SERVICE

MANUAL
SJ9241 RT, SJ9250 RT
ROUGH TERRAIN SCISSORS

157958AFA
October 18, 2023
CE
 This manual is based on Serial Numbers:
SJ9241 RT: 55 000 033 to 55 000 067
SJ9250 RT: 50 000 746 to 50 001 023

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

other serial numbers, the most recent technical manuals, animations,
and USB software.

The original instructions are in English.

 THIS SAFETY ALERT SYMBOL MEANS ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED.

The Safety Alert Symbol identifies important safety

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

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

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

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

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

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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 Aerial Platform Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-2 Purpose of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-3 Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-4 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-5 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-6 Service Policy and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1-7 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-1 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2-3 Maintenance and Service Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Hydraulic System & Component Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3-1 Maintenance Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3-2 Railing Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 About this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4-1 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4-2 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4-3 Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Owner’s Annual Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6-1 Labels (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6-2 Limit Switches (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6-3 Emergency Lowering Access Rod (Model 9241) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-4 Electrical and Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6-5 Fuel and Hydraulic Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6-6 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.6-7 Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.6-8 Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6-9 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6-10 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Section 2 – Maintenance Tables and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Maximum Platform Capacities (Evenly Distributed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Floor Loading Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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2.5 Rough Terrain Scissor Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

3.1 Electrical Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Hydraulic Symbol Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Hydraulic Component Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4 Electrical Component Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5 Platform Control Console Wiring - All Options (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6 Control Cable Assemblies Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.7 Outrigger & Hydraulic Generator Control Console Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.8 Base Control Console Wiring (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.9 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.10 Hydraulic Manifold Components & Port Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.11 Main Manifold Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.12 Hydraulic Generator - Electrical Panel Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13 Emergency Lowering System - Wiring Diagram (Model 9250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.14 Emergency Lowering System - Electrical Wiring Diagram (Model 9241) . . . . . . . . . . . . . . . . . . . . . . 62
3.15 Auto-Leveling Outrigger Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.16 Powered Extension Platform - Electrical Wiring Diagram (Model 9250) . . . . . . . . . . . . . . . . . . . . . . 64
3.17 Horn, Light, Beeper & Transducer Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.18 Engine Wiring Diagram - Kubota Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.19 Flashing Light Relay Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.20 Electrical Panel Diagram - All Options (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.21 Electrical Schematic - Kubota Diesel Engine with All Option (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Section 4 – Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-1 All Controls Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-2 No Power to Platform (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2-3 All Functions Inoperative from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2-4 All Functions Inoperative (Additional for machines with Load Sensing System) . . . . . . . . . . . . . . 73
4.2-5 Engine will Not Crank from Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2-6 Engine will Not Crank from Base Controls (Kubota diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2-7 Engine Cranks but Stops Cranking after a few seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2-8 Glow Plugs Inoperative from Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2-9 Glow Plugs Inoperative from Platform (Additional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2-10 Engine Cranks but will Not Start (Kubota diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2-11 High Throttle Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2-12 Drive and Steer Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2-13 Brakes will Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2-14 Steer Right Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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 4.2-15 Steer Left Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2-16 Reverse Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2-17 Forward Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2-18 First Drive Speed and Steering Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-19 Second Drive Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2-20 Third Drive Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2-21 High/Low Range Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2-22 Up Circuit Inoperative from Platform or Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2-23 Platform will Not Lift from Platform or Base Controls with Outriggers Extended . . . . . . . . . . . . . . 85
4.2-24 Platform will Not Lift from Platform or Base Controls with Outriggers Retracted
(lift operates correctly with outriggers extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2-25 Up Circuit Inoperative from Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-26 Down Circuit Inoperative from Platform or Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2-27 No Down Function (Additional for machines with Load Sensing System) . . . . . . . . . . . . . . . . . . . 88
4.2-28 Down Circuit Inoperative from Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-29 Powered Extension Platform Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2-30 Powered Extension Platform will Not Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-31 Powered Extension Platform will Not Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-32 Hydraulic Generator Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2-33 Hydraulic Generator will Not Shut Off from Generator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-34 All Outriggers Inoperative (Auto-level and manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2-35 All Outriggers Inoperative (Auto-level and manual from platform controls) . . . . . . . . . . . . . . . . . . 92
4.2-36 All Outriggers Inoperative (base controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2-37 All Outriggers Inoperative (Auto-level)
A: Led Power Indicator Light at Outrigger Control Module (OCM1) Not on Constant . . . . . . . . . . 93
4.2-38 All Outriggers Inoperative (Auto Level)
B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing . . . . . . . . . . . . . . . . 94
4.2-39 Left Front Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-40 Right Front Outrigger Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-41 Right Rear Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.2-42 Left Rear Outriggers Inoperative Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-43 Individual Outrigger Functions Inoperative (Auto-level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-44 Auto-level Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2-45 Auto All Up Inoperative (Retract). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3-1 All Functions Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3-2 Steering Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3-3 Steer and First Drive Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3-4 Lift and Second Drive Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3-5 Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3-6 Reverse Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3-7 Forward Drive Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3-8 Brakes Do Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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 4.3-9 Brakes will Not Release (Internal Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3-10 Brake Slips (Internal Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.3-11 Brake Drags or Runs Hot (Internal Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.3-12 Up Circuit Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.3-13 Down Circuit Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3-14 Powered Extension Platform Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3-15 Hydraulic Generator Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3-16 All Outriggers Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3-17 Left Front Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3-18 Right Front Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3-19 Right Rear Outrigger Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3-20 Left Rear Outrigger Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3-21 Outriggers Drift In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Section 5 – Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.1-1 Safety and workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.2 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2-1 Adjust the gate spring hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3 Scissors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3-1 Replace and adjust the high speed cutout (LS5) and lift cutout (LS1) limit switches . . . . . . . . . 104
5.4 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.4-1 Inspect and torque the wheel bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.4-2 Install and torque the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.4-3 Front axle hub procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.5 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5-1 Hydraulic system and brake adjustment procedure (if equipped) . . . . . . . . . . . . . . . . . . . . . . . 109
5.5-2 Brake assembly and disassembly (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.5-3 Multiple disc brake assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.5-4 Holding torque testing procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.5-5 Adjust the system lift and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.5-6 Change the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.6 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.6-1 Outrigger mechanical limit switch wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.6-2 Replace and adjust the outrigger upper limit switch (LS61, LS62, LS63, LS64) . . . . . . . . . . . . . 115
5.6-3 Replace and adjust the outrigger lower limit switch (LS65, LS66, LS67, LS68) . . . . . . . . . . . . . 116
5.7 Control Modules Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.7-1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.8 EZcal Diagnostic Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.8-1 Hand held EZcal calibration and diagnostic tool key functions . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.8-2 Flash the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.8-3 Outrigger codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.8-4 Curve/group codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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5.9 Auto-leveling Outrigger PC Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.10 GP-102 (CM1) Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.10-1 Set up the GP-102 load sence controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.10-2 GP-102 Load sense controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.10-3 LED Error codes – quick reference chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.10-4 LED Error codes – code breakdown chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.10-5 Control module load calibration - code messages & definitions . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.11 GP-106 (OCM1) Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.11-1 Outrigger control module (PG-106/OCM1) instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.11-2 Auto-leveling outrigger setting and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.11-3 Auto-leveling outrigger error code breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.11-4 Set up the GP-106 outrigger controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.11-5 GP-106 Outrigger controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.12 GP-108 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.12-1 Set up the GP-108 overload/outrigger controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.12-2 GP-108 Overload/outrigger controller pin reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.12-3 GP-108 LED error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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 Notes

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Section 1 – Scheduled Maintenance
1.1 Read and Heed 1.1-5 Operator
The operator must read and completely understand
Skyjack is continuously improving and expanding
both this operating manual and the safety panel label
product features on its equipment, therefore,
located on the platform and all other warnings in this
specifications and dimensions are subject to change
manual and on the aerial platform. Compare the labels
without notice.
on the aerial platform with the labels found within this
manual. If any labels are damaged or missing, replace
1.1-1 Aerial Platform Definition them immediately.
A mobile device that has an adjustable position
platform supported from ground level by a struc- 1.1-6 Service Policy and Warranty
ture. SKYJACK warrants each new SJRT series work platform
to be free of defective parts and workmanship for the
1.1-2 Purpose of Equipment first 24 months. Any defective part will be replaced or
The SKYJACK Rough Terrain’s mid and full size aerial repaired by your local SKYJACK dealer at no charge for
platforms (MEWP) are designed to transport and raise parts or labor. Contact the SKYJACK Service Department
personnel, tools and materials to overhead work areas. for warranty statement extensions or exclusions.

1.1-3 Use of Equipment

The aerial platform is a highly maneuverable, mobile 1.1-7 Optional Accessories
work station. Lifting and driving must be on a flat, level, The SKYJACK aerial platform is designed to accept a
compacted surface. It can be driven over uneven terrain variety of optional accessories. These are listed under
only when the platform is fully lowered. the “Standard and Optional Features” Table of the
operating manual. Operating instructions for these
1.1-4 Manual options (if equipped) are located in the “Operation”
Operating Manual: The operating manual is Section of the operating manual.
considered a fundamental part of the aerial platform.
It is a very important way to communicate necessary 1. For non-standard components or systems,
safety information to users and operators. A complete contact the SKYJACK Service Department at
and legible copy of this manual must be kept in the 2.
provided weather-resistant storage compartment on
the aerial platform at all times. 3. ( : 44-1691-676-235
Service & Maintenance: The purpose of this is 4. 7 : 44-1691-676-238
to provide the customer with the servicing and 5.
maintenance procedures essential for the promotion 6. Include the model and serial number for each
of proper machine operation for its intended purpose. applicable aerial platform.
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 Inspection Schedule

1.2 Maintenance and 1.2-3 Maintenance and Service Safety

Tips
Inspection Schedule 8. Maintenance and repair should only be performed
7. The actual operating environment of the work by personnel who are trained and qualified to service
platform governs the use of the maintenance this aerial platform.
schedule. The inspection points covered in .
Maintenance and lnspection Checklist, indicates 9. All maintenance and service procedures should be
the areas of the aerial platform to be maintained or performed in a well lighted and well ventilated area.
inspected and at what intervals the maintenance and
inspections are to be performed.
10. Anyone operating or servicing this aerial platform
must read and completely understand all operating
1.2-1 Owner’s Annual Inspection Record
instructions and safety hazards in this manual and
It is the responsibility of the owner to arrange operating manual.
quarterly and annual inspections of the aerial
platform. Owner’s Annual Inspection Record. Owner’s
11. All tools, supports and lifting equipment to be
Annual lnspection Record is to be used for recording
used must be of proper rated load and in good
the date of the inspection, owner’s name, and the
working order before any service work begins. Work
person responsible for the inspection of the work
area should be kept clean and free of debris to avoid
platform..
contaminating components while servicing.

1.2-2 Replacement Parts

12. All service personnel must be familiar with
Use only original replacement parts. Parts such employer and governmental regulations that apply to
as batteries, wheels, railings, etc. with weight and servicing this type of equipment.
dimensions different from original parts will affect
stability of the aerial platform and must not be used
13. Keep sparks and flames away from all flammable
without manufacturer’s consent.
or combustible materials.
All replacement tires must be of the same size and load
rating as originally supplied tires; to maintain safety and 14. Properly dispose of all waste material such
stability of aerial platform. as lubricants, rags, and old parts according to the
relative law provisions obtaining in the country.
Consult SKYJACK’s Service Department for optional
tires specifications and installation. 15. Before attempting any repair work, turn Battery
. Disconnect Switch to the “OFF” position.

WARNING 16. Preventive maintenance is the easiest and least

expensive type of maintenance.
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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Hydraulic System & Component Maintenance and Repair Section 1 – Scheduled Maintenance

1.3 Hydraulic System & 7. All hydraulic components must be disassembled

in spotlessly clean surroundings. During
Component Maintenance disassembly, pay particular attention to
the identification of parts to assure proper
and Repair reassembly. Clean all metal parts in a clean
The following points should be kept in mind when mineral oil solvent. Be sure to thoroughly clean
working on the hydraulic system or any component: all internal passages. After the parts have been
dried thoroughly, lay them on a clean, lint-free
WARNING surface for inspection.
8. Replace all O-rings and seals when overhauling
Escaping fluid from a hydraulic pressure leak can
any component. Lubricate all parts with clean
damage your eyes, penetrate the skin and cause
hydraulic oil before reassembly. Use small
serious injury. Use proper personal preotection at
amounts of petroleum jelly to hold O-rings in
all times.
place during assembly.
1. Any structure has limits of strength and 9. Be sure to replace any lost hydraulic oil when
durability. To prevent failure of structural parts of completing the installation of the repaired
hydraulic components, relief valves which limit component, and bleed any air from the system
pressure to safe operating values are included in when required.
the hydraulic circuits. 10. All hydraulic connections must be kept tight. A
2. Tolerance of working parts in the hydraulic loose connection in a pressure line will permit
system is very close. Even small amounts of dirt the oil to leak out or air to be drawn into the
or foreign materials in the system can cause system. Air in the system can cause damage
wear or damage to components, as well as to the components and noisy or erratic system
general faulty operation of the hydraulic system. operation.
Every precaution must be taken to assure
absolute cleanliness of the hydraulic oil. 1.3-1 Maintenance Hints
3. Whenever there is a hydraulic system failure Three simple maintenance procedures have the
which gives reason to believe that there are greatest effect on the hydraulic system performance,
metal particles or foreign materials in the system, efficiency, and life. Yet, the very simplicity of them may
drain and flush the entire system and replace the be the reason they are so often overlooked. They are
filter cartridges. A complete change of oil must simply these:
be performed under these circumstances. 1. Change filters annually. The filters will need
4. Whenever the hydraulic system is drained, to be changed more often depending on the
check the magnets in the hydraulic reservoir for operating conditions. Dirty, dusty, high moisture
metal particles. If metal particles are present, environments may cause the hydraulic system
flush the entire system and add a new change to be contaminated more quickly.
of oil. The presence of metal particles also may 2. Maintain a sufficient quantity of clean hydraulic
indicate the possibility of imminent component oil of the proper type and viscosity in the
failure. A very small amount of fine particles is hydraulic reservoir.
normal.
3. Keep all connections tight.
5. All containers and funnels used in handling
hydraulic oil must be absolutely clean. Use a
funnel when necessary for filling the hydraulic
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 Hydraulic System & Component Maintenance and Repair

1.3-2 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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 Notes

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Section 1 – Scheduled Maintenance About this Section

1.4 About this Section 1.4-3 Maintenance Instructions

5. This manual consists of four schedules to be done
This section contains the maintenance and inspection
for maintaining on an aerial platform. Inspection
schedule that is to be performed.
schedule frequency is shown below:
References are made to the procedures in Section 6.
5 that outline detailed step-by-step instructions for
checks and replacements. Inspection Schedule
7. Daily A
1.4-1 Service Bulletins 8. Frequently A+B
Before performing any scheduled maintenance 9. Annually A+B+C
inspection procedure, refer to service bulletins found 10. Bi-annually A+B+C+D
on our website: www.skyjack.com for updates related ▪ Make copies of the maintenance and inspection
to service and maintenance of this MEWP. checklist to be used for each inspection.
▪ Check the schedule on the checklist for the type
1.4-2 Maintenance and Inspection of inspection to be performed.
Death or injury can result if the MEWP is not kept in ▪ Place a check in the appropriate box after each
good working order. Inspection and maintenance inspection procedure is completed.
should be performed by competent personnel who
▪ Use the maintenance and inspection checklist
are trained and qualified on maintenance of this
and step-by-step procedures in section 5 to
MEWP.
perform these inspections.
▪ If any inspection receives a fail, tag and remove
WARNING the aerial platform from service.
Failure to perform each procedure as presented ▪ If any aerial platform component(s) has been
and scheduled may cause death, serious injury or repaired, an inspection must be performed again
substantial damage. before removing the tag. Place a check in the
repair column.

NOTE Legend
Preventive maintenance is the easiest and least Pass P
expensive type of maintenance.
Fail F
4.
Unless otherwise specified, perform each Repaired R
▪
maintenance procedure with the aerial platform Not applicable N/A
in the following configuration:
▪ Aerial platform parked on a flat and level
surface
▪ Disconnect the battery by turning the main
power disconnect switch to the “OFF” position.
▪ Repair any damaged or malfunction
components before operating aerial platform.
▪ Keep records on all inspections.

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Owner’s Annual Inspection Record Section 1 – Scheduled Maintenance

Table 1.5 Owner’s Annual Inspection Record

**
2

Figure 01 This decal is located on the scissor assembly. 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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Section 1 – Scheduled Maintenance Owner’s Annual Inspection Record

Pre-Delivery/Maintenance Inspection Checklist

Vertical Mast, SJIII, & Rough Terrain

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 P - Pass

 PDI B B - Perform PDI prior to each delivery or Frequent Inspections every 3 months or 150 hrs. For further details refer to Service & Operating F - Fail
 Frequent B Manuals. R - Repaired
 Annual B+C C - Perform Scheduled Maintenance Inspections every year. For further details refer to Service & Operating Manuals. 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 skyjack.com for the latest service bulletins. B Engine Control Console. Secure & no damage. B
Ensure Annual Inspection has been completed within the Engine Air Filter. No damage or missing parts. B, C
B
last 13 months. Engine Oil. Level between "L" and "H". Ensure oil change
B
Manuals & Required Documents. In storage box, in interval has not been exceeded.
B
good condition & legible. Radiator. Secure & no damage or missing parts. Check
B, C
Labels. In place, secure & legible. B coolant level.
Limit Switches. Secured & no obstructions or damage. B Muffler and Exhaust. Secure & no damage. B
Main Power Disconnect Switch. Cables secure & in Fuel Shut-off Valve. No damage or missing parts. B
B
working order. Fuel Tank. Filler cap is secure & no damage. B
Battery/ Hydraulic Tray. Latch is secure, & no missing Fuel Leaks. Tight fittings and hoses & no damage or
B B
parts. leaks.
Battery Charger. Secure, & no damage. B Propane Tank. Straps fastened to brackets & coupler
B
Battery. No damage, tight connections, fluid levels correct. tight.
B
Clean terminals and cable ends. Propane Tank Leaks. No leaks (refer to service manual
B
Manifolds. Tight fittings and hoses & no damage or leaks. for procedure).
B, C
Tight wire connections & no missing parts. Scissor Assembly. No deformation/damage. Pins secure.
B
Motor Controller. Secure & no damage. No loose Cables & wires routed with no damage.
B
connections. Mast Assembly. No damage or deformation. Lubricated B, C
Electrical Panel / Control Module. Secure & no Mast Chains. No damage or missing parts. B, C
B
damage. Tight wire connections and fasteners. Control Cables. No damage or missing parts. B, C
Hydraulic Tank. Filler cap secure & no damage or leaks. B Rollers. Secure & no obstructions, dirt, or damage/wear. B, C
Hydraulic Oil. Level at, or slightly above top mark. B, C Wear Pads. No damage/wear or missing parts. Fasteners
B, C
Hydraulic Components & Hoses. Secure & no damage tightened.
B
or leaks. Scissor Bumpers. Secure & no damage. B
Base Weldment. No deformation or cracks. B Sliders. Secure & no obstructions, dirt, or damage/wear. B
Base Control Switches. Switches to neutral position & no Maintenance Support. Secure & no damage. B
B
damage. Lift Cylinder(s). No damage or missing parts. Tight
B
Free-wheeling Valve Knob. Secure & no damage or fittings and hoses & no leaks.
B
missing parts. Scissor Pins. No damage/wear or missing parts. B
Ladder. Secure & no damage. B Platform Control Console. Switches to neutral position &
B
AC Power to Platform (Plug Cord Receptacle). No secure. No missing parts.
B
obstructions, dirt or damage. Raillings and Gate/Chain. Secure & no damage or
B
Pothole Protection Device. Check both sides for missing parts.
B
obstructions, dirt, or damage. Lanyard Attachment Anchorage. Attachment rings
B
Brakes. Secure & no damage or leaks. B, C secure & no damage.
Steer Cylinder Assembly. Secure & no damage, leaks or AC Outlet. No obstructions, dirt, or damage. B
B
missing parts. Powered Extension Control Console. Switches to
B
Wheel/Tire Assembly. Check all tires for damage, wear neutral position & secure. No missing parts.
B
& proper alignment. Lug nuts torqued as recommended. Extension Deck. Secure & no damage or missing parts.
B
Axles. Secure & no missing parts. Tight fittings and hoses Check fluid level (if applicable).
B
& no leaks. Outriggers. No damage or missing parts. B
Tie Rod. End studs locked & no damage. B Scissor Guards. Secure & no damage. B
Tilt (Load) Sensor. Secure & no damage. B Greasing Points. No obstructions, dirt, or damage. B, C
Emergency Lowering Access Rod. Secure & no Function Tests (Refer to your corresponding Serial #'s Operating  PASS
B
damage. Manual for information on running these tests.)  FAIL
Engine Tray. No damage or missing parts. 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 skyjack.com for a printable copy of this form. 167830AC

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

5 4 1

1.6 Scheduled Maintenance areas:

• hydraulic tank filter, fittings, hoses,
Inspections emergency power unit (if equipped) and
base surfaces
Begin the scheduled maintenance inspections by
checking each item in sequence for the conditions listed • engine compartment fittings, hoses, main
in this section. pump, and filter
• all hydraulic cylinders
WARNING • all hydraulic manifolds
To avoid injury, do not operate an aerial platform • the underside of the base 1

until all malfunctions have been corrected. • ground area under the aerial platform 2

• outriggers 3
WARNING
1.6-1 Labels (B)
To avoid possible injury, ensure aerial platform
power is off during your visual and daily Refer to the labels section in this manual and determine
maintenance inspections that all labels are in place and are legible.

1.6-2 Limit Switches (B)

Electrical 4 Limit Switches (B)
Maintaining the electrical components is essential to
good performance and service life of the aerial platform. Detecting limit switch malfunction is essential to safe
Inspect the following areas for chafed, corroded aerial platform operation. Ensure limit switches are
and loose wires: properly secured with no signs of visible damage and
• base to platform cables and wiring harness movement is not obstructed.
• engine compartment electrical panel Visually inspect all limit switch located inside the
scissor arms and the outrigger assemblies for the
• engine wiring harness following:
• hydraulic/electrical wiring harnesses • broken or missing actuator arm
Hydraulic • missing fasteners
Maintaining the hydraulic components is essential to • loose wiring
good performance and service life of the aerial platform.
Perform a visual inspection around the following

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19
Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

6 9 7
10

8 11

1.6-3 Emergency Lowering Access Rod

(Model 9241) WARNING
▪ Ensure rod is properly secured and there is no Battery acid is extremely corrosive - Wear proper
visible damage. eye and facial protection as well as appropriate
protective clothing. If contact occurs, immediately
1.6-4 Electrical and Control Components flush with cold water and seek medical attention.
5 Electrical and Control Components
▪ Ensure all compartment latches are secure 1. Check battery case for damage.
and in proper working order.
2. B - Frequent Inspection
6 Main Power Disconnect Switch (B)
▪ Clean battery terminals and cable ends
▪ Turn main power disconnect switch to “ ” off thoroughly with a terminal cleaning tool or wire
position. brush.
▪ Ensure all cables are secure and switch is in 3. Ensure all battery connections are tight.
proper working condition. 4. If applicable, check battery fluid level.
7 Base Control Switches (B)
▪ B - Frequent Inspection
▪ Ensure there are no signs of visible damage If plates are not covered by at least 1/2
and all switches are in their neutral positions. in. (13 mm) of solution, add distilled or
8 Battery (B) demineralized water.
▪
5. B - Frequent Inspection
▪ Proper battery condition is essential to Replace battery if damaged or incapable of
good performance and operational safety.
Improper fluid levels or damaged cables and holding a lasting charge
connections can result in component damage
and hazardous conditions.
WARNING
Use original or manufacturer-approved parts and
components for the aerial platform.
WARNING
Explosion hazard. Keep flames and sparks away.
Do not smoke near batteries.

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20
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

9
6 10 7

8 11

▪ 9 Manifolds (B,C) ▪ Hydraulic Oil (B,C)

▪ Ensure all fittings and hoses are properly ▪ Ensure platform is fully lowered, and outriggers
tightened and there is no evidence of hydraulic retracted, and then visually inspect the sight
leakage. gauge located on the side of the hydraulic
oil tank. Check oil level against label that
▪ Ensure there are no loose wires or missing indicates minimum and maximum oil levels.
fasteners.
10 Electrical Panel (B)
▪ C - Annual Inspection
▪ Ensure panel is properly secured and there is ▪ Refer to Section 1 - Hydraulic System &
no visible damage. Component Maintenance and Repair
▪ Ensure there are no loose wires or missing
fasteners.
▪ Load/Tilt Sensor (B,C)
▪ Ensure load/tilt sensor is properly secure and
there is no visible damage.
11 Hydraulic Tank (B)
▪
▪ Ensure hydraulic filler cap is secure.
▪ Ensure tank shows no visible damage and no
evidence of hydraulic leakage.

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

1.6-5 Fuel and Hydraulic Compartment ▪ Fuel Leaks (B)

▪ Ensure all compartment latches are secure and ▪ Ensure that there no fuel leaks.
in proper working order.
▪ 1 Fuel Tank (B)
DANGER
Engine fuels are combustible. Inspect the aerial
platform in an open, well-ventilated area away
IMPORTANT
from heaters, sparks and flames. Always have an
Before using your aerial platform ensure there is approved fire extinguisher within easy reach.
enough fuel for expected use.

▪ Ensure fuel filler cap is secure.

▪ Ensure tank shows no visible damage and no ▪ Ensure fuel tank, hoses and fittings show no
evidence of fuel leakage. visible damage and no evidence of fuel leakage.

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22
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

4 3 2
1

1.6-6 Engine Compartment ▪ 4 Muffler and Exhaust (B)

1 Engine Compartment ▪ Ensure muffler and exhaust system are
properly secured, with no evidence of damage.

WARNING
▪ 5 Engine Tray (B)
Beware of hot engine components.
▪ Ensure there are no loose or missing parts and
no visible damage to the engine tray. Ensure
that both tray-securing bolts are in place.
1. Pull on the two latches to pull out engine
compartment. ▪ 6 Hydraulic Pump (B)
▪ Ensure there are no loose or missing parts and
2 Engine Control Console (B) there is no visible damage.
▪
Ensure muffler and exhaust system are ▪ Ensure all bolts are properly tightened.
▪
properly secured, with no evidence of damage ▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
leakage.
▪ 3 Radiator (B,C)
▪ Ensure radiator is secure.
▪ Ensure there are no loose or missing parts and
there is no visible damage.
▪ Check coolant level and add as needed.
▪ C - Annual Inspection
▪ For recommand coolant change, refer to
engine manual.

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

4 1 3 2

▪ Engine Oil Level (B,C) ▪ Fuel Leaks (B,C)

▪ Maintaining the engine components is ▪ Ensure there are no fuel leaks.
essential to good performance and service life
of the aerial platform.
Check oil level on dipstick DANGER
▪ Oil level should be between the “L” and “H”
Engine fuels are combustible. Inspect the aerial
marks.
platform in an open, well-ventilated area away
B - Frequent Inspection from heaters, sparks and flames. Always have an
▪ For recommand oil change, refer to engine approved fire extinguisher within easy reach.
manual

▪ Ensure fuel pump, fuel filter, hoses and fittings

▪ 7 Engine Air Filter (B,C) show no visible damage and no evidence of fuel
▪ Ensure there are no loose or missing parts and leakage.
there is no visible damage. ▪ C - Annual Inspection
B - Frequent Inspection ▪ For engine fuel filter replacement procedure,
▪ For engine air filter maintenance procedure, refer to engine manual.
refer to engine manual. 2. 2. Push in engine compartment until the two
C - Annual Inspection latches lock to base.
▪ For engine air filter replacement procedure,
refer to engine manual.

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

4
5

1.6-7 Platform Assembly ▪ 4 Platform Control Console (B)

▪ Ensure all switches and controller are returned
to neutral and are properly secured.
WARNING Ensure there are no loose or missing parts and
▪
Ensure that you maintain three points of contact to there is no visible damage.
mount/dismount platform.
.
▪ 5 Powered Extension Control Console (B)
1. Use the ladder of aerial platform to access ▪ Ensure all switches are returned to neutral and
platform. are properly secured.
2. Close the gate. ▪ 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 fasteners are securely in place. WARNING
▪ Ensure all railings 2 are properly positioned Ensure that you maintain three points of contact to
and secured. mount/dismount platform.
▪ Ensure gate is in good working order.
▪ 3 Lanyard Attachment Anchorage (B) 3. Use the ladder to dismount from platform.
▪ Ensure attachment rings are secure and have ▪ 6 Powered Extension Deck (B)
no visible damage. ▪ Ensure assembly is securely attached to the
▪ AC Outlet on Platform (B) bottom of the platform.
▪ Ensure outlet has no visible damage and free ▪ Ensure there are no loose or missing parts and
from dirt or obstructions. there is no visible damage or leaks.

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

1 3

1.6-8 Lifting Mechanism ▪ 4 Scissor Bumpers (B)

▪ Ensure bumpers are secure and shows no
Scissor Guards sign of visible damage.
▪ Ensure there are no loose or missing parts and ▪ Scissor Pin Inspection (B)
there is no visible damage. ▪ Complete a structural inspection of the scissor
▪ 1 Sliders (B) pin connections, looking for indicators of pin
and/or scissor arm damage. These indicators
▪ Ensure sliders are secure and there is no include, but are not limited to:
visible damage.
▪ Ensure sliders’ path of travel are free from dirt ▪ Noise coming from binding/seized pins
and obstructions. ▪ Rust forming near pin joint
1. Raise the platform until there is adequate ▪ Cracks in welds or in surrounding metal
clearance to swing down the maintenance ▪ Evidence of metal dust or shavings from
support. wearing components
2 Maintenance Support (B)
▪ ▪ Broken/missing pin retainer bolts
▪ Ensure maintenance support is properly ▪ Broken/missing pin retainers
secured and shows no visible damage.
▪ 3 Scissor Assembly (B)
▪ Rotated pin
▪ Ensure scissor assembly shows no visible
▪ Elongation/enlargement of pin hole
damage and no signs of deformation in
weldments.
▪ Ensure all pins are properly secured.
▪ Ensure cables and wires are properly routed
and shows no signs of wear and/or physical
damage.

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Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

1 3

Examples of pivot pin connections with no

damage:

▪ No rust Pin retainer bolts

Pin has not rotated
in place
▪
▪ Area is clear of dust/metal shavings
▪ Pin retainer/retainer bolts are in place

Center pin pivot - Outer

Pin retainer in place

Center pin pivot - Middle

No rust. Pin has

not rotated.
Area is clean
of dust/metal
shavings

Center pin pivot - Inner

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Section 1 – Scheduled Maintenance Scheduled Maintenance Inspections

1 3

Examples of damaged pin connections:

▪ 5 Lift Cylinder(s) (B)

Broken retain- ▪ Ensure each lift cylinder is properly secured,

there are no loose or missing parts and there
er bolt
is no evidence of damage.
▪ Ensure all fittings and hoses are properly
tightened and there is no evidence of hydraulic
Rust is evident leakage.
around 2. Raise the platform until there is adequate
pin clearance to swing up the maintenance
support into storage bracket.
Retainer bolt hole out of line
indicates pin has rotated 3. Fully lower the platform.

Rust around pin

boss

Thrust washer

Pin boss is broken

out of the scissor
arm
Stress cracks

WARNING
Any units showing the above listed and/or
depicted signs of damage should be immediately
removed from service and repaired by a qualified
technician.

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28
Scheduled Maintenance Inspections Section 1 – Scheduled Maintenance

4 2

1.6-9 Base ▪ 4 Steer Cylinder Assembly (B)

▪ Ensure steer cylinder assembly is properly
▪ 1 Base Weldment (B) secured, there are no loose or missing parts,
▪ Ensure there are no visible cracks in welds all fittings and hoses are properly tightened
or structure and there are no signs of and there is no evidence of hydraulic leakage.
deformation. ▪ 5 Tie Rod (B)

▪ 2 Wheel/Tire Assembly (B) ▪ Ensure there are no loose or missing parts,

The aerial platform is equipped with foam- tie rod end studs are locked and there is no
filled tires. Tire and/or wheel failure could visible damage.
result in an aerial platform tipover. Component ▪ 6 Ladder (B)

damage may also result if problems are not ▪ Ensure there are no loose or missing parts and
discovered and repaired in a timely fashion. there is no visible damage.
▪ Check all tire treads and sidewalls for cuts, 7 Outriggers (If Equipped) (B)
cracks, punctures and unusual wear. ▪
▪ Check each wheel for damage and cracked ▪ Ensure there are no loose or missing parts and
there is no visible damage.
welds.
▪ Check each lug nut for proper torque to ensure 1.6-10 Manuals
none are loose.
Ensure a copy of the operating manual, and
other important documents are enclosed in
Refer to refer to 2.4 Tire Specifications for wheel/ manual storage box.
tire specifications.

▪ 3 Axles (B)
▪ Check to be sure manual storage box is
present and in good condition.
▪ Ensure axles are properly secured, there Ensure manuals are legible and in good
are no loose or missing parts, all fittings and
▪
condition.
hoses are properly tightened and there is no
evidence of hydraulic leakage. ▪ Always return manuals to the manual storage
box after use.

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 Notes

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Section 2 – Maintenance Tables and
Diagrams

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31
Section 2 – Maintenance Tables and Diagrams Specifications and Features

2.1 Specifications and Features

MODEL 8831 8841 9241 9250

Weight* 5684 kg 6173 kg 6718 kg 7407 kg
Overall Width 2.2 m 2.34 m
Overall Length 3.7 m 4.55 m
Platform Size (inside) 1.7 m x 3.5 m 1.85 m x 4.39 m
Height
Working Height 11.4m 14.5 m 14.5 m 17.2 m
Platform Elevated Height 9.6 m 12.5 m 12.5 m 15.2 m
Stowed Platform Height 1.5 m 1.8 m 1.68 m 2m
Drive Height Full 9.1m
Standard Operating Times
Lift Time (Rated Load) 52 s 56 s 62 s 64 s
Lower Time (Rated Load) 47 s 53 s 59 s 86 s
Chassis
Normal Drive Speed 4.2 km/h 3.8 km/h
Elevated Drive Speed 0.35 km/h 0.72 km/h
Gradeability (Ramp Angle) 30% 25%
Tires (Solid Rubber) Refer to Table 4.6 for tire specification and usage.
Hydraulic Oil
Type ATF Dexron III
Tank Capacity (Liters) 75.71 67.38
Engine (RPM)
Engine Type Kubota D1305
RPM Settings 1400 (Low) / 2800 (High)
Fuel Type Diesel
Fuel Tank Capacity (Liters) 49.21 64.35
Engine Oil Type SAE 10W-30
Recommended Alternative Engine Oil 10W-30, API Service Designation CG-4, CF-4, CF, CD, SH
Engine Oil Capacity (Liters) 6
Coolant Type Anti-freeze / Water
Coolant Capacity (Liters) 4
Sound Pressure Level (ISO 3744) 67dB(A)
Guaranteed MaximumSound Power
103dB
Level (ISO 4871)
* Weights are approximate; refer to serial nameplate for specific weight. Values shown for models 8831, 8841 are 1638
for standard 4WD aerial platforms on foam filled tires and two rollout extension platforms. Values shown for models
9241 & 9250 are for standard 4WD on foam tires with two powered extension platforms.

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Maximum Platform Capacities (Evenly Distributed) Section 2 – Maintenance Tables and Diagrams

2.2 Maximum Platform Capacities (Evenly Distributed)

Total First Extension Second Extension Tilt

Maxi- Maxi- Tilt
Cutout
mum mum Cutout
Model Side Wind Setting
Setting
Number of Number of Number of (Outriggers)
Capacity Capacity Capacity Force Speed (Degrees)
Occupants Occupants Occupants (Degrees)

Two
8831

Extension 681kg 5 227kg 2 227kg 2 400N 12.5 m/s 2.5x4.5 1.5x1.5

Platform
Two
8841

Extension 681kg 5 227kg 2 227kg 2 400N 12.5 m/s 2.5x4.5 1.5x1.5

Platform
Two
9241

Extension 681kg 5 227kg 2 227kg 2 400N 12.5 m/s 2.5x4.5 1.5x1.5

Platform
Two
9250

Extension 681kg 5 227kg 2 227kg 2 400N 12.5 m/s 2.5x4.5 1.5x1.5

Platform
1639AA
NOTE
Occupants and materials are not to exceed rated load.
Capacities listed are for standard machines equipped with #6 tires
Refer to capacity label at sides of platform for additional information and for models
equipped with options.

WARNING
Maximum Wind Speed = 12.5 m/sec

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Section 2 – Maintenance Tables and Diagrams Floor Loading Pressure

2.3 Floor Loading Pressure

First Extension
Total Aerial Platform
Model Weight
WHEEL LCP ** OUP **

kg kg kPa kg/m2
min* 5536 2214 1254 719
8831
max* 6788 2715 1399 882
8831 min* 5831 2333 451 690
Outrigger Pads max* 6788 2715 525 804
min* 6174 2448 1312 795
8841
max* 7145 2858 1455 928
8841 min* 6174 2566 496 759
Outrigger Pads max* 7145 2858 553 846
min* 6718 2687 1408 887
9241
max* 7448 2979 1495 893
9241 min* 6718 2687 520 700
Outrigger Pads max* 7448 2979 577 705
min* 7407 2963 1490 969
9250
max* 8137 3255 1576 975
9250 min* 7407 2963 573 765
Outrigger Pads max* 8137 3255 630 770
* 1636AA
min - Total aerial platform weight with no options
max - Aerial platform weight + all options + capacity
**
LCP - Locally Concentrated Pressure is a measure of how hard the aerial platform presses on the areas in direct contact
with the floor. The floor covering (tile, carpet, etc.) must be able to withstand more that the indicated values above.
OUP - Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface directly
underneath it. The structure of the operating surface (beams, etc.) must be able to withstand more than the indicated values
above.

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

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Floor Loading Pressure Section 2 – Maintenance Tables and Diagrams

Floor Loading Pressure

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

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

2
πD
or = (for outriggers)
4
Weight of Aerial Platform + Capacity Weight of Aerial Platform + Capacity*
LCP = 0.4 x OUP =
Foot Print Area Base Area

Length

Width
Width

Length

Width

Diameter (D)

Length

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Section 2 – Maintenance Tables and Diagrams Tire Specifications

2.4 Tire Specifications

WARNING
Tires must be checked by end user on a daily basis. Do not intermix tires of different
types on one aerial platform. Use only tires of type originally supplied.

Full-Size
Tire Size
Fill Ply Pressure (Factory)

8831

8841

9241

9250
Type Rating (KPa)

10-16.5
#6F 10 N/A S S S s
CARLISLE US LOADER
Foam
10-16.5 OTR OUTRIGGER
#6F 10 N/A O O O O
(Non-Marking)
*Usage: (S)tandard OR (O)ptional 1641
(N/A) Not Available

Backspace A

Rim Backspace Diagram Inboard Outboard

SECTION A-A A

Backspace
Tire Size
8831 8841 9241 9250
#6F 121mm 121mm 95mm 95mm
1642

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

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36
Rough Terrain Scissor Fluids Section 2 – Maintenance Tables and Diagrams

2.5 Rough Terrain Scissor Fluids

Gear Oil and Additive

Component Type Capacity (Liters) Capacity (US gal) Oil Type
Axle (Front/Rear) 2.4 0.634
Gear Oil, 80W-90 GL5
Center Drive 0.8 0.21
Axle (Front) 0.12 0.032 Friction Modifier, DANA 816289Ch
Hydraulic Oil
Model Capacity (Liters) Capacity (US gal) Oil Type
SJ71XXRT 80.5 21.26 ATF Dexron III
SJ88X1RT 75.7 20.00 ATF Dexron III
SJ92XXRT 67.4 17.80 Shell Naturelle HF-E 32 (biodegradable)
Engine Oil
Recommended
Engine Type Capacity (Liters) Capacity (US gal) Engine Oil Type
Equivalent Oil
Kubota D1105 3.1 0.818 10W-30 - API Ser-
Kubota D1305 3.1 0.818 vice Designation
CG-4,
Kubota D972 3.4 0.898 SAE 10W-30 CF-4, CD, SH
10W-30 - API Ser-
GM 1.6L 3.7 0.977 vice Designation
SF/CC
Engine Coolant
Engine Type Capacity (Liters) Capacity (US gal) Coolant Type
Kubota D1105 5.1 1.346 50/50 mix of Anti-freeze / Distilled Water
Kubota D1305 5.1 1.346 Anti-freeze 50/50 Premix
Kubota D972 3.5 0.924 Anti-freeze 50/50 Premix
50/50 mix of Extended Life Anti-freeze /
GM 1.6L 6 1.584
Distilled Water
Engine Fuel
Kubota D1105/ Kubota D972 / GM
Engine Type Capacity (Liters) Capacity (US gal)
D1305 1.6 L
SJ71XXRT 80.48 21.26 Diesel Unleaded Gasoline
SJ88X1RT 49.21 13 Diesel Unleaded Gasoline
SJ92XXRT 64.35 17 Diesel Unleaded Gasoline
1622AA

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Section 2 – Maintenance Tables and Diagrams Torque Specifications

2.6 Torque Specifications

CARTRIDGE

Size
Torque
8 38 58 10 12 16
Lb-ft (max) 20 25 35 50
Lb-in (max) 240 300 420 600
Nm (max) 27.12 33.9 47.46 67.8
COILS
Size
Torque
All coils
Lb-ftt (max) 4 to 5
Lb-in (max) 48 to 60
Nm (max) 5.42 to 6.78
SAE PLUGS
Size
Torque
2 4 5 6 8 10 12 16
Lb-ft (max) 3 10 15 25 30 35
Lb-in (max) 36 120 180 300 360 420
Nm (max) 4.07 13.56 20.34 33.9 40.68 47.46
BOLTS
Type of Bolt Torque (ft-lb) Torque (Nm)
Directional valve m ounting bolts 2.33 (28-32 in-lb) 3.16 - 3.61
Wheel mounting bolts 140 189.8
Center drive sprocket mounting bolts 110 - 115 (242 Loctite) 149 -156
Hydraulic drive motor mounting
120 (242 Loctite) 162
bolts
Positive battery post cable/fuse nut 7.5 (90 in-lb) 10.2
Newton-meter = Nm Foot-Pound Force = ft-lb Inch-Pound Force = in-lb
1623AA

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Torque Specifications Section 3 – System Component Identification and Schematics

Section 3 – System Component

Identification and Schematics

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Section 3 – System Component Identification and Schematics Electrical Symbol Chart

Table 3.1 Electrical Symbol Chart

ANGLE
WIRE CROSSING HOURMETER KEY SWITCH
TRANSDUCER

WIRES JOINED LIGHT FOOT SWITCH PRESSURE

TRANSDUCER

HYDRAULIC LIMIT SWITCH

BATTERY TOGGLE SWITCH
VALVE COIL N.O.

PROPORTIONAL LIMIT SWITCH

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

LIMIT SWITCH
ELECTRIC
FUSE ROTARY SWITCH N.C.
MOTOR

CIRCUIT LIMIT SWITCH

HORN LIMIT SWITCH
BREAKER N.C. HELD OPEN

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

PROXIMITY
CAPACITOR RESISTOR TILT SWITCH
SWITCH

SINGLE POLE
PNP
POTENTIOMETER LEVEL SENSOR SINGLE THROWN
TRANSISTOR
RELAY

SINGLE POLE DOUBLE POLE DOUBLE POLE

DOUBLE THROW NPN
DOUBLE THROW SINGLE THROW
RELAY TRANSISTOR
RELAY RELAY

TRIPLE POLE PRESSURE/

DOUBLE THROW DIODE TRANSISTOR VACUUM
RELAY SWITCH

TEMPERATURE
SWITCH

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Hydraulic Symbol Chart Section 3 – System Component Identification and Schematics

Table 3.2 Hydraulic Symbol Chart

VARIABLE
LINE CROSSING DISPLACEMENT SHUTTLE VALV VELOCITY FUSE
PUMP

ACCUMULATOR, SINGLE ACTING

LINE JOINED HAND PUMP GAS CHARGED CYLINDER

HYDRAULIC CUSHION DOUBLE ACTING

TANK RELIEF VALVE CYLINDER CYLINDER

HYDRAULIC PRESSURE DOUBLE ACTING

FILTER WITH REDUCING PRESSURE
DOUBLE
BYPASS VALVE SWITCH
RODDED

ELECTRIC MOTION SPRING APPLIED

MOTOR FIXED ORIFICE CONTROL VALVE HYDRAULIC
RELEASED
BRAKE

ADJUSTABLE FLOW DIVIDER BRAKE

ENGINE FLOW CONTROL COMBINER CYLINDER

FIXED
DISPLACEMENT COUNTER ROTARY
CHECK VALVE BALANCE VALVE ACTUATOR
PUMP

THREE POSITION BI DIRECTIONAL

FOUR WAY HYDRAULIC
OIL COOLER VALVE COIL
PROPORTIONAL MOTOR

SERIES TWO POSITION THREE POSITION

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

TWO POSITION THREE POSITION THREE POSITION

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

VARIABLE
PRESSURE PILOT LINES Dashed DISPLACEMENT
MAIN LINES Solid
TRANSDUCER HYDRAULIC MOTOR

QUICK
SERVO DISCONNECT

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Section 3 – System Component Identification and Schematics Hydraulic Component Parts List

3.3 Hydraulic Component Parts List

Index Skyjack
Description
No. Part No.
2H-13A 103655 VALVE, Control (Lowering)
2H-13A-1 107269 VALVE, Control (Holding) (Model 9241)
103655 VALVE, Control (Holding) (Model 9250)
2H-13A-2 107269 VALVE, Control (Holding) (Model 9241)
103655 VALVE, Control (Holding) (Model 9250)
2H-13A-3 103655 VALVE, Control (Holding) (Model 9250)
2H-13A-4 103655 VALVE, Control (Holding) (Model 9250)
2H-14B 103655 VALVE, Control (Lift)
2H-17A 114365 VALVE, Control (Large pump dump)
2H-17B 103655 VALVE, Control (Outrigger holding)
2H-18A 103656 VALVE, Control (Small pump dump)
2H-25 102626 VALVE, Control (Quick brake)
2H-30A 112218 VALVE, Control (Free-wheeling)
2H-30A-1 103656 VALVE, Control (Brake dump)
2H-30A-2 103655 VALVE, Control (Brake feed)
2H-86C 104412 VALVE, Control (Hydraulic generator option)
2H-98-1 103655 VALVE, Control (Auxiliary lowering) (Model 9250)
2H-98-2 103655 VALVE, Control (Auxiliary lowering) (Model 9250)
2H-98-3 103655 VALVE, Control (Auxiliary lowering) (Model 9250)
2H-98-4 103655 VALVE, Control (Auxiliary lowering) (Model 9250)
3H-20A 103623 VALVE, Control (Series/Parallel)
4H-15B 139256 VALVE, Control (Reverse drive) (includes 4H-16B)
4H-16B - VALVE, Control (Forward drive)
4H-23A 153336 VALVE, Control (Right steer) (includes 4H-24A)
4H-24A - VALVE, Control (Left steer)
4H-26 153336 VALVE, Control (Front powered extension platform extend) (includes 4H-27)
4H-27 - VALVE, Control (Front powered extension platform retract)
4H-26A 153336 VALVE, Control (Rear powered extension platform extend) (includes 4H-27A)
4H-27A - VALVE, Control (Rear powered extension platform retract)
4H-71 153336 VALVE, Control (Left front outrigger retract) (includes 4H-75)
4H-72 153336 VALVE, Control (Right front outrigger retract) (includes 4H-76)
4H-73 153336 VALVE, Control (Right rear outrigger retract) (includes 4H-77)
4H-74 153336 VALVE, Control (Left rear outrigger retract) (includes 4H-78)
4H-75 - VALVE, Control (Left front outrigger extend)
4H-76 - VALVE, Control (Right front outrigger extend)
4H-77 - VALVE, Control (Right rear outrigger extend)
4H-78 - VALVE, Control (Left rear outrigger extend)
BP1 133441 BRAKE PACK
C1 120349 CYLINDER (Lift) (Model 9241)
120353 CYLINDER (Lift) (Model 9250)
C2 120349 CYLINDER (Lift) (Model 9241)
120353 CYLINDER (Lift) (Model 9250)
C3 120353 CYLINDER (Lift) (Model 9250)
C4 120353 CYLINDER (Lift) (Model 9250)
C5 120422 CYLINDER (Brake)
C6 120422 CYLINDER (Brake)

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Hydraulic Component Parts List Section 3 – System Component Identification and Schematics

Index Skyjack
Description
No. Part No.
C7 133474 CYLINDER (Steer)
C8 107752 CYLINDER (Cushion)
C9 132694 CYLINDER (Left front outrigger)
C10 132694 CYLINDER (Right front outrigger)
C11 132694 CYLINDER (Right rear outrigger)
C12 132694 CYLINDER (Left rear outrigger)
C13 120255 CYLINDER (Front powered platform)
C14 120255 CYLINDER (Rear powered platform)
CBV1 132249 VALVE, Counterbalance (Motion control)
(for 9241 serial number 55000049 and below)
CBV2 132249 VALVE, Counterbalance (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
CBV2 158530 VALVE, Counterbalance (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
CV1 104624 VALVE, Check (Small pump)
CV2 104624 VALVE, Check (Large pump)
CV3 104624 VALVE, Check (Lift)
CV4 104415 VALVE, Check (Left front outrigger)
CV5 104415 VALVE, Check (Right front outrigger)
CV6 104415 VALVE, Check (Right rear outrigger)
CV7 104415 VALVE, Check (Left rear outrigger)
CV11 132248 VALVE, Check (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
CV11 158531 VALVE, Check (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
CV12 132248 VALVE, Check (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
CV12 158531 VALVE, Check (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
CV13 132248 VALVE, Check (Motion control)
CV14 132248 VALVE, Check (Motion control)
DCMI 300248 DC MOTOR, 12 Volt
F1 109568 RETURN FILTER ASSEMBLY
104254 • ELEMENT, Filter
GM1 113875 GENERATOR MOTOR, Hydraulic (option)
HP2 110652 HAND PUMP, Brake release
M1 109311 MOTOR, Center drive hydraulic
MB1 114178 BLOCK, Manifold (Main)
MB2 103137 BLOCK, Manifold (Emergency lowering)

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Section 3 – System Component Identification and Schematics Hydraulic Component Parts List

Index Skyjack
Description
No. Part No.

MB3 130443 BLOCK, Manifold (Holding valve) (Model 9241)

130444 BLOCK, Manifold (Holding valve) (Model 9250)
MB4 106688 BLOCK, Manifold (Holding valve) (Model 9241)
118345 BLOCK, Manifold (Holding valve) (Model 9250)
MB5 118345 BLOCK, Manifold (Holding valve) (Model 9250)
MB6 118345 BLOCK, Manifold (Holding valve) (Model 9250)
MB7 125430 BLOCK, Manifold (Lift line)
MB8 125430 BLOCK, Manifold (Lift line) (Model 9250)
MB9 113494 BLOCK, Manifold (Controlled lowering)
MB10 111943 BLOCK, Manifold (Disc brake)
MB11 111970 BLOCK, Manifold (Outrigger)
MB12 103137 BLOCK, Manifold (Hydraulic generator option)
MB13 111291 BLOCK, Manifold (Front powered platform)
MB14 111291 BLOCK, Manifold (Rear powered platform)
MB15 103615 BLOCK, Manifold (Free-wheeling valve)
MB16 132261 BLOCK, Manifold (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
MB16 158529 BLOCK, Manifold (Motion control)
(for 9241 serial number 55000049 and below)
(for 9250 serial number 50000874 and below)
MC1 132244 MOTION CONTROL ASSEMBLY
O1 131927 ORIFICE (.096 diameter) (Main) (Model 9250)
O2 105501 ORIFICE (0.094 diameter) (Lift cylinder)
O5 108721 ORIFICE (0.055 diameter) (Controlled lowering)
O7 125244 ORIFICE (0.120 diameter) (Lift line) (Model 9241)

OC1 114284 OIL COOLER (option)

P1 110460 PUMP, Hydraulic dual (0.488/0.854)
P3 113173 PUMP, Powered platform
PT1 134432 TRANSDUCER, Pressure
QD1 122419 QUICK DISCONNECT (System pressure)
R1 104534 VALVE, Relief (System)
R2 104534 VALVE, Relief (Lift)
R3 106557 VALVE, Relief (Cylinder) (Model 9241)
104534 VALVE, Relief (Cylinder) (Model 9250)
R4 106557 VALVE, Relief (Cylinder) (Model 9241)
104534 VALVE, Relief (Cylinder) (Model 9250)
R5 104534 VALVE, Relief (Cylinder) (Model 9250)
R6 104534 VALVE, Relief (Cylinder) (Model 9250)
R8 113286 VALVE, Relief (Set at 500psi) (Powered platform)
V1 107271 VALVE, Emergency lowering
V2 113556 VALVE, Controlled lowering
V6 113752 VALVE, Brake release (Auto reset)

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

3.4 Electrical Component Parts List

RELAY DIAGRAM

COMMON

COIL COIL
CONTROL CONTROL
(B+) (B-)
12 VOLT
RELAY
(SPDT)
SINGLE
POLE
DOUBLE
THROW

NORMALLY
CLOSED
CONTACT

NORMALLY
OPEN
CONTACT

COMMON

COIL COIL
CONTROL CONTROL
(B+) (B-)
12 VOLT
RELAY
(DPDT)
DOUBLE
POLE
DOUBLE
THROW

NORMALLY NORMALLY
CLOSED CLOSED
CONTACT CONTACT

NORMALLY
OPEN
CONTACT

SJ9241 RT, SJ9250 RT 157958AFA

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

Index Skyjack
Description
No. Part No.
1TD 103207 RELAY, 12 Volt DPDT (Drive time delay)
2D37 147131 SOLENOID, Stop (Diesel Engines)
9CR2 127131 RELAY, 12 Volt (Outrigger enable)
9CR3 127131 RELAY, 12 Volt (Outrigger enable proof)
9BCR 111787 CONTACTOR, 12 Volt (powered extension platform option)
10ACR1 103207 RELAY, 12 Volt DPDT (Engine protection relay)
10ACR2 127035 RELAY, 12 Volt DPDT (Hydraulic generator/oil cooler)
10BCR1 103207 RELAY, 12 Volt DPDT (Engine on)
12BCR 127035 RELAY, 12 Volt SPDT (Controller enable)
13DCR 103316 RELAY, 12 Volt SPDT (Down)
14DCR 103316 RELAY, 12 Volt SPDT (Up)
15CR 103316 RELAY, 12 Volt SPDT (Reverse Drive)
16CR 103316 RELAY, 12 Volt SPDT (Forward Drive)
17CR 103316 RELAY, 12 Volt SPDT (2nd speed/large pump)
17ACR 103316 RELAY, 12 Volt SPDT (Small pump)
17DCR 127131 RELAY, 12 Volt SPDT (Outrigger trigger)
18CR 103316 RELAY, 12 Volt SPDT (3rd speed)
20CR 103316 RELAY, 12 Volt SPDT (Series/Parallel drive)
23CR 103316 RELAY, 12 Volt SPDT (Right steer)
24CR 103316 RELAY, 12 Volt SPDT (Left steer)
28CR1 103207 RELAY, 12 Volt DPDT (Tilt switch)
28CR2 103316 RELAY, 12 Volt SPDT (Down Enable)
28ECR1 103207 RELAY, 12 Volt DPDT (Auxiliary tilt)
28ECR2 103316 RELAY, 12 Volt SPDT (Auxiliary down enable)
30CR 103316 RELAY, 12 Volt SPDT (Brake)
31CR 103316 RELAY, 12 Volt SPDT (Choke/Glow plug)
31ACR 127035 RELAY, 12 Volt SPDT (Kubota diesel engine glow plug)
32CR 103207 RELAY, 12 Volt DPDT (Engine Start (DPDT)
32ACR 147125 SOLENOID, Engine starter (Kubota diesel)
34BCR 103316 RELAY, 12 Volt SPDT (Low/High throttle)
35CR 103207 RELAY, 12 Volt DPDT (Tilt override)
49CR 103316 RELAY, 12 Volt SPDT (Horn)
61CR 127131 RELAY, 12 Volt SPDT (Outrigger drive enable)
65CR 127131 RELAY, 12 Volt SPDT (Outrigger lift enable)
86ACR 103316 RELAY, 12 Volt SPDT (hydraulic generator)
86BCR 103207 RELAY, 12 Volt DPDT (hydraulic generator stop)
97ACR-1 103207 RELAY, 12 Volt DPDT (Powered extension platform)
97ACR-2 111787 RELAY, 12 Volt SPDT (Powered extension platform)
99CR 300242 SOLENOID, 12 Volt motor (Powered extension platform)
2002CR 143805 RELAY, 12 Volt (20A/35A) (Power unit)
2H-13A 103613 COIL, 12 Volt (Lowering valve)

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

Index Skyjack
Description
No. Part No.
2H-13A-2 104410 COIL, 12 Volt (Lift cylinder holding valve)
2H-13A-3 104410 COIL, 12 Volt (Lift cylinder holding valve)
2H-13A-4 104410 COIL, 12 Volt (Lift cylinder holding valve)
2H-13A-5 104410 COIL, 12 Volt (Lift cylinder holding valve)
2H-14B 103613 COIL, 12 Volt (Lift valve)
2H-17A 106272 COIL, 12 Volt (Large pump dump valve)
2H-17B 103613 COIL, 12 Volt (Outrigger holding valve)
2H-18A 103613 COIL, 12 Volt (Small pump dump valve)
2H-25 103613 COIL, 12 Volt (Brake valve)
2H-30A 103613 COIL, 12 Volt (Free-wheeling valve)
2H-30A-1 103613 COIL, 12 Volt (Brake dump valve)
2H-30A-2 103613 COIL, 12 Volt (Brake feed valve)
2H-86C 106272 COIL, 12 Volt (Hydraulic generator valve)
2H-98-1 104410 COIL, 12 Volt (Auxiliary holding valve)
2H-98-2 104410 COIL, 12 Volt (Auxiliary holding valve)
2H-98-3 104410 COIL, 12 Volt (Auxiliary holding valve)
2H-98-4 104410 COIL, 12 Volt (Auxiliary holding valve)
3H-20A 103613 COIL, 12 Volt (Series/Parallel drive valve)
4H-15B 128321 COIL, 12 Volt (Reverse drive valve)
4H-16B 128321 COIL, 12 Volt (Forward drive valve)
4H-23A 153337 COIL, 12 Volt (Right steer valve)
4H-24A 153337 COIL, 12 Volt (Left steer valve)
4H-26 153337 COIL, 12 Volt (Front powered extension platform extend valve)
4H-27 153337 COIL, 12 Volt (Front powered extension platform retract valve)
4H-26A 153337 COIL, 12 Volt (Rear powered extension platform extend valve)
4H-27A 153337 COIL, 12 Volt (Rear powered extension platform retract valve)
4H-71 153337 COIL, 12 Volt (Left front outrigger retract)
4H-72 153337 COIL, 12 Volt (Right front outrigger retract)
4H-73 153337 COIL, 12 Volt (Right rear outrigger retract)
4H-74 153337 COIL, 12 Volt (Left rear outrigger retract)
4H-75 153337 COIL, 12 Volt (Left front outrigger extend)
4H-76 153337 COIL, 12 Volt (Right front outrigger extend)
4H-77 153337 COIL, 12 Volt (Right rear outrigger extend)
4H-78 153337 COIL, 12 Volt (Left rear outrigger extend)
AT1 130440 TRANSDUCER, Angle
B1 103295 BATTERY, 12 Volt
B2 108789 BATTERY, 12 Volt (Auxiliary)
BP-29 117967 BEEPER (XL-600 9-28 VDC)
CAP1 103319 CAPACITOR, 50 Volt (1000MFD)
CAP2 103319 CAPACITOR, 50 Volt (1000MFD)
CB1 117326 BREAKER, Circuit (20 Amp)
CB3 117326 BREAKER, Circuit (20 Amp)
CB4 117325 BREAKER, Circuit (15 Amp) (Hydraulic generator option)
CM1 130439 MODULE, Load sensing control

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47
Section 3 – System Component Identification and Schematics Electrical Component Parts List

Index Skyjack
Qty. Description
No. Part No.
CRD1 115283 1 CABLE ASSEMBLY (Platform)
CRD2 115280 1 CABLE ASSEMBLY (Scissor) (Model 9250)
148300 1 CABLE ASSEMBLY (Scissor) (Model 9241)
CRD3 134417 1 CABLE ASSEMBLY (Electrical panel)
DA2 129434 1 DIODE ASSEMBLY (D30A)
DA4 129284 1 DIODE ASSEMBLY (D10E)
DA5 134304 1 DIODE ASSEMBLY (D20A)
DA6 127685 1 DIODE ASSEMBLY (D86C-1) (Hydraulic generator option)
DA7 127926 1 DIODE ASSEMBLY (D86C-2) (Hydraulic generator option)
DA8 129303 1 DIODE ASSEMBLY (D14B-2) (Hydraulic generator option)
DA9 132807 1 DIODE ASSEMBLY (D17A, D18A)
DA11 105657 1 DIODE ASSEMBLY (D15A-2, D16A-2)
DA13 134305 1 DIODE ASSEMBLY (D15A-1, D16A-1, D23A, D24A)
D02-XX 700166 AR DIODE, Small
DXX 102921 AR DIODE, Common
DCM1 300248 1 MOTOR, 12 Volt (Powered extension platform)
EGP1 KUBOTA 1 GLOW PLUG, Engine (Diesel fuel engine)
F2 111282 1 FUSE (100 Amp) (Powered extension platform)
F4 119469 1 FUSE (200 Amp) (Inverter Option)
F5 120658 1 FUSE (10 Amp) (Powered extension platform)
FAN 115384 1 FAN, Oil cooler
FL-22 126677 1 FLASHING LIGHT, 12 Volt
FL-29 103743 1 FLASHER
G 137138 1 ALTERNATOR (Diesel fuel engine)
GPL1 132884 1 LIGHT, Glow Plug Indicator (Diesel fuel engine)
GPT1 132883 1 TIMER, Glow Plug (Diesel fuel engine)
H1 146652 1 HORN, 12 Volt
HTS-34A 106370 1 SOLENOID, High throttle (Diesel fuel engine)
INV1 124047 1 INVERTER, 1500 Watt (110/220V)
LED1 147229 1 POWER INDICATOR LIGHT (Platform control console)
LED2 147229 1 POWER INDICATOR LIGHT (Base control console)
LED3 147229 1 POWER INDICATOR LIGHT (Platform control console)
LS1 119375 1 LIMIT SWITCH (26 Feet lift cut-out)
LS4 115658 1 LIMIT SWITCH (End-of-stroke)
LS5 119296 1 LIMIT SWITCH (Elevation/High speed cut-out)
LS61 115658 1 LIMIT SWITCH (Left front outrigger extend)
LS62 115658 1 LIMIT SWITCH (Right front outrigger extend)
LS63 115658 1 LIMIT SWITCH (Right rear outrigger extend)
LS64 115658 1 LIMIT SWITCH (Left rear outrigger extend)
LS65 115658 1 LIMIT SWITCH (Left front outrigger retract)
LS66 115658 1 LIMIT SWITCH (Right front outrigger retract)
LS67 115658 1 LIMIT SWITCH (Right rear outrigger retract)
LS68 115658 1 LIMIT SWITCH (Left rear outrigger retract)
M 147125 1 MOTOR, Engine starter (Diesel fuel engine)
OCM1 132804 1 MODULE, Auto-level control (Outrigger)

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

Index Skyjack
Qty. Description
No. Part No.
OPS1 102838 1 SWITCH, Oil pressure (Diesel fuel engine)
PT1 134432 1 TRANSDUCER, Pressure
RL-22 107098 1 LIGHT, Rotating amber beacon
RST2 108788 1 RESISTOR (3 Ohm/100W)
S1 119726 1 SWITCH, Main power disconnect
S2 147054 2 N.O. CONTACT (Base - up/off/down switch)
S3 147054 1 N.O. CONTACT (Platform - off/lift/drive select key switch)
147053 2 N.C. CONTACT (Platform - off/lift/drive select key switch)
S4 147053 2 N.C. CONTACT, Emergency stop switch (Platform)
S5 147054 2 N.O. CONTACT, Up/Down switch (Platform)
S6 147053 1 N.C. CONTACT, Emergency stop switch (Base control console)
S7 132537 1 DRIVE/STEER CONTROLLER ASSEMBLY
S7-1 122869 1 • SWITCH (2nd speed)
S7-2 122877 1 • SWITCH (Right steer)
S7-3 122877 1 • SWITCH (Left steer)
S7-4 122869 1 • SWITCH (Reverse drive)
S7-5 122869 1 • SWITCH (Forward drive)
S7-6 122869 1 • SWITCH (3rd speed)
S7-7 122872 1 • SWITCH (Enable pushbutton)
S8 147054 1 N.O. CONTACT (Platform - Horn pushbutton)
S9 147054 1 N.O. CONTACT (Platform - Lift enable switch)
EGP1 KUBOTA 1 GLOW PLUG, Engine (Diesel fuel engine)
S9A 102853 1 SWITCH, Toggle (Outrigger enable)
S9B 127132 1 SWITCH, Toggle (Outrigger enable)
S10 147054 1 N.O. CONTACT (Base - idle/platform/base key switch)
147053 1 N.C. CONTACT (Base - idle/platform/base key switch)
S11 102853 1 SWITCH, Toggle (Front powered platform extend/retract)
S11A 102853 1 SWITCH, Toggle (Rear powered platform extend/retract)
S12 102853 1 SWITCH, Toggle (Hydraulic generator option)
S13 147054 1 N.O. CONTACT (Platform - choke/glow plug switch)
S14 147054 1 N.O. CONTACT (Platform - low/high throttle switch)
S15 147054 1 N.O. CONTACT (Platform - engine start switch)
S20 102853 1 SWITCH, Toggle (Platform - left front outrigger extend/retract)
S21 102853 1 SWITCH, Toggle (Platform - right front outrigger extend/retract)
S22 102853 1 SWITCH, Toggle (Platform - right rear outrigger extend/retract)
S23 102853 1 SWITCH, Toggle (Platform - left rear outrigger extend/retract)
S20A 127132 1 SWITCH, Toggle (Base - left front outrigger extend/retract)
S21A 127132 1 SWITCH, Toggle (Base - right front outrigger extend/retract)
S22A 127132 1 SWITCH, Toggle (Base - right rear outrigger extend/retract)
S23A 127132 1 SWITCH, Toggle (Base - left rear outrigger extend/retract)
S24 102853 1 SWITCH, Toggle (Platform - outrigger auto-level)
S29 147054 1 N.O. CONTACT (Platform - low/high range)
S30 124446 1 SWITCH, Toggle (Engine panel - engine off/on)
S31 102853 1 SWITCH, Toggle (Kubota engine panel - glow plug)
S34 102853 1 SWITCH, Toggle (Front powered platform enable)
S34A 102853 1 SWITCH, Toggle (Rear powered platform enable)

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

Index Skyjack
Qty. Description
No. Part No.
OPS1 102838 1 SWITCH, Oil pressure (Diesel fuel engine)
PT1 134432 1 TRANSDUCER, Pressure
RL-22 107098 1 LIGHT, Rotating amber beacon
RST2 108788 1 RESISTOR (3 Ohm/100W)
S1 119726 1 SWITCH, Main power disconnect
S2 147054 2 N.O. CONTACT (Base - up/off/down switch)
S3 147054 1 N.O. CONTACT (Platform - off/lift/drive select key switch)
147053 2 N.C. CONTACT (Platform - off/lift/drive select key switch)
S4 147053 2 N.C. CONTACT, Emergency stop switch (Platform)
S5 147054 2 N.O. CONTACT, Up/Down switch (Platform)
S6 147053 1 N.C. CONTACT, Emergency stop switch (Base control console)
S7 132537 1 DRIVE/STEER CONTROLLER ASSEMBLY
S7-1 122869 1 • SWITCH (2nd speed)
S7-2 122877 1 • SWITCH (Right steer)
S7-3 122877 1 • SWITCH (Left steer)
S7-4 122869 1 • SWITCH (Reverse drive)
S7-5 122869 1 • SWITCH (Forward drive)
S7-6 122869 1 • SWITCH (3rd speed)
S7-7 122872 1 • SWITCH (Enable pushbutton)
S8 147054 1 N.O. CONTACT (Platform - Horn pushbutton)
S9 147054 1 N.O. CONTACT (Platform - Lift enable switch)
EGP1 KUBOTA 1 GLOW PLUG, Engine (Diesel fuel engine)
S9A 102853 1 SWITCH, Toggle (Outrigger enable)
S9B 127132 1 SWITCH, Toggle (Outrigger enable)
S10 147054 1 N.O. CONTACT (Base - idle/platform/base key switch)
147053 1 N.C. CONTACT (Base - idle/platform/base key switch)
S11 102853 1 SWITCH, Toggle (Front powered platform extend/retract)
S11A 102853 1 SWITCH, Toggle (Rear powered platform extend/retract)
S12 102853 1 SWITCH, Toggle (Hydraulic generator option)
S13 147054 1 N.O. CONTACT (Platform - choke/glow plug switch)
S14 147054 1 N.O. CONTACT (Platform - low/high throttle switch)
S15 147054 1 N.O. CONTACT (Platform - engine start switch)
S20 102853 1 SWITCH, Toggle (Platform - left front outrigger extend/retract)
S21 102853 1 SWITCH, Toggle (Platform - right front outrigger extend/retract)
S22 102853 1 SWITCH, Toggle (Platform - right rear outrigger extend/retract)
S23 102853 1 SWITCH, Toggle (Platform - left rear outrigger extend/retract)
S20A 127132 1 SWITCH, Toggle (Base - left front outrigger extend/retract)
S21A 127132 1 SWITCH, Toggle (Base - right front outrigger extend/retract)
S22A 127132 1 SWITCH, Toggle (Base - right rear outrigger extend/retract)
S23A 127132 1 SWITCH, Toggle (Base - left rear outrigger extend/retract)
S24 102853 1 SWITCH, Toggle (Platform - outrigger auto-level)
S29 147054 1 N.O. CONTACT (Platform - low/high range)
S30 124446 1 SWITCH, Toggle (Engine panel - engine off/on)
S31 102853 1 SWITCH, Toggle (Kubota engine panel - glow plug)
S34 102853 1 SWITCH, Toggle (Front powered platform enable)
S34A 102853 1 SWITCH, Toggle (Rear powered platform enable)

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

Index Skyjack
Qty. Description
No. Part No.
S41 114373 1 SWITCH, Toggle (Platform - high/low torque)
S51 103141 1 N.O. CONTACT (Emergency lowering switch)
S52 103141 1 N.O. CONTACT (Emergency retraction switch)
TPS1 113400 1 TEMPERATURE SWITCH, Engine (Kubota diesel)
TT 103336 1 HOUR METER

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Section 3 – System Component Identification and Schematics Platform Control Console Wiring - All Options (CE)

3.5 Platform Control Console Wiring - All Options (CE)

CONTROL BOX HARNESS PIN # - FUNCTION JOYSTICK HARNESS
24 BLUE/BLACK PIN 1 - LEFT 24 WHITE/RED
12 BROWN/RED PIN 2 - JOYSTICK VS+ 12 WHITE/BLACK
23 BLACK/WHITE PIN 3 - RIGHT 23 WHITE
16 WHITE /BLACK PIN 4 - FORWARD 16 YELLOW
12A BROWN/RED PIN 5 - STEERING VS+ 12A WHITE/GREEN
15 BLUE PIN 6 - REVERSE 15 GREY
19 ORANGE/BLACK PIN 7 - 2nd SPEED 19 BROWN
12A BROWN/RED PIN 8 - ENABLE VS+ 12A WHITE/BLUE
18B RED/BLACK PIN 9 - 3rd SPEED 18B RED/BLACK

KEY SWITCH
POWER ON/LOAD SENSING LIGHT THROTTLE 02

12 10
NO 3 NC 1 NC 1

12
4

10 12A
09
2

3
X2

X1

JOYSTICK CONTROL

NO
08 10 60 00
2

10 34

WITH ENABLE

08
7A 12
NC 1

13
NO 3

NO 3
2

4
X2

X1

7C 10D NORM./HIGH
NC 1

5
6
14
NO 3

18B 18
TORQUE
2

9A
20B 20

2
3
EMERGENCY STOP UP/DOWN HIGH/LOW RANGE

09 10 10 08
16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA

16GA
00

3 NO 3 NO 3 NO 3 NO
02 7A 09 10 13 14 15 16 18 19 20 23 24 31 32 34 49 7C 10D 60
4 4 4 4
00
18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA

18GA
9A 32 31 49

LIFT CHOKE/ HYDR.

START HORN
ENABLE GLOW PLUG GEN

BACK VIEW BACK VIEW

MALE MALE

(16) WHITE BLACK 8 16 GREEN WHITE (34) (77) GREEN BLACK WHITE 24 32
(15) BLUE 7 15 GREEN BLACK (32) (76) RED GREEN 23 31
(14) BLACK 6 14 RED WHITE (31) (75) WHITE RED 22 30
(13) ORANGE 5 13 BLUE BLACK (24) (74) BLACK RED 21 29 RED BLACK GREEN (7C)
(10) BLUE WHITE 4 12 BLACK WHITE (23) (73) ORANGE GREEN 20 28 WHITE RED GREEN (10D)
(09) ORANGE RED 3 11 BLACK WHITE RED (20) (72) WHITE BLACK RED 19 27 BLACK RED GREEN (60)
(7A) RED 2 10 ORANGE BLACK (19) (71) BLUE RED 18 26 ORANGE BLACK WHITE (85)
(02) WHITE 1 9 RED BLACK (18) (49) GREEN 17 25 RED BLACK WHITE (78)

GROUND (00)
BLUE BLACK WHITE (GROUND) TO TERMINAL STRIP

M147223AE

157958AFA SJ9241 RT, SJ9250 RT

52
Control Cable Assemblies Diagram Section 3 – System Component Identification and Schematics

3.6 Control Cable Assemblies Diagram

INSERTS 1-16 INSERTS: 17-32

PIN 1 - WHITE (02) PIN 17 - GREEN (49)
PIN 2 - RED (7A) PIN 18 - BLUE RED (71)
PIN 3 - ORANGE RED (09) PIN 19 - WHITE BLACK RED (72)
24

PIN 20 - ORANGE GREEN (73)

16

32
8

PIN 4 - BLUE WHITE (10)

PIN 5 - ORANGE (13) PIN 21 - BLACK RED (74)
PIN 6 - BLACK (14) PIN 22 - WHITE RED (75)
PIN 7 - BLUE (15) PIN 23 - RED GREEN (76)
PIN 8 - WHITE BLACK (16) PIN 24 - GREEN BLACK WHITE (77)
PIN 9 - RED BLACK (18) PIN 25 - RED BLACK WHITE (78)
PIN 10 - ORANGE BLACK (19) PIN 26 - ORANGE BLACK WHITE (85)
25
1

17

PIN 11 - BLACK WHITE RED (20) PIN 27 - BLACK RED GREEN (60)
PIN 12 - BLACK WHITE (23) PIN 28 - WHITE RED GREEN (10D)
PIN 13 - BLUE BLACK (24) PIN 29 - RED BLACK GREEN (7C)
PIN 14 - RED WHITE (31) PIN 30 - EMPTY
PIN 15 - GREEN BLACK (32) PIN 31 - EMPTY
PIN 16 - GREEN WHITE (34) PIN 32 - EMPTY
GROUND TERMINAL - BLUE BLACK WHITE GROUND TERMINAL - EMPTY

TO CONTROL BOX
BACK VIEW
FEMALE

(34) GREEN WHITE 16 8 WHITE BLACK (16)

(32) GREEN BLACK 15 7 BLUE (15)
25

17
9

1
32

16
24

(31) RED WHITE 14 6 BLACK (14)

(24) BLUE BLACK 13 5 ORANGE (13)
(23) BLACK WHITE 12 4 BLUE WHITE (10)
(20) BLACK WHITE RED 11 3 ORANGE RED (09)
(19) ORANGE BLACK 10 2 RED (7)
(18) RED BLACK 9 1 WHITE (02)
17
25

1
9

32

24
16

(GROUND) BLUE BLACK WHITE TO (00)

GROUND
BACK VIEW
FEMALE

32 24 GREEN BLACK WHITE (77)

31 23 RED GREEN (76)
30 22 WHITE RED (75)
(7D) RED BLACK GREEN 29 21 BLACK RED (74)
(10D) WHITE RED GREEN 28 20 ORANGE GREEN (73)
(60) BLACK RED GREEN 27 19 WHITE BLACK RED (72)
TO CONTROL BOX (85) ORANGE BLACK WHITE 26 18 BLUE RED (71)
(78) RED BLACK WHITE 25 17 GREEN (49))

M115279AD_M115284AE

SJ9241 RT, SJ9250 RT 157958AFA

53
Section 3 – System Component Identification and Schematics Outrigger & Hydraulic Generator Control Console Wiring

3.7 Outrigger & Hydraulic Generator Control Console Wiring

TO HYDRAULIC GENERATOR SWITCH
PIN 1 - 86 WHITE
PIN 2 - 09 BLACK
PIN 3 - 85 GREEN

TO CONTROL BOX
TEN PIN CONNECTOR PLUG
PIN 1 - 74 BLACK

09
86

85
PIN 2 - 73 BLUE

1
2
3
PIN 3 - 78 BLACK/WHITE
PIN 4 - 77 BLUE/BLACK
PIN 5 - 35D PURPLE WHITE
TO AUTO OUTRIGGER SWITCH PIN 6 - NOT USED
PIN 1 - 79 GREEN PIN 7 - 71 ORANGE
35D

PIN 2 - 35D PURPLE/WHITE

79
70

PIN 8 - 72 RED
PIN 3 - 70 GREEN/BLACK PIN 9 - 75 ORANGE/BLACK
1
3
2

35D
PIN 10 - 76 RED/BLACK
35C
TO OUTRIGGER ENABLE SWITCH 35D 70A
1
3
2

PIN 1 - 35D PURPLE/WHITE

35C
35D

35D

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

HYDRAULIC GENERATOR CONTROL CABLE

TO ELECTRIC PANEL
86 WHITE
09 BLACK
85 GREEN

1 2 3

4 5 6

7 8 9

10 11 12

13 14 15
OUTRIGGER CONTROL CABLE
TO ELECTRIC PANEL
PIN 1 - 02 WHITE PIN 9 - 75 ORANGE/BLACK
PIN 2 - 35C WHITE/BLACK PIN 10 - 76 RED/BLACK
PIN 3 - 70 GREEN/BLACK PIN 11 - 77 BLUE/BLACK
PIN 4 - 70A RED/WHITE PIN 12 - 78 BLACK/WHITE
PIN 5 - 71 ORANGE PIN 13 - 79 GREEN
PIN 6 - 72 RED PIN 14 - 35C BLUE/WHITE
PIN 7 - 73 BLUE PIN 15 - 35C GREEN/WHITE
PIN 8 - 74 BLACK M129301AD

157958AFA SJ9241 RT, SJ9250 RT

54
Base Control Console Wiring (CE) Section 3 – System Component Identification and Schematics

3.8 Base Control Console Wiring (CE)

7A
10E 10E 10E
BASE CONTROLS - 9 WIRES
NO 3 NC 1 NO 3 NO 3
02 - WHITE
4 4
4 2
07 - RED
10D 14E 13D 7A - RED/WHITE
7C 07
7C - RED/GREEN/BLACK
10A - BLUE/WHITE

NC 1
2
10D - WHITE/RED/GREEN

X2

X1
02 10A
10E - BLUE/WHITE
13D - ORANGE/RED
14E - BLACK/RED

BASE CONTROLS
CONTACT ORIENTATION
BACK VIEW

7A UP/DOWN SWITCH
10E N.O. CONTACT
PLTF/BASE SWITCH 10E
PIN 4 - 14E BLACK
N.O. CONTACT
PIN 3 - 10E BLUE/WHITE
PIN 3 - 10E BLUE/WHITE
PIN 4 - 10D WHITE/RED/GREEN NO 3 NC 1 NO 3 NO 3

4 2 4 4
UP/DOWN SWITCH
PLTF/BASE SWITCH N.O. CONTACT
N.C. CONTACT PIN 4 - 13D ORANGE
PIN 1 - 7A RED 10D 7C PIN 3 - 10E BLUE/WHITE
PIN 2 - 7C RED/GREEN/BLACK 13D
7C 14E
02
07
NC 1
2

10A
X2

X1

E-STOP SWITCH N.C. CONTACT / LED-2 LIGHT

PIN 1 - 07 RED
PIN 2 - 7C RED/WHITE
PIN X1 - 10A BLUE/WHITE
PIN X2 - 02 WHITE M129301AB

SJ9241 RT, SJ9250 RT 157958AFA

55
3.9 Hydraulic Schematic

A B C D E F G H

POWERED EXTENSION
C13 FRONT C14 REAR
PLATFORM OPTION
EXTENSION EXTENSION MC1 MOTION CONTROL VALVE ASSEMBLY V
CYLINDER CYLINDER MB16 MOTION CONTROL MANIFOLD BLOCK
BASE/DRIVE ASSEMBLY
C4 LIFT CYLINDER C3 LIFT CYLINDER C2 LIFT CYLINDER C1 LIFT CYLINDER MB13 POWERED MB14 REAR CBV1
CV11 MB15 FREE
EXTENSION POWERED EXTENSION CV12
3H-20A WHEEL MANIFOLD
MB6 HOLDING VALVE MB5 HOLDING VALVE MB4 HOLDING VALVE MB3 HOLDING VALVE MANIFOLD BLOCK MANIFOLD BLOCK
MANIFOLD MANIFOLD MANIFOLD MANIFOLD SERIES/PARALLEL 2H-30A
4H-27 VALVE
A B A B FREE WHEEL
2H-98-4 2H-98-4 2H-98-2 2H-98-1 RETRACT
VALVE
AUXILIARY AUXILIARY AUXILIARY AUXILIARY VALVE M1
LOWERING LOWERING LOWERING P T P T TWO STAGE
LOWERING
VALVE VALVE VALVE P3 DCM1 4H-26 4H-27A 4H-26A HYDRAULIC
VALVE
PRESSURE M EXTEND RETRACT EXTEND MOTOR C8
OVERLOAD VALVE VALVE VALVE
2H-13A-4 2H-13A-3 2H-13A-2 2H-13A-1 CUSHION
HOLDING HOLDING HOLDING TRANSDUCE HOLDING CYLINDER
R8
VALVE VALVE VALVE OPTION VALVE RELIEF CV13
O2 O2 O2 O2 RESERVOIR VALVE CV14
LIFT LIFT LIFT LIFT CBV2
ORIFICE ORIFICE ORIFICE
PT1
PRESSURE ORIFICE W
Ø 0.094 Ø 0.094 Ø 0.094 OVERLOAD Ø 0.094 HP2 BP1 CASE DRAIN
R6 R5 R4 R3
TRANSDUCER RELIEF HAND BRAKE
RELIEF RELIEF RELIEF
PUMP PACK
VALVE VALVE VALVE VALVE
MB7 V6
LIFT LINE AUTO
MANIFOLD RESET
MB8
VALVE MB10 DISC BRAKE
LIFT LINE
O5 2H-25 MANIFOLD BLOCK
MANIFOLD MB9 V2
CONTROLLED CONTROLLED CONTROLLED QUICK
LOWERING LOWERING LOWERING BRAKE
ORIFICE VALVE
MANIFOLD VALVE C7 STEER
Ø 0.055
CYLINDER
MB2 MB1 MAIN MANIFOLD
MANUAL LOWERING A B
VALVE MANIFOLD 2H-13A MAIN
V1 LOWERING X
P T
MANUAL LOWERING VALVE 4H-23A 4H-24A C12 LEFT REAR C9 LEFT FRONT C10 RIGHT FRONT C11 RIGHT REAR
VALVE RIGHT LEFT OUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER
STEER STEER
VALVE VALVE CV4 CV5 CV6 CV7
HYDRAULIC O1 MAIN LOWERING
CHECK CHECK CHECK CHECK
GENERATOR OPTION VALVE ORIFICE
VALVE VALVE VALVE VALVE
Ø 0.096 4H-16B
CV3
GM1 FORWARD
CHECK R2 LIFT
GENERATOR DRIVE
VALVE RELIEF
MOTOR VALVE P A
VALVE MB11 OUTRIGGER
T B
2H-14B MANIFOLD BLOCK
MB12 2H-86C
LIFT 2H-30A-2 2H-30A-1
HYDRAULIC HYDRAULIC 4H-78 4H-75 4H-76 4H-77
VALVE BRAKE BRAKE
GENERATOR VALVE GENERATOR 4H-15B LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR
FEED DUMP
MANIFOLD VALVE REVERSE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
CV2 CHECK VALVE VALVE
DRIVE EXTEND EXTEND EXTEND EXTEND
VALVE
VALVE VALVE VALVE VALVE VALVE
P A P A P A P A
Y
2H-17A LARGE T B T B T B T B
PUMP DUMP
OC1 OIL COOLER VALVE
DIESEL OPTION

4H-74 4H-71 4H-72 4H-73

CV1 CHECK R1 LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR
ENGINE 2H-18A SYSTEM 2H-17B
VALVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
SMALL RELIEF
HOLDING RETRACT RETRACT RETRACT RETRACT
PUMP DUMP VALVE
LARGE SMALL VALVE VALVE VALVE VALVE VALVE
VALVE
PUMP PUMP

P1 DUAL
QD1 SYSTEM PRESSURE
INLET
PUMP OC1 OIL COOLER QUICK DISCONNECT Serial Breakdown
DUAL FUEL EFI
Reference Chart
Model Serial Number Z
F1 9241 55000049 & below
FILTER
9250 50000874 & below

RESERVOIR
M139727AC

157958AFA SJ9241 RT, SJ9250 RT

56
3.9 Hydraulic Schematic

A B C D E F G H

POWERED EXTENSION
C13 FRONT C14 REAR
PLATFORM OPTION MC1 MOTION CONTROL VALVE ASSEMBLY
EXTENSION EXTENSION V
CYLINDER CYLINDER MB16 MOTION CONTROL MANIFOLD BLOCK
BASE/DRIVE ASSEMBLY
C4 LIFT CYLINDER C3 LIFT CYLINDER C2 LIFT CYLINDER C1 LIFT CYLINDER MB13 POWERED MB14 REAR CBV1
CV11 MB15 FREE
EXTENSION POWERED EXTENSION
3H-20A WHEEL MANIFOLD
MB6 HOLDING VALVE MB5 HOLDING VALVE MB4 HOLDING VALVE MB3 HOLDING VALVE MANIFOLD BLOCK MANIFOLD BLOCK
MANIFOLD MANIFOLD MANIFOLD MANIFOLD SERIES/PARALLEL 2H-30A
4H-27 VALVE FREE WHEEL
2H-98-4 2H-98-4 2H-98-2 2H-98-1 RETRACT
VALVE
AUXILIARY AUXILIARY AUXILIARY AUXILIARY VALVE M1
LOWERING LOWERING LOWERING LOWERING TWO STAGE
VALVE VALVE VALVE VALVE P3 DCM1 4H-26 4H-27A 4H-26A HYDRAULIC
PRESSURE EXTEND RETRACT EXTEND MOTOR C8
OVERLOAD VALVE VALVE VALVE
2H-13A-4 2H-13A-3 2H-13A-2 2H-13A-1 CUSHION
HOLDING HOLDING HOLDING TRANSDUCE HOLDING R8 CYLINDER
VALVE VALVE VALVE OPTION VALVE RELIEF
O2 O2 O2 O2 RESERVOIR CV14
VALVE
LIFT LIFT LIFT PT1 LIFT CBV2
ORIFICE ORIFICE ORIFICE ORIFICE
0.094 0.094 0.094
PRESSURE
0.094 BP1 CASE DRAIN
W
R6 R5 R4 OVERLOAD R3 HP2
RELIEF RELIEF RELIEF TRANSDUCER RELIEF HAND BRAKE
VALVE PUMP PACK
VALVE VALVE VALVE
MB7 V6
LIFT LINE AUTO
MANIFOLD RESET
MB8 VALVE MB10 DISC BRAKE
LIFT LINE
O5 2H-25 MANIFOLD BLOCK
MANIFOLD MB9 V2
CONTROLLED CONTROLLED CONTROLLED QUICK
LOWERING LOWERING LOWERING BRAKE
MANIFOLD ORIFICE VALVE VALVE
C7 STEER
0.055
CYLINDER
MB2 MB1 MAIN MANIFOLD
MANUAL LOWERING
VALVE MANIFOLD 2H-13A MAIN
V1 LOWERING
MANUAL LOWERING VALVE 4H-23A 4H-24A C12 LEFT REAR C9 LEFT FRONT C10 RIGHT FRONT C11 RIGHT REAR X
VALVE RIGHT LEFT OUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER
STEER STEER
O1 MAIN LOWERING VALVE VALVE CV4 CV5 CV6 CV7
HYDRAULIC CHECK CHECK CHECK CHECK
GENERATOR OPTION VALVE ORIFICE 0.096
VALVE VALVE VALVE VALVE
4H-16B
CV3
GM1 FORWARD
CHECK R2 LIFT
GENERATOR DRIVE
VALVE RELIEF
MOTOR VALVE
VALVE MB11 OUTRIGGER
MB12 2H-14B MANIFOLD BLOCK
2H-86C 2H-30A-1
HYDRAULIC LIFT 2H-30A-2 4H-78 4H-75 4H-76 4H-77
HYDRAULIC BRAKE
GENERATOR VALVE VALVE BRAKE 4H-15B LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR
GENERATOR DUMP
MANIFOLD VALVE FEED REVERSE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
CV2 CHECK VALVE VALVE DRIVE EXTEND EXTEND EXTEND EXTEND
VALVE VALVE VALVE VALVE VALVE VALVE
2H-17A LARGE Y
PUMP DUMP
OC1 OIL COOLER VALVE
DIESEL OPTION

4H-74 4H-71 4H-72 4H-73

CV1 CHECK R1 LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR
ENGINE 2H-18A SYSTEM 2H-17B
VALVE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER
SMALL RELIEF
HOLDING RETRACT RETRACT RETRACT RETRACT
PUMP DUMP VALVE
LARGE SMALL VALVE VALVE VALVE VALVE VALVE
VALVE
PUMP PUMP
P1 DUAL
QD1 SYSTEM PRESSURE
INLET
OC1 OIL COOLER QUICK DISCONNECT
PUMP
NISSAN STANDARD Serial Breakdown
Reference Chart
Z
F1
Model Serial Number
FILTER
9241 55000050 & above
9250 50000875 & above
RESERVOIR
M139727AD

SJ9241 RT, SJ9250 RT 157958AFA

57
3.10 Hydraulic Manifold Components & Port Identifications
A B C D E F G H

2H-17A TO OUTRIGGER TO TO HYDRAULIC TO EMERGENCY

MANIFOLD RETURN TANK LOWERING MANIFOLD
LARGE PUMP
DUMP VALVE FILTER
TO
2H-30A-2 LARGE TO MAIN TO BRAKE
BRAKE FEED PUMP MANIFOLD CYLINDER V
MANIFOLD VALVE
PLUG CV3
CHECK
VALVE
Auto Reset
4H-24A Brake Manifold
4H-15B
LEFT STEER
REVERSE TO EMERGENCY
VALVE
DRIVE LOWERING
VALVE TO 2H - 25 V6
CV2 SMALL QUICK BRAKE BRAKE RELEASE
CHECK PUMP 2H-18A VALVE OVERRIDE VALVE
VALVE W
SMALL PUMP
R2 DUMP VALVE
LIFT
RELIEF
VALVE
O1
LOWERING
ORIFICE
CV2 (Model 9250) HP2
CHECK HAND PUMP
VALVE
4H - 71A 4H - 74A
OUTRIGGER OUTRIGGER X
LEFT FRONT 2H - 17B
LEFT REAR
RETRACT OUTRIGGER
TO RETRACT
4H - 72A HOLDING
4H-23A
MOTION 2H-30A-1 OUTRIGGER VALVE
RIGHT STEER
CONTROL BRAKE DUMP 2H-13A RIGHT FRONT
VALVE 4H-16B RETRACT
VALVE VALVE LOWERING
FORWARD
VALVE
DRIVE
VALVE
TO OUTRIGGER
MANIFOLD 4H - 73A 4H - 78A
TEST OUTRIGGER OUTRIGGER
RIGHT REAR LEFT REAR
PORT MANIFOLD RETRACT EXTEND Y
TO PLUG
R1
BRAKE
SYSTEM
CYLINDER 4H - 75A
RELIEF OUTRIGGER
VALVE LEFT FRONT
EXTEND

OPTIONAL
TEST
TO STEER PORT
CYLINDER
2H-14B
LIFT 4H - 76A Z
OUTRIGGER OUTRIGGER
VALVE TO LIFT CONTROL
RIGHT FRONT CYLINDER
LOWERING BLOCK 4H - 77A
TO MOTION OUTRIGGER EXTEND
CONTROL
VALVE Main Manifold Outrigger Manifold RIGHT REAR
EXTEND
M50152AB HMC-Pl2 HMC-Pl1

157958AFA SJ9241 RT, SJ9250 RT

58
3.11 Main Manifold Wiring Diagram
A B C D E F G H

V
BRAKE DUMP VALVE TO ELECTRIC PANEL - 14 WIRES
30A - BROWN (2x) 00 - WHITE (14 AWG)
02 - WHITE 02 - WHITE
03 - BLUE (14 AWG)
LARGE PUMP DUMP VALVE 09 - ORANGE/RED
17A - BLUE/RED 13A - ORANGE
MAIN DISCONNECT 02 - WHITE 14B - BLACK
03 - BLUE (14 AWG) 15B - BLUE
QUICK BRAKE VALVE
16B - WHITE/BLACK
POWER DECK CONTACTOR 25 - ORANGE/GREEN
17A - BLUE/RED
09 - ORANGE/RED 02 - WHITE
FREE WHEELING VALVE 18A RED/BLACK
02 - WHITE 23A - BLACK/WHITE
30A - BROWN SMALL PUMP DUMP VALVE W
02 - WHITE 18A - RED/BLACK 24A - BLUE/BLACK
02 - WHITE 25 - ORANGE/GREEN
30A - BROWN
BRAKE FEED VALVE
30A - BROWN (2x)
02 - WHITE

LOWERING VALVE
13A - ORANGE (2x)
02 - WHITE (2x)

HOLDING VALVE HARNESS

FORWARD VALVE 13A - ORANGE X
BLACK HEIRSHMAN 02 - WHITE
PIN 1 - 16B WHITE/BLACK
PIN 2 - 02 WHITE
BATTERY NEGATIVE
00 - WHITE (14 AWG)
LIFT VALVE
14B - BLACK
02 - WHITE

REVERSE VALVE
GREY HEIRSHMAN
PIN 1 - 15B BLUE
PIN 2 - 02 WHITE Y

RIGHT STEER VALVE LEFT STEER VALVE

BLACK HEIRSHMAN GREY HEIRSHMAN
PIN 1 - 23A BLACK/WHITE PIN 1 - 24A BLUE/BLACK
PIN 2 - 02 WHITE PIN 2 - 02 WHITE Z

M129218AD

SJ9241 RT, SJ9250 RT 157958AFA

59
3.12 Hydraulic Generator - Electrical Panel Diagram
A B C D E F G H

BACK VIEW
CN14

86A
10A

36A
01

61
09
17

02
02

36
04

44
OUTRIGGER ELECTRIC PANEL
12 PIN CONNECTOR PLUG
D86C-2
V

D17B-2
PIN 3 - 86A ORG/BLK/WHT CN21

D73
17B
10ACR2

D17B-1

71
02
78
73
77

75
72
76
74

REAR RIGHT
REAR LEFT
43 41 05

D74
R

7 8 9 10 11 12 4 42 34B 41 32

D77
CN20

10A
2A
4 5 6 7 8 9 3

35C

71
78
73
77

75
72
76
74

D78
1 2 3 4 5 6 2
9CR3 9CR2 34B 32

FRONT RIGHT
FRONT LEFT
1 2 3 1
36B
86A
10A

01

61
09

D72
17

35
02
02

36
04

CR CR

85A

10A
86D

2A
D71
43

D76
34A 02 32A

J17D

D75
61CR 17BCR 65CR ENABLE

J17E
86
JUMP J17E W
10A
10A
10A
10A
61

01
62
62
63
63

65
64
64

-
-
-

D36
CN22 09 D86

85A 09 86B 10A 17 10C

NOTE: EACH STRANDED D14B-2

WIRE AT THE TERMINAL 2A 86B 02 86A 02 28E 02 35

STRIP MUST BE TERMINATED

D17A
16GA
02 00
WITH A FERRULE
18GA
86B 86A 28E 35
TO OIL COOLER FAN

D14E-2
CR CR CR2 CR
86D - BLACK 85 35B
00 - WHITE 05 03

13D

14D
10D

14B
34B
10A

10E
14E
10A

17A

18A
7C
7A
09
00
02
02
02

07

25
33

60
86C 85 13C 19A 44
86D X

D18A
D14B-1
D14E-1
D86C-1
85 85A 03
00

02

HYDRAULIC GENERATOR INTERNAL WIRING

86C
EUROPEAN COLOURS
TO HYDRAULIC GENERATOR SOLENOID LOAD BROWN
LOAD NEUTRAL BLUE
86C - BLACK GROUND GREEN/YELLOW
02 - WHITE Y
87
86
HYDR GEN CONTROL CABLE
87a
85 09 - BLACK
30
85 - GREEN
86 - WHITE GROUND
LOAD NEUTRAL
GROUND

LOAD NEUTRAL LOAD LOAD

OIL COOLER RELAY - 10ACR2
PIN 30 - 85A ORG/BLK/WHT
PIN 85 - 10A BLU/WHT 220V 15A GENERATOR 110V 15A GENERATOR
PIN 86 - 2A BLK/RED
RED BLK RED BLK
PIN 87 - 86D BLK Z
PIN 87a - N/U

M149512AC

157958AFA SJ9241 RT, SJ9250 RT

60
3.13 Emergency Lowering System - Wiring Diagram (Model 9250)
A B C D E F G H
POWER DECK RETRACT
97A - BLACK
00 - WHITE

EMERGENCY POWER DECK

RETRACT CONTACTOR
EMERGENCY POWER 97A - BLACK (2x)
DECK RETRACT RELAY TO POWER DECK CONTROL BOX - FRONT
PIN 1 - 100A RED
02 - WHITE (2x)
V
PIN 4 - 9B ORANGE/RED
PIN 9 - 100 RED TO POWER DECK CONTROL BOX - REAR
PIN 12 - 09 ORANGE/RED
PIN 13 - 02 WHITE
PIN 14 - 97A GREEN, BLACK
TO POWER DECK DIRECTIONAL VALVES

UNDERNEATH
PLATFORM
POWER DECK CONTACTOR
9B - ORANGE/RED
02 - WHITE (2x)

TO POWER DECK MOTOR CONTACTOR

00 - WHITE
103B - BLACK
99 - GREEN

TO ENGINE

RST2
X

GRAY GRAY GRAY GRAY

B1 MAIN BATTERY

S52 BACK VIEW

LIFT CYLINDER MANIFOLD
TYP (4 PLACES)
EMERGENCY DECK RETRACTION
PIN 3 - 97 BLACK
98 - BLACK PIN 4 - 97A GREEN
00 - WHITE

B2 AUX. BATTERY

MANUAL LOWERING VALVE Z

S51
EMERGENCY LOWERING
97 - BLACK PIN 3 - 97 BLACK (2x)
97A - GREEN PIN 4 - 98 WHITE
98 - WHITE GRAY

BLACK M11442AA

SJ9241 RT, SJ9250 RT 157958AFA

61
3.14 Emergency Lowering System - Electrical Wiring Diagram (Model 9241)
A B C D E F G H

POWER DECK RETRACT

97A - BLACK
00 - WHITE

EMERGENCY POWER DECK

V

97
EMERGENCY POWER RETRACT CONTACTOR TO POWER DECK CONTROL BOX - FRONT
DECK RETRACT RELAY 97A - BLACK (2x)
100 09
PIN 1 - 100A RED 02 - WHITE (2x)

97A

02
02 97A
PIN 4 - 9B ORANGE/RED TO POWER DECK CONTROL BOX - REAR EM RETRACT
PIN 9 - 100 RED
PIN 12 - 09 ORANGE/RED

97A

02
PIN 13 - 02 WHITE

120844AB
02 97A

100A 9B TO POWER DECK DIRECTIONAL VALVES

PIN 14 - 97A GREEN, BLACK CTRL BOX

103B
NOTE: OPEN UP THE HARNESS AND PULL OUT 27
26 09 12A 12D 09 26A 27A

THE 09 ORANGE/RED WIRE SO THAT IT IS 5" MANIFOLD

A
103
HIGHER. CUT OFF THE RING TERMINAL AND

10
N CONNECT TO EMERGENCY P.D. RETRACT RELAY UNDERNEATH 27 26 02 02 02 02 26A 27A

103B
PLATFORM BASE FEED

103A
POWER DECK CONTACTOR
9B - ORANGE/RED PMP PWR 02 12D 12A

9B

02
02 - WHITE (2x)

02
NOTE: TRIM BATTERY BOOT

103B
FOR ADDITIONAL CABLE
99

103B 103B
103

103
TO POWER DECK MOTOR CONTACTOR
00

103
00 00 - WHITE
103B - BLACK
99 - GREEN
103 103 103 NOTE: FASTEN TO PUMP BODY
TO ENGINE

2
00
ENABLE

2
03

X
100
100A

96

00
D96
100

00
100 00
00

Y
97

00

97 97 00 BACK VIEW
EMERGENCY DECK RETRACTION
PIN 3 - 97 BLACK
PIN 4 - 97A GREEN

NOT CONNECTED
MANUAL LOWERING VALVE
(TIE- WRAP TO THE CABLE) Z
97 - BLACK
98

97A - GREEN
98 - WHITE

M148308AA_1

157958AFA SJ9241 RT, SJ9250 RT

62
3.15 Auto-Leveling Outrigger Connection Diagram
A B C D E F G H
TO OUTRIGGER LIMIT SWITCHES LEFT FRONT OUTRIGGER: RIGHT FRONT OUTRIGGER: RIGHT REAR OUTRIGGER: LEFT REAR OUTRIGGER:
PIN 1 - BLACK (10A) PIN 1 - BLACK (10A) PIN 1 - BLACK (10A) PIN 1 - BLACK (10A)
PIN 2 - WHITE (65A) PIN 2 - WHITE (66A) PIN 2 - WHITE (67A) PIN 2 - WHITE (68A)
PIN 3 - GREEN (62) PIN 3 - GREEN (63) PIN 3 - GREEN (64) PIN 3 - GREEN (01)
PIN 4 - RED (61) PIN 4 - RED (62) PIN 4 - RED (63) PIN 4 - RED (64)
BACK VIEW
FEMALE
PIN 1 - BLACK ( )
2 3
PIN 2 - WHITE ( )
PIN 3 - GREEN ( ) V
1 4 PIN 4 - RED ( )
61

61CR

9CR3
62 D17B-1
62
63 D17B-2

CN14
63
64

17BCR
04
OUTRIGGER LIMIT SWITCHES

9CR2
64
01 17
10A 86A
SIXTEEN PIN CONNECTOR PLUG 10A 10A

CN21
10A 17B 09

CN20
INSTALLED TO CABTIRES ON MACHINE CN22 10A 35C 02 44

65CR
- 78 78 01
PIN 1 - 61 RED - 73 73 02
LEFT FRONT PIN 2 - 62 GREEN - 77 02
77
65 74 74 36A
RIGHT FRONT PIN 3 - 62 RED J17D 71 71 61

CN22
PIN 4 - 63 GREEN 75 75 36
RIGHT REAR PIN 5 - 63 RED J17E 72 72
D36 76 76
PIN 6 - 64 GREEN
LEFT REAR PIN 7 - 64 RED
FRONT LEFT REAR LEFT
PIN 8 - 01 GREEN

ENABLE
TO CONTROL MODULE

JUMP J17E
PIN 9 - 10A BLACK (2)
PIN 1 - 65 GREEN/BLACK
PIN 2 - 65A WHITE
BACK VIEW
PIN 10 - 10A BLACK (2)
FRONT RIGHT REAR RIGHT
W
PIN 3 - 66A WHITE PIN 11 - 10A BLACK (2)
3 2 1
PIN 4 - 67A WHITE 6 5 4
PIN 12 - 10A BLACK (2) D75 D76 D71 D72 D78 D77 D74 D73

PIN 5 - 68A WHITE PIN 13 - (N/U) PIN 1 - 78 BLACK/WHITE PIN 1 - 75 ORANGE/BLACK PIN 1 - 76 RED/BLACK PIN 1 - 77 BLUE/BLACK
PIN 6 - N/U PIN 14 - (N/U) OUTR MANIFOLD TEN PIN CONNECTOR PLUG CN21 PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE
1 2 3 PIN 15 - (N/U) PIN 1 - 17B WHITE/BLACK
TO LIMIT SWITCHES 4 5 6
PIN 16 - 65 GREEN/BLACK PIN 2 - 02 WHITE
PIN 1 - 65 GREEN/BLACK PIN 3 - 78 BLACK/WHITE
2 1 2 1 2 1 2 1
BACK VIEW
PIN 2 - 65A GREEN/WHITE PIN 4 - 73 BLUE 02 78 02 75 02 76 02 77
PIN 3 - 66A BLUE/WHITE PIN 5 - 77 BLUE/BLACK
PIN 4 - 67A RED/WHITE PIN 6 - 74 BLACK GREY GREY GREY GREY
PIN 5 - 68A WHITE PIN 7 - 71 ORANGE
PIN 6 - N/U OUTR CTRL BOX PIN 8 - 75 ORANGE/BLACK
TO OUTRIGGER PCB CN20 PIN 9 - 72 RED

1
PIN 1 - 35C WHITE/BLACK PIN 10 - 76 RED/BLACK

2
3
PIN 2 - 78 BLACK/WHITE

4
PIN 3 - 73 BLUE

6 5
PIN 4 - 77 BLUE/BLACK 02 02

7
PIN 5 - 74 BLACK

8
PIN 6 - 71 ORANGE
X

9
PIN 7 - 75 ORANGE/BLACK 17B
PIN 8 - 72 RED
PIN 9 - 76 RED/BLACK
02

17B - WHITE/BLACK
02 - WHITE

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

OCM1 - OUTRIGGER CONTROL MODULE

BLACK BLACK BLACK BLACK

BACK VIEW BACK VIEW

CONTROL MODULE - P2
Y
TO CONTROL MODULE - P4 2 1 2 1 2 1 2 1
3 2 1
3 2 1
PIN 1 - 68A WHITE
PIN 1 - 78 BLACK/WHITE (2x) 6 5 4
6 5 4
PIN 2 - 67A RED/WHITE 02 74 02 71 02 72 02 73
PIN 2 - 77 BLUE/BLACK (2x) 9 8 7
9 8 7
PIN 3 - 66A BLUE/WHITE
PIN 3 - 76 RED/BLACK (2x) 12 11 10 TO CONTROL BOX TO "ELECTRIC PANEL" PIN 1 - 74 BLACK PIN 1 - 71 ORANGE PIN 1 - 72 RED PIN 1 - 73 BLUE
PIN 4 - 65A GREEN/WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE PIN 2 - 02 WHITE
PIN 4 - 75 ORANGE/BLACK (2x) PIN 5 - 70 GREEN/BLACK PIN 1 - 02 WHITE PIN 9 - 75 ORANGE/BLACK PIN 1 - 02 WHITE PIN 9 - 75 ORANGE/BLACK
PIN 5 - 74 BLACK (2x) PIN 6 - 79 GREEN PIN 2 - 35C WHITE/BLACK PIN 10 - 76 RED/BLACK PIN 2 - 35C WHITE/BLACK PIN 10 - 76 RED/BLACK
PIN 6 - 73 BLUE (2x) PIN 7 - 70A RED/WHITE PIN 3 - 70 GREEN/BLACK PIN 11 - 77 BLUE/BLACK PIN 3 - 70 GREEN/BLACK PIN 11 - 77 BLUE/BLACK 35C WHITE/BLACK
PIN 7 - 72 RED (2x) PIN 4 - 70A RED/WHITE PIN 12 - 78 BLACK/WHITE PIN 4 - 70A RED/WHITE PIN 12 - 78 BLACK/WHITE

02
PIN 8 - 65 GREEN/BLACK 70 GREEN/BLACK
PIN 8 - 71 ORANGE (2x) PIN 5 - 71 ORANGE PIN 13 - 79 GREEN PIN 5 - 71 ORANGE PIN 13 - 79 GREEN
PIN 9 - N/U 79 GREEN 70A
PIN 9 - 35C WHITE/BLACK (2x) PIN 10 - 35 BROWN/RED PIN 6 - 72 RED PIN 14 - 35C WHITE/BLACK PIN 6 - 72 RED PIN 14 - 35C BLUE/WHITE
PIN 11 - 02 WHITE (2x) PIN 7 - 73 BLUE PIN 15 - 35C WHITE/BLACK PIN 7 - 73 BLUE PIN 15 - 35C GREEN/WHITE TO "CONTROL BOX"
PIN 12 - 10A BLUE/WHITE PIN 8 - 74 BLACK PIN 8 - 74 BLACK 35D TEN PIN CONNECTOR PLUG
PIN 1 - 74 BLACK

1
PIN 2 - 73 BLUE

2
1 2 3
PIN 3 - 78 BLACK/WHITE

3
4
4 5 6
PIN 4 - 77 BLUE/BLACK

5
7 8 9
PIN 5 - 35D PURPLE/WHITE

6
10 11 12

7
13 14 15 PIN 6 - N/U

8
PIN 7 - 71 ORANGE

9 10
TO ELECTRIC PANEL
79
PIN 8 - 72 RED
PIN 9 - 75 ORANGE/BLACK
Z
02 - WHITE
10A BLUE/WHITE 70 PIN 10 - 76 RED/BLACK
35 BROWN/RED 35D PURPLE/WHITE

35C
70A RED/WHITE

35C
35C BLUE/WHITE 02 WHITE
35C GREEN/WHITE

M50333AC_1

SJ9241 RT, SJ9250 RT 157958AFA

63
64
157958AFA
TO ELECTRIC PANEL
A

POWER DECK CONTACTOR

09 - ORANGE/RED
02 - WHITE

F2
100 AMP
FUSE
B

S1 MAIN DISCONNECT SWITCH

C

POSITIVE NEGATIVE

B1 MAIN BATTERY
D
3.16 Powered Extension Platform - Electrical Wiring Diagram (Model 9250)

TO ENGINE
E

TO POWER DECK CONTROL BOX - FRONT

TO POWER DECK CONTROL BOX - REAR

F

TO POWER DECK DIRECTIONAL VALVE

G

TO POWER DECK MOTOR CONTACTOR

TO CONTACTOR
00 - WHITE
103B - BLACK
99 - GREEN
H

M50296AB
Z
Y
X
V

SJ9241 RT, SJ9250 RT

3.17 Horn, Light, Beeper & Transducer Wiring Diagram
A B C D E F G H

M134226AF

SJ9241 RT, SJ9250 RT 157958AFA

65
3.18 Engine Wiring Diagram - Kubota Diesel Engine
A B C D E F G H
86
87 BACK VIEW
103 103

6
87a
85 1 12
30

DEUTSCH
2 11
3 10
31A 91A 103 ALTERNATOR MAIN MAIN STARTER 4 9

02
GLOW PLUG RELAY 5
6
8
7

PIN 30 - 103 RED

PIN 87 - 91A - RED
PIN 86 - 31A RED/WHITE V
PIN 85 - 02 WHITE ELECTRIC PANEL
PIN 87a - N/U PIN 1 - 31A RED/WHITE
PIN 2 - 34A GREEN/WHITE
GLOW PLUG TIMER PIN 3 - 02 WHITE
PIN 1 - N/U PIN 4 - 32A GREEN/BLACK
PIN 2 - N/U PIN 5 - N/U
PIN 3 - 02 WHITE PIN 6 - N/U
PIN 4 - 91A RED PIN 7 - N/U
PIN 5 - 32A GREEN/BLACK PIN 8 - N/U
PIN 6 - 90 RED 91A 02 PIN 9 - 2A BLACK/RED
PIN 10 - 37 BLUE/WHITE
PIN 11 - 07 RED
02 PIN 12 - 05 PURPLE/WHITE
1
4

91A
5
2

90
3
6

32A

37
02
W

MAIN STARTER

32A
57
GLOW PLUG LIGHT 103 - RED

103
90 90

2B

2A
90 - RED
91A

57
91A
91A - RED
PRESSURE SWITCH
2A - BLACK/RED
07
2B - WHITE STARTER MOTOR
57 - BLACK/WHITE
07 31A GLOW PLUG SWITCH 02 - WHITE
1

31A 31A - RED/WHITE

2

07
07 5A - PURPLE/WHITE BACK VIEW - FEMALE STARTER SOLENOID
3

07 37 BLUE/WHITE 32A - GREEN/BLACK

X
FRONT VIEW - MALE
37 - IG
IG
N/U - L

WHITE "PIGTAIL" WIRE ON STARTER

L

N/U - L ALTERNATOR TRIGGER

OFF / ON / START SWITCH
37 BLUE/WHITE
05 - PURPLE/WHITE
6

6 3
07 - RED
05 05
5

5 2 32A - GREEN/BLACK
05

32A
05

07

32A 4 1 07
4

TEMPERATURE SWITCH 2B
2B - WHITE

Y
FUEL VALVE ON ENGINE 37 37
37 - BLUE/WHITE
57 - BLACK/WHITE 57 57

FUEL VALVE GROUND 00

00 - WHITE

34A
THROTTLE SOLENOID
34A - GREEN/WHITE 02
02 - WHITE

00

ENGINE GROUND Z
GLOW PLUG 00 - WHITE
91A - RED

91A

M147615AA_2

157958AFA SJ9241 RT, SJ9250 RT

66
3.19 Flashing Light Relay Harness
A B C D E F G H

J3 V

22CR W
10A

P3
X

10A J3 P3 RELAY 22CR

22CR BACK VIEW BACK VIEW BOTTOM VIEW

3 2 1 1 2 3
22-BK-16 10A-BU/BK-16 22A-BK-16 6 5 4 4 5 6 Y
29-GN-16 29-GN-16

60-BK/WH-16 60-BK/WH-16
PIN 1 - 22 - BLACK PIN 1 - 22A - BLACK TO RELAY
28-GN/BK-16 28-GN/BK-16 P3
J3 PIN 2 - 29 - GREEN PIN 2 - 29 - GREEN 30 - 10A - BLUE/BLACK
SP02 02-WH-16 85 - 02 - WHITE
PIN 3 - 60 - BLACK/WHITE PIN 3 - 60 - BLACK/WHITE
28E-GN/WH-16 28E-GN/WH-16 PIN 4 - 28 - GREEN/BLACK PIN 4 - 28 - GREEN/BLACK 86 - 22 - BLACK
PIN 5 - 02 - WHITE PIN 5 - 02 - WHITE 87 - 22A - BLACK
Z
ELEC. SCHEMATIC PIN 6 - 28E - GREEN/WHITE PIN 6 - 28E - GREEN/WHITE 87a - N/C

M239681AA-2

SJ9241 RT, SJ9250 RT 157958AFA

67
3.20 Electrical Panel Diagram - All Options (CE)
A B C D E F G H I J K L M N O

OUTRIGGER ELECTRIC PANEL 12 PIN CONNECTOR PLUG - CN14

PIN 1 - 04 RED/BLUE PIN 7 - 01 RED/BLUE R
NOTE: ON SJ9241 ONLY, JUMPER WIRE PIN 2 - 17 BLUE/RED PIN 8 - 02 WHITE CONTROL MODULE - P2
IS BETWEEN 61 & 36 (PIN 11 & 12) PIN 3 - 86A ORG/BLK/WHT PIN 9 - 02 WHITE PIN 10 - 35 BROWN/RED
10 11 12

PIN 10 - 36B YELLOW 7 8 9

10A
2A

05
PIN 4 - 10A BLUE/WHITE PIN 11 - 02 WHITE (2x) 15 16

02
00
PIN 5 - 09 ORANGE/RED PIN 11 - 61 BLACK 4 5 6
PIN 12 - 10A BLUE/WHITE
PIN 6 - 44 RED PIN 12 - 36 BLACK/WHITE 1 2 3
05 31 49 32 2A 10 13A 15 16 23 24 03
1 2 3 4 5 6 7 8 9 10 11 12

CN14

86A

36A
10A

01

61
09

02
02

36
04

44
17
D10

D17B-2
CN21 S

D73
D17B-1

17B

71
02
78
73
77

75
72
76
74

REAR RIGHT
REAR LEFT
05 05 43 41 05 02 10A 05 05 13A 36B 04 04 04 04 04

D74
R
36B
86A
10A

R R R R R R
01

61
09

02
02

36
04

44
17

7 8 9 10 11 12 4 02 31 02 49 42 34B 41 32 2A 10A 02 10B 02 13D 02 14D 02 15 02 16 02 23 02 24 02 30

D77
CN20

10A

2A
4 5 6 7 8 9 3

35C

71
78
73
77

75
72
76
74

D78
1 2 3 4 5 6 2

1000 uF
9CR3 9CR2 31 49 34B 32 10A 13D 14D 15 16 23 24 30

FRONT RIGHT
FRONT LEFT
1 2 3 1

D72
CR CR CR CR CR1 CR CR CR CR CR CR CR

D71
43 41 40

D76
31A 49A 34A 02 32A 42 37 10A 10C 13B 14A 15A 16A 23A 24A 30A T
J17D

D75
61CR 17BCR 65CR 49A
J17E
ENABLE 31A 34A 32A 37 10C D15A-1 D16A-1 D23A D24A

JUMP J17E 23A 24A 30A

10A
10A
10A
10A
01
61
62
62
63
63

65
64
64

-
-
-

D36

CN22
28E 28 18 20
D15A-2 D16A-2

10A 13B 14A 1B 14B 1B 15A 16A 18A 18A 17A 44 17 10C U
R R
02 28E 02 28 02 28E 02 28 02 40 02 18 02 17A 02 17 02 20 02 35
14D D10E D30 60
00 02

1000 uF
28E 28 28E 28 18 17A 17 20 35
CR2 CR2 CR1 CR1 CR CR CR CR CR
15B 16B 21 35B
03 05

D17A
13C 13C 14C 10A 14C 01 10A 10A 20A 19A 44

D14E-2
D19 V
15B 16B

34B
13D

14D
10D

14B
10A

10E
14E
10A

17A

18A
19

7C
7A
09
00
02
02
02

07

25
33

60
35B

D14B-1
D14E-1

D18A
NOTE: THE 1000uF CAPACITOR IS NOT REQUIRED
ON MACHINES EQUIPPED WITH WET BRAKES.

TWO SPEED MOTOR

20A - BLACK
00 00 02 02 02 02 09 09 13D D13 D14 10D 10E 10A 14B D34
07 17A 7A 25 D20A
33 7C 60 18A
02 - WHITE
W
02 13 14 34

TO ENGINE
TO JOYSTICK BOX
20A

PLATFORM CONTROL BOX

MAIN MANIFOLD HARNESS ENGINE HARNESS LOAD SENSE CONTROL MODULE X
CABLE CONNECTOR
HIGH SPEED 00 - WHITE (14 AWG) PIN 1 - 31A ORANGE 02 - WHITE
10A - BLACK LEGEND:
02 - WHITE PIN 2 - 34A WHITE/BLACK 10C - BLUE/BLACK BACK VIEW BACK VIEW
35 - BLK/WHT
MAIN MANIFOLD HARNESS 03 - BLUE (14 AWG) PIN 3 - 02 WHITE 10E - BLUE/WHITE FEMALE FEMALE
09 - ORANGE/RED PIN 4 - 32A ORANGE/BLACK 13D - ORANGE
ENGINE HARNESS 13A - ORANGE PIN 5 - N/U 14D - BLACK
(34) GREEN WHITE 16 8 WHITE BLACK (16) 32 24 GREEN BLACK WHITE (77)
PLATFORM CONTROL BOX 14B - BLACK PIN 6 - N/U 15 - BLUE
(32) GREEN BLACK 15 7 BLUE (15) 31 23 RED GREEN (76)
26' LIFT CUTOUT 15B - BLUE PIN 7 - 33 GREEN 16 - WHITE/BLACK
(31) RED WHITE 14 6 BLACK (14) 30 22 WHITE RED (75)
61 - BLACK BASE CONTROL BOX 16B - WHITE/BLACK PIN 8 - 10A GREEN/BLACK 28 - GREEN/BLACK
(24) BLUE BLACK 13 5 ORANGE (13) (7C) RED BLACK GREEN 29 21 BLACK RED (74) Y
36 - BLK/WHT 17A - BLUE/RED PIN 9 - 2A RED/BLACK 28E - GREEN/WHITE
LOAD SENSE CONTROL MODULE (23) BLACK WHITE 12 4 BLUE WHITE (10) (10D) WHITE RED GREEN 28 20 ORANGE GREEN (73)
18A - RED/BLACK PIN 10 - 37 BLUE/BLACK 35B - RED/BLACK (20) BLACK WHITE RED 11 3 27 19 WHITE BLACK RED (72)
ORANGE RED (09) (60) BLACK RED GREEN
NOTE: LIMIT SWITCH NOT USED ON SJ9241 23A - BLACK/WHITE PIN 11 - 07 RED 49A - GREEN 2
(19) ORANGE BLACK 10 RED (7A) (85) ORANGE BLACK WHITE 26 18 BLUE RED (71)
24A - BLUE/BLACK PIN 12 - 05 BLUE 60 - BLACK/WHITE (18) RED BLACK 9 1 25 17 GREEN (49))
WHITE (02) (78) RED BLACK WHITE BACK VIEW
3.19 Drawing Title
25 - ORANGE/GREEN BLACK (TIED BACK) RED (TIED BACK)

12 11 10 9 8 7

1 2 3 4 5 6
30A - BROWN BLACK/WHITE (TIED BACK) RED/WHITE (TIED BACK) (GROUND) BLUE BLACK WHITE TO (00)
ORANGE/BLACK (TIED BACK) GROUND

M123456AA M147867AC

SJ9241 RT, SJ9250 RT 157958AFA

68
 S10
IDLE/PLTF/BASE S6
KEY SWITCH EMERGENCY
S4 CONTROL BOX BASE (IN IDLE POSITION) STOP
EMERGENCY KUBOTA DIESEL ENGINE
STOP (*) KUBOTA SUPPLIED WIRE
SWITCH
08 7A RED 07 07
A

7A 7A 7C 07
NEGATIV
NCHO

SJ9241 RT, SJ9250 RT

S30 MAIN S31 -
ENGINE SW GLOW PLUG
10E 10D
OFF/ON/START SWITCH 1
NO
05 05 07 31A
2
GPT1
10D 7C RED/BLACK/GREEN 7C 32A 32A 02 GLOW PLUG
3 TIMER
31ACR
05 31A 31A 31A 02
4 GLOW PLUG
RELAY
HTS-34A
05 43 34A 34A 34A
5 HIGH THROTTLE
SOLENOID
90
10D WHITE/RED/GREEN 10D 33 D02-39 GLOW PLUG
GPL1 6 INDICATOR
EGP1
10E 103 91A ENGINE
7 GLOW PLUGS
05 32A 32A 37 2D37 DIESEL VALVE
8 SOLENOID
S2 D57
UP/DOWN 10A 57
OPS1 OIL 9
SELECTOR
HOURMETER PRESSURE D02-40
SWITCH SWITCH 32ACR
10A 32A
B

TT 10 ENGINE STARTER
CONTACTOR
10ACR1
13D 10E 10A 2A 2A 2A 2B 2B TPS1
11 TEMPERATURE
DN SWITCH
ENGINE
14E 10E 10A 37 37 TEMPERATURE
SWITCH 12
S3 UP
KEY SWITCH
02 02
OFF/LIFT/DRIVE
13
(IN OFF POSITION)
00
10A 02 *104 ENGINE STARTER
D10E M 14
EL. MOTOR
D10 LED-2
08 10 10 BLUE/WHITE 10 POWER ON
G 15 ALTERNATOR
NC HELD LIGHT-BASE
S13
OPEN 10 31 31 31
GLOW PLUG SWITCH RED/WHITE
16 GLOW PLUG RELAY
31CR
41
17

18
S15
ENGINE START 10 32 GREEN/BLACK 32 32 41
19 START RELAY
S14 D34 32CR
LOW/HIGH THROTTLE 10 34 GREEN/WHITE 34 34B 42
C

20 THROTTLE RELAY
DCM1 S1
D14E-2 34BCR MAIN POWER
P.M.T. UNIT
DISCONNECT 21
MOTOR F2
FUSE 100 B1
00 103B 103B 103B 103A 103 12V
M 22 12V BATTERY
F5 100 AMP
103C FUSE 103B 03
23
10 AMP 20A BREAKER INVERTER OPTION
D26 99 05 05 03
S34 24 P.M.T. CONTACTOR
S11 D02-34 CB1 F4
ENABLE
99CR 4H-26 103 FUSE INV1
OUT 26 FRONT DECK
103C 25
D27 D02-35 200 AMP OUT SOLENOID
IN 4H-27 34A
27 FRONT DECK
S34A 26
D26A D02-36 IN SOLENOID
ENABLE S11A
OUT 26A 4H-26A REAR DECK
103C 27
D27A D02-37 OUT SOLENOID
4H-27A D34A
IN 27A REAR DECK
28
D02-38 IN SOLENOID

29

D97A-1 B2
103B 97 12V
D

30 AUXILIARY 12V BATTERY

D97A-2
POWER DECK OPTION 00 00
31
S52 EMERGENCY 2H-98-1
DECK RETRACION AUXILIARY AUXILIARY HOLDING
32 VALVE SOLENOID
EMERGENCY D02-1
LOWERING
3.21 Electrical Schematic - Kubota Diesel Engine with All Option (CE)

97A 97A 97A 97 2H-98-2

SYSTEM AUXILIARY HOLDING
33 VALVE SOLENOID
SJ9250 ONLY D02-2
D02-33
97A EMERGENCY EXT. DECK
34 RETRACT CONTACTOR
97ACR-2
97A EMERGENCY EXT. DECK
35 RETRACT RELAY
97ACR-1 S51
AUX. EMERGENCY 2H-98-3
LOWERING AUXILIARY HOLDING
36
RST2 D02-3 VALVE SOLENOID
LED-1 3 OHM D96
100 100A 96 97 98 2H-98-4
POWER ON LIGHT 37 AUXILIARY HOLDING
D02-4 VALVE SOLENOID
CB3
60 00 00 BLUE/BLACK/WHITE 00 00 02
38 20 A BREAKER
CAP2
10B
39
10BCR1
60 00 10B
E

40 ENGINE ON RELAY
LED-3
POWER ON LIGHT 09 9B POWER DECK OPTION
41 BASE CONTACTOR

10A 10A 05 9BCR 2H-13A-5

42 HOLDING VALVE
D02-5 SOLENOID (SJ9250 ONLY)
D02-32
10C 05 2H-13A-4
43 HOLDING VALVE
D02-6 SOLENOID (SJ9250 ONLY)
05 2H-13A-3
44 HOLDING VALVE
D02-7 SOLENOID
2H-13A-2
45 HOLDING VALVE
D02-8 SOLENOID
10A 10A 13C 13B 13A 2H-13A
46 MAIN LOWERING
D02-9 VALVE SOLENOID
28ECR2
28E AUX. DOWN
47
ENABLE RELAY
28CR2
28 DOWN
48
ENABLE RELAY
CRD1 CRD2 CRD3 28ECR1
28E
49 AUX. TILT RELAY
S8 28CR1
HORN 28
F

50 TILT RELAY
49CR
08 49 GREEN 49 49
51 HORN RELAY
H1
HORN
05 49A
52 HORN

60 BLACK/RED/GREEN 60 PT1 AT1

53
PRESSURE ANGLE
10C TRANSDUCER TRANSDUCER 02
54 ANGLE TRANSDUCER

55 PRESSURE TRANSDUCER

56

57 CONTROL MODULE
CM1

28 = P3-4
29 = P3-2

60 = P3-3
02 = P3-5
16 = P2-7
15 = P2-8
22 = P3-1
902 = P4-8

28E = P3-6
900 = P4-7
28B = P4-3

60A = P4-2
910 = P4-6

10E = P2-2
13D = P2-4
14D = P2-3

02 = P2-11
910A = P4-9

35B = P2-10

10C = P2-12

22 ROTATING AMBER
58
RL-22 BEACON OPTION
22
59 FLASHING LIGHT
S9 S5 FL-22
LIFT LIFT D13
13 ORANGE 13 29
ENABLE UP/DOWN 60 BEEPER
G

BP-29
10 DN 13D
LFT 09 09 9A D14E-1
61 DOWN RELAY
NC 14DCR
UP D14 13DCR
14 BLACK 14 14D
62 UP RELAY
10ACR2 FAN
85A 86D 00
F 63 OIL COOLER FAN

10A 10A 2A
64 OIL COOLER RELAY

09 (BLACK) 09 09 09 85
65
CB4
03 85A 85A 86C 2H-86C
66 HYDR. GENERATOR
S12 15A BREAKER D02-10 SOLENOID
HYDRAULIC 2A
GENERATOR 67
SWITCH HYDRAULIC GENERATOR
85 GREEN 85 OPTION 85 86B 2A
86B HYDR. GENERATOR
ON 68
09 RELAY
86BCR
86 WHITE 86 86A
OFF 69 HYDR. GENERATOR
STOP RELAY
D86 86ACR
34B D86C-2
70
H

D86C-1 D14B-2
71
17ACR
09 ORANGE/RED 09 33 17A 72
SMALL PUMP RELAY
D17A
10A 10A 17A 2H-17A
73 LARGE PUMP DUMP
D02-11 VALVE SOLENOID
36A 36B 36B 14A 14C 14B 2H-14B
D18A 74 LIFT VALVE
D14B-1 D02-12 SOLENOID
35CR END OF STROKE
35 JUMPER
S29 S41 75 ELEVATION/HI SPD
CUTOUT RELAY
HIGH/LOW HIGH/LOW
RANGE TORQUE 10C 35B
76
20CR
12 20B 20 BLACK/WHITE/RED 20 20
77 SERIES/PARELLEL
RELAY
10C 44 44 20A D20A 3H-20A
S7-1 78 SERIES/PARELLEL
JOYSTICK ENABLE VALVE SOLENOID
2ND D02-13
10 ENABLE RELAY
DR 12 12 12A SPEED 19 ORANGE/BLACK 19 19A 17 17 17
NO 79 2ND SPEED/LARGE
PUMP RELAY
D19 17CR
12 12B 02 02 WHITE 02
I

80
12BCR 2H-30A
81 FREE-WHEELING
D02-14 VALVE SOLENOID
2H-30A-1
82 BRAKE DUMP
D02-15 VALVE SOLENOID
04 30A 2H-30A-2
83 BRAKE FEED
D02-16 VALVE SOLENOID
35 10A
84 CAPACITOR (NOTE: REMOVED ON
CAP1 MACHINES WITH WET BRAKES)
LS5 26' DRIVE 1TD
CUTOUT 04 04 40
JUMPER 85 TIME DELAY #1
TILT OVERRIDE/ 4H-15B
HIGH DRIVE CUTOUT 1A 04 15A 15A 15B REVERSE
LIMIT SWITCH 86
D02-17 VALVE SOLENOID
NORMALLY CLOSED
10A D15A-1 D15A-2 D30
1B 01 25 2H-25 QUICK BRAKE VALVE (NOTE: FOR
87
D02-18 MACHINES WITH WET BRAKES ONLY)
D16A-1 D16A-2
30
88 BRAKE RELAY
30CR
S7 04 16A 16A 16B 4H-16B
FORWARD
JOYSTICK 89
D02-19 VALVE SOLENOID
CONTROLLER
04 23A 4H-23A RIGHT STEERING
90
J

D02-20 VALVE SOLENOID

D23A
04 24A 4H-24A LEFT STEERING
91
D02-21 VALVE SOLENOID
D24A
21 18A 2H-18A SMALL PUMP DUMP
92
D02-22 VALVE SOLENOID
10A 10A 18A
S7-6 93
3RD
SPEED 18B 18 RED/BLACK 18 18 3RD SPEED
94 RELAY
S7-5
16 18CR
FWD 16 WHITE/BLACK 16
95 FORWARD RELAY
S7-4
15 16CR
REV 15 BLUE 15
96 REVERSE RELAY
S7-2
23 15CR
RIGHT 23 BLACK/WHITE 23
97 RIGHT RIGHT
S7-3
24 23CR
LEFT 24 BLUE/BLACK 24 LEFT RELAY
98
24CR
EE FF CC HH KK GG BB PP II,JJ
OUTRIGGER OPTION 99
WITH AUTO LEVELLING
D17B-1 D17B-2
100
K

01 1A 17E 17B 2H-17B OUTRIGGER

101 HOLDING SOLENOID
J17E D02-23
10A 10A 36A
102
OUTRIGGER UP LIMIT SWITCHES
NORMALLY OPEN HELD CLOSED
65
103 OUTRIGGER LIFT
26' LIFT CUTOUT ENABLE RELAY
LS64 LS63 LS62 LS61 D36 65CR
01 64 63 62 61 61 N.C. (SJ9250 ONLY)
104 OUTRIGGER DRIVE
LS1 ENABLE RELAY
LEFT RIGHT RIGHT LEFT 61CR
REAR REAR FRONT FRONT 61 36
105
CUT
OUTRIGGERS SHOWN IN J17D
MM NN
RETRACTED POSITION 106
9CR3 J36 (SJ9241 ONLY)
09 OUTRIGGER
107 PROOF RELAY
9CR2
09 OUTRIGGER
108 ENABLE RELAY
S20A S21A S22A S23A
44 35B 35C 35C 35E FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT 17D OUTRIGGER
109 LIFT DISABLE RELAY

S9B UP UP UP UP 17DCR
OUTRIGGER
OUTRIGGER 110 CONTROL MODULE
L

ENABLE DN DN DN DN OCM1
D71
71
71 = P4-8 111 LEFT FRONT UP
D72
72
72 = P4-7 112 RIGHT FRONT UP
D73
73
73 = P4-6 113 RIGHT REAR UP
D74
74
74 = P4-5 114 LEFT REAR UP
D75
75
75 = P4-4 115 LEFT FRONT DOWN
D76
76
76 = P4-3 116 RIGHT FRONT DOWN
D77
77
77 = P4-2 117 RIGHT REAR DOWN
D78
78
78 = P4-1 118 LEFT REAR DOWN

35 TILT OVERRIDE/
35 = P2-10 119
HIGH DRIVE CUTOUT

N/U = P2-9 120 TILT

M

OUTRIGGER DOWN LIMIT SWITCHES

65 NORMALLY CLOSED HELD OPEN
65 = P2-8 121 LIFT ENABLE
LS68
10A 10A 68A
68A = P2-1 122 LEFT REAR DOWN
LEFT REAR
LS67
10A 67A
67A = P2-2 123 RIGHT REAR DOWN
RIGHT REAR
LS66
10A 66A
66A = P2-3 124 RIGHT FRONT DOWN
RIGHT FRONT
LS65
35C GREEN/WHITE 35C 10A 65A
65A = P2-4 125 LEFT FRONT DOWN
S9A LEFT FRONT
OUTRIGGER 35C BLUE/WHITE 35C 10A
ENABLE 10A = P2-12 126 POWER
OUTRIGGERS SHOWN IN
35D 35C 35C WHITE/BLACK 35C 35C RETRACTED POSITION
35C = P4-9 127 OUTRIGGER ENABLE
S24
AUTO 79 GREEN 79
ALL UP 79 = P2-6 128 AUTO RETRACT
MODE 35D
70 GREEN/BLACK 70
LEVEL 70 = P2-5 129 AUTO LEVEL

02 70A RED/WHITE 70A

70A = P2-7 130 OUTRIGGER LIGHT
N

OL1
OUTRIGGER 02 = P2-11 131 GROUND
LIGHT
02 WHITE 02
132
S20
71 ORANGE 71 71 4H-71 LEFT FRONT UP
FRONT
UP 133 OUTRIGGER SOLENOID
LEFT 35D D02-24
75 ORANGE/BLACK 75 75 4H-75 LEFT FRONT DOWN
DN 134 OUTRIGGER SOLENOID
D02-25
S21
72 RED 72 72 4H-72 RIGHT FRONT UP
157958AFA

FRONT
UP 135 OUTRIGGER SOLENOID
RIGHT 35D D02-26
76 RED/BLACK 76 76 4H-76 RIGHT FRONT DOWN
DN 136
OUTRIGGER SOLENOID
D02-27
S22
73 BLUE 73 73 4H-73 RIGHT REAR UP
REAR 137
RIGHT UP OUTRIGGER SOLENOID
35D D02-28
77 BLUE/BLACK 77 77 4H-77 RIGHT REAR DOWN
DN 138
OUTRIGGER SOLENOID
D02-29
S23
74 BLACK 74 74 4H-74 LEFT REAR UP
REAR 140
LEFT UP OUTRIGGER SOLENOID
35D D02-30
78 BLACK/WHITE 78 78 4H-78 LEFT REAR DOWN
DN 141
OUTRIGGER SOLENOID
D02-31
O

M147856AD
Z
T

Y
X
S
R

69
 Notes

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

1. Probable cause Remedy

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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 switch
Close switch. Replace if defective.
S1.
4. Loose or broken wire #03 from main power
Check continuity. Replace if defective.
disconnect switch S1 to circuit breaker CB1.
Reset breaker. Check for defective wiring.
5. Tripped or defective circuit breaker CB1.
Replace breaker if defective.
6. Loose or broken wire #05 from breaker CB1 to relay
Check continuity. Replace if defective.
10BCR1.
7. Loose or broken wire #05 from relay 31CR to base
Check continuity. Replace if defective.
engine switch S30.
8. Loose or broken wire #00 from battery B1 to base
Check continuity. Replace if defective.
terminal block TB-1.
9. Loose or broken wire #00 from base terminal block
Check continuity. Replace if defective.
TB-1 to circuit breaker CB3.
Reset breaker. Check for defective wiring.
10. Tripped or defective circuit breaker CB3.
Replace breaker if defective.
11. Loose or broken wire #02 from circuit breaker CB3
Check continuity. Replace if defective.
to base terminal block TB-1.

4.2-2 No Power to Platform (CE)

1. Open or defective base engine switch S30. Check switch. Replace if defective.
2. Loose or broken wire #07 from engine start switch
Check continuity. Replace if defective.
S30 to base terminal block TB-1.
3. Loose or broken wire #07 from base terminal block
Check continuity. Replace if defective.
TB-1 to emergency stop switch S6.
4. Open or defective emergency stop switch S6. Check switch. Replace if defective.
5. Loose or broken wire #7C from emergency stop
Check continuity. Replace if defective.
switch S6 to platform/base switch S10.

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Electrical System Section 4 – Troubleshooting Information

Select platform on switch. Check switch.

6. Open or defective platform/base switch S10.
Replace if defective.
7. Loose or broken wire #7A from platform/base
Check continuity. Replace if defective.
switch S10 to platform emergency stop switch S4.
8. Open or defective platform emergency stop switch
Check switch. Replace if defective.
S4.

4.2-3 All Functions Inoperative from Platform

1. Loose or broken wire #08 from emergency stop
Check continuity. Replace if defective.
switch S4 to off/lift/drive key switch S3.
2. Open or defective off/lift/drive key switch S3. Check switch. Replace if defective.
3. Loose or broken wire #10 from off/lift/drive key
Check continuity. Replace if defective.
switch S3 to platform terminal block.
4. Loose or broken wire #10 from platform terminal
Check continuity. Replace if defective.
block to diode D10 located at relay 10BCR1.
5. Open diode D10 or diode D10 is not connected at
Check diode. Replace if defective.
relay 10BCR1.

4.2-4 All Functions Inoperative (Additional for machines with Load Sensing System)
Check for 12 Volts at P2-12. If no voltage
1. Loose or broken wire #10C from base terminal strip
present, check wire continuity. Replace if
to control module CM1 at pin #P2-12.
defective.
Check for 12 Volts at P3-4. If voltage present,
check for 12 Volts at wire #28A on outrigger
connector plug CN-14 at pin #1. If voltage
2. Loose or broken wire #28 from control module CM1
present, check for 12 Volts on wire #28A at
at pin #P3-4 to 28CR1 tilt relay and 28CR2 Down
28ACR1 Relay and 28ACR2 Relay. If voltage
Enable Relay.
present, check operation of relays. If no voltage
present, check wire continuity. Replace if
defective.
Check for 12 Volts at P3-6. If voltage present,
3. Loose or broken wire #28E from control module check for 12 Volts at wire #28E at 28ECR1
CM1 at pin #P3-6 to 28ECR1 auxiliary tilt relay and and 28ECR2 relays. If voltage present, check
28ECR2 auxiliary down enable relay. operation of relays. If no voltage present, check
wire continuity. Replace if defective.
4. Defective pressure transducer PT1 or angle
Refer to transducer troubleshooting charts.
transducer AT1 or related wiring.

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Section 4 – Troubleshooting Information Electrical System

4.2-5 Engine will Not Crank from Platform

1. Open or defective key switch S3. Check switch. Replace if defective.
2. Loose or broken wire #10 from key switch S3 to
Check continuity. Replace if defective.
start switch S15.
3. Defective start switch S15. Check switch. Replace if defective.
4. Loose or broken wire #32 from start switch S15 to
Check continuity. Replace if defective.
relay 32CR.
5. Defective relay 32CR. Check relay. Replace if defective.
6. Loose or broken wire #41 from relay 32CR to relay
Check continuity. Replace if defective.
10ACR1.
7. Loose or broken wire #02 from relay 10ACR1 to
Check continuity. Replace if defective.
base terminal block.
8. Loose or broken wire #05 from base terminal block
Check continuity. Replace if defective.
to relay 32CR.
9. Loose or broken wire #32A from relay 32CR to
Check continuity. Replace if defective.
starter contactor 32ACR.
10. Defective starter contactor 32ACR. Check contactor. Replace if defective.
11. Loose or broken wire #00 from starter contactor
Check continuity. Replace if defective.
32ACR to engine ground.
12. Loose or broken wire #103 from main power
disconnect switch S1 to starter contactor 32ACR. Check continuity. Replace if defective.
(Kubota Diesel)
13. Loose or broken wire #104 from starter contactor
Check continuity. Replace if defective.
32ACR to starter motor. (Kubota Diesel)
14. Defective starter motor. Check motor. Repair or replace if defective.

4.2-6 Engine will Not Crank from Base Controls (Kubota diesel)
1. Loose or broken wire #05 from base terminal block to
Check continuity. Replace if defective.
base engine switch S30.

2. Loose or broken jumper wire #05 on base engine

Check continuity. Replace if defective.
switch S30.
3. Defective engine start switch S30. Check switch. Replace if defective.
4. Loose or broken wire #32A from engine start switch
Check continuity. Replace if defective.
S30 to starter contactor 32ACR.

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Electrical System Section 4 – Troubleshooting Information

4.2-7 Engine Cranks but Stops Cranking after a few seconds

1. Loose or broken jumper wire #41 on relay 32CR. Check continuity. Replace if defective.
2. Loose or broken wire #02 from relay 32CR to base
Check continuity. Replace if defective.
terminal block TB-1.

4.2-8 Glow Plugs Inoperative from Engine Controls

1. Loose or broken wire #07 from engine start switch
Check continuity. Replace if defective.
S30 to glow plug switch S31.
2. Defective glow plug switch S31. Check switch. Replace if defective.
3. Loose or broken wire #31A from glow plug switch
Check continuity. Replace if defective.
S31 to glow plug relay 31ACR.
4. Loose or broken wire #02 from glow plug relay
Check continuity. Replace if defective.
31ACR to base terminal block TB1.
5. Loose or broken wire #103 from starter solenoid
Check continuity. Replace if defective.
32ACR to relay 31ACR.
6. Loose or broken wire #91A from relay 31ACR to
Check continuity. Replace if defective.
engine glow plugs EGP1.
7. Defective glow plug relay 31ACR. Check relay. Replace if defective.
8. Defective glow plugs. Check glow plugs. Replace if defective.

4.2-9 Glow Plugs Inoperative from Platform (Additional)

1. Loose or broken wire #10 from key selector switch
Check continuity. Replace if defective.
S3 to glow plug switch S13.
2. Defective glow plug switch S13. Check switch. Replace if defective.
3. Loose or broken wire #31 from glow plug switch
Check continuity. Replace if defective.
S13 to glow plug relay 31CR.
4. Loose or broken wire #02 from relay 31CR to base
Check continuity. Replace if defective.
terminal block TB1.
5. Loose or broken wire #05 from base terminal block
Check continuity. Replace if defective.
TB1 to relay 31CR.
6. Loose or broken wire #31A from relay 31CR to glow
Check continuity. Replace if defective.
plug relay 31ACR.
7. Defective relay 31CR. Check relay. Replace if defective.

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Section 4 – Troubleshooting Information Electrical System

4.2-10 Engine Cranks but will Not Start (Kubota diesel)

1. Loose or broken wire #37 from base terminal block
Check continuity. Replace if defective.
to diesel valve solenoid 2D37.
2. Loose or broken wire #57 from starter contactor
Check continuity. Replace if defective.
32ACR to diesel valve solenoid 2D37.
3. Defective fuel valve solenoid 2D37. Check solenoid. Replace if defective.
See glow plugs inoperative above. Repair if
4. Defective glow plug circuit.
necessary.

4.2-11 High Throttle Inoperative

1. Loose or broken wire #10 from key switch S3 to
Check continuity. Replace if defective.
high/low throttle switch S14.
2. Defective high/low throttle switch S14. Check switch. Replace if defective.
3. Loose or broken wire #34 from high/low throttle
Check continuity. Replace if defective.
switch S14 to diode D34 at base terminal block TB-1.
4. Open or loose diode D34. Check diode. Replace if defective.
5. Loose or broken wire #34B from base terminal block
Check continuity. Replace if defective.
TB-1 to relay 34BCR. (CE only)
6. Defective relay 34BCR. Check relay. Replace if defective.
7. Loose or broken wire #42 from relay 34BCR to relay
Check continuity. Replace if defective.
10ACR1.
8. Defective relay 10ACR1. Check relay. Replace if defective.
9. Loose or broken wire #02 from relay 10ACR1 to
Check continuity. Replace if defective.
base terminal block TB1.
10. Loose or broken wire #05 from base terminal block
Check continuity. Replace if defective.
TB1 to relay 32CR.
11. Defective relay 32CR. Check relay. Replace if defective.
12. Loose or broken wire #43 from relay 32CR to relay
Check continuity. Replace if defective.
34BCR.
13. Loose or broken wire #34A from relay 34BCR to
Check continuity. Replace if defective.
engine harness plug.
14. Loose or broken wire #34A from engine harness
plug to high throttle solenoid HTS-34A. (Kubota Check continuity. Replace if defective.
Diesel)

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Electrical System Section 4 – Troubleshooting Information

4.2-12 Drive and Steer Inoperative

1. Outriggers not fully retracted Fully retract outrigger cylinders
2. Key switch S3 in lift position. Turn switch to drive position.
3. Defective drive contacts in key switch S3. Check contacts. Replace if defective.
1. Loose or broken wire #12 from key switch S3 to
Check continuity. Replace if defective.
joystick enable switch S7-7.
2. Defective joystick enable switch S7-7. Check switch. Replace if defective.
3. Loose or broken wire #12A from joystick enable
relay 12BCR to speed, steer and direction switches Check continuity. Replace if defective.
S7-1 to S7-6.
4. Loose or broken wire #12B from joystick enable
Check continuity. Replace if defective.
switch S7-7 to joystick enable relay 12BCR.
5. Defective joystick enable relay 12BCR. Check continuity. Replace if defective.
6. Loose or broken wire #02 from joystick enable relay
Check continuity. Replace if defective.
12BCR to controller harness.
7. Loose or broken wire #10A from base terminal block
Check continuity. Replace if defective.
to relay 28ECR1.
8. Defective relay 28ECR1. Check relay. Replace if defective.
9. Loose or broken wire #1B from relay 28ECR1 to
Check continuity. Replace if defective.
relay 28CR1.
10. Defective relay 28CR1. Check relay. Replace if defective.
11. Loose or broken wire #1 from relay 28CR1 to pin #7
Check continuity. Replace if defective.
on connector CN14 at the outrigger board.
12. Left rear outrigger limit switch LS64 is out of Check continuity through switch. Adjust switch
adjustment or defective. if out of adjustment. Replace if defective.
13. Right rear outrigger limit switch LS63 is out of Check continuity through switch. Adjust switch
adjustment or defective. if out of adjustment. Replace if defective.
14. Right front outrigger limit switch LS62 is out of Check continuity through switch. Adjust switch
adjustment or defective. if out of adjustment. Replace if defective.
15. Left rear outrigger limit switch LS64 is out of Check continuity through switch. Adjust switch
adjustment or defective. if out of adjustment. Replace if defective.
16. Right rear outrigger limit switch LS63 is out of
Check relay. Replace if defective.
adjustment or defective.
17. Right front outrigger limit switch LS62 is out of
Check continuity. Replace if defective.
adjustment or defective.
18. Left front outrigger limit switch LS61 is out of Check continuity through switch. Adjust switch
adjustment or defective. if out of adjustment. Replace if defective.

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Section 4 – Troubleshooting Information Electrical System

19. Defective drive enable relay 61CR. Check relay. Replace if defective.
20. Loose or broken wire #4 from pin #1 on connector
Check continuity. Replace if defective.
CN14 at the outrigger board to relay 30CR.

4.2-13 Brakes will Not Release

1. Loose or broken wire #30 from diodes D15A-2 and
Check continuity. Replace if defective.
D16A-2 to relay 30CR.
2. Defective relay 30CR. Check relay. Replace if defective.
3. Loose or broken wire #02 from relay 30CR to base
Check continuity. Replace if defective.
terminal block TB-1.
4. Loose or broken wire #4 from pin #1 on plug CN14
Check continuity. Replace if defective.
at outrigger board to relay 30CR.
5. Loose or broken wire #30A from relay 30CR to brake
Check continuity. Replace if defective.
dump valve 2H-30A-1 or brake feed valve 2H-30A-2.
6. Defective valve coil brake dump 2H-30A-1 or brake Check continuity through coil. Replace if
feed 2H-30A-2. defective.
7. Loose or broken wire #02 from valve coil brake
dump 2H-30A-1 or brake feed 2H-30A-2 to base Check continuity. Replace if defective.
terminal block TB-1.
8. Loose or broken wire #30 from relay 30CR to diode
Check continuity. Replace if defective.
D30 at base terminal block TB-1.
9. Open diode D30. Check diode. Replace if defective.
10. Loose or broken wire #25 from diode D30 to base
Check continuity. Replace if defective.
terminal block TB-1. (Internal Brakes only)
11. Loose or broken wire #25 from base terminal block
TB-1 to quick brake valve coil 2H-25. (Internal Check continuity. Replace if defective.
Brakes only)
12. Defective quick brake valve coil 2H-25. (Internal Check continuity through coil. Replace if
Brakes only) defective.
13. Loose or broken wire #02 from quick brake valve
2H-25 to base terminal block TB-1. (Internal Brakes Check continuity. Replace if defective.
only)

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Electrical System Section 4 – Troubleshooting Information

4.2-14 Steer Right Inoperative

1. Defective steer right switch S7-2 in joystick S7. Check switch. Replace if defective.
2. Loose or broken wire #23 from steer right switch
Check continuity. Replace if defective.
S7-2 to platform terminal block.
3. Loose or broken wire #23 from platform terminal
Check continuity. Replace if defective.
block to relay 23CR.
4. Defective relay 23CR. Check relay. Replace if defective.
5. Loose or broken wire #04 from base terminal block
Check continuity. Replace if defective.
to relay 23CR.
6. Loose or broken wire #23A from relay 23CR to base
Check continuity. Replace if defective.
terminal block.
7. Loose or broken wire #02 from relay 23CR to base
Check continuity. Replace if defective.
terminal block.
8. Loose or broken wire #23A from base terminal block
Check continuity. Replace if defective.
to steer right valve coil 4H-23A.
9. Defective steer right valve coil 4H-23A. Check coil. Replace if defective.
10. Loose or broken wire #02 from steer right valve coil
Check continuity. Replace if defective.
4H-23A to base terminal block.
11. Open diode D23A. Check diode. Replace if defective.

4.2-15 Steer Left Inoperative

1. Defective steer left switch S7-3 in joystick S7. Check switch. Replace if defective.
2. Loose or broken wire #24 from steer left switch S7-3
Check continuity. Replace if defective.
to platform terminal block.
3. Loose or broken wire #24 from platform terminal
Check continuity. Replace if defective.
block to relay 24CR.
4. Defective relay 24CR. Check relay. Replace if defective.
5. Loose or broken wire #04 from base terminal block
Check continuity. Replace if defective.
to relay 24CR.
6. Loose or broken wire #24A from relay 24CR to base
Check continuity. Replace if defective.
terminal block.
7. Loose or broken wire #02 from relay 24CR to base
Check continuity. Replace if defective.
terminal block.
8. Loose or broken wire #24A from base terminal block
Check continuity. Replace if defective.
to steer left valve coil 4H-24A.
9. Defective steer left valve coil 4H-24A. Check coil. Replace if defective.

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10. Loose or broken wire #02 from steer left valve coil
Check continuity. Replace if defective.
4H-24A to base terminal block.
11. Open diode D24A. Check diode. Replace if defective.

4.2-16 Reverse Drive Inoperative

1. Defective drive reverse switch S7-4 in joystick S7. Check switch. Replace if defective.
2. Defective joystick S7. Check joystick. Replace if defective.
3. Loose or broken wire #15 from joystick S7 to
Check continuity. Replace if defective.
platform terminal block.
4. Loose or broken wire #15 from platform terminal
Check continuity. Replace if defective.
block to relay 15CR.
5. Defective relay 15CR. Check relay. Replace if defective.
6. Loose or broken wire #02 from relay 15CR to base
Check continuity. Replace if defective.
terminal block.
7. Loose or broken wire #04 from base terminal block
Check continuity. Replace if defective.
to relay 15CR.
8. Loose or broken wire #15A from relay 15CR to time
Check continuity. Replace if defective.
delay relay 1TD.
9. Defective time delay relay 1TD. Check relay. Replace if defective.
10. Loose or broken wire #15B from time delay relay
Check continuity. Replace if defective.
1TD to reverse valve coil 4H-15B.
11. Defective reverse valve coil 4H-15B. Check coil. Replace if defective.
12. Loose or broken wire #02 from reverse valve coil
Check continuity. Replace if defective.
4H-15B to base terminal block.
13. Open diode D15A-1 or D15A-2. Check diodes. Replace if defective.

4.2-17 Forward Drive Inoperative

1. Defective drive forward switch S7-5 in joystick S7. Check switch. Replace if defective.
2. Defective joystick S7. Check joystick. Replace if defective.
3. Loose or broken wire #16 from joystick S7 to
Check continuity. Replace if defective.
platform terminal block.
4. Loose or broken wire #16 from platform terminal
Check continuity. Replace if defective.
block to relay 16CR.
5. Defective relay 16CR. Check relay. Replace if defective.
6. Loose or broken wire #02 from relay 16CR to base
Check continuity. Replace if defective.
terminal block.

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7. Loose or broken wire #04 from base terminal block

Check continuity. Replace if defective.
to relay 16CR.
8. Loose or broken wire #16A from relay 16CR to time
Check continuity. Replace if defective.
delay relay 1TD.
9. Defective time delay relay 1TD. Check relay. Replace if defective.
10. Loose or broken wire #16B from time delay relay
Check continuity. Replace if defective.
1TD to forward valve coil 4H-16B.
11. Defective forward valve coil 4H-16B. Check coil. Replace if defective.
12. Loose or broken wire #02 from forward valve coil
Check continuity. Replace if defective.
4H-16B to base terminal block.
13. Open diode D16A-1 or D16A-2. Check diodes. Replace if defective.

4.2-18 First Drive Speed and Steering

Inoperative
1. Loose or broken wire #21 from diode D24A to relay
Check continuity. Replace if defective.
17ACR.
2. Defective relay 17ACR. Check relay. Replace if defective.
3. Loose or broken wire #18A from relay 17ACR to
Check continuity. Replace if defective.
small pump dump valve solenoid 2H-18A.
4. Defective small pump dump valve coil 2H-18A. Check coil. Replace if defective.
5. Loose or broken wire #02 from small pump dump
Check continuity. Replace if defective.
solenoid 2H-18A to base terminal block.

4.2-19 Second Drive Speed Inoperative

1. Defective second speed switch S7-1 in joystick S7. Check switch. Replace if defective.
2. Defective joystick S7. Check joystick. Replace if defective.
3. Loose or broken wire #19 from controller S7-1 to
Check continuity. Replace if defective.
platform terminal block.
4. Loose or broken wire #19 from platform terminal
Check continuity. Replace if defective.
block to diode D19 at relay 35CR.
Tighten diode. Check diode. Replace if
5. Loose or Open diode D19.
defective.
6. Loose or broken wire #10A from base terminal block
Check continuity. Replace if defective.
to high drive/tilt override limit switch LS5.
7. Misadjusted or defective high drive/tilt override limit
Adjust switch. Replace if defective.
switch LS5.

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8. Loose or broken wire #35 from high drive/tilt

Check continuity. Replace if defective.
override limit switch LS5 to base terminal block.
9. Loose or broken wire #35 from base terminal block
Check continuity. Replace if defective.
to relay 35CR.
10. Loose or broken wire #02 from relay 35CR to base
Check continuity. Replace if defective.
terminal block.
11. Defective relay 35CR. Check relay. Replace if defective.
12. Loose or broken wire #17 from relay 35CR to relay
Check continuity. Replace if defective.
17CR.
13. Defective relay 17CR. Check relay. Replace if defective.
14. Loose or broken wire #02 from relay 17CR to base
Check continuity. Replace if defective.
terminal block.
15. Loose or broken wire #10A from base terminal block
Check continuity. Replace if defective.
to relay 17CR.
16. Loose or broken wire #17A from relay 17CR to base
Check continuity. Replace if defective.
terminal block.
17. Loose or broken wire #17A from relay 17CR to relay
Check continuity. Replace if defective.
17ACR.
18. Defective relay 17ACR. Check relay. Replace if defective.
19. Loose or broken wire #02 from relay 17ACR to base
Check continuity. Replace if defective.
terminal block.
20. Loose or broken wire #17A from base terminal block
Check continuity. Replace if defective.
to large pump dump valve solenoid 2H-17A.
21. Loose or broken wire #02 from large pump dump
Check continuity. Replace if defective.
valve solenoid 2H-17A to base terminal block.
22. Defective large pump dump valve solenoid 2H-17A. Check solenoid. Replace if defective.

4.2-20 Third Drive Speed Inoperative

1. High/Low torque switch S41 in high torque position Turn high/low torque switch to low torque
or defective. position. Replace if defective.

2. Defective third speed switch S7-6 in joystick S7. Check switch. Replace if defective.

3. Defective joystick S7. Check joystick. Replace if defective.

4. Loose or broken wire #18B from controller S7-6 to

Check continuity. Replace if defective.
low/high torque switch S41.
5. Loose or broken wire #18 from low/high torque
Check continuity. Replace if defective.
switch S41 to platform terminal block.

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6. Loose or broken wire #18 from platform terminal

Check continuity. Replace if defective.
block to relay 18CR.
7. Defective relay 18CR. Check relay. Replace if defective.
8. Loose or broken wire #02 from relay 18CR to base
Check continuity. Replace if defective.
terminal block.
9. Loose or broken wire #10A from base terminal block
Check continuity. Replace if defective.
to relay 18CR.
10. Loose or broken wire #18A from relay 18CR to small
Check continuity. Replace if defective.
pump dump valve 2H-18A.
11. Loose or broken wire #02 from small pump dump
Check continuity. Replace if defective.
valve 2H-18A to base terminal block.
12. Defective small pump dump valve solenoid 2H-18A. Check solenoid. Replace if defective.

4.2-21 High/Low Range Speed Inoperative

1. Loose or broken wire #12 from joystick enable
Check continuity. Replace if defective.
switch S7-7 to high/low range switch S29.
2. Defective high/low range switch S29. Check switch. Replace if defective.
3. Loose or broken wire #20B from high/low range
Check continuity. Replace if defective.
switch S29 to high/low torque switch S41.
4. Defective high/low torque switch S41. Check switch. Replace if defective.
5. Loose or broken wire #20 from high/low torque
Check continuity. Replace if defective.
switch S41 to relay 20CR.
6. Defective relay 20CR. Check relay. Replace if defective.
7. Loose or broken wire #02 from relay 20CR to base
Check continuity. Replace if defective.
terminal block.
8. Loose or broken wire #10C from base terminal block
Check continuity. Replace if defective.
to relay 35CR.

9. Defective relay 35CR. Check relay. Replace if defective.

10. Loose or broken wire #44 from relay 35CR to relay

Check continuity. Replace if defective.
20CR.
11. Loose or broken wire #20A from relay 20CR to base
Check continuity. Replace if defective.
terminal block TB-1.
12. Loose or broken wire #20A from base terminal block
Check continuity. Replace if defective.
to series parallel valve coil 3H-20A.

13. Defective series/parallel valve coil 3H-20A. Check coil. Replace if defective.

14. Loose or broken wire #02 from series/parallel valve

Check continuity. Replace if defective.
coil 3H-20A to base terminal block.

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4.2-22 Up Circuit Inoperative from Platform or Base

Select lift position. Check switch. Replace if
1. Lift/Off/Drive switch S3 in drive position or defective.
defective.
2. Loose or broken wire #09 from lift/off/drive switch S3
Check continuity. Replace if defective.
to lift enable switch S9.
3. Defective lift enable switch S9. Check switch. Replace if defective.
4. Loose or broken wire #9A from enable switch S9 to
Check continuity. Replace if defective.
up/down switch S5.
5. Defective up/down switch S5. Check switch. Replace if defective.
6. Loose or broken wire #14 from up/down switch S5
Check continuity. Replace if defective.
to diode D14 at base terminal block TB-1.
Tighten diode. Check diode. Replace if
7. Loose or Open diode D14.
defective.
8. Loose or broken wire #14D from base terminal block
Check continuity. Replace if defective.
to relay 14DCR.
9. Loose or broken wire #02 from relay 14DCR to base
Check continuity. Replace if defective.
terminal block.
10. Defective relay 14DCR. Check relay. Replace if defective.
11. Loose or broken wire #36A from pin #10 on
connector CN14 at the outrigger board to terminal Check continuity. Replace if defective.
block TB-1.
12. Loose or broken wire #36A from terminal block TB-1
Check continuity. Replace if defective.
to end of stroke limit switch LS4.

13. Defective end of stroke limit switch LS4. Check switch. Replace if defective.

14. Loose or broken wire #36B from end of stroke limit

Check continuity. Replace if defective.
switch LS4 to relay 14CR.

15. Defective relay 14CR. Check relay. Replace if defective.

16. Loose or broken wire #14A from relay 14CR to relay

Check continuity. Replace if defective.
28CR.
17. Loose or broken wire #14B from relay 28CR to base
Check continuity. Replace if defective.
terminal block.
18. Loose or broken wire #14B from base terminal block
Check continuity. Replace if defective.
to lift valve solenoid 2H-14B.
19. Loose or broken wire #02 from lift valve solenoid
Check continuity. Replace if defective.
2H-14B to base terminal block.

20. Defective lift valve solenoid 2H-14B. Check solenoid. Replace if defective.

21. Open diode D14B-1. Check diode. Replace if defective.

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4.2-23 Platform will Not Lift from Platform or Base Controls with Outriggers Extended
Extend outriggers to take weight off tires (refer
1. Outriggers not extended enough.
to operator section).
2. Loose or broken wire #10A from terminal block TB-1
Check continuity. Replace if defective.
to pin #4 on connector CN14 at the outrigger board.
3. Loose or broken wire #10A from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS68.
4. Defective outrigger limit switch LS68. Check switch. Replace if defective.
5. Loose or broken wire #68A from outrigger limit
Check continuity. Replace if defective.
switch LS68 to outrigger control module at pin P2-1.
6. Loose or broken wire #10A from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS67.
7. Defective outrigger limit switch LS67. Check switch. Replace if defective.
8. Loose or broken wire #67A from outrigger limit
Check continuity. Replace if defective.
switch LS67 to outrigger control module at pin P2-2.
9. Loose or broken wire #10A from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS66.
10. Defective outrigger limit switch LS66. Check switch. Replace if defective.
11. Loose or broken wire #66A from outrigger limit
Check continuity. Replace if defective.
switch LS66 to outrigger control module at pin P2-3.
12. Loose or broken wire #10A from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS65.

13. Defective outrigger limit switch LS65. Check switch. Replace if defective.

14. Loose or broken wire #65A from outrigger limit

Check continuity. Replace if defective.
switch LS65 to outrigger control module at pin P2-4.
15. Check for power on wire #65 at outrigger control If no voltage present, proceed to outrigger
module at pin P2-8. control module troubleshooting.
16. Loose or broken wire #65 from outrigger control
module at pin P2-8 to outrigger board CN22 pin Check continuity. Replace if defective.
#16.

17. Defective lift enable relay 65CR. Check relay. Replace if defective.

18. Defective lift disable relay 17DCR. Check relay. Replace if defective.

19. Loose or broken wire #36A from pin #10 on

connector CN14 at the outrigger board to terminal Check continuity. Replace if defective.
block TB-1.
20. Loose or broken wire #36A from terminal block TB-1
Check continuity. Replace if defective.
to end of stroke limit switch LS4.

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21. Defective end of stroke limit switch LS4. Check switch. Replace if defective.
22. Loose or broken wire #36B from end of stroke limit
Check continuity. Replace if defective.
switch LS4 to relay 14CR.
23. Defective relay 14CR. Check relay. Replace if defective.
24. Loose or broken wire #14A from relay 14CR to relay
Check continuity. Replace if defective.
28CR.
25. Loose or broken wire #14B from relay 28CR to base
Check continuity. Replace if defective.
terminal block.
26. Loose or broken wire #14B from base terminal block
Check continuity. Replace if defective.
to lift valve solenoid 2H-14B.
27. Loose or broken wire #02 from lift valve solenoid
Check continuity. Replace if defective.
2H-14B to base terminal block.
28. Defective lift valve solenoid 2H-14B. Check solenoid. Replace if defective.

4.2-24 Platform will Not Lift from Platform or Base Controls with Outriggers Retracted
(lift operates correctly with outriggers extended)
1. Outriggers not fully retracted. Fully retract outrigger cylinders.

2. Loose or broken wire #1 from relay 28CR1 to pin #7

Check continuity. Replace if defective.
on connector CN14 at the outrigger board.
3. Loose or broken wire #1 from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS64.

4. Defective outrigger limit switch LS64. Check switch. Replace if defective.

5. Loose or broken wire #64 from outrigger limit switch

Check continuity. Replace if defective.
LS64 to outrigger board.
6. Loose or broken wire #64 from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS63.

7. Defective outrigger limit switch LS63. Check continuity. Replace if defective.

8. Loose or broken wire #63 from outrigger limit switch

Check continuity. Replace if defective.
LS63 to outrigger board.
9. Loose or broken wire #63 from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS62.

10. Defective Limit Switch LS62. Check switch. Replace if defective.

11. Loose or broken wire #62 from outrigger limit switch

Check continuity. Replace if defective.
LS62 to outrigger board.
12. Loose or broken wire #62 from outrigger board to
Check continuity. Replace if defective.
outrigger limit switch LS61.

13. Defective outrigger limit switch LS61. Check switch. Replace if defective.

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14. Loose or broken wire #61 from outrigger limit switch

Check continuity. Replace if defective.
LS61 to outrigger board .

15. Open diode D36 on outrigger board. Check diode. Replace if defective.

4.2-25 Up Circuit Inoperative from Base

1. Loose or broken wire #7C from base emergency
stop switch S6 to platform emergency stop switch Check continuity. Replace if defective.
S4.
2. Defective platform emergency stop switch S4. Check switch. Replace if defective.
3. Loose or broken wire #10D from platform
emergency stop switch S4 to idle/platform/base key Check continuity. Replace if defective.
switch S10.

4. Defective idle/platform/base key switch S10. Check switch. Replace if defective.

5. Loose or broken wire #10E from idle/platform/base

Check continuity. Replace if defective.
key switch S10 to up/down switch S2.
6. Loose or broken wire #14E from up/down switch S2
Check continuity. Replace if defective.
to base terminal block.

7. Defective up/down switch S2. Check switch. Replace if defective.

Tighten diode. Check diode. Replace if

8. Loose or Open diode D14E-1 or D10E.
defective.
9. Loose or broken wire #10E from base terminal block
Check continuity. Replace if defective.
to control module CM1 at pin #P2-2.

4.2-26 Down Circuit Inoperative from Platform or Base

Select lift position. Check switch. Replace if
1. Lift/Off/Drive switch S3 in drive position or defective.
defective.
2. Loose or broken wire #09 from lift/off/drive switch S3
Check continuity. Replace if defective.
to lift enable switch S9.

3. Defective lift enable switch S9. Check switch. Replace if defective.

4. Loose or broken wire #9A from enable switch S9 to

Check continuity. Replace if defective.
up/down switch S5.

5. Defective up/down switch S5. Check switch. Replace if defective.

6. Loose or broken wire #13 from up/down switch S5

Check continuity. Replace if defective.
to diode D13 at base terminal block TB-1.

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Tighten diode. Check diode. Replace if

7. Loose or Open diode D13.
defective.
8. Loose or broken wire #13D to relay 13DCR. Check continuity. Replace if defective.
9. Loose or broken wire #02 from relay 13DCR to base
Check continuity. Replace if defective.
terminal block TB-1.
10. Defective relay 13DCR. Check relay. Replace if defective.
11. Loose or broken wire #13A from relay 13DCR to
Check continuity. Replace if defective.
base terminal block.
12. Loose or broken wire #13A from base terminal block
to holding valve solenoid 2H-13A-1 or 2H-13A-2 or Check continuity. Replace if defective.
2H-13A-3 or 2H-13A-4.
13. Loose or broken wire #02 from holding valve
solenoid 2H-13A-1 or 2H-13A-2 or 2H-13A-3 or Check continuity. Replace if defective.
2H-13A-4 to base terminal block TB-1.
14. Defective holding valve solenoid 2H-13A-1 or
Check solenoid. Replace if defective.
2H-13A-2 or 2H-13A-3 or 2H-13A-4.
15. Loose or broken wire #13A from base terminal block
Check continuity. Replace if defective.
to lowering valve solenoid 2H-13A.
16. Loose or broken wire #02 from lowering valve
Check continuity. Replace if defective.
solenoid 2H-13A to base terminal block.

17. Defective lowering valve solenoid 2H-13A. Check solenoid. Replace if defective.

4.2-27 No Down Function (Additional for machines with Load Sensing System)
1. Loose or broken wire #02 from base terminal strip
TB-1 to down enable relay 28CR2 or auxiliary down Check continuity. Replace if defective.
enable relay 28ECR2.
2. Defective down enable relay 28CR2 or auxiliary
Check relay. Replace if defective.
down enable relay 28ECR2.
3. Loose or broken wire #28 from control module CM1
Check continuity. Replace if defective.
at pin #P3-4 to down enable relay 28CR2.
4. Loose or broken wire #28E from control module
CM1 at pin #P3-6 to auxiliary down enable relay Check continuity. Replace if defective.
28ECR2.
5. Loose or broken wire #10A from base terminal block
Check continuity. Replace if defective.
to auxiliary down enable relay 28ECR2.
6. Loose or broken wire #13C from auxiliary down
Check continuity. Replace if defective.
enable relay 28ECR2 to down enable relay 28CR2.
7. Loose or broken wire #13B from down enable relay
Check continuity. Replace if defective.
28CR2 to down relay 28DCR.

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4.2-28 Down Circuit Inoperative from Base

1. Loose or broken wire #7C from base emergency
stop switch S6 to platform emergency stop switch Check continuity. Replace if defective.
S4.
2. Defective platform emergency stop switch S4. Check switch. Replace if defective.
3. Loose or broken wire #10D from platform
emergency stop switch S4 to idle/platform/base key Check continuity. Replace if defective.
switch S10.
4. Defective idle/platform/base key switch S10. Check switch. Replace if defective.
5. Loose or broken wire #10E from idle/platform/base
Check continuity. Replace if defective.
key switch S10 to up/down switch S2.
6. Loose or broken wire #13D from up/down switch S2
Check continuity. Replace if defective.
to base terminal block TB-1.

7. Defective up/down switch S2. Check switch. Replace if defective.

4.2-29 Powered Extension Platform

Inoperative

1. Loose or broken battery cable from main power

Check continuity. Replace if defective.
disconnect switch S1 to fuse F2 (100 Amp).

2. Open fuse F2. Check fuse. Replace if open.

3. Loose or broken battery cable #103A from fuse F2

Check continuity. Replace if defective.
to contactor 9CR1.

4. Defective contactor 9CR1. Check contactor. Replace if defective.

5. Loose or broken battery cable #103B from contactor

Check continuity. Replace if defective.
9CR1 to motor contactor 99CR.

6. Defective motor contactor 99CR. Check contactor. Replace if defective.

7. Loose or broken wire #103B from battery cable

Check continuity. Replace if defective.
#103B to fuse F5.

8. Defective fuse F5. Check fuse. Replace if defective.

9. Loose or broken wire #103C from fuse F5 to

Check continuity. Replace if defective.
powered platform enable switch S34 or S34A.
10. Loose or broken wire #103D from enable switch
S34or S34A to platform extend retract switch S11 or Check continuity. Replace if defective.
S11A.

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4.2-30 Powered Extension Platform will Not

Extend
1. Defective platform extend/retract switch S11 or
Check switch. Replace if defective.
S11A.
2. Loose or broken wire #26 or #26A from platform
extend/retract switch S11 or S11Ato platform extend Check continuity. Replace if defective.
valve coil 4H-26 or 4H-26A.
3. Open diode D26 or D26A. Check diode. Replace if defective.
4. Defective platform extend valve coil 4H-26 or
Check coil. Replace if defective.
4H-26A.
5. Loose or broken wire #00 from platform extend
Check continuity. Replace if defective.
valve coil 4H-26 or 4H-26A to battery cable #00.

4.2-31 Powered Extension Platform will Not

Retract
1. Defective platform extend/retract switch S11 or
Check switch. Replace if defective.
S11A.
2. Loose or broken wire #27 or #27A from platform
extend/retract switch S11 or S11A to platform retract Check continuity. Replace if defective.
valve coil 4H-27 or 4H-27A.

3. Open diode D27 or D27A. Check diode. Replace if defective.

4. Defective platform retract valve coil 4H-27 or 4H-27A. Check coil. Replace if defective.

5. Loose or broken wire #00 from platform retract valve

Check continuity. Replace if defective.
coil 4H-27 or 4H-27A to battery cable #00.

4.2-32 Hydraulic Generator Inoperative

1. Key switch S3 in drive position. Turn switch to lift position.

2. Loose or broken wire #9 from base terminal block

Check continuity. Replace if defective.
TB-1 to generator relay 86BCR.
3. Loose or broken wire #9 from generator relay
Check continuity. Replace if defective.
86BCR to generator switch S12.

4. Defective generator switch S12. Check switch. Replace if defective.

5. Loose or broken wire #85 from generator switch S12

Check continuity. Replace if defective.
to generator relay 86ACR.
6. Loose or broken wire #85 from generator relay
Check continuity. Replace if defective.
86ACR to generator relay 86BCR.

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7. Loose or broken wire #86B from generator relay

Check continuity. Replace if defective.
86ACR to generator relay 86BCR.
8. Defective relay 86ACR. Check relay. Replace if defective.
9. Defective relay 86BCR. Check relay. Replace if defective.
10. Open diode D86C-1. Check diode. Replace if defective.
11. Loose or broken wire #17 from diodes D86B-1 to
Check continuity. Replace if defective.
relay 17CR.
12. Loose or broken wire #2A from relays 10ACR2 and
Check continuity. Replace if defective.
86BCR to relay 10ACR1.
13. Loose or broken wire #85A from circuit breaker CB4
Check continuity. Replace if defective.
to relay 86BCR.

14. Tripped or defective circuit breaker CB4. Reset circuit breaker. Replace if defective.

15. Loose or broken wire #3 from circuit breaker CB4 to

Check continuity. Replace if defective.
circuit breaker CB1.
16. Loose or broken wire #86C from relay 86BCR to
Check continuity. Replace if defective.
generator valve coil 2H-86C.
17. Loose or broken wire #02 from base terminal block
Check continuity. Replace if defective.
to generator valve coil 2H-86C.

18. Defective generator valve coil 2H-86C. Check coil. Replace if defective.

4.2-33 Hydraulic Generator will Not Shut Off from Generator Switch

1. Defective generator switch S12. Check switch. Replace if defective.

2. Loose or broken wire #86 from generator switch S12

Check continuity. Replace if defective.
to diode D86.

3. Open diode D86. Check diode. Replace if defective.

4. Defective relay 86ACR. Check relay. Replace if defective.

5. Loose or broken wire #02 from base terminal block

Check continuity. Replace if defective.
to relay 86ACR.

4.2-34 All Outriggers Inoperative (Auto-level

and manual)

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

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NOTE
For the outriggers to function the upper control
console must be in the lift position.

If no power is present ensure there is power on

1. No power on wire #44 at relay 35CR.
wire #35 and relay 35CR operates correctly.
2. Loose or broken wire #44 from relay 35CR to pin #6
Check for continuity. Replace if defective.
on connector CN14 on outrigger board.
If no power is present check for continuity
3. No power at wire #9 at pin #5 on connector CN14
on wire #9 back to base terminal block TB-1.
on outrigger board.
Replace if defective.
4. Defective relay 9CR2 or 9CR3 on outrigger board. Check relays. Replace if defective.
5. Defective relay 17DCR on outrigger board. Check relay. Replace if defective.
6. Open or broken jumper J17E on outrigger board. Check jumper. Replace if defective.

7. Open diode D17B-1 on outrigger board. Check diode. Replace if defective.

8. Loose or broken wire #17 from pin #2 on connector

CN14 on outrigger board to relay 35CR or relay Check for continuity. Replace if defective.
17CR.
9. Loose or broken wire #17B from pin #1 or wire #02
from pin #2 on connector CN21 on outrigger board Check for continuity. Replace if defective.
to outrigger holding valve coil 2H-17B.

10. Defective outrigger holding valve coil 2H-17B. Check coil. Replace if defective.

4.2-35 All Outriggers Inoperative (Auto-level and manual from platform controls)
1. Loose or broken wire #35C from pin #1 on
connector CN20 on outrigger board through
Check for continuity. Replace if defective.
outrigger cables and plugs to the outrigger enable
switch S9A in the control console.
2. Loose or broken wire #35D from outrigger enable
switch S9A to pin #5 on the outrigger control Check for continuity. Replace if defective.
console plug.

3. Defective outrigger enable switch S9A. Check switch. Replace if defective.

4.2-36 All Outriggers Inoperative (base

controls)
1. Defective outrigger enable switch S9B. Check switch. Replace if defective.

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4.2-37 All Outriggers Inoperative (Auto-level)

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

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4.2-38 All Outriggers Inoperative (Auto Level)

B: Led Power Indicator Light at Outrigger Control Module (OCM1) Flashing
Flash Code Probable Cause Remedy
1/1 1. Outriggers are all up and machine is tilted. 1. Level the machine.
1. Lower the scissor stack below high speed limit switch.
1. Machine is elevated.
1/2 2. Loose or broken wire # 35.
2. Check for input voltage on wire #35 at pin P2-10 of the
outrigger control module (OMC1). Replace if defective.
1. At least one outrigger is not fully retracted.
1. Fully retract all outriggers.
2. Defective outrigger rod limit switch (LS61,
2/2 LS62, LS63, LS64) or wiring.
2. Replace defective or damaged switch(es) or wiring.
3. Check for continuity. Replace if defective.
3. Defective diode (D36) on outrigger board.
1. Outriggers are all down and the machine is
2/1 not fully level.
1. Move machine to less sloped terrain if it will not lift.

1. Check for power on wire #70 or #79 at pin P2-5 or P2-6 of the
1. Power on wire #70 or #79 at power on.
outrigger control module. Replace defective component.
5/5 2. Power on wire #70 or #79 when manually
2. Check for power on wire #70 or #79 while manually operating
operating outriggers.
an outrigger.
1. Check battery and charging system to ensure minimum 9 volts.
1. Low or no voltage on wire #35c.
5/2 2. Loose or broken wire on #35c.
2. Check for input voltage on wire #35c at pin P4-9 of outrigger
control module (OCM1).
1. Excessive vibration. 1. Outrigger control module cannot read tilt sensor.
7/1 2. Defective outrigger control module. 2. Replace.
6/6 1. Outriggers are being manually controlled. 1. Indicates function activated. No repair necessary.
1. Turn off power to reset the outrigger control module. Turn
1. Error occured while self diagnosing the
7/8 hardware fail safe.
power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Check for minimum 9 volts between wire #02 at pin P2-11 and
5/1 1. Low input voltage to outrigger control module.
wire #10A at pin P2-12 at outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
7/7 1. Startup error occurred while self diagnosing. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
7/5 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
7/2 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
8/1 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
8/2 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
8/3 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
8/4 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
8/5 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1. Turn off power to reset the outrigger control module. Turn
7/6 1. Internal failure of OCM1. power back on and see if the code has cleared. If problem
persists, replace outrigger control module.
1624

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4.2-39 Left Front Outrigger Inoperative Manually

1. Defective left front outrigger switch S20 at platform,

Check switch. Replace if defective.
or S20A at base.
2. Loose or broken wire #71 from outrigger control
console to pin #6 on connector CN20 at outrigger Check continuity. Replace if defective.
board (retract), or from wire #75 to pin #7 (extend).
3. Open diode D71 (retract) or D75 (extend) on
Check diode. Replace if defective.
outrigger board.
4. Loose or broken wire #71 from pin #7 on connector
CN21 at outrigger board to valve coil 4H-71 (retract) Check continuity. Replace if defective.
, or wire #75 from pin #8 to 4H-75 (extend).
5. Loose or broken wire #02 from valve coil 4H-71
(retract) or 4H-75 (extend) to pin #2 on connector Check continuity. Replace if defective.
CN21 at the outrigger board.

4.2-40 Right Front Outrigger Inoperative Manually

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

4.2-41 Right Rear Outriggers Inoperative Manually

1. Defective right rear outrigger switch S22 at platform,
Check switch. Replace if defective.
or S22A at base
2. Loose or broken wire #73 from outrigger control
console to pin #3 on connector CN20 at outrigger Check continuity. Replace if defective.
board (retract), or from wire #77 to pin #4 (extend).

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Section 4 – Troubleshooting Information Electrical System

3. Open diode D73 (retract) or D77 (extend) on

Check diode. Replace if defective.
outrigger board.
4. Loose or broken wire #73 from pin #4 on connector
CN21 at outrigger board to valve coil 4H-73 (retract), Check continuity. Replace if defective.
or wire #77 from pin #4 to 4H-77 (extend).
5. Loose or broken wire #02 from valve coil 4H-73
(retract) or 4H-77 (extend) to pin #2 on connector Check continuity. Replace if defective.
CN21 at the outrigger board.

4.2-42 Left Rear Outriggers Inoperative Manually

1. Defective left rear outrigger switch S23 at platform,
Check switch. Replace if defective.
or S23A at base.
2. Loose or broken wire #74 from outrigger control
console to pin #5 on connector CN20 at outrigger Check continuity. Replace if defective.
board (retract), or from wire #78 to pin #2 (extend).
3. Open diode D74 (retract) or D78 (extend) on
Check diode. Replace if defective.
outrigger board.
4. Loose or broken wire #74 from pin #6 on connector
CN21 at outrigger board to valve coil 4H-74 (retract), Check continuity. Replace if defective.
or wire #78 from pin #3 to 4H-78 (extend).
5. Loose or broken wire #02 from valve coil 4H-74
(retract) or 4H-78 (extend) to pin #2 on connector Check continuity. Replace if defective.
CN21 at the outrigger board.

4.2-43 Individual Outrigger Functions Inoperative (Auto-level)

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

4.2-44 Auto-level Inoperative

1. Loose or broken wire #35D from outrigger enable
Check continuity. Replace if defective.
switch S9A to auto mode outrigger switch S24.

2. Defective auto mode outrigger switch S24. Check switch. Replace if defective.

3. Loose or broken wire #10A at pin #P2-12 on Check for power at P2-12. If no voltage present,
outrigger control module OCM1. check continuity of wire. Replace if defective.

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Electrical System Section 4 – Troubleshooting Information

4. Loose or broken wire #35 at pin #P2-10 on Check for power at P2-10. If no voltage present,
outrigger control module OCM1. check continuity of wire. Replace if defective.
5. Loose or broken wire #02 at pin #P2-11 on Check for ground at P2-11. If no ground present,
outrigger control module OCM1. check continuity of wire. Replace if defective.
6. Loose or broken wire #70 from auto mode outrigger
switch S24 to pin #P2-5 on outrigger control module Check continuity. Replace if defective
OCM1.

4.2-45 Auto All Up Inoperative (Retract)

1. Loose or broken wire #35D from outrigger enable
Check continuity. Replace if defective.
switch S9A to auto mode outrigger switch S24.

2. Defective auto mode outrigger switch S24. Check switch. Replace if defective.

3. Loose or broken wire #10A at pin #P2-12 on Check for power at P2-12. If no voltage present,
outrigger control module OCM1. check continuity of wire. Replace if defective.
4. Loose or broken wire #35 at pin #P2-12 on Check for power at P2-10. If no voltage present,
outrigger control module OCM1. check continuity of wire. Replace if defective.
5. Loose or broken wire #02 at pin #P2-11 on Check for ground at P2-11. If no ground present,
outrigger control module OCM1. check continuity of wire. Replace if defective.
6. Loose or broken wire #70 from auto mode outrigger
switch S24 to pin #P2-5 on outrigger control module Check continuity. Replace if defective.
OCM1.

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Section 4 – Troubleshooting Information Hydraulic System

4.3 Hydraulic System

4.3-1 All Functions Inoperative

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

4.3-2 Steering Inoperative

1. Stuck or defective brake feed valve 2H-30A-2. Check valve. Repair or replace if defective.
2. Stuck or defective steer right valve 4H-23A or
Check valves. Replace if defective.
steer left valve 4H-24A.
3. Steer cylinder C7 damaged or bypassing
Check cylinder. Repair or replace if defective.
internally.

4.3-3 Steer and First Drive Speed Inoperative

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

4.3-4 Lift and Second Drive Speed Inoperative

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

4.3-5 Drive Inoperative

1. Stuck or defective drive reverse valve 4H-15B or
Check valves. Repair or replace if defective.
drive forward valve 4H-16B.
2. Defective motion control valve MC1. Check valve. Repair or replace if defective.
3. Missing or defective check balls in series/parallel Repair or replace balls. Refer to Section 5 for
valve manifold 3H-20A. proper location.
4. Stuck or defective main series/parallel valve
Check valve. Repair or replace if defective.
spool V3 in drive motor.

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Hydraulic System Section 4 – Troubleshooting Information

5. Defective drive motor M1. Check motor. Repair or replace if defective.

6. Free wheeling valve 2H-30A stuck. Check valve. Repair or replace if defective.
7. Cushion cylinder C8 bypassing internally. Check cylinder. Repair or replace if defective.

4.3-6 Reverse Drive Inoperative

1. Stuck or defective drive valve 4H-15B. Check valve. Repair or replace if defective.
2. Stuck or defective check valve in motion control
Check valves. Clean or replace if defective
assembly MC1.

4.3-7 Forward Drive Inoperative

1. Stuck or defective drive valve 4H-16B. Check valve. Repair or replace if defective.
2. Stuck or defective check valve in motion control
Check valves. Clean or replace if defective.
assembly MC1.

4.3-8 Brakes Do Not Release

1. Stuck or defective brake feed valve 2H-30A-2. Check valve. Repair or replace if defective.
2. Stuck or defective brake dump valve 2H-30A-1. Check valve. Repair or replace if defective.
3. Stuck or defective brake valve 2H-25. (If
Check valve. Repair or replace if defective.
equipped)
4. Stuck or defective auto reset valve V6. (If
Check valve. Repair or replace if defective.
equipped)
5. Defective disc brake pack BP1. (Internal brake) Check brake pack. Repair or replace if defective.

6. Defective brake cylinder C5 or C6. (External

Check cylinder. Repair or replace if defective.
brake cylinders)

4.3-9 Brakes will Not Release (Internal

Brake)
1. Bad o-rings internal to brake. (If release piston Check for hydraulic oil in axle. Replace o-rings if
will not hold pressure, brake will not release.) defective.
2. Discs frozen. (These brakes are designed for only
limited dynamic braking. A severe emergency Check for abnormal wear. Replace disc stack if
stop or prolonged reduced release pressure defective.
operation may result in this type of damage.)

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Section 4 – Troubleshooting Information Hydraulic System

4.3-10 Brake Slips (Internal Brake)

1. Excessive pressure in hydraulic system. (If there
Check filters, hose size, restrictions in other
is back pressure in the actuation line of the
hydraulic components.
brake, holding torque will be reduced)
2. Oil in brake if designed for dry use. (Wet linings
generate 67% of the dry torque rating. If the Replace oil seal in brake. Check motor seal.
brake has oil in it, check the type of oil hydraulic Check piston seals.
or gearbox. i. Gearbox oil ii. Hydraulic oil)

NOTE
Internal components will need to be inspected,
cleaned and replaced as required.

Check brake’s holding torque is sufficient.

1. Make sure the machine is parked on level
ground.
2. Locate the brake feed valve (2H30A-2) on
the main manifold. Disconnect the electrical
connectors from this valve. This will prevent
the hydraulic system from releasing the brake.
1. Disc plates worn. (The thickness of the disc 3. With the engine running, machine in drive
stack sets the torque level. A thin stack reduces mode, engine on high idle, high torque
torque.) selected and low speed range selected, hold
the enable switch on the
4. if the brake slips and the machine starts to
move in this condition, either the brake plates
are worn or the springs have broken. Both the
springs and the brake plates must be replaced
to return the brake to its original holding
torque.

4.3-11 Brake Drags or Runs Hot (Internal

Brake)
Place pressure gauge in brake line. Brakes use
1. Low brake pressure.
system pressure. (Minimum 335 psi required)
2. Bearing failure (If the bearing should fail, a large
Replace bearing
amount of drag can be generated)

4.3-12 Up Circuit Inoperative

1. Stuck or defective lift valve 2H-14B. Check valve. Repair or replace if defective.
2. Stuck check valve CV3. Check valve. Replace if defective.

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Hydraulic System Section 4 – Troubleshooting Information

1. Misadjusted or defective lift relief valve R2. Adjust valve. Replace if defective.
2. Stuck or defective lowering valve 2H-13A. Check valve. Repair or replace if defective.
3. Stuck or defective manual lowering valve V1. Check valve. Repair or replace if defective.
4. Open or defective brake feed valve 2H-30A-2. Check valve. Repair or replace if defective.
5. Open manual override on holding valve 2H-13A-1 or Depress and turn manual override clockwise to
2H-13A-2 or 2H-13A-3 or 2H-13A-4. close. Replace if defective.
6. Stuck holding valve 2H13A-1 or 2H13A-2 or
Check valves. Repair or replace if defective.
2H-13A-3 or 2H-13A-4.

4.3-13 Down Circuit Inoperative

1. Stuck or defective lowering valve 2H-13A. Check valve. Repair or replace if defective.
2. Stuck holding valve 2H13A-1 or 2H13A-2 or
Check valves. Repair or replace if defective.
2H-13A-3 or 2H-13A-4.
3. Plugged lowering orifice O1. Clean or replace orifice.

4.3-14 Powered Extension Platform

Inoperative
1. Defective powered extension pump P3. Check pump. Repair or replace if defective.
2. Misadjusted or defective relief valve R5. Adjust valve. Replace if defective.
3. Stuck or defective deck extend valve 4H-26 or
Check valves. Repair or replace if defective.
4H-26A or retract valve 4H-27 or 4H-27A.
4. Defective powered extension cylinder C13 front or
Check cylinder. Repair or replace if defective.
C14 rear.

4.3-15 Hydraulic Generator Inoperative

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

4.3-16 All Outriggers Inoperative

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

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Section 4 – Troubleshooting Information Hydraulic System

4.3-17 Left Front Outrigger Inoperative

2. Stuck or defective retract valve 4H-71 or extend valve
Clean valve. Replace if defective.
4H-75.
3. Stuck or defective check valve CV5. Check valve. Replace if defective.
4. Bypassing outrigger cylinder C9. Repack cylinder. Replace if defective.

4.3-18 Right Front Outrigger Inoperative

1. Stuck or defective retract valve 4H-72 or extend valve
Clean valve. Replace if defective.
4H-76.
2. Stuck or defective Check valve CV6. Check valve. Replace if defective.
3. Bypassing outrigger cylinder C10. Repack cylinder. Replace if defective

4.3-19 Right Rear Outrigger Inoperative

1. Stuck or defective retract valve 4H-73 or extend valve
Clean valve. Replace if defective.
4H-77.
2. Stuck or defective check valve CV7. Check valve. Replace if defective.
3. Bypassing outrigger cylinder C11. Repack cylinder. Replace if defective

4.3-20 Left Rear Outrigger Inoperative

1. Stuck or defective retract valve 4H-74 or extend valve
Clean valve. Replace if defective.
4H-78.
2. Stuck or defective check valve CV4. Check valve. Replace if defective.
3. Bypassing outrigger cylinder C12. Repack cylinder. Replace if defective

4.3-21 Outriggers Drift In

1. Defective check valve left front (CV4), right front
Clean valve. Replace if defective.
(CV5), right rear (CV6) or left rear (CV7)
2. Outriggers cylinder bypassing left front (C9), right
Repack cylinder. Replace if defective
front (C10), right rear (C11) or left rear (C12).

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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 Fall hazard. Use the three points of contact
procedures contained in this chapter. principle when you use the MEWP to enter or exit
the platform. If you do not obey, there is a risk of
death or serious injury.
NOTE
The illustrations in this manual are for instructional
purposes only. The models and components shown
may appear somewhat different from those on your WARNING
actual MEWP. Do not operate the platform controls without the
correct fall protection attached to the designated
5.1-1 Safety and workmanship location in the platform. Failure to do so could
result in death or serious injury!
Your safety, and that of others, is the first
consideration when engaging in the maintenance of
equipment. Always be conscious of weight. Never
attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest WARNING
in an unstable position. When raising a portion of the Make sure there are no people or obstructions in
equipment, ensure that adequate support is provided. the test area, and there is sufficient space for the
scissor and drive functions required for the given
procedures.
Unless specifically noted otherwise, before beginning
any procedure:
1. Park the MEWP on a firm, level surface. Fully
lower the machine.
2. Push in the emergency stop buttons on the
platform control console and the base control
console.
3. Turn the off/platform/base key switch to the off
position. Remove the key.
4. Turn the main power disconnect switch to the off
position.

After you complete a procedure which involves

the modification, adjustment, or replacement of
a hydraulic or electrical component, do all of the
function tests given in your unit’s Operation Manual.

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Section 5 – Procedures Platform

5.2 Platform 5.3 Scissors

5.2-1 Adjust the gate spring hinge 5.3-1 Replace and adjust the high speed
cutout (LS5) and lift cutout (LS1)
1. The tension of the spring hinges should be limit switches
such that when the gate is opened halfway
and released, it will close fully and latch. Machine preparation
2. To adjust the tension of the spring hinges, first
remove the safety locking screw located at 1. Ensure the MEWP is parked on a firm level
the top or bottom of each hinge. Retain the surface.
screws for reinstallation later. 2. Chock or block the wheels to keep the MEWP
3. To increase the tension, insert a 5/32" hex from rolling forward or backward.
wrench in the screw socket, and turn the
wrench clockwise. To release the tension, Remove the limit switch
depress the hex wrench in the socket, let it
rotate counterclockwise, then release the hex 1. Raise the platform to give access to the limit
wrench. switch cable(s), and deploy the maintenance
stand.
2. Turn the emergency main power disconnect
switch to the OFF position.
3. Remove the bolts, washers, and nuts (x2)
securing the limit switch cover. Set aside the
hardware and cover for reinstallation later.
4. Remove the bolts and washers (x2) securing
the limit switch to the bracket. Set aside for
reinstallation later.

5. Adjust the tension on both hinges until the gate

releases and latches from a half open position.
6. Reinstall the safety locking screws into the
hinges when tension adjustment is complete.

5. Remove the limit switch(es) and free the limit

switch cable(s) by cutting the tie wraps.
6. Follow the cable(s) into the electrical panel,
and disconnect the limit switch wires from the
electrical panel. Discard the limit switch(es).

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Platform Section 5 – Procedures

Replace the limit switch 4. Loosen the set screws (x2) on the high speed
cutout cam, and rotate the cam until it depresses
1. Mount the new limit switch(es) (119296 for High the limit switch plunger. Apply a small amount of
Speed Cutout, and 119375 for Lift Cutout) on the Loctite to both set screws, and tighten them.
bracket, using the hardware removed previously
5. For the lift cutout limit switch (Model 9250
(apply a small amount of Loctite to the bolts).
only) - Raise the platform until the distance
from the standing surface of the platform to the
ground measures 26 ft (7.92 m).
NOTE
The High Speed Cutout Limit Switch is the one 6. Loosen the set screws (x2) on the lift cutout
closest to the scissor arm. cam, and rotate the cam until it depresses the
limit switch plunger. Apply a small amount of
Limit switch electrical connections Loctite to both set screws, and tighten them.

1. Route the new limit switch cable(s) along the

same path as the old one(s) into the electrical
panel cabinet. Use tie wraps as needed to
secure them at regular intervals.
2. For the high speed cutout limit switch - Strip
the cable jacket back to separate the wires. Cut
the wires to length if needed, strip the ends, and
insert them into the terminal block (refer to 3.20
Electrical Panel Diagram - All Options (CE)).
3. For the lift cutout limit switch (model 9250
only) - Strip the cable jacket back to separate
the wires. Cut the wires to length if needed, strip
the ends, and crimp ferrules onto the wire ends.
Insert them into the 45° header on the PC board
(refer to 1.3 Hydraulic System & Component
Maintenance and Repair). Test the limit switch
4. Stow the maintenance stand and fully lower the
platform. 1. For the high speed cutout limit switch - Raise
the platform less than 10 ft (3.05 m), and drive
Set up the limit switch cam the unit at full speed. Then raise the platform
over 10 ft (3.05 m). The unit should automatically
1. Turn emergency main power disconnect switch switch from high speed to low speed.
to the ON position, and start the engine. 2. For the lift cutout limit switch (Model 9250
2. Attach the end of a measuring tape to the side of only) - Raise the platform over 26 ft (7.92 m) and
the platform with a tie wrap, in such a way that try to drive the unit. The unit should not drive.
the measuring tape will hang down freely to the Then lower the platform to below 26 ft (7.92 m).
ground. The unit should drive.

NOTE
The end of the measuring tape should be level
with the standing surface of the platform.
3. For the high speed cutout limit switch - Raise
the platform until the distance from the standing
surface of the platform to the ground measures
10 ft (3.05 m).

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Section 5 – Procedures Base

5.4 Base 5.4-2 Install and torque the wheels

5.4-1 Inspect and torque the wheel bolts When a wheel is removed or replaced, you must
follow the procedure below to make sure it is installed
and nuts correctly.
You must do a check of the torque on all wheel
nuts and wheel bolts at pre-delivery, after 8 hours of 1. Inspect wheel fastener threads for damage of
operation, and at weekly intervals. Use the following defects. Replace if defective.
procedure.
2. Clean the mounting surfaces of the hub and
wheel rim of debris, rust, excess paint, etc.
1. Confirm that each wheel fastener is torqued to 3. Mount wheel on the hub, centering mounting
140 ft-lb. All fasteners must be torqued using the holes on the wheel studs or bolt holes. Use
tightening sequence shown below. appropriate lifting device as required.
4. Install wheel nuts or wheel bolts and hand
tighten to center the rim.
1 5. Torque nuts or bolts to approximately 50 ft-lb using
the tightening sequence in 5.4-1.
3 5 6. Torque again to 100 ft-Ib using the same
sequence.
7. Torque again to 140 ft-lb using the same
8 sequence.
7
8. Repeat the tightening sequence to confirm
that none have changed from 140 ft-lb. If any
are found below 140 ft-lb, repeat complete
6 4 sequence until there is no change in torque
values. If possible, drive the machine prior to
checking torques.
2 9. Check torque values after 8 hours of operation
and then at weekly intervals.
2. Again, confirm that each wheel fastener is
torqued to the specified tolerance. Re-torque
as necessary until all fasteners are properly
torqued.

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Base Section 5 – Procedures

5.4-3 Front axle hub procedure 8. Flip hub over and then remove and discard inner
bearing cone (item 8) and grease seal (item 10).
For front axle hub components, refer to your MEWP’s
9. Remove and discard both inner and outer
parts manual.
bearing cups (items 6 & 8) from hub.
10. Remove grease from spindle arm and hub and
look for signs of visible damage. If damage
is found on the hub or on the spindle arm,
contact Service Department immediately
7 using information found in page 2 for further
11 instructions.
5
10 11. Press new bearing cups (items 6 & 8) into hub.
4 9
12. Pack replacement inner and outer bearings by
8 either pressing wheel bearing grease into each
roller by hand or using a bearing packer and
grease gun. Ensure that grease is forced into all
6 surfaces of the bearing.
3
2 NOTE
1 Use only recommended wheel bearing grease
- NLGI (National Lubricating Grease Institute)
Grade #2 or equivalent.
NOTE
Keep work area clean and visibly free from
NOTE
The bearings must be packed before installing.
contamination at all times.

1. Ensure MEWP is parked on a firm, level surface. 13. Install replacement inner bearing in the race and
Chock or block the wheels to keep the MEWP then seat the new grease seal. Flip hub over and
from rolling forward or backward. install replacement outer bearing.
2. Fully lower the platform. 14. Install hub on the spindle.
3. Using a suitable lifting device or outriggers 15. Install replacement washer and replacement
(if equipped), lift the end of the MEWP with the castle flanged nut. Hand tighten the castle
steer axle. flanged nut until it touches the washer. Turn
hub by hand to ensure smooth running. No
resistance should be felt at this time.
CAUTION 16. Take a torque wrench and set it at 30 ft-lb, and
while continuously rotating hub, tighten castle
Use a suitably-rated support stand to support
flanged nut. While hub is being turned and nut
MEWP while performing the following operations.
tightened, resistance will increase.
17. Using an open-ended wrench, loosen castle
4. Turn emergency main power disconnect switch flanged nut a 1/4 turn while turning the wheel
to “ ” off position. hub. It should turn easily. The nut should not
5. Remove wheel assembly. come completely loose.
6. Remove dust cap (item 1) to access internal 18. Using a torque wrench set to 15 ft-lb, tighten
components of hub assembly. castle flanged nut. Turn wheel hub and check for
7. Pull cotter pin (item 2) out of spindle arm smooth turning.
(item 11) and then remove castle nut (item 3),
washer (item 4) and outer bearing cone (item 5).
Dispose of dust cap, cotter pin, castle nut,
washer, and outer bearing cone.

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Section 5 – Procedures Base

19. Check for alignment of the castle flanged nut

with one of the cross holes in spindle arm. If
required, loosen nut to align with nearest hole.
Use an open-ended wrench to be able to see the
cross holes. The nut should not be turned more
than 15°.
20. Secure with new cotter pin. Check again for
smooth turning of wheel hub. The wheel hub
should turn but with slight resistance.
21. Grab the top and bottom of the hub and check
for play. There should be no evidence of play.
22. Install dust cap back on hub assembly.
23. Install wheel assembly. Torque nuts or bolts to
140 ft-lb.
24. Repeat steps 5 to 22 for the other hub assembly.
25. Lower the MEWP.

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Hydraulics Section 5 – Procedures

5.5 Hydraulics HOLD ACTUATOR ARM

TO FULL COUNTER-CLOCKWISE

5.5-1 Hydraulic system and brake

adjustment procedure (if equipped) 1/2”

1. Ensure MEWP is on a firm level surface

and block wheels to prevent rolling in either
direction.
2. Turn emergency main power disconnect switch
to OFF position.
3. Locate brake manifold in hydraulic/electric side BRAKE ADJUSTER
cabinet.
4. Depress and turn red knurled knob on brake
valve counter-clockwise to a fully closed position
or depress black knob (current manifold). Diagram 5.2 Plug removal and replacement
5. Grasp red plunger and rapidly depress until 10. Using a 1/4" Allen wrench, turn brake adjuster
plunger can no longer be depressed and brake counter-clockwise until it bottoms out. Turn
is fully released. Allen wrench clockwise 1/2 turn clockwise to set
6. Inspect caliper and brake pads for binding. Pads adjustment.
should move freely on the pins. 11. Replace plastic plug back into the end of the
7. Remove pin from brake cylinder clevis and brake caliper shaft.
actuating lever. Rotate actuating lever counter- 12. Depress red knurled knob on brake valve and
clockwise to the end of its stroke turn clockwise to a fully open position.
13. Remove Wheel blocks. Turn emergency main
HOLD ACTUATOR ARM power disconnect switch to ON position.
TO FULL COUNTER-CLOCKWISE Operate drive several times to seat pads to
brake disc.

1/2”

BRAKE ADJUSTER

. Diagram 5.1 Brake adjustment

8. Reinstall clevis pin back into the clevis actuating

lever.
9. Remove plastic plug located on the end of the
caliper shaft. See Diagram 5.2.

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Section 5 – Procedures Hydraulics

5.5-2 Brake assembly and disassembly Assembly (refer to 5.5-3)

(if equipped)
1. Use an alkaline wash to clean parts before
assembly.
NOTE 2. Press new oil seal into cover until it is flush with
This literature services various models in this bearing shoulder. Note direction of seal.
brake series. The components shown in 5.5-3 3. Install shaft, dowel pins, spring retainer and
may appear different than what is found in your new spring in cover. Be sure to install springs
brake according to pattern and color recorded during
disassembly.
Disassembly (refer to 5.5-3) 4. Position new return plate on springs.
1. Remove pressure plate from cover by removing
cap screws.
NOTE
Be careful to avoid contaminating friction
CAUTION surfaces with oil.
Pressure plate is under spring tension of
approximately 1633 kgf (3600 lb). The two cap 5. nstall new rotor discs and new stator discs
screws must be loosened evenly to relieve this in the same sequence as recorded during
force. If a hydraulic press is available, 2041 kg disassembly.
(4500 lb) minimum, the pressure plate can be held 6. Install new back-up rings and new o-rings on
in position while removing the cap screws. piston. Note order of o-rings and back-up rings.
Insert piston into pressure plate.
2. Remove case seal from cover. 7. Install new case seal on cover.
3. Remove piston from pressure plate. 8. Position pressure plate on cover aligning dowel
pins with holes in pressure plate.
4. Remove o-rings and back-up rings from piston.
9. Install cap screws and tighten evenly to draw
5. Before removing stator discs and rotor discs,
pressure plate to cover. Torque cap scerws
record the stacking arrangement for reassembly
74.6 N•m (55 lb-ft).
purposes. Remove stator discs, rotor discs,
return plate and shaft from cover.
NOTE
6. Before removing springs, record the pattern and
A hydraulic press will simplify installation of
color for reassembly purposes. Remove dowel
pressure plate on cover. Clamp pressure plate in
pins, springs and spring retainer from cover.
position while tightening cap screws.
7. Press oil seal from cover.

Spring Chart WARNING

Model Yellow Red Blue If hydrostatic testing is performed on brake
Spring (14) Spring (14) Spring (14) assembly, release pressure must not exceed 69
21-100-114 16 0 0 bar (1000 psi) unless six additional bolts are used
for supplemental clamping.

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Hydraulics Section 5 – Procedures

5.5-3 Multiple disc brake assembly diagram

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Section 5 – Procedures Hydraulics

5.5-4 Holding torque testing procedure 5.5-5 Adjust the system lift and pressure
All adjustments must be made with a calibrated
1. Ensure MEWP is on a firm level surface. hydraulic gauge. Refer to the serial number nameplate
2. Locate brake feed valve (2H30A-2) on main located on the rear of the MEWP for system and lift
manifold and disconnect electrical connectors pressure values.
from valve. This will prevent the hydraulic system
Adjust the system relief pressure
from releasing the brake.
3. With engine running (MEWP in drive mode, 1. Locate right steer hydraulic line on main
engine on high idle, high torque selected and manifold. (Refer to Hydraulic Manifold
low speed range selected), hold enable switch Component and Port Identification found in
on controller and push controller forward as if section 3 for location.)
you were to drive forward. This provides torque 2. Tee in a calibrated 3000 psi gauge into the right
from the drive motor to unreleased brake. steer line.
4. If brake slips and MEWP starts to move in 3. Remove operator’s control console from
this condition, either brake plates are worn or guardrail and disconnect it from scissors control
springs have broken. Both brake plates and cable.
springs must be replaced to return brake to its
4. Locate electrical panel cable plug in
original holding torque.
hydraulic/electric cabinet.
5. Disconnect scissors control cable and connect
operator’s control console cable.
6. At main manifold, loosen locknut on system
relief valve (R1). (Refer to Hydraulic Manifold
Component and Port Identification found in
section 3 for location.)
7. On platform control console, select “drive”
position with lift/drive switch.
8. Engage right steer switch on top of controller
handle and hold.
9. Observe reading on pressure gauge. Adjust
system relief valve (R1) to pressure listed on the
serial number nameplate.

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

10. Release steer switch and retighten locknut on

system relief valve (R1).
11. Remove gauge from steer line.

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Hydraulics Section 5 – Procedures

Adjust the lift pressure 5.5-6 Change the hydraulic oil

WARNING
NOTE
Fully lower the platform.
Samples of hydraulic oil should be drawn from
the reservoir and tested annually. These samples
1. Locate lift line on main manifold. (Refer to should be taken when the oil is warmed through
Hydraulic Manifold Component and Port normal operation of the system. The sample
Identification found in section 3 for location.) should be analyzed by a qualified lubrication
2. Open manual lowering valve with platform fully specialist to determine if it is suitable for
lowered. Remove lift line from main manifold. continued use. Oil change intervals will depend
on the care used in keeping the oil clean, and
3. Install a 3000 psi gauge into lift line port fitting on
the operating conditions. Dirt and/or moisture
main manifold. Plug lift line going to lift cylinders.
cotamination will dictate that the oil should be
4. Loosen locknut on lift relief valve (R2). (Refer changed more often. Under normal use and
to Hydraulic Manifold Component and Port operating conditions, the hydraulic oil should be
Identification found in section 3 for location.) changed every two years. Refer to Table 1.2 of
5. Close the manual lowering valve. this manual.
6. Using base controls in hydraulic/electric cabinet, 1. Ensure MEWP is on a firm level surface, fully
depress and hold up pushbutton switch. lowered, and outriggers (if equipped) fully
7. Observe reading on pressure gauge. Adjust lift retracted.
relief valve (R2) to pressure listed on the serial 2. Allow hydraulic oil to warm up.
number nameplate.
3. Turn main power disconnect switch to off
position.
NOTE
4. Place suitable container under the hydraulic
Turning the stem on relief valve clockwise will
tank.
increases pressure. Turning the stem counter-
clockwise will decreases pressure. 5. Remove oil drain plug and allow all hydraulic oil
to drain into container.
8. Release up pushbutton and retighten locknut on 6. Install oil drain plug with new seal ring and
lift relief valve (R2). tighten firmly.
9. Remove gauge from lift line port fitting and 7. Refill hydraulic tank with new oil as per
reconnect lift line to main manifold. specifications. (Refer to section 2 of this manual)
8. Check for leakage.
WARNING 9. Clean up any oil that may have spilled during
this procedure.
Ensure MEWP does not lift more than rated load. 10. Check hydraulic oil level. (The hydraulic oil level
should be at or slightly above the top mark on
the sight gauge)

NOTE
Refer to your national/local regulations on how to
dispose of used filter and oil.

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Section 5 – Procedures Outriggers

5.6 Outriggers
5.6-1 Outrigger mechanical limit switch wiring diagram

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

BACK VIEW - MALE BACK VIEW - MALE

PIN 1 - BLACK PIN 1 - BLACK

3 2 PIN 2 - BLACK / WHITE 3 2
PIN 2 - BLACK / WHITE
PIN 3 - BLUE PIN 3 - BLUE
4 1 PIN 4 - BROWN 4 1
PIN 4 - BROWN

RIGHT FRONT OUTRIGGER

PIN 1 - BLACK (10A)
BACK VIEW - FEMALE PIN 2 - WHITE (66A) BACK VIEW - FEMALE
LEFT FRONT OUTRIGGER PIN 3 - GREEN (63)
2 3 PIN 1 - BLACK (10A) PIN 4 - RED (62) 2 3
PIN 2 - BLACK / WHITE (65A)
PIN 3 - BLUE (62)
1 4 PIN 4 - BROWN (61) 1 4

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

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

SIXTEEN PIN CONNECTOR PLUG LEFT FRONT

OUTRIGGER PCB ON ELECTRICAL PANEL
PIN 1 - 61 RED PIN 9 - 10A BLACK (2) RIGHT FRONT
PIN 2 - 62 GREEN PIN 10 - 10A BLACK (2)
PIN 3 - 62 RED PIN 11 - 10A BLACK (2)
PIN 4 - 63 GREEN PIN 12 - 10A BLACK (2)
PIN 5 - 63 RED PIN 13 - (N/U)
PIN 6 - 64 GREEN PIN 14 - (N/U) RIGHT REAR
PIN 7 - 64 RED PIN 15 - (N/U)
PIN 8 - 01 GREEN PIN 16 - 65 GREEN / BLACK
LEFT REAR
TO CONTROL MODULE
PIN 1 - 65 GREEN / BLACK
PIN 2 - 65A WHITE
PIN 3 - 66A WHITE
PIN 4 - 67A WHITE
PIN 5 - 68A WHITE
PIN 6 - (N/U) O.R. UP SWITCH (NO) - BLUE & BROWN
O.R. UP SWITCH (NO) - BLUE & BROWN
BACK VIEW - MALE
BACK VIEW - MALE PIN 1 - BLACK
PIN 2 - BLACK / WHITE 3 2
3 2 PIN 1 - BLACK
PIN 3 - BLUE
PIN 2 - BLACK / WHITE 4 1
PIN 4 - BROWN
4 1 PIN 3 - BLUE
PIN 4 - BROWN RIGHT REAR OUTRIGGER
PIN 1 - BLACK (10A)
BACK VIEW - FEMALE
PIN 2 - WHITE (67A) BACK VIEW - FEMALE
LEFT REAR OUTRIGGER PIN 3 - GREEN (64)
2 3 PIN 1 - BLACK (10A) PIN 4 - RED (63) 2 3
PIN 2 - WHITE (68A)
PIN 3 - GREEN (01)
1 4 PIN 4 - RED (64) 1 4

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

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

M11449AC

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Outriggers Section 5 – Procedures

5.6-2 Replace and adjust the outrigger Replace the limit switch
upper limit switch (LS61, LS62, 1. Mount the new limit switch (115658) loosely
LS63, LS64) on the bracket, using the hardware removed
previously
Machine preparation 2. Starting from the top, place the new limit switch
1. Ensure the MEWP is parked on a firm level cable in the split loom.
surface. 3. Adjust the cable in the split loom as needed, and
2. Fully retract the outriggers. close the split loom by wrapping electrical tape
around it at regular intervals. Tie wrap the split
3. Turn the emergency main power disconnect loom to the hoses.
switch to the OFF position.
4. Cut off any unneeded length from the cable, and
4. Chock or block the wheels to keep the MEWP strip the end to exposed the wires beneath.
from rolling forward or backward.
5. Strip the ends from each wire and crimp a ferrule
to each wire end.
Remove the limit switch
6. nsert the wires into the connector end removed
1. Remove the bolts and washers (x4) securing previously (refer to 3.15 Auto-Leveling Outrigger
the upper limit switch/hose cover. Set aside the Connection Diagram). Reconnect the connector
hardware and cover for reinstallation later.
2. Remove the washers, bolts, and nuts (x2) Adjust the limit switch
securing the limit switch to the bracket. Set
aside for reinstallation later. 1. With the outriggers retracted, slide the limit
switch on the bracket until the plunger is
depressed against the actuator rod cap. Apply a
small amount of Loctite to the bolts, and tighten
the bolts and nuts.

3. Remove the limit switch cable from the split loom

tubing, cutting tie wraps and tape as needed to
free it.
4. Disconnect the connector, and remove the
applicable limit switch wires and ferrules, Test the limit switch
retaining the connector for reuse later. Discard
the old limit switch and cable. 1. Turn emergency main power disconnect switch
to the ON position, and start the engine.
2. With the outriggers fully retracted, the unit
should be driveable. With the outriggers
extended more than halfway, the unit should not
be driveable.

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Section 5 – Procedures Outriggers

5.6-3 Replace and adjust the outrigger Replace the limit switch
lower limit switch (LS65, LS66, 7. Install a new limit switch (115658) to the
LS67, LS68) mounting block using the hardware removed
earlier.
Machine preparation 8. Feed the new cable through the rubber
1. Ensure the MEWP is parked on a firm level grommet, and place the grommet in the hole in
surface. the outrigger weldment.
2. Fully retract the outriggers. 9. Feed the cable up through the outrigger
weldment, until it comes out the top.
3. Turn the emergency main power disconnect
switch to the OFF position. 10. Working from top to bottom, adjust the cable
in the split loom and close the split loom by
4. Chock or block the wheels to keep the MEWP wrapping electrical tape around it at regular
from rolling forward or backward. intervals. Tie wrap the split loom to the hoses.
11. Cut off any unneeded length from the cable, and
Remove the limit switch
strip the end to exposed the wires beneath.
1. Remove the bolts and washers (x4) securing 12. Strips the ends from each wire and crimp a
the upper limit switch/hose cover. Set aside the ferrule to each wire end.
hardware and cover for reinstallation later. 13. Insert the wires into the connector end removed
2. Remove the screws (x2) securing the lower limit previously (refer to 3.15 Auto-Leveling Outrigger
switch cover. Set aside the hardware and cover Connection Diagram). Reconnect the connector.
for reinstallation later.
3. Remove the washers and screws (x2) securing Adjust the limit switch
the limit switch to the mount. Set aside for
reinstallation later. 1. Loosen the bolts securing the mounting block to
the outrigger, and slide the block until the limit
switch plunger is depressed halfway against the
base weldment. Apply a small amount of Loctite
to the bolts, and tighten them.

4. Cut the tie wraps and tape around the split loom
as needed to expose the limit switch cable.
5. Disconnect the applicable wires from the
connector, and cut the ferrules off of the wires
on the end of the cable. Retain the connector for
reuse later. Test the limit switch
6. Remove the cable from the split loom. Gently 1. Turn emergency main power disconnect switch
pull the cable down through the outrigger to the ON position, and start the engine.
weldment, and through the rubber grommet. 2. With the outriggers fully retracted, the unit
Retain the rubber grommet. Discard the old limit should be driveable. With the outriggers
switch and cable. extended more than halfway, the unit should not
be driveable.

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Control Modules Identification Section 5 – Procedures

5.7 Control Modules Identification

5.7-1 Identification

GP-102/CM1 GP-106/OCM1

GP-108

Outrigger
PC board

GP-102 Controller: Load sensing

GP-106 Controller: Outriggers
GP-108 Controller: Load sensing and outriggers (replaces GP-102 and GP-106 together)
OCM1 Controller: Outriggers auto-levelling

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Section 5 – Procedures EZcal Diagnostic Tool

5.8 EZcal Diagnostic Tool

5.8-1 Hand held EZcal calibration and diagnostic tool key functions

WARNING
Only trained and authorized personnel shall be permitted to service a MEWP.

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

Symbol Key Functions

? EZcal Pro Help

?
Displays the current help menu
while viewing any controller menu.
Release the button to return to the
original menu display.

ESC ENTER ESC/ENTER

ESC ENTER Use these to move back and forth

between menus and submenus
and to make a selection.

Up/Down
Adjust the settings values.

Left/Right
Select the menus and settings to
be adjusted.

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EZcal Diagnostic Tool Section 5 – Procedures

5.8-2 Flash the controller

HELP: PRESS ENTER
1. Plug the red EZcal Pro device into a USB port on
your computer.
2. Open the EZcal device folder on your computer.
3. Copy the new software flash file to this folder.
?+ ESC
Note the name of the file.
4. When the file is copied, eject the EZcal Pro.
Unplug the USB cable.
5. Plug the EZcal Pro into port P1 on the GP
controller board. EZcal Pro MENU:
SETUP

x4

EZcal Pro MENU:

PGFLASH

ENTER

EZcal Pro MENU:

XXXXXXX :NO
If there are multiple software flash files saved
on the EZcal Pro, press the enter key until it
displays the required file.

EZcal Pro MENU:

XXXXXXX :YES

ENTER

PGFLASH WORKING
XX%
Wait for the flash to finish.
This could take several minutes.

PGFLASH
OK/VX.X FINSHED

ESC

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Section 5 – Procedures EZcal Diagnostic Tool

5.8-3 Outrigger codes

Model Standard Outrigger Code
SJ9241 RT All 8
SJ9250 RT All 8

5.8-4 Curve/group codes

Curve Group
Model Extension Decks
Code Code
SJ9241 RT 2 powered decks 58 15
SJ9250 RT none 52 10
SJ9250 RT 1 powered deck 53 10
SJ9250 RT 2 powered decks 54 10

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 61
62 D17B-1

SJ9241 RT, SJ9250 RT

61CR
9CR3
62
63 D17B-2
63
64 CN14
04
Auto-leveling Outrigger PC Board Layout

64

9CR2
17

17BCR
01

CN22
10A 86A
10A 10A
10A 17B 09
10A 35C 02 44
- 78 78 01

65CR
- 73 73 02
- 77 77 02
CN21

65 74 CN20 74 36A
J17D 71 71 61
75 75 36
J17E 72 72
D36 76 76
5.9 Auto-leveling Outrigger PC Board Layout

FRONT LEFT REAR LEFT

ENABLE FRONT RIGHT REAR RIGHT

D75 D76 D71 D72 D78 D77 D74 D73

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Section 5 – Procedures
Section 5 – Procedures GP-102 (CM1) Control Module

5.10 GP-102 (CM1) Control Module

5.10-1 Set up the GP-102 load sence controller

1. Move the aerial platform to a test area where the platform can be elevated to its maximum working height
and reach.
2. Ensure the aerial platform is parked on a firm, level surface.

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

IMPORTANT
Make sure the aerial platform is on BASE mode.

NOTE
To ensure a good and clear contact, clean the
wire terminals before attaching the jumper clip.

3. Locate the main manifold inside the hydraulic/electric tray.

4. Disconnect the black wire #14 from the lift coil.
5. Locate the contactor on the electrical panel assembly.
6. The jumper connection must be connected between the contractor (wire #19B) and the lift coil (instead of
the black wire #14)
7. Connect the Easy-Cal tool to the P1 connector on the CONTROL MODULE.
8. The display will show “Help: Press Enter”. By using Left/Right buttons, select the “Access Level ( ? )” from
the menu and press the ENTER button.

Contact Skyjack Service Department at:

(44) 1691-676 236 for your Access Level Code Number.

9. The display will show “Access Level Code (xxxx)”.

By using the Up/Down buttons, enter the Access Level Code (xxxx) followed by pressing the ENTER button.
10. The display will show “Access Level 2”.
By using Left/Right buttons, select the “Setups” from the menu and press the ENTER button.
11. The display will show “Machine Defaults”.
Select the “Machine Defaults” from the menu and press the ENTER button.
12. The display will show “Defaults, 0 = Custom”.
By using Left/Right buttons, select the “X = Group Code” from the menu and press the ENTER button.

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GP-102 (CM1) Control Module Section 5 – Procedures

13. The display will show “X=GROUP CODE”.

By using the Up/Down buttons, enter the “Group Code (?)” then by using Left/Right buttons, select the “Curve”
from the menu.

14. The display will show “X=CURVE”.

By using the Up/Down buttons, enter the “Curve Code (?)” followed by pressing the ESCAPE button.

15. The display will show “Machine Defaults”.

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

16. The display will show “Tilt Setups: Calibrate Level”.

Select the “Tilt Setups: Calibrate Level” from the menu and press the ENTER button.

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

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

19. The display will show “Tilt Setups Calibrate Level”.

Select the “ESCAPE” from the menu once again.

20. The display will show “Setups Tilt Setups”.

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

21. The display will show “Load Setups: Calibrate Load”.

Select the “Load Setups: Calibrate Load” from the menu and press the ENTER button.

22. At this point, elevate the aerial platform at full height, check the harness and making sure it is not stretched
tight, then lower down the platform.

23. The display will show “Calibrate Load: Platform Down?”.

Asking for confirmation that the platform is fully lowered?
Check that the platform is fully lowered then press the ENTER button to confirm.

24. The display will show “Calibrate: Loaded Empty? No”.

Asking for confirmation that the platform is empty?
Check that the platform is empty

25. By using the Up/Down buttons, enter the “Yes” followed by pressing the ENTER button.

26. The display will show “Calibrate Load: Please Lift......”.

Waiting for the lift switch to be activated.

27. Hold the lift switch and keep holding it until the platform is fully elevated.

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IMPORTANT
If the lift switch is released earlier than full-height position, the
calibration will have to be aborted and repeated from the beginning!

28. When the system detects the lift switch closed, the display will show “Calibrate Load: Lift Empty”.

29. After a delay, the system will stop the platform lifting and will take height & pressure measurements; the display
will show “MEASURING # xx” When the measurements have been taken, the platform will resume lifting.

NOTE
The Lifting......stopping.......measuring....lifting process will
continue until the platform reaches full height.

30. When the platform reaches full height release the lift switch.

31. The display will briefly show “TOTAL DATA: 04” to indicate the number of measurements taken.

32. The display will show “Calibrate Load: Please Lower......”.

IMPORTANT
If the lower switch is released earlier than full-lower position, the
calibration will have to be aborted and repeated from the beginning!

33. Hold the lower switch and keep holding it until the platform is fully lowered.

34. When the system detects the lower switch closed, the display will show “Calibrate Load: Lower Empty”

35. After a delay, the system will stop the platform lowering and will take height & pressure measurements; the.
display will show “MEASURING #xx”. When the measurements have been taken, the platform will resume
lowering.

NOTE
The lowering......stopping.......measuring....lowering process will
continue until the platform is fully lowered.

36. When the platform is fully lowered (and height 0% is displayed), release the lower switch.

37. The display will show briefly “TOTAL DATA: 04” to indicate the number of measurements taken.

38. The display will show “Calibrate Load: Caldate: mm/dd/yy”.

It is recommended that the current date be entered here to provide easy taking of the data of last calibration.
The current date must be entered using the LEFT/RIGHT and UP/DOWN buttons.

39. Press ENTER to complete date entry (the system will store it).

40. The display will show “Calibrate Load” option.

41. Press the ESC button to exit the “Calibrate Load” option.

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42. Remove the jumper wire and re-connect the black wire #14 to the coil removed earlier.

43. Close the hydraulic/electric tray.

NOTE
Continuing partially complete load calibration.

Once a calibration phase has been successfully completed, it is not required to do it again (unless of course
a change to the vehicle such as a replacement sensor requires that calibration be repeated). This is useful if
the calibration procedure is interrupted – the remaining phases can be completed at a later time.

If a calibration phase has been successfully completed, a “REDO” message is displayed:

REDO DYNAMIC: NO
REDO LOADED: NO
REDO EMPTY: NO

If the phase does not need to be repeated, just press ENTER to move on.
If the phase does need to be repeated, press UP or DOWN to change “NO” to “YES” then press ENTER.

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5.10-2 GP-102 Load sense controller pin reference table

PIN WIRE #
PLUG WIRE FUNCTION
# AND COLOUR
P1 The Calibration Connection
P2 1 Not Used Not Used
P2 2 10E Black/White Input Power From Base Terminal Strip To Confirm Lower Control Is Selected
P2 3 14D Black Raise Platform Input
P2 4 13D Orange Lower Platform Input
P2 5 Not Used Not Used
P2 6 Not Used Not Used
P2 7 16 White/Black Forward Direction Input
P2 8 15 Blue Reverse Direction Input
P2 9 Not Used Not Used
P2 10 35B Red/Black Input From LS1 High Speed Limit Switch To Verify ON/OFF Limits
P2 11 02 White Negative Input From Base Terminal Strip
P2 12 10C Red Main Power Input From Base Terminal Strip
P3 1 22 Red Output To FL-22 Flashing Light
P3 2 29 Black Output To BP-29 Beeper
P3 3 60 Black/White Output To Overload Warning Light On Control Box
P3 4 28 Green/Black Output To 28CR1 Tilt Relay And 28CR2 Down Relay
P3 5 02 White Negative for Flashing Light and Beeper
P3 6 28E Green/White Output To 28ECR1 Aux. Tilt Relay And 28ECR2 Aux. Down Relay
P4 1 Not Used Not Used
P4 2 60A Green Varied Input From Transducer
P4 3 28B Green Varied Input From Angle Transducer
P4 4 Not Used Not Used
P4 5 Not Used Not Used
P4 6 910 Black Positive Signal To Angle Transducer
P4 7 902 White Negative Signal To Angle Transducer
P4 8 900 White Negative Signal To Pressure Transducer
P4 9 910 Black Positive Signal To Pressure Transducer
60303AD

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5.10-3 LED Error codes – quick reference HELP Message LED indication
chart EVERYTHING OK Steady on
IN GROUND MODE! Steady on
OVERLOAD FUNCTIONS DISABLED! 6/6
Read the codes VEHICLE TILTED 1/1
VEHICLE OVERLOADED 1/2
A sequence of pauses and flashes are seen on the LED WAITING FOR B+ ON P2-12 5/2
mounted on the GP-102 module which allows you to ARMGUARD ACTIVE! 1/3
read the codes. The codes are continuously displayed TOO HIGH - DRIVE PREVENTED 1/4
TOO HIGH - LIFT UP PREVENTED 1/5
by the LED until the fault is cleared, the GP-102 resets 7/8
TESTING HWFS
and no longer detects the fault, or idle timeout becomes IDLE TIMEOUT ACTIVE! Always off
active. WAITING FOR NEUTRAL 5/5
ELEVATION SWITCH SHIFTED? 2/1
ELEVATION SWITCH STUCK? 2/2
The sequence is as follows:
NO LAST CALDATE! 6/3
1. Quarter second flashes followed by quarter second LOAD NOT CALIBRATED 6/2
pauses indicate the first digit. DRIVE/LIFT INPUTS FAULTY! 5/6
2. A 1.5 second pause. UP/DOWN SELECT INPUTS ACTIVE TOGETHER 5/4
3. Quarter second flashes followed by quarter second INVALID LOAD - CHECK SENSORS 6/4
HEIGHT NOT CALIBRATED 6/1
pauses indicate the second digit
INVALID HEIGHT - CHECK SENSOR 6/5
4. A 4 second pause. Repeat Steps 1–4. EMS INPUTS FAULTY! 5/2
B+ SUPPLY TOO LOW 5/1
The GP-102 only reports one error at a time — only one P4-1 OR P5-1 SHORT TO 0V? 4/1
P3-4 SHORT TO SUPPLY! 4/2
code can be read from the LED per instance. If the
P3-4 SHORT TO 0V? 4/3
initial error is cleared but another error remains, that P3-4 SHORT TO SUPPLY? 4/4
error is then shown. P3-6 SHORT TO 0V? 4/5
P3-6 SHORT TO SUPPLY? 4/6
FAULT: BAD TILT SENSOR 7/1
FAULT: BAD HWFS 7/2
FAULT: BAD SLAVE ANALOGS 7/3
FAULT: BAD STRAIN MONITORS 7/4
FAULT: BAD SLAVE MICRO 7/5
FAULT: HWFS STALLED! 7/6
STARTUP! 7/7
FACTORY OVERRIDE 6/7
60405AA

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5.10-4 LED Error codes – code breakdown chart

LED Flash Code Meaning Action

63 No Last Caldate

62 Load Not Calibrated An EZcal is required!

61 Height Not Calibration

55 Waiting For Neutral

56 Drive/Lift Inputs Faulty!

Check inputs on P2 pins 1,2,3,4,5,6,7,8.
Up/Down Select Inputs Active
54
Together

52 EMS Inputs Faulty!

42 P3-4 Short To Supply!

Disconnect plug P3. If fault clears there is a
problem with the wiring from P3–4 or P3–6 to
44 P3-4 Short To Supply?
the rest of the vehicle.
46 P3-6 Short To Supply?
23 Armguard Active! If the 23 flash code is triggered by armguard,
it will occur once then clean. This is not a true
21 Elevation Switch Shifted?
fault but just an indication of the reason for
the vehicle stop. If the 21 or 22 flash code is
triggered by a fault with the elevation switch, it
22 Elevation Switch Stuck? does not clear. Check that the elevation switch
correctly opens/closes when the platform is
raised/lowered.

43 P3-4 Short To 0 V?
Disconnect plug P3. If fault clears there is a
wiring fault from P3-4 or P3-6 to the rest of the
45 P3-6 Short To 0 V? vehicle.

Check the voltage out of the pressure

transducer, into P4-2. It should be between
45 Invalid Load – Check Sensors 0.5 V (zero pressure) and 4.5 V (maximum
pressure) and should vary as the platform load
& position varies.

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LED Flash Code Meaning Action

52 Waiting For B+ on P2-12 Check that the battery voltage is not too low.
Verify battery voltage on P2-12.
51 B+ Supply Too Low
Disconnect plug P4 – if the fault clears there is a
41 P4-1 Or P5-1 Short To 0V? wiring fault from P4-1 to the rest of the vehicle.
11 Vehicle Tilted
These are not true faults but an indication
12 Vehicle Overloaded that vehicle movement is prevented. Remove
excessive load from the platform. Lower the
14 Too High – Drive Prevented platform if close to maximum height. Move the
vehicle to level ground.
15 Too High – Lift Up Prevented
Check the voltage out of the height transducer,
65 Invalid Height – Check Sensor into P4-3. It should be between 0.4 V and 4.6 V
and should vary as the platform position varies.
78 Testing HWFS These are not true faults unless they do not
clear the start-up tests should only occur for a
77 Start Up! short time.

66 Overload Functions Disabled! These are not true faults – the GP102 has been
configured to suppress overload functionality.
67 Factory Override
Always Off Idle Timeout Active!
71 Fault: Bad Tilt Sensor
Action a function to clear the idle timeout if
72 Fault: Bad HWFS it occurred. Ensure the GP102 is correctly
mounted – incorrect mounting can cause the
73 Fault: Bad Slave Analogs
bad tilt sensor diagnostic to occur. Otherwise
74 Fault: Bad Strain Monitors there may be an internal problem with the
GP102.
75 Fault: Bad Slave Micro
76 Fault HWFS Stalled!

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5.10-5 Control module load calibration - code messages & definitions

During calibration the following failure message may appear:

(Refer to 5.8-1 for hand held calibration/diagnostic tool key functions)

Code F01: Check HWFS

This message is given if the GP102 startup tests have not completed.
▪ Check HELP message for more information.
Code F02: Not Ground Mode
This message is given if the machine is not in ground mode (P2-2 must be high).
▪ Calibration can only be carried out in ground mode.
Code F03: Not Stopped
This message is given if any function switch is closed.
▪ Check DIAGNOSTICS / SWITCHES to see which function switch is closed.
Code F04: Tilted
This message is given if the machine is tilted.
▪ Calibration must be carried out with the machine level. If the machine is level, use the SETUPS / TILT
SETUPS to set the GP102 level.

Code F05: Bad Height

This message is given if the height sensor output (P4-3) is out of range at the start of calibration.
▪ The height sensor output must be 3.7V. Check DIAGNOSTICS / SENSORS to see the output. A reading of
0V or 5V is probably due to a wiring problem.

Code F06: Check Elev

This message is given if the elevation switch (P2-10) is closed at the start of calibration, when the operator has
confirmed the “PLATFORM DOWN?” question.
▪ If the platform is down, check the elevation switch wiring.
Code F08: Check Elev
This message is given if the elevation switch (P2-10) is closed at the end of calibration, when the platform should
be fully raised.
▪ This message would occur if the UP switch was accidentally opened near the start of the lift. If the
platform is fully raised, check the elevation switch wiring.

Code F09: Bad Height

This message is given if the height sensor output (P4-3) is out of range at the start of calibration.
▪ The height sensor output must be 3.7V. Check DIAGNOSTICS / SENSORS to see the output.
Code F10: Bad Height
This message is given if the height sensor output (P4-3) is out of range at the end of calibration.
▪ The height sensor output must be between 0.9V and 4.1V. Check DIAGNOSTICS / SENSORS to see the
output. A reading of 0V or 5V is probably due to a wiring problem.

Code F11: Not Up

This message occurs at the start of calibration if the operator selects a function other than UP.
▪ Select the UP function only.

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Code F13: Low Height Range

This message occurs at the end of calibration if the height sensor output did not change sufficiently to give a
reasonably accurate platform height estimate.

This message could occur if the UP switch was accidentally opened too early (when the platform is not fully
raised). DIAGNOSTICS / SENSORS can be used to check the height sensor output (P4-3). A difference of at
least 1V is to be expected.
Code F15: Check Elev
This message is given if the elevation switch (P2-10) is closed when the platform has been fully lowered at the
end of calibration.

This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered.
If the platform is fully lowered, check the elevation switch.

Code F16: Low Elev.open

This message is given if the elevation switch (P2-10) opened during lift at a too low height (below 5%).
▪ Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch
opened. Set up elevation switch to manufacturers’ specifications and calibrate load.

Code F17: High Elev.open

This message is given if the elevation switch (P2-10) opened during lift at a too high height (above 25%).
▪ Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch
opened. Set up elevation switch to manufacturers’ specifications and calibrate load.

Code F18: Low Elev.close

This message is given if the elevation switch (P2-10) closed during lower at a too low height (below 5%).
▪ Check CALIBRATIONS / HEIGHT CALS; the “ElevDown” value shows the recorded height where the
switch opened. Set up elevation switch to manufacturers’ specifications and calibrate load.

Code F19: High Elev.close

This message is given if the elevation switch (P2-10) closed during lower at a too high height (above 25%).
▪ Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch
opened. Set up elevation switch to manufacturers’ specifications and calibrate load.

Code F20: Height<>0%

This message occurs if the platform height is not 0% after the platform has been fully lowered during either
STATIC lift.

The platform must return to the same height each time it is fully lowered.
▪ Check DIAGNOSTICS / SYSTEM to check the height.
Code F28: Bad Height
This message indicates a problem with the height sensor output (P4-3) during calibration.

The height sensor output must be between 1.0V and 4.0V at all times.
▪ Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring
problem.
Code F42: Low Pressure
This message indicates that the pressure transducer output (P4-2) is too low (0.5V or less) at the beginning of
calibration.
▪ Check DIAGNOSTICS / SENSORS to read output.

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Code F43: High Pressure

This message indicates that the pressure transducer output (P4-2) is too high (4.5V or more) at the beginning
of calibration.
▪ Check DIAGNOSTICS / SENSORS to read output.
Code F44: Low Pressure
This message indicates that the pressure transducer output (P4-2) is too low (0.5V or less) at a measurement
point.
▪ Check DIAGNOSTICS / SENSORS to read output.
Code F45: High Pressure
This message indicates that the pressure transducer output (P4-2) is too high (4.5V or more) at a measurement
point.
▪ Check DIAGNOSTICS / SENSORS to read output.
Code F46: Check Elev
This message indicates that the elevation switch opened more than once during calibration lifting.

Code F47: Check Elev

This message indicates that the elevation switch closed more than once during calibration lower.

Code F48: Bad Pressure

This message indicates that the pressure transducer output (P4-2) is out of range at the beginning of calibration.
▪ Check DIAGNOSTICS / SENSORS to read output.
Code F52: Too Few
This message indicates that not enough measurements were recorded during calibration lifting or lowering.

Code F98: Out of Range

This message indicates that the “fine tune” calibration is unacceptable.

This is probably due to a faulty transducer or faulty/open holding valve(s)/ emergency lowering valve.

During calibration the following information messages may appear:

Platform Down?
This message is prompting for confirmation that the platform is fully lowered. If necessary the DOWN switch
can be activated to lower the platform. Press ENTER to confirm when the platform is fully lowered.

Platform Empty?
This message is prompting for confirmation that the platform is completely empty. Press ENTER to confirm if
the platform is empty.

Platform Loaded?
This message is prompting for confirmation that the platform is loaded to rated load Press ENTER to confirm
if the platform is loaded.

Please Lift
This message is prompting for the platform to be raised. The UP switch should be closed.

Please Lower
This message is prompting for the platform to be lowered. The DOWN switch should be closed.

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Lift Empty
This message is displayed while the platform is being raised to the next measurement height, when an EMPTY
platform is being calibrated.

Lift Loaded
This message is displayed while the platform is being raised to the next measurement height, when a LOADED
platform is being calibrated.

Lifting
This message is displayed while the platform is being raised, during HEIGHT-only calibration.

Measuring #
This message is displayed when the platform is stopped during calibration, when the GP102 takes a measurement.
There will be a short delay while the machine is allowed to stabilize after movement is stopped.

Must Go Down!
This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be lowered.

Must Go Up!
This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be raised.

Please Wait
This message indicates that the GP102 is busy; the delay will be short (no more than 5 s).

Lower Empty
This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY
platform is being calibrated.

Lower Loaded
This message is displayed while the platform is being lowered to the next measurement height, when an EMPTY
platform is being calibrated.

Lowering
This message is displayed while the platform is being lowered, during HEIGHT-only calibration.

Total Data:
This message is displayed at the end of each phase, to confirm the number of measurements recorded by the
GP102.

Caldate
This message is prompting for the date to be entered; it is stored to identify when the machine was calibrated.

The last calibrate date can be viewed in DIAGNOSTICS / LOG. Press LEFT & RIGHT to select the flashing digits.
Press UP & DOWN to change the flashing digits. Press ENTER when the entry is complete. IMPORTANT: The
date 00/00/00 is not allowed!

Finished
This message confirms that calibration is complete and successful.

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5.11 GP-106 (OCM1) Control Module

5.11-1 Outrigger control module (PG-106/OCM1) instructions
When EZcal hand-held device is connected to the OCM1 control module, a two line displays shows various menus
and settings. At any time the top line of the display describes the currently selected menu and the bottom line shows
the currently selected item in that menu.

Six buttons on EZcal allow easy navigation through the menus:

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

Top Level Menu Options

Help Select This Menu To See A Description Of Current OCM1 Status
Diagnostics Select this menu to see switch input status and logged data
Access Level Select this menu and enter correct code to enable adjustments and calibrations
Select This menu to see and adjust OCM1 settings.
Adjustments NOTE: this menu provides adjustments which may be needed for different work
activities
Select this menu to carry out initial set-up of the OCM1.
Setups NOTE: This menu provides set-ups needed to configure the OCM1 for a particular
vehicle.

Help Menu Options

A message displays current OCM1 status, indicating if everything is OK or if there is
(help message)
an error code (see LED Error Codes – 5.11-2)

Diagnostic Menu Options

System Select this menu to see general OCM1 system information.
Switches Select this menu to see switch input status
Outputs Select this menu to see OCM1 output status
Log Select this menu to see logged information

Diagnostic / System Menu Options

Outriggers Displays various status during the auto-level function
Tilt Displays vehicle tilt in X and Y orientations measured by integral sensor
Tilted Displays whether vehicle is tilted (YES or NO)
Battery Displays battery supply voltage (on P2-12)

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Diagnostic / Switches Menu Options

LR/P2-1 High when the left rear outrigger is in contact with the ground.
RR/P2-2 High when the right rear outrigger is in contact with the ground
RF/P2-3 High when the right front outrigger is in contact with the ground
LF/P2-4 High when the left front outrigger is in contact with the ground.

EXTEND/P2-5 High to activate the auto-level function

RETRACT/P2-6 High to activate the auto-retract function
High when the scissor stack is stowed (elevated input indicates that the vehicle is
ELEV/P2-10
stowed).

Diagnostic / Outputs Menu Options

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

Diagnostic / Log Menu Options

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

Access Level Menu Options

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

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Adjustments Menu Options (factory set – not adjustable)

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

Machine Setup Menu Options (factory set – not adjustable)

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

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5.11-2 Auto-leveling outrigger setting and LED ERROR CODES

error codes EVERYTHING OK ON
VEHICLE TILTED 1/1
Read the codes OUTRIGGERS CANNOT BE MOVED! 1/2
Error codes are indicated with the flashing LED on the OUTRIGGERS NOT HOME 2/2
control module. When there is a fault, the LED on the NOT FULLY LEVEL 2/1
outrigger control module flashes to indicate the error RELEASE OUTRIGGER DEMAND! 5/5
code number.
CHECK OUTRIGGER SUPPLY (P4-9) 5/2
Identify the error code by counting the flashes as CANNOT LEVEL : BAD TILT SENSOR 7/1
follows:
OUTRIGGERS MANUALLY CONTROLLED! 6/6
1. The first digit is indicated by half-second flashes TESTING HWFS 7/8
followed by half-second pauses.
B+ SUPPLY TOO LOW 5/1
2. A 2.5-second pause follows.
STARTUP! 7/7
3. The second digit is then indicated by half-second
FAULT: BAD SLAVE MICRO 7/5
flashes followed by half-second pauses.
FAULT: BAD TILT SENSOR 7/1
4. A 5-second pause follows, then the cycle repeats.
FAULT: BAD HWFS 7/2
FAULT: P2-5 FAULTY 8/1
The LED continuously displays codes until the fault is
FAULT: P2-6 FAULTY 8/2
cleared, the outrigger control module is reset and no
longer detects the fault, or idle timeout becomes active. FAULT: P2-8 STUCK ON 8/3
FAULT: P2-8 ALWAYS ON 8/4

Since the outrigger control module only reports one FAULT: P2-8 ALWAYS OFF 8/5
error, only one code can be read from the LED per FAULT: HWFS STALLED! 7/6
instance. If the error is cleared and another is present, it 60402AC
will then be presented.

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5.11-3 Auto-leveling outrigger error code breakdown

RELEASE OUTRIGGER DEMAND! 5/5
Check inputs on P2 pins 5 & 6 - the “auto-level” or “auto-retract” input is active at power-on or when it is not allowed to
carry out the function.
OUTRIGGERS CANNOT BE MOVED! 1/2
Check input on P2 pin 10 – “auto-level” or “auto-retract” has been requested but the platform is elevated.
NOT FULLY LEVEL 2/1
The outrigger legs are all down (touching the ground) but the platform is not fully level.
OUTRIGGERS NOT HOME 2/2
The outrigger legs are not all down (touching the ground) and also are not all home (fully retracted).
B+ SUPPLY TOO LOW 5/1
CHECK OUTRIGGER SUPPLY (P4-9) 5/2
Check that the battery voltage is not too low.
VEHICLE TILTED 1/1
This is not a true fault – move the vehicle to level ground!
TESTING HWFS 7/8
STARTUP! 7/7
These are not true faults unless they do not clear – the start-up tests should only occur for a short time.
OUTRIGGERS MANUALLY CONTROLLED! 6/6
This is not a true fault – the outriggers are being manually operated (one or more outrigger legs on P4 pins 1-8 is high,
when the outrigger control module is not active.
CANNOT LEVEL (BAD TILT SENSOR) 7/1
FAULT: BAD TILT SENSOR 7/1
FAULT: BAD HWFS 7/2
FAULT: BAD SLAVE MICRO 7/5
FAULT: HWFS STALLED! 7/6
FAULT: P2-5 FAULTY 8/1
FAULT: P2-6 FAULTY 8/2
FAULT: P2-8 STUCK ON 8/3
FAULT: P2-8 ALWAYS ON 8/4
FAULT: P2-8 ALWAYS OFF 8/5
These are internal faults. If the fault persists after the power has been reset, the outrigger control module may need to be
replaced.
1506AA

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5.11-4 Set up the GP-106 outrigger By using Up/Down buttons, select the “Defaults:
controller Code Setting for your Model (for default code,
refer to 5.8-3)” from the menu and press the ENTER
button and followed by ESCAPE button.
IMPORTANT
Each phase must be completed before the next 11. The display will show “Setups Change Defaults”.
phase can be carried out. By using Left/Right buttons, select the “Calibrate
All phases must be completed before the aerial Level” from the menu and press the ENTER.
platform can be operated.
Always follow the instructions of the Calibration 12. The display will show “Calibrate Level: Yes:
instrument Enter, No: ESC”. Select the “Yes” from the menu
by press the ENTER button.
1. Ensure aerial platform is parked on a firm and level
surface. 13. The display will show “Calibrate Level: Tilt 0.0’
, 0.0’”. Select the “ESCAPE” from the menu
2. Elevate the scissors high enough to lay a level once.
accross the base tubes. Ensure there is no debris
on the base and the level sits flat. Do not elevate 14. The display will show “Setups Calibrate Level”.
aerial platform higher than the high speed/tilt Select the “ESCAPE” from the menu once again.
override limit switch.
15. The Calibration procedure is complete, unplug and
3. Manually operate the outriggers and level the remove the EZ-Cal.
machine in 4 places: left side, right side, front and
rear. All 4 outriggers must be firmly placed and all 16. Close the hydraulic/electric cabinet.
4 tires are off the ground.

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

4 points.

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

CONTROL MODULE.

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

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

7. The display will show “Access Level: Code

(0000)”.
By using the Up/Down buttons, enter the Access
Level Code (1 1  2  2) followed by pressing
the ENTER button.

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

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

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

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

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

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5.11-5 GP-106 Outrigger controller pin reference table

LED

GP106 Control Module

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

60401AB

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5.12 GP-108 Control Module

5.12-1 Set up the GP-108 overload/outrigger controller

Preparation

1. Turn the main power disconnect switch to the on position.

2. Insert the key.
3. Pull out the e-stop button on the base control console.
4. Pull out the e-stop button on the platform control console.
5. Make sure the MEWP is on a firm, level surface.
6. Retract the extension decks and outriggers, if equipped.
7. Empty the platform.
8. Connect an EZ-Cal tool to the P1 connector on the GP-108 controller. Follow the flowcharts to set up the
controller.
9. Turn the base/off/platform keyswitch to the base position and hold it there.

NOTE
Hold the keyswitch in the base position during the entire setup process.
If you let go of the keyswitch in the middle of the process, the controller resets and you have to start again
from the beginning.

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HELP: PRESS ENTER ACCESS LEVEL 3 ENTER CODE 0000

CODE 1122 ENTER ACCESS LEVEL 2

SETUPS: GP102 P/N:

SETUPS ENTER CHANGE DEFAULTS
ENTER 0=?

SETUPS:
Select the region. ESC CHANGE DEFAULTS
ENTER

GP102 DEFAULTS: Select

Selectthe
the group code.
code. SETUPS:
0=CUSTOM Refer
Referto
to 5.8-4
3.5-6
ESC CHANGE DEFAULTS

CURVE: Select
Selectthe
the curve code.
code.
ENTER 0=? Refer
Referto
to 5.8-4
3.5-6
ESC

SETUPS: GP106 DEFAULTS

CHANGE DEFAULTS
ENTER 1=O.R. SETTING

Select
Selectthe
the outrigger code.
outrigger code. SETUPS:
Refer to 5.8-3
Refer to 3.5-7
ESC CHANGE DEFAULTS

SETUPS: TILT SETUPS:

TILT SETUPS
ENTER CALIBRATE LEVEL
ENTER

CALIBRATE LEVEL: YES:ENTER, NO:ESC

YES:ENTER, NO:ESC
ENTER TILT 0.0’, 0.0’
ENTER ESC ESC

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SETUPS: LOAD SETUPS:

LOAD SETUPS
ENTER CALIBRATE LOAD
ENTER

Put a 100% rated load on

CALIBRATE LOAD: Make sure the platform the platform now.
PLATFORM DOWN? is fully lowered.
ENTER OR
Make sure the platform is
completely empty.

CALIBRATE LOAD:
PLATFORM LOADED? Activate the lift switch
CALIBRATE LOAD:
ENTER PLEASE LIFT!
and raise the platform
CALIBRATE LOAD: to full height.
PLATFORM EMPTY?

After a delay, the system automatically When the platform reaches

stops the platform lift and takes height MEASURING #XX full height release the
and pressure measurements four times. lift switch.

Activate the lower switch After a delay, the system automatically

CALIBRATE LOAD: stops the platform lower and takes
until the platform is
PLEASE LOWER! height and pressure measurements
fully lowered.

When the platform is

CALIBRATE LOAD:
MEASURING #XX fully lowered release
CALDATE: 00/00/00
the lower switch.
(mm/dd/yy)
Enter the date.

CALIBRATE LOAD: Push and pull the

ENTER FINISHED!
ESC To the home screen. emergency stop button to
cycle the power and
save the settings.

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5.12-2 GP-108 Overload/outrigger controller pin reference table

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

WIRE #
PLUG PIN WIRE FUNCTION
& COLOUR
Calibration Connection (RS232)
P1 1 B+
P1 2 Rx
Not connected –used for hand held calibration device connection
P1 3 Tx
P1 4 GND (-)
Inputs
P2 1 Not Used Not Used
12V Input from S10 PLTF/Idle/Base Key Switch for Base selected
P2 2 10E Blue/White
*required for any movement from Base*
P2 3 14 Black 12V Input from S3 Lift/Off/Drive switch for Raise requested
P2 4 13 Orange 12V Input from S3 Lift/Off/Drive switch for Lower requested
12V Input IF BOTH Emergency Stops are energized
P2 5 10 Red
*required for any movement from Platform*
P2 6 Not Used Not Used
P2 7 16 White/Black 12V Input thru S3 Lift/Off/Drive switch from Joystick Forward drive requested
P2 8 15 Blue 12V Input thru S3 Lift/Off/Drive switch from Joystick Reverse drive requested
P2 9 Not Used Not Used
P2 10 35B Red/Black 12V Input From LS1 High Speed Limit Switch To Verify ON/OFF Limits
P2 11 02 White 0V GND (-) Negative Reference From Base Terminal Strip
P2 12 10A Blue/Black 12V Main Power Input thru Main Power Relay 10BCR From Base Terminal Strip

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WIRE #
PLUG PIN WIRE FUNCTION
& COLOUR
Outputs
P3 1 22 Black 12V Output to Flashing light Harness 22CR
P3 2 29 Green Through flashing light harness
P3 3 60 Black/White Through flashing light harness
12V Output To 28ACR1 & 28ACR2 Pump Dump Enable Relay’s and 28CR Down
P3 4 28 Green/Black
Enable Relay
P3 5 02 White Through flashing light harness
P3 6 28E Green/White 12V Output To 28ECR1, 28ECR2 and 28ECR3 Pump Dumps Aux. Enable Relay’s
Analogs
P4 1 Not Used Not Used
P4 2 60A Green 0-5V Proportional Input from PT1 Pressure Transducer Analog Output signal
P4 3 28B Green 0-5V Proportional Input from AT1 Angle Transducer Analog Output signal
P4 4 Not Used Not Used
P4 5 Not Used Not Used
P4 6 910 Black Output supply 12V (B+) for AT1 Angle Transducer
P4 7 900 White 0V GND (-) Negative Reference for PT1 Pressure Transducer
P4 8 902 White 0V GND (-) Negative Reference for AT1 Angle Transducer
P4 9 910A Black Output supply 12V (B+) for PT1 Pressure Transducer
Inputs
P5 1 68A White 12V Input from LS68 Left Rear Outrigger Down limit switch
P5 2 67A Red/White 12V Input from LS67 Right Rear Outrigger Down limit switch
P5 3 66A Blue/White 12V Input from LS66 Right Front Outrigger Down limit switch
P5 4 65A Green/White 12V Input from LS65 Left Front Outrigger Down limit switch
P5 5 70 Green/Black 12V Input from S24 Outrigger Auto Level request signal
P5 6 79 Green 12V Input from S24 Outrigger Auto All-Up request signal
P5 7 70A Red/White 12V Output for Outrigger Light OL1
12V Input from LS61, LS62, LS63 & LS64 Outriggers limit switch Up signal ** (all
P5 8 65 Green/Black
switch contacts must be closed to produce in series signal)
P5 9 Not Used Not Used
P5 10 44 Red 12V Input from 35CR Elevation Tilt Override/High Speed Cutout Relay
P5 11 02 White GND B- 0V Reference Input from Base Terminal Strip
P5 12 10A Black 12V B+ Input thru Main Power Relay 10BCR From Base Terminal Strip
Output
P6 1 78 Black/White 12V Output for Outrigger Left Rear Down signal to 4H-78 Solenoid
P6 2 77 Blue/Black 12V Output for Outrigger Right Rear Down signal to 4H-77 Solenoid
P6 3 76 Red/Black 12V Output for Outrigger Right Front Down signal to 4H-76 Solenoid
P6 4 75 Orange/Black 12V Output for Outrigger Left Front Down signal to 4H-75 Solenoid
P6 5 74 Black 12V Output for Outrigger Left Rear Up signal to 4H-74 Solenoid
P6 6 73 Blue 12V Output for Outrigger Right Rear Up signal to 4H-73 Solenoid
P6 7 72 Red 12V Output for Outrigger Right Front Up signal to 4H-72 Solenoid
P6 8 71 Orange 12V Output for Outrigger Left Front Up signal to 4H-71 Solenoid
P6 9 35C White/Black 12V Output for Outrigger Enable signal from Enable switch S9A or Relay 9CR3

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5.12-3 GP-108 LED error codes

Code Description
ON EVERYTHING OK
ON GROUND MODE ACTIVE!
STARTUP!
VEHICLE TILTED
NOT FULLY LEVEL
OUTRIGGERS NOT HOME
1/1 VEHICLE TILTED AND NOT LOWERED
1/1 HEIGHT NOT CALIBRATED
1/2 VEHICLE OVERLOADED
1/3 ARMGUARD ACTIVE!
1/4 TOO HIGH - DRIVE PREVENTED
1/5 TOO HIGH - LIFT UP PREVENTED
2/2 RELEASE OUTRIGGER DEMAND!
3/2 FAULT: ENERGIZED VALVE - CHECK WIRING!
3/2 FAULT: VALVE FEEDBACK HIGH!
3/4 FAULT: BAD INTERNAL SAFETY SWITCH!
4/1 GP102 P4-1 OR P5-1 SHORT TO 0V?
4/2 GP102 P3-4 SHORT TO SUPPLY!
4/2 FAULT: BAD INTERNAL 5V!
4/2 FAULT: BAD INTERNAL SLAVE!
4/3 GP102 P3-4 SHORT TO 0V?
4/4 FAULT: BATTERY VOLTAGE TOO LOW!
4/4 FAULT: BATTERY VOLTAGE TOO HIGH!
4/4 GP106 P2-8 SHORT TO SUPPLY!
4/4 GP106 P2-x SHORT TO SUPPLY?
4/4 GP106 P4-x SHORT TO SUPPLY?
4/4 GP102 P3-4 SHORT TO SUPPLY?
4/4 GP102 P3-6 SHORT TO SUPPLY?
4/4 B+ SUPPLY TOO LOW
4/5 GP106 P4-x SHORT TO 0V?
4/5 GP106 P2-8 SHORT TO 0V?
4/5 GP106 P2-x SHORT TO 0V?
4/5 GP102 P3-6 SHORT TO 0V?
4/6 GP106 P2-x FAILURE?
4/6 GP102 P3-6 FAILURE?
5/2 WAITING FOR B+ ON P4-9
5/2 WAITING FOR B+ ON P2-12
5/4 UP/DOWN SELECT INPUTS ACTIVE TOGETHER
5/5 WAITING FOR NEUTRAL: LIFT/DRIVE
5/5 FAULT: OUTPUTS!
5/5 FAULT: GP106 OUTPUTS!
5/5 FAULT: GP102 OUTPUTS!
5/6 DRIVE/LIFT INPUTS FAULTY!
6/1 FAULT: CHECK HEIGHT1 SENSOR
6/1 FAULT: CHECK HEIGHT2 SENSOR
6/1 FAULT: CHECK HEIGHT SENSORS
6/2 FAULT: CHECK PRESSURE SENSOR
6/4 FAULT: CHECK ELEVATION SWITCH
7/8 TESTING HWFS
F/F IDLE TIMEOUT ACTIVE!
F/F CHECK GP106 CONNECTIONS!
F/F CHECK GP102 CONNECTIONS!
F/F FACTORY OVERRIDE
60665AB

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