left from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.2-27 No Turret Right from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2-28 No Telescope In from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2-29 No Telescope Out from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2-30 No Platform Rotate Left from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2-31 No Platform Rotate Right from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2-32 No Jib Up from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-33 No Jib Down from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2-34 No Jib Rotate Left from Platform Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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 4.2-35 No Jib Rotate Right from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2-36 No Manual Platform Level Up from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.2-37 No Manual Platform Level Down from Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.2-38 Brake will not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2-39 No Drive and Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2-40 No Forward Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2-41 No Reverse Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2-42 No High Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2-43 No Left Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2-44 No Right Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.2-45 Direction Sensing Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3-2 No Main Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3-3 No Main Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3-4 No Riser Boom Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-5 No Riser Boom Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-6 No Turret Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-7 No Turret Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3-8 No Boom Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3-9 No Boom Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3-10 No Jib Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.3-11 No Jib Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3-12 No Platform Rotation Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3-13 No Platform Rotation Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3-14 No Jib Rotation Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3-15 No Jib Rotation Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3-16 Platform will not Level Down Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3-17 Platform will not Level Up Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3-18 No Left Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.3-19 No Right Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.4 Load Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.4-1 Green Power LED is not Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.4-2 Load Cell red Alarm LED is ON (with platform empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.4-3 Red Error LED is ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.4-4 Load Cell red Alarm LED is OFF (with platform overloaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.4-5 Platform Indicator Light does not turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.4-6 Audible Alarm does not turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.1-1 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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 5.2-1 Human Machine Interface (HMI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.1-2 User Interface Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2-2 SCM Character Functions Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2-3 SCM Operating Values Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.2-4 How to Unlock and Modify the SCM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.2-5 How to Adjust the SCM Pump Motor Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2-6 How to Set the SCM Valve Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.2-7 SCM Pin Voltage Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2-8 Platform Controller Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.2-9 Telescope, Riser & Jib Switch Voltage References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.3 Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.3-1 Verify Proper Operation of the Load Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.3-2 Calibration of Load Sensing System (with “Teach In” Handset) . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.4 Boom & Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-1 Check Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-2 Shimming Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-3 Cable Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.4-4 Master Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.4-5 Jib Rotary Actuator Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.4-6 Platform Rotary Actuator Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.5 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.5-1 Hydraulic Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.5-2 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.5-3 Hydraulic System Main Relief Valve Adjustment (RV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.5-4 Main Pump Relief Valve Adjustment (RV5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.5-5 Emergency Pump Relief Valve Adjustment (RV6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.5-6 Turret Rotate Relief Valve Adjustment (RV3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.5-7 Riser Down Relief Valve Adjustment (RV7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.5-8 Boom Extend Relief Valve Adjustment (RV4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.5-9 Platform Level Relief Valve Adjustment (RV2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.6 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.6-1 Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.6-2 Ring Gear Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.6-3 Check Torque Hub Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.6-4 Electronic Tilt Switch Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.6-5 Motor Controller Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.6-6 Motor Controller Panel Pin Interface - Connector A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.6-7 Motor Controller Panel Pin Interface - Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.6-8 Motor Controller Connectors Pin Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.6-9 ZAPI MDI-CAN Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.6-10 ZAPI MDI-CAN Controller Master Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.6-11 ZAPI “Skyjack PC CAN Console” Software Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.7 Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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 5.7-1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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Section 1 – Scheduled Maintenance
1.1 Read and Heed 1.1-5 Service Policy and Warranty
Skyjack warrants each new product to be free of
Skyjack is continuously improving and expanding
defective parts and workmanship for the first 2
product features on its equipment, therefore,
years or 3000 hours, whichever occurs first. Any
specifications and dimensions are subject to change
defective part will be replaced or repaired by your
without notice.
local Skyjackdealer at no charge for parts or labor.
In addition, all products have a 5 year structural
1.1-1 Mobile Elevating Work Platform warranty. Contact the Skyjack Service Department for
(MEWP) Definition warranty statement extensions or exclusions.
A mobile device that has a positionable platform
supported from ground level by a structure. 1.1-6 Operator Safety Reminders,
Warnings and Precautions
1.1-2 Purpose of Equipment Operator safety is Skyjack’s priority. The operator
The Skyjack Electric Articulating Boom Series MEWPs should comply with all applicable safety-related
are designed to transport and raise personnel, tools reminders, warnings and precautions found in
and materials to overhead work areas. the Operating Manual. They should be read and
understood completely before operating the MEWP.
1.1-3 Use of Equipment
The MEWP is a highly maneuverable, mobile work
station. Work platform elevation and elevated driving
must only be done on a firm, level surface.

1.1-4 Manual
Operating Manual: The operating manual is
considered a fundamental part of the MEWP. It is a
very important way to communicate necessary safety
information to users and operators. A complete
and legible copy of this manual must be kept in the
provided weather-resistant storage compartment on
the MEWP at all times.
Service & Maintenance: The purpose of this is
to provide the customer with the servicing and
maintenance procedures essential for the promotion
of proper machine operation for its intended purpose.
All information in this manual should be read and
understood before any attempt is made to service the
machine. The updated copy of the manuals are found
on the company’s website: www.skyjack.com.

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Section 1 – Scheduled Maintenance Maintenance and Service

1.2 Maintenance and Service 1.2-4 Maintenance and Service Safety

Tips
1.2-1 Maintenance and Inspection Maintenance and repair should only be performed by
Schedule personnel who are trained and qualified to service this
MEWP.
The actual operating environment of the work platform
governs the use of the maintenance schedule. All maintenance and service procedures should be
The inspection points covered in 1.5 Pre-Delivery/ performed in a well lighted and well ventilated area.
Maintenance Inspection Checklistt, indicates the areas Anyone operating or servicing this MEWP must read
of the MEWP to be maintained or inspected and at and completely understand all operating instructions
what intervals the maintenance and inspections are to and safety hazards in this manual and operating
be performed. manual.
All tools, supports and lifting equipment to be used
1.2-2 Owner’s Annual Inspection Record must be of proper rated load and in good working
It is the responsibility of the owner to arrange quarterly order before any service work begins. Work area
and annual inspections of the MEWP. Table 1.4 should be kept clean and free of debris to avoid
Owner’s Annual Inspection Record is to be used for contaminating components while servicing.
recording the date of the inspection, owner’s name,
Ensure personnel are clear from under unsupported
and the person responsible for the inspection of the
components/systems that are at risk of movement
work platform.
during maintenance.

1.2-3 Replacement Parts All service personnel must be familiar with employer
and governmental regulations that apply to servicing
Use only original replacement parts. Parts such
this type of equipment.
as batteries, wheels, railings, etc. with weight and
dimensions different from original parts will affect Keep sparks and flames away from all flammable or
stability of the MEWP and must not be used without combustible materials.
manufacturer’s consent. Properly dispose of all waste material such as
All replacement tires must be of the same size and lubricants, rags, and old parts according to the
load rating as originally supplied tires; to maintain relative law provisions obtaining in the country.
safety and stability of MEWP. Before attempting any repair work, disconnect the
Consult Skyjack’s Service Department for optional main power connectors.
tires specifications and installation. Preventive maintenance is the easiest and least
expensive type of maintenance.
WARNING
Any unit that is damaged or not operating properly
must be immediately tagged and removed from
service until proper repairs are completed.

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Maintenance and Service Section 1 – Scheduled Maintenance

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

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Section 1 – Scheduled Maintenance Maintenance and Service

1.2-7 Railing Maintenance and Repair

Skyjack MEWPs have been designed to ensure
compliance with the relevant design standards
applicable for that particular unit at the time of
manufacture. As such, any repairs made to the
guardrail or basket structure need to ensure this
compliance is not compromised and must return the
structure to its original condition.
Any damage must be repaired by returning the railing
assembly to its undamaged state. Damage includes,
but is not limited to, the items listed below:
▪ bent/deformed guardrail sections
▪ cracks or broken welds in railing sections
▪ damaged pin connections
▪ missing pins or broken pin lanyards
▪ missing railing hardware
▪ loose or missing parts
▪ additional holes in guardrail sections other than
those approved by Skyjack
Additionally, the guardrails must be properly
positioned and secured, and the entry gate must be
in good working order.
The strength of the guardrail system, and therefore
its ability to provide fall protection for platform
occupants, depends upon the design being secure
and undamaged.
Skyjack railings are designed for modular
replacement, and Skyjack recommends replacement
of any damaged railing section. Skyjack-approved
replacement parts will meet this requirement.

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Scheduled Maintenance Section 1 – Scheduled Maintenance

1.3 Scheduled Maintenance 1.3-3 Maintenance Instructions

This manual consists of four schedules to be done for
This section contains the maintenance and inspection
maintenance on a MEWP. The inspection schedule
schedule that is to be performed.
frequency is shown below:
References are made to the procedures in Section
5 that outline detailed step-by-step instructions for Issue or Symptom
checks and replacements.
PDI/Frequent B Perform a PDI prior to each
1.3-1 Service Bulletins delivery, or a Frequent
Before performing any scheduled maintenance Inspection every 3 months
inspection procedure, refer to the service bulletins or 150 hours.
found on our website: www.skyjack.com for updates
Annual B+C Perform Scheduled
related to the service and maintenance of this MEWP.
Maintenance Inspections
every year.
1.3-2 Maintenance and Inspection
Death or injury can result if the MEWP is not kept in Additional * Perform at time sensitive
good working order. Inspection and maintenance maintenance intervals.
should be performed by competent personnel who
are trained and qualified on maintenance of this ▪ Make copies of the maintenance and inspection
MEWP. checklist to be used for each inspection.
▪ Check the schedule on the checklist for the type
WARNING of inspection to be performed.
Failure to perform each procedure as presented ▪ Place a check in the appropriate box after each
and scheduled may cause death, serious injury or inspection procedure is completed.
substantial damage. ▪ Use the maintenance and inspection checklist
and step-by-step procedures in Section 1 to
perform these inspections.
NOTE If any inspection receives a fail, tag and remove
Preventive maintenance is the easiest and least
▪
the MEWP from service.
expensive type of maintenance.
▪ If any MEWP component(s) has been repaired,
▪ Unless otherwise specified, perform each an inspection must be performed again before
maintenance procedure with the MEWP in the removing the tag. Place a check in the repair
following configuration: column.
▪ MEWP parked on a flat and level surface Legend
▪ Disconnect the batteries by disconnecting the Pass P
main power connectors.
▪ Repair any damaged or malfunction Fail F
components before operating MEWP.
Repaired R
▪ Keep records on all inspections.
Not applicable N/A

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15
Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record

Table 1.4 Owner’s Annual Inspection Record

**
2

Figure 01 This decal is located on the controls side cowling. It must be completed after an
annual inspection has been completed. Do not use the MEWP if an inspection has not been
recorded in the last 13 months.

Description Label Pictorial Description Label Pictorial

2 Inspector
1 Inspection Date
Signature

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Pre-Delivery/Maintenance Inspection Checklist Section 1 – Scheduled Maintenance

1.5 Pre-Delivery/Maintenance Inspection Checklist

Pre-Delivery/Maintenance Inspection Checklist
Electric Articulating Booms
Serial Number: Product Owner:

Model:

Hourmeter Reading: Product User:

Date/Time:
Use this form for Pre-Delivery Inspections (PDI) prior to each rental, lease or sale, or as a guide for all Frequent Inspections and Annual Inspections. Refer to
the applicable Operating and Service Manuals for inspection details (eg. Visual Inspection and Function Tests, Torque Specs., Engine Oil, Chain Inspection
Intervals, etc.).
Inspection Type Schedule
q PDI B B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 150 hrs. For further details refer to P - Pass
q Frequent B Service & Operating Manuals. F - Fail
q Annual B+C C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals. R - Repaired
q Additional * * - Perform time sensitive maintenance intervals. Refer to the Service Manual. N/A - Not Applicable
Check the appropriate box as each item is inspected. If an item is found to be not acceptable, please describe the issue in the comments box provided.

Items for Inspection P F R N/A Items for Inspection P F R N/A

Refer to www.skyjack.com for the latest service bulletins. B, C Battery Charger. Secure and no damage. B
Ensure Annual Inspection has been completed within the Batteries. No damage, tight connections, adequate fluid
B B
last 13 months. levels. Clean terminals and cable ends.
Manuals & Required Documents. In storage box, in Battery Trays. Latches and lids are secure. No missing
B B
good condition and legible. parts.
Labels. In place, secure and legible. B Pothole Protection. No cracks, damage or deformation. B
Limit Switches. Secure. No obstructions or damage. B Electrical Panel. Secure and no damage. Tight wire
B
Base Control Console. Switches in neutral position and connections and fasteners.
B
no damaged or missing parts. Platform Assembly. No damage or missing parts. B
Main Manifold. Tight fittings and hoses and no leaks. Raillings and Gate. Secure and no damage or missing
B, C B
Tight wire connections. parts.
Hydraulic Tank. Filler cap secure and no damage or Platform Control Console. Switches in neutral position
B B
leaks. and secure. No damage or missing parts.
Hydraulic Filter. Secure and no damage, missing parts SGE. Secure. No damage or missing parts. B
B, C
or leaks. Platform Rotary Actuator. No damage or missing parts.
B
Hydraulic Pump/Motor. Tight fittings, hoses and bolts. Tight fittings, hoses and bolts and no leaks.
B
No damage, missing parts or leaks. Jib Rotary Actuator. No damage or missing parts. Tight
B
Hydraulic Oil. Level between min. and max. marks. B fittings, hoses and bolts, and no leaks.
Emergency Power Unit. Tight fittings and hoses. No Jib. No damage or missing parts. Tight hoses and bolts and
B
leaks. Tight wire connections and no damage or missing B no leaks.
parts. Boom. No damage or missing parts. No deformation or
B
Turret Rotation Motor/Gear. Tight fittings, hoses and cracks in welds. Tight hoses and bolts and no leaks.
B, C
bolts. No damage, missing parts or leaks. Pins & Bushings. No damage/wear, or loose or missing
B
Main Power Connectors. Cables secure and in working parts.
B
order. No damage or missing parts. Control Cables and Hoses. No damage or missing parts. B
Wheel Motors. Secure. No damage or missing parts. B Cylinders. Secure and no damage or leaks. B
Torque Hubs. Secure, and no damage or missing parts. Wear Pads. No damage or missing parts. Bolts tightened. B
B
Tight fittings, hoses and bolts. No leaks. Riser. Secure and no damage/deformation or missing parts. B
Steer Cylinder Assembly. Secure and no missing parts. E-Chain. No damage or missing parts. B
B
Tight fittings and hoses. No leaks. Special Options and Approved Attachments. Secure
Tie Rod. No damage/wear or missing parts. B and no damage or missing parts.
Wheel/Tire Assembly. Check all tires for damage, wear
B, C Function Tests. Refer to the corresponding Operating Manual q PASS
& proper alignment. Lug nuts torqued as recommended.
for your serial number for information on running these tests. q FAIL
Base Weldment. No cracks or deformation. B

Comments:

The undersigned confirms that all areas listed have been inspected, and any and all discrepancies have been brought to the attention of the owner.
Furthermore, the undersigned confirms that all discrepancies have been corrected prior to using this machine.

Owner: __________________________________________ / __________________________________________ / __________________________________________

Print Name Signature Date (DD/MM/YY)

User: __________________________________________ / __________________________________________ / __________________________________________

Print Name Signature Date (DD/MM/YY)

Note: Visit www.skyjack.com for a printable copy of this form. 210016AA

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

1 Limit Switch Locations

1 1

1.6 Scheduled Maintenance 1.6-2 Electrical

Maintaining the electrical components is essential to
Inspections the good performance and service life of the MEWP.
Begin the scheduled maintenance inspections by Inspect the following areas for chafed, corroded, and
checking each item in sequence for the conditions listed loose wires:
in this section.
▪ boom to platform cable harness
WARNING ▪ engine compartment electrical panel
To avoid injury, do not operate a MEWP until all ▪ engine wiring harness
malfunctions have been corrected. ▪ rotary manifold wiring

1.6-3 Limit Switches (B)

WARNING
Ensure limit switches 1 are properly secured with
To avoid possible injury, ensure the MEWP power no signs of visible damage, and movement is not
is off during your visual and daily maintenance obstructed.
inspections.
1.6-4 Hydraulic
CAUTION Maintaining the hydraulic components is essential to
the good performance and service life of the MEWP.
Ensure the MEWP is on a firm, level surface.
Perform a visual inspection around the following
areas:
NOTE ▪ hydraulic tank filter, fittings, hoses, emergency
While performing visual and daily inspections power unit and turret/base surface
in different areas, be sure to also inspect limit
▪ engine compartment fittings, hoses, main pump,
switches, electrica,l and hydraulic components.
filter and turret/base surface
▪ all hydraulic cylinders
1.6-1 Labels (B)
▪ all hydraulic manifolds
Refer to the labels section in the operating manual
▪ the underside of the turret
and ensure all labels are in place and are legible.
▪ the underside of the base
▪ the ground area under the MEWP

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

1.6-5 Control Compartment

▪ Ensure all compartment latches are secure and
in proper working order.
1 Base Control Console (B)
▪ Ensure all switches are returned to their
neutral positions.
▪ Ensure there are no loose or missing parts and
there is no visible damage.
2 Main Manifold (B)
▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
leakage.
▪ Ensure there are no loose wires or missing
fasteners.

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

1.6-6 Motor/Hydraulic Compartment 5 Emergency Power Unit (B)

▪ Ensure all compartment latches are secure and ▪ Ensure there are no loose or missing parts and
in proper working order. there is no visible damage.
1 Hydraulic Tank (B) ▪ Ensure there are no loose wires or missing
▪ Ensure the hydraulic filler cap is secure. fasteners.
▪ Ensure the tank shows no visible damage and ▪ Ensure all fittings and hoses are properly
no evidence of hydraulic leakage. tightened and there is no evidence of hydraulic
leakage.
2 Hydraulic Pump/Motor (B)
6 Turret Rotation Motor/Gear (B,C)
▪ Ensure there are no loose or missing parts and
there is no visible damage. ▪ Ensure there are no loose or missing parts and
there is no visible damage.
▪ Ensure all bolts are properly tightened.
▪ Ensure all bolts are properly tightened.
▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic ▪ Ensure all fittings and hoses are properly
leakage. tightened and there is no evidence of hydraulic
leakage.
3 Hydraulic Oil (B)
C - Annual Inspection
▪ Ensure the boom is in the stowed position, and
then visually inspect the sight gauge located on ▪ For the lubrication procedure refer to section 2.6
the side of the hydraulic oil tank. Tire Specifications.
▪ Ensure the hydraulic oil level is within the
minimum and maximum range found on the
hydraulic oil level indicator label. Add oil as
needed. Refer to 2.9 Hydraulic Specifications for
recommended oil type.
4 Hydraulic Filter (B)
▪ Ensure the housing is secure and shows no
visible damage or leakage.

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

2
3

1.6-7 Base 6 Wheel/Tire Assembly (B,C)

1 Main Power Connectors (B) The MEWP is equipped with solid rubber tires. Tire
▪ Disconnect and lock out the connector on either and/or wheel failure could result in a MEWP tip-over.
the left or right side of the MEWP. Component damage may also result if problems are
not discovered and repaired in a timely fashion.
▪ Ensure all cables are secure and the connector
is in proper working condition and has no visible ▪Check all tire treads and sidewalls for cuts,
damage. cracks, punctures and unusual wear.
2 Electrical Panel ▪ Check each wheel for damage and cracked
welds.
▪ Ensure the panel is properly secured and there
is no visible damage. ▪ Check each bolt for proper torque to ensure
none are loose.
▪ Ensure there are no loose wires or missing
fasteners. ▪ Check the wheel motor assembly for loose or
missing parts and signs of visible damage.
3 Torque Hubs (B)
▪ Ensure the drive axle is properly secured, there
▪ Ensure the wheels are aligned and true vertically
and horizontally.
are no loose or missing parts, all fittings and
hoses are properly tightened and there is no Refer to 2.6 Tire Specifications for tire/wheel
evidence of hydraulic leakage. specifications.
4 Steer Cylinder Assembly (B)
WARNING
▪ Ensure the steer cylinder assembly is properly
secured, there are no loose or missing parts, all Do not use tires other than those specified for this
fittings and hoses are properly tightened, and machine. Do not mix different types of tires. Tires
there is no evidence of hydraulic leakage. other than those specified can adversely affect
stability. Failure to operate with matched, approved
5 Steering Linkage (B)
tires in good condition can result in death or
▪ Ensure there are no loose or missing parts, tie serious injury. Replace tires with the exact,
rod end studs are locked, and there is no visible Skyjack-approved types only.
damage.

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

10

7 Pothole Protection
WARNING
▪ Ensure there are no visible cracks and there
are no signs of damage or deformation. Battery acid is extremely corrosive. Wear proper
eye and facial protection as well as appropriate
8 Battery Trays
protective clothing. If contact occurs, immediately
▪ Ensure tray latches are secure and in proper flush with cold water and seek medical attention.
working order.
9 Battery Charger ▪ Check the battery cases for damage.
▪ Ensure the charger is secure and shows no B - Frequent Inspection
visible damage.
10 Batteries (B)
▪ Clean the battery terminals and cable ends
thoroughly with a terminal cleaning tool or wire
▪ Proper battery condition is essential to brush.
good performance and operational safety. ▪ Ensure all battery connections are tight.
Improper fluid levels or damaged cables and
connections can result in component damage ▪ If applicable, check the battery fluid level.
and hazardous conditions. B - Frequent Inspection
▪ If the plates are not covered by at least 13 mm
WARNING (1/2") of solution, add distilled or demineralized
water.
Explosion hazard. Keep flames and B - Frequent Inspection
sparks away. Do not smoke near the
batteries.
▪ Replace the battery if it is damaged or
incapable of holding a lasting charge.

WARNING
Use original or manufacturer-approved parts and
components for the MEWP.

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

1 2

7 3

4
5

1.6-10 Platform 7 Manuals

Platform Assembly (B) ▪ Ensure a copy of the operating manual and
▪ Ensure there are no loose or missing parts and other important documents are enclosed in the
there is no visible damage. manual storage box.
▪ Ensure all fasteners are securely in place. ▪ Check to be sure the manual storage box is
present and in good condition.
▪ Ensure fall protection anchorage(s) 1 are
secure and there is no visible damage. ▪ Ensure the manuals are legible and in good
condition.
▪ Ensure all railings 2 are properly positioned
and secured. ▪ Always return manuals to the manual storage
Ensure the gate/drop bar 3 is in good box after use.
▪
working order.
▪ Ensure the footswitch 4 is in good working
order and has not been modified, disabled or
blocked.
▪ Ensure the AC outlet 5 has no visible damage
and is free from dirt or obstruction.

6 Platform Control Console (B)

▪ Ensure all switches/controllers are returned to
neutral.
▪ Ensure there are no loose or missing parts and
there is no visible damage.

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

2
5

4
8

1.6-11 Boom 5 Wear Pads (B)

1 Main and Fly 2 booms (B) ▪ Ensure all bolts are tight, there is no visible
▪ Ensure there are no loose or missing parts and damage to the wear pads, and no parts are
there is no visible damage. missing.
▪ Ensure all bolts and pins are properly tightened. 6 E-Chain (B)
▪ Ensure there are no visible cracks in the welds or ▪ Ensure there are no loose or missing parts and
structure, and there are no signs of deformation. there is no visible damage.
▪ Ensure all hoses are properly tightened and 7 Jib (Non-Rotating and Rotating) (B)
there is no evidence of hydraulic leakage. Ensure there are no loose or missing parts and
▪
3 Riser (B) there is no visible damage.
▪ Ensure there are no loose or missing parts and ▪ Ensure all bolts and pins are properly tightened.
there is no visible damage. ▪ Ensure all hoses are properly tightened and
▪ Ensure all bolts and pins are properly tightened. there is no evidence of hydraulic leakage.
▪ Ensure there are no visible cracks in the welds or 8 Rotary Actuator (B)
structure, and there are no signs of deformation. Ensure there are no loose or missing parts and
▪
▪ Ensure all hoses are properly tightened and there is no visible damage.
there is no evidence of hydraulic leakage. Ensure all bolts and pins are properly tightened.
▪
4 Cylinders (B) Ensure all hoses are properly tightened and
▪
▪ Ensure all cylinders are properly secured and there is no evidence of hydraulic leakage.
there is no evidence of leakage.
▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of damage.

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

4 5 1

1.6-12 Optional Equipment/Attachments

1 Work Light
▪ Ensure the lamps are properly secured with no
signs of visible damage.
▪ Ensure the mounting bracket is properly
secured.
▪ Ensure there are no loose wires or missing
fasteners.
2 Flashing Amber Light
▪ Ensure the lamp is properly secured with no
signs of visible damage.
3 Inverter
▪ Ensure the inverter is properly secured with no
signs of visible damage.
4 Pipe Rack
▪ Ensure the pipe rack assemblies are properly
secured with no signs of visible damage.
5 Control Box Cover
▪ Ensure the control box cover is properly
secured with no signs of visible damage.
6 Air Line
▪ Ensure the air line is properly secured with no
signs of visible damage.

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Section 1 – Scheduled Maintenance Function Tests

1.7 Function Tests

Function tests are designed to discover any
malfunctions before a MEWP is put into service. The
operator must understand and follow the step-by-step
instructions to test all MEWP functions.

IMPORTANT
Never use a malfunctioning MEWP. If malfunctions
are discovered, the MEWP must be tagged and
placed out of service. Repairs to the MEWP may
only be made by qualified/competent repair
personnel.

After repairs are completed, the operator must

perform a pre-operation inspection and a series of
function tests again before putting the MEWP into
service.

Prior to performing function tests, be sure to read

and understand the “Start Operation” section of the
operating manual.

For function test that are to be performed, please

refer to the operating manual that corresponds to
the correct serial number. Found there are detailed
instructions for which tests to perform, as well as
how to properly and successfully perform them.

NOTE
All-function motion alarm should sound while
operating any boom and drive function.

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Section 2 – Maintenance Tables and
Diagrams
Table 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
H02 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R13
H03 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R17
H04 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R13
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
H08 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R4
H09 FEMALE, 37° JIC, SWIVEL 45°, FEMALE, 37° JIC, SWIVEL 100R4
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
H25 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R4
H30 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H31 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H32 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H33 MEDIUM 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H34 SHORT 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H35 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H36 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H37 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R4
H38 SHORT 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R4
H39 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R4
H40 SHORT 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R16
H43 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R16
H51 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H52 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H53 MEDIUM 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H54 SHORT 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H55 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H56 LONG 90°, 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
H60 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R17
H61 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R16
H62 SHORT 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R16
H63 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R16
H64 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R16
H65 MEDIUM 67°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R12
H66 FEMALE, 37° JIC, SWIVEL NO FITTING 100R4
H67 FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19
H68 SHORT 45°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19
H69 MEDIUM 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19
H70 LONG 90°, FEMALE, 37° JIC, SWIVEL FEMALE, 37° JIC, SWIVEL 100R19
H71 LONG 90°, FEMALE, SAE ORFS, SWIVEL FEMALE, SAE ORFS, SWIVEL 100R15

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MEWP Torque Specifications Section 2 – Maintenance Tables and Diagrams

Table 2.2 MEWP Torque Specifications

Torque
Location Description
ft-lb Nm
Base
Drive Motor BOLT, Hex head (1/2"-13 x 1.75", Grade 8) 75-85 102-115
Torque Hub BOLT, Hex head (5/8"-11 x 1.75", Grade 8) 170 230
Wheel Nut (torque hub) NUT, Wheel (5/8"-18) 180 244
Wheel Nut (free spinning hub) NUT, Wheel (5/8"-18) 180 244
Swing Drive BOLT, Hex head (5/8"-11 x 4.00", Grade 8) 170 230
Turret
Ring Gear BOLT, Hex head (5/8"-11 x 4.00", Grade 8) 170 230
Turret Counterweight BOLT, Hex Head (3/4"-10 x 3.00", Grade 8) 250 339
Riser Counterweight BOLT, Hex head (3/8"-16 x 3.25", Grade 5) 30 41
Cylinders
PISTON 578 784
Main Lift PISTON SET SCREW 11 15
GLAND 491 666
ROD NUT 289 392
Extension
GLAND 318 431
PISTON 542 735
Master PISTON SET SCREW 11 15
GLAND 462 626
ROD NUT 289 392
Slave
GLAND 462 626
PISTON 434 588
Riser PISTON SET SCREW 6 8
GLAND 376 510
PISTON 324 439
Jib PISTON SET SCREW 6 8
GLAND 318 431
PISTON 361 489
Steer PISTON SET SCREW 6 8
GLAND 318 413
Jib
BOLT, Hex head, patch (3/8"-16 x 0.875", Grade 8) 35 47
Rotary Actuator
NUT, Torque Lock (1-8, Grade 3) 770 1044
Platform
BOLT, Hex head, patch (3/8"-16 x 0.75", Grade 8) 35 47
Rotary Actuator
NUT, Torque Lock (3/4"-10, Grade C) 380 512
BOLT, Hex head (1/2"-13 x 2.25", Grade 8) 80 108
Load Cell
BOLT, Hex head patch (ZP, M16 x 1.5 x 4.5, Grade 8.8) 130 177
1388AC

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29
Section 2 – Maintenance Tables and Diagrams Torque Specifications for Fasteners (US)

Table 2.3 Torque Specifications for Fasteners (US)

Torque SAE2 SAE 5 SAE 8 Torque SAE2 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, or uncured Loctite.
1374AA

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Torque Specifications for Fasteners (Metric) Section 2 – Maintenance Tables and Diagrams

Table 2.4 Torque Specifications for Fasteners (Metric)

Torque SAE2 SAE 5 SAE 8

Size
Type Dry Lubed Dry Lubed Dry Lubed
(in-lb) (54) (41) (78) (59) (12) (9)
M5 x 0.80
Nm 6.1 4.6 8.8 6.7 1.4 1.0
(in-lb) (92) (69) (133) (99) (13) (10)
M6 x 1.00
Nm 10.4 7.8 15 11.2 1.5 1.1
(in-lb) (156) (116) (222) (167) (23) (17)
M7 x 1.00
Nm 17.6 13.1 25.1 18.9 2.6 1.9
(in-lb) (225) (169) (333) (242) (25) (19)
M8 x 1.25
Nm 25.4 19.1 37.6 27.3 2.8 2.1
ft-lb 37 28 53 40 (41) (31)
M10 x 1.50
Nm 50 38 72 54 4.6 3.5
ft-lb 65 49 93 69 (43) (32)
M12 x 1.75
Nm 88 66 126 94 4.9 3.6
ft-lb 104 78 148 111 (60) (45)
M14 x 2.00
Nm 141 106 201 150 6.8 5.1
ft-lb 161 121 230 172 (68) (51)
M16 x 2.00
Nm 218 164 312 233 7.7 5.8
ft-lb 222 167 318 238 12 9
M18 x 2.50
Nm 301 226 431 323 16 12
ft-lb 314 235 449 337 14 10
M20 x 2.50
Nm 426 319 609 457 19 14
ft-lb 428 321 613 460 25 18
M22 x 2.50
Nm 580 435 831 624 34 24
ft-lb 543 407 776 582 25 20
M24 x 3.00
Nm 736 552 1052 789 34 27
ft-lb 796 597 1139 854 45 35
M27 x 3.00
Nm 1079 809 1544 1158 61 47
ft-lb 1079 809 1543 1158 50 35
M30 x 3.50
Nm 1463 1097 2092 1570 68 47
ft-lb 1468 1101 2101 1576 70 55
M33 x 3.50
Nm 1990 1493 2849 2137 95 75
ft-lb 1886 1415 2699 2024 80 60
M36 x 4.00
Nm 2557 1918 3659 2744 108 81

NOTE: Lubed includes lubricants such as lubrizing, oil, grease, or uncured Loctite. 1375AA

SJ30AJE, SJ30ARJE 196274AF

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Section 2 – Maintenance Tables and Diagrams Torque Specifications for Hydraulic Couplings & Hoses

Table 2.5 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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Tire Specifications Section 2 – Maintenance Tables and Diagrams

Table 2.6 Tire Specifications

SJ30AJE/ SJ30ARJE
Tire Size 22 in. x 7 in. (559 cm x 178 cm)
Type Solid Rubber
Wheel Nuts Torque 180 ft-lb (244 Nm)
1171AA_ANSI

WARNING
Do not use tires other than those specified for this machine. Do not mix different types of tires. Tires other
than those specified can adversely affect stability. Failure to operate with matched, approved tires in good
condition can result in death or serious injury. Replace tires with the exact, Skyjack-approved types only.

Table 2.7 Maximum Platform Capacities

SJ30AJE/ SJ30ARJE
INDOOR OUTDOOR
500 lb. (227 kg)
Total Capacity
2 Person(s) 1 Person(s)
Maximum Wind 0 mph (0 m/s) 28 mph (12.5 m/s)
Maximum Side Force 90 lbf (400 N) 45 lbf (200 N)
1172AA_ANSI

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Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure

Table 2.8 Floor Loading Pressure

Gross Aerial Platform Total Aerial Platform Load

MODEL STANDARD Weight Wheel Load LCP OUP
lb. kg lb. kg psi kPa psf kPa
SJ30AJE ANSI/CSA 15,080 6,840 7,750 3,515 236 1,627 530 25.4

ANSI/CSA 15,080 6,840 7,750 3,515 236 1,627 530 25.4

SJ30ARJE CE & KC 13,177 5,977 7,176 3,255 218 1,505 464 22.2

AS 12,824 5,817 7,176 3,255 218 1,505 451 21.6

1212AA
n Gross Aerial Platform Weight = Weight + platform capacity
n LCP – Locally Concentrated Pressure – is a measure of how hard the aerial platform tire tread presses on the area in direct contact with the
floor. The floor covering (tile, carpet, etc.) must be able to withstand more than the indicated values above.
n OUP – Overall Uniform Pressure – is a measure of the average load the aerial platform imparts on the whole surface projected directly
underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values above.
NOTE:
The LCP or OUP that an individual surface can withstand varies from structure to structure and is generally determined by the engineer or
architect for that particular structure.

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

Foot Print Area identified by test. Base Area = Length x Width

Wheel Load Weight of MEWP + Capacity

LCP = OUP =
Foot Print Area Base Area

Foot Print Area

Base Width

Base Length

196274AF SJ30AJE, SJ30ARJE

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Hydraulic Specifications Section 2 – Maintenance Tables and Diagrams

Table 2.9 Hydraulic Specifications

SJ30AJE/ARJE
SPECIFICATIONS
US Imperial Metric
Pressure 3300 psi 228 bar
Main Pumps
Pumps Displacement 0.155 CI 2.54 CC
Pressure 3250 psi 224 bar
Emergency Pump
Displacement 0.073 CI 1.19 CC
Filter Return Line Filter Pressure 25 psi 1.724 bar
Flow 3.05 gal/m 11.55 L/min
Motor Swing Drive Motor
Pressure 1774 psi 12.23 MPa
Displacement 8.05 CI 132 CC
Platform Rotary Actuator
Rotary Pressure 3000 psi 207 bar
Actuators Displacement 14.3 CI 234.3 CC
Jib Rotary Actuator
Pressure 3000 psi 207 bar
Bore 1.96 in 5.0 cm
Rod Diameter 1.38 in 3.5 cm
Extension Cylinder Stroke 46 in 116.8 cm
Maximum Operating Pressure 1250 psi 86 bar
Test Pressure 3000 psi 207 bar
Bore 3.15 in 8.0 cm
Rod Diameter 1.77 in 4.5 cm
Main Boom Lift Cylinder
Stroke 2400 psi 56.6 cm
Test Pressure 3000 psi 207 bar
Cylinders Bore 2.36 in 6.0 cm
Rod Diameter 1.77 in 4.5 cm
Riser Cylinder Stroke 27.87 in 70.8 cm
Maximum Operating Pressure 2000 psi 138 bar
Test Pressure 3000 psi 207 bar
Bore 3 in 7.5 cm
Rod Diameter 1.57 in 4.0 cm
Master Cylinder Stroke 11 in 28.3 cm
Maximum Operating Pressure 3000 psi 207 bar
Test Pressure 3000 psi 207 bar

1211AD-1

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Section 2 – Maintenance Tables and Diagrams Hydraulic Specifications

Table 2.9 Hydraulic Specifications

SJ30AJE/ARJE
SPECIFICATIONS
US Imperial Metric
Bore 3 in 7.5 cm
Rod Diameter 1.57 in 4.0 cm
Slave Cylinder Stroke 11.7 in 29.6 cm
Maximum Operating Pressure 3000 psi 207 bar
Test Pressure 3000 psi 207 bar
Bore 1.77 in 4.5 cm
Rod Diameter 1.38 in 3.5 cm
Cylinders Jib Cylinder Stroke 22.2 in 56.4 cm
Maximum Operating Pressure 2000 psi 138 bar
Test Pressure 3000 psi 207 bar
Bore 2 in 5.0 cm
Rod Diameter 1 in 2.5 cm
Steer Cylinder Stroke 7.44 in 18.9 cm
Maximum Operating Pressure 2000 psi 138 bar
Test Pressure 3000 psi 207 bar
Shell Tellus T46
Standard -15°F to 100°F -26°C to 38°C
Hydraulic Oil Petro-Canada Hydrex MV46
Biodegradable Shell Naturelle HF-E 46 -4°F to 194°F -20°C to 90°C
Hydraulic Tank Capacity 4.3 gal 16.2 L

1211AD-2

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Specifications and Features - ANSI/CSA Section 2 – Maintenance Tables and Diagrams

Table 2.10 Specifications and Features - ANSI/CSA

SJ30AJE SJ30ARJE
ANSI/CSA ANSI/CSA
Working Height - maximum 36' 3" 11.1 m 36' 1" 11.0 m
Platform Height - maximum 29' 8" 9.04 m 29' 6" 9.00 m

Height and Up & Over Clearance - at Main Boom 13' 1" 4.00 m 13' 5/8" 3.98 m
Reach Data Horizontal Reach - maximum 20' 7" 6.27 m 20' 6-5/8" 6.26 m
Horizontal Reach - Retracted 16' 9" 5.11 m 16' 8-5/8" 5.10 m
Tailswing 0" 0m 0" 0m
Platform Size 30" x 46" 0.76 x 1.17 m 30" x 46" 0.76 x 1.17 m
Platform Rotation 180° 180° 180° 180°
Platform
Platform Height - Stowed 1' 3" 0.38 m 1' 0.30 m
Data
Overall Railing Height 4' 6" 1.37 m 4' 6" 1.37 m
Platform Railing Height 3' 7-1/2" 1.10 m 3' 7-1/2" 1.10 m
Height - stowed 6' 6" 1.98 m 6' 6" 1.98 m
Length - stowed 18' 2" 5.64 m 18' 1" 5.51 m
Height - transport 8' 3" 2.51 m 8' 2" 2.49 m
Length - transport 13' 1" 3.99 m 12' 5" 3.78 m
Width 3' 11" 1.19 m 3' 11" 1.19 m
Dimensional
Wheelbase 5' 5" 1.80 m 5' 5" 1.80 m
Data
Ground Clearance (Chassis) 4" 0.10 m 4" 0.10 m
Turning Radius (Inside, Left - Right) 5' 1/2" - 5' 5" 1.54 x 1.65 m 5' 1/2" - 5' 5" 1.54 x 1.65 m
Turning Radius (Outside, Left - Right) 10' 6" - 10' 11" 3.20 x 3.33 m 10' 6" - 10' 11" 3.20 x 3.33 m
Turning Angle 76° 76° 76° 76°
Turret Rotation 352° 352° 352° 352°
Jib Length 4' 1" 1.24 m 4' 1" 1.24 m
Jib vertical Range of Motion 7' 8" 2.34 m 7' 8" 2.34 m
Jib Data Jib Range - Up 77.5° 77.5° 77.5° 77.5°
Jib Range - Down 65.5° 65.5° 65.5° 65.5°
Jib rotation N/A N/A 180° 180°
Boom Up Angle 75° 75° 75° 75°
Boom Data
Boom Down Angle 5° 5° 5° 5°
Lift Capacity - Indoor 500 lbs 226 kg 500 lbs 226 kg
Lift Capacity - Outdoor 500 lbs 226 kg 500 lbs 226 kg
Lift Capacity Number of Persons - Indoor 2 2 2 2
Number of Persons - Outdoor 1 1 1 1
Wind rating 41 ft/s 12.5 m/s 41 ft/s 12.5 m/s

11384AA-1

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37
Section 2 – Maintenance Tables and Diagrams Specifications and Features - ANSI/CSA

Table 2.10 Specifications and Features - ANSI/CSA

SJ30AJE SJ30ARJE
ANSI/CSA ANSI/CSA
Gradeability - Maximum 35% 35% 35% 35%
Drive Speed - Stowed 3.0 mph 4.8 km/h 3.0 mph 4.8 km/h
Drive Speed - Elevated 0.4 mph 0.6 km/h 0.4 mph 0.6 km/h
Turret Rotation Time 70-90 s 70-90 s 70-90 s 70-90 s
Platform Rotation Time 7-10 s 7-10 s 7-10 s 7-10 s
Main Boom Up Time 20-24 s 20-24 s 20-24 s 20-24 s
Main Boom Down Time 18-20 s 18-20 s 18-20 s 18-20 s
Performance
Fly Boom Extend Time 17-19 s 17-19 s 17-19 s 17-19 s
and Speeds
Fly Boom Retract Time 12-16 s 12-16 s 12-16 s 12-16 s
Riser Up Time 14-18 s 14-18 s 14-18 s 14-18 s
Riser Down Time 22-26 s 22-26 s 22-26 s 22-26 s
Jib Swing Time 14-16 s 14-16 s 14-16 s 14-16 s
Jib Up Time 18-20 s 18-20 s 18-20 s 18-20 s
Jib Down Time 12-16 s 12-16 s 12-16 s 12-16 s
Steer Left/Right Time 2-4 s 2-4 s 2-4 s 2-4 s
Tire Size 22" x 7" 5.59 x 1.78 m 22" x 7" 5.59 x 1.78 m
Tire Data Diameter, Outside 22" 5.59 m 22" 5.59 m
Width 7" 1.78 m 7" 1.78 m

Electrical Battery Voltage 48V DC 48V DC 48V DC 48V DC

Data Battery Type Lead/Acid Lead/Acid Lead/Acid Lead/Acid
Overall Weight - No Options 14580 lbs 6613 kg 14580 lbs 6613 kg
Wheel Load - Transport with No Load 4220 lbs 1914 kg 4220 lbs 1914 kg
Wheel Load - Maximum with Load 7750 lbs 3515 kg 7750 lbs 3515 kg
Weights &
Pressure LCP - Transport with No Load 161 psi 1110 kPa 161 psi 1110 kPa
Data
LCP - Maximum with Load 236 psi 1627 kPa 236 psi 1627 kPa
OUP - No Load 513 lb/ft² 24.6 kPa 513 lb/ft² 24.6 kPa
OUP - With Load 530 lb/ft² 25.4 kPa 530 lb/ft² 25.4 kPa

1384AA-2

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Specifications and Features - CE, AS & KC Section 2 – Maintenance Tables and Diagrams

Table 2.11 Specifications and Features - CE, AS & KC

SJ30ARJE SJ30ARJE SJ30ARJE
CE AS KC
Working Height - maximum 11.0 m 11.0 m 11.0 m
Platform Height - maximum 9.00 m 9.00 m 9.00 m

Height and Up & Over Clearance - at Main Boom 4.00 m 4.00 m 4.00 m
Reach Data Horizontal Reach - maximum 6.26 m 6.26 m 6.26 m
Horizontal Reach - Retracted 5.10 m 5.10 m 5.10 m
Tailswing 0m 0m 0m
Platform Size 0.76 x 1.17 m 0.76 x 1.17 m 0.76 x 1.17 m
Platform Rotation 180° 180° 180°
Platform
Platform Height - Stowed 0.30 m 0.30 m 0.30 m
Data
Overall Railing Height 1.37m 1.37 m 1.37 m
Platform Railing Height 1.10 m 1.10 m 1.10 m
Height - stowed 1.98 m 1.98 m 1.98 m
Length - stowed 5.51 m 5.51 m 5.51m
Height - transport 2.50 m 2.50 m 2.50 m
Length - transport 3.80 m 3.80 m 3.8 m
Width 1.19 m 1.19 m 1.19 m
Dimensional
Wheelbase 1.65 m 1.65 m 1.65 m
Data
Ground Clearance (Chassis) 0.01 m 0.01 m 0.01 m
Turning Radius (Inside, Left - Right) 1.53 - 1.65 m 1.53 - 1.65 m 1.53 - 1.65 m
Turning Radius (Outside, Left - Right) 3.21 - 3.32 m 3.21 - 3.32 m 3.21 - 3.32 m
Turning Angle 76° 76° 76°
Turret Rotation 352° 352° 352°
Jib Length 1.24 m 1.24 m 1.24 m
Jib vertical Range of Motion 2.34 m 2.34 m 2.34 m
Jib Data Jib Range - Up 77.5° 77.5° 77.5°
Jib Range - Down 65.5° 65.5° 65.5°
Jib rotation 180° 180° 180°
Boom Up Angle 75° 75° 75°
Boom Data
Boom Down Angle 5° 5° 5°
Lift Capacity - Indoor 227 kg 227 kg 227 kg
Lift Capacity - Outdoor 227 kg 227 kg 227 kg
Lift Capacity Number of Persons - Indoor 2 2 2
Number of Persons - Outdoor 1 1 1
Wind rating 12.5 m/s 12.5 m/s 12.5 m/s

1385AA-1

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39
Section 2 – Maintenance Tables and Diagrams Specifications and Features - CE, AS & KC

Table 2.11 Specifications and Features - CE, AS & KC

SJ30ARJE SJ30ARJE SJ30ARJE
CE AS KC
Gradeability - Maximum 35% 35% 35%
Drive Speed - Stowed 4.8 km/h 4.8 km/h 4.8 km/h
Drive Speed - Elevated 0.6 km/h 0.6 km/h 0.6 km/h
Turret Rotation Time 70-90 s 70-90 s 70-90 s
Platform Rotation Time 7-10 s 7-10 s 7-10 s
Main Boom Up Time 20-24 s 20-24 s 20-24 s
Main Boom Down Time 18-20 s 18-20 s 18-20 s
Performance
Fly Boom Extend Time 17-19 s 17-19 s 17-19 s
and Speeds
Fly Boom Retract Time 12-16 s 12-16 s 12-16 s
Riser Up Time 14-18 s 14-18 s 14-18 s
Riser Down Time 22-26 s 22-26 s 22-26 s
Jib Swing Time 14-16 s 14-16 s 14-16 s
Jib Up Time 18-20 s 18-20 s 18-20 s
Jib Down Time 12-16 s 12-16 s 12-16 s
Steer Left/Right Time 2-4 s 2-4 s 2-4 s
Tire Size 5.59 x 1.78 m 5.59 x 1.78 m 5.59 x 1.78 m
Tire Data Diameter, Outside 5.59 m 5.59 m 5.59 m
Width 1.78 m 1.78 m 1.78 m

Electrical Battery Voltage 48V DC 48V DC 48V DC

Data Battery Type Lead/Acid Lead/Acid Lead/Acid
Overall Weight - No Options 5750 kg 5590 kg 5750 kg
Wheel Load - Transport with No Load 1590 kg 1590 kg 1590 kg
Wheel Load - Maximum with Load 3255 kg 3255 kg 3255 kg
Weights & Pressure
LCP - Transport with No Load 954 kPa 954 kPa 954 kPa
Data
LCP - Maximum with Load 1505 kPa 1505 kPa 1505 kPa
OUP - No Load 21.4 kPa 20.8 kPa 21.4 kPa
OUP - With Load 22.2 kPa 21.6 kPa 22.2 kPa

11385AA-2

196274AF SJ30AJE, SJ30ARJE

40
Reach Diagram - SJ30AJE Section 2 – Maintenance Tables and Diagrams

Diagram 2.12 Reach Diagram - SJ30AJE

40 ft

35 ft

30 ft

25 ft

20 ft

15 ft

10 ft

5 ft

0 ft
-5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft

SJ30AJE, SJ30ARJE 196274AF

41
Section 2 – Maintenance Tables and Diagrams Dimesion Diagram - SJ30AJE

Diagram 2.13 Dimesion Diagram - SJ30AJE

77.5°

36’ 3”
[11.1 m]

75°

2’ 11”
29’ 8” [0.90 m]
[9.04 m]

4’ 1”
[1.24 m]

5°

13’ 1”
[4.00 m]

8’ 3”
6’ 6” 4’ 3” [2.51 m]
[1.98 m] [1.30 m]

65.5° 1’ 3”
[0.38 m]
4”
[0.10 m]
5’ 5”
[1.65 m]
13’ 1”
[3.99 m]
18’ 2”
[5.64 m]

20’ 7”
[6.27 m]
16’ 9”
[5.11 m]

5’ 5” 3’ 10”
[1.65 m] [1.17 m]

2’ 6”
[0.76 m]

196274AF SJ30AJE, SJ30ARJE

42
Reach Diagram - SJ30ARJE Section 2 – Maintenance Tables and Diagrams

Diagram 2.14 Reach Diagram - SJ30ARJE

10 ft

5 ft

180

5 ft

10 ft

35 ft

30 ft

25 ft

20 ft

15 ft

10 ft

5 ft

0
-5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft

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43
Section 2 – Maintenance Tables and Diagrams Dimension Diagram - SJ30ARJE

Diagram 2.15 Dimension Diagram - SJ30ARJE

77.5°

36’ 1”
[11 m]
75°

29’ 6” 2’ 11”
[9 m] [0.90 m]

4’ 1”
[1.24 m]

5°

13’ 1”
[4 m]

8’ 2”
[2.5 m]
6’ 6” 4’ 3”
[1.98 m] [1.30 m]

1’
66.5°
[0.30 m]
4”
[0.10 m]
5’ 5”
[1.65 m]
12’ 5”
[3.78 m]

18’ 1”
[5.51 m]

20’ 7”
[6.26 m]
16’ 9” 2’ 6”
[5.10 m] [0.76 m]

3’ 11” 3’ 10”
[1.19 m] [1.17 m]

196274AF SJ30AJE, SJ30ARJE

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Section 3 – System Component
Identification and Schematics

SJ30AJE, SJ30ARJE 196274AF

45
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

196274AF SJ30AJE, SJ30ARJE

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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

P T
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

P T

MOTOR CLOSED CENTER

A

CLOSED PORT

SJ30AJE, SJ30ARJE 196274AF

47
Section 3 – System Component Identification and Schematics Wire Number and Color Code

3.3 Wire Number and Color Code

WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE WIRE
WIRE COLOR
NO. COLOR NO. NO. COLOR NO. COLOR NO. COLOR
00 WHT 20 ORG/BLU 44 YEL/WHT 67 ORG/BRN 92 GRN SHLD

000 WHT 21 WHT/RED 45 YEL/ORG 68 GREY 93 BLK SHLD

B1 BLU/PINK 23 BLK/WHT 46 RED/BLK 69 WHT/GRN 95 YEL/GREY

01 PUR/BLK 24 BLU/BLK 47 PUR/ORG 70 ORG/PINK 96 WHT/GREY

02 WHT 25 BRN/BLK 48 YEL/GREY 71 RED/ORG 97 ORG/GREY

03 GRN/PUR 26 BLU/YEL 49 GRN/RED 72 RED/BRN 98 RED SHLD

04 RED/YEL 27 RED/BLK/WHT 50 BRN 73 RED/PINK 98A BLK SHLD

GRN/
05 PUR 28 GRN 51 BLK/GRN 74 99 BLK/GREY
GREY
06 29 GREY/ORG 52 GRN/BLU 75 GREY/PUR 103 BLK/PUR

07 RED 30 RED/GRN 53 BRN/RED 76 BRN/BLU 104 GRN/ORG

08 PUR/WHT 31 RED/WHT 54 PUR/RED 77 BRN/GREY 105 GRN/BRN

09 YEL 32 GRN/BLK 55 YEL/PUR 78 RED/BLU 106 GRN/PINK

10 BLU/WHT 33 GRN/WHT 56 YEL/BLK 79 BRN/PUR 107 BLK/BLU

GREY/
11 WHT/ORG 34 ORG/BLK 57 BRN/GRN 80 WHT 108 YEL/BRN
RED/YEL/
12 35 ORG/WHT 58 WHT/PUR 81 GREY/BLK 109 GRN/YEL
BLK
13 ORG 36 RED/PUR 59 YEL/BLU 82 BRN/WHT 110A BLU
WHT/RED/
14 BLK 37 60 WHT/BLU 83 BLU/GREY 110B BRN
BLK
WHT/BLK/
15 BLU 38 ORG/RED 61 GREY/BRN 84 111 GREY/GRN
PUR
16 WHT/BLK 39 BLK/RED 62 GREY/RED 85 GREY/BLU 112 BLU/ORG

17 BLU/GRN 40 BLU/RED 63 GREY/YEL 86/87 PUR/BLU 113 BLU/BRN

18 GRN/BLU 41 BLU/PUR 64 WHT/BRN 88 BLK/ORG 114 YEL/RED

19 ORG/GRN 42 PINK 65 YEL/PINK 90 RED/GREY 115 WHT/PUR

22 PUR/GRN 43 WHT/YEL 66 ORG/YEL 91 RED SHLD 118 PUR/PINK

This table is to be used as a wire number/color reference for all electrical drawings and schematics. All wire
numbers will retain their origional color coding, for example if wire 7 is red, wire 7A, 7B, and 7C will also be red.

196274AF SJ30AJE, SJ30ARJE

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Hydraulic Parts List Section 3 – System Component Identification and Schematics

3.4 Hydraulic Parts List

Index Skyjack
Qty. Description
No. Part No.

C1 192078 1 CYLINDER, Steer

C2 192073 1 CYLINDER, Main boom lift
C3 207328 1 CYLINDER, Riser (serial number 90 000 013 & above)
C3 192072 1 CYLINDER, Riser (serial numbers 90 000 001 to 90 001 012)
C4 192074 1 CYLINDER, Fly boom extension
C5 207339 1 CYLINDER, Jib
C6 192077 1 CYLINDER, Slave (platform levelling)
C7 192076 1 CYLINDER, Master
CB1 209153 1 VALVE, Counterbalance (main boom)
CB2 209153 1 VALVE, Counterbalance (main boom)
CB3 141453 1 VALVE, Counterbalance (fly boom extend)
CB4 141453 1 VALVE, Counterbalance (fly boom retract)
CB5 209153 1 VALVE, Counterbalance (platform level)
CB6 209153 1 VALVE, Counterbalance (platform level)
CB7 149372 1 VALVE, Counterbalance (jib elevation)
CB8 149372 1 VALVE, Counterbalance (jib elevation)
CB9 209153 1 VALVE, Counterbalance (platform rotary actuator)
CB10 209153 1 VALVE, Counterbalance (platform rotary actuator)
CB11 141453 1 VALVE, Counterbalance (jib rotary actuator)
CB12 141453 1 VALVE, Counterbalance (jib rotary actuator)
CV1 199471 1 VALVE, Check (main manifold)
CV2 208883 1 VALVE, Check (main manifold)
CV3 199471 1 VALVE, Check (riser cylinder)
CV4 197770 1 VALVE, Check (main manifold)
CV5 199471 1 VALVE, Check (main manifold)
F1 108628 1 FILTER, Hydraulic oil
M1 207350 1 MOTOR, Turret rotation swing drive
MB1 192161 1 MANIFOLD, Main
MB2 192162 1 MANIFOLD, Jib (SJ30AJE)
MB2 192055 1 MANIFOLD, Jib (SJ30ARJE)
OR1 208880 1 ORIFICE (0.040") (main manifold)
OR2 209023 1 ORIFICE (0.025") (jib manifold)
OR3 192122 1 ORIFICE (0.020") (jib manifold)
OR4 192122 1 ORIFICE (0.020”) (jib manifold)
OR5 208880 1 ORIFICE (0.040”) (riser cylinder)
P1 209056 1 PUMP, Main
P2 192176 1 PUMP, Auxiliary

SJ30AJE, SJ30ARJE 196274AF

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Section 3 – System Component Identification and Schematics Hydraulic Parts List

Index Skyjack
Qty. Description
No. Part No.

RA1 192206 1 ACTUATOR, Turret rotator

RA2 192208 1 ACTUATOR, Platform rotator
RA3 192207 1 ACTUATOR, Jib rotator
RV1 208876 1 VALVE, Relief (main manifold)
RV2 208877 1 VALVE, Relief (main manifold)
RV3 208878 1 VALVE, Relief (main manifold)
RV4 208879 1 VALVE, Relief (main manifold)
RV5 209058 1 VALVE, Relief (main pump)
RV6 209058 1 VALVE, Relief (auxiliary pump)
RV7 209110 1 VALVE, Relief (riser cylinder)
V1 208872 1 VALVE, Control (steer cylinder)
V2 166036 1 VALVE, Control (master cylinder)
V3 166041 1 VALVE, Control (main boom lift)
V4 208875 1 VALVE, Control (turret rotary actuator)
V5 208874 1 VALVE, Control (riser cylinder)
V6 166050 1 VALVE, Control (flow enable)
V7 166036 1 VALVE, Control (fly boom)
V8 166036 1 VALVE, Control (jib cylinder)
V9 166036 1 VALVE, Control (platform rotary actuator)
V10 166036 1 VALVE, Control (jib rotary actuator)
V11 209109 1 VALVE, Counterbalance (riser cylinder)

196274AF SJ30AJE, SJ30ARJE

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Electrical Parts List Section 3 – System Component Identification and Schematics

3.5 Electrical Parts List

SUPPLY (B+) (Common)

CONTROL (B+) GROUND (B-)

NORMALLY NORMALLY
CLOSED OPEN
CONTACT CONTACT

Index Skyjack
Qty. Description
No. Part No.

51CCR1 127131 1 RELAY, 12V 40 amp (base controls) (KC)

51CCR2 127131 1 RELAY, 12V 40 amp (base controls) (KC)
51CCR3 127131 1 RELAY, 12V 40 amp (base controls) (KC)
51CCR4 127131 1 RELAY, 12V 40 amp (platform controls) (KC)
28CR 127131 1 RELAY, 12V 40 amp (platform controls)
60ACR 127131 1 RELAY, 12V 40 amp (base controls)
60CR 127131 1 RELAY, 12V 40 amp (base controls)
162BCR 127131 1 RELAY, 12V 40 amp (base controls) (CE)
162CR 127131 1 RELAY, 12V 40 amp (base controls)
204CR 127131 1 RELAY, 12V 40 amp (platform controls)
208CR 127131 1 RELAY, 12V 40 amp (base controls)
208CR1 127131 1 RELAY, 12V 40 amp (platform controls)
259CR 127131 1 RELAY, 12V 40 amp (base controls)
2H-20A 166127 1 COIL, 12 Volt (flow enable)
2H-30 159821 1 COIL, 12 Volt (riser down)
2H-31 208881 1 COIL, 12 Volt (riser up)
4H-13 208881 1 COIL, 12 Volt (main boom down)
4H-14 208881 1 COIL, 12 Volt (main boom up)
4H-224 208881 1 COIL, 12 Volt (steer left)
4H-223 208881 1 COIL, 12 Volt (steer right)
4H-34 209028 1 COIL, 24 Volt (jib down) (SJ30AJE)
4H-34 208882 1 COIL, 12 Volt (jib down) (SJ30ARJE)

SJ30AJE, SJ30ARJE 196274AF

51
Section 3 – System Component Identification and Schematics Electrical Parts List

Index Skyjack
Qty. Description
No. Part No.

4H-35 209028 1 COIL, 24 Volt (jib up) (SJ30AJE)

4H-35 208882 1 COIL, 12 Volt (jib up) (SJ30ARJE)
4H-36 209028 1 COIL, 24 Volt (platform left) (SJ30AJE)
4H-36 208882 1 COIL, 12 Volt (platform left) (SJ30ARJE)
4H-37 209028 1 COIL, 24 Volt (platform right) (SJ30AJE)
4H-37 208882 1 COIL, 12 Volt (platform right) (SJ30ARJE)
4H-38 208882 1 COIL, 12 Volt (fly boom retract)
4H-39 208882 1 COIL, 12 Volt (fly boom extend)
4H-40 208881 1 COIL, 12 Volt (platform level down)
4H-41 208881 1 COIL, 12 Volt (platform level up)
4H-42 208882 1 COIL, 12 Volt (jib rotate left)
4H-43 208882 1 COIL, 12 Volt (jib rotate right)
5H-32 208881 1 COIL, 12 Volt (turret rotate left)
5H-33 208881 1 COIL, 12 Volt (turret rotate right)
A1 138224 1 JOYSTICK, Drive/steer
A2 138225 1 JOYSTICK, Boom/turret
A3 138226 1 SWITCH, Speed control
BP1 144387 1 ALARM, Tilt
BP2 103057 1 ALARM, All motion
BP3 144387 1 ALARM, Overload
BP4 166110 1 BEEPER, SGE
CAP1 164511 1 CAPACITOR, 10 000 µF
CB1 137919 1 CIRCUIT BREAKER, 25 amp
CB2 137919 1 CIRCUIT BREAKER, 25 amp
DXX 102921 A/R DIODE
H 167234 1 HOURMETER
LB1 144078 1 LIGHT, Flashing
LB2 171888 1 LIGHT, Work
LB3 171888 1 LIGHT, Work
LB4 166110 1 BEACON, SGE
LS1 192758 1 LIMIT SWITCH, Direction sensing
LS2 192177 1 LIMIT SWITCH, Riser Down
LS3 192177 1 LIMIT SWITCH, Boom down
LS4 192178 1 LIMIT SWITCH, Fly in
PL2 147229 1 LIGHT, LED block (emergency stop)
PL3 164832 1 LIGHT, Pilot (tilt)
PL4 171501 1 LIGHT, Pilot (enable active)
PL5 164832 1 LIGHT, Pilot (overload)
PL6 171502 1 LIGHT, Pilot (low battery)

196274AF SJ30AJE, SJ30ARJE

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Electrical Parts List Section 3 – System Component Identification and Schematics

Index Skyjack
Qty. Description
No. Part No.

PL7 164832 1 LIGHT, Pilot (overload)

R1 151643 1 RESISTOR, 250 ohm
R2 151643 1 RESISTOR, 250 ohm
R3 151643 1 RESISTOR, 250 ohm
R4 151643 1 RESISTOR, 250 ohm
R5 151643 1 RESISTOR, 250 ohm
R6 151643 1 RESISTOR, 250 ohm
R7 151643 1 RESISTOR, 250 ohm
R8 151643 1 RESISTOR, 250 ohm
R9 151643 1 RESISTOR, 250 ohm
R10 151643 1 RESISTOR, 250 ohm
R11 151643 1 RESISTOR, 250 ohm
R12 151643 1 RESISTOR, 250 ohm
R13 144492 1 RESISTOR, 680 ohm
S2 144647 1 SWITCH, Emergency stop (base)
S3 138277 1 SWITCH, Base/off/platform (base) (ANSI/CSA, AS & KC)
S3 144366 1 SWITCH, Base/off/platform (base) (CE)
S4 144647 1 SWITCH, Emergency stop (platform)
S5 144648 1 SWITCH, Horn (platform)
S6 700187 1 FOOTSWITCH (platform)
S7 102853 1 SWITCH, Riser up/down (platform)
S8 102853 1 SWITCH, Telescope in/out (platform)
S9 102853 1 SWITCH, Jib up/down (platform)
S10 102853 1 SWITCH, Jib rotate (platform) (SJ30ARJE)
S11 102853 1 SWITCH, Platform rotate (platform)
S12 102853 1 SWITCH, Platform leveling (platform)
S13 102853 1 SWITCH, Platform leveling (base)
S14 102853 1 SWITCH, Platform rotate (base)
S15 102853 1 SWITCH, Jib rotate (base)
S16 102853 1 SWITCH, Jib up/down (base)
S17 102853 1 SWITCH, Telescope in/out (base)
S18 102853 1 SWITCH, Riser up/down (base)
S19 102853 1 SWITCH, Turret left/right (base)
S20 102853 1 SWITCH, Boom up/down (base)
S21 102853 1 SWITCH, Function enable (base)
S22 102853 1 SWITCH, Work light (platform)
S23 102853 1 SWITCH, Emergency pump (base)
S24 102853 1 SWITCH, Emergency pump (platform)
S25 166087 1 SWITCH, SGE reset (platform)

SJ30AJE, SJ30ARJE 196274AF

53
Section 3 – System Component Identification and Schematics Jib Valves and Port Identifications

3.6 Jib Valves and Port Identifications

SJ30ARJE
T P
To Main Manifold (T2) To Main Manifold (POUT)

4H-42
JR Jib Left
To Jib Rotator (Right)

JL
4H-43

JR
PA
JL Jib Right
To Jib Rotator (Left)

PB
4H-37

JA
PA Platform Right

JB
To Platform Rotator (Right)

JA
To Jib Cylinder (Extend) 4H-36 4H-35
Platform Left Jib Up

PB
To Platform Rotator (Left) 4H-34
Jib Down

JB
To Jib Cylinder (Retract)

SJ30AJE
T P
To Main Manifold (T2) To Main Manifold (POUT)

4H-36
Platform Left
PA

4H-37
Platform Right
PB
JA

JA
JB

To Jib Cylinder (Extend)

4H-35
JB Jib Up
To Jib Cylinder (Retract)

PB JR 4H-34
To Platform Rotator (Left) To Jib Rotator (Right) Jib Down

196274AF SJ30AJE, SJ30ARJE

54
3.7 Main Manifold Hose Port Identification

A B C D E F G H

GP
To Test Port
V

EB
To Extension Cylinder (Retract) EB
W

EB EA
To Extension Cylinder (Extend) RA

RA PO SW
To Riser Cylinder (Extend) UT A ST
R
T2

T2
To Jib Manifold SW
B PIN PL
A LB
X
POUT RB ST
L
To Jib Manifold
LA
T1
SWA
To Swing Drive Motor PL
B

RB
To Riser Cylinder (Retract)
Y
SWB
To Swing Drive Motor
STR
To Steer Cylinder PIN
To Pumps
STL
To Steer Cylinder PLA
To Master Cylinder
LB
To Boom Lift Cylinder (Retract)
T1
Z
To Hydraulic Tank
PLB
To Master Cylinder
LA
To Boom Lift Cylinder (Extend)
M192161AC - 1

SJ30AJE, SJ30ARJE 196274AF

55
3.8 Main Manifold Electrical Component Identification

A B C D E F G H

2H-20A EN
AB
Flow Enable LE
FL
Y W
4H-38 PL
AT
Fly Boom Retract FOR
M

RIS
ER
TU
RR
ET
X
4H-39 ST BO
EE OM
Fly Boom Extend R
5H-32
Turret Left
2H-31
Riser Up
2H-30
Riser Down Y
(located on riser cylinder) 5H-33
Turret Right

4H-40
Platform Level Down
4H-41
Platform Level Up 4H-14
Boom Up Z
4H-224
Steer Left 4H-223 4H-13
Steer Right Boom Down
M192161AC-2

196274AF SJ30AJE, SJ30ARJE

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3.9 Main Manifold Component Identification

A B C D E F G H

RV1
RV4 Relief Valve RV3
Relief Valve Relief Valve V

CV1
Check Valve

RV4 RV2 W
GP RV3 Relief Valve
GP
Test Port RV1

OR
CV1
F1 RV2
X

CV2
CV3
DC
1

CV2
Check Valve
OR1
Orifice
CV3 Z
DPOCV1 Check Valve
Check Valve

M192161AC-3

SJ30AJE, SJ30ARJE 196274AF

57
 SJ30AJE, SJ30ARJE
W
V

Z
H

WIRE LIST
WIRE 1 - 13 - ORANGE
WIRE 2 - 14 - BLACK
WIRE 3 - 20B - WHITE/RED
WIRE 4 - 223 - BLACK/WHITE
WIRE 5 - 224 - BLUE/BLACK
WIRE 6 - 31 - RED/WHITE
WIRE 7 - 32 - GREEN/BLACK
G

WIRE 8 - 33 - GREEN/WHITE
WIRE 9 - 38 - ORANGE/RED
WIRE 10 - 39 - BLACK/RED
WIRE 11 - 40 - BLUE/RED
WIRE 12 - 41 - BLUE/PURPLE
WIRE 13 - 02 - WHITE (SPLICE #1) [14 GA.]
WIRE 14 - 02 - WHITE (SPLICE #2) [14 GA.]
WIRE 15 - 7A - RED
F
E
D

PLATFORM LEVEL DOWN BOOM UP

PIN 1 - 40 BLUE/RED PIN 1 - 14 BLACK
1

PIN 2 - 02 WHITE

1
PIN 2 - 02 WHITE
PLATFORM LEVEL UP
BOOM DOWN
PIN 1 - 41 BLUE/PURPLE
1

PIN 1 - 13 ORANGE

1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
3.10 Main Manifold Harness - ANSI/CSA, CE & AS

TURRET ROTATE LEFT STEER RIGHT

PIN 1 - 32 GREEN/BLACK PIN 1 - 7A RED
1

1
PIN 2 - 02 WHITE PIN 2 - 223 BLACK/WHITE
TURRET ROTATE RIGHT STEER LEFT
1

1
PIN 1 - 33 GREEN/WHITE PIN 1 - 7A RED
PIN 2 - 02 WHITE PIN 2 - 224 BLUE/BLACK
B

FLOW ENABLE TELESCOPE OUT

PIN 1 - 20B WHITE/RED PIN 1 - 38 ORANGE/RED

1
PIN 2 - 02 WHITE

1
PIN 2 - 02 WHITE
RISER UP TELESCOPE IN

1
A

PIN 1 - 31 RED/WHITE PIN 1 - 39 BLACK/RED

PIN 2 - 02 WHITE PIN 2 - 02 WHITE

M192101AG

196274AF
58
 59
196274AF
W
V

Z
H

WIRE LIST
WIRE 1 - 13 - ORANGE
WIRE 2 - 14A - BLACK
WIRE 3 - 20B - WHITE/RED
WIRE 4 - 223 - BLACK/WHITE
WIRE 5 - 224 - BLUE/BLACK
WIRE 6 - 31A - RED/WHITE
WIRE 7 - 32 - GREEN/BLACK
G

WIRE 8 - 33 - GREEN/WHITE
WIRE 9 - 38 - ORANGE/RED
WIRE 10 - 39A - BLACK/RED
WIRE 11 - 40 - BLUE/RED
WIRE 12 - 41 - BLUE/PURPLE
WIRE 13 - 02 - WHITE (SPLICE #1) [14 GA.]
WIRE 14 - 02 - WHITE (SPLICE #2) [14 GA.]
WIRE 15 - 7A - RED
F
E
D

PLATFORM LEVEL DOWN BOOM UP

PIN 1 - 40 BLUE/RED PIN 1 - 14A BLACK
1

1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
PLATFORM LEVEL UP BOOM DOWN
PIN 1 - 13 ORANGE
1

PIN 1 - 41 BLUE/PURPLE

1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
TURRET ROTATE LEFT STEER RIGHT
C

PIN 1 - 32 GREEN/BLACK PIN 1 - 7A RED

1

1
PIN 2 - 02 WHITE PIN 2 - 223 BLACK/WHITE
TURRET ROTATE RIGHT STEER LEFT
1

PIN 1 - 33 GREEN/WHITE PIN 1 - 7A RED

1
PIN 2 - 02 WHITE PIN 2 - 224 BLUE/BLACK
3.11 Main Manifold Harness - KC

FLOW ENABLE TELESCOPE IN

PIN 1 - 20B WHITE/RED PIN 1 - 38 ORANGE/RED

1
PIN 2 - 02 WHITE PIN 2 - 02 WHITE
RISER UP TELESCOPE OUT
PIN 1 - 31A RED/WHITE

1
PIN 1 - 39A BLACK/RED
PIN 2 - 02 WHITE PIN 2 - 02 WHITE

SJ30AJE, SJ30ARJE
A

M209042AB
3.12 Control Cables & Harnesses

A B C D E F G H

Control Cable “A” Control Cable “B” Motor Controller Harness “A”

WIRE POSITIONS: WIRE POSITIONS: WIRE POSITIONS:

POSITION 1: BLACK POSITION 1: BLACK V

POSITION 1: PURPLE/BLACK
POSITION 2: RED POSITION 2: WHITE POSITION 2: WHITE
POSITION 3: RED POSITION 3: RED POSITION 3: RED
POSITION 4: BLUE/WHITE POSITION 4: GREEN POSITION 4: GREEN
POSITION 5: RED/YELLOW/BLACK POSITION 5: ORANGE POSITION 5: ORANGE
POSITION 6: ORANGE POSITION 6: BLUE POSITION 6: BLUE
POSITION 7: BLACK POSITION 7: WHITE/BLACK POSITION 7: WHITE/BLACK
POSITION 8: ORANGE/BLUE POSITION 8: RED/BLACK POSITION 8: RED/BLACK
POSITION 9: BLACK/WHITE POSITION 9: GREEN/BLACK POSITION 9: GREEN/BLACK
POSITION 10: BLUE/BLACK POSITION 10: ORANGE/BLACK POSITION 10: ORANGE/BLACK
POSITION 11: BLUE/YELLOW POSITION 11: BLUE/BLACK POSITION 11: BLUE/BLACK
POSITION 12: RED/GREEN POSITION 12: BLACK/WHITE POSITION 12: BLACK/WHITE W
POSITION 13: RED/WHITE POSITION 13: RED/WHITE POSITION 13: RED/WHITE
POSITION 14: GREEN/BLACK POSITION 14: GREEN/WHITE POSITION 14: GREEN/WHITE
POSITION 15: GREEN/WHITE POSITION 15: BLUE/WHITE POSITION 15: BLUE/WHITE
POSITION 16: ORANGE/BLACK POSITION 16: BLACK/RED POSITION 16: BLACK/RED
POSITION 17: ORANGE/WHITE POSITION 17: WHITE/RED
POSITION 18: RED/PURPLE POSITION 18: ORANGE/RED
POSITION 19: WHITE/RED/BLACK POSITION 19: BLUE/RED
POSITION 20: YELLOW/ORANGE POSITION 20: RED/GREEN
POSITION 21: YELLOW/PINK POSITION 21: ORANGE/GREEN
POSITION 22: PINK/WHITE POSITION 22: BLACK/WHITE/RED
POSITION 23: PINK/PURPLE POSITION 23: WHITE/BLACK/RED
POSITION 24: PINK/BLACK POSITION 24: RED/BLACK/WHITE X
POSITION 25(GROUND): GREEN/BLACK/WHITE

Steering Sensor Harness Motor Controller Harness “B”

WIRE POSITIONS:

PIN 1 - RED - 259

PIN 2 - ORANGE - 60
Y
PIN 3 - BLUE - 04A
PIN 4 - WHITE - 01A
PIN 1 - BLACK PIN 1 - BLACK PIN 5 - BLACK - 30B
PIN 2 - WHITE PIN 2 - GREEN PIN 6 - RED/BLACK - 204
PIN 3 - GREEN PIN 3 - WHITE

Riser Cylinder Harness Charger Harness

30 60 Z
02 60A

SOCKET 1 - BLACK SOCKET 1 - BLACK

M192194AD_M192196AD SOCKET 2 - WHITE SOCKET 2 - WHITE
M192096AD, M207820AD
M192194AB, 192111AC, 192181AB

196274AF SJ30AJE, SJ30ARJE

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3.13 Platform Limit Switch Harness - KC AB

A B C D E F G H

Platform Limit Switch Harness Lower Control Upper Control

Harness Harness
A B
3 1 V
4 2

D D
SECTION D-D
A B
ID # COLOUR LABEL ID # COLOUR LABEL
3 1 1 GREEN 60 1 GREEN 60 3 1
2 RED 52A 2 BLACK 52
4 2 3 WHITE 51A 2
3 WHITE 51A 4
4 BLACK 51 4 RED 52A
SECTION A-A
SECTION B-B

W
C C

ID # COLOUR LABEL
1 GREEN 60
2 NOT USED
3 WHITE 51A
4 BLACK 51
SECTION C-C
X

60 - GREEN S60 60 - GREEN

1 1
52A - RED 52 - BLACK
2 2
51A - WHITE S51A 51A - WHITE
3 3
51 - BLACK 52A - RED Y
4 4
51A - WHITE

60 - GREEN
51 - BLACK

SCHEMATIC VIEW

4 3 2 1

Z
ID # COLOUR LABEL TERMINAL
ID # COLOUR LABEL 1 RED 60 121050
1 BLACK 51 2 NOT USED
2 WHITE 51A 3 WHITE 51A 105359
3 GREEN 51C 4 BLACK 51 105359

M207314AC_M209079AA_M209806AA

SJ30AJE, SJ30ARJE 196274AF

61
3.14 Emergency Pump Base Controls Wiring

A B C D E F G H

01 BLACK
01

M211083AA

196274AF SJ30AJE, SJ30ARJE

62
3.15 Direction Sensing Limit Switch Base Control Wiring

A B C D E F G H

BLACK WIRE
09

WHITE WIRE
17

M211101AA

SJ30AJE, SJ30ARJE 196274AF

63
 AB
3.16 High Speed Cut - Out Limit Switches Base Controls Wiring

A B C D E F G H

WHITE WIRE V

BLACK WIRE
09

RI
SE
R
WHITE WIRE LIM
IT
SW
BLACK WIRE MA ITC X
IN H
BO
OM
BLACK WIRE LIM
IT S
FLY WI
WHITE WIRE BOO TC
29 ML H
29A IMIT
59 SWI
T CH

M211104AB

196274AF SJ30AJE, SJ30ARJE

64
3.17 Overload Sensor Platform Controls Wiring

A B C D E F G H

WIRE 3 (BLACK) GREEN/YELLOW

WIRE 1 (BLACK)
WIRE 5 (BLACK)

118

162
82

02
Y

60
WIRE 4 (BLACK)

WIRE 2 (BLACK)

M211100AA

SJ30AJE, SJ30ARJE 196274AF

65
3.18 Footswitch Platform Controls Wiring

A B C D E F G H

BLACK WIRE

WHITE WIRE

8A

04
Y

M211102AA

196274AF SJ30AJE, SJ30ARJE

66
3.19 SGE Platform Controls Wiring

A B C D E F G H

BLACK WIRE

WHITE WIRE

04
Y
PIN 7

M211103AA

SJ30AJE, SJ30ARJE 196274AF

67
 A B C D E F G H

196274AF SJ30AJE, SJ30ARJE

68
3.20 Hydraulic Schematic - SJ30AJE
A B C D E F G H I J K L M N O

C5
JIB ELEVATION
CYLINDER
R

RA2
PLATFORM ROTART ACTUATOR
DISPL: 132CC (8.05CI)

CB7 CB8 CB9 CB10

CBBB-LHN CBBB-LHN CACA-LHN CACA-LHN
3000 PSI 3000 PSI 3300 PSI 3300 PSI
1.5:1 1.5:1 3:1 3:1
JA JB PA PB

C6 MB2
PLATFORM LEVELING PLATFORM CONTROL
SLAVE CYLINDER VALVE ASSEMBLY

V8 V9 T

4H-35 4H-34 4H-37 4H-36

UP DOWN RIGHT LEFT

P
OR3
OR2 0.020"
0.025"

T
U

CB5 CB6
CACA-LHN CACA-LHN
3000 PSI 3000 PSI
3:1 3:1

C3
RISER V
C7
CYLINDER
MASTER
CYLINDER
C4
C2 FLY BOOM EXTENSION
MAIN BOOM LIFT CYLINDER
CYLINDER

RV7
RA1
TURRET ROTATION
SWING DRIVE MOTOR 3250
PSI
C1
M1
STEER CYLINDER OR5
0.040" 2H-30
DOWN
CB1 CB2 CV5 V11 CB3 CB4
CACA-LHN CACA-LHN CBCA-LIN CBCA-LIN
3000 PSI 3000 PSI 1000 PSI 1000 PSI
CV4
3:1 3:1 3:1 3:1 X

24VDC RV6 STL STR PLA PLB LA LB SWA SWB RA RB EA EB

1.19CC
MOTOR 0.073CI 3300
P2 PSI MB1
MAIN CONTROL CV3
VALVE ASSEMBLY

DP0CV1 CV2

AUXILIARY RV2
PMU V2 3050
PSI
V1 V3 V4 V5 V7

4H-41 4H-40 Y
UP DOWN
OR1
4H-224 4H-223 4H-14 4H-13 5H-33 5H-32 2H-31 4H-39 4H-38
0.040"
LEFT RIGHT UP DOWN RIGHT LEFT UP EXTEND RETRACT
CV3
P POUT

RV5 RV1 CV1 2H-20A RV4

48VDC 2.54CC 25
MOTOR 0.155CI 3300 3150 RV3 FLOW V6 1500
PSI PSI PSI 2100 ENABLE PSI
P1
PSI
T T2

PRIMARY 25 F1 GP
PMU PSI RETURN LINE Z
FILTER
(10 MICRON)

M207302AC 3.20 Hydraulic Schematic - SJ30AJE

196274AF SJ30AJE, SJ30ARJE

69
3.21 Hydraulic Schematic - SJ30ARJE
A B C D E F G H I J K L M N O

C5
JIB ELEVATION
CYLINDER
R

RA2 RA3
PLATFORM ROTART ACTUATOR JIB ROTARY ACTUATOR
DISPL: 132CC (8.05CI) DISPL: 435CC (26.6CI)

CB7 CB8 CB9 CB10 CB11 CB12

CBBB-LHN CBBB-LHN CACA-LHN CACA-LHN CACA-LHN CACA-LHN
3000 PSI 3000 PSI 3300 PSI 3300 PSI 3300 PSI 3300 PSI
1.5:1 1.5:1 3:1 3:1 3:1 3:1
JA JB PA PB JR JL

C6 MB2
PLATFORM LEVELING PLATFORM CONTROL
SLAVE CYLINDER VALVE ASSEMBLY

V8 V9 V10 T

4H-35 4H-34 4H-37 4H-36 4H-43 4H-42

UP DOWN RIGHT LEFT RIGHT LEFT

P
OR3 OR4
OR2 0.020" 0.020"
0.025"

T
U

CB5 CB6
CACA-LHN CACA-LHN
3000 PSI 3000 PSI
3:1 3:1

C3
RISER
V
C7
CYLINDER
MASTER
CYLINDER
C4
C2 FLY BOOM EXTENSION
MAIN BOOM LIFT CYLINDER
CYLINDER

RV7
RA1
TURRET ROTATION
SWING DRIVE MOTOR 3250
PSI
C1 M1
STEER CYLINDER OR5
0.040" 2H-30
DOWN
CB1 CB2 CV5 V11 CB3 CB4
CACA-LHN CACA-LHN CBCA-LIN CBCA-LIN
3000 PSI 3000 PSI 1000 PSI 1000 PSI
CV4
3:1 3:1 3:1 3:1
X

24VDC RV6 STL STR PLB PLA LA LB SWA SWB RA RB EA EB

1.19CC
MOTOR 0.073CI 3300
PSI MB1
P2
MAIN CONTROL CV3
VALVE ASSEMBLY

DP0CV1 CV2

AUXILIARY RV2
PMU V2 3050
PSI
V1 V3 V4 V5 V7

4H-41 4H-40 Y
UP DOWN
OR1
4H-224 4H-223 4H-14 4H-13 5H-33 5H-32 2H-31 4H-39 4H-38
0.040"
LEFT RIGHT UP DOWN RIGHT LEFT UP EXTEND RETRACT
CV3
P POUT

RV5 RV1 CV1 RV4

48VDC 2.54CC 25
MOTOR 0.155CI 3300 3150 RV3 2H-20A 1500
PSI PSI PSI 2100 FLOW V6 PSI
P1 ENABLE
PSI
T T2

PRIMARY 25 F1 GP
PMU PSI RETURN LINE Z
FILTER
(10 MICRON)

M192070AD 3.21 Hydraulic Schematic - SJ30ARJE

196274AF SJ30AJE, SJ30ARJE

70
3.22 Platform Controls Schematic - SJ30AJE ANSI/CSA AB

A B C D E F G H I J K L M N O

A2
BOOM/TURRET
JOYSTICK R

POWER
04 (RED/YELLOW) RED (+)

02 (WHITE) GROUND BLK (-)

A1
RED WHT (X)
X-SIGNAL
L
R9
34B DRIVE/STEER
BLUE Y-SIGNAL BLU (Y)
R1
30B JOYSTICK

S7
RISER S9
UP/DOWN JIB
S12 UP/DOWN
PLATFORM
RED POWER 04 (YELLOW)
LEVEL 30B 34B BLK GROUND 02 (WHITE)

A3
41 YEL
WHT/RED
D-SIGNAL
LEFT
BLACK
24 (BLUE/BLACK)
S
WHT/YEL RIGHT 23 (BLACK/WHITE)
SPEED CTRL. 40B
R3
30A
R11
34A
SELECTOR R4 R12

40

2B 2C
2B
R2
02
2C
R10

S8
TELESCOPE
S11 IN/OUT
PLATFORM
ROTATE S10
JIB
36 38B
ROTATE

GROUND

L
R7
37 38A

R8
2A
43 42
08 08

02 C L

8C 08
D08

01A

S25
04B
02
SGE RESET SWITCH
WITH LIGHT
04

02 2A
R6
L
R5
38B
U
S24
EMERGENCY S4
PUMP E-STOP
04 49
PL4 PL3 PL5 PL6 04 7A
01
01 04 08 28A 82 04
+ + + +
04
02
08
- - - - 3B
01 02 02 02
3C
290

S5
HORN
01

D01

01A

208CR1
28CR 204CR 204CR1
30
08 208
204
28 28A 04B
60 02 04 04

204
04 60 04 30C

02 162
R13

LB4 04B 02 04B

28

SGE D02
08A 08B
D08A BEACON La N Lb 02

31 32 33 34 35 36 37 38 39 28 162 D

24P-FEMALE
01
JIB MANIFOLD HARNESS - 192112

(A)
7A 7A 3B 3C 13 14 20B 23 24 60 30

WIRE 1 - 34 - ORANGE/BLACK X
WIRE 2 - 35 - ORANGE/WHITE
WIRE 3 - 36 - RED/PURPLE
08A

01A
08B

162

118

82
02
02
02
02
04
04
08

34
35
36
37
40
41
42
43

60
82

D118

WIRE 4 - 37 - WHITE/RED/BLACK
20B
118
D20A

20A
WIRE 5 - 42 - PINK
WIRE 6 - 43 - PURPLE/RED
WIRE 7 - 02 - WHITE

08A

01A
08B

162

118
02
02
02
02
04
04
08

34
35
36
37
40
41
42
43

60
82
JIB MANIFOLD HARNESS - 192112
59B 30B 204 43 42 41 40 70

08A
04 16
02
24 1 FOOTSWITCH CABLE - 192112
04
Y

16P-MALE
04
36 37 40 41 42 43
02
13 04
D36 D37 D40 D41 D42 D43 34A 25 2
02
14 L
36A 36A 40A 40A 42A 42A 26 3

(B)
42A
30A
15 30B 35 37 43
27 4
16 01A 208 08B 49 290 02 02
X-SIG
28 5
35
02 34 36 42
36A
Y-SIG
17 40B
40A
29 6
C
18 34
30C
30 7 + 118
59B
19 13
33
31 8 BP3 BLACK WIRE
38A
20 _
02
+ 28A 32 9
38
21 WHITE WIRE
BP1 08
33 10
31
_ 14
02 22 39
20A 34 11
32
23 70 23 24
35 12 D23 D24

23A 23A

M207960AE 3.22 Platform Controls Schematic - SJ30AJE ANSI/CSA

196274AF SJ30AJE, SJ30ARJE

71
3.23 Platform Controls Schematic - SJ30ARJE ANSI/CSA, CE & AS AB

A B C D E F G H I J K L M N O

A2
BOOM/TURRET
JOYSTICK

POWER
04 (RED/YELLOW) RED (+)

02 (WHITE) GROUND BLK (-)

A1
RED WHT (X)
X-SIGNAL
L
R9
34B DRIVE/STEER
BLUE Y-SIGNAL BLU (Y)
R1
30B JOYSTICK

S7
RISER S9
UP/DOWN JIB
S12 UP/DOWN
PLATFORM
RED POWER 04 (YELLOW)
LEVEL 30B 34B BLK GROUND 02 (WHITE)
YEL D-SIGNAL BLACK
41
A3 WHT/RED LEFT 24 (BLUE/BLACK)
WHT/YEL RIGHT 23 (BLACK/WHITE)
SPEED CTRL.
SELECTOR
40B
R3

R4
30A
R11

R12
34A
S
40

2B 2C
2B
R2
02
2C
R10

S8
TELESCOPE
S11 IN/OUT
PLATFORM
ROTATE S10
JIB
36 38B
ROTATE

GROUND

L
R7
37 38A

R8
2A
43 42
T
08 08

02 C L

8C 08
D08

01A

S25
04B
02
SGE RESET SWITCH
WITH LIGHT
04

02 2A
R6
L 38B
R5
S24
EMERGENCY S4
U
PUMP E-STOP
04 49
PL4 PL3 PL5 PL6 04 7A
01
01 04 08 28A 82 04
+ + + +
04
02
08
- - - - 3B
01 02 02 02
3C
290

S5
HORN
01

D01

01A

208CR1
28CR 204CR 204CR1
30
08 208
204
28 28A 04B
60 02 04 04

204
04 60 04 30C

02 162
R13

W
LB4 04B 02 04B
28

SGE D02
08A 08B
D08A BEACON La N Lb 02

31 32 33 34 35 36 37 38 39 28 162 D

24P-FEMALE
01
JIB MANIFOLD HARNESS - 192112

(A)
7A 7A 3B 3C 13 14 20B 23 24 60 30

WIRE 1 - 34 - ORANGE/BLACK
X
WIRE 2 - 35 - ORANGE/WHITE
WIRE 3 - 36 - RED/PURPLE
08A

01A
08B

162

118

82
02
02
02
02
04
04
08

34
35
36
37
40
41
42
43

60
82

D118

WIRE 4 - 37 - WHITE/RED/BLACK
20B
118
D20A

20A
WIRE 5 - 42 - PINK
WIRE 6 - 43 - PURPLE/RED
WIRE 7 - 02 - WHITE

08A

01A
08B

162

118
02
02
02
02
04
04
08

34
35
36
37
40
41
42
43

60
82
JIB MANIFOLD HARNESS - 192112
59B 30B 204 43 42 41 40 70

08A
04 16
02
24 04
1 FOOTSWITCH CABLE - 192112

16P-MALE
04
13
36

D36
37

D37
40

D40
41

D41
42

D42
43

D43 34A
02
25 2
04
Y
02
14 L
36A 36A 40A 40A 42A 42A 26 3

(B)
42A
30A
15 30B 35 37 43
27 4
16 01A 208 08B 49 290 02 02
X-SIG
28 5
35
02 34 36 42
36A
Y-SIG
17 40B
40A
29 6
C
18 34
30C
30 7 + 118
59B
19 13
33
31 8 BP3 BLACK WIRE
38A
20 _
02
+ 28A 32 9
38
21 WHITE WIRE
BP1 08
33 10
31
_ 14
02 22 39
20A 34 11
32
23 70 23 24
35 12 D23 D24

23A 23A

M207832AG 3.23 Platform Controls Schematic - SJ30ARJE ANSI/CSA, CE & AS

196274AF SJ30AJE, SJ30ARJE

72
3.24 Platform Controls Schematic - SJ30ARJE KC
A B C D E F G H I J K L M N O

A2
BOOM/TURRET
JOYSTICK

POWER
04 (RED/YELLOW) RED (+)

02 (WHITE) GROUND BLK (-)

A1
RED WHT (X)
X-SIGNAL
L
R9
34B DRIVE/STEER
BLUE Y-SIGNAL BLU (Y)
R1
30B JOYSTICK

S7
RISER S9
UP/DOWN JIB
S12 UP/DOWN
PLATFORM
RED POWER 04 (YELLOW)
LEVEL 30B 34B BLK GROUND 02 (WHITE)
YEL D-SIGNAL BLACK
41
A3 WHT/RED LEFT 24 (BLUE/BLACK)
23 (BLACK/WHITE)

S
WHT/YEL RIGHT
SPEED CTRL. 40B
R3
30A
R11
34A
SELECTOR R4 R12

40

2B 2C
2B
R2
02
2C
R10

S8
TELESCOPE
S11 IN/OUT
PLATFORM
ROTATE S10
JIB
36 38B
ROTATE

GROUND

L
R7
37 38A

R8

08
2A
43
08
42
T
02 C L

04B 01A NOTE: TIE BACK

02 04 WIRES.

02 2A
R6
L 38B
R5
S24
EMERGENCY S4 U
PUMP E-STOP
04 49
PL4 PL3 PL5 PL6 04 7A
01
01 04 08 28A 82 04
+ + + +
04
04 02

- - - - 3B
01 02 02 02
3C
290 AD

S5
HORN
01

D01

01A

208CR1 51CCR4
28CR 204CR 51C
35

08 208
28 28A 04B 204
04 02 04 35A

04 04 04 5"

02 162
R13
51C

W
28
04B 02 04B
D02
08A 08B
D08A 02

JIB MANIFOLD HARNESS - 192112

31 32 33 34 35 36 37 38 39 28 162 D

24P-FEMALE
WIRE 1 - 34 - ORANGE/BLACK
01

WIRE 2 - 35 - ORANGE/WHITE

(A)
7A 7A 3B 3C 13 14 20B 23 24 60 30
WIRE 3 - 36 - RED/PURPLE
WIRE 4 - 37 - WHITE/RED/BLACK
WIRE 5 - 42 - PINK X
08A

01A
08B

162

118

82
02
02
02
02
04
04
08

34
35
36
37
40
41
42
43

60
82

D118

118
20B WIRE 6 - 43 - PURPLE/RED
D20A
WIRE 7 - 02 - WHITE

08A

01A
08B

162

118
20A

02
02
02
02
04
04
08

34
35
36
37
40
41
42
43

60
82
JIB MANIFOLD HARNESS - 192112

08A

04
FOOTSWITCH CABLE - 192112

59B 30B 204 43 42 41 40 70

04 16 35 37 43
02
24 04
1

16P-MALE
36 37 40 41 42 43
02
13 04 02 34 36 42
D36 D37 D40 D41 D42 D43 34A 25 2
14
36A 36A 40A 40A 42A 42A
02
26 3
L
Y

(B)
42A
30A
15 30B
27 4
16 01A 208 08B 49 290 02 02
X-SIG
28 5
35A
BLACK WIRE
36A
Y-SIG
17 40B
40A
29 6 WHITE WIRE
C
18 34
30
30 7 + 118
59B
19 13
33
31 8 BP3
38A
20 _
02
+ 28A
38
32 9
BP1 08
21 31
_ 14
33 10
02 22 39
20A 34 11
32
23 70
35 12

M208958AE 3.24 Platform Controls Schematic - SJ30ARJE KC

196274AF SJ30AJE, SJ30ARJE

73
3.25 Base Controls Schematic - SJ30AJE ANSI/CSA AB

A B C D E F G H I J K L M N O

C01 1 2 3

HOURMETER R

B+
4 5 6

3"
CONNECTOR J1
259CR 208CR 60CR 162CR 60ACR 01DCR
SOCKET 1 - PLUG
SOCKET 2 - 3B
S23 6" SOCKET 3 - B+
E-PUMP 30
7A 60 9A 60 09 02 162 02 60A 02 7C
7D 01D 3B SOCKET 4 - 00
CANH
01B 01
259 208
162A
7C
CANL SOCKET 5 - PLUG
3C 01B 3D 00
D01B-1
60 09 07 60 30A
D01D 01D
J1 SOCKET 6 - PLUG
CB1 CB2
SOCKET 7 - CANH
3B 10
SOCKET 8 - CANL
3C 01B SOCKET 9 - 01D
3" SOCKET 10 - PLUG S
3C 05 02
01 162C
SOCKET 11 - PLUG
D01-2
SOCKET 12 - PLUG

00
02
03 02 7D
S2 07 S3 02
60 05
E-STOP KEYSWITCH 01 D7D

10 D162-1 01C
7A 10 7A
PL7 7A 162C 162CCR
3B 3B
OVERLOAD 09 30B CONNECTOR J2
60
60
162C 02 HM+ PIN 1 - HM+
HM-

3A
+ 162A
162 CANL PIN 2 - HM-
3A 02 07 10A 10 10A 10A
162C
30
CANH
PIN 3 - CAN L T
13
-
02 14 J2 PIN 4 - CAN H
PIN 5 - NOT USED
D59-2
S21 37
59
ENABLE 36
38 D02-3
30B
PIN 6 - NOT USED
S14 39
43 0" 120"
PLATFORM
39 ROTATE
S20
42
40
30B DIODE CONNECTION DIAGRAM
10A 13 1 2 02 3 4
MAIN 41
5 6 02 7 8
10A 10A 36 37
BOOM 32 72-3 72 13 13-4
10A 10A 9 10 02 11 12 D13
33
S17 1 2 01 3 4
14
31
FLY 1 2 10 3 4 71-3 71 14 14-4
30 D14
01B BOOM 1 2 7A 3 4
38 35
5 6 7A 7 8 73 37
34 73-3 37-4
D01B 20B
1 2 09 3 4 D37
U
1 2 60 3 4
71 73 36
10A 5 6 60 7 8 73-4 36-4
71 D36
1 2 162 3 4
72
1 2 10A 3 4 72-4 72 38 38-4
40
72 D38
34 1 2 13 3 4
73
1 2 14 3 4
30A 73 71-4 71 39 39-4
33 1 2 37 3 4 D39
S19 29
1 2 36 3 4
10A 10A 10A 10A 10A TURRET 29A
1 2 38 3 4 73-7 73 43 43-4
S16 S18 ROTATE 59 D43
S13 1 2 39 3 4
RISER 41 17
JIB PLATFORM 32 1 2 43 3 4 73 42
10A 60A 73-8 42-4
35 1 2 42 3 4 D42
31 LEVEL 8B
1 2 40 3 4
9A 73 40
1 2 41 3 4 73-2 40-4
CANH D40
1 2 32 3 4
CANL
7C
1
1
2
2
33
31
3
3
4
4
72-7 72
D41
41 41-4 V
1 2 30 3 4
71-7 71 32 32-4
1 2 35 3 4 D32
1 2 34 3 4
1 2 20B 3 4 71-8 71 33 33-4
D33
1 2 71 3 4
5 6 71 7 8 71 31
71-2 31-4
1 2 72 3 4 D31
02
5 6 72 7 8
MOTOR CONTROLLER HARNESS "A" - 192096 1 2 73 3 4 72-8 72 35 35-4
D35

BLACK WIRE FROM BEEPER 5 6 73 7 8

MOTOR CONTROLLER HARNESS "B" - 207820

MOTOR CONTROLLER HARNESS "A" - 192096

WIRE 1 - 3D - BLACK MAIN MANIFOLD HARNESS - 192101

MAIN MANIFOLD HARNESS - 192101

1 2 29 3 4 73-6 73 34 34-4
D34
1 2 29A 3 4
WIRE 2 - 00 - WHITE 1 2 59 3 4
WIRE 3 - 03 - RED WIRE 1 - 13 - ORANGE 02 02
1 2 17 3 4
8B-4 8B
D10A
10A 10A-3

WIRE 4 - 3C - GREEN WIRE 2 - 14 - BLACK 02 02

1 2 60A
8B
3 4
20B 10A 10A-4 W
D 28 1 2 3 4 20B-4
WIRE 5 - 10 - ORANGE WIRE 3 - 20B - ORANGE/BLUE 02 D10A-1
02
1 2 9A 3 4
01C D01-3 01
WIRE 6 - 7A - BLUE WIRE 4 - 223 - BLACK/WHITE 10 10
1
1
2
2
CANH
CANL
3
3
4
4
7A-3 7A
7A-3-1
7C 7C-1

WIRE 7 - D - WHITE/BLACK WIRE 5 - 224 - BLUE/BLACK 7A

7A
7A
7A
28
D59
59 1 2 7C 3 4
10 7C
WIRE 8 - 28 - RED/BLACK WIRE 6 - 31 - RED/WHITE 09
10-2 D10-2
7C-2

60 60
WIRE 9 - 17 - GREEN/BLACK WIRE 7 - 32 - GREEN/BLACK 60 60
WIRE 10 - 59 - ORANGE/BLACK WIRE 8 - 33 - GREEN/WHITE 162 162
10A
WIRE 11 - 8C - BLUE/BLACK WIRE 9 - 38 - ORANGE/RED 13 13
WIRE 12 - 8B - BLACK/WHITE WIRE 10 - 39 - BLACK/RED 14 14
37
PLATFORM CONNECTOR "A" - 192164 HARNESS TO HARNESS CONNECTIONS:
WIRE 13 - 24 - RED/WHITE WIRE 11 - 40 - BLUE/RED 36 162 39 38 37 36 35 34 33 32 31
223 223 223
WIRE 14 - 23 - GREEN/WHITE WIRE 12 - 41 - BLUE/PURPLE
38 38 24
223

WIRE 15 - 224 - BLUE/WHITE

39 39
X
WIRE 13 - 02 - WHITE (SPLICE #1) [14 GA.] 43 224 224 224 224
42
WIRE 16 - 223 - BLACK/RED WIRE 14 - 02 - WHITE (SPLICE #2) [14 GA.] 40 40
WIRE 17 - 290 - WHITE/RED WIRE 15 - 7A - RED 41 41
32 32
WIRE 18 - 162 - ORANGE/RED 33 33
1
WIRE 19 - 70 - BLUE/RED 31 31
01 HARNESSES FROM MIDDLE STRAIN RELIEF ON SIDE OF BOX.
30 30 60 20B 14 13 3C 3B 7A 7A
WIRE 20 - 71 - RED/GREEN 35
WIRE 21 - 72 - ORANGE/GREEN 20B
34
20B
CHARGER CUTOUT HARNESS - 192111

WIRE 22 - 73 - BLACK/WHITE/RED 71 71
71 204 30B RISER LOWERING HARNESS - 192181
WIRE 23 - 60A - WHITE/BLACK/RED 24 23
72 72 PLATFORM CONNECTOR "B" - 192166
WIRE 24 - 01 - RED/BLACK/WHITE 72
73. 73 70
WIRE 25(GROUND) - N/U - GREEN/BLACK/WHITE 73 CHARGER CUTOUT HARNESS - 192111 CHARGER CUTOUT HARNESS - 192111 Y
29 40 41 42 43 59B

MOTOR CONTROLLER HARNESS "B" - 207820 29A 16 WIRE 1 - 60 - BLACK WIRE 1 - 30 - BLACK
59 59
17 17 WIRE 2 - 60A - WHITE WIRE 2 - 02 - WHITE
WIRE 1 - 259 - RED 60A
60A 60A
WIRE 2 - 60 - ORANGE 8B 8B 8B
RED WIRE FROM BEEPER
9A
WIRE 3 - 04A - BLUE CANH
WIRE 4 - 01A - WHITE CANL 1
7C
WIRE 5 - 30B - BLACK
WIRE 6 - 204 - RED 208

01A
290 04A
8B
02
02 Z

49

M207954AI 3.25 Base Controls Schematic - SJ30AJE ANSI/CSA

196274AF SJ30AJE, SJ30ARJE

74
3.26 Base Controls Schematic - SJ30ARJE ANSI/CSA & AS AB

A B C D E F G H I J K L M N O

C01
HOURMETER

B+
CONNECTOR J1
SOCKET 1 - PLUG R
1 2 3
SOCKET 2 - 3B
259CR 208CR 60CR 162CR 60ACR 01DCR (ADD RELAY FOR T/UNIT) SOCKET 3 - B+
4 5 6

3B
SOCKET 4 - 00
CANH SOCKET 5 - PLUG
J1
30 CANL

7A 60 9A 60 09 02 162 02 60A 02 7C 7D 01D SPLICE

01D SOCKET 6 - PLUG
S23
E-PUMP 01B 01
259 208
162A SOCKET 7 - CANH
D01B-1 7C
60 09 07 60 30A
D01D SOCKET 8 - CANL
3C 01B 3D 00
SOCKET 9 - 01D
CB1 CB2
3B 10
SOCKET 10 - PLUG
3C 01B SOCKET 11 - PLUG

00
SOCKET 12 - PLUG
3C 05 02
S
01 162C
D01-2

02
03 02
S2 07 S3 02 162
60 05
E-STOP KEYSWITCH 01
SPLICE
10
7A
D162-1
CONNECTOR J2
7A 10
PL7 7A 162C 162CCR HM+ PIN 1 - HM+
HM-
3B 3B
OVERLOAD 09 30B CANL PIN 2 - HM-
60 162C 02 CANH
60 PIN 3 - CAN L
162A

3A 02
3A
+

10A 10 10A
162
10A
162C
30
J2 PIN 4 - CAN H
PIN 5 - NOT USED
-
02
13
PIN 6 - NOT USED T
14
D59-2
S21 37
36 59
ENABLE 30B
38 D02-3

S14 39
PLATFORM 43
42
39 ROTATE 30B
S20 40
10A 10A 13 MAIN 41
BOOM 32
10A 10A 36 37 10A 10A
33
DIODE CONNECTION DIAGRAM
S15 S17 1 2 02 3 4
31
42 10B 43
JIB FLY 14
5 6 02 7 8
30 72 13 13-4
01B
ROTATE BOOM 9 10 02 11 12 72-3
D13
38 35
34 1 2 01 3 4
1 2 10 3 4 71-3 71 14 14-4
D01B 20B
1 2 7A 3 4
D14 U
71
10A 5 6 7A 7 8
71 73-3 73 37 37-4
72 1 2 09 3 4 D37

72 1 2 60 3 4
34 40 60 73-4 73 36 36-4
73 5 6 7 8 D36
73 7D
1 2 162 3 4
30A 33
S19 29 1 2 10A 3 4 72-4 72 38 38-4
D7D D38
TURRET 29A 1 2 13 3 4
10A 10A 10A 10A 10A
ROTATE 59 01C 1 2 14 3 4
S16 S18 71-4 71 39 39-4
S13 41 17 1 2 37 3 4 D39
JIB RISER 32 36
PLATFORM 60A 1 2 3 4
10A
35 LEVEL 1 2 38 3 4 73-7 73 43 43-4
31 8B D43
9A 1 2 39 3 4
CANH 1 2 43 3 4 73 42 42-4
73-8
1 2 42 3 4 D42
CANL
1 2 40 3 4
7C
1 2 41 3 4 73-2 73
D40
40 40-4 V
1 2 32 3 4
1 2 33 3 4 72-7 72 41 41-4
D41
1 2 31 3 4
1 2 30 3 4
71-7 71 32 32-4
1 2 35 3 4 D32
1 2 34 3 4
1 2 20B 3 4 71-8 71 33 33-4
02 D33
1 2 71 3 4
MOTOR CONTROLLER HARNESS "A" - 192096 5 6 71 7 8
71-2 71 31 31-4
BLACK WIRE FROM BEEPER 1 2 72 3 4 D31
MOTOR CONTROLLER HARNESS "B" - 207820

MOTOR CONTROLLER HARNESS "A" - 192096

MAIN MANIFOLD HARNESS - 192101

MAIN MANIFOLD HARNESS - 192101

WIRE 1 - 3D - BLACK 5 6 72 7 8
72-8 72 35 35-4
1 2 73 3 4 D35
WIRE 2 - 00 - WHITE 5 6 73 7 8
WIRE 3 - 03 - RED WIRE 1 - 13 - ORANGE 02 02
1 2 29 3 4 73-6 73 34 34-4
D34
WIRE 4 - 3C - GREEN WIRE 2 - 14 - BLACK 02 02
D 28
1 2 29A 3 4
W
1 2 59 3 4
02 02 8B 10A 10A-3
WIRE 5 - 10 - ORANGE WIRE 3 - 20B - ORANGE/BLUE 01C D01-3 01
1 2 17 3 4
8B-4
D10A

WIRE 6 - 7A - BLUE WIRE 4 - 223 - BLACK/WHITE 10 10

1 2 60A 3 4
20B 10A 10A-4
1 2 8B 3 4 20B-4
7A 7A D10A-1
WIRE 7 - D - WHITE/BLACK WIRE 5 - 224 - BLUE/BLACK 7A 7A
28
D59
59 1 2 9A 3 4
1 2 CANH 3 4
WIRE 8 - 28 - RED/BLACK WIRE 6 - 31 - RED/WHITE 09
1 2 CANL 3 4
7A-3 7A
D7A-3
7C 7C-1
60 60
WIRE 9 - 17 - GREEN/BLACK WIRE 7 - 32 - GREEN/BLACK 60 60 1 2 7C 3 4
10-2 10 7C 7C-2
WIRE 10 - 59 - ORANGE/BLACK WIRE 8 - 33 - GREEN/WHITE 162 162 D10-2

10A
WIRE 11 - 8C - BLUE/BLACK WIRE 9 - 38 - ORANGE/RED 13 13
WIRE 12 - 8B - BLACK/WHITE 14 14
WIRE 10 - 39 - BLACK/RED 37
WIRE 13 - 24 - RED/WHITE PLATFORM CONNECTOR "A" - 192164
WIRE 11 - 40 - BLUE/RED 36 162 39 38 37 36 35 34 33 32 31

WIRE 14 - 23 - GREEN/WHITE WIRE 12 - 41 - BLUE/PURPLE

38 38 24 HARNESS TO HARNESS CONNECTIONS:
39 39 X
WIRE 15 - 224 - BLUE/WHITE WIRE 13 - 02 - WHITE (SPLICE #1) [14 GA.] 43 223 223 223 223
42
WIRE 16 - 223 - BLACK/RED WIRE 14 - 02 - WHITE (SPLICE #2) [14 GA.] 40 40 224 224 224 224
WIRE 17 - 290 - WHITE/RED WIRE 15 - 7A - RED 41 41
32 32
WIRE 18 - 162 - ORANGE/RED 33 33
1
WIRE 19 - 70 - BLUE/RED 31 31
20B 14 01
30 30 60 13 3C 3B 7A 7A
WIRE 20 - 71 - RED/GREEN 35
WIRE 21 - 72 - ORANGE/GREEN 34 HARNESSES FROM MIDDLE STRAIN RELIEF ON SIDE OF BOX.
20B 20B
WIRE 22 - 73 - BLACK/WHITE/RED 71 71 CHARGER CUTOUT HARNESS - 192111
71 204 30B
WIRE 23 - 60A - WHITE/BLACK/RED 72 72
24 23
PLATFORM CONNECTOR "B" - 192166
WIRE 24 - 01 - RED/BLACK/WHITE 72 RISER LOWERING HARNESS - 192181

WIRE 25(GROUND) - N/U - GREEN/BLACK/WHITE

73. 73 70
Y
73
29 40 41 42 43 59B

MOTOR CONTROLLER HARNESS "B" - 207820 29A 16 CHARGER CUTOUT HARNESS - 192111 CHARGER CUTOUT HARNESS - 192111
59 59
17 17
WIRE 1 - 259 - RED 60A 60A 60A WIRE 1 - 60 - BLACK WIRE 1 - 30 - BLACK
8B 8B
WIRE 2 - 60 - ORANGE 8B
RED WIRE FROM BEEPER WIRE 2 - 60A - WHITE WIRE 2 - 02 - WHITE
9A
WIRE 3 - 04A - BLUE CANH
WIRE 4 - 01A - WHITE CANL 1
7C
WIRE 5 - 30B - BLACK
208
WIRE 6 - 204 - RED
01A
290 04A
8B
02
02 Z

49

3.26 Base Controls Schematic - SJ30ARJE

M207819AJ ANSI/CSA & AS

196274AF SJ30AJE, SJ30ARJE

75
3.27 Base Controls Schematic - SJ30ARJE CE AB

A B C D E F G H I J K L M N O

1 2 3
C01 CAP1 R

B+
4 5 6
HOURMETER 60ACR
_
+ 30
259CR 208CR 60CR 162CR 60A 02
SPLICE

S23 162BCR 01DCR 30A 3B

CANH
E-PUMP
60 9A 60 09
J1
01D CANL
7A 02 162 02 162B 02 7C
7D SPLICE 01D
259 208
162A 01B
01B 01
D01B-1
7C D01D
3C
60 09 07 10 01
01B 3D 00
60 P N 02
3B 07
CB1 CB2 01B
SPLICE R I 01B CONNECTOR J1
3C 01B D01B-2
60B SOCKET 1 - PLUG S

00
3C
10 SOCKET 2 - 3B
05 02
60B
SOCKET 3 - B+
60 01
SOCKET 4 - 00
02
HM+ SOCKET 5 - PLUG
03 02 HM-
S2
60
07 S3 02
D01-2
CANL SOCKET 6 - PLUG
05
E-STOP KEYSWITCH 01 162C CANH
SOCKET 7 - CANH
SPLICE
162
10
SOCKET 8 - CANL
7B 10
PL7
7A
7A
162B
D162-1
J2 SOCKET 9 - 01D
3B 3B
OVERLOAD 09 D162
162C SOCKET 10 - PLUG
60
60
162 162CCR 01BCR SOCKET 11 - PLUG
162A 30B
3A
+
162
SPLICE 162C 02 01B 02 CONNECTOR J2 SOCKET 12 - PLUG
3A 02 07 10A 10 10A 10A 7A
PIN 1 - HM+ T
13 SPLICE SPLICE SPLICE
-
02 14 162C
30 7B
PIN 2 - HM-
S21 37
36
D59-2 PIN 3 - CAN L
ENABLE
38 59 PIN 4 - CAN H
S14 39
30B PIN 5 - NOT USED
PLATFORM 43 162C 02 01B 02
42
D02-3 D02-4 SPLICE PIN 6 - NOT USED
39 ROTATE
S20 40
10A 10A 13 MAIN 41
10A 10A 36 37
BOOM 32 30B
10A 10A
S15 33
S17 31
42 10B 43
JIB FLY 14
30
01B
ROTATE BOOM
38 35
34
D01B 20B
DIODE CONNECTION DIAGRAM U
162B
71 1 2 02 3 4
10A 5 6 02 7 8
D59 71 72-3 72 13 13-4
72 9 10 02 11 12 D13
59 1 2 01 3 4
40
72
34 D7D 1 2 10 3 4 71-3 71 14 14-4
73 D14
73 1 2 7A 3 4
30A 33
S19 29 5 6 7A 7 8 73 37 37-4
73-3
TURRET 29A 1 2 09 3 4 D37
10A 10A 10A 10A 10A
ROTATE 59 1 2 60 3 4
S16 S18 73-4 73 36 36-4
S13 41 17
SPLICE 5 6 60 7 8 D36
JIB RISER 32 1 2 162 3 4
PLATFORM 10A 60A
35 31 LEVEL 8B 1 2 10A 3 4 72-4 72 38 38-4
D38
9A 1 2 13 3 4
CANH 1 2 14 3 4
71-4 71 39 39-4
CANL 1 2 37 3 4 D39

7C 1 2 36 3 4
73 43
V
1 2 38 3 4 73-7 43-4
D43
1 2 39 3 4
1 2 43 3 4 73 42 42-4
73-8
1 2 42 3 4 D42

1 2 40 3 4
73-2 73 40 40-4
1 2 41 3 4 D40
1 2 32 3 4
1 2 33 3 4 72-7 72 41 41-4
D41
1 2 31 3 4
MOTOR CONTROLLER HARNESS "A" - 192096 1 2 30 3 4
71-7 71 32 32-4
1 2 35 3 4
MOTOR CONTROLLER HARNESS "B" - 207820

MOTOR CONTROLLER HARNESS "A" - 192096

02 D32
MAIN MANIFOLD HARNESS - 192101
MAIN MANIFOLD HARNESS - 192101

WIRE 1 - 3D - BLACK 1 2 34 3 4
71 33
1 2 20B 3 4 71-8 33-4
WIRE 2 - 00 - WHITE 1 2 71 3 4
D33

WIRE 3 - 03 - RED WIRE 1 - 13 - ORANGE 02 02

5 6 71 7 8
71-2 71 31 31-4
D31
WIRE 4 - 3C - GREEN WIRE 2 - 14 - BLACK 02 02
D 28
1 2 72 3 4
W
5 6 72 7 8
02
WIRE 5 - 10 - ORANGE WIRE 3 - 20B - ORANGE/BLUE 01 D01-3 01 02 1 2 73 3 4 72-8 72
D35
35 35-4

WIRE 6 - 7A - BLUE WIRE 4 - 223 - BLACK/WHITE SPLICE 10 10

5 6 73 7 8
1 2 29 3 4 73-6 73 34 34-4
7A 7A
WIRE 7 - D - WHITE/BLACK WIRE 5 - 224 - BLUE/BLACK 7A 7A
28
D59
59 1 2 29A 3 4
D34

1 2 59 3 4
WIRE 8 - 28 - RED/BLACK WIRE 6 - 31 - RED/WHITE 09
1 2 17 3 4 8B-4 8B
D10A
10A 10A-3
60 60
WIRE 9 - 17 - GREEN/BLACK WIRE 7 - 32 - GREEN/BLACK 60 60 1 2 60A 3 4
1 2 8B 3 4 20B-4 20B 10A 10A-4
WIRE 10 - 59 - ORANGE/BLACK WIRE 8 - 33 - GREEN/WHITE 162 162
1 2 9A 3 4
D10A-1

10A
WIRE 11 - 8C - BLUE/BLACK WIRE 9 - 38 - ORANGE/RED 13 13
1 2 CANH 3 4
7A-3 7A 7C 7C-1
1 2 CANL 3 4 D7A-3
WIRE 12 - 8B - BLACK/WHITE 14 14
WIRE 10 - 39 - BLACK/RED 37
1 2 7C 3 4
WIRE 13 - 24 - RED/WHITE PLATFORM CONNECTOR "A" - 192164 10 7C
WIRE 11 - 40 - BLUE/RED 36 162 39 38 37 36 35 34 33 32 31 10-2 D10-2
7C-2
38 38
WIRE 14 - 23 - GREEN/WHITE WIRE 12 - 41 - BLUE/PURPLE 39 39
24

WIRE 15 - 224 - BLUE/WHITE WIRE 13 - 02 - WHITE (SPLICE #1) [14 GA.] 43 X

42
WIRE 16 - 223 - BLACK/RED WIRE 14 - 02 - WHITE (SPLICE #2) [14 GA.] 40 40
WIRE 17 - 290 - WHITE/RED WIRE 15 - 7A - RED 41 41
32 32
WIRE 18 - 162 - ORANGE/RED 33 33
HARNESS TO HARNESS CONNECTIONS:
1
WIRE 19 - 70 - BLUE/RED 31 31
20B 14 01
223 223 223 223
30 30 60 13 3C 3B 7A 7A
WIRE 20 - 71 - RED/GREEN 35 224 224 224 224
34
WIRE 21 - 72 - ORANGE/GREEN 20B 20B
WIRE 22 - 73 - BLACK/WHITE/RED 71 71 HARNESSES FROM MIDDLE STRAIN RELIEF ON SIDE OF BOX.
71 204 30B
WIRE 23 - 60A - WHITE/BLACK/RED 72 72
24 23
PLATFORM CONNECTOR "B" - 192166 CHARGER CUTOUT HARNESS - 192111
WIRE 24 - 01C - RED/BLACK/WHITE 72
73. 73 70
WIRE 25(GROUND) - N/U - GREEN/BLACK/WHITE 73 Y
RISER LOWERING HARNESS - 192181
29 40 41 42 43 59B

MOTOR CONTROLLER HARNESS "B" - 207820 29A 16

59 59
17 17
WIRE 1 - 259 - RED 60A
60A 60A
CHARGER CUTOUT HARNESS - 192111 CHARGER CUTOUT HARNESS - 192111
8B 8B 8B
WIRE 2 - 60 - ORANGE
WIRE 3 - 04A - BLUE
9A WIRE 1 - 60 - BLACK WIRE 1 - 30 - BLACK
CANH
WIRE 4 - 01A - WHITE CANL WIRE 2 - 60A - WHITE WIRE 2 - 02 - WHITE
1
7C
WIRE 5 - 30B - BLACK
208
WIRE 6 - 204 - RED
01A
290 04A
HARNESS CONNECTION DIAGRAM 8B
02
02
Z

49

3.27 Base Controls Schematic - SJ30ARJE

M207968AJ CE

196274AF SJ30AJE, SJ30ARJE

76
3.28 Base Controls Schematic - SJ30ARJE KC AD

A B C D E F G H I J K L M N O

R
C01
HOURMETER

60ACR 8CCR

30
259CR 208CR 60CR 162CR 60A 02 02

S23 30A 30C

E-PUMP

24+
60 60 09 02 162 02 OR J1
259 208
162A SOCKET 1 - PLUG
01B
D01B-1
60
SOCKET 2 - 3B S
3C 09 SOCKET 3 - 24+
00
CB1 01B 3B
SOCKET 4 - 00
3B 07 CANH
CANL
SOCKET 5 - PLUG
D01B-2
01D SOCKET 6 - PLUG
SOCKET 7 - CANH
SOCKET 8 - CANL
05
SOCKET 9 - 01D
SOCKET 10 - PLUG
01

00
02
SOCKET 12 - PLUG
02 D01-2
07 S3 02
60 05
KEYSWITCH 01 162C CONNECTOR J2
SPLICE
162 HM+ PIN 1 - HM+
HM-
7B CANL PIN 2 - HM-
D162-1 CANH
PL7 PIN 3 - CAN L
3B 3B
OVERLOAD 09
162C PIN 4 - CAN H
60
60
162CCR 01BCR PIN 5 - NOT USED
PIN 6 - NOT USED
T
162A
162 30B
162C 02
02 07 10A 10A 10A
SPLICE SPLICE SPLICE
02 162C
30C
S21 37
D59-1
ENABLE 36
38 59
39
30B
PLATFORM 162C
D02-3 D02-4 SPLICE
42
OTAT
S20 40
10A
MAIN
37
BOOM 32 30B
33

42 10B LY 30
ATE BOOM 35
34
D01B 20B
DIODE C M U
71 02
10A 02
72-3 72
72 D13

40
72
73 71-3
D14
30A
29 73-3 73 37-4
D37
10A 10A 10A TURRE 29A
60
ATE 59 73
60 73-4
D36
RISER 162
PLATFORM 10A 60A
VEL 8B 10A 72-4 72 38-4
D38

71-4 39-4
CANL D39

7C
73-7 43-4

43
73-8 42-4 V
42
01DCR (ADD RELAY 40
CR1 CR2 51CCR3 73-2 73 40-4
8C
FOR T/UNIT)
02
51CCR4 SPLICE
72-7 72 41-4
51C 02 02 01D SPLICE
7D

TOR CONTR " - 192096 7C

71-7
D32
32-4
39 8B
MOTOR CONTROLLER HARNESS "B" - 207820

MOTOR CONTROLLER HARNESS "A" - 192096

20B 71-8
MAIN MANIFOLD HARNESS - 192101
MAIN MANIFOLD HARNESS - 192101

WIRE 1 - 3D - BLACK D7D 71

D33

WIRE 2 - 00 - WHITE 02 02
71
71-2
D31
WIRE 3 - 03 - RED WIRE 1 - 13 - ORANGE 02 02
72
72
WIRE 4 - 3C - GREEN WIRE 2 - 14 - BLACK 02 51C
73 72-8 72
D35
D01-3 02
WIRE 5 - 10 - ORANGE WIRE 3 - 20B - ORANGE/BLUE SPLICE
73
73-6 73
WIRE 4 - 223 - BLACK/WHITE D34

WIRE 7 - D - WHITE/BLACK WIRE 5 - 224 - BLUE/BLACK 09 8B-4 8B

D10A
10A 10A-3 W
60 60
WIRE 8 - 28 - RED/BLACK WIRE 6 - 31 - RED/WHITE 60 60
60A
20B 10A 10A-4
WIRE 9 - 17 - GREEN/BLACK WIRE 7 - 32 - GREEN/BLACK 162 162 20B-4 D10A-1

10A
WIRE 10 - 59 - ORANGE/BLACK WIRE 8 - 33 - GREEN/WHITE CANH
7C-1
CANL D7A-3
WIRE 11 - 8C - BLUE/BLACK WIRE 9 - 38 - ORANGE/RED 28
D59
59
37
WIRE 12 - 8B - BLACK/WHITE WIRE 10 - 39 - BLACK/RED 36
10-2 7C 7C-2 HARNESS TO HARNESS CONNECTIONS:
WIRE 13 - 24 - RED/WHITE WIRE 11 - 40 - BLUE/RED 38 38
223 223 223
39 39
WIRE 14 - 23 - GREEN/WHITE WIRE 12 - 41 - BLUE/PURPLE 43
224 224
42
WIRE 15 - 224 - BLUE/WHITE WIRE 13 - 02 - WHITE (SPLICE #1) [14 GA.] 40 40
WIRE 16 - 223 - BLACK/RED WIRE 14 - 02 - WHITE (SPLICE #2) [14 GA.]
WIRE 15 - 7A - RED 32 32 PLA OR "A" - 192164
WIRE 17 - 290 - WHITE/RED 33 33
162 38 37 32

WIRE 18 - 162 - ORANGE/RED HARNESSES FROM MIDDLE STRAIN RELIEF ON SIDE OF BOX.
30
WIRE 19 - 70 - BLUE/RED 35
CHARGER CUTOUT HARNESS - 192111
X
WIRE 20 - 71 - RED/GREEN 34
20B 20B
WIRE 21 - 72 - ORANGE/GREEN 71
RISER LOWERING HARNESS - 192181
WIRE 22 - 73 - BLACK/WHITE/RED 71
72
WIRE 23 - 60A - WHITE/BLACK/RED 72
30 60 20B 3C
73. 73
WIRE 24 - 01C - RED/BLACK/WHITE 73
CHARGER CUTOUT HARNESS - 192111 CHARGER CUTOUT HARNESS - 192111
WIRE 25(GROUND) - N/U - GREEN/BLACK/WHITE 29
29A WIRE 1 - 60 - BLACK WIRE 1 - 30 - BLACK
59 59
MO OR CONTROLLER HARNESS "B" - 207820 24 23 204 30B WIRE 2 - 60A - WHITE WIRE 2 - 02 - WHITE
60A PLATFORM CONNECTOR "B" - 192166
60A 60A
WIRE 1 - 259 - RED 8B 8B 8B
70
WIRE 2 - 60 - ORANGE CANH
40 43 59B
WIRE 3 - 04A - BLUE CANL
7C
WIRE 4 - 01A - WHITE Y
WIRE 5 - 30B - BLACK
WIRE 6 - 204 - RED

208

HARNESS CONNECTION DIAGRAM 04A

8B
02

49

3.28 Base Controls Schematic - SJ30ARJE

M208950AH KC

196274AF SJ30AJE, SJ30ARJE

77
 196274AF
M192071AH
A
B
3.29 Electrical Schematic - ANSI/CSA
C

1
3B(48+)

00 2
1 AMP 4 3
LINE
VOLTAGE B+ 3
TRACK UNIT
IEC 9.1

TELEMATICS TRACK UNIT TELEMATICS

D02-5 4
9 7 8
7C 01D
5
01D

NOTE A
CAN L

BATTERY
CAN H

01DCR 6 BATTERY CHARGER

7C JMPR1
D

CHARGER 7C 01D
7
L1CR
D10 D7A
8
7C 7D
9

MAIN DISCONNECT 7D 10
RIGHT D7D
B4 B3 B2 B1
B+ + - + - + - + - B- B- 01A 11 BATTERY TRAY - RIGHT SIDE

60 60A MOTOR CONTROLLER

SEE SHEET 2 FOR DETAILS 12

MAIN DISCONNECT 13
B8 B7 B6 B5 LEFT
48+ + - + - + - + - 24+ B- Battery - HM1 - Hour Meter + 14 BATTERY TRAY - LEFT SIDE

60 BLUE/YELLOW 60 48+ Battery + HM1 - Hour Meter - H 15 HOUR METER

S24 POSITION 11 - A
EMERGENCY 60A
60A 60A A23 - Charger Cutout HM3 - CAN L 16
PUMP
B-
08 08 8C 8C 01 01 PURPLE/BLACK 01 01 HM3 - CAN H 17 EMERGENCY PUMP
M4
POSITION 1 - A 3CCR
D08
E

10 01B 01B 01 24+ 24+ 3C(48+) TO RM12 18 MAIN CONTACTOR

D01B
S3 3A(48+) 3A(48+) 3C(48+) 19
S4
EMERGENCY KEY SWITCH S2
01
STOP 7A RED 7A BASE/OFF/PLATFORM EMERGENCY S23
D01 01 01 02 48+ 48+ 20 EMERGENCY PUMP CONTACTOR
POSITION 2 - A STOP EMERGENCY
01A 04 04 7A 7A RED 7A PUMP
7A
PL5 07 07 05 05 CB1 25 AMP 3D 01 01 02 01CR DC-DC CONVERTER 21
POSITION 3 - A 10
OVERLOAD 48+
D02-5 48V 48+
82 02 3C(48+) 3B(48+) 3B(48+) BLUE/WHITE 3B(48+) 3A(48+) 03(48+) D48+ 22 48V - 12V DC-DC CONVERTER
TO
POSITION 4 - A 12V B-
82 3B(48+) PL1
3C(48+) RED/YELLOW/BLK 3C(48+) 60 02 01 01 01A 01A
D118 BP3
A24 - E-Pump Enable F1-10A 23
OVERLOAD
POSITION 5 - A 3D 00
PL2 D01-3
118 118 ALARM 02 02 04 04 02 02 BLACK 02 02 3D A1 - Controls 12V 24
POSITION 1 - B 60CR
PLATFORM LOAD SENSOR S5 02 WHITE 02 60 02
CB2 25 AMP 00 00 00 A2 - Controls Ground 25 POWER RELAY
HORN SWITCH POSITION 2 - B
118 4 1 60 60 04 04 49 49 GREEN 03(48+) A3 - E-Stop Feed 03 M1 26 PUMP MOTOR
POSITION 4 - B
82 5 7 02 02 PL3 3C(48+) 3C(48+) A4 - E-Stop Return 27
TILT
162 3 2 60 60 28A 02 02 10 10 10 10 A5 - Base Mode 28 DRIVE MOTOR - RIGHT
M2

7A 7A 7A 7A A6 - Platform Mode 29 DRIVE MOTOR - LEFT

PL4 M3
F

ENABLE ACTIVE
08 08 08 02 02 49 02 LS1 70 70 30 HORN
A19 - PMU Speed
DIRECTION
SENSING
D D A7 - Throttle 31
BP1 N/C.H/O
TILT
R13=680 ohm
162 02 28A ALARM 02 02 07 09 09 17 17 A9 - Direction Sense AT2 - Tilt Output 28 32
BP4
04B 02 28 PINK/WHITE 28 28 28 A8 - Tilt AT4 - Angle Sensor 128 33 RELAY - TILT
SGE 28CR POSITION 22 - A N/C N/C N/C
BEEPER D59
04B 02 28 02 02 09 29 29A 59 59 59 A10 - Elevated Drive 34 TILT SWITCH
LS2 LS3 LS4 59
LB4 OPTIONAL
SGE BEACON 02 208 RISER DN BOOM DN FLY IN 208 AT1 - 12V Input 60 35
A11 - Enable Out
81
S22 S6
WORK LB2
60 60 28A WORK FOOT 8B A12 - Enable In AT3 - Tilt Ground 00 36
LIGHT SWITCH 7A
LIGHT 162CR
04 04 28A 81 02 04 8A 162 02 02 23 23 D7A
A14 - Steer R 37 RELAY - BASE OVERLOAD
3B(48+) 8B 60
208CR
LB3 D10A
WORK 60 208 24 24 A13 - Steer L 38 RELAY - BEEPER
LIGHT 10A
59 01
08 08 04 04 224 A15 - Steer L Valve 39
D59-2 D01-2 10

09 162C 162C D10

8A 8B 8B ORANGE 8B 9A 223 A16 - Steer R Valve 40
POSITION 5 - B 60
D8A
G

162 162 PINK/PURPLE 162 PL7 71 A20 - Base Speed 1 41

POSITION 23 - A OVERLOAD S21
60 60 208 208 BLUE 208 60 162A 162A 02 FUNCTION 72 A21 - Base Speed 2 42 RELAY - PLATFORM ENABLE
POSITION 6 - B ENABLE
08 208CR1 10 10 10A 73 A22 - Base Speed 3 43
PL6
04 04 290 290 RED 290 290 A17 - Battery LED 44
POSITION 3 - B
SENSOR BAR LOW BATTERY
02 02 60 60 60 B2 - 12V Output 60 45
204CR
04 204 204 GREEN/WHITE 204 204 B6 - SGE Output 46 RELAY - SGE ALARM
POSITION 14 - B
04 04 04A 04A WHITE/BLACK 04A 04A B3 - SGE Input 47
POSITION 7 - B
04B 04 04 01A 01A RED/BLACK 01A 01A B4 - SGE Reset 48
POSITION 8 - B
04B 04B 02 SCM-VALVE DRIVER 30B BLUE/WHITE 30B 30B B5 - Riser Down 49
POSITION 15 - B 259CR
S25 1 24
SGE RESET SWITCH 04 02 7A 7A 259 259 B1 - Stowed Limit 50 RELAY - STOWED LIMIT
204CR1 WITH LIGHT
04 204 04 2 25 02 02 162 162 A18 - Overload 51

04 13 26 02 59B BLACK/RED 59B 59B 60 52

POSITION 16 - B
H

30 30C 23A 16 33 08 53
23A 23A
12 70 70 70 70 4H-223 223
D24 GREEN/BLACK 7A 54 STEER - RIGHT
D23 POSITION 9 - B
24 SUPPR.
04 04 DRIVE 23 23 BLACK/WHITE 23 23
Vbat Right 55
POSITION 9 - A
Left 24 24 24 4H-224 224 162
BLUE/BLACK 24 7A 56 STEER - LEFT
A1 POSITION 10 - A D162-1
DRIVE/STEER SUPPR.
JOYSTICK Output D D PINK/BLACK D D 162C
57
POSITION 24 - A 162C
S20 14 BP2
Ground 02 02 9A 02 02 58
BOOM 10A
UP/DOWN 13 ALL-MOTION 4H-14
22 14 14 BLACK 14 ALARM 14 14 02 59 BOOM - UP
POSITION 7 - A
BOOM/TUR 4H-13
04 04 X 28 8 13 13 ORANGE 13 13 13 02 60 BOOM - DOWN
Vbat Xaxis
POSITION 6 - A
A2 4H-32
BOOM/ Y 29 20 32 32 GREEN/BLACK 32 32 32 02 61 TURRET - LEFT
TURRET Yaxis POSITION 14 - A
JOYSTICK 4H-33
02 35 33 33 GREEN/WHITE 33 33 33 02 62 TURRET - RIGHT
Gnd
POSITION 15 - A
5H-20B
02 23 20A 20A 20B 20B ORANGE/BLUE 20B 20B 02 63 FLOW ENALE
POSITION 8 - A
D20A 2H-30B
I

SPEEDC C 30 19 30C 30 RED/GREEN 30 30 30B 30B 02 64 RISER - DOWN

A3 POSITION 12 - A
SPEED CTRL. 2H-31
02 10 31 31 RED/WHITE 31 31 31 02 65 RISER - UP
SELECTOR R POSITION 13 - A
20B
L L 3 31 59B D10A-1 66

4 10A
30B 10A 10A 71 162C 02 02 67
30 32 S19 60ACR D39
TURRET 162CCR D02-3
10A 02 60A 60A 162C 02 02 68 RISER - DOWN CUT OFF RELAY
LEFT/RIGHT 39
R3=250 ohm
33 OPTIONAL 69
R1=250 ohm S18
S7 31
L 30B RISER
RISER 30A 27 9A 9A 02 02
02 R2=250 ohm 2B
10A UP/DOWN 70
UP/DOWN 30A 30
30A LB1
FLASHING LIGHT 71
R4=250 ohm
11 39 39 4H-39 02
YELLOW/PINK 39 39 72 FLY BOOM - EXTEND
POSITION 21 - A 39
R7=250 ohm SUPPR.
02
73
R5=250 ohm
31
S8 R6=250 ohm L 38B 32 S17 02
02 2A 38A D31 74
TELESCOPE 10A TELESCOPE
IN/OUT IN/OUT 71
75
J

R8=250 ohm
21 38 YELLOW/ORANGE 38 38 4H-38 02
38 76 FLY BOOM - RETRACT
POSITION 20 - A
SUPPR.
5 35 ORANGE/WHITE 35 35 72 77
POSITION 17 - A 35 13 38
R11=250 ohm D35 D33 D13 D38
4H-35 33 71 78
R9=250 ohm 02 35
JIB UP SOLENOID 72 72
S9 L 34B S16
R10=250 ohm 34A 14 32 71 79
JIB 02 2C SUPPR. 10A JIB
UP/DOWN 34 UP/DOWN D32
02
JIB DOWN SOLENOID 14 71 80
4H-34
R12=250 ohm D14
7 34 ORANGE/BLACK 34 34 34 73 72 81
POSITION 16 - A
D34
OPTIONAL 42 BLACK/WHITE 42 42 73 82
42 POSITION 12 - B 42
D42
4H-42 42 83
D42-1 02 JIB ROTATE LEFT SOLENOID
S10 LT S15
08 42A 15 73 73 73 84
JIB SUPPR. 10A JIB
ROTATE RT 02 43 ROTATE
D43-1 JIB ROTATE RIGHT SOLENOID 85
4H-43
D43
43 43 RED/WHITE 43 43 43 73 86
POSITION 13 - B
K

36 RED/PURPLE 36 36 73 87
36 POSITION 18 - A 36
D36
D36-1 4H-36 36 88
02
S11 PLATFORM ROTATE LEFT SOLENOID
LT S14
PLATFORM 08 36A 17 73 73 89
SUPPR. 10A PLATFORM
ROTATE
RT 02 37 ROTATE 72
PLATFORM ROTATE RIGHT SOLENOID 90
D37-1 4H-37 D41
D37
37 37 WHITE/RED/BLK 37 37 37 73 41 91
POSITION 19 - A
41 41 4H-41 02
BLUE/BLACK 41 92 PLATFORM LEVEL - UP
41 POSITION 11 - B 41 SUPPR.
D41-1 93
S12 UP S13
40B 40A 18 6 40B 73
PLATFORM 10A PLATFORM 94
LEVELING LEVELING D40
DN
D40-1 40 95

40 40 40 40 4H-40 02
ORANGE/BLACK 40 96 PLATFORM LEVEL - DOWN
POSITION 10 - B
SUPPR.
97

40B 40B 110A WHITE 110A 98 POWER TO PLATFORM

L

30C 30C 110B BLACK 110B M 99

30 30 GND GREEN GND 100

101

102

NOTE A: JMPR1 REMOVED WITH TRACK UNIT OPTION

M
N
O

3.29 Electrical Schematic - ANSI/CSA

Z
T

Y
X
S
R

W
AC

78
SJ30AJE, SJ30ARJE
 196274AF
M207303AH
A
B
3.30 Electrical Schematic - CE
C

1
3B(48+)

00 2
1 AMP 4 3
LINE
VOLTAGE B+ 3
TRACK UNIT
IEC 9.1

TELEMATICS TRACK UNIT TELEMATICS

D02-5 4
9 7 8
7C 01D
5
01D

NOTE A
CAN L

BATTERY
CAN H

01DCR 6 BATTERY CHARGER

CHARGER 7C JMPR1
7C 01D
7
L1CR
D10 D7A
D

8
7C 7D
9

MAIN DISCONNECT 7D 10
RIGHT D7D
B4 B3 B2 B1
B+ + - + - + - + - B- B- 01A 11 BATTERY TRAY - RIGHT SIDE

60 60A MOTOR CONTROLLER

SEE SHEET 2 FOR DETAILS 12

MAIN DISCONNECT 13
B8 B7 B6 B5 LEFT
48+ + - + - + - + - 24+ B- Battery - HM1 - Hour Meter + 14 BATTERY TRAY - LEFT SIDE

60 BLUE/YELLOW 60 48+ Battery + HM1 - Hour Meter - H 15 HOUR METER

S24 POSITION 11 - A
EMERGENCY 60A 60A
60A A23 - Charger Cutout HM3 - CAN L 16
PUMP
B-
08 08 8C 8C 01 01 PURPLE/BLACK 01 HM3 - CAN H 17 EMERGENCY PUMP
M4
POSITION 1 - A 01BCR 3CCR
D08 D01B-1
01B 02 07 07 01B 01 24+ 24+ 3C(48+) TO RM12 18 MAIN CONTACTOR
01B
D02-4 S3 3A(48+)
S4 3A(48+) 3C(48+) D01B-2 19
E

EMERGENCY KEY SWITCH S2 S23

01 CAP1 - 10000uF 10
STOP 7A RED 7A BASE/OFF/PLATFORM EMERGENCY EMERGENCY
D01 60 60B 01 01 02 48+ 48+ 20 EMERGENCY PUMP CONTACTOR
POSITION 2 - A STOP PUMP
01A 04 04 7A 7A RED 7A D02-5
7B
PL5 07 07 05 05 CB1 25 AMP 3D 01 02 01CR 02 DC-DC CONVERTER 21
POSITION 3 - A 10
OVERLOAD 162BCR 48+
3C(48+) 3B(48+) 48V 48+
82 02 3B(48+) BLUE/WHITE 3B(48+) 3A(48+) 03(48+) 162B 02 02 D48+ 22 48V - 12V DC-DC CONVERTER
COUNTER TO
POSITION 4 - A 12V B-
82 3B(48+) PL1
3C(48+) RED/YELLOW/BLK 3C(48+) 60 02 60 01A 01 01 01 01A 01A
D118 BP3 P I A24 - E-Pump Enable F1-10A 23
OVERLOAD
POSITION 5 - A 3D 00
PL2 N R
118 118 ALARM 02 02 04 04 02 02 BLACK 02 02 02 3D A1 - Controls 12V 24
POSITION 1 - B 60CR
PLATFORM LOAD SENSOR S5 02 WHITE 02 60 02
CB2 25 AMP 00 00 00 A2 - Controls Ground 25 POWER RELAY
HORN SWITCH POSITION 2 - B
118 4 1 60 60 04 04 49 49 GREEN 03(48+) A3 - E-Stop Feed 03 M1 26 PUMP MOTOR
POSITION 4 - B
82 5 7 02 02 PL3 3C(48+) 3C(48+) A4 - E-Stop Return 27
TILT
162 3 2 60 60 28A 02 02 10 10 10 10 A5 - Base Mode 28 DRIVE MOTOR - RIGHT
M2

7A 7A 7A 7A A6 - Platform Mode 29 DRIVE MOTOR - LEFT

PL4 M3
ENABLE ACTIVE 162B
08 08 08 02 02 49 02 LS1 70 70 30 HORN
A19 - PMU Speed
DIRECTION D59
F

SENSING 162 D D A7 - Throttle 31

BP1 N/C.H/O
TILT
R13=680 ohm 02
162 28A ALARM 02 02 07 09 09 17 17 A9 - Direction Sense AT2 - Tilt Output 28 32
BP4
04B 02 28 PINK/WHITE 28 28 28 A8 - Tilt AT4 - Angle Sensor 128 33 RELAY - TILT
SGE 28CR POSITION 22 - A N/C N/C N/C
D59-1
BEEPER 04B 02 28 02 02 09 29 29A 59 59 59 A10 - Elevated Drive 34 TILT SWITCH
LS2 LS3 LS4 59
LB4 OPTIONAL
SGE BEACON 02 208 RISER DN BOOM DN FLY IN 208 60 AT1 - 12V Input 60 35
A11 - Enable Out
81
S22 S6
WORK LB2
60 60 28A WORK FOOT 8B A12 - Enable In AT3 - Tilt Ground 00 36
LIGHT SWITCH 7A
LIGHT 162CR
04 04 28A 81 02 04 8A 162 02 02 23 23 D7A
A14 - Steer R 37 RELAY - BASE OVERLOAD
3B(48+) 8B 60
208CR
LB3 D10A
WORK 60 208 24 24 A13 - Steer L 38 RELAY - BEEPER
LIGHT 10A
60A
08 08 04 04 224 A15 - Steer L Valve 39
10
01
09 162B D10
8A 8B 8B ORANGE 8B 9A 59 D01-2 223 A16 - Steer R Valve 40
POSITION 5 - B 60
D8A D59-2 162C D162
162 162 PINK/PURPLE 162 PL7 162 71 A20 - Base Speed 1 41
162C
POSITION 23 - A OVERLOAD S21
G

60 60 208 208 BLUE 208 60 162A 162A 02 FUNCTION 72 A21 - Base Speed 2 42 RELAY - PLATFORM ENABLE
POSITION 6 - B ENABLE
08 208CR1 10 10 10A 73 A22 - Base Speed 3 43
PL6
04 04 290 290 RED 290 290 A17 - Battery LED 44
POSITION 3 - B
SENSOR BAR LOW BATTERY
02 02 60 60 60 60 B2 - 12V Output 60 45
204CR
04 204 204 GREEN/WHITE 204 204 B6 - SGE Output 46 RELAY - SGE ALARM
POSITION 14 - B
04 04 04A 04A WHITE/BLACK 04A 04A B3 - SGE Input 47
POSITION 7 - B
04B 04 04 01A 01A RED/BLACK 01A 01A B4 - SGE Reset 48
POSITION 8 - B
04B 04B 02 SCM-VALVE DRIVER 30B BLUE/WHITE 30B 30B B5 - Riser Down 49
POSITION 15 - B 259CR
S25 1 24
SGE RESET SWITCH 04 02 7A 7A 259 259 B1 - Stowed Limit 50 RELAY - STOWED LIMIT
204CR1 WITH LIGHT
04 204 04 2 25 02 02 162 162 A18 - Overload 51

04 13 26 02 59B 59B 59B 60 162C 162

BLACK/RED 52
POSITION 16 - B D162-1
30 30C 23A 16 33 08 02 53
H

23A 23A
12 70 70 70 70 4H-223 223
D24 GREEN/BLACK 7A 54 STEER - RIGHT
D23 POSITION 9 - B
24 SUPPR.
04 04 DRIVE 23 23 BLACK/WHITE 23 23
Vbat Right 55
POSITION 9 - A
Left 24 24 24 4H-224 224
BLUE/BLACK 24 7A 56 STEER - LEFT
A1 POSITION 10 - A
DRIVE/STEER SUPPR.
JOYSTICK Output D D PINK/BLACK D D 57
POSITION 24 - A 162C 162C
S20 OPTIONAL BP2
02 14 02
Ground 02 BOOM 9A 02 58
10A
UP/DOWN 13 ALL-MOTION 4H-14
22 14 14 BLACK 14 ALARM 14 14 02 59 BOOM - UP
POSITION 7 - A
BOOM/TUR 4H-13
04 04 X 28 8 13 13 ORANGE 13 13 13 02 60 BOOM - DOWN
Vbat Xaxis
POSITION 6 - A
A2 4H-32
BOOM/ Y 29 20 32 32 GREEN/BLACK 32 32 32 02 61 TURRET - LEFT
TURRET Yaxis POSITION 14 - A
JOYSTICK 4H-33
02 35 33 33 GREEN/WHITE 33 33 33 02 62 TURRET - RIGHT
Gnd
POSITION 15 - A
5H-20B
02 23 20A 20A 20B 20B ORANGE/BLUE 20B 20B 02 63 FLOW ENALE
POSITION 8 - A
D20A 2H-30
C 30 19 30C 30 RED/GREEN 30 30B 30B 02
SPEEDC 64 RISER - DOWN
A3 POSITION 12 - A
I

SPEED CTRL. 2H-31

02 10 31 31 RED/WHITE 31 31 31 02 65 RISER - UP
SELECTOR R POSITION 13 - A
20B
L L 3 31 59B D10A-1 162C 02 02 66 RISER - DOWN OVERLOAD RELAY

10A D02-3
4 30B 10A 10A 71 162CCR 162C 02 02 67
30 32 S19 60ACR D39
TURRET 02 60A 68 RISER - DOWN CHARGER CUTOFF RELAY
10A 60A
LEFT/RIGHT 39
R3=250 ohm
33 OPTIONAL 69
S7 R1=250 ohm 31
L 30B S18
RISER 30A 27 9A 9A 02 02
02 R2=250 ohm 2B
10A RISER 70
UP/DOWN 30A 30
UP/DOWN
30 LB1
FLASHING LIGHT 71
R4=250 ohm
11 39 39 4H-39 02
YELLOW/PINK 39 39 72 FLY BOOM - EXTEND
POSITION 21 - A 39
R7=250 ohm SUPPR.
02 02
73
R5=250 ohm
31 02
S8 R6=250 ohm L 38B 32 S17
02 2A 38A D31 74
TELESCOPE 10A TELESCOPE
IN/OUT IN/OUT 71
75
R8=250 ohm
4H-38
J

21 38 YELLOW/ORANGE 38 38 38 02 76 FLY BOOM - RETRACT

POSITION 20 - A
SUPPR.
5 35 ORANGE/WHITE 35 35 72 77
POSITION 17 - A 35 13 38
R11=250 ohm D35 D33 D13 D38
4H-35 33 71 78
R9=250 ohm 02 35
JIB UP SOLENOID 72 72
S9 L 34B S16
R10=250 ohm 34A 14 32 71 79
JIB 02 2C SUPPR. 10A JIB
UP/DOWN 34 UP/DOWN D32
02
JIB DOWN SOLENOID 14 71 80
4H-34
R12=250 ohm D14
7 34 ORANGE/BLACK 34 34 34 73 72 81
POSITION 16 - A
D34
42 BLACK/WHITE 42 42 73 82
42 POSITION 12 - B 42
D42
4H-42 42 83
D42-1 02 JIB ROTATE LEFT SOLENOID
S10 LT S15
08 42A 15 73 73 73 84
JIB SUPPR. 10A JIB
ROTATE RT 02 43 ROTATE
D43-1 JIB ROTATE RIGHT SOLENOID 85
4H-43
D43
43 43 RED/WHITE 43 43 43 73 86
POSITION 13 - B
36 RED/PURPLE 36 36 73 87
K

36 POSITION 18 - A 36
D36
D36-1 4H-36 36 88
02
S11 PLATFORM ROTATE LEFT SOLENOID
LT S14
PLATFORM 08 36A 17 73 73 89
SUPPR. 10A PLATFORM
ROTATE
RT 02 37 ROTATE 72
PLATFORM ROTATE RIGHT SOLENOID 90
D37-1 4H-37 D41
D37
37 37 WHITE/RED/BLK 37 37 37 73 41 91
POSITION 19 - A
41 41 4H-41 02
BLUE/BLACK 41 92 PLATFORM LEVEL - UP
41 POSITION 11 - B 41 SUPPR.
D41-1 93
S12 UP S13
40B 40A 18 6 40B 73
PLATFORM 10A PLATFORM 94
LEVELING LEVELING D40
DN
D40-1 40 95

40 40 40 40 4H-40 02
ORANGE/BLACK 40 96 PLATFORM LEVEL - DOWN
POSITION 10 - B
SUPPR.
97

40B 40B 110A WHITE 110A 98 POWER TO PLATFORM

L

30C 30C 110B BLACK 110B M 99

30 30 GND GREEN GND 100

101

102

NOTE A: JMPR1 REMOVED WITH TRACK UNIT OPTION

M
N
O

3.30 Electrical Schematic - CE

Z
T

Y
X
S
R

W
AC

79
SJ30AJE, SJ30ARJE
 196274AF
M207304AH
A
B
3.31 Electrical Schematic - AS
C

1
3B(48+)

00 2
1 AMP 4 3
LINE
VOLTAGE B+ 3
TRACK UNIT
IEC 9.1

TELEMATICS
4 TRACK UNIT TELEMATICS
D02-5
9 7 8
7C 01D
5
01D
CAN L

BATTERY NOTE A
CAN H

01DCR 6 BATTERY CHARGER

CHARGER 7C JMPR1
7C 01D
7
D

L1CR
D10 D7A
8
7C 7D
9

MAIN DISCONNECT 7D 10
RIGHT D7D
B4 B3 B2 B1
B+ + - + - + - + - B- B- 01A 11 BATTERY TRAY - RIGHT SIDE

60 60A MOTOR CONTROLLER

SEE SHEET 2 FOR DETAILS 12

MAIN DISCONNECT 13
B8 B7 B6 B5 LEFT
48+ + - + - + - + - 24+ B- Battery - HM1 - Hour Meter + 14 BATTERY TRAY - LEFT SIDE

60 BLUE/YELLOW 60 48+ Battery + HM1 - Hour Meter - H 15 HOUR METER

S24 POSITION 11 - A
EMERGENCY 60A
60A 60A A23 - Charger Cutout HM3 - CAN L 16
PUMP
B-
08 08 8C 8C 01 01 PURPLE/BLACK 01 01 HM3 - CAN H 17 EMERGENCY PUMP
M4
POSITION 1 - A 3CCR
D08
10 01B 01B 01 24+ 24+ 3C(48+) TO RM12 18 MAIN CONTACTOR
D01B
E

S3 3A(48+) 3A(48+) 3C(48+) 19

S4
EMERGENCY KEY SWITCH S2
01
STOP 7A RED 7A BASE/OFF/PLATFORM EMERGENCY S23
D01 01 01 02 48+ 48+ 20 EMERGENCY PUMP CONTACTOR
POSITION 2 - A STOP EMERGENCY
01A 04 04 7A 7A RED 7A PUMP
7A
PL5 07 07 05 05 CB1 25 AMP 3D 01 01 02 01CR DC-DC CONVERTER 21
POSITION 3 - A 10
OVERLOAD 48+
D02-5 48V 48+
82 02 3C(48+) 3B(48+) 3B(48+) BLUE/WHITE 3B(48+) 3A(48+) 03(48+) D48+ 22 48V - 12V DC-DC CONVERTER
TO
POSITION 4 - A 12V B-
82 3B(48+) PL1
3C(48+) RED/YELLOW/BLK 3C(48+) 60 02 01 01 01A 01
D118 BP3 A24 - E-Pump Enable F1-10A 23
OVERLOAD
POSITION 5 - A 3D 00
PL2 D01-3
118 118 ALARM 02 02 04 04 02 02 BLACK 02 02 3D A1 - Controls 12V 24
POSITION 1 - B 60CR
PLATFORM LOAD SENSOR S5 02 WHITE 02 60 02
CB2 25 AMP 00 00 00 A2 - Controls Ground 25 POWER RELAY
HORN SWITCH POSITION 2 - B
118 4 1 60 60 04 04 49 49 GREEN 03(48+) A3 - E-Stop Feed 03 M1 26 PUMP MOTOR
POSITION 4 - B
82 5 7 02 02 PL3 3C(48+) 3C(48+) A4 - E-Stop Return 27
TILT
162 3 2 60 60 28A 02 02 10 10 10 10 A5 - Base Mode 28 DRIVE MOTOR - RIGHT
M2

7A 7A 7A 7A A6 - Platform Mode
PL4 M3 29 DRIVE MOTOR - LEFT
ENABLE ACTIVE
08 08 08 02 02 49 02 LS1 70 70
F

A19 - PMU Speed 30 HORN

DIRECTION
SENSING
D D A7 - Throttle 31
BP1 N/C.H/O
TILT
R13=680 ohm
162 02 28A ALARM 02 02 07 09 09 17 17 A9 - Direction Sense AT2 - Tilt Output 28 32
BP4
04B 02 28 PINK/WHITE 28 28 28 A8 - Tilt AT4 - Angle Sensor 128 33 RELAY - TILT
SGE 28CR POSITION 22 - A N/C N/C N/C
BEEPER D59
04B 02 28 02 02 09 29 29A 59 59 59 A10 - Elevated Drive 34 TILT SWITCH
LS2 LS3 LS4 59
LB4 OPTIONAL
SGE BEACON 02 208 RISER DN BOOM DN FLY IN 208 AT1 - 12V Input 60 35
A11 - Enable Out
81
S22 S6
WORK LB2
60 60 28A WORK FOOT 8B A12 - Enable In AT3 - Tilt Ground 00 36
LIGHT SWITCH 7A
LIGHT 162CR
04 04 28A 81 02 04 8A 162 02 02 23 23 D7A
A14 - Steer R 37 RELAY - BASE OVERLOAD
3B(48+) 8B 60
208CR
LB3 D10A
WORK 60 208 24 24 A13 - Steer L 38 RELAY - BEEPER
LIGHT 10A
59 01
08 08 04 04 224 A15 - Steer L Valve 39
D59-2 D01-2 10

09 162C 162C D10

8A 8B 8B ORANGE 8B 9A 223 A16 - Steer R Valve 40
POSITION 5 - B 60
D8A
162 162 PINK/PURPLE 162 PL7 71 A20 - Base Speed 1 41
POSITION 23 - A OVERLOAD
G

S21
60 60 208 208 BLUE 208 60 162A 162A 02 FUNCTION 72 A21 - Base Speed 2 42 RELAY - PLATFORM ENABLE
POSITION 6 - B ENABLE
08 208CR1 10 10 10A 73 A22 - Base Speed 3 43
PL6
04 04 290 290 RED 290 290 A17 - Battery LED 44
POSITION 3 - B
SENSOR BAR LOW BATTERY
02 02 60 60 60 60 B2 - 12V Output 60 45
204CR
04 204 204 GREEN/WHITE 204 204 B6 - SGE Output 46 RELAY - SGE ALARM
POSITION 14 - B
04 04 04A 04A WHITE/BLACK 04A 04A B3 - SGE Input 47
POSITION 7 - B
04B 04 04 01A 01A RED/BLACK 01A 01A B4 - SGE Reset 48
POSITION 8 - B
04B 04B 02 SCM-VALVE DRIVER 30B BLUE/WHITE 30B 30B B5 - Riser Down 49
POSITION 15 - B 259CR
S25 1 24
SGE RESET SWITCH 04 02 7A 7A 259 259 B1 - Stowed Limit 50 RELAY - STOWED LIMIT
204CR1 WITH LIGHT
04 204 04 2 25 02 02 162 162 A18 - Overload 51

04 13 26 02 59B BLACK/RED 59B 59B 60 52

POSITION 16 - B
23A 16 33
H

30 30C 08 53
23A 23A
12 70 70 70 70 4H-223 223
D24 GREEN/BLACK 7A 54 STEER - RIGHT
D23 POSITION 9 - B
24 SUPPR.
04 04 DRIVE 23 23 BLACK/WHITE 23 23
Vbat Right 55
POSITION 9 - A
Left 24 24 24 4H-224 224 162
BLUE/BLACK 24 7A 56 STEER - LEFT
A1 POSITION 10 - A D162-1
DRIVE/STEER SUPPR.
JOYSTICK Output D D PINK/BLACK D D 162C
57
POSITION 24 - A 162C
S20 14 BP2
Ground 02 02 9A 02 02 58
BOOM 10A
UP/DOWN 13 ALL-MOTION 4H-14
22 14 14 BLACK 14 ALARM 14 14 02 59 BOOM - UP
POSITION 7 - A
BOOM/TUR 4H-13
04 04 X 28 8 13 13 ORANGE 13 13 13 02 60 BOOM - DOWN
Vbat Xaxis
POSITION 6 - A
A2 4H-32
BOOM/ Y 29 20 32 32 GREEN/BLACK 32 32 32 02 61 TURRET - LEFT
TURRET Yaxis POSITION 14 - A
JOYSTICK 4H-33
02 35 33 33 GREEN/WHITE 33 33 33 02 62 TURRET - RIGHT
Gnd
POSITION 15 - A
5H-20B
02 23 20A 20A 20B 20B ORANGE/BLUE 20B 20B 02 63 FLOW ENALE
POSITION 8 - A
D20A 2H-30B
C 30 19 30C 30 RED/GREEN 30 30 30B 30B 02 64 RISER - DOWN
I

SPEEDC
A3 POSITION 12 - A
SPEED CTRL. 2H-31
02 10 31 31 RED/WHITE 31 31 31 02 65 RISER - UP
SELECTOR R POSITION 13 - A
20B
L L 3 31 59B D10A-1 66

4 10A
30B 10A 10A 71 162C 02 02 67
30 32 S19 60ACR D39
TURRET 162CCR D02-3
10A 02 60A 60A 162C 02 02 68 RISER - DOWN CUT OFF RELAY
LEFT/RIGHT 39
R3=250 ohm
33 OPTIONAL 69
R1=250 ohm S18
S7 31
L 30B RISER
RISER 30A 27 9A 9A 02 02
02 R2=250 ohm 2B
10A UP/DOWN 70
UP/DOWN 30A 30
30A LB1
FLASHING LIGHT 71
R4=250 ohm
11 39 39 4H-39 02
YELLOW/PINK 39 39 72 FLY BOOM - EXTEND
POSITION 21 - A 39
R7=250 ohm SUPPR.
02
73
R5=250 ohm
31
S8 R6=250 ohm L 38B 32 S17 02
02 2A 38A D31 74
TELESCOPE 10A TELESCOPE
IN/OUT IN/OUT 71
75
R8=250 ohm
J

21 38 YELLOW/ORANGE 38 38 4H-38 02
38 76 FLY BOOM - RETRACT
POSITION 20 - A
SUPPR.
5 35 ORANGE/WHITE 35 35 72 77
POSITION 17 - A 35 13 38
R11=250 ohm D35 D33 D13 D38
4H-35 33 71 78
R9=250 ohm 02 35
JIB UP SOLENOID 72 72
S9 L 34B S16
R10=250 ohm 34A 14 32 71 79
JIB 02 2C SUPPR. 10A JIB
UP/DOWN 34 UP/DOWN D32
02
JIB DOWN SOLENOID 14 71 80
4H-34
R12=250 ohm D14
7 34 ORANGE/BLACK 34 34 34 73 72 81
POSITION 16 - A
D34
42 BLACK/WHITE 42 42 73 82
42 POSITION 12 - B 42
D42
4H-42 42 83
D42-1 02 JIB ROTATE LEFT SOLENOID
S10 LT S15
08 42A 15 73 73 73 84
JIB SUPPR. 10A JIB
ROTATE RT 02 43 ROTATE
D43-1 JIB ROTATE RIGHT SOLENOID 85
4H-43
D43
43 43 RED/WHITE 43 43 43 73 86
POSITION 13 - B
36 RED/PURPLE 36 36 73 87
K

36 POSITION 18 - A 36
D36
D36-1 4H-36 36 88
02
S11 PLATFORM ROTATE LEFT SOLENOID
LT S14
PLATFORM 08 36A 17 73 73 89
SUPPR. 10A PLATFORM
ROTATE
RT 02 37 ROTATE 72
PLATFORM ROTATE RIGHT SOLENOID 90
D37-1 4H-37 D41
D37
37 37 WHITE/RED/BLK 37 37 37 73 41 91
POSITION 19 - A
41 41 4H-41 02
BLUE/BLACK 41 92 PLATFORM LEVEL - UP
41 POSITION 11 - B 41 SUPPR.
D41-1 93
S12 UP S13
40B 40A 18 6 40B 73
PLATFORM 10A PLATFORM 94
LEVELING LEVELING D40
DN
D40-1 40 95

40 40 40 40 4H-40 02
ORANGE/BLACK 40 96 PLATFORM LEVEL - DOWN
POSITION 10 - B
SUPPR.
97

40B 40B 110A WHITE 110A 98 POWER TO PLATFORM

L

30C 30C 110B BLACK 110B M 99

30 30 GND GREEN GND 100

101

102

NOTE A: JMPR1 REMOVED WITH TRACK UNIT OPTION

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 M207305AI

196274AF
A
B
3.32 Electrical Schematic - KC

1
3B(48+)

00 2
1 AMP 4 3
LINE
C

VOLTAGE B+ 3
TRACK UNIT
IEC 9.1

TELEMATICS TRACK UNIT TELEMATICS

D02-5 4
9 7 8
7C 01D
5
01D
CAN L

BATTERY NOTE A
CAN H

01DCR 6 BATTERY CHARGER

CHARGER 7C JMPR1
7C 01D
7
L1CR
D10 D7A
8
7C 7D
9

MAIN DISCONNECT 7D 10
RIGHT D7D
B4 B3 B2 B1
B+ + - + - + - + - B- B- 01A 11 BATTERY TRAY - RIGHT SIDE

60 60A MOTOR CONTROLLER

SEE SHEET 2 FOR DETAILS 12

MAIN DISCONNECT 13
B8 B7 B6 B5 LEFT
7A 48+ + - + - + - + - 24+ B- Battery - HM1 - Hour Meter + 14 BATTERY TRAY - LEFT SIDE
7A
60 BLUE/YELLOW 60 48+ Battery + HM1 - Hour Meter - 15 HOUR METER
D

H
S24 POSITION 11 - A
EMERGENCY 60A
60A 60A A23 - Charger Cutout HM3 - CAN L 16
PUMP
01B 01B B-
8B 8B 8C 8C 01 01 PURPLE/BLACK 01 01 HM3 - CAN H 17 EMERGENCY PUMP
M4
POSITION 1 - A 01BCR 02 3CCR
D08B D01B-1
01B 02 07 01B 01 24+ 24+ 3C(48+) TO RM12 18 MAIN CONTACTOR
01B
D02-4 S3 3A(48+)
S4 3A(48+) 3C(48+) D01B-2 19
EMERGENCY KEY SWITCH S2
01
STOP 7A RED 7A BASE/OFF/PLATFORM EMERGENCY S23 10
D01 01 01 02 48+ 48+ 20 EMERGENCY PUMP CONTACTOR
POSITION 2 - A STOP EMERGENCY
01A 04 04 7A 7A RED 7A PUMP
7B 01CR
PL5 07 07 05 05 CB1 25 AMP 3D DC-DC CONVERTER 21
POSITION 3 - A 10
OVERLOAD 48+
3C(48+) 3B(48+) 48V
82 02 3B(48+) BLUE/WHITE 3B(48+) 3A(48+) 03(48+) 02 D48+ 22 48V - 12V DC-DC CONVERTER
TO
POSITION 4 - A 12V B-
82 3B(48+) PL1
3C(48+) RED/YELLOW/BLK 3C(48+) 60 02 01 01 01A 01A
01
D118 BP3 A24 - E-Pump Enable F1-10A 23
OVERLOAD
POSITION 5 - A 3D 00
PL2 D01-3
118 118 ALARM 02 02 04 04 02 02 BLACK 02 02 3D A1 - Controls 12V 24
POSITION 1 - B 60CR
PLATFORM LOAD SENSOR S5 02 WHITE 02 60 02
CB2 25 AMP 00 00 00 A2 - Controls Ground 25 POWER RELAY
HORN SWITCH POSITION 2 - B
118 4 1 60 60 60 04 04 49 49 GREEN 03(48+) A3 - E-Stop Feed 03 M1 26 PUMP MOTOR
POSITION 4 - B
E

82 5 7 02 02 PL3 3C(48+) 3C(48+) A4 - E-Stop Return 27

TILT
162 3 2 60 28A 02 02 10 10 10 10 A5 - Base Mode 28 DRIVE MOTOR - RIGHT
M2

7A 7A 7A 7A A6 - Platform Mode 29 DRIVE MOTOR - LEFT

PL4 M3
ENABLE ACTIVE D01-2
08 08 02 02 49 02 LS1 70 70 30 HORN
A19 - PMU Speed
DIRECTION
SENSING
D D A7 - Throttle 31
BP1 N/C.H/O
TILT 162C
R13=680 ohm 02
162 28A ALARM 02 02 07 09 09 17 17 A9 - Direction Sense AT2 - Tilt Output 28 32
BP4
04B 02 28 PINK/WHITE 28 28 28 A8 - Tilt AT4 - Angle Sensor 128 33 RELAY - TILT
SGE 28CR POSITION 22 - A N/C N/C N/C
OPTIONAL D59 D59-1
BEEPER 04B 02 28 02 02 09 29 29A 59 59 A10 - Elevated Drive 34 TILT SWITCH
LS2 LS3 LS4 59
LB2 OPTIONAL
SGE BEACON 02 208 RISER DN BOOM DN FLY IN 208 AT1 - 12V Input 60 35
A11 - Enable Out
81
S22 S6
WORK LB2
04 04 04 28A WORK FOOT 8B 8C 8C A12 - Enable In AT3 - Tilt Ground 00 36
LIGHT SWITCH 7A
LIGHT 162CR
60 60 28A 81 02 04 8A 162 02 02 23 23 D7A
A14 - Steer R 37 RELAY - BASE OVERLOAD
3B(48+) 8B 60
208CR
LB3 D10A
WORK 60 208 24 24 A13 - Steer L 38 RELAY - BEEPER
F

LIGHT 10A
08 08 04 04 51C 02 224 A15 - Steer L Valve 39
10

09 D10
8A 8B 8B ORANGE 8B 9A 51CCR4 223 A16 - Steer R Valve 40
POSITION 5 - B 60
8B D8A
162 162 PINK/PURPLE 162 PL7 02 02 71 A20 - Base Speed 1 41
POSITION 23 - A OVERLOAD S21
04 208 208 BLUE 208 10 162A 162A 02 FUNCTION 72 A21 - Base Speed 2 42 RELAY - PLATFORM ENABLE
POSITION 6 - B ENABLE
08 208CR1 10 10B 10B 10A 73 A22 - Base Speed 3 43
PL6
04 04 290 290 RED 290 290 A17 - Battery LED 44
OPTIONAL POSITION 3 - B
SENSOR BAR LOW BATTERY
02 02 60 60 60 B2 - 12V Output 60 45
204CR
04 204 204 GREEN/WHITE 204 204 B6 - SGE Output 46 RELAY - SGE ALARM
POSITION 14 - B
04 04A 04A WHITE/BLACK 04A 04A B3 - SGE Input 47
POSITION 7 - B
04B 04 04 01A 01A RED/BLACK 01A 01A B4 - SGE Reset 48
POSITION 8 - B
04B 04B 02 02 SCM-VALVE DRIVER 30B BLUE/WHITE 30B 30B B5 - Riser Down 49
POSITION 15 - B 259CR
S25
04 1 24 02 7A 7A 259
G

SGE RESET SWITCH 259 B1 - Stowed Limit 50 RELAY - STOWED LIMIT

WITH LIGHT
D162-1
04 2 25 02 02 162 162 A18 - Overload 51

04 13 26 02 59B BLACK/RED 59B 59B 60 8C 52

POSITION 16 - B
23A 16 33 08 53
23A 23A
12 70 70 70 70 4H-223 223
D24 GREEN/BLACK 7A 54 STEER - RIGHT
D23 POSITION 9 - B 8CCR
24 SUPPR.
04 04 DRIVE 23 23 BLACK/WHITE 23 23 8C 8C 02 02
Vbat Right 55
POSITION 9 - A 162CCR
Left 24 24 24 24 4H-224 224 162C 162C 02 02
BLUE/BLACK 7A 56 STEER - LEFT
A1 POSITION 10 - A 51CCR1
DRIVE/STEER SUPPR.
JOYSTICK Output D D PINK/BLACK D D 51C 02 02 57 BOOM-UP CUTOFF RELAY
POSITION 24 - A 51C D02-3
S20 14 BP2
Ground 02 02 9A 02 02 58
BOOM 10A
UP/DOWN 13 ALL-MOTION 4H-14A
22 14 14 BLACK 14 ALARM 14 14 14A 14A 02 59 BOOM - UP
POSITION 7 - A
BOOM/TUR 4H-13
04 04 X 28 8 13 13 ORANGE 13 13 13 02 60 BOOM - DOWN
Vbat Xaxis
POSITION 6 - A
A2 4H-32
BOOM/ Y 29 20 32 32 GREEN/BLACK 32 32 32 02 61 TURRET - LEFT
TURRET Yaxis POSITION 14 - A
H

JOYSTICK 4H-33
02 35 33 33 GREEN/WHITE 33 33 33 02 62 TURRET - RIGHT
Gnd
POSITION 15 - A
5H-20B
02 23 20A 20A 20B 20B ORANGE/BLUE 20B 20B 02 63 FLOW ENALE
POSITION 8 - A
D20A 2H-30B
SPEEDC C 30 19 30 30 RED/GREEN 30 30 30C 30B 02 64 RISER - DOWN
A3 POSITION 12 - A
SPEED CTRL. 2H-31A
02 10 31 31 RED/WHITE 31 31 31 31A 31A 02 65 RISER - UP
SELECTOR R POSITION 13 - A
20B
L L 3 31 59B D10A-1 66

4 10A
30B 10A 10A 71 51C 51C 02 02 67 RISER - UP CUTOFF RELAY
32 S19 60ACR D39
TURRET 02 60A 60A 51CCR2 68 RISER - DOWN CUT OFF RELAY
10A 39
LEFT/RIGHT
R3=250 ohm
33 OPTIONAL
S18 69
S7 R1=250 ohm 31
L 30B RISER
RISER 30A 27 9A 9A 02 02 02
02 R2=250 ohm 2B
10A UP/DOWN 70
UP/DOWN 30A 30
30A LB1
FLASHING LIGHT 71
R4=250 ohm
11 39 39 39 4H-39 02
YELLOW/PINK 39 39A 72 FLY BOOM - EXTEND
POSITION 21 - A 39
R7=250 ohm 02 SUPPR.
02
I

73
R5=250 ohm
31
S8 R6=250 ohm L 38B 32 S17
38A D31 51C 51C 02 02 74 FLY BOOM - EXTEND CUTOFF RELAY
TELESCOPE 02 2A 10A TELESCOPE
IN/OUT IN/OUT 71
51CCR3 75
R8=250 ohm
21 38 YELLOW/ORANGE 38 38 4H-38 02
38 76 FLY BOOM - RETRACT
POSITION 20 - A
SUPPR.
5 35A 35 ORANGE/WHITE 35 35 72 77
POSITION 17 - A 35 13 38
R11=250 ohm D35 D33 D13 D38
4H-35 33 71 78
R9=250 ohm 02 35
JIB UP SOLENOID 72 72
S9 L 34B S16
R10=250 ohm 34A 14 32 71 79
JIB 02 2C SUPPR. 10A JIB
UP/DOWN 34 UP/DOWN D32
02
JIB DOWN SOLENOID 14 71 80
4H-34
R12=250 ohm D14
7 34 ORANGE/BLACK 34 34 34 73 72 81
POSITION 16 - A
D34
42 BLACK/WHITE 42 42 73 82
42 POSITION 12 - B 42
D42
4H-42 42 83
D42-1 02 JIB ROTATE LEFT SOLENOID
S10 LT S15
08 42A 15 73 73 73 84
JIB SUPPR. 10A JIB
ROTATE RT 02 43 ROTATE
J

D43-1 JIB ROTATE RIGHT SOLENOID 85

4H-43
D43
43 43 RED/WHITE 43 43 43 73 86
POSITION 13 - B
36 RED/PURPLE 36 36 73 87
36 POSITION 18 - A 36
D36
D36-1 4H-36 36 88
02
S11 PLATFORM ROTATE LEFT SOLENOID
LT S14
PLATFORM 08 36A 17 73 73 89
SUPPR. 10A PLATFORM
ROTATE
RT 02 37 ROTATE 72
PLATFORM ROTATE RIGHT SOLENOID 90
D37-1 4H-37 D41
D37
37 37 WHITE/RED/BLK 37 37 37 73 41 91
POSITION 19 - A
41 41 4H-41 02
BLUE/BLACK 41 92 PLATFORM LEVEL - UP
41 POSITION 11 - B 41 SUPPR.
D41-1 93
S12 UP S13
40B 40A 18 6 40B 73
PLATFORM 10A PLATFORM 94
LEVELING LEVELING D40
DN
D40-1 40 95

40 40 40 40 4H-40 02
ORANGE/BLACK 40 96 PLATFORM LEVEL - DOWN
POSITION 10 - B
K

SUPPR.
97

98 POWER TO PLATFORM

35A 99
51CCR5
51C 02 02 100 JIB - UP CUTOFF RELAY

101

60 35A 35 35 102

LS5B 103 ANTI OVER-RISING RELAY 1

51ACR
52A 51 51A 02 02 104 ANTI OVER-RISING RELAY 2
51CR
7A 7A 51A 51A 51 02 02 105

OPTIONAL LS5C 106

52B 52A 60 60 51B 51B 51C 51C GREEN 51C 51C

POSITION 3 - C 107

7A 7A 51A 51A
L

108

LS5D 109

52A 52B
110

7A 7A 51A 51A
111

LS5A
112
7A 7A 52A
113
7A 51A 51A
110A BROWN 110A 114

110B BLUE 110B M 115

GND GREEN/YELLOW GND 116

M

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 196274AF
M192071AH-2
A
B

STEER SENSOR + - 3D

STEER SENSOR OUTPUT

STEER SENSOR
+ BATTERY TERMINAL - BATTERY TERMINAL
STEER SENSOR - B-
48+
ZAPI INTERFACE CONNECTOR

INTERFACE + - 3D 3D

INTERFACE -
3.33 Motor Controller Electrical Schematic

CAN H

CAN L 48+ 48+

C

MAIN CONTACTOR
3CCR
R15=120 ohm
3C CONTACTOR GROUND

RIGHT MOTOR ENCODER CONNECTOR

48+ 48+ 48+ 48+

ENCODER +

ENCODER A 00 48+ 48+

NEGATIVE

ENCODER B 00
48V TO 12 V
ENCODER - 3D CONVERTER

3D 3D POSITIVE - 12V
D

B-
48+
D48+
RIGHT MOTOR BRAKE CONNECTOR 03
48+

RIGHT MOTOR
BRAKE +
RIGHT MOTOR CONTROLLER CONNECTOR
BRAKE - F1 - 10A CU CV CW

8B B-
RM 1
F3 - 400A
48+
RM 2
F2 - 10A
3D 3E RM 3
RIGHT MOTOR TEMP. CONNECTOR 48+
BRAKE - RM 4

THERMAL - ENCODER - RM 5
E

PUMP MOTOR
THERMAL + 59 RM 6

RM 7
P-
208 RM 8

224 224 RM 9
HOUR METER CONNECTOR
3C 3C RM 10

HM 1 HOUR METER + 223 RM 11 P-

HM 2 HOUR METER - CONTACTOR GROUND RM 12

HM 3 CAN L ENCODER B RM 13

HM 4 CAN H ENCODER A RM 14
F

HM 5 D RM 15

HM 6 24 RM 16

RM 17

3C RIGHT MOTOR
3C RM 18 CONTROLLER
MASTER
23 RM 19
MOTOR CONTROLLER HARNESS - A
10 10 RM 20

A1 CONTROLS 12V - 3D 3D
RM 21

A2 CONTROLS GROUND - 00 00 THERMAL + RM 22

A3 E-STOP FEED - 03 03
RM 23

A4 E-STOP RETURN - 3C 3C 00
G

RM 24

A5 BASE MODE - 10 10 ENCODER + RM 25

A6 PLATFORM MODE - 7A 7A 90 RM 26

A7 THROTTLE - D D CAN L RM 27

A8 TILT OUTPUT - 28 28 CAN H RM 28

A9 DIRECTION SENSE - 17
RM 29

A 10 ELEVATED DRIVE - 59 59 STEER SENSOR RM 30

A 11 ENABLE OUT - 208 208 17 17 RM 31

A 12 ENABLE IN - 8B 8B 28 RM 32
BASE CONTROL
BOX A 13 STEER LEFT - 24 23 259 RM 33
H

A 14 STEER RIGHT - 23 24
RM 34

A 15 STEER LEFT VALVE - 224 224 7A RM 35

A 16 STEER RIGHT VALVE - 223 223

A 17 BATTERY LIGHT - 290 90

10
A 18 OVERLOAD - 162 162 00
D10
60 LEFT MOTOR CONTROLLER CONNECTOR
R14=20 Kohm
A 19 PMU SPEED - 70 70

A 20 BASE SPEED 1 - 71 8B B-
LM 1
F4 - 400A
A 21 BASE SPEED 2 - 72 71 48+
LM 2

A 22 BASE SPEED 3 - 73 72 72 3D LM 3
48+
I

A 23 CHARGER CUTOUT - 60A 73 73 BRAKE - LM 4

A 24 EMERGENCY PUMP ACTIVE - 01A 7A ENCODER - LM 5

D7A
60 LM 6

60A 60A LM 7

LM 8
MOTOR CONTROLLER HARNESS - B
LM 9

B1 STOWED TILT - 259 3C LM 10

B2 12V OUTPUT - 60 60 204 LM 11

B3 SGE INPUT - 04A 204

LM 12

B4 SGE RESET - 01A ENCODER B LM 13

J

B5 RISER DOWN ACTIVE - 30A ENCODER A LM 14

B6 SGE ALARM - 204 204 70 LM 15

01A 01A LM 16

04A 04A LM 17
LEFT MOTOR
LM 18 CONTROLLER
TILT SWITCH CONNECTOR SLAVE
162 LM 19

AT 1 12V INPUT - 60 60 71 71 LM 20

AT 2 TILT OUTPUT - 28 28
LM 21
TILT SWITCH
AT 3 TILT GROUND - 00 00 THERMAL + LM 22
R16=470 ohm
K

AT 4 ANGLE SENSOR - 128 128 00

LM 23

30A
LM 24

ENCODER + LM 25

LM 26
LEFT MOTOR ENCODER CONNECTOR
CAN L LM 27

ENCODER + CAN H LM 28

ENCODER A 30A 30A LM 29

ENCODER B 128 128 LM 30

ENCODER - 72 72 LM 31

73 73 LM 32
L

LM 33

LM 34
LEFT MOTOR BRAKE CONNECTOR
01A 01A LM 35
LEFT MOTOR
BRAKE +
CU CV CW
BRAKE -

LEFT MOTOR TEMP. CONNECTOR

M

THERMAL -

THERMAL +
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SJ30AJE, SJ30ARJE
Section 4 – Troubleshooting Information
4.1 Introduction major component in which the trouble occurs, isolate
whether the problem is electrical or hydraulic, and
The following pages contain a table of then isolate and correct the specific problem.
Troubleshooting for locating and correcting most
The content of this section is separated into “probable
service trouble which can develop. Careful and
cause” and “remedy.” The information preceded
accurate analysis of the systems listed in the table
by a number represents the “probable cause.”
of Troubleshooting will localize the trouble more
The following line, noted by a dash represents the
quickly than any other method. This manual cannot
“remedy” to the “probable cause” directly above it.
cover all possible troubles and deficiencies that may
See example below for clarification.
occur. If a specific trouble is not listed, isolate the

1. Probable cause. Remedy.

SJ30AJE, SJ30ARJE 196274AF

83
Section 4 – Troubleshooting Information Electrical System

4.2 Electrical System

4.2-1 All Controls Inoperative

1. Battery disconnected or discharged. Reconnect battery. Recharge if discharged.

2. Loose or dirty battery cables. Clean and tighten battery cables.
3. Open or defective main power disconnect right Close disconnect. Replace if defective.
or left.
4. Charger plugged into AC source. Make sure batteries are charged. Unplug from AC
source.
5. Loose or broken wire #60 from base terminal Check continuity. Replace if defective.
block to charger cutout relay L1CR.
6. Defective relay L1CR. Check relay. Replace if defective.
7. Loose or broken wire #60A from charger cutout Check continuity. Replace if defective.
relay L1CR to base terminal block.
8. Loose or broken wire #60A from base terminal Check continuity. Replace if defective.
block to motor control harness A.
9. Loose or broken wire #60A from motor control Check continuity. Replace if defective.
harness A pin #23 to left motor controller pin
#LM7.
10. Loose or broken wire #48+ from motor contactor Check continuity. Replace if defective.
3CCR to diode D48+.

11. Open or defective diode D48+. Check diode. Replace if defective.

12. Loose or broken wire #48+ from diode D48+ to Check continuity. Replace if defective.
fuse F1.
13. Defective fuse F1 (10Amp). Check fuse. Replace if defective.
14. Loose or broken wire #03 from fuse F1 to base Check continuity. Replace if defective.
emergency stop switch S6.
15. Defective base emergency stop switch S6. Check switch. Replace if defective.
16. Loose or broken wire #3A from base emergency Check continuity. Replace if defective.
stop switch S6 to base key switch S3.
17. Defective base key switch S3. Check switch. Select either base or platform.
Replace if defective.
18. Loose or broken wire #3B from base emergency Check continuity. Replace if defective.
stop switch S6 to platform plug A pin #4 in base
control console.
19. Loose or broken wire #3B in boom cable A or its Check for continuity between pins #4 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.

196274AF SJ30AJE, SJ30ARJE

84
Electrical System Section 4 – Troubleshooting Information

20. Loose or broken wire #3B from plug A pin #4 Check continuity. Replace if defective.
to emergency stop switch S4 in platform control
console.
21. Defective platform emergency stop switch S4. Check continuity. Replace if defective.
22. Loose or broken wire #3C from platform Check continuity. Replace if defective.
emergency stop switch S4 to platform plug A pin
#5 in platform control console.
23. Loose or broken wire #3C in boom cable A or its Check for continuity between pins #5 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
24. Loose or broken wire #3C from plug A pin #5 to Check continuity. Replace if defective.
base emergency pump switch S23.
25. Loose or broken wire #3C from base emergency Check continuity. Replace if defective.
pump switch S23 to motor control harness A.
26. Loose or broken wire #3C from motor control Check continuity. Replace if defective.
harness A pin #4 to right motor controller pin
#RM10, left motor controller pin #LM10 and
contactor 3CCR.
27. No negative output from right motor controller pin Check continuity. Replace if defective.
#RM12 to contactor 3CCR.
28. Defective contactor 3CCR. Check contactor. Replace if defective.
29. Defective main fuse F3 or F4 (400Amp). Check fuse. Replace if defective.
30. Defective DC/DC converter. Check continuity. Replace if defective.
31. Loose or broken wire #3D from DC/DC converter Check continuity. Replace if defective.
to fuse F2.
32. Defective fuse F2 (10Amp). Check fuse. Replace if defective.
33. Loose or broken wire #3D from fuse F2 to right Check continuity. Replace if defective.
motor controller pin #RM3 or left motor controller
pin #LM3.
34. Loose or broken wire #3D from DC/DC converter Check continuity. Replace if defective.
to circuit breaker CB1.
35. Tripped or defective circuit breaker CB1. Reset breaker. Check for defective wiring. Replace
breaker if defective.
36. Loose or broken wire #5 from circuit breaker Check continuity. Replace if defective.
CB1 to base emergency stop switch S2.
37. Defective base emergency stop switch S2. Check switch. Replace if defective.
38. Loose or broken wire #7 from base key switch Check continuity. Replace if defective.
S3 to relay 60CR.

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4.2-2 All Controls Inoperative If Equipped with Elevate/Trackunit Telematics

NOTE
If the unit is equipped with an Access keypad, a passcode is required from the machine owner.

1. Loose or broken B+ wire from battery + to Check continuity. Replace if defective.

telematics pin 3.
2. Loose or broken B- wire 00 from battery - to Check continuity. Replace if defective.
telematics pin 4.
3. Loose or broken wire 07A and/or 10 from base Check continuity. Replace if defective.
terminal strip to Diode(s) D7A and D10.
4. Defective diode(s) D7A and or D10. Check diode. Replace if defective.
5. Loose or broken wire 7C from diode(s) D7A and/ Check continuity. Replace if defective.
or D10 to 01DCR pin 86.
6. Loose or broken wire 7C from diode(s) D7A and/ Check continuity. Replace if defective.
or D10 to 01DCR pin 30.
7. Loose or broken wire 01D from telematics pin 9 Check continuity. Replace if defective.
to 01DCR pin 85.
8. If telematics device is not installed: loose, broken Check continuity. Replace if defective or missing.
or missing Jumper JMPR1 from 57DCR pin 85 to
ground 00.
9. Missing output from telematics pin 9. Check for ground on pin 9. If no ground; contact
the machine owner.
10. Defective relay 01DCR. Check relay. Replace if defective.
11. Loose or broken wire 7D from 01DCR pin 87A to Check continuity. Replace if defective.
diode D7D.
12. Defective diode D7D. Check diode. Replace if defective.
13. Loose or broken wire 01A from D7D to motor Check continuity. Replace if defective.
controller pin A24.
14. Defective telematics module. Check telematics assembly, repair or replace as
required.

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4.2-3 No Power To Platform

1. Open or defective key select switch S3. Close switch. Replace if defective.
2. Loose or broken wire #07A from key select Check continuity. Replace if defective.
switch S2 to platform plug A pins #2 & 3 in base
control console.
3. Loose or broken wire #07A from plug A pins Check continuity. Replace if defective.
#2 & 3 in platform control console to platform
emergency stop switch S4.
4. Open or defective platform emergency stop Check switch. Replace if defective.
switch S4.

4.2-4 All Functions Inoperative from Base Control Console

1. Loose or broken wire #10 from base key switch Check continuity. Replace if defective.
S3 to base terminal block.
2. Loose or broken wire #10 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
3. Loose or broken wire #10 from motor control Check continuity. Replace if defective.
harness A pin #5 to right motor controller pin
#RM20.
4. Loose or broken wire #10 from right motor Check continuity. Replace if defective.
controller pin #RM20 to diode D10 in tilt switch
harness.
5. Open or defective diode D10. (Diode is in tilt Check diode. Replace if defective.
switch harness close to the tilt switch)
6. Loose or broken wire #60 from diode D10 in tilt Check continuity. Replace if defective.
switch harness to motor control harness B pin
#2.
7. Loose or broken wire #60 from motor control Check continuity. Replace if defective.
harness B pin #2 to base terminal block.
8. Loose or broken wire #60 or #02 from base Check continuity. Replace if defective.
terminal block to relay 60CR.
9. Loose or broken wire #07 from base key switch Check continuity. Replace if defective.
S3 to relay 60CR.
10. Loose or broken wire #09 from relay 60CR to Check continuity. Replace if defective.
base terminal block.
11. Defective relay 60CR. Check relay. Replace if defective.
12. Loose or broken wire #10 from base terminal Check continuity. Replace if defective.
block to relay 162CR.
13. Platform overloaded. Remove excessive weight.

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14. Loose or broken wire #162 or #02 from base Check continuity. Replace if defective.
terminal block to relay 162CR.
15. Loose or broken wire #10B from relay 162CR to Check continuity. Replace if defective.
base enable switch S21.
16. Open or defective base enable switch S21. Close switch. Replace if defective.
17. Loose or broken wire #10A from base enable Check continuity. Replace if defective.
switch S21 to base terminal block.
18. Open or defective diode D10A or D10A-1. Check diode. Replace if defective.

4.2-5 No Boom Up from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to boom switch S20.
2. Defective boom switch S20. Check continuity through switch while activating
up function between wires #10A and #14. Replace
switch if no continuity found.
3. Loose or broken wire #14 from boom switch S20 Check continuity. Replace if defective.
to base terminal block.
4. Open or defective diode D14. Check diode. Replace if defective.
5. Loose or broken wire #71 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #71 from motor control Check continuity. Replace if defective.
harness A pin #20 to left motor controller pin
#LM20.
7. Loose or broken wire #14 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #2.
8. Loose or broken wire #14 from main manifold Check continuity. Replace if defective.
harness plug pin #2 to boom up valve 4H-14.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to boom up valve 4H-14.
10. Defective boom up coil 4H-14. Check continuity and resistance through coil.
Replace if defective.

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4.2-6 No Boom Down from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to boom switch S20.
2. Defective boom switch S20. Check continuity through switch while activating
down function between wires #10A and #13.If no
continuity found, replace switch.
3. Loose or broken wire #13 from boom down Check continuity. Replace if defective.
switch S20 to base terminal block.
4. Open or defective diode D13. Check diode. Replace if defective.
5. Loose or broken wire #72 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #72 from motor control Check continuity. Replace if defective.
harness A pin #21 to left motor controller pin
#LM31.
7. Loose or broken wire #13 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #1.
8. Loose or broken wire #13 from main manifold Check continuity. Replace if defective.
harness plug pin #1 to boom down valve 4H-13.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to boom down valve 4H-13.
10. Defective boom down coil 4H-13. Check continuity and resistance through coil.
Replace if defective.

4.2-7 All Controls Inoperative

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to riser switch S18.
2. Defective riser switch S18. Check continuity through switch while activating
up function between wires #10A and #31. Replace
switch if no continuity.
3. Loose or broken wire #31 from riser switch S18 Check continuity. Replace if defective.
to base terminal block.
4. Open or defective diode D31. Check diode. Replace if defective.
5. Loose or broken wire #71 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #71 from motor control Check continuity. Replace if defective.
harness A pin #20 to left motor controller pin
#LM20.
7. Loose or broken wire #31 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #6.

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8. Loose or broken wire #31 from main manifold Check continuity. Replace if defective.
harness plug pin #6 to riser up valve 2H-31.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to riser up valve 2H-31.
10. Defective boom up coil 2H-31. Check continuity and resistance through coil.
Replace if defective.

4.2-8 No Riser Down from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to riser switch S18.
2. Defective riser switch S18. Check continuity through switch while activating
down function between wires #10A and #30. If no
continuity found, replace switch.
3. Loose or broken wire #60A or #02 from base Check continuity. Replace if defective.
terminal block to relay 60ACR.
4. Loose or broken wire #30A from riser switch S18 Check continuity. Replace if defective.
to relay 60ACR.
5. Loose or broken wire #30 from relay 60ACR to Check continuity. Replace if defective.
base terminal block.
6. Defective relay 60ACR. Check relay. Replace if defective.
7. Loose or broken wire #30 from base terminal Check continuity. Replace if defective.
block to relay 162CCR.
8. Loose or broken wire #162C from diodes D162-1 Check continuity. Replace if defective.
and D59-2 to relay 162CCR.
9. Loose or broken wire #02 from base terminal Check continuity. Replace if defective.
block to relay 162CCR.
10. Defective relay 162CCR. Check relay. Replace if defective.
11. Loose or broken wire #02 from base terminal Check continuity. Replace if defective.
block to riser down harness.
12. Loose or broken wire #30B from relay 162CCR to Check continuity. Replace if defective.
riser down harness.
13. Loose or broken wire #30B or #02 from riser Check continuity. Replace if defective.
down harness to riser down valve 2H-30B.
14. Defective riser down coil 2H-30B. Check continuity and resistance through coil.
Replace if defective.

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4.2-9 No Turret Rotate Left from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to turret rotate switch S19.
2. Defective turret rotate switch S19. Check continuity through switch while activating
rotate left function between wires #10A and #32. If
no continuity found, replace switch.
3. Loose or broken wire #32 from turret rotate Check continuity. Replace if defective.
switch S19 to base terminal block.
4. Open or defective diode D32. Check diode. Replace if defective.
5. Loose or broken wire #71 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #71 from motor control Check continuity. Replace if defective.
harness A pin #20 to left motor controller pin
#LM20.
7. Loose or broken wire #32 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #7.
8. Loose or broken wire #32 from main manifold Check continuity. Replace if defective.
harness plug pin #7 to rotate left valve 5H-32.
9. Loose broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to rotate left valve 5H-32.
10. Defective rotate left coil 5H-32. Check continuity and resistance through coil.
Replace if defective.

4.2-10 No Turret Rotate Right from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to turret rotate switch S19.
2. Defective turret rotate switch S19. Check continuity through switch while activating
rotate right function between wires #10A and #33.
If no continuity found, replace switch.
3. Loose or broken wire #33 from turret rotate Check continuity. Replace if defective.
switch S19 to base terminal block.
4. Open or defective diode D33. Check diode. Replace if defective.
5. Loose or broken wire #71 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #71 from motor control Check continuity. Replace if defective.
harness A pin #20 to left motor controller pin
#LM20.

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7. Loose or broken wire #33 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #8.
8. Loose or broken wire #33 from main manifold Check continuity. Replace if defective.
harness plug pin #8 to rotate right valve 5H-33.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to rotate right valve 5H-33.
10. Defective rotate right coil 5H-33. Check continuity and resistance through coil.
Replace if defective.

4.2-11 No Telescope Retract from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to telescope switch S17
2. Defective telescope switch S17. Check continuity through switch while activating
retract function between wires #10A and #38. If no
continuity found, replace switch.
3. Loose or broken wire #38 from telescope switch Check continuity. Replace if defective.
S17 to base terminal block.
4. Open or defective diode D38. Check diode. Replace if defective.
5. Loose or broken wire #72 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #72 from motor control Check continuity. Replace if defective.
harness A pin #21 to left motor controller pin
#LM31.
7. Loose or broken wire #38 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #9.
8. Loose or broken wire #38 from main manifold Check continuity. Replace if defective.
harness plug pin #9 to telescope retract valve
4H-38.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to telescope retract valve 4H-38.
10. Defective telescope retract coil 4H-38. Check continuity and resistance through coil.
Replace if defective.

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4.2-12 No Telescope Extend from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to telescope switch S17.
2. Defective telescope switch S17. Check continuity through switch while activating
extend function between wires #10A and #39. If no
continuity found, replace switch.
3. Loose or broken wire #39 from telescope switch Check continuity. Replace if defective.
S17 to base terminal block.
4. Open or defective diode D39. Check diode. Replace if defective.
5. Loose or broken wire #71 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #71 from motor control Check continuity. Replace if defective.
harness A pin #20 to left motor controller pin
#LM20.
7. Loose or broken wire #39 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #10.
8. Loose or broken wire #39 from main manifold Check continuity. Replace if defective.
harness plug pin #10 to telescope extend valve
4H-39.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to telescope extend valve 4H-39.
10. Defective telescope retract coil 4H-39. Check continuity and resistance through coil.
Replace if defective.

4.2-13 No Platform Rotate Left from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to platform rotate switch S14.
2. Defective platform rotate switch S14. Check continuity through switch while activating
rotate left function between wires #10A and #36. If
no continuity found, replace switch.
3. Loose or broken wire #36 from platform rotate Check continuity. Replace if defective.
switch S14 to base terminal block.
4. Open or defective diode D36. Check diode. Replace if defective.
5. Loose or broken wire #73 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #73 from motor control Check continuity. Replace if defective.
harness A pin #22 to left motor controller pin
#LM32.
7. Loose or broken wire #36 from base control Check continuity. Replace if defective.
block to platform plug A pin #18 in base control
console.

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8. Loose or broken wire #36 in boom cable A or its Check for continuity between pins #18 on cable
connectors. A. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
9. Loose or broken wire #36 plug A pin #18 to Check continuity. Replace if defective.
platform terminal block.
10. Loose or broken wire #36 from platform terminal Check continuity. Replace if defective.
block to platform rotate left valve 4H-36.
11. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to platform rotate left valve 4H-36.
12. Defective platform rotate left valve coil 4H-36. Check continuity and resistance through coil.
Replace if defective.

4.2-14 No Platform Rotate Right from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to platform rotate switch S14.
2. Defective platform rotate switch S14. Check continuity through switch while activating
rotate right function between wires #10A and #37.
If no continuity found, replace switch.
3. Loose or broken wire #37 from platform rotate Check continuity. Replace if defective.
switch S14 to base terminal block.
4. Open or defective diode D37. Check diode. Replace if defective.
5. Loose or broken wire #73 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #73 from motor control Check continuity. Replace if defective.
harness A pin #22 to left motor controller pin
#LM32.
7. Loose or broken wire #37 from base control Check continuity. Replace if defective.
block to platform plug A pin #19 in base control
console.
8. Loose or broken wire #37 in boom cable A or its Check for continuity between pins #19 on cable
connectors. A. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
9. Loose or broken wire #37 plug A pin #19 to Check continuity. Replace if defective.
platform terminal block.
10. Loose or broken wire #37 from platform terminal Check continuity. Replace if defective.
block to platform rotate left valve 4H-37.
11. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to platform rotate left valve 4H-37.
12. Defective platform rotate left valve coil 4H-37. Check continuity and resistance through coil.
Replace if defective.

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4.2-15 No Jib Up from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to jib switch S16.
2. Defective jib switch S16. Check continuity through switch while activating
jib up function between wires #10A and #35. If no
continuity found, replace switch.
3. Loose or broken wire #35 from jib switch S16 to Check continuity. Replace if defective.
base terminal block.
4. Open or defective diode D35. Check diode. Replace if defective.
5. Loose or broken wire #72 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #72 from motor control Check continuity. Replace if defective.
harness A pin #21 to left motor controller pin
#LM31.
7. Loose or broken wire #35 from base control Check continuity. Replace if defective.
block to platform plug A pin #17 in base control
console.
8. Loose or broken wire #35 in boom cable A or its Check for continuity between pins #17 on cable
connectors. A. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
9. Loose or broken wire #35 plug A pin #17 to Check continuity. Replace if defective.
platform terminal block.
10. Loose or broken wire #35 from platform terminal Check continuity. Replace if defective.
block to jib up valve 4H-35.
11. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective. Check
block to jib up valve 4H-35. continuity. Replace if defective.
12. Defective platform jib up coil 4H-35. Check continuity and resistance through coil.
Replace if defective.

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4.2-16 No Jib Down from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to jib switch S16.
2. Defective jib switch S16. Check continuity through switch while activating jib
down function between wires #10A and #34. If no
continuity found, replace switch.
3. Loose or broken wire #34 from jib switch S16 to Check continuity. Replace if defective.
base terminal block.
4. Open or defective diode D34. Check diode. Replace if defective.
5. Loose or broken wire #73 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #73 from motor control Check continuity. Replace if defective.
harness A pin #22 to left motor controller pin
#LM32.
7. Loose or broken wire #34 from base control Check continuity. Replace if defective.
block to platform plug A pin #16 in base control
console.
8. Loose or broken wire #34 in boom cable A or its Check for continuity between pins #16 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
9. Loose or broken wire #34 plug A pin #16 to Check continuity. Replace if defective.
platform terminal block.
10. Loose or broken wire #34 from platform terminal Check continuity. Replace if defective.
block to jib down valve 4H-34.
11. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to jib down valve 4H-34.
12. Defective platform jib down coil 4H-34. Check continuity and resistance through coil.
Replace if defective.

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4.2-17 No Jib Rotate Right from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to jib rotate switch S15.
2. Defective jib rotate switch S15. Check continuity through switch while activating jib
rotate right function between wires #10A and #43.
If no continuity found, replace switch.
3. Loose or broken wire #43 from jib rotate switch Check continuity. Replace if defective.
S15 to base terminal block.
4. Open or defective diode D43. Check diode. Replace if defective.
5. Loose or broken wire #73 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #73 from motor control Check continuity. Replace if defective.
harness A pin #22 to left motor controller pin
#LM32.
7. Loose or broken wire #43 from base control Check continuity. Replace if defective.
block to platform plug B pin #13 in base control
console.
8. Loose or broken wire #43 in boom cable B or its Check for continuity between pins #13 on cable
connectors. B. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
9. Loose or broken wire #43 plug B pin #13 to Check continuity. Replace if defective.
platform terminal block.
10. Loose or broken wire #43 from platform terminal Check continuity. Replace if defective.
block to jib rotate right valve 4H-43.
11. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to jib rotate right valve 4H-43.
12. Defective platform jib rotate right coil 4H-43. Check continuity and resistance through coil.
Replace if defective.

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4.2-18 No Jib Rotate Left from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to jib rotate switch S15.
2. Defective jib rotate switch S15. Check continuity through switch while activating jib
rotate left function between wires #10A and #42. If
no continuity found, replace switch.
3. Loose or broken wire #42 from jib rotate switch Check continuity. Replace if defective.
S15 to base terminal block.
4. Open or defective diode D42. Check diode. Replace if defective.
5. Loose or broken wire #73 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #73 from motor control Check continuity. Replace if defective.
harness A pin #22 to left motor controller pin
#LM32.
7. Loose or broken wire #42 from base control Check continuity. Replace if defective.
block to platform plug B pin #12 in base control
console.
8. Loose or broken wire #42 in boom cable B or its Check for continuity between pins #12 on cable
connectors. B. Check for loose or corroded connections on
cable connectors. Replace if wire is defective.
9. Loose or broken wire #42 plug B pin #12 to Check continuity. Replace if defective.
platform terminal block.
10. Loose or broken wire #42 from platform terminal Check continuity. Replace if defective.
block to jib rotate left valve 4H-42.
11. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to jib rotate left valve 4H-42.
12. Defective platform jib rotate left coil 4H-42. Check continuity and resistance through coil.
Replace if defective.

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4.2-19 No Manual Platform Level Up from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to platform level switch S13.
2. Defective platform level switch S13. Check continuity through switch while activating
platform level up function between wires #10A and
#41.If no continuity found, replace switch.
3. Loose or broken wire #41 from platform level Check continuity. Replace if defective.
switch S13 to base terminal block.
4. Open or defective diode D41. Check diode. Replace if defective.
5. Loose or broken wire #72 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #72 from motor control Check continuity. Replace if defective.
harness A pin #21 to left motor controller pin
#LM31.
7. Loose or broken wire #41 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #12.
8. Loose or broken wire #41 from main manifold Check continuity. Replace if defective.
harness plug pin #12 to platform level up valve
4H-41.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to platform level up valve 4H-41.
10. Defective platform level up coil 4H-38. Check continuity and resistance through coil.
Replace if defective.
11. Loose or broken wire #10A from ignition/pump Check continuity. Replace if defective.
switch S5 to platform level switch S15.
12. Defective platform level switch S15. Check continuity through switch while activating
level up function between wires #10A and#41. If no
continuity found replace switch.
13. Loose or broken wire #41 from platform level Check continuity. Replace if defective.
switch S15 to base terminal block.
14. Loose or broken wire #41 from base terminal Check continuity. Replace if defective.
block to main harness pin plug pin#16.
15. Loose or broken wire #41 from main harness pin Check continuity. Replace if defective.
plug pin#16 platform level up valve 4H-41.
16. Loose or broken wire #02 from turret harness pin Check continuity. Replace if defective.
plug platform level up valve 4H-41.
17. Defective platform level up valve coil 4H-41. Check continuity and resistance through coil.
Replace if defective.

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4.2-20 No Manual Platform Level Down from Base Control Console

1. Loose or broken wire #10A from enable switch Check continuity. Replace if defective.
S21 to platform level switch S13.
2. Defective platform level switch S13. Check continuity through switch while activating
platform level down function between wires #10A
and #40. If no continuity found, replace switch.
3. Loose or broken wire #40 from platform level Check continuity. Replace if defective.
switch S13 to base terminal block.
4. Open or defective diode D40. Check diode. Replace if defective.
5. Loose or broken wire #73 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
6. Loose or broken wire #73 from motor control Check continuity. Replace if defective.
harness A pin #22 to left motor controller pin
#LM32.
7. Loose or broken wire #40 from base terminal Check continuity. Replace if defective.
block to main manifold harness pin #11.
8. Loose or broken wire #40 from main manifold Check continuity. Replace if defective.
harness plug pin #11 to platform level down
valve 4H-40.
9. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness plug to platform level down valve 4H-40.
10. Defective platform level down coil 4H-40. Check continuity and resistance through coil.
Replace if defective.

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4.2-21 All Controls Inoperative from Platform Control Console

1. Loose or broken wire #04 from emergency stop Check continuity. Replace if defective.
switch S4 to platform terminal block.
2. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block to footswitch S6.
3. Open or defective footswitch S6. Check continuity through switch while activating
footswitch function between wires #04 and if no
continuity found replace switch.
4. Loose or broken wire #08A from footswitch S11 Check continuity. Replace if defective.
to platform terminal block.
5. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block to valve driver pin #1, 2 & 13.
6. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to valve driver pin #24, 25 & 26.
7. Open or defective diode D8A. Check diode. Replace if defective.
8. Loose or broken wire #8B from platform terminal Check continuity. Replace if defective.
block to plug B pin #5 in platform control
console.
9. Loose or broken wire #8B in boom cable B or its Check continuity. Replace if defective.
connectors.
10. Loose or broken wire #8B from plug B pin #5 to Check continuity. Replace if defective.
base terminal block.
11. Loose or broken wire #8B from base terminal Check continuity. Replace if defective.
block to motor control harness A.
12. Loose or broken wire #8B from motor control Check continuity. Replace if defective.
harness A pin #12 to left motor controller pin
#LM1 and right motor controller pin #RM1.
13. Loose or broken wire #208 from right motor Check continuity. Replace if defective.
controller pin #RM6 to motor control harness A
pin #11.
14. Loose or broken wire #208 from motor control Check continuity. Replace if defective.
harness A to 208CR relay.
15. Loose or broken wire #208 from 208CR relay to Check continuity. Replace if defective.
platform plug B pin #6 in base control console.
16. Loose or broken wire #208 in boom cable B or Check for continuity between pins #6 on cable B.
its connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
17. Loose or broken wire #208 from plug B pin #5 in Check continuity. Replace if defective.
platform control console to relay 208CR1.

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18. Loose or broken wire #4 (2 places) or #8 from Check continuity. Replace if defective.
platform terminal block to 208CR1 relay.
19. Defective relay 208CR1. Check relay. Replace if defective.

4.2-22 No Boom Up from Platform Control Console

1. Loose or broken wire #04 from platform terminal

block to joystick controller A2.
2. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
3. No output on y-axis of joystick controller A2.
4. Loose or broken wire “Y” from joystick controller Check continuity. Replace if defective.
A2 to valve driver pin #29.
5. No output on pin #12 of the valve driver to wire Check pin #12 for proportional voltage. If no
#70. voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
6. No output on pin #22 of the valve driver to wire Check pin #22 for minimum 7 volts. If no voltage
#14. present with foot on footswitch check section 5 for
OCM pin voltage reference.
7. Loose or broken wire #14 from valve driver pin Check continuity. Replace if defective.
#22 to plug A pin #7 in platform control console.
8. Loose or broken wire #14 in boom cable A or its Check for continuity between pins #7 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
9. Loose or broken wire #14 from base connector Check continuity. Replace if defective.
plug A pin #7 to base terminal block.
10. Loose or broken wire #14 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
11. Loose or broken wire #14 from main harness to Check continuity. Replace if defective.
boom up valve 4H-14.
12. Loose or broken wire #02 from main harness to Check continuity. Replace if defective.
boom up valve 4H-14.
13. Defective boom up valve coil 4H-14. Check continuity and resistance through coil.
Replace if defective.

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4.2-23 No Boom Down from Platform Control Console

1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
2. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
3. No output on y-axis of joystick controller A2. Refer to joystick test procedure in section 5.
4. Loose or broken wire “Y” from joystick controller Check continuity. Replace if defective.
A2 to valve driver pin #29.
5. No output on pin #12 of the valve driver to wire Check pin #12 for proportional voltage. If no
#70. voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
6. No output on pin #8 of the valve driver to wire Check pin #8 for minimum 5.5 volts. If no voltage
#13. present with foot on footswitch check section 5 for
OCM pin voltage reference.
7. Loose or broken wire #13 from valve driver pin Check continuity. Replace if defective.
#8 to plug A pin #6 in platform control console.
8. Loose or broken wire #13 in boom cable A or its Check for continuity between pins #6 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
9. Loose or broken wire #13 from base connector Check continuity. Replace if defective.
plug A pin #6 to base terminal block.
10. Loose or broken wire #13 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
11. Loose or broken wire #13 from main manifold Check continuity. Replace if defective.
harness to boom down valve 4H-13.
12. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to boom down valve 4H-13.
13. Defective boom down valve coil 4H-13. Check continuity and resistance through coil.
Replace if defective.

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4.2-24 No Riser Up from Platform Control Console

1. Loose or broken L wire from speed controller to Check continuity. Replace if defective.
resistor R1 in platform control console.
2. Open or defective resistor R1.
3. Loose or broken wire #30B from resistor R1 to Check continuity. Replace if defective.
riser switch S7.
4. Defective riser switch S7. Check continuity through switch while activating
the function between wires #30B and #30A.
5. Loose or broken wire #30A from riser switch S7 Check continuity. Replace if defective.
to valve driver pin #27.
6. Voltage out of range at valve driver pin #32. Check voltage while operating riser up. Voltage
should be 2.41 volts. Refer to toggle switch voltage
reference worksheet in section 5 if out of range.
7. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
8. No output on pin #23 of the valve driver to wire Check pin #10 for minimum 4.5 volts. If no voltage
#20A. present with foot on footswitch check section 5 for
OCM pin voltage reference.
9. Loose or broken wire #31 from valve driver Check continuity. Replace if defective.
pin #10 to plug A pin #13 in platform control
console.
10. Loose or broken wire #31 in boom cable A or its Check for continuity between pins #13 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
11. Loose or broken wire #31 from base connector Check continuity. Replace if defective.
plug A pin #13 to base terminal block.
12. Loose or broken wire #31 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
13. Loose or broken wire #31 from main manifold Check continuity. Replace if defective.
harness to riser up valve 2H-31.
14. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to riser up valve 2H-31.
15. Defective riser up valve coil 2H-31. Check continuity and resistance through coil.
Replace if defective.

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4.2-25 No Riser Down from Platform Control Console

1. Loose or broken L wire from speed controller to Check continuity. Replace if defective.
resistor R1 in platform control console.
2. Open or defective resistor R1. Check resistor. Replace if defective.
3. Loose or broken wire #30B from resistor R1 to Check continuity. Replace if defective.
riser switch S7.
4. Defective riser switch S7. Check continuity through switch while activating
the function between wires #30B and #30A.
5. Loose or broken wire #30A from riser switch S7 Check continuity. Replace if defective.
to valve driver pin #27.
6. Voltage out of range at valve driver pin #32. Check voltage while operating riser down. Voltage
should be 4.83 volts. Refer to toggle switch voltage
reference worksheet in section 5 if out of range.
7. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
8. No output on pin #19 of the valve driver to wire Check pin #19 for minimum 6.2 volts. If no voltage
#30C. present with foot on footswitch check section 5 for
OCM pin voltage reference.
9. Loose or broken wire #30C from valve driver pin Check continuity. Replace if defective.
#19 to relay 204CR1.
10. Defective N/C contacts in relay 204CR1. Check continuity between wires #30C and #30.
Replace if continuity not found.
11. Loose or broken wire #30 from relay 204CR1 to Check continuity. Replace if defective.
plug A pin #12 in platform control console.
12. Loose or broken wire #30 in boom cable A or its Check for continuity between pins #12 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
13. Loose or broken wire #30 from base connector Check continuity. Replace if defective.
plug A pin #12 to base terminal block.
14. Loose or broken wire #30 from base terminal Check continuity. Replace if defective.
block to relay 162CCR.
15. Loose or broken wire #162C from diodes D162-1 Check continuity. Replace if defective.
and D59-2 to relay 162CCR.
16. Loose or broken wire #02 from base terminal Check continuity. Replace if defective.
block to relay 162CCR.
17. Defective relay 162CCR. Check relay. Replace if defective.
18. Loose or broken wire #02 from base terminal Check continuity. Replace if defective.
block to riser down harness.

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19. Loose or broken wire #30B from relay 162CCR to Check continuity. Replace if defective.
riser down harness.
20. Loose or broken wire #30B or #02 from riser Check continuity. Replace if defective.
down harness to riser down valve 2H-30B.
21. Defective riser down coil 2H-30B. Check continuity and resistance through coil.
Replace if defective.

4.2-26 No Turret Left from Platform Control Console

1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
2. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
3. No output on x-axis of joystick controller A2. Refer to joystick test procedure in section 5.
4. Loose or broken wire “X” from joystick controller Check continuity. Replace if defective.
A2 to valve driver pin #28.
5. No output on pin #12 of the valve driver to wire Check pin #12 for proportional voltage. If no
#70. voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
6. No output on pin #20 of the valve driver to wire Check pin #20 for minimum 6.2 volts. If no voltage
#32. present with foot on footswitch check section 5 for
OCM pin voltage reference.
7. Loose or broken wire #32 from valve driver Check continuity. Replace if defective.
pin #20 to plug A pin #14 in platform control
console.
8. Loose or broken wire #32 in boom cable A or its Check for continuity between pins #14 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
9. Loose or broken wire #32 from base connector Check continuity. Replace if defective.
plug A pin #14 to base terminal block.
10. Loose or broken wire #32 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
11. Loose or broken wire #32 from main manifold Check continuity. Replace if defective.
harness to turret left valve 5H-32.
12. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to turret left valve 5H-32.
13. Defective turret left valve coil 5H-32. Check continuity and resistance through coil.
Replace if defective.

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4.2-27 No Turret Right from Platform Control Console

1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
2. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to joystick controller A2.
3. No output on x-axis of joystick controller A2. Refer to joystick test procedure in section 5.
4. Loose or broken wire “X” from joystick controller Check continuity. Replace if defective.
A2 to valve driver pin #28.
5. No output on pin #12 of the valve driver to wire Check pin #12 for proportional voltage. If no
#70. voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
6. No output on pin #35 of the valve driver to wire Check pin #35 for minimum 6.9 volts. If no voltage
#33. present with foot on footswitch check section 5 for
OCM pin voltage reference.
7. Loose or broken wire #33 from valve driver Check continuity. Replace if defective.
pin #35 to plug A pin #15 in platform control
console.
8. Loose or broken wire #33 in boom cable A or its Check for continuity between pins #15 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
9. Loose or broken wire #33 from base connector Check continuity. Replace if defective.
plug A pin #15 to base terminal block.
10. Loose or broken wire #33 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
11. Loose or broken wire #33 from main manifold Check continuity. Replace if defective.
harness to turret right valve 5H-33.
12. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to turret right valve 5H-33.
13. Defective turret right valve coil 5H-33. Check continuity and resistance through coil.
Replace if defective.

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4.2-28 No Telescope In from Platform Control Console

1. Loose or broken L wire from speed controller to Check continuity. Replace if defective.
resistor R5 in platform control console.
2. Open or defective resistor R5. Check resistor. Replace if defective.
3. Loose or broken wire #38B from resistor R5 to Check continuity. Replace if defective.
telescope switch S8.
4. Defective telescope switch S8. Check continuity through switch while activating
the function between wires #38B and #38A.
5. Loose or broken wire #38A from riser switch S8 Check continuity. Replace if defective.
to valve driver pin #32.
6. Voltage out of range at valve driver pin #32. Check voltage while operating telescope in. Voltage
should be 4.83 volts. Refer to toggle switch voltage
reference worksheet in section 5 if out of range.
7. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
8. No output on pin #21 of the valve driver to wire Check pin #21 for 12 volts. If no voltage present
#38. with foot on footswitch check section 5 for OCM pin
voltage reference.
9. Loose or broken wire #38 from valve driver Check continuity. Replace if defective.
pin #21 to plug A pin #20 in platform control
console.
10. Loose or broken wire #38 in boom cable A or its Check for continuity between pins #20 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
11. Loose or broken wire #38 from base connector Check continuity. Replace if defective.
plug A pin #20 to base terminal block.
12. Loose or broken wire #38 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
13. Loose or broken wire #38 from main manifold Check continuity. Replace if defective.
harness to telescope in valve 4H-38.
14. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to telescope in valve 4H-38.
15. Defective telescope in valve coil 4H-38. Check continuity and resistance through coil.
Replace if defective.

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4.2-29 No Telescope Out from Platform Control Console

1. Loose or broken L wire from speed controller to Check continuity. Replace if defective.
resistor R5 in platform control console.
2. Open or defective resistor R5. Check resistor. Replace if defective.
3. Loose or broken wire #38B from resistor R5 to Check continuity. Replace if defective.
telescope switch S8.
4. Defective telescope switch S8. Check continuity through switch while activating
the function between wires #38B and #38A.
5. Loose or broken wire #38A from riser switch S8 Check continuity. Replace if defective.
to valve driver pin #32.
6. Voltage out of range at valve driver pin #32. Check voltage while operating telescope out.
Voltage should be 2.41 volts. Refer to toggle switch
voltage reference worksheet in section 5 if out of
range.
7. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
8. No output on pin #11 of the valve driver to wire Check pin #11 for 12 volts. If no voltage present
#39. with foot on footswitch check section 5 for OCM pin
voltage reference.
9. Loose or broken wire #39 from valve driver Check continuity. Replace if defective.
pin #11 to plug A pin #21 in platform control
console.
10. Loose or broken wire #39 in boom cable A or its Check for continuity between pins #21 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
11. Loose or broken wire #39 from base connector Check continuity. Replace if defective.
plug A pin #21 to base terminal block.
12. Loose or broken wire #39 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
13. Loose or broken wire #39 from main manifold Check continuity. Replace if defective.
harness to telescope out valve 4H-39.
14. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to telescope out valve 4H-39.
15. Defective telescope out valve coil 4H-39. Check continuity and resistance through coil.
Replace if defective.

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4.2-30 No Platform Rotate Left from Platform Control Console

1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective.
block to platform rotate switch S11.
2. Defective platform rotate switch S11. Check continuity through switch while activating
rotate left function between wires #08 and #36.
3. Loose or broken wire #36 from platform rotate Check continuity. Replace if defective.
switch S11 to platform terminal block.
4. Open or defective diode D36-1. Check diode. Replace if defective.
5. Loose or broken wire #36A from platform Check for 12 volts at pin #17. Check continuity.
terminal block to valve driver pin #17. Replace if defective.
6. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
7. Loose or broken wire #36 or #02 from platform Check continuity. Replace if defective.
terminal block to rotate left valve 4H-36.
8. Defective rotate left valve coil 4H-36. Check continuity and resistance through coil.
Replace if defective.

4.2-31 No Platform Rotate Right from Platform Control Console

1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective.
block to platform rotate switch S11.
2. Defective platform rotate switch S11. Check continuity through switch while activating
rotate right function between wires #08 and #37.
3. Loose or broken wire #37 from platform rotate Check continuity. Replace if defective.
switch S11 to platform terminal block.
4. Open or defective diode D37-1. Check diode. Replace if defective.
5. Loose or broken wire #36A from platform Check for 12 volts at pin #17. Check continuity.
terminal block to valve driver pin #17. Replace if defective.
6. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
7. Loose or broken wire #37 or #02 from platform Check continuity. Replace if defective.
terminal block to rotate right valve 4H-37.
8. Defective rotate right valve coil 4H-37. Check continuity and resistance through coil.
Replace if defective.

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4.2-32 No Jib Up from Platform Control Console

1. Loose or broken L wire from speed controller to Check continuity. Replace if defective.
resistor R9 in platform control console.
2. Open or defective resistor R9. Check resistor. Replace if defective.
3. Loose or broken wire #34B from resistor R9 to Check continuity. Replace if defective.
riser switch S9.
4. Defective riser switch S9. Check continuity through switch while activating
the function between wires #34B and #34A.
5. Loose or broken wire #34A from riser switch S9 Check continuity. Replace if defective.
to valve driver pin #14.
6. Voltage out of range at valve driver pin #14. Check voltage while operating jib up. Voltage
should be 2.41 volts. Refer to toggle switch voltage
reference worksheet in section 5 if out of range.
7. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
8. No output on pin #5 of the valve driver to wire Check pin #5 for 12 volts. If no voltage present with
#35 at the platform terminal block. foot on footswitch check section 5 for OCM pin
voltage reference.
9. Loose or broken wire #35 or #02 from platform Check continuity. Replace if defective.
terminal block to jib up valve 4H-35.
10. Defective jib up valve coil 4H-35. Check continuity and resistance through coil.
Replace if defective.

4.2-33 No Jib Down from Platform Control Console

1. Loose or broken L wire from speed controller to Check continuity. Replace if defective.
resistor R9 in platform control console.
2. Open or defective resistor R9. Check resistor. Replace if defective.
3. Loose or broken wire #34B from resistor R9 to Check continuity. Replace if defective.
riser switch S9.
4. Defective riser switch S9. Check continuity through switch while activating
the function between wires #34B and #34A.
5. Loose or broken wire #34A from riser switch S9 Check continuity. Replace if defective.
to valve driver pin #14.

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6. Voltage out of range at valve driver pin #14. Check voltage while operating jib down. Voltage
should be 4.83 volts. Refer to toggle switch voltage
reference worksheet in section 5 if out of range.
7. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
8. No output on pin #7 of the valve driver to wire Check pin #7 for 12 volts. If no voltage present with
#34 at the platform terminal block. foot on footswitch check section 5 for OCM pin
voltage reference.
9. Loose or broken wire #34 or #02 from platform Check continuity. Replace if defective.
terminal block to jib down valve 4H-34.
10. Defective jib down valve coil 4H-34. Check continuity and resistance through coil.
Replace if defective.

4.2-34 No Jib Rotate Left from Platform Control Console

1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective.
block to jib rotate switch S10.
2. Defective jib rotate switch S10. Check continuity through switch while activating
rotate left function between wires #08 and #42.
3. Loose or broken wire #42 from jib rotate switch Check continuity. Replace if defective.
S10 to platform terminal block.
4. Open or defective diode D42-1. Check diode. Replace if defective.
5. Loose or broken wire #42A from platform Check for 12 volts at pin #15. Check continuity.
terminal block to valve driver pin #15. Replace if defective.
6. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
7. Loose or broken wire #42 or #02 from platform Check continuity. Replace if defective.
terminal block to rotate left valve 4H-42.
8. Defective rotate left valve coil 4H-42. Check continuity and resistance through coil.
Replace if defective.

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4.2-35 No Jib Rotate Right from Platform Control Console

1. Loose or broken wire #08 from platform terminal Check continuity. Replace if defective.
block to jib rotate switch S10.
2. Defective jib rotate switch S10. Check continuity through switch while activating
rotate right function between wires #08 and #43.
3. Loose or broken wire #43 from jib rotate switch Check continuity. Replace if defective.
S10 to platform terminal block.
4. Open or defective diode D43-1. Check diode. Replace if defective.
5. Loose or broken wire #42A from platform Check for 12 volts at pin #15. Check continuity.
terminal block to valve driver pin #15. Replace if defective.
6. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
7. Loose or broken wire #43 or #02 from platform Check continuity. Replace if defective.
terminal block to rotate right valve 4H-43.
8. Defective rotate right valve coil 4H-43. Check continuity and resistance through coil.
Replace if defective.

NOTE
Platform level function will not operate if you are commanding any other boom function.

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4.2-36 No Manual Platform Level Up from Platform Control Console

1. No output on pin #6 of the valve driver to Check pin #6 for 12 volts. If no voltage present
platform level switch S12 on wire #40B. with foot on footswitch check section 5 forOCM pin
voltage reference.
2. Defective platform leveling switch S12. Check continuity through switch while activating
level up function between wires #40B and #41.
3. Loose or broken wire #41 from platform level Check continuity. Replace if defective.
switch S12 to platform terminal block.
4. Open or defective diode D41. Check diode. Replace if defective.
5. Loose or broken wire #40A from platform Check for 12 volts at pin #18. Check continuity.
terminal block to valve driver pin #18. Replace if defective.
6. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
7. Loose or broken wire #41 from platform terminal Check continuity. Replace if defective.
block to plug B pin #11 in platform control
console.
8. Loose or broken wire #41 in boom cable B or its
connectors.
9. Loose or broken wire #41 from base connector Check continuity. Replace if defective.
plug B pin #11 to base terminal block.
10. Loose or broken wire #41 from base terminal Check continuity. Replace if defective.
block to main manifold harness.
11. Loose or broken wire #41 from main manifold Check continuity. Replace if defective.
harness to platform level up valve 4H-41.
12. Loose or broken wire #02 from main manifold Check continuity. Replace if defective.
harness to platform level up valve 4H-41.
13. Defective platform level up coil 4H-41. Check continuity and resistance through coil.
Replace if defective.

NOTE
Platform level function will not operate if you are commanding any other boom function.

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Electrical System Section 4 – Troubleshooting Information

4.2-37 No Manual Platform Level Down from Platform Control Console

1. No output on pin #6 of the valve driver to Check pin #6 for 12 volts. If no voltage present with
platform level switch S12 on wire #40B. foot on footswitch check section 5 for OCM pin
voltage reference.
2. Defective platform leveling switch S12. Check continuity through switch while activating
level down function between wires #40B and #40.
3. Loose or broken wire #40 from platform level Check continuity. Replace if defective
switch S12 to platform terminal block.
4. Open or defective diode D40. Check diode. Replace if defective.
5. Loose or broken wire #40A from platform Check for 12 volts at pin #18. Check continuity.
terminal block to valve driver pin #18. Replace if defective.
6. No output on pin #23 of the valve driver to wire Check pin #23 for proportional voltage. This
#20A. voltage varies with the A3 boom speed control. If
no voltage present with foot on footswitch check
section 5 for OCM pin voltage reference.
7. Loose or broken wire #40 from platform terminal Check continuity. Replace if defective
block to plug B pin #10 in platform control
console.
8. Loose or broken wire #40 in boom cable B or its Check for continuity between pins #10 on cable B.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
9. Loose or broken wire #40 from base connector Check continuity. Replace if defective
plug B pin #10 to base terminal block.
10. Loose or broken wire #40 from base terminal Check continuity. Replace if defective
block to main manifold harness.
11. Loose or broken wire #40 from main manifold Check continuity. Replace if defective
harness to platform level down valve 4H-40.
12. Loose or broken wire #02 from main manifold Check continuity. Replace if defective
harness to platform level down valve 4H-40.
13. Defective platform level down coil 4H-40. Check continuity and resistance through coil.
Replace if defective

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Section 4 – Troubleshooting Information Electrical System

4.2-38 Brake will not Release

1. Loose or broken wire #48+ (yellow wire) from Check continuity. Replace if defective.
main contactor 3CCR to grey plug pin #1 at left
and right drive motors.
2. Loose or broken blue wire from grey plug pin Check continuity. Replace if defective.
#2 at left drive motor to left motor controller pin
#LM4.
3. Loose or broken blue wire from grey plug pin #2 Check continuity. Replace if defective.
at right drive motor to right motor controller pin
#RM4.

4.2-39 No Drive and Steer

NOTE
MEWP will not drive or steer if it is tilted and off limit switches.

1. Loose or broken wire #04 from platform terminal Check continuity. Replace if defective.
block to drive joystick A1.
2. Loose or broken wire #02 from platform terminal Check continuity. Replace if defective.
block to drive joystick A1.

4.2-40 No Forward Drive

1. No output on “D” when forward is selected on See drive joystick test procedure in section 5.
drive joystick A1.
2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective.
joystick A1 to plug A pin #24 in platform control
console.
3. Loose or broken wire “D” in cable A or its Check for continuity between pins #24 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
4. Loose or broken wire “D” from base plug A pin Check continuity. Replace if defective.
#24 to motor control harness A.
5. Loose or broken wire “D” from motor control Check continuity. Replace if defective.
harness A to right motor controller pin #RM15.

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Electrical System Section 4 – Troubleshooting Information

4.2-41 No Reverse Drive

1. No output on “D” when reverse is selected on See drive joystick test procedure in section 5.
drive joystick A1.
2. Loose or broken wire ”D-signal” from drive Check continuity. Replace if defective.
joystick A1 to plug A pin #24 in platform control
console.
3. Loose or broken wire “D” in cable A or its Check for continuity between pins #24 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
4. Loose or broken wire “D” from base plug A pin Check continuity. Replace if defective.
#24 to motor control harness A.
5. Loose or broken wire “D” from motor control Check continuity. Replace if defective.
harness A to right motor controller pin #RM15.

4.2-42 No High Speed Drive

NOTE
Aerial platform must be level and boom must be fully retracted and horizontal or below.

1. Loose or broken wire #09 from base terminal Check continuity. Replace if defective.
block to limit switch LS2.
2. Open or defective limit switch LS2. Ensure boom is horizontal or below and fully
retracted. Adjust switch if required. Check
continuity through switch. Replace if required.
3. Loose or broken wire #29 from limit switch LS2 Check continuity. Replace if defective.
to base terminal block.
4. Loose or broken wire #29 from base terminal Check continuity. Replace if defective.
block to limit switch LS3.
5. Open or defective limit switch LS3. Ensure boom is fully retracted and horizontal or
below. Adjust switch if required. Check continuity
through switch. Replace if defective.
6. Loose or broken wire #29A from limit switch LS3 Check continuity. Replace if defective.
to base terminal block.
7. Loose or broken wire #29A from base terminal Check continuity. Replace if defective.
block to limit switch LS4.
8. Open or defective limit switch LS4. Ensure boom is fully retracted and horizontal or
below. Adjust switch if required. Check continuity
through switch. Replace if defective.

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Section 4 – Troubleshooting Information Electrical System

9. Loose or broken wire #59 from limit switch LS4 Check continuity. Replace if defective.
to base terminal block.
10. Loose or broken wire #59 from base terminal Check continuity. Replace if defective.
block to motor control harness A.
11. Loose or broken wire #59 from motor control Check continuity. Replace if defective.
harness to right motor controller pin #RM6
12 volt input from LS2 riser/ LS3 boom elevation
limit switches and LS4 telescope limit switch on
wire 59.
12 volts= full speed. 0 volts= creep speed (one
or more limit switches open).

4.2-43 No Left Steer

1. Loose or broken wire #24 from drive joystick A1 Check continuity. Replace if defective.
to plug A pin #10 in platform control console.
2. Loose or broken wire #24 in boom cable A or its Check for continuity between pins #10 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
3. Loose or broken wire #24 from base plug A pin Check continuity. Replace if defective.
#10 to motor control harness A.
4. Loose or broken wire #24 from motor control Check continuity. Replace if defective.
harness A pin #13 to right motor controller pin
#RM19.
5. Loose or broken wire #224 from right motor Check continuity. Replace if defective.
controller pin #RM9 to motor control harness A
pin #15.
6. Loose or broken wire #224 from motor control Check continuity. Replace if defective.
harness A to main manifold harness.
7. Loose or broken wire #7A from base terminal Check continuity. Replace if defective.
block to main manifold harness.
8. Loose or broken wire #224 or #7A from main Check continuity. Replace if defective.
manifold harness to left steer valve 4H-224.
9. Defective left steer valve coil 4H-224. Check continuity and resistance through coil.
Replace if defective.

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Electrical System Section 4 – Troubleshooting Information

4.2-44 No Right Steer

1. Loose or broken wire #23 from drive joystick A1 Check continuity. Replace if defective.
to plug A pin #9 in platform control console.
2. Loose or broken wire #23 in boom cable A or its Check for continuity between pins #9 on cable A.
connectors. Check for loose or corroded connections on cable
connectors. Replace if wire is defective.
3. Loose or broken wire #23 from base plug A pin Check continuity. Replace if defective.
#9 to motor control harness A.
4. Loose or broken wire #23 from motor control Check continuity. Replace if defective.
harness A pin #14 to right motor controller pin
#RM16.
5. Loose or broken wire #223 from right motor Check continuity. Replace if defective.
controller pin #RM11 to motor control harness A
pin #16.
6. Loose or broken wire #223 from motor control Check continuity. Replace if defective.
harness A to main manifold harness.
7. Loose or broken wire #7A from base terminal Check continuity. Replace if defective.
block to main manifold harness.
8. Loose or broken wire #223 or #7A from main Check continuity. Replace if defective.
manifold harness to right steer valve 4H-223.
9. Defective right steer valve coil 4H-223. Check continuity and resistance through coil.
Replace if defective.

4.2-45 Direction Sensing Inoperative

1. Loose or broken wire #09 from base terminal Check continuity. Replace if defective.
block to limit switch LS1.
2. Open or defective limit switch LS1. Adjust limit switch if required. 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.
4. Loose or broken wire #17 from base terminal Check continuity. Replace if defective.
block to motor control harness.
5. Loose or broken wire #17 from motor control Check continuity. Replace if defective.
harness pin #9 to right motor controller pin
#RM31. Turret position for direction sensor. 12
volt input from limit switch LS1 on wire 17.
0 volts= Platform over drive axle.
12 volts= Platform over steer axle.

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Section 4 – Troubleshooting Information Hydraulic System

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.
3. Stuck or defective relief valve RV3. Set valve to specifications. Check O-rings and
clean valve. Repair or replace valve as required.
4. Stuck or defective relief valve RV1. Set valve to specifications. Check O-rings and
clean valve. Repair or replace valve as required.
5. Stuck or defective check valve CV4. Clean valve. Check operation of valve. Repair or
replace valve as required.
6. System pump P1 defective. Test pump with flow meter. Replace if defective.

4.3-2 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 counterbalance valve CB1 or Clean valve. Check O-rings on valve. Repair or
CB2. replace valve as required.
3. Defective lift cylinder C2. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

4.3-3 No Main Boom Down

1. Stuck or defective lift down valve 4H-13. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective counterbalance valve CB1 or Clean valve. Check O-rings on valve. Repair or
CB2. replace valve as required.
3. Defective lift cylinder C2. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

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Hydraulic System Section 4 – Troubleshooting Information

4.3-4 No Riser Boom Up

1. Stuck or defective riser up valve 2H-31. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective check valve CV5. Clean valve. Check O-rings on valve. Check
operation of valve. Repair or replace valve as
required.
3. Stuck or defective riser down valve 2H-30. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective relief valve RV7. Set valve to specifications. Check O-rings and
clean valve. Repair or replace valve as required.
5. Defective riser cylinder C3. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

4.3-5 No Riser Boom Down

1. Stuck or defective riser down valve 2H-30. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR5. Check orifice. Replace if plugged or defective.

4.3-6 No Turret Rotate Left

1. Stuck or defective rotate left valve 5H-32. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective relief valve RV3. Set valve to specifications. Check o-rings and clean
valve. Repair or replace valve as required.
3. Worn or defective swing drive motor RA1. Check motor. Repair or replace if defective.

4.3-7 No Turret Rotate Right

1. Stuck or defective rotate right valve 5H-33. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective relief valve RV3. Set valve to specifications. Check O-rings and
clean valve. Repair or replace valve as required.
3. Worn or defective swing drive motor RA1. Check motor. Repair or replace if defective.

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Section 4 – Troubleshooting Information Hydraulic System

4.3-8 No Boom Extend

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective boom extend valve 4H-39. Clean valve. Check operation of valve. Repair or
replace valve as required.
3. Stuck or defective relief valve RV4. Set valve to specifications. Check O-rings and
clean valve. Repair or replace valve as required.
4. Stuck or defective counterbalance valve CB3 or Clean valve. Check O-rings on valve. Repair or
CB4. replace valve as required.
5. Defective extension cylinder C4. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

4.3-9 No Boom Retract

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Stuck or defective boom retract valve 4H-38. Clean valve. Check operation of valve. Repair or
replace valve as required.
3. Stuck or defective counterbalance valve CB3 or Clean valve. Check O-rings on valve. Repair or
CB4. replace valve as required.
4. Defective extension cylinder C4. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

4.3-10 No Jib Up

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR2. Check orifice. Replace if plugged or defective.
3. Stuck or defective jib up valve 4H-35. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective counterbalance valve CB7 or Clean valve. Check O-rings on valve. Repair or
CB8. replace valve as required.
5. Defective extension cylinder C5. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

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Hydraulic System Section 4 – Troubleshooting Information

4.3-11 No Jib Down

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR2. Check orifice. Replace if plugged or defective.
3. Stuck or defective jib down valve 4H-34. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective counterbalance valve CB7 or Clean valve. Check O-rings on valve. Repair or
CB8. replace valve as required.
5. Defective extension cylinder C5 Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

4.3-12 No Platform Rotation Right

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR3. Check orifice. Replace if plugged or defective.
3. Stuck or defective rotate right valve 4H-37. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective counterbalance valve CB9 or Clean valve. Check O-rings on valve. Repair or
CB10. replace valve as required.
5. Defective rotary actuator RA2. Check actuator. Repair or replace as necessary.

4.3-13 No Platform Rotation Left

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR3. Check orifice. Replace if plugged or defective.
3. Stuck or defective rotate left valve 4H-36. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective counterbalance valve CB9 or Clean valve. Check O-rings on valve. Repair or
CB10. replace valve as required.
5. Defective rotary actuator RA2. Check actuator. Repair or replace as necessary.

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Section 4 – Troubleshooting Information Hydraulic System

4.3-14 No Jib Rotation Right

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR4. Check orifice. Replace if plugged or defective.
3. Stuck or defective rotate right valve 4H-43. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective counterbalance valve CB11 or Clean valve. Check O-rings on valve. Repair or
CB12. replace valve as required.
5. Defective rotary actuator RA3. Check actuator. Repair or replace as necessary.

4.3-15 No Jib Rotation Left

1. Stuck or defective flow enable valve 2H-20A. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Plugged or defective orifice OR4. Check orifice. Replace if plugged or defective.
3. Stuck or defective rotate left valve 4H-42. Clean valve. Check operation of valve. Repair or
replace valve as required.
4. Stuck or defective counterbalance valve CB11 or Clean valve. Check O-rings on valve. Repair or
CB12. replace valve as required.
5. Defective rotary actuator RA3. Check actuator. Repair or replace as necessary.

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Hydraulic System Section 4 – Troubleshooting Information

4.3-16 Platform will not Level Down Manually

1. Plugged or defective orifice OR1. Check orifice. Replace if plugged or defective.

2. Stuck or defective platform level down valve 4H- Clean valve. Check operation of valve. Repair or
40. replace valve as required.
3. Stuck or defective dual pilot operated check Clean valve. Check O-rings on valve. Check
valve DPOCV1. operation of valve. Repair or replace valve as
required.

4. Stuck or defective check valve CV2. Clean valve. Check O-rings on valve. Check
operation of valve. Repair or replace valve as
required.
5. Stuck or defective relief valve RV2. Set valve to specifications. Check O-rings and
clean 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 leveling cylinder C7 or slave cylinder Check seals on cylinder. Replace as necessary.
C6. Replace cylinder if defective.

4.3-17 Platform will not Level Up Manually

1. Plugged or defective orifice OR1. Check orifice. Replace if plugged or defective.

2. Stuck or defective platform level up valve 4H-41. Clean valve. Check operation of valve. Repair or
replace valve as required.
3. Stuck or defective dual pilot operated check Clean valve. Check O-rings on valve. Check
valve DPOCV1. operation of valve. Repair or replace valve as
required.
4. Stuck or defective check valve CV3. Clean valve. Check O-rings on valve. Check
operation of valve. Repair or replace valve as
required.
5. Stuck or defective relief valve RV2. Set valve to specifications. Check O-rings and
clean 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 leveling cylinder C7 or slave cylinder Check seals on cylinder. Replace as necessary.
C6. Replace cylinder if defective.

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Section 4 – Troubleshooting Information Hydraulic System

4.3-18 No Left Steer

1. Stuck or defective left steer valve 4H-224. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Defective steer cylinder C1. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

4.3-19 No Right Steer

1. Stuck or defective right steer valve 4H-223. Clean valve. Check operation of valve. Repair or
replace valve as required.
2. Defective steer cylinder C1. Check seals on cylinder. Replace as necessary.
Replace cylinder if defective.

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4.4 Load Sensing System

4.4-1 Green Power LED is not Flashing

1. Loose or broken wires #60 and #02 at platform Check for connections. Check for voltage (12V).
terminal block.
2. Load cell has lost its calibration. Refer to calibration procedure for recalibration of
load cell.

4.4-2 Load Cell red Alarm LED is ON (with platform empty)

1. Load cell has lost its calibration. Refer to calibration procedure for recalibration of
load cell.

4.4-3 Red Error LED is ON

1. Open safety contact circuit. Check for connections with wires #60 and #162 at
platform terminal block and base terminal block.
Check resistor R13 for 680 ohms.

4.4-4 Load Cell red Alarm LED is OFF (with platform overloaded)

1. Open safety contact circuit. Check for connections with wires #60 and #162 at
platform terminal block and base terminal block.
Check resistor R13 for 680 ohms.

4.4-5 Platform Indicator Light does not turn ON

1. Defective lamp. Check lamp. Replace if defective.

2. Defective load cell. Defective if 0V is measured between wire #82 and
#02 from platform terminal block.

4.4-6 Audible Alarm does not turn ON

1. Defective alarm BP3. Check alarm. Replace if defective.
2. Open or defective diode D118. Check diode. Replace if defective.
3. Load cell circuit not operating. Check for connections with wires #02 and #118 at
platform terminal block.
4. Defective load cell. Defective if 0V is measured between wire #118 and
#02 from platform terminal block.

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 Notes

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Section 5 – Procedures
5.1 General
WARNING
The following information is provided to assist you in
the use and application of servicing and maintenance Ensure you maintain three points of contact when
procedures contained in this chapter. mounting/dismounting the platform.

NOTE WARNING
The illustrations in this manual are for instructional
DO NOT operate any control on the platform
purposes only. The models and components
control console without proper fall protection
shown may appear somewhat different from
secured to the designated location in the platform.
those on your actual MEWP.
Failure to avoid this hazard could result in death or
serious injury!

5.1-1 Safety and Workmanship

Your safety, and that of others, is the first
consideration when engaging in the maintenance of WARNING
equipment. Always be conscious of weight. Never Ensure there are no people or obstructions in
attempt to move heavy parts without the aid of a the test area, and there is sufficient space for the
mechanical device. Do not allow heavy objects to rest boom and drive functions required for the given
in an unstable position. When raising a portion of the procedures.
equipment, ensure that adequate support is provided.

Unless specifically noted otherwise, before beginning

any procedure:
1. Park the mobile elevating work platform (MEWP)
on a firm, level surface.
2. Retract and lower the boom, riser, and platform
until the MEWP is in the stowed position.
3. Pull out the emergency stop buttons on the
base controls and on the platform controls.
4. Turn the keyswitch to the off position .
5. Disconnect one of the battery connectors.

After completing any procedure which involves

modifying, adjusting, or replacing any hydraulic or
electrical components, perform all of the function tests
given in your unit’s Operating Manual.

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Section 5 – Procedures Platform

5.2 Platform
5.2-1 Human Machine Interface (HMI)

Maintaining proper calibration is essential for the good

performance of the MEWP.
To access the SCM console, open the platform control
cover.
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
adjustments. The Human Machine Interface (referred
to as the HMI) will serve as your window into the
application software to allow the operator to monitor/
adjust the following information:

▪ Active Function Being Used

▪ Part Number and Serial Number
▪ Restore the Factory Default Settings
▪ Output Calibrations (Tresh, Max, Ramp.etc)
▪ I-O Status
▪ CANBus Status

5.1-2 User Interface Keys

MENU 1.0-1 <MENU> Enters a new menu screen and/or

1.0 SELECT
1.0-2 <SELECT> select the flashing item.

1.1-1 <MINUS> Decreases an adjustable parameter such as

---- ramp time.
1.1
1.1-2 <DOWN> Selects the previous item in the current menu’s
list.

1.2-1 <PLUS> Increases an adjustable parameter.

1.2
1.2-2 <UP> selects the next item in the current menu’s list.
+

SAVE 1.3-1 <SAVE> Saves the new data to EEPROM (permanent

1.3
memory storage).

---- Simultaneously pressing <UP> and <DOWN> resets the HMI to

1.4
menu screen 0.
+

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Platform 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

SCM Function (Channel) Names

FLOW ENABLE Fn01A Flow Enable
RISER DN 2A Fn05A Riser Down
RISER UP 2B Fn05B Riser Up
BOOM DOWN Fn03A Main Boom Down
BOOM UP Fn03B Main Boom Up
ROTATE L Fn04A Turret Rotate Left
ROTATE R Fn04B Turret Rotate Right

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Section 5 – Procedures Platform

5.2-3 SCM Operating Values Chart

Input (Analog) Expected Value Description

AI 1 0.5V to 8.5V Riser Switch (Resistors)
AI 2 0.5V to 8.5V Turret Rotate Controller
AI 3 0.5V to 8.5V Boom Elevation Controller
AI 4 0.5V to 8.5V Rotary Speed Selector
AI 6 0.5V to 8.5V Fly Boom Switch (Resistors)
AI 7 0.5V to 8.5V Jib Elevation Switch (Resistors)
Input (Digital) Expected Value Description
DI 1 0 or 1 Jib Rotate Common
DI 3 0 or 1 Platform Rotate Common
DI 4 0 or 1 Platform Level Common
DI 5 0 or 1 Master Enable
DI 11 0 or 1 Stowed Limit
Output (Digital) Expected Value Description
DOUT 1 0 or 1 Riser Down Active
DOUT 2 0 or 1 Jib Up Valve
DOUT 3 0 or 1 Platform Level Allowed
DOUT 4 0 or 1 Jib Down Valve
DOUT 7 0 or 1 Fly Out Valve
DOUT 8 0 or 1 Fly In Valve

1387AA

For Output (PWM) values, refer to 5.2-6 How to Set the SCM Valve Characteristics.

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Platform Section 5 – Procedures

5.2-4 How to Unlock and Modify the SCM Settings

CE & AS Models MODE= XX/XX LTD

FUNCTIONS OFF
▲
STARTING
OR ▬▬▬
SCREEN ┼
ANSI/CSA & KC MODE= XX/XX STD
Models FUNCTIONS OFF

MENU UNLOCK SETUP? ▲

▬▬▬▬ PRESS SELECT ▬▬▬ SOFTWARE REVISION
SELECT (FLASHING) ┼

7X 5X

ENTER PASSWORD ▲ ENTER PASSWORD MENU ENTER PASSWORD ▲

0** ▬▬▬ 7** ▬▬▬▬ 70* ▬▬▬
0 (FLASHING) ┼ 7 (FLASHING) SELECT 0 (FLASHING) ┼

5X
ENTER PASSWORD ▲ ENTER PASSWORD MENU ENTER PASSWORD
MENU
755 ▬▬▬ 750 ▬▬▬▬ 75*
▬▬▬▬
5 (FLASHING) ┼ 0 (FLASHING) SELECT 5 (FLASHING)
SELECT

SETUP UNLOCKED ▲ SET PMU MOD PCT

PRESS - OR + ▬▬▬ PRESS SELECT
(FLASHING) ┼ (FLASHING)

MENU SAVE
▬▬▬▬ ▬▬▬▬
SELECT EXIT

To adjust To Adjust the

PUMP/FUNCTION THRESH/MAXOUT/LOWRNG/
speeds, see RAMPUP/RAMPDN, see
"How to Adjust the SCM "How to Set the SCM Valve
Pump Motor Speed" Characteristics"

NOTE: 1. Recycle power to the OCM with the e-stop to re-enable the password protection.
2. If the OCM is inactive for more than 5 minutes, the password must be re-entered. 1217AB

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Section 5 – Procedures Platform

5.2-5 How to Adjust the SCM Pump Motor Speed

Continued from the previous page.

SET PMU MOD PCT

PRESS SELECT
(FLASHING)

MENU
▬▬▬▬
SELECT

MENU JIB ROT FNCT ▲ JIB ROT FNCT

(JIB ROTATE FNCT) ▬▬▬▬ (MIN) ▬▬▬ (MAX)
(FLASHING)
SELECT (FLASHING) ┼ (FLASHING)

▲
▬▬▬
┼ MENU MENU
▬▬▬▬ ▬▬▬▬
SELECT SELECT

(PLAT ROT FNCT)

(FLASHING)
(%) (%)

TOGGLE
▲ Increases
▬▬▬ Value
┼
▲
▬▬▬
┼

Decreases
Function Value
Jib Rotate
Plat. Rotate ▬
▬▬▬
Plat. Level
▼
Riser Up
Turret 
Boom Up
Tele In
Tele Out
Jib Up
Jib Down
Once the value has been
Boom Down adjusted within the
Motor Speeds
parameter of the function Setting 
Function
selected, you may continue (Min/Max)
to another adjustable Jib Rotate 13% / 25%
parameter or save/exit all
the way out to the start
Plat. Rotate 13% / 20%
screen. Plat. Level 35% / 35%
Riser Up 30% / 100%
Turret  15% / 60%
Boom Up 15% / 100%
Tele In 15% / 55%
Tele Out 15% / 100%
Jib Up 17% / 32%
Jib Down 15% / 27%
Boom Down 15% / 50%

NOTE: 1. Recycle power to the OCM with the e-stop to re-enable the password protection.
2. If the OCM is inactive for more than 5 minutes, the password must be re-entered. 1216AB

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5.2-6 How to Set the SCM Valve Characteristics

Continued from page 133.
This page is to adjust the THRESHOLD, MAX OUT, LOW RANGE, RAMP UP, RAMP DOWN for FLOW ENABLE, RISER
DOWN, RISER UP, BOOM DOWN, BOOM UP, TURRET LEFT, TURRET RIGHT.

SAVE MODE: 30E MENU MENU

▬▬▬▬ ▬▬▬▬ ADJUST ▬▬▬▬
FUNCTIONS OFF
EXIT SELECT (FLASHING) SELECT
DISPLAYED

▲ ▲ (FLOW ENAB) THRESH
(RISER DN) THRESH
▬▬▬ ▬▬▬ Fn01A VALUE= % 
Fn01B VALUE= %
┼ ┼
(FLASHING) (FLASHING)

(RISER UP) THRESH Fn02A VALUE= % MENU

+ (BOOM DN) THRESH Fn02B VALUE= % ▬▬▬▬
+ (BOOM UP) THRESH Fn03A VALUE= % SELECT
+ (TURRET LT) THRESH Fn03B VALUE= %
+ (TURRET RT) THRESH Fn04A VALUE= %
(FLASHING)
▲
▬▬▬
┼

MENU XXXX XX
(THRESH/MAXOUT/ XXXX XX (THRESH)
▬▬▬▬
LOWRNG/RAMPUP/RAMPDN) TOGGLE Fn0XX VALUE= %
SELECT
Fn0XX VALUE= % (FLASHING)
(FLASHING)
▬
▬▬▬
▼
▲
▬▬▬
┼ Once the value has been
Increases adjusted within the parameter
XXXX XX (XXXXXX) SAVE of the function selected, you
Value
Fn0XX VALUE = % or ▬▬▬▬ may continue to another
SEC EXIT adjustable parameter, or
save/exit all the way out to
the start screen.
▬
▬▬▬
▼
Decreases
Value

Output Expected Function THRESH MAXOUT LOWRNG RAMPUP RAMPDN

Description
(PWM) Valve FLOW ENAB 30% 100% 30% 2 0.6
PWM 1 30% - 100% Flow Enable RISER DN 29% 65% 100% 0.6 0.8
PWM 2 29% - 65% Riser Down RISER UP 35% 100% 50% 1 0.6
PWM 3 35% - 100% Riser Up BOOM DN 25% 100% 20% 1.5 1.2
PWM 4 25% - 100% Main Boom Down BOOM UP 40% 100% 8% 2 1
PWM 5 40% - 100% Main Boom Up TURRET LT 45% 100% 2% 0.5 0.8
PWM 6 45% - 100% Turret Rotate Left TURRET RT 45% 100% 16% 0.5 0.8
PWM 7 45% - 100% Turret Rotate Right
PWM 8 0% - 100% PMU Speed

NOTE: 1. Recycle power to the OCM with the e-stop to re-enable the password protection.
2. If the OCM is inactive for more than 5 minutes, the password must be re-entered. 1307AB

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5.2-7 SCM Pin Voltage Reference

1 12
13 23
24 35

All voltages given are with the SCM controller at maximum % adjustable settings.
All voltages should be tested with the key on and the foot switch depressed.
All tests should be performed with the platform over the drive axle, the boom fully stowed, and on flat level surface.

Pin 1 - 12 volt input from wire 4.

Test between pin 1 and 02 wire.

Pin 2 - 12 volt input from wire 4.

Test between pin 2 and 02 wire.

Pin 3 - 8 volt output from wire L to boom speed controller.

7.5 volts= speed controller in circuit.
Test between pin 3 and 02 wire.

Pin 4 - 12 Volt output on wire 30B to motor controller. Riser active signal. Gravity down.
Test between pin 4 and 02 wire.

Pin 5 - 12 volt output on wire 35 to jib up valve 4H-35.

Test between pin 5 and 02 wire while operating jib up.

Pin 6 - 12 volt output on wire 40B to platform level switch S12 (no output if operating another boom function).
Test between pin 6 and 02 wire.

Pin 7 - 12 volt output on wire 34 to jib down valve 4H-34.

Test between pin 7 and 02 wire while operating jib down.

Pin 8 - Boom down selected. Proportional output on wire 13 to boom down valve 4H-13.
0 volts to 11.1 volts depending on position of joystick. Threshold= 5.5 volt.
Test between pin 8 and 02 wire while operating boom down.

Pin 9 - Not used.

Pin 10 - Riser up selected. Proportional output on wire 31 to riser up valve 4H-31.

0 volts to 11.2 volts depending on position of joystick. Threshold= 4.5 volts.
Test between pin 10 and 02 wire while operating boom down.

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Pin 11 - Telescope out selected. 12 volt output on wire 39 to telescope out valve 4H-39.
Test between pin 11 and 02 wire while operating telescope out.

Pin 12 - PMU accelerator output. Variable output on wire 70. 10-100% of maximum pump speed (PWM signal).
Test for varied output at pin 12 while operating from upper controls.

Pin 13 - 12 volt input from wire 4.

Test between pin 13 and 02 wire.

Pin 14 - Jib function selected. Input from wire 34A.

Neutral position= 3.58 volts.
Jib down function= 4.83 volts.
Jib up function= 2.41 volts.
Test between pin 14 and 02 wire.

Pin 15 - Jib rotate selected. 12 volt input from wire 42A.

Test between pin 15 and 02 wire.

Pin 16 - Not used.

Pin 17 - Platform rotate selected. 12 volt input from wire 36A.

Test between pin 17 and 02 wire.

Pin 18 - Platform level selected. 12 volt input from wire 40A.

Test between pin 18 and 02 wire.

Pin 19 - Riser down selected. Proportional output on wire 30 to riser down valve 4H-30.
0 volts to 8.9 volts depending on boom speed control potentiometer position. Threshold= 6.2 volts.
Test between pin 19 and 02 wire.

Pin 20 - Turret rotate left selected. Proportional output on wire 32 to turret rotate left valve 4H-32.
0 volts to 11.2 volts depending on position of joystick. Threshold= 6.2 volts.
Test between pin 20 and 02 wire while operating turret rotate left.

Pin 21 - Telescope in selected. 12 volt output on wire 38 to telescope in valve 4H-38.

Test between pin 21 and 02 wire while operating telescope in.

Pin 22 - Boom up selected. Proportional output on wire 14 to boom up valve 4H-14.

0 volts to 11.2 volts depending on joystick position. Threshold= 7.0 volts.
Test between pin 22 and 02 wire while operating boom up.

Pin 23 - Proportional Flow Enable Valve. Variable output on wire 20A (PWM signal).
Depending on position of Boom speed control potentiometer.
Test between pin 23 and 02 wire while operating reverse drive.

Pin 24 - Battery negative. Wire 02.

Pin 25 - Battery negative. Wire 02.

Pin 26 - Battery negative. Wire 02.

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Pin 27 - Riser function selected. Input from wire 30A.

Neutral position= 3.58 volts.
Riser down function= 2.41 volts.
Riser up function= 4.83 volts.
Test between pin 27 and 02 wire.

Pin 28 - Turret rotate input. Wire X from boom joystick controller.

Neutral position= 4.2 volts to 4.8 volts.
Rotate right function= 4.9 volts to 8.5 volts.
Rotate left function= 4.1 volts to .5 volts.
Test between pin 28 and 02 wire.

Pin 29 - Boom elevation input. Wire Y from boom joystick controller.

Neutral position= 4.2 volts to 4.8 volts.
Boom up function= 4.9 volts to 8.5 volts.
Boom down function= 4.1 volts to .5 volts.
Test between pin 29 and 02 wire.

Pin 30 - Accelerator input. Signal wire C from boom speed controller.

Proportional voltage. .5 volts= slow speed up to 7.5 volts= fast speed.
Test between pin 30 and 02 wire while operating jib, telescope or platform rotate junctions.

Pin 31 - Drive/ Boom function Enable- 12 volt input on wire 59B.

- Machine stowed and tilted= Boom up, riser up and telescope out functions allowed until limit switches
are activated (LS2, LS3 or LS4). Drive remains active.
- Machine elevated and tilted= All boom functions remain active. Drive is cut out.
Test between pin 31 and 02 wire.

Pin 32 - Telescope function selected. Input from wire 38A.

Neutral position= 3.58 volts.
Telescope in function= 4.83 volts.
Telescope out function= 2.41 volts.
Test between pin 32 and 02 wire.

Pin 33 - 12 volt input from 208CR1 on wire 8. Foot switch activated (inactive after 7 seconds= times out).
Test between pin 33 and 02 wire.

Pin 34 - Not used.

Pin 35 - Turret rotate right selected. Proportional output on wire 33 to turret rotate right valve 4H-33.
0 volts to 11.2 volts depending on position of joystick. Threshold= 6.9 volts.
Test between pin 35 and 02 wire while operating turret rotate right.

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5.2-8 Platform Controller Voltage References

Boom/Turret (A2) 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 (A1) Controller

12 Volts
Drive Forward

04 YEL POWER RED

02 WHT GROUND BLK

Neutral
BLK D-SIGNAL YEL Position
Pin 24
4.2 - 4.8
24 BLU/BLK LEFT WHT/RED Volts
Pin 10
23 BLK/WHT RIGHT WHT/YEL
Pin 9

PLUG A

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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Section 5 – Procedures Platform

5.2-9 Telescope, Riser & Jib Switch Voltage References

This example shows the Telescopic Switch Voltage Divider Circuit

R5

250 OHMS

250 OHMS R7
TELESCOPE IN
WIRE
L
PIN WIRE#38A +
32
4.83V
> >> P1-32 FLY TOGGLE SWITCH
7.25V
-

GND
TELESCOPE OUT O2
250 OHMS
R8

R6

250 OHMS

R5

250 OHMS

250 OHMS R7
TELESCOPE IN
WIRE
L

PIN WIRE#38A +
32
2.41V
> >> P1-32
FLY TOGGLE SWITCH 7.25V
-

GND
TELESCOPE OUT O2
250 OHMS
R8

R6

250 OHMS

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Load Sensing System Section 5 – Procedures

5.3 Load Sensing System

The Skyjack boom platform overload sensing system is based on load cell or electronic scale technology. The
deck steel structure is isolated from the MEWP. The load cell is permanently bolted between the deck and the
rotary actuator mount. The load cell will only respond to the vertical component of the load in the platform. There
are four external bolted connections that serve as a redundant back up system for the load cell connection. The
system is first calibrated with an empty platform to set the tare weight to zero. The following steps of the process
set the overload limit as regulated by applicable safety standards for Mobile Elevated Work Platforms.

MEWP
(Rotary Actuator Mount)

Error LED
Alarm LED Deck
Interface Connector
Zero/Tare LED
Power LED
External Bolts Load Cell Permanent Bolts

Bottom View of Deck

Load Cell
LED Display
“T” Label
Overload Light
“4” Button

Platform Control Console

Indicator Module “Teach in” Handset
(Service only)
Error LED - Continously on when there is a system error.
Alarm LED - Continously on when the platform is overload or has base contact.
Interface Connector - Storage of limit valve (“Teach in” handset connects here).
Orange LED - Continously on when the tare value is zero ± 15kg.
Green LED - Flashes slowly on when the system is powered and calibrated.

NOTE
When the power is turned on and after a four second time period elapses, the overload light and audible alarm
pulses two times. This indicates the system is active and there are no faults.

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Section 5 – Procedures Load Sensing System

5.3-1 Verify Proper Operation of the Load Sensing System

Overload Status Chart

Indicator Load Cell Audible MEWP

Weight
Light LED Display Alarm Functions

Error - OFF
Alarm - OFF
Zero/Tare - ON (orange)
Power - FLASHING (green)
(Zero) OFF OFF ENABLED

Error - OFF
Alarm - FLASHING (red)
Zero/Tare - OFF
(Work Mode Power - FLASHING (green)
@ 244+) FLASHING PULSING
DISABLED

Error - OFF
Alarm - FLASHING (red)
Zero/Tare - OFF
(Travel Mode Power - FLASHING (green)
@ 244+) FLASHING PULSING ENABLED

1. Ensure the MEWP is on firm, level ground.

2. Fully retract and lower the boom .
3. Pull out both emergency stops .
4. Turn the keyswitch to the base position .
5. Activate the enable switch .
Result: The overload indicator light and audible alarm pulses two times.
6. Ensure the platform is unloaded and is free from any surface contact.
Result: The green power LED flashes, the orange LED is ON, the red alarm LED is OFF, and the red error
LED is OFF.
7. Place a 244 kg (538 lb) load on the platform.
Result: The platform indicator light flashes, the load cell red alarm LED is ON, and the audible alarm pulses.
8. Using the base controls, extend the boom more than 30 cm (1 ft).
Result: All drive and boom function are disabled.
9. Remove the load from the platform.
Result: All drive and boom function are enabled and all warning indicators are OFF.

NOTE
Refer to section 4 for load sensing system troubleshooting.

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5.3-2 Calibration of Load Sensing System (with “Teach In” Handset)

WARNING
Do not interrupt the system power or rest your hand or foot on the platform during this procedure.

1. Ensure the MEWP is on firm, level ground.

2. Fully retract and lower the boom .
3. Turn the keyswitch off .
4. Ensure both emergency stops are pulled out and platform engine enable switch is in the on position .
Result: The overload indicator light and audible alarm pulse two times.
5. Ensure the platform is unloaded and is free from any surface contact.
6. Remove the cap from the load cell interface connector.
7. Connect the “Teach in” handset to the interface connector.
Result: The “T” label on the handset will flash at a high frequency of 5Hz. If not, recheck that power is on and
the handset is properly connected.

WARNING
Do not disconnect the handset at any point of the following steps until instructed to do so.

8. On the “Teach in” handset, depress the “4” button for four seconds.
Result: The “T” label on the handset lights up constantly.
9. Add a test load of 244 kg (538 lb) onto the center of the platform.
10. Depress the “4” button for four seconds.
Result: The “T” label on the handset will go from flashing to constantly on.
11. Disconnect the “Teach in” handset from the interface connector.
12. Wait for four seconds and then add a test load exceeding 244 kg (538 lb) to test the load sensing system.
Result: On the platform control console, the overload light flashes and an audible alarm pulses.
13. Remove the test load from the platform.
Result: The green power LED flashes, the orange LED is ON, the red alarm LED is OFF, the audible alarm is
OFF, and the red error LED is OFF.
14. Re-cap the interface connector and place the provided “calibrated” label over the interface connector.

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Section 5 – Procedures Boom & Jib

5.4 Boom & Jib 5.4-3 Cable Carrier Repair

5.4-1 Check Wear Pads The cable carrier can be repaired by simply using a
screwdriver.
1. Ensure the MEWP is on a firm level surface and
is in the stowed position.
2. Activate the function enable switch from the Each crossbar can be snapped off from either side of
base control console. the links either by hand or by using a screwdriver as
3. Raise the main boom to a comfortable working a lever. New crossbars may be installed by snapping
height (chest high), and then extend the fly them onto the link.
boom approximately 30 cm (1 ft).
4. Measure the thickness of each wear pad and Links can be replaced by first removing the upper and
replace wear pad if it is less than 11 mm (7/16"). lower crossbars, then unsnapping the old link and
5. If the wear pad is within the specified thickness, snapping in a new one. Reinstall the crossbars after
shim it as necessary. the new link is in place.
6. Apply grease to the wear pads for smoother
movement.

5.4-2 Shimming Wear Pads

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 the extend fly boom until
the wear pads are accessible.
3. Loosen the wear pad fasteners.
4. Shim the wear pads as necessary to obtain zero
Crossbars
to 0.8 mm (1/32") clearance and zero drag.
Links

Fly Boom

1/32” Feeler
Gauge

Shim
Wear Pad

5. Extend and retract the fly boom through the

entire range of motion and observe for loose
points.

NOTE
Always maintain squareness between the main and fly
booms.

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5.4-4 Master Cylinder Replacement 5. Disconnect the hoses one by one, being sure to
plug the hoses and cap the fittings (size 04).
6. Remove the bolt, washer, and keeper pin
securing the upper cylinder pin.
NOTE
This procedure requires a suitably rated lifting device
capable of supporting the boom arm.

1. Park the MEWP on a firm and level surface and

bring it to the stowed position. Lift the jib until
the platform is about 30 cm (1 ft) off the ground.
2. Use the base controls to raise the riser and main
boom until the master cylinder’s upper pin is
accessible.

7. Use a rubber coated mallet and driver to tap out

the cylinder’s upper pin.
8. Remove the pin.
9. Pull the top of the cylinder back toward the
knuckle.
10. Remove the oil pan, but leave some rags in place
to catch dripping oil.
11. Lower the riser all the way until the lower knuckle
pins are accessible, taking care not to crush the
dangling hoses.
3. Place an oil pan inside the riser under the master 12. Place a sling around the tip of the fly boom (but
cylinder to catch leaking oil. not around the cylinder rod or hydraulic hoses).
Attach the sling to a suitably rated lifting device,
4. Use tags or a paint marker to label the master
and raise it until there is no slack in the sling.
cylinder hoses (x4), indicating where they are
connected to the cylinder.

Front Back

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13. Lift the riser back up slightly to take the pressure 18. Repeat steps 14 through 17 with the opposite
off of the knuckle pins. pin. There will be more pressure on this pin, so
14. Remove the retaining bolt and washer from one use the lifting device to adjust the boom slightly
of the lower knuckle pins. as needed to make the pin easier to remove.
19. Lift the riser until the lower master cylinder pin is
accessible.
20. Remove the screw securing the pin, then use a
driver and mallet to tap out the pin.

15. Use either a 3/8" threaded rod with a nut welded

on the end, or two 3/8" fully threaded bolts about
3" (7.5 cm) long and thread them into one or
both of the spare threaded holes on the pin
flange.
16. Turn the rod/bolts clockwise, which will start
forcing the pin out. Continue until the pin can be
pulled out the rest of the way by hand.
21. Lift the riser up about 46 cm (1.5'), and place a
4x4 block of wood in the riser.
22. Carefully push the master cylinder forward, then
rotate it ¼ turn. Bring the cylinder down and out
through the gap in the riser.

17. Place a temporary holding pin (part 207288) in

place of the original pin, and secure it using the
original bolt and washer. NOTE: This temporary
pin is necessary to provide enough clearance for
the master cylinder’s lower pin to be removed.

23. Working one at a time, remove the T fittings from

the cylinder, and install port plugs in their place.
Working one at a time, remove the port plugs
from the new cylinder and install the T fittings
from the old cylinder. Cap the fittings with size
04 caps. Transfer the hose markings to the new
cylinder.

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24. Bring the new cylinder over to the riser and orient 29. Set the original pin back in place and start
it so the rod end is up, and the fitting ports are tapping it in with a mallet, making sure the shims
facing side-to-side. Lift it in through the gap in between the knuckle and arm are aligned while
the riser, then rotate it so the lower port is facing tapping the pin in.
away from you, and set it in place.
25. Remove the wooden block, and bring the riser
down until the cylinder’s lower pin is accessible
for reinstallation.
26. Use a rubber mallet to tap in the original lower
cylinder pin. Apply Loctite 242 to the original
retaining bolt, and reinstall the bolt.

30. Use a large adjustable wrench on the pin flange

to align the retaining screw holes on the pin and
knuckle, and finish tapping the pin in. Apply
Loctite 242 to the original retaining bolt, and
reinstall the bolt and washer.

27. Lower the riser all of the way down, then raise
it back up slightly to take the pressure off of the
temporary knuckle pins.
28. Remove the bolt and washer holding one of the
temporary pins, and remove the pin.

31. Repeat the process with the other pin, adjusting

the boom as needed with the lifting device to
assist in alignment.
32. Place an oil pan and/or rags inside the riser
under the cylinder to catch leaking oil.

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Section 5 – Procedures Boom & Jib

33. One by one, remove the cylinder fitting caps 35. Align the cylinder rod end with the pin holes
and reconnect the hoses (x4), lifting the riser if (use the riser lift/lower and/or platform up/down
needed to access the lower fitting. functions to help align the holes), and tap the
original pin back in. Reinstall the keeper pin,
bolt and washer, applying Loctite 242 to the bolt
before installing it.

Front Back

36. Remove the oil pan and clean up any leaked oil.
37. Remove the sling from the fly boom.
34. Lift the riser and main boom until the upper
cylinder pin hole is accessible. 38. Raise the boom to provide clearance, then use
the platform level switch on the base controls to
fully raise and lower the platform 3 times.

39. Check for leaks at the master cylinder fittings and

hoses.

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5.4-5 Jib Rotary Actuator Bolt Torque 5.4-6 Platform Rotary Actuator Bolt
Sequence Torque Sequence

1. Park the MEWP on a firm level surface in the 1. Park the MEWP on a firm level surface in the
stowed position. stowed position.
2. Disconnect one of the main power connectors. 2. Disconnect one of the main power connectors.
3. Set the torque wrench to 23 Nm (17 ft-Ib) and 3. Set the torque wrench to 23 Nm (17 ft-Ib) and
tighten the mounting bolts in a criss-cross tighten the mounting bolts in a criss-cross
pattern sequence. pattern sequence.

1 1

8 5 8 5

4 3 4 3

7 7
6 6

2 2

4. Set the torque wrench to 47 Nm (35 ft-Ib) 4. Set the torque wrench to 47 Nm (35 ft-Ib)
and tighten the mounting bolts with the same and tighten the mounting bolts with the same
sequence. sequence.
5. Torque the center bolt to 1044 Nm (770 ft-lb). 5. Torque the center bolt to 512 Nm (380 ft-lb).

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Section 5 – Procedures Turret

5.5 Turret 5.5-2 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.

5.5-1 Hydraulic Oil Replacement

1. Park the MEWP on a firm level surface in the

stowed position.
2. Allow the hydraulic oil to warm up.
3. Disconnect one of the main power connectors.
4. Place a suitable container under the hydraulic
tank.
5. Remove the oil drain plug and allow all of the
hydraulic oil to drain into the container.
6. Reinstall the drain plug with a new seal ring and
tighten the plug firmly. 3. Use a filter wrench to remove the filter from the
7. Refill the hydraulic tank with new oil. Refer to 2.9 head. Throw out the filter.
Hydraulic Specifications. 4. Apply hydraulic oil to the o-ring on the new filter,
8. Check for leakage. and screw the filter into place.
9. Clean up any oil that may have spilled during 5. Tighten the filter with the filter wrench.
this procedure.
10. Check the hydraulic oil level. The hydraulic oil NOTE
level should be at or slightly above the fill line on Refer to your national/local regulations on how to
the tank. dispose of used filters and oil.

NOTE
Refer to your national/local regulations on how to
dispose of 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 will 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 2.9 Hydraulic Specifications.

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5.5-3 Hydraulic System Main Relief Valve 5.5-4 Main Pump Relief Valve Adjustment
Adjustment (RV1) (RV5)

1. Locate test port GP on the main manifold, and 1. Locate test port GP on the main manifold, and
connect a 350 bar (5000 psi) pressure gauge to connect a 350 bar (5000 psi) pressure gauge to
it. it.

RV1
GP
GP

2. Pull out the base and platform e-stops.

3. From the base controls, use the telescope
2. Pull out the base and platform e-stops. retract switch to activate the pressure on the
3. From the base controls, use the telescope gauge. Check the reading while still retracting.
retract switch to activate the pressure on the 4. The pressure should be 228 bar (3300 psi).
gauge. Check the reading while still retracting. Follow the next steps for adjusting the pressure
4. The pressure should be 217 bar (3150 psi). if needed.
Follow the next steps for adjusting the pressure 5. Locate relief valve RV5 on the main pump.
if needed.
5. Locate the main system relief valve RV1.
6. Loosen the lock nut on the relief valve.
7. Turn the adjusting stem clockwise to increase
the pressure and counterclockwise to decrease
the pressure until 217 bar (3150 psi) is observed
on the gauge.
8. Tighten the lock nut.

RV5

6. Loosen the lock nut on the relief valve.

7. Turn the adjusting stem clockwise to increase
the pressure and counterclockwise to decrease
the pressure until 3300 psi is observed on the
gauge.
8. Tighten the lock nut.

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5.5-5 Emergency Pump Relief Valve 5.5-6 Turret Rotate Relief Valve
Adjustment (RV6) Adjustment (RV3)

1. Locate test port GP on the main manifold, and 1. Locate test port GP on the main manifold, and
connect a 350 bar (5000 psi) pressure gauge to connect a 350 bar (5000 psi) pressure gauge to
it. it.

RV3
GP
GP

2. Pull out the base and platform e-stops.

3. Raise the jib to ensure the platform will not
contact the ground.
4. Rotate the turret fully in one direction until it
cannot go any further and hold the joystick
there. Check the reading on the gauge.
5. The pressure should be 145 bar (2100 psi).
Follow the next steps for adjusting the pressure
if needed.
RV6 6. Locate turret rotate relief valve RV3.
2. Pull out the base and platform e-stops. 7. Loosen the lock nut on the relief valve.
3. From the base controls, use the e-pump switch 8. Turn the adjusting stem clockwise to increase
in combinating with the telescope retract switch pressure and counterclockwise to decrease
to activate the pressure on the gauge. Check pressure until 145 bar (2100 psi) is observed on
the reading while still retracting. the gauge.
4. The pressure should be 228 bar (3300 psi). 9. Tighten the lock nut.
Follow the next steps for adjusting the pressure
if needed.
5. Locate relief valve RV6 on the e-pump.
6. Loosen the lock nut on the relief valve.
7. Turn the adjusting stem clockwise to increase
the pressure and counterclockwise to decrease
the pressure until 228 bar (3300 psi) is observed
on the gauge.
8. Tighten the lock nut.
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5.5-7 Riser Down Relief Valve 5.5-8 Boom Extend Relief Valve
Adjustment (RV7) Adjustment (RV4)

1. Locate test port GP on the main manifold, and 1. Locate test port GP on the main manifold, and
connect a 350 bar (5000 psi) pressure gauge connect a a 5000 psi pressure gauge to it.
to it.
RV4
GP
GP

2. Pull out the base and platform e-stops.

3. Raise the jib to ensure the platform will not 2. Pull out the base and platform e-stops.
contact the ground.
3. Raise the jib to ensure the platform will not
4. Fully lower the riser, and with the toggle switch contact the ground.
still held down, check the reading on the
gauge. 4. Fully retract the boom, and with the toggle
switch still pressed up, check the reading on
5. The pressure should be 224 bar (3250 psi). the gauge.
Follow the next steps for adjusting the pressure
if needed. 5. The pressure should be 103 bar (1500 psi).
Follow the next steps for adjusting the pressure
6. Locate relief valve RV7 on the riser cylinder. if needed.
6. Locate platform leveling relief valve RV4.
7. Loosen the lock nut on the relief valve.
8. While the toggle switch is pressed upward,
turn the adjusting stem clockwise to increase
pressure and counterclockwise to decrease
pressure until 103 bar (1500 psi) is observed on
the gauge.
9. Tighten the lock nut.

RV7

7. Loosen the lock nut on the relief valve.

8. While the toggle switch is pressed down,
turn the adjusting stem clockwise to increase
pressure and counterclockwise to decrease
pressure until 3250 psi is observed on the
gauge.
9. Tighten the lock nut.
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5.5-9 Platform Level Relief Valve 5.6 Base

Adjustment (RV2)
5.6-1 Battery Replacement
1. Locate test port GP on the main manifold, and
connect a 350 bar (5000 psi) pressure gauge
to it. 1. Disconnect the main power connector by
pulling the red handle straight back.
RV2 2. Pull the latch knob to unlock the battery tray.
GP Swing the tray out.
3. Remove the wingnuts securing the battery tray
lid (one on each end), and remove the lid.

Main power
connector

Tray latch

Wingnut

2. Pull out the base and platform e-stops.

4. Remove the positive and negative connectors
3. Raise the jib to ensure the platform will not
from the battery.
contact the ground.
5. Remove the battery.
4. Fully raise or lower the platform using the
platform level toggle switch and with the toggle 6. Install the new battery.
switch still held, check the reading on the 7. Clean the terminal posts and clamps of the
gauge. battery, and apply acid-free and acid-resistant
5. The pressure should be 210 bar (3050 psi). grease.
Follow the next steps for adjusting pressure if 8. Reconnect the battery with the positive and
needed. negative connector cables (ensure the clamps
6. Locate platform leveling relief valve RV2. make good contact).
7. Loosen the lock nut on the relief valve.
8. With the toggle switch still held, turn the
adjusting stem clockwise to increase pressure
and counterclockwise to decrease pressure
until 210 bar (3050 psi) is observed on the
gauge.
9. Tighten the lock nut.

9. Reinstall the lid, securing it with the wingnuts.

10. Swing the battery tray back into place, ensuring
the latch catches.
11. Reconnect the main power connector.

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5.6-2 Ring Gear Bolt Torque Sequence 5.6-3 Check Torque Hub Oil Level

Maintaining proper torque is essential to safe MEWP 1. Drive the MEWP to rotate the hub until the plug
operation. Improper bolt torque could result in an is located at the 3 o’clock or 9 o’clock position.
unsafe operating condition and component damage.
2. Remove the plug and check the oil level. The oil
1. Park the MEWP on a firm level surface in the level should be even with the bottom of the plug
stowed position. hole. Add oil if needed. For oil specifications,
2. Disconnect one of the main power connectors. refer to 2.9 Hydraulic Specifications.
3. Apply Loctite 242 blue to the inner (upper) gear
mounting bolts, and hand tighten them.
4. Set a torque wrench to 68 Nm (50 ft-lb) and
tighten the inner gear mounting bolts in a criss-
cross pattern sequence.
5. Repeat with the torque wrench set to 115 Nm
(85 ft-lb).
6. Repeat with the torque wrench set to 230 Nm
(170 ft-lb).
7. Repeat the previous steps with the outer (lower)
gear mounting bolts.

16 1
12 5
8 9
4 13
18 17
14 3
10 7
6 11
2 19 15

16 1 14
11 5
8 9
18 3
4 17
13 7
6 12
10 2 15

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5.6-4 Electronic Tilt Switch Setup 7. Install the new switch onto the mount and
Procedure connect the switch plug to the 4 pin connector.
The following information is supplied for replacement
or reprogramming of the electronic tilt switch. Also
NOTE
included are test and verification instructions. Follow The tilt circuit is only powered when the controls
the appropriate procedures below. are powered up.

8. Turn the main disconnect switch to the ON

Tilt Switch Replacement position .
9. Turn the base/off/platform key switch to the
Y AXIS
X AXIS
base position .
10. Pull out both emergency stop buttons .
11. Verify the switch is powered (the red or green
LED will be continually blinking).

Red LED Red LED

Green LED Green LED

12. Program the tilt switch:

a. Press and release the set up button 3 times.
1. Ensure the MEWP is parked on a firm, level Observe the LED flash codes as shown
surface. below.
2. Fully lower the platform and retract the fly b. Only the red LED
boom. blinks for 4 seconds.
3. Chock or block the wheels to keep the MEWP Red LED

from rolling forward or backward. Green LED

4. Push in the emergency stop buttons and

disconnect one of the main power connectors. c. Both LEDs flash for 1
5. Disconnect the tilt switch from the 4 pin second.
connector. Results: The switch is Red LED
learning the new zero Green LED

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

learned.
e. The green LED flashes and then the
red LED turns on solid for 2 seconds.
Results: The switch is verifying the new zero
position.

Red LED Red LED

Green LED Green LED

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f. Only the red LED blinks Reprogramming the Existing Tilt Switch
for 4 seconds. The set up button is located on
Red LED Light Indicators this face next to the harness
Green LED

13. Disconnect one of the main power connectors.

14. Push in the emergency stop buttons . R
Gre ed LE
15. Remove the chock or wheel blocks. en
LE
D
D

16. Proceed to Verify the Tilt Circuit.

1. Ensure the MEWP is parked on a firm level

surface.
2. Fully lower the platform and retract the fly
boom.
3. Chock or block the wheels to keep the MEWP
from rolling forward or backward.

NOTE
The tilt circuit is only powered when the controls
are powered up.

4. Connect the main power connectors.

5. Pull out both emergency stop buttons .
6. Turn the base/off/platform key switch to the
base position .
7. Verify the switch is powered (the red or green
LED will be continually blinking).
8. Reprogram the Tilt Switch

a. Press and hold the

set up button for 3
seconds. Red LED
Results: Both LEDs Green LED

are OFF.

b. Both LEDs flash.

Red LED
Green LED

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Verify the Tilt Circuit

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

c. Press and release the set up button 3 times.

R
Gre ed LE
d. If the 5 second period has expired prior to en
LE
D
D
completion, repeat steps “a”, “b” and “c”.

e. Observe the program

delay / stabilization
time (only the red LED Red LED
blinks for 4 seconds). Green LED

f. Both LEDs flash for Operations of the Tilt Switch

1 second.
The following describes the LED’s and what they
Results: The switch is Red LED
indicate.
learning the new zero Green LED

position. Illuminated whenever both tilt

axes are within the specified
g. Both LEDs turn on
degrees of the zero/ home
solid for 1 second. learned position.
Results: The new Green LED
Red LED Flashes when transitioning in
zero position has been Green LED or out of tilt angle limits, but
learned. built in time delay has not fully
occurred.
h. The green LED flashes and then the red LED
turns on solid for 2 seconds. Illuminated whenever tilt on one
Results: The switch is verifying the new zero or more axes is more than the
Red LED
position. specified degrees out from the
zero/ home position.
On together, no blinking when
Green & Red LED
fault detected.
Red LED Red LED
Green LED Green LED

i. The green LED turns

on solid.
Results: The switch Red LED
is ready for normal Green LED

operation.

9. Disconnect one of the main power connectors.

10. Push in the emergency stop buttons .
11. Remove the chock or wheel blocks.
12. Proceed to Test and Verify Tilt Circuit.

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5.6-5 Motor Controller Thermal Sensor

If the controller temperature exceeds 85°C (185°F), the maximum current is reduced in proportion to the
thermal increase. The temperature can never exceed 105°C (221°F).

Imax
Maximum current = 100%

Maximum current = 75%

Maximum current = 50%

85°C 90°C 95°C 105°C T(°C)

Ambient
Resistance (ohm)
Temperature
°C °F Min Typ Max
-40 -40 340 359 379
-30 -22 370 391 411
-20 -4 403 424 446
-10 14 437 460 483
0 32 474 498 522
10 50 514 538 563
20 68 555 581 607
25 77 577 603 629
30 86 599 626 652
40 104 645 672 700
50 122 694 722 750
60 140 744 773 801
70 158 797 826 855
80 176 852 882 912
90 194 910 940 970
100 212 970 1000 1030
110 230 1029 1062 1096
120 248 1089 1127 1164
130 266 1152 1194 1235
140 284 1216 1262 1309
150 302 1282 1334 1385

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5.6-6 Motor Controller Panel Pin Interface - Connector A

Pin 1 - 12 volt output on wire 3D to CB1 circuit breaker.

Test between pin 1 and battery negative.

Pin 2 - 00/ battery negative to CB2 circuit breaker.

Test for continuity between pin 2 and battery negative.

Pin 3 - 48 volt output on wire 3 from line contactor to E stop switch. (Fused 10amp)
Test between pin 3 and battery negative.

Pin 4 - 48 volt input on wire 3C to motor controller and line contactor when key on selected.
Test between pin 5 and battery negative with key on.

Pin 5 - Base Mode input. 12 volt input on wire 10 = Base control mode.
Test for 12 volts between pin 5 and battery negative while in Base position.

Pin 6 - Platform Mode input. 12 volt input on wire 7A = Platform control mode.
Test for 12 volts between pin 6 and battery negative while in Platform position.

Pin 7 - Accelerator input. Wire D from drive joystick controller.

Neutral position= 4.2 volts to 4.8 volts.
Forward function= 4.9 volts to 8.5 volts.
Reverse function= 4.1 volts to .5 volts.
Test between pin 7 and 02 wire.

Pin 8 - Tilt sensor output to tilt relay 28CR on wire 28. 12V= Level. 0V= Tilted.
Test between pin 8 and 02 wire.

Pin 9 - Turret position for direction sensor. 12 volt input from limit switch LS1 on wire 17.
0 volts= Platform over drive axle.
12 volts= Platform over steer axle.
Test between pin 9 and 02 wire.

Pin 10 - 12 volt input from LS2 riser/ LS3 boom elevation limit switches and LS4 telescope limit switch on wire 59.
12 volts= full speed. 0 volts= creep speed (one or more limit switches open).
Test for continuity between pin 10 and battery negative while in drive mode.

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Pin 11 - Enable out- Negative output on wire 208 to relays 208CR and 208CR1.
Test for negative at pin 11 while operating from base or upper controls.

Pin 12 - Enable in- 12 volt input on wire 8B from footswitch S6 or base enable switch S21.
Test between pin 12 and battery negative while activating footswitch or base enable switch.

Pin 13 - 12 volt input on wire 24 from left steer switch.

Test between pin 13 and battery negative while operating left steer.

Pin 14 - 12 volt input on wire 23 from right steer switch.

Test between pin 14 and battery negative while operating right steer.

Pin 15 - Negative output on wire 224 to left steer valve 4H-224.

Test pin 15 for negative while operating left steer. (Platform must be over drive axle)

Pin 16 - Negative output on wire 223 to right steer valve 4H-223.

Test pin 16 for negative while operating right steer. (Platform must be over drive axle)

Pin 17 - Variable negative output on wire 90 to battery condition light PL4.

(No light= Charged… Solid light= Warning… Blinking light= Limp mode)
Test for negative at pin 17.

Pin 18 - 12 volt input from platform Load cell on wire 162.

12 volts= within platform capacity. 0 volts= overload.
Test for continuity between pin 18 and battery negative while no load in platform. Refer to Load Sense
troubleshooting in section 5 for additional information.

Pin 19 - PMU accelerator input. Variable input from wire 70. 10-100% of maximum pump speed. (PWM signal)
Test for varied input at pin 19 while operating from upper controls.

Pin 20 - Base speed 1 input on wire 71. 70% of pump speed.

Test continuity on wire 71 between pin 20 and base terminal block.

Pin 21 - Base speed 2 input on wire 72. 50% of pump speed.

Test continuity on wire 72 between pin 21 and base terminal block.

Pin 22 - Base speed 3 input on wire 73. 8% of pump speed.

Test continuity on wire 73 between pin 22 and base terminal block.

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Pin 23 - Charger cutout. 12 volt input on wire 60A from charger interlock relay L1CR.
12 volts= machine operable. 0 volts= machine disabled.
Test for 12 volts between pin 23 and battery negative without charger plugged in.

Pin 24 - 12 volt input on wire 01. 12 volts= Main PMU disabled and Emergency PMU available.
Test for 12 volts between pin 24 and battery negative while operating Emergency controls.

5.6-7 Motor Controller Panel Pin Interface - Connector B

Pin 1 - Drive/ Boom function Enable- Negative output on wire 259 to relay 259CR.
- Machine stowed and tilted= Boom up, riser up and telescope out functions allowed until limit switches are
activated (LS2, LS3 or LS4). Drive remains active.
- Machine elevated and tilted= All boom functions remain active. Drive is cut out.
Test for negative at pin 1 while machine is stowed.

Pin 2 - 12 volt output on wire 60 from diodes D7A or D10.

Test for 12 volts between pin 2 and battery negative.

Pin 3 - SGE input - 12 volt input on wire 04A from SGE sensor bar.
SGE sensor bar active for less than 1 second= Functions automatically return.
SGE sensor bar active for more than 1 second= Reset is required.
Test between pin 3 and battery negative while pressing sensor bar.

Pin 4 - SGE reset- 12 volt input on wire 01A from SGE reset switch S25. (Emergency controls also provides reset)
Test between pin 4 and battery negative while activating reset switch.

Pin 5 - 12 volt input from riser down function on wire 30B. (Enable timer- Riser is gravity down No PMU active)
Test for 12 volts between pin 5 and battery negative while in Base position.

Pin 6 - Negative output on wire 204 to relay 204CR for SGE system. No negative = Alarm and Light activated.
Test for negative at pin 6 while SGE is not activated.

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5.6-8 Motor Controller Connectors Pin Reference

LM RM

Right Motor Controller Connector

RM 1 - Enable in - 12 volt input on wire 8B from motor controller harness A pin #A12.
Test between RM 1 and battery negative while activating footswitch or base enable switch.

RM 2 - Not used.

RM 3 - 12 volt input on wire 3E through fuse F2 from DC/DC converter on wire 3D.
Test between RM 3 and battery negative with both upper and lower E stop switches activated.

RM 4 - Negative output to right motor brake connector.

Test for 48 volts between brake positive and brake negative. If no voltage found test for continuity between
RM 4 and brake negative at right motor brake connector. Replace if defective.

RM 5 - Negative output to right motor encoder connector.

Test for continuity between RM 5 and encoder negative at right motor encoder connector. Replace if
defective.

RM 6 - 12 volt input through motor controller harness A pin #A10 from LS2 riser/ LS3 boom elevation limit
switches and LS4 telescope limit switch on wire 59.
12 volts= full speed. 0 volts= creep speed (one or more limit switches open).
Test for 12 volts at RM6 and battery negative while in drive mode and boom fully stowed.

RM 7 - Not used.

RM 8 - Negative output on wire 208 through motor controller harness A pin #A11 to relays 208CR and 208CR1.
Test for negative at pin RM 8 while operating from base or upper controls.

RM 9 - Negative output on wire #224 through motor controller harness A pin #A15 to left steer valve.
Test for negative at RM 9 while operating left steer.

RM 10 - E stop return- 48 volt input on wire 3C from motor controller harness A pin #A4.
Test between RM 10 and battery negative with both upper and lower E stop switches activated.

RM 11 - Negative output on wire #223 through motor controller harness A pin #A16 to right steer valve.
Test for negative at RM 11 while operating right steer.

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RM 12 - Negative output to main contactor 3CCR. Must see 48V on pins RM10 and LM10 before negative is
supplied.
Test for negative at RM 12.

RM 13 - Encoder B signal from right motor Encoder.

Test for 2.5 volts approximately between negative and RM 13 while driving. Replace encoder if no voltage
found.

RM 14 - Encoder A signal from right motor Encoder.

Test for 2.5 volts approximately between negative and RM 14 while driving. Replace encoder if no voltage
found.

RM 15 - Accelerator input. Wire D from drive joystick controller.

Neutral position= 4.2 volts to 4.8 volts.
Forward function= 4.9 volts to 8.5 volts.
Reverse function= 4.1 volts to .5 volts.
Test between pin RM 15 and 02 wire.

RM 16 - 12 volt input on wire 24 from left steer switch.

Test between RM 16 and battery negative while operating left steer.

RM 17 - Not used.

RM 18 - Not used.

RM 19 - 12 volt input on wire 23 from right steer switch.

Test between RM 19 and battery negative while operating right steer.

RM 20 - Base Mode input. 12 volt input on wire 10 = Base control mode.

Test for 12 volts between RM 20 and battery negative while in Base position.

RM 21 - Not used.

RM 22 - Thermal sensor input.

Refer to thermal sensor resistance table in section 5 of this manual. Replace if out of range.

RM 23 - Not used.

RM 24 - Not used.

RM 25 - 5 volt signal to right motor Encoder.

Test for 5 volts between negative and RM 25 while driving.

RM 26 - Variable negative output through motor controller harness A pin #A17 on wire 290 to battery condition
light PL4.
(No light= Charged… Solid light= Warning… Blinking light= Limp mode)
Test for negative at RM 26.

RM 27 - CAN L- Low level CAN-BUS voltage I/O.

RM 28 - CAN H- High level CAN-BUS voltage I/O.

RM 29 - Not used.

RM 30 - Variable voltage input from steer sensor. 3.3 volts to 4.1 volts.

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(Steer hard right= 3.3 volts… Steered straight= 3.7 volts… Steer hard left= 4.1 volts)
Test between negative and RM 30.

RM 31 - Turret position for direction sensor. 12 volt input through motor controller harness A pin #A9 from limit
switch LS1 on wire 17.
0 volts= Platform over drive axle.
12 volts= Platform over steer axle.
Test between RM 31 and 02 wire.

RM 32 - Tilt sensor input on wire 28. 12V= Level. 0V= Tilted.

Test between RM 32 and 02 wire.

RM 33 - Drive/ Boom function Enable- Negative output through motor controller harness B pin #B1 on wire 259 to
relay 259CR.
Machine stowed and tilted= Boom up, riser up and telescope out functions allowed until limit switches are
activated (LS2, LS3 or LS4). Drive remains active.
Machine elevated and tilted= All boom functions remain active. Drive is cut out.
Test for negative at RM 33 while machine is stowed.

RM 34 - Not used.

RM 35 - Platform Mode input. 12 volt input on wire 7A = Platform control mode.

Test for 12 volts between RM 35 and battery negative while in Platform position.

Left Motor Controller Connector

LM 1 - Enable in- 12 volt input on wire 8B from motor controller harness A pin #A12.
Test between LM 1 and battery negative while activating footswitch or base enable switch.

LM 2 - Not used.

LM 3 - 12 volt input on wire 3D from DC/DC converter.

Test between LM 3 and battery negative with both upper and lower E stop switches activated.

LM 4 - Negative output to left motor brake connector.

Test for 48 volts between brake positive and brake negative. If no voltage found test for continuity between
LM 4 and brake negative at left motor brake connector. Replace if defective.

LM 5 - Negative output to left motor encoder connector.

Test for continuity between LM 5 and encoder negative at left motor encoder connector. Replace if
defective.

LM 6 - Not used.

LM 7 - Charger cutout. 12 volt input through motor controller harness A pin #A23 on wire 60A from charger
interlock relay L1CR.
12 volts= machine operable. 0 volts= machine disabled.
Test for 12 volts between LM 7 and battery negative without charger plugged in.

LM 8 - Not used.

LM 9 - Not used.

LM 10 - E stop return- 48 volt input on wire 3C from motor controller harness A pin #A4.

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Test between LM 10 and battery negative with both upper and lower E stop switches activated.

LM 11 - Negative output on wire 204 through motor controller harness B pin #B6 to relay 204CR for SGE system.
No negative = Alarm and Light activated.
Test for negative at LM11 while SGE is not activated.

LM 12 - Not used.

LM 13 - Encoder B signal from right motor Encoder.

Test for 2.5 volts approximately between negative and LM 13 while driving. Replace encoder if no voltage
found.

LM 14 - Encoder A signal from right motor Encoder.

Test for 2.5 volts approximately between negative and LM 14 while driving. Replace encoder if no voltage
found.

LM 15 - PMU accelerator input. Variable input from wire 70. 10-100% of maximum pump speed. (PWM signal)
Test for varied input at LM 15 while operating from upper controls.

LM 16 - 12 volt input on wire 01. 12 volts= Main PMU disabled and Emergency PMU available.
Test for 12 volts between LM 16 and battery negative while operating Emergency controls.

LM 17 - SGE input- 12 volt input through motor controller harness B pin #B3 on wire 04A from SGE sensor bar.
SGE sensor bar active for less than 1 second= Functions automatically return.
SGE sensor bar active for more than 1 second= Reset is required.
Test between LM 17 and battery negative while pressing sensor bar.

LM 18 - Not used.

LM 19 - 12 volt input through motor controller harness A pin #A18 from platform Load cell on wire 162.
12 volts= within platform capacity. 0 volts= overload.
Test for continuity between LM 19 and battery negative while no load in platform. Refer to Load Sense
troubleshooting in section 5 for additional information.

LM 20 - Base speed 1 input on wire 71. 70% of pump speed.

Test continuity on wire 71 between LM 20 and base terminal block.

LM 21 - Not used.

LM 22 - Thermal sensor input.

Refer to thermal sensor resistance table in section 5 of this manual. Replace if out of range.

LM 23 - Not used.

LM 24 - Not used.

LM 25 - 5 volt signal to left motor Encoder.

Test for 5 volts between negative and LM 25 while driving.

LM 26 - Not used.

LM 27 - CAN L- Low level CAN-BUS voltage I/O.

LM 28 - CAN H- High level CAN-BUS voltage I/O.

LM 29 - 12 volt input from riser down function on wire 30B. (Enable timer- Riser is gravity down No PMU active)

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Test for 12 volts between LM 29 and battery negative while in Base position.

LM 30 - Variable voltage input from tilt sensor on wire #128.

(Level ground= 1.88 volts… 25% grade= 9.4 volts)
Test between negative and LM 30.

LM 31 - Base speed 2 input on wire 72. 50% of pump speed.

Test continuity on wire 72 between LM 31 and base terminal block.

LM 32 - Base speed 3 input on wire 73. 8% of pump speed.

Test continuity on wire 73 between LM 32 and base terminal block.

LM 33 - Not used.

LM 34 - Not used.

LM35 - SGE reset - 12 volt input through motor controller harness B pin #B4 on wire 01A from SGE reset switch
S25. Emergency controls also provides reset.
Test between LM 35 and battery negative while activating reset switch.

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5.6-9 ZAPI MDI-CAN Display

The ZAPI Multi-function Digital Indicator (MDI)-CAN display gives indication of the alarms of the motor controller,
which it is connected via CAN-BUS, with a corresponding code. When the display powers up, it shows the
general information shown on the MDI display (if a turtle appears, it signifies Creep Mode which happens when
the batteries are low on charge), then it flashes the software revision of the MDI display, followed by the software
revision of the motor controller, and lastly, the machine hours used.

When an alarm is generated, the red LED blinks and the symbol of the monkey wrench appears, to attract the
attention of the operator. Note: if the wrench symbol does not appear, the code shown is not a fault code.

Decoding the Alarms Displayed on the MDI-CAN

The format of the string shown on the display below is XXAYY, where XX and AYY represent the alarmed node
and the alarmed code respectively.

The First two digits The Final two digits

represent the Node of the represent the Alarm Code
Controller where the Alarm (see Table).
is present.
For SJ30AJE/ARJE, this will
The Third digit represents which
be 03 for the right traction
Sub Node the Alarm is present.
controller and 04 for the left
traction controller. This will be A:
A - represents an Alarm on Sub
Node

With the Controller Alarm Codes on the MDI-CAN display referenced against the Controller Master Codes Table
(refer to 5.6-10 ZAPI MDI-CAN Controller Master Codes), the operator can solve the fault and correct the error. The
codes tables contain the flash codes, the probable cause and the recommended remedy. If the Alarm information
suggests a serious problem that can not be addressed by the codes tables, contact the Skyjack Service
Department.

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5.6-10 ZAPI MDI-CAN Controller Master Codes

Flash 
Displayed on MDI Probabable Cause Remedy
Code

1. Cycle keyswitch 
0XA08 WATCHDOG ACE3 Controller logic selfcheck 2. Factory reset (Clear Eeprom) 
3. Replace controller.

1. Cycle keyswitch 
2. Factory reset (Clear Eeprom) 
The software is corrupted or the 
0XA08 FLASH CHECKSUM 3. The software was not correctly written into the flash 
flash on the controller is damaged
memory or the flash memory is damaged. Replace the 
controller.

1. Cycle keyswitch 
Failure in high current HW protection  2. Factory reset (Clear Eeprom) 
0XA17 LOGIC FAIL #3
circuit 3. Hardware problem in logic circuit card for high current 
(overload) protection. Internal issue. Replace controller.

1. Cycle keyswitch 
2. Factory reset (Clear Eeprom) 
0XA26 SENS. KO The current sensor is damaged. 3. One of the current sensor, used to measure the value on 
the motor phases, is damaged. Internal issue. Replace 
controller.

One of the phases on the drive 
0XA27 PHASE KO Check battery cables to the drive motors
motors is open

1. Check wiring to Pump/ Motor
Pump motor is low compared to 
0XA28 PUMP VMN LOW 2. Test Motor 
PWM signal applied.
3. Replace Motor

1. Check wiring to Pump/ Motor
Pump motor is high compared to 
0XA29 PUMP VMN HIGH 2. Test Motor 
PWM signal applied.
3. Replace Controller if Motor tests OK.

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ZAPI MDI-CAN Controller Master Codes (continued)

Flash 
Displayed on MDI Probabable Cause Remedy
Code

Cause 1:
Before switching the Line Contactor on, the software 
checks the power bridge: it turns on alternatingly the Low 
side Power Mosfets and expects the phases voltage to 
decrease down to ‐BATT. If the phases voltage is igher than 
10% of nominal battery voltage, this alarm occurs.

Cause 2:
This alarm may occur also when the start up diagnosis is 
overcome, and so the Line Contactor is closed. In this 
condition, the phases’ voltages are expected to be lower 
than 1/2 battery voltage. If it is higher than that value, 
fault status is entered.

Self check of Power components and 
0XA31 VMN HIGH Troubleshooting:
Motor
‐ If the problem occurs at start up (the Line Contactor does 
not close at all), check:
‐ Motor internal connections (ohm internal connections 
continuity)
‐ Motor power cables connections
‐ If the motor connection are OK, the problem is inside the 
controller, replace Controller.
‐ If the problem occurs after closing the Line Contactor (the 
Line Contactor closed and then opens back again), check:
‐ Motor connections
‐ Make sure motor phases windings/cables do not have 
leakages towards chassis
‐ If no problems are found on the motor/ cables, the 
problem is inside the controller, Replace controller.

1. Cycle keyswitch 
0XA40 AUX. DRIV.SHRT. Mos for electric brake is shorted 2. Check for short or low ‐ impedence to electric brakes
3. Replace controller that shows the fault.

At start‐up, the controller checks the battery voltage and 
verify it is within a window around the nominal value.
Troubleshooting:
‐ Check that the controller SET BATTERY parameter value 
Controller rejects the battery voltage 
0XA41 WRONG SET BAT. matches the battery nominal voltage.
reading
‐ Check that TESTER MENU / BATTERY VOLTAGE parameter 
shows same value as the battery voltage measured with a 
voltmeter. If it does not match, then do an “ADJUST 
BATTERY” function.

1. Check wiring between controller and electric brake 
Driver of electric brake is damaged 
0XA42 AUX. DRIV.OPEN. 2. Replace electric brakes
(not able to close)
3. Replace controller that shows the fault.
Lift and lower requested at the same  Check joystick outputs.
0XA49 LIFT & LOWER
time. Factory reset (Clear Eeprom) 

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ZAPI MDI-CAN Controller Master Codes (continued)

Flash 
Displayed on MDI Probabable Cause Remedy
Code

Warning when the joystick is released, after a fixed period 
No operator input, machine in  of time of standby (30 seconds) the main contactor opens.
0XA51 TILLER OPEN
standby Troubleshooting:
At the next function request the warning will disappear.

1. Check wiring to Pump/ Motor
Pump motor is always 0 amps even 
0XA52 PUMP I=0 EVER 2. Recycle keyswitch 
when pump motor is running
3. Replace Controller.

1. Cycle keyswitch (If code remains see next)
Cause:
The current transducer or the current feedback circuit is 
0XA53 STBY I HIGH Internal Controller check damaged in the Controller
Troubleshooting:
This type of fault is not related to external components so, 
when it is present, it is necessary to replace the controller

The outputs of the amplfiers (used to 
1. Cycle keyswitch 
measure motor voltage) are checked. 
0XA53 WRONG ZERO 2. Factory reset (Clear Eeprom) 
This alarm occurs when voltage 
3. Replace controller.
signals >3V or <2V.

1. Check battery for load induced voltage drop.  Low 
voltage could be causing an under voltage condition.  
Over voltage/ under voltage 
0XA54 LOGIC FAIL #1 Check battery cables.
condition has been detected
2. Factory reset (Clear Eeprom) 
3. Replace controller.

1. Cycle keyswitch 
Motor voltage feedback circuits are 
0XA55 LOGIC FAIL #2 2. Factory reset (Clear Eeprom) 
damaged
3. Replace controller.

1. Cycle keyswitch 
Pump current sensor feedback is out 
0XA56 PUMP I NO ZERO 2. Factory reset (Clear Eeprom) 
of permitted standby range
3. Replace controller.

1. Check battery voltage
0XA60 CAPACITOR CHARGE Startup test
2. Check battery and motor cables

Cause:
The output of the controller thermal sensor is out of range.
0XA61 THERMIC SENS. KO Controller Troubleshooting:
This type of fault is not related to external components; 
replace the controller.

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ZAPI MDI-CAN Controller Master Codes (continued)

Flash 
Displayed on MDI Probabable Cause Remedy
Code

Cause:
This alarm occurs when the temperature of the base plate 
is higher than 85°.
Then the maximum current decreases proportionally with 
the temperature increases from 85° up to 105°. At 105° the 
Current is limited to 0 Amps.
Troubleshooting:
Controller High temp alarm, if high 
0XA62 TH. PROTECTION It is necessary to improve the controller cooling. In case of 
temp is not real proceed to remedy
thermal dissipation realised with the controller base plate 
installed on chassis it is important the thickness of frame 
and the planarity and roughness of its surface. If the alarm 
is signalled when the controller is cold, the possible 
reasons are a thermal sensor failure or a failure in the logic 
card. In this case, it is necessary to
replace the controller.

Cause:
This warning occurs when the temperature sensor has 
overtaken the threshold of 150° 
Troubleshooting:
Check the thermal sensor inside the motor (use the 
0XA65 MOTOR TEMPERAT. Motor temp high. MOTOR TEMPERATURE reading in the TESTER menu); 
check the sensor ohmic value and the sensor wiring. If the 
sensor is OK, improve the cooling of the
motor. If the warning is present when the motor is cool, 
then the problem is inside the controller. Replace 
controller.

Check that the controller SET BATTERY parameter value 
matches the battery normal voltage.
Battery is <= 10% when the  Check that the TESTER MENU/ BATTERY VOLTAGE 
0XA65 BATTERY LOW parameter BATTERY CHECK is set to  parameter shows same value as the battery voltage 
0. measured with a volt meter. If it does not match, then do a 
"ADJUST BATTERY" function.
If above OK, Replace controller.

Cause:
The output of the motor thermal sensor is out of range.
Troubleshooting:
05X67 SENS MOT TEMP KO Motor temp sensor damaged Check the sensor ohm value (at 20C the Sensor should 
read approx 600 Ohms) and the sensor wiring. If the sensor 
is OK, then the problem is inside the controller Replace 
controller.

1. Cycle keyswitch
2.Check that both nodes are present on the network using 
Alarm condition active. Waiting for 
05X68 WAITING FOR NODE Can Console.
communication between controllers
3. Check wiring to the missing controller.  If everything OK. 
Replace controller with node missing.

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ZAPI MDI-CAN Controller Master Codes (continued)

Flash 
Displayed on MDI Probabable Cause Remedy
Code
1. Cycle keyswitch 
Error is detected in Eeprom or 
0XA71 EEPROM KO 2. Factory reset (Clear Eeprom) 
Eeprom management
3. Replace controller.

‐ If the problem occurs at start up (the Line Contactor does 
not close at all), check:
‐ Motor internal connections (ohm internal connections 
continuity)
‐ Motor power cables connections
‐ If the motor connection are OK, the problem is inside the 
controller,
Self check of Power components and 
0XA72 VMN LOW replace Controller.
Motor
‐ If the problem occurs during motor running check:
‐ Motor connections
‐ Make sure motor phases windings/cables do not have 
leakages towards chassis
‐ If no problems are found on the motor/ cables, the 
problem is inside the controller,
Replace controller.

Make sure coil wires on line contactor are connected 
Driver for  line contactor coil is  securely.
0XA74 DRIVER SHORTED shorted or line contactor coil is  Check for 48 volts at coil wires.
disconnected Make sure harness to coil is not shorted.
Replace controller.

EV1/5 valve driver  Replace valve. If no short found,
0XA74 Check valve/ wiring for any short
shorted (always ON) Replace controller
EV2 valve driver  Replace valve. If no short found,
0XA74 Check valve/ wiring for any short
shorted (always ON) Replace controller
EV3 valve driver  Replace valve. If no short found,
0XA74 Check valve/ wiring for any short
shorted (always ON) Replace controller
EV4 valve driver  Replace valve. If no short found,
0XA74 Check valve/ wiring for any short
shorted (always ON) Replace controller

0XA75 CONTACTOR CLOSED Line contactor contacts are stuck Replace contactor

Check wiring to coil of contactor for a short
0XA75 CONTACTOR DRIVER Driver unable to close contactor
Replace contactor
Repair wiring. Replace coil. If no issue found,
0XA75 CONT. DRV. EV1 Check coil/ check for open wiring
Replace controller
Repair wiring. Replace coil. If no issue found,
0XA75 CONT. DRV. EV2 Check coil/ check for open wiring
Replace controller
Repair wiring. Replace coil. If no issue found,
0XA75 CONT. DRV. EV3 Check coil/ check for open wiring
Replace controller
Repair wiring. Replace coil. If no issue found,
0XA75 CONT. DRV. EV4 Check coil/ check for open wiring
Replace controller
Repair wiring. Replace coil. If no issue found,
0XA75 CONT. DRV. EV5 Check coil/ check for open wiring
Replace controller

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ZAPI MDI-CAN Controller Master Codes (continued)

Flash 
Displayed on MDI Probabable Cause Remedy
Code

This code is displayed when the coil of the line contactor or 
Check the Line Contactor and electric  electric brake coil is shorted or the wiring to the coil is 
0XA76 MC COIL SHOR.
brake coil shorted. Check coil and wiring. If error code remains it is an 
internal fault in the controller. Replace ACE3.

1. Check battery voltage
0XA76 KEY‐OFF SHORTED Key off signal is low when key is on 2. Check aux equipment is not pulling key voltage low
3. Replace controller that shows the fault
1. Check coils and wiring for short circuits
0XA76 COIL SHORT EV Short circuit on On/Off valves
2. Replace controller
1. Make sure coil wires on line contactor are connected 
correctly.
0XA77 LC COIL OPEN Contactor coil test
Replace line contactor. 
2. Replace controller which shows the fault.
Re‐program VACC
0XA78 VACC NOT OK Incorrect signal from Joystick
If condition is still present check joystick input wiring. 
1. Moving Joystick, before Enable switch selected. Make 
sure enable is selected before any movement.
0XA79 INCORRECT START Wrong input sequence 
2. Joystick out of range. (Potentiometer not centered) ‐
Check VACC calibration.
Re‐program VACC
Receives both forward and reverse 
0XA80 FORWARD+BACWARD If condition is still present check wiring.
signals at the same time
If OK replace controller
1. Check for 12 volt output at DC/DC converter
0XA80 EMERGENCY No 12 volt input to controllers 2. Check fuse F2
3. Check for 12 volts at RM3 and LM3.

Cause:
This fault is signaled in following conditions: the frequency 
supplied to the motor is higher than 40 Hz and the signal 
feedback from the encoder has a jump higher than 40 Hz 
in few tens mSec. This condition is related to a 
malfunctioning of the encoder.
Troubleshooting:
‐ Check both the electric and the mechanical encoder 
0XA82 ENCODER ERROR Motor feedback sensor fault
functionality, the wires connections.
‐ Check the encoder mechanical installation, if the encoder 
slips inside its compartment raising this alarm condition.
‐ Also the electromagnetic noise on the sensor bearing can 
be a cause for the alarm. In these cases try to replace the 
encoder.
‐ If the problem is still present after replacing the encoder, 
the failure is in the controller. Replace controller.

1. Cycle keyswitch 
0XA89 POWERMOS SHORTED Internal Controller check 2. Factory reset (Clear Eeprom) 
3. Replace controller.

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ZAPI MDI-CAN Controller Master Codes (continued)

Flash 
Displayed on MDI Probabable Cause Remedy
Code

1. Check wiring.
The pump accelator value is higher 
2. Aquire joystick VACC.
0XA89 PUMP VACC NOT OK than the minmum value recorded, 
3. Replace joystick/ switch.
and the lift/ lower switches are open.
Replace controller

1. Cycle keyswitch 
0XA92 CURRENT GAIN Internal Controller check 2. Factory reset (Clear Eeprom) 
3. Replace controller.

Cause:
This alarm occurs when the A/D conversion of the analog 
inputs gives frozen value, on all of the converted signals, 
for more than 400msec. The goal of this diagnosis is to 
detect a failure of the A/D converter or a problem in the 
0XA96 ANALOG INPUT Analog to digital failure
code flow that omits the refreshing of the analog signal 
conversion.
Troubleshooting:
If the problem occurs permanently it is necessary to 
Replace controller

1. Cycle keyswitch 
Error on the parameters of the slip 
0XA99 SLIP PROFILE 2. Factory reset (Clear Eeprom) 
profile setting.
3. Replace controller.

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5.6-11 ZAPI “Skyjack PC CAN Console” Software Guide

Configure the USB-to-CAN Device

After launcing the software it is necessary to configure the USB-to-CAN device.

1. From the drop down menu Configuration, select Can Device. The following window will open.

2. In this example, an IXXAT device set with a Baud Rate of 125 kbps (this depends on the controller) and
with Standard Protocol (this means Zapi Protocol) is selected. After clicking the OK button, a configuration
window opens. Tick the USE IXXAT CONFIGURATION box as shown.

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3. After clicking OK, the IXAAT device connected to the PC which is used for communication to the controller
must be selected. In this example, there is only one device.

4. Proceed with the connection to the network nodes by clicking Connection, then Set Node. In the following
example, there is a master node (node 3.0) and a slave node (node 4.0). Node 3.0 is the Master Combi
AC0 and drives the Right Traction Motor and the Hydraulic Pump Motor. Node 4.0 is the Slave ACE0
Inverter and drives the Left Traction Motor.

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5. After selecting the node and the sub-node numbers, proceed making the connection by clicking the Start
button in the main window. The status LED in the lower part of the window indicates successful operation,
while the central part of the window contains information concerning the software version, node number,
nominal battery voltage and current, the hour counter and finally, alarms (if present).

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Making Changes to the Parameters

To make changes to the paramters, it is necessary to do both of the following:

1. From the drop down menu Configuration, select Enter Password. In the window that appears, enter the
password 1122 and click OK.

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2. From the main menu, select Function, then Parameter to open a new window that allows you to modify all
the parameters (after clicking the Receive button).

3. You can modify the parameters manually in the different sub-menus: Parameter Change, Set Options,
Adjustment, Special Adjustment, and Hardware Setting. Decrease and increase their values using the
applicable - and + icons. To save the changes you must click on the Store icon.
4. It is possible to save the parameters list. In the top left corner of the window, select File, then Save. Specify
the folder and file name, selecting .csv format (so it can be opened as an Excel file).
5. To reset to the default parameters, select Memory, then Restore.
6. Lastly, you can load a parameters list into the controller from a previouisly saved .csv file by clicking Open,
and choosing the specific file.
7. To return to the main menu, you have to close the current window using the Close button.

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8. Note: for some parameters (for example the ones in the Special Adjustment menus), it is necessary to have
a key re-cycle in order to save them in the controller memory. This involves the loss of connection to the
node, so a new connection to the node may be required.
9. In the Tester menu, is is possible to have some measurements in real time of the digital input and output
stage (Active/Off), of analog input voltage valve, or the values of some variables used for the motor or
hydraulic control.

10. You can see up to four measured variables at the same time. When you select the desired variable, you will
be able to see its value in real time in the Test Value column, and also in the graphic chart below it.

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11. In the Function menu you can open the alarm Logbook. This lists all alarms present, or which have
occured during operation of the controller. In the table all alarms are listed with the number of occurences,
the inverer temperature, and the time at which the event occurs.

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Programming the Traction Joystick

1. Receive the parameters and enter them into the Adjustments menu.

2. You will see three settings: Throttle Neutral, Throttle Max, and Throttle Min. It is necessary to program
each setting individually.
3. Throttle Neutral: With the joystick in the neutral position, click Aquire next to Throttle Neutral. The
following dialogue box appears.

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4. Without moving the position of the joystick, click Stop Teach. The dialogue box closes and the value is
stored. You may now move on to programming Throttle Max.

5. Throttle Max: Click Aquire next to Throttle Max. The same dialogue box appears, displaying the value of
the neutral position.

6. Now push the joystick to its maximum position (fully forward). You will see the voltage rise as the joystick is
moved.

7. With the joystick at the maximum position, click Stop Teach. The dialogue box closes and the maximum
value is stored. Note: do not release the joystick until Stop Teach has been pressed and the dialogue box
closes.

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8. Throttle Min: Click Aquire next to Throttle Min. The same dialogue box appears, displaying the value of
the neutral position.

9. Now push the joystick to its minimum position (fully backwards). You will see the voltage drop as the
joystick is moved.

10. With the joystick at the minimum position, click Stop Teach. The dialogue box closes and the minimum
value is stored. Note: do not release the joystick until Stop Teach has been pressed and the dialogue box
closes.
11. The traction joystick is now programmed.

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Programming the Steer Potentiometer

1. Receive the parameters and enter them into the Adjustments menu.

2. You will see three settings: Set Steer 0-Pos, Set Steer Right, and Set Steer Left. It is necessary to program
each setting individually.
3. Note that when installing the feedback device to the machine, when the wheels are in the straight ahead
position, the reading from the device should be 1/2 the maximum value (approximately 5 V).

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4. Set Steer 0-Pos: Ensure the steered wheels are in the straight ahead position and click Aquire next to
Steer 0-Pos. The following dialogue box will be displayed.

5. The value should be in the region of 5 V when the wheels are straight. Now click Stop Teach to store the
value and close the dialogue box.
6. Set Steer Right: First you need to steer the wheels fully to the right. Click Aquire next to Set Steer Right.
The following dialogue box will be displayed.

7. With the wheels at the fully right position, the voltage should be higher than the Set Steer 0-Pos value.
Press Stop Teach to store the value and close the dialogue box.
8. Set Steer Left: Steer the wheels fully to the left. Click Aquire next to Set Steer Left. The following dialogue
box will be displayed.

9. With the wheels at the fully left position, the voltage should be lower than the Set Steer 0-Pos value. Now
click Stop Teach to store the value and close the dialogue box.
10. The steering feedback device is now programmed.

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Section 5 – Procedures Grease Points

5.7 Grease Points

5.7-1 Lubrication
Maintaining proper lubrication is essential for the good performance and service life of the mobile elevating work
platform. If the bearing and gear of the MEWP are improperly greased, it could result in component damage.

Grease the Swing Drive

1. Pump grease into each of the three grease nipples located on the front of the swing drive housing.

Grease the Turret Rotation Ring Gear

1. Open the control side cowling.
2. Locate the grease line attached to the lower left side of the base control box.
3. Pump grease into the line until new grease appears around the ring gear.
4. Rotate the turret in increments of 10 to 13 cm (4 to 5 inches) at a time, and repeat step 3 until the entire
bearing has been greased.

Grease the Steer Cylinder Bearing

1. Remove the front base cover to access the steer cylinder.
2. Pump grease into the steer cylinder bearing grease nipple until new grease appears all around the bearing
lip.
Recommended Grease
Swing Drive
Ring Gear Mobilgrease XHP 462 Moly
Steer Cylinder

Grease Line
to Ring Gear

Swing Drive Steer Cylinder

(3 places) Bearing

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