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Service Manual Full-Size Rough Terrain Series

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4. PIN 1 04 RED BLUE PIN 7 01 RED BLUE x NOTE ON J9241 JUMPER WIRE PIN 2 17 BLUEIRED PIN 8 02 WHIT
5. lt N 859 x gt N AO s GION31OS H3OOlHIDO L 15200 1441 sz 9L ee L N9 N HIDING 061600
6. J BHD J E F J 64 0 H 7 V BACK VIEW HYDRAULIC GENERATOR INTERNAL WIRING OUTRIGGER ELECTRIC PANEL ue n mE pu 2 77 12 PIN CONNECTOR PLUG PIN 3 86A ORGIBLKIHT _ NORTH AMERICAN COLOURS reer ES LOAD BLACK 11 woe P4 P2 ems lt
7. PIN6 44RED PIN 12 10A BLUENIHITE TA V 05 49 34 30 ON 10 13 14 15 16 23 24 4 mc 5 OO OO OO OI O O O O OQ 8 DD D ml ml n CA 11 i1 1 i1 gt 1 5 TO FLASHER 6 Bt Te tt gt te J
8. 5 O gt Q GION31OS H3OOIHIQO GZ 1441 82 gt GIONSTOS OG ase 14 1391 8 t t 1 an ae vl vi yava vi a GION31OS399II0O 1 56 900 NMOG ns m xovig ama 0 1 9 _ GION3IOS H3O9lH1nO 1 27698 dn SSE
9. CONTROL BOXHARNESS PIN FUNCTION JOYSTICK HARNESS 5 i 4 PIN1 LEFT 4 WHITE RED arts LIS 12 BROWN RED PIN2 JOYSTICKVS 129 WHITE BLACK 23 BLACK WHITE PIN3 RIGHT 23 WHITE 16 WHITE BLACK PIN4 FORWARD 16 YELLOW 124 BROWN RED PIN5 STEERINGVS 12 WHITE GREEN 15 PING REVERSE 15 GREY 19 ORANGEBLACK 7 2nd SPEED 19 BROWN 12A BROWN RED PIN8 ENABLE VS 124 WHITE BLUE 18B RED BLACK PIN9 3rd SPEED 18B RED BLACK KEY SWITCH POWER ONLOAD SENSINGLIGHT TH
10. SKYJACK Page 40 TWR GREEN 1 BLACK LT GREEN 18 SHD BLACK WHITE 18 EGO 1 GASOLINE SENSOR INTERFACE Warde OXS2 D F B WHITE LT GREEN 18 GPS1 PINK DK GREEN 18 BLACK LT GREEN 18 OXS1 D BLACK YELLOW 18 1 WHITE RED 48 A PINK DK GREEN 18 1__ GREEN ORANGE 18 TPS2 TWR 2P 56 2 18 BLACK LT GREEN 18 WHITE BLACK 18 DK GREEN ORANGE 18 LOCKOFF A PINK TAN 18 _PINK TAN 18 4 LPG TEMPERATURE 5 PURPLE LT BLUE 18 6 BLUE DK BLUE 18 7 GREEN 18 8 TAN DK GREEN 18 9 DK BLUE ORAN
11. TO CONTROL BOX BACK VIEW c FEMALE Gz SY GREEN WHITE 1615 WHITE BLACK 16 N 32 GREEN BLACK 8 7 BLUE 15 lo Po c 8 REDWHITE 14 6 BLACK ia 2 54 24 BLUE BLACK 3 2 6 5 ORANGE 3 23 BLACK WHITE 12 4 L BLUE WHITE 10 5 5 20 BLACK WHITE RED 11 ORANGE RED 09 oollloo 19 ORANGE BLACK 0 2 RED 7 a oS RED BACK DOT RO O Oy d O o GROUND BLUE BLACK WHITE TO 00 J X A GROUND A BACK VIEW O FEMALE O if 56 GREEN BLACK WHITE 77 at G RED GREEN 76 39 2 WHITE RED 75 7D RED BLACK GREEN 29 21 BLACK RED 74 10D WHITE RED GREEN 128 20 ORANGE GREEN 73 60 BLACK RED GREEN 27 WHITE BLACK RED 72 B5 ORANGE BLACK WHITE j BLUE RED 71 RED BLACK WHITE 2 JO GREEN 49 CONTROL KO OPO AGO AO O n u
12. CONTROL HARNESS FUNCTION JOYSTICK HARNESS Vi ew 4 BLUEIBLACK PIN1 LEFT WHITERED Parts List 12 BROWN RED PIN2 JOYSTICK VS 12 WHITE BLACK 23 BLACK WHITE PIN3 RIGHT 23 WHITE 16 WHITE BLACK PIN4 FORWARD 16 YELLOW 12A BROWN RED PIN5 STEERING VS 12A WHITE GREEN 15 BLUE PIN6 REVERSE 15 GREY 19 ORANGE BLACK PIN7 2nd SPEED 19 BROWN 12 BROWN RED PIN8 ENABLE VS 12A WHITE BLUE 18B RED BLACK PIN9 3rd SPEED 18B RED BLACK KEY SWITCH POWER ON LIGHT THROTTLE et 08 J T 12 Ore te Hokar JOYSTCKCONTROL WITH ENABLE 9 ES L NORM HIGH TORQUE EMERGENCY STOP UPIDOWN HIGH LOW RANGE Em 09 10 E 08 ABR nam nmi mx 10104012100 one enenenenoe Ma 2 o le noenenenmo oA 2 E V CUR 2122 LIFT START NOTUSEDOR HYDR HORN ENABLE GLOW PLUG GEN OR CHOKE BACK VIEW BACK VIEW MALE MALE V L N 16 WHITE BLACK G Jig GREEN WHITE 34 77 GREEN BLACK WHITE 1 132 H 15 B
13. 55 Vee 4 vie ve 77 m 50 20 10 80 slo HOLIMS ALIVO3N 3015 HOLIMS AON3OU3N3 asva XO 1OH1NOO PS 95 N v gt N 99 1 08 909 x NMOG 1451 8 8z 31IHWMOv18 1 4 5 W399MInO gi 1 Secca dn 6 1491 a 1431 27 uvau vL vL ces w 8200 C NMOd LL H LL 4 LNG Pa oul o r 99 y ez ez amg z avay em GIONIOS H3DOILNO gi 1 75400 NMOG 1 9 Hb 9L 9 1 qION31OS se r OS 601 4 1 083 1NOH3 2L
14. 100A 96 51 TO ENGINE 00 18 gt 100 100 096 B1 MAIN BATTERY B2 AUX BATTERY I em 98 BLACK 00 WHITE 97 BLACK 97A GREEN 98 WHITE EMERGENCY DECK RETRACTION PIN 3 97 BLACK PIN 4 97A GREEN MANUAL LOWERING VALVE 4 BACK VIEW 3 S51 EMERGENCY LOWERING PIN 3 97 BLACK 2x PIN 4 98 WHITE a
15. Section 5 Procedures LL UP SWITCH NO BLUE amp BROWN O R UP SWITCH NO BLUE amp BROWN o l i BACK VIEW MALE BACK VIEW MALE PIN 1 BLACK PIN 2 BLACK WHITE PIN2 BLAGK WHITE PIN 4 BROWN o7 PIN 4 BROWN RIGHT FRONT OUTRIGGER PIN 1 BLACK 10 BACK VIEW FEMALE PIN 2 WHITE pet BACK VIEW FEMALE LEFT FRONT OUTRIGGER PIN 3 GREEN 63 8 PIN 1 BLACK 10A PIN 4 62 2 PIN 2 BLACK WHITE 65 PIN 3 BLUE 62 4 PIN 4 BROWN 61 1 N H H 2 O R DOWN SWITCH BLACK 4 BLACK WHITE O R DOWN SWITCH NC BLACK amp BLACK WHITE 2 LEFT FRONT OUTRIGGER
16. Battery Engine Air Filter Enigne Fuel Filter Ensure there are no loose or missing Ensure there are no loose or missing parts and there is no visible damage parts and there is no visible damage Frequent Inspection C Annual Inspection For engine air filter maintenance For engine fuel filter replacement procedure refer to engine manual procedure refer to engine manual C Annual Inspection For engine air filter replacement procedure refer to engine manual Engine Oil Level Maintaining the engine components is essential to good performance and service life of the aerial platform Check oil level on dipstick Oil level should be between the 1 and H marks B Frequent Inspection For recommand oil change refer to engine manual SKYJACK Page 22 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Service and Maintenance Inspections Typical Model 71xx shown Propane Tank Fuel Tank 1 1 6 Fuel and Hydraulic Oil Supply Fuel Tank IMPORTANT Before using
17. Nise 55 5 23 5 99 5 2 3 cg C 5 1 48 s lt lt L cc 2 9CR3 Xm adu ados te LLI S a J E a amp _ 5 0 5 SICR BCR SR oeb ENABLE ru PD X CN22 ERU 5 5 5 25 55 55 55 8 m H H EDT 50318 Mid Size amp Full Size SKYJACK Page 23 Rough Terrain Series Service and Maintenance 5 3 2 Outrigger Mechanical Limit Switch Wiring Diagram
18. OUTRIGGER ELECTRIC PANEL 12 PIN CONNECTOR PLUG CN14 3 31 Electrical Panel Diagram CE All Option ____ 9 View Parts List
19. 2 Ct PLATFORM OPTION MC1 MOTION CONTROL VALVE ASSEMBLY LIFT LIFT MBA HOLDING VALVE CYLINDER MBS HOLDING VALVE CYLINDER CYLINDER MANIFOLD BLOCK MANIFOLD BLOCK p BASE DRIVE ASSEMBLY 28942 MB13 POWERED MBI4 REAR of E Ec xm MBI5 FREE HOLDING HOLDING EXTENSION POWERED EXTENSION r2 T WHEEL MANIFOLD VALVE VALVE MANIFOLD BLOCK MANIFOLD BLOCK k SERIES PARALLEL 2830 OVERLOAD 4H 27 N VALVE FREE WHEEL 7 x TRANSDUCER d ET RETRACT W M LM VALVE op OPTION VALVE 8 7 2 N Z TWO STAGE W i LIFT m S E LIFT P3 4 46284 HYDRAULIC 5 S EXTEND RETRACT EXTEND J X MOTOR 8 000 PRESSURE 000 VALVE VALVE VADE TX CUSHION 2 Z t 7 1 CYLINDER H 4 TRANSDUCER don R8 E M lc m AESERVOR i QM ut RELIEF x RELIEF 6 i mx HP2 BP CASE DRAIN MANIFOLD BLOCK Ee TB BRAKE PACK EON e TNE M UM PUMPIMOTOR TENK UNIT PILOT a ORIFICE 0 120 ud E WITH DIRECTIONAL VALVE OPERATED AUTO CHECK Y CONTROLLED A y CONTROLLED LOWERING VALVE MBIO DISC BRAKE e 2X X nie LOWERING X LOWERING MANIFOLD BLOCK T 77 9 MANIFOL
20. Base Control Motion Control Manifold Cushion Cylinder Brake Manifold Switches Manifolds Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Ensure there are no loose wires or missing fasteners e Electrical Panel Ensure panel is properly secured and there is no visible damage Ensure there are no loose wires or missing fasteners Tilt Sensor If Equipped Ensure tilt sensor is properly secured and there is no visible damage Load Tilt Sensor CE Ensure load tilt sensor is properly secure and there is no visible damage SKYJACK Page 20 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Service and Maintenance Inspections Typical Model 71xx shown Muffler and Exhaust Radiator Engine Control Console Engine Air Filter Hydraulic Pump Engine Tray
21. Cushion Cylinder 1 1 3 Emergency Lowering Access Rod All models except 9250 Ensure rod is properly secured and there is no visible damage 1 1 4 Electrical and Control Components Ensure all compartment latches are secure and in proper working order Main Power Disconnect Switch Turn main power disconnect switch to off position Ensure all cables are secure and switch is in proper working condition Base Control Switches Ensure there are no signs of visible damage and all switches are in their neutral positions Battery Proper battery condition is essential to good performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions WARNING Explosion hazard Keep flames and sparks away Do not smoke near batteries Base Control Brake Manifold Switches N WARNING Battery acid is extremely corrosive Wear proper eye and facial protec tion as well as appropriate protective clothing If contact occurs immediately flush with cold water and seek medical attention Check battery case for damage Clean battery terminals and cable ends thoroughly with a terminal cleaning tool or wire brush Ensure all battery connections are tight If applicable check
22. c T EXTENSION EXTENSION MCt MOTION CONTROL VALVE ASSEMBLY 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 277 s E MBS FREE EXTENSION POWERED EXTENSION 01 HOLDING VALVE HOLDING VALVE HOLDING VALVE M83 HOLDING VALVE MANIFOLD BLOCK MANIFOLD BLOCK 4 pel a us MANIFOLD MANIFOLD MANIFOLD MANIFOLD 15 oe den 28994 94 28992 q 2498 RETRACT NUXLARY AUXLIARY Lu AUNLIARY VALVE wal wal Erica Linn LOWERING LOWERING LOWERING LOWERING Jui Em am V TWO STAGE i 21 A PRESSURE SE ME AN m DU UN x 2 MOTOR C8 O 5 gt woe CUSHION _ HOLDING 0 HOLDING 0 HOLDING bu F HOLDING R8 lelg CYLINDER X VALVE __ u ___ RELIEF 0 02 ma 02 02 RESERVOIR 1 QS oy 421 X LIFT Pr L CB ORIFICE ORIFICE ORIFICE PRESSURE 1 ORIFICE 97 0 094 Em RG 0 094 5 0 094 4 OVERLOAD 0 094 R3 HP2 m CASE DRAIN
23. ate Tne POWERED EXTENSION PLATFORM OPTION MB16 MOTION CONTROL MANIFOLD BLOCK V BASE DRIVE ASSEMBLY C13 FRONT C14 REAR C4 LIFT CYLINDER C3 LIFT CYLINDER C2 LIFT CYLINDER _ EXTENSION Slow 95 BIS FREE MBG HOLDING VALVE MBS HOLDING VALVE HOLDING VALVE MBS HOLDING VALVE CYLINDER 1 gm MANIFOLD MANIFOLD MANIFOLD MANIFOLD 9 SERIES PARALLEL 2H 30A P c i et FREE WHEEL 2H 98 4 2984 292 296 MB13 POWERED MB14 REAR ___ E
24. Battery 1 1 5 Engine Compartment Muffler and Exhaust Ensure muffler and exhaust system are WARNING properly secured with no evidence of damage Beware of hot engine components e Engine Tray 1 Pull on the two latches to pull out engine Ensure there are no loose or missing compartment parts and no visible damage to the engine tray Ensure that both tray securing bolts e Engine Control Console are in place Ensure muffler and exhaust system are properly secured with no evidence of damage Hydraulic Pump Ensure there are no loose or missing parts and there is no visible damage Radiator secure Ensure all bolts are properly tightened Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Ensure there are no loose or missing parts and there is no visible damage Check coolant level and add as needed C Annual Inspection Forrecommand coolant change refer to engine manual Mid Size amp Full Size SKYJACK Page 21 Rough Terrain Series Service and Maintenance Inspections Section 1 Scheduled Maintenance Typical Model 71xx shown Muffler and Exhaust Radiator Engine Control Console Engine Air Filter
25. 25 4 1 36 Powered Extension Platform will Not 25 4 1 37 Powered Extension Platform will Not Retract 26 4 1 38 Hydraulic Generator Inoperative NETT DTP 26 4 1 39 Hydraulic Generator will Not Shut Off from Generator Switch 27 4 1 40 All Outriggers Inoperative Auto level and rr 27 4 1 41 All Outriggers Inoperative Auto level and manual from platform controls 28 Full Size RT s SKYJACK Page 1 Engine Powered Table of Contents Continued 4 1 43 All Outriggers Inoperative Auto level A Led Power Indicator Light at Outrigger Control Module OCM1 Not on 28 4 1 44 All Outriggers Inoperative Auto Level B Led Power Indicator Light at Outrigger Control Module OCM1 29 4 1 45 Left Front Outrigger Inoperative 30 4 1 46 Right Front Outrigger Inoperative 30 4 1 47 Right Rear Outriggers Inoperative 30 4 1 48 Left Rear Outriggers Inoperative 31 4 1 49 Individual Outrigger Functions Inoperative auto lev
26. 98 Lo 60 19 I NO HO1VH3N39 t 9 898 se 09 4 T P HOLIMS I 1 215 6 t soe I 298 2 998 vse vse 60 I l 780 85 58 60 60 60 _ 29 AvidHH31000 10 98 l 1 ve L voL 99 3 l 28 1 H31OOO 110 o 3 gn med i Anadan rS 4 i vL vL xovg vL eS 018 ET v a na ve VA 60 naviy N I zs NOLOW Tv mod N E zsa yoare i i 55 un AVISHGILLOHHL i i 20 en oe ave ve YIS 1919 os I HELL L 7 62 49 s ze 2 8r m AVIJHSWOHO 4 MOTD I NDERIT quur 16 i OL
27. LIFT CYLINDER MANIFOLD TYP 4 PLACES SKYJACK Page 30 f X Was oO NOTE ALL CABTIRES RUN IN TRACK WITH CONTROL CABLE B1 MAIN BATTERY 7 arg ao 000008 B2 AUX BATTERY 551 H 211 n 2 H PIN 4 98 WHITE Print View This Page Parts List ac M11443AA Full Size Rough Terrain Series Models 9241 amp 9250 143905 Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 21 Emergency Lowering System Wiring Diagram CE Model 9250 ____ 2 f POWER DECK RETRACT 97A BLACK 00 WHITE PIN 13 02 WHITE PIN 14 97A GREEN BLACK EMERGENCY POWER DECK RETRACT RELAY PIN 1 100A RED 09 PIN 4 98 ORANGE RED D 9 100 RED 2 PIN 12 09 ORANGE RED SN A lex
28. DO OO NOTE OPEN UP THE HARNESS AND PULL OUT om c N THE 09 ORANGE RED WIRE SO THAT IT IS 5 HIGHER CUT OFF THE RING TERMINAL AND CONNECT TO EMERGENCY PD RETRACT RELAY UNDERNEATH PLATFORM EE O POWER DECK CONTACTOR UK TD 27 4 F MANIFOLD 9B ORANGE RED 02 WHITE 20 NOTE TRIM BATTERY BOOT FOR ADDITIONAL CABLE 2 TO POWER DECK MOTOR CONTACTOR x i 00 WHITE 1098 BLACK _ Z A 99 GREEN aif b TH 1 NOTE FASTEN TO PUMP BODY S TO ENGINE pA SE ER ENABLE fou X 8 100 ES U 100 m
29. I n RST2 POWER DECK CONTACTOR 9B ORANGE RED 02 WHITE 2x 9 5 O EMERGENCY POWER DECK 97 BLACK 2x 02 WHITE 2x 27 POWER DECK CONTROL BOX FRONT 5 Q POWER DECK CONTROL BOX REAR Fe EE d 5 cry Q POWER DECK DIRECTIONAL VALVES CIRL BO Q r al 26 09 12 120 09 26 27 Ld tien ll gt F 2 2 UNDERNEATH ES PLATFORM PNP PWR 02 1
30. 17 17 S 17 1 O LLI OINId 30118 N 9 2 vol ISNA v lt 5 2 7 lt N33HO LIMOVIE 1 2 L LVH L LSW V 4 2541 V 8j 1541 asnd 84 VSL ISNA 2 Old v 25 1 v 8 LSXO d 1001 LID yA 2 HHD p B 7 V 1842 S 3 3LIHWNMOHS MG AVHD Yre NMOY9 3LIHM 8 gt gt NYL 4 amg 9 MOTISA AM1 H 1 N aa MMC N O N LLI d 1105 01 S3HIM LSIML 5 O ANIDNA I33 N3399 H Full Size Rough Terrain Series Models 9241 amp 9250 LO e o s Section 4 TROUBLESHOOTING INFORMATION Table of Contents I rset ens uzi IE AIEEE I OES EE EA AE 5
31. TO POWER DECK MOTOR CONTACTOR 00 WHITE 103B BLACK 99 GREEN LIFT CYLINDER MANIFOLD TYP 4 PLACES Print This Page View Parts List M11442AA SKYJACK Page 31 Print View This Page Parts List 3 22 Emergency Lowering System Electrical Wiring Diagram CE Model 9241 ____ 2 9 ____ 6 POWER DECK RETRACT w 3 BLACK fr NN 00 WHITE N EMERGENCY POWER DECK RETRACT RELAY PIN 1 100A RED PIN 4 9B ORANGE RED EMERGENCY POWER DECK RETRACT CONTACTOR 97A BLACK Dj 2 02 WHITE 20 LEE TO POWER DECK CONTROL BOX FRONT 0 0 19 100 00 00 ID ID lo TO POWER DECK CONTROL BOX REAR PIN 9 100 RED PIN 12 09 ORANGE RED PIN 13 02 WHITE PIN 14 97A GREEN BLACK EM RETRACT U IO IO ID 00 ID ID ID IIIJ 778001 TO POWER DECK DIRECTIONAL VALVES U U CTRL BOX
32. I 1490 j i 20 HOLL 20 ALIHM 20 o i P c 4 4 put 6r 3Ov18 3DNVHO 6L 45 PON QION31OS 3ATVA 91 200 185 31 99 lt I I 48 0 Woe 1 VOL 1 18 1 vs oz 2 35012 ATIVINHON I G3u 3LIHWMOVv18 0c goz i AV13u 3701 40 p INT I 56 3nouoL gg IA 9 981 9985 MOYHOIH t dm Gir Ver aoe v var 16 625 GIONTIOS SAWA 1 kaska zn wor san AVIAY 09 4 hos 1 1 AvidHH31009 10 9 l i 4 ve d VOL em 41000710 Zv 55 3 La 2 5 2 a98 V 50 I 60 9 60 9 vL vl vi ols Ldn e ON AVISHNMOG Sp 4 gb ug ev
33. 5 uaiuvis zo ANION OL ANIONS OL e 17 Ze VOL 4 4 ve ve VOL LHOWOL lL T T T VOL VOL l T T vol vee wee lt 0 e 8 om 3NION3 gt gt 2 D T SKYJACK Page 46 View Parts List Print This Page 3 36 Interface amp Engine Electrical Schematic GM Dual Fuel Engine CR YOLOW 19 YALYVLS GION3IOS YALYVLS YALYVLS SNION3 HOLIMS HOLOAIAS 3NVdOHd SVO GION3IOS 340901 AV T3H di And 1903 HOLIMS HOLIMS LYVLS 3NION3 1913 HOLIMS NIV HOSN3S ATLLOWHL HOSN3S VW HOSN3S odi HOSN3S ANY 1OOO 3NION3 H3MOd 1VO LSOd HOSN3S N39AXO 199 HOSN3S N39AXO H3QNITAO 1 SVO 2s HO LO3fNI SVO H3QNI1AO YOLOAPNI SVO YOLOAPNI SVO HOSN3S NOILISOd ldVHSM4NVHO noa 89 19 99 59 v9 59 MSA 29 1 16
34. GIONJIOS3AWA gz mE SNIH3MOT aN W31SAS Z ze zoa GIONFIOS gz gt 1 96 HOLOVINOO 3SV8 62 1 0 00 00 7 5 GIONTIOSNI gt wed Fal Y viz LN p GION310S ino rad 9 vaz L Ino gt gt vus 3lgvN3 GION310S NI 002 P ves 12 1NOH3 Send 4 qioN31os 110 rad ve zoa DEOL 0 2 324 gt ScHv Y us savna 140 H31H3ANI gt ezoa ves HOlOVINOO e 0 50 66 180 0 50 060 YOLOW 7 UNAITWA 00 AH311V8 AZL ig 001 50 8601 00 9 d NIV SL HOIVNH3IV vl al 13 gt waluvisaNiona j 3 vol 00 e 20 T HOLIMS 4 AA 4 SUN LWHadWAL 16 ze 1 voL hous 3NION3 5 OL 1 a 77 vol voL HOIDVINOO m A 18 3NION3 TR 6 200
35. Ou C dC BACK VIEW EMERGENCY DECK RETRACTION 97 BLACK PIN 4 97A GREEN 3 NOT CONNECTED MANUAL LOWERING VALVE TIE WRAP TO THE CABLE 97 BLACK 97A GREEN 98 WHITE M148308AA_1 SKYJACK Page 32 Full Size Rough Terrain Series Models 9241 amp 9250 143905 View Parts List Print This Page 3 23 AutoLeveling Outrigger Connection Diagram D Jj F 20 A3H0DGQ TO OUTRIGGER LIMIT SWITCHES LEFTFRONT OUTRIGGER RIGHT FRONT OUTRIGGER RIGHT REAR OUTRIGGER LEFT REAR OUTRIGGER mm PIN 1 BLACK 104 PIN 1 BLACK 104 PIN1 BLACK 100 PINT BLACK 104 PIN 2 WHITE 65A PIN 2 WHITE 66 PIN 2 WHITE 67 PIN 2 WHITE 684 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 ox o 5 PIN 1 BLACK PIN 2 WHITE o PNS GREER PIN 4 RED 61 lt gt
36. 57 vee vol o zoa d Y3LIWYNOH HOLIMS 6 1580 28 vol NMOQ dn 46 es 9109105 g 4 M 139310 p Ze vee 50 Soma MOTO t t vie 01 T3091 gt gt HOLVOIONI 9 Indo er MOTO aor aor QION310S 4 A er S 5 um Tm we w 5 5 SMa vie VIE 50 yan 4 MOTO 9 dos E vee 94 OL 90 6 2 ve 20 50 50 de ON HOLIMS 1HVIS NO 33O Tu MOTD MS 165 NIV 066 AUVOSN ly 70 70 20 oL Ups w 80 m Hee Sn 3NION3 XO810ulNOO 4018 asva TOHLNOS 5 HOLIMS 95 018 View Parts List Print This Page 3 34 Electrical Schematic ANSI CSA amp AS All Options with GM Dual Fuel Engine 1 9 1 686 y
37. M115279AD_M115284AE Full Size Rough Terrain Series Models 9241 amp 9250 143905 SKYJACK Page 17 3 8 Outrigger amp Hydraulic Generator Control Console Wiring View Parts List TO HYDRAULIC GENERATOR SWITCH PIN 86 WHITE PIN 2 09 BLACK PIN 3 85 GREEN TOAUTOOUTRIGGERSWITCH PIN 1 79 GREEN PIN 2 35D PURPLE WHITE SEI PIN 3 70 GREENIBLACK WD TO OUTRIGGER ENABLE SWITCH Tm PIN 1 35D PURPLEWHITE E nw PIN 3 350 PURPLEWHITE WHITE HYDRAULIC GENERATOR CONTROL CABLE U OUTRIGGER CONTROL CABLE M129301AB SKYJACK Page 18 Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 9 Base Control Console Wiring ANSI CSA 10F BLUE WHITE 1 75 10E BLUE WHITE 4 T 10E H 56 J 10A Hoe L lt BASE CONTROLS CONTACT ORIENTATION BACK VIEW 10E 10E ENABLE SWITCH N O CONTACT IW
38. 8 110 1540 4 D 29 VOL vor GION310S mhi lt 4 4 4 195310 amp vee vee A w somd 65 3NON3 9 T we 1493 gt gt HOLVOIGNI 1149 LO 06 GION310S a N v 4 4 HOIH We we m VvE S1H vie vie wie 27 80 lt BoMia 2 E 20 ug Ve vee 5 1 v e w we 20 I 50 50 NI E 3ALVO3N HOLIMS 1HVLS NO 34O Sma MOTD MS 3NISN3 C N 166 NIV OES o 10 10 10 we 80 Need ind N LO HOLIMS 13931 vLoany HOLIMS XO8 10HINOO 4015 4018 AONSOH3INS 5 95 o gt ST View Parts List Print This Page
39. ATIVWHON 99 S3HOLIMS NMOG H399IH100 ru 6 24 82 gz 1 01 9 90 hed Se 1391 201 Ld 8 bs NMOGHV3HIHOIH 901 LL ua NMOG LNOY4 LHDIH SOL bd 92 Y 3 1491 01 SL sa GL 1427 601 Std EL a dnlNOH4lHOlH 101 00 4 TOHINOO 2 a v A HOLL dQ dl dl zs dl zs Sem 150 ge 4 Fh m YaDOIULNO 94 1481 1 1451 398 a O88 ose 8 pp 22 I 16 ne ne we I 0 60 l 2806 40088 96 HSDOIULNO 60 ger LNO 2806 96 e e 1 1 NI NMOHS SH395IH1n0 i 1 NN WIN d 9 uvau A 19 1331 1HOlH 1431 1 1ST am mm H359IH1n0 T 5 B 5 8099 438010 ATIVINHON T 10 Jussu IANOLND 92 1951 2951 6951 7951 26 oo Q3S019 SSHOLIMS 4399141N0 voi
40. GP106 Control Module OU DOO DOG 666 aoa a com LED WIRE FUNCTION The Calibration Connection Input indicating that the LEFT REAR outrigger is in contact with the ground Input indicating that the RIGHT REAR outrigger is in contact with the ground Input indicating that the RIGHT FRONT outrigger is in contact with the ground Input indicating that the LEFT FRONT outrigger is in contact with the ground Input for AUTO LEVEL function to extend the outriggers to level the machine Input for AUTO RETRACT function to retract the outriggers until the switch is released 70A Red White Outrigger Light on Outrigger Control Box STABLE output to indicate that all outriggers are in contact with the ground TILT output to indicate that the machine is level ANSI CSA only Tilt override High Drive Cutout 02 White Negative Input 10A Black Main Power Input 78 Black White Output used to extend the LEFT REAR outrigger Output used to extend the RIGHT REAR outrigger Output used to extend the RIGHT FRONT outrigger Output used to extend the LEFT FRONT outrigger Output used to retract the LEFT REAR outrigger Output used to retract the RIGHT REAR outrigger Output used to retract the RIGHT FRONT outrigger 71 Orange Output used to retract the LEFT FRONT outrigger 35C White Black Power input for outriggers 6 9 6 EN
41. 7 5 1 7 Wheel Bolt Nut Inspection and Torquing ra 9 5 1 8 Wheel Reinstallation and Torquing Procedure 9 uis gt 10 giU Electroni Tit Switch Setup PIOCOOHIE _ _ 12 YO ETUR 12 Pon Es sung 14 t t ip 15 Engines pal 16 1 KICK A eared 17 523 GM Mop and JAT Sens r AM REA GE S R 18 5 2 4 Engine Coolant Temperature Sensor GM 19 525S LFG Temperature Sensor 20 924 Fuse HE eT EIC METRE 21 5 2 7 Kubota Dual Fuel DF972 Resistance 22 Outriggers Option 5 3 1 Auto Leveling Outrigger Board 23 5 3 2 Outrigger Mechanical Limit Switch Wiring 24 5 3 3 Auto Leveling Outrigger Setting and Error Codes 25 5 3 4 Auto Leveling Outrigger Error Code 26 5 3 5 Held
42. 1 AZLAHVHIXDY Og 62 NI avay 8 gt Ni GION310S LNO Z 60 vis INOH3 vee 002 LNO LNOH4 LANI 3553 01 ino gt gt v3 igo HOlOVINOO 2 o i ves 50 90 voz dWv OL L 0 geot 9801 001 S4 zz IL 001 veoh 00 ig 3snd HOLOW 1 TINA TNA 2 4 D zr LI gre ve ve OL JILLOHHL H IH MOT pli 15 19168 6 Ir ze ze ze 1HVIS 3NION3 Sis 4 9 n n n T o HOLIMS Ord w 515 ON 9i ul 9 1 80 HOLOW me f zo 7 lt MOLT 00 4 ex 440 NI m 20 14 44 HOLIMS HOLIMS 4 4 4 es 3univu3dWal n vol 304 DOD ANENA 4 n 4 no A ve va voL 30i aer HOLOVINOD gx HVOF cu 18
43. IL L L Full Size Rough Terrain Series Models 9241 amp 9250 3 4 Electrical Component Parts List Continued Skyjack er o Parts list continued from the previous page BEEPER XL 600 9 28 VDC CE CAPACITOR 50 Volt CAPACITOR 50 1000 CE CIRCUIT BREAKER 20 Amp CIRCUIT BREAKER 20 Amp CIRCUIT BREAKER 20 Amp hydraulic generator option LIGHT Check engine GM MODULE Load sensing control CE SENSOR Crankshaft position GM CABLE ASSEMBLY 32 pin control console CABLE ASSEMBLY 32 pin scissor control Model 9250 CABLE ASSEMBLY 32 pin scissor control Model 9241 CABLE ASSEMBLY 32 pin electrical panel DIODE ASSEMBLY with 1 diode D28A ANSI CSA DIODE ASSEMBLY with 1 diode D30A DIODE ASSEMBLY with 1 diode D44 ANSI CSA DIODE ASSEMBLY with 1 diode D10E CE DIODE ASSEMBLY with 1 diode D20A CE DIODE ASSEMBLY with 1 diode D86C 1 Hydraulic generator option CE DIODE ASSEMBLY with 1 diode D86C 2 Hydraulic generator option CE DIODE ASSEMBLY with 1 diode D14B 2 Hydraulic generator option CE DIODE ASSEMBLY with 2 diodes D17A D18A D15A 016 ANSI CSA D15A 2 D16A 2 CE D15A 1 D16A 1 D23A D24A ANSI CSA D15A 1 D16A 1 D23A D24A CE DIODE ASSEMBLY with 2 diodes DIODE ASSEMBL
44. PIN 1 02 WHITE PIN 2 35C WHITE BLACK PIN 3 70 GREEN BLACK PIN 4 70A RED WHITE PIN 5 71 ORANGE PIN 6 72 RED PIN 7 73 BLUE PIN 8 74 BLACK OOo 42227 PIN 9 75 ORANGE BLACK PIN 10 76 RED BLACK PIN 11 77 BLUE BLACK PIN 12 78 BLACK WHITE PIN 13 79 GREEN PIN 14 35C BLUE WHITE PIN 15 350 GREEN WHITE a 0 1 02 7 72 Q PIN 1 73 BLUE PIN 2 02 WHITE PIN 1 71 ORANGE PIN 1 72 RED PIN 2 02 WHITE PIN 1 74 BLACK PIN 2 02 WHITE PIN 2 02 WHITE 35C WHITE BLACK 70 GREENBLACK gt 79 GREEN lt 8 Le 966666666 O O O O NC 36D PURPLEMHITE RED WHITE 350 BLUEWHITE 9 02 WHITE 35C GREENWHITE TO CONTROL TEN PIN CONNECTOR PLUG PIN 1 74 BLACK PIN 2 73 BLUE PIN 3 78 BLACK WHITE PIN 4 77 BLUE BLACK PIN 5 35D PURPLE WHITE PIN 6 N U PIN 7 71 ORANGE PIN 8 72 RED PIN 9 75 ORANGE BLACK PIN 10 76 RED BLACK d PIN 7 75 ORANGEIBLACK X PIN 8 72 RED PIN 9 76 RED BLACK 02 17B WHITE BLACK 02 WHITE M50333AC_
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46. Operator s Responsibility for Maintenance Service and Maintenance SKYJACK is continuously improving and expanding product features on its equipment therefore specifications and dimensions are subject to change without notice Aerial Platform Definition A mobile device that has an adjustable position platform supported from ground level by a structure Purpose of Equipment The SKYJACK Rough Terrain s mid and full size aerial platforms are designed to transport and raise personnel tools and materials to overhead work areas Use of Equipment The aerial platform is a highly maneuverable mobile work station Lifting and driving must be on a flat level compacted surface It can be driven over uneven terrain only when the platform is fully lowered Manuals Operating The operating manual is considered a fundamental part of the aerial platform It is a very important way to communicate necessary safety information to users and operators A complete and legible copy of this manual must be kept in the provided weather resistant storage compartment on the aerial platform at all times Service amp Maintenance The purpose of this is to provide the customer with the servicing and maintenance procedures essential for the promotion of proper machine operation for its intended purpose All information in this manual should be read and understood before any attempt is made to service the machine The updated copy of the manuals are found
47. 143905 Print View This Page Parts List 3 17 Hydraulic Generator Electrical Panel Diagram ANSI CSA Dual Fuel Engine
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50. BLACK BLACK x I oW BLACK B F BACK VIEW BACK VIEW TOCONTROLMODULE P4 Em eL CONTROL MODULE P2 B eu f PIN 7BBLACKINHITE 2 PIN2 77 BLUEIBLACK 29 PIN3 76REDBLACK x CEL PIN 75 ORANGEIBLACK 2 PIN 1 68A WHITE PIN 2 67A RED WHITE SI PIN 3 BLUE WHITE PIN 4 65A GREEN WHITE PIN 5 70 GREEN BLACK PINS 74 BLACK 2x PIN6 73 BLUE 2x PIN 72 RED 20 PIN 8 71 ORANGE 2 PIN 9 35C WHITEIBLACK a EL PIN 65 GREEN BLACK PIN 6 79GREEN 7 REDIWHITE PING NIU PIN 11 02 WHITE 2 PIN 10 35 BROWN RED PIN 12 10A BLUE WHITE TO ELECTRIC PANEL 02 WHITE 10A BLUE WHITE 35 BROWN RED TO CONTROL BOX PIN 1 02 WHITE PIN 2 35C WHITE BLACK PIN 3 70 GREEN BLACK PIN 4 70A RED WHITE PIN 5 71 ORANGE PIN 6 72 RED PIN 7 73 BLUE PIN 8 74 BLACK PIN 9 75 ORANGE BLACK PIN 10 76 RED BLACK PIN 11 77 BLUE BLACK PIN 12 78 BLACK WHITE PIN 13 79 GREEN PIN 14 350 WHITE BLACK PIN 15 956 WHITE BLACK
51. Section 5 Procedures Back Up Rings O Rings Service and Maintenance 7 8 Diagram 5 3 Multiple Disc Brake Assembly Oil Seal Cover Dowel Pins e Spring Retainer Springs Return Plate Rotor Discs ir a 4 4 D k lt Stator Discs x e Piston P Back Up Rings Mid Size amp Full Size Rough Terrain Series O Rings ye lt Case Seal Pressure 7 Cap Screws 5 n S N NN E M11512AA SKYJACK Page 5 Service and Maintenance Section 5 Procedures 5 1 3 Holding Torque Testing Procedure 1 Ensure aerial platform is on a firm level surface 2 Locate brake feed valve 2H30A 2 on main manifold and disconnect electrical connectors from valve This will prevent the hydraulic system from releasing the brake 3 With engine running aerial platform in drive mode engine on high idle high torque selected and low speed range selected hold enable switch on controller and push controller forward as if you were to drive forward This provides torque from the drive motor to unreleased brake 4 f brake slips and aerial platform starts to move in this condition either brake plates are worn or springs have broken Both brake plates and springs must be replaced to return brake to
52. Kubota 0902 Kubtoa 01105 Kubota DF972 GM 1 6 Nissan A15 Liters Gallons SJRT 68xx 8688 2295 SJRT 7127 7127 v N A pu RT 7135 80 48 21 26 8243 SJRT 8850 8850 N A v 8831 49 21 N A SJRT 8841 8841 9241 64 35 SJRT 9250 9250 All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water Mid Size amp Full Size SKYJACK Page 19 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 6 Torque Specifications Directional valve mounting bolts Wheel mounting bolts Center drive sprocket mounting bolts Hydraulic drive motor mounting bolts Positive battery post cable fuse nut Lbf ft max __ max _ 5 42 to 6 78 SAE Plugs Lbf ft max 4 to 5 48 to 60 Torque 2 5 6 Lbfft max 3 300 33 90 Newton meter Nm Pound force foot Ibf ft Pound force inch Ibf in SKYJACK Page 20 Mid Size amp Full Size Rough Terrain Series Section 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS Table of Contents Charts 3 1 oO 3 3 2 SVImDOILCNart U LLULLU 4 Parts List 3 3 gue Fans Uoi UL UU ey ee a T TN 5 3 4 Component Parts B i MENTRE EE E RT 8 Diagram
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54. emergency stop button and restart engine Test Base Lift Enable For ANSI CSA amp AS 1 base control console select and hold lower neutral raise switch T to raise position without selecting 7 gb lift enable switch Result Platform should not rise For CE 1 On base control console select and hold lower neutral raise switch T to raise position without selecting off platform base key switch to base position Result Platform should not rise SKYJACK Page 34 Test Lower Neutral Raise Switch For ANSI CSA amp AS 1 On base control console select 7 gt hold lift enable switch and T raise the platform with lower neutral raise switch Result Platform should rise 1 2 Select and 1 2 5 lift enable switch and fully lower the platform with lower neutral raise switch Result Platform should fully lower For CE 1 control console select and hold 17 7 off plattorm base key switch to base position and amp T raise the platform with lower neutral raise switch Result Platform should rise 2 Select and hold off platform base key switch to base position and fully lower the platform with lower neutral raise switch Result Platform should fully lower Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Base Control Console
55. 28 1 8 N3399 17 4 AVHD MOTISA 66 ALIHW NVL Ot 09 64 LT 3LIHA L MOTI3A MOV 18 64 31IHWN33HO 22 MOTTA LE LT NMOHS 29 19 12 A1dHNd ALIHM 18 610v 18 69 ZZ ama LS 29 82 AVHD 89 28 27 MOTISA AM 9 q3u NV1 MOWIE NVL 92 Sc 8 LNOA AYALLIVE OL LOANNOOSIG NIYIN OL YOLVNYSLIV 5709 3snd M148223AA_1 SKYJACK Page 47 31aund 16 28 1 15 ve ISNA V VOL VOL OINId 3018 17 4 lt gt MOTI3A N33U5 5001 5001 RS VOL gt NMOHS NV I H 0S ees Tans ve ISNA MOTI3A MNId LL lt lt vol MOTIAA NId 2 2005 77 S0 S0 05 330 Ve
56. Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 9 6 10 13 Defective relay 24CR Check relay Replace if defective Loose or broken wire 04 from base terminal block to relay 24CR Check continuity Replace if defective Loose or broken wire 24A from relay 24CR to base terminal block Check continuity Replace if defective Loose or broken wire 02 from relay 24CR to base terminal block Check continuity Replace if defective Loose or broken wire 24A from base terminal block to steer left valve coil 4H 24A Check continuity Replace if defective Defective steer left valve coil 4H 24A Check coil Replace if defective Loose or broken wire 02 from steer left valve coil 4H 24A to base terminal block Check continuity Replace if defective Open diode D24A Check diode Replace if defective 4 1 21 Reverse Drive Inoperative 1 2 3 10 11 12 13 Defective drive reverse switch 57 4 in joystick 57 Check switch Replace if defective Defective joystick S7 Check joystick Replace if defective Loose or broken wire 15 from joystick S7 to platform terminal block Check continuity Replace if defective Loose or broken wire 15 from platform terminal block to relay 15CR Check continuity Replace if defective Defective relay 15CR Check relay Replace if defective Loose or broken wire 02 from relay 15CR
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58. RELIEF m RELIEF TRANSDUCER ey RELEF 25 HAND bici WAVE VALVE oe VALVE bd VALVE PUMP V6 i 4 AUTO MANIFOLD RESET iie VALVE MB10 DISC BRAKE 5 x MANIFOLD BLOCK CONTROLLED CONTROLLED CONTROLLED cj QUICK VE C7 STEER SR CYLINDER MB MB1 MAIN MANIFOLD MANUAL LOWERING Sa VALVE MANIFOLD W V LOWERNG HA P C12 LEFT REAR C9 LEFT FRONT C10 RIGHT FRONT C11 RIGHT REAR VALVE RIGHT LEFT OUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER mss STEER STEER y renee HYDRAULIC OTMAINLOWERING VALVE VALE O7 M a CHECK CHECK CHECK CHECK GENERATOR OPTION VALVE ORIFICE VALVE VALVE VALVE T 0096 8 _ FORWARD GENERATOR 2 DRIVE MOTOR RELEF Wwe ES NES ME 4 OUTRIGGER T ia 2 MANIFOLD BLOCK lt gt 32 772 7757 MORAG HYDRAULIC si 4H78 4 16 GENERATOR VALVE GENERATOR HUE 4 LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR MANIFOLD VALVE REVERSE OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER i VALVE DANE EXTEND Ll EXTEND G Em 1 VALVE VANE WE VALE 2H 17A LARGE O T f TL B Teg TL PUMP DUMP OCIOLCOOLER VALVE D
59. TPS1 SIGNAL 5 VOLTS LT BLU DK BLU LT GRN RED Mid Size amp Full Size Rough Terrain Series SKYJACK Page 17 Service and Maintenance Section 5 Procedures 5 2 3 GM Map and IAT Sensor GM 1 BLK LT GRN SENSOR GROUND YEL GRY 5 VOLTS q PAL 2 INTAKE AIR TEMPERATURE SIGNAL IAT 3 LT GRN RED 5 VOLTS 4 LT GRN MANIFOLD ABSOLUTE PRESSURE SIGNAL MAP IAT Sensor Resistance TEMPERATURE TOLERANCE 10 F OHMS 248 239 221 203 284 383 522 721 60597AA SKYJACK Page 18 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 2 4 Engine Coolant Temperature Sensor GM TAL TAN WHITE 5 VOLTS B BLK LT GREEN SENSOR GROUND Temperature Sensor Resistance TEMPERATURE TOLERANCE 10 F OHMS 242 4 101 209 302 534 90 40 60595AA Mid Size amp Full Size SKYJACK Page 19 Rough Terrain Series Service and Maintenance Section 5 Procedures 5 2 5 LPG Temperature Sensor GM WHITE RED 5 VOLTS B BLK LT GREEN SENSOR GROUND Temperature Sensor Resistance TEMPERATURE TOLERANCE 10 DEGREES F OHMS 220 153 7 254 20 40 60596AA SKYJACK Page 20 Mid Size amp Full Size Roug
60. 29 3 20 Emergency Lowering System Wiring Diagram ANSI CSA Model 9250 30 3 21 Emergency Lowering System Wiring Diagram CE Model 9250 31 3 22 Emergency Lowering System Electrical Wiring Diagram CE Model 9241 32 3 23 AutoLeveling Outrigger Connection 33 3 24 Powered Extension Platform Electrical Wiring Diagram Model 9250 34 3 25 Horn Light Beeper Wiring Diagram ANSI CSA Model 9250 35 3 26 Horn Light Beeper amp Load Sensing Wiring 36 3 27 cR pg milii ri RETE 37 3 28 Engine Wiring Diagram Kubota Diesel Engine 39 3 29 Engine Harnesses GM Dual Fuel Engine 2 40 3 30 Electrical Panel Diagram ANSI CSA All 41 3 31 Electrical Panel Diagram CE All 42 3 32 Electrical Schematic ANSI CSA 8 AS All Option with Kubota Diesel Engine 43 3 33 Electrical Schematic CE All Option with Kubota Diesel Engine 44 3 34 Electrical Schematic ANSI CSA amp AS All Opti
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63. As each item is inspected write the apropriate grade in the box INSPECTION FREQUENCY DAILY P PASS LJ FREQUENTLY F FAIL LJ ANNUALLY R REPAIRED L BI ANNUALLY Schedule Schedule Maintenance I nspections Labels Limit Switches Emergency Lowering Access Rod If Equipped Electrical and Control Components Main Power Disconnect Switch Base Control Switches Battery Manifolds Electrical Panel Tilt Sensor Equipped Load Tilt Sensor CE m 5 5 3 d 3 a Engine Control Console B B B B B B B B B B Radiator B C B B B B B B B B B B B B B B B B Muffler and Exhaust Engine Tray Hydraulic Pump Engine Air Filter Engine Oil Level Engine Fuel Filter 9 2 lt 9 5 lt Hydraulic Tank Hydraulic Oil 3 3 5 lt Lanyard Attachment Anchors AC Outlet on Platform Platform Control Console Powered Extension Control Console Equipped z 8 y 5 3 Scissor Guards Equipped Sliders Maintenance Support Scissor Assembly Scissor Bumpers Lift Cylinder s Inspection Schedule A Frequently t Annuallyt Bi annuallyt A B C D 9 gt gt Base Weldment Wheel Tire Assembly Axles Steer Cylinder As
64. Check continuity Replace if defective 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 switch 53 to platform terminal block Check continuity Replace if defective 4 Loose or broken wire 10 from platform terminal block to diode 010 located at relay 1 1 Check continuity Replace if defective 5 Open diode 010 or diode D10 is not connected at relay 10BCR1 Check diode Replace if defective All Functions Inoperative Additional for machines with Load Sensing System CE 1 Loose or broken wire 10C from base terminal strip to control module at pin P2 12 Check for 12 Volts at P2 12 If no voltage present check wire continuity Replace if defective 2 Loose or broken wire 28 from control module CM1 at pin P3 4 to 28CH1 tilt relay and 28CR2 Down Enable Relay Check for 12 Volts at P3 4 If voltage present check for 12 Volts at wire 728A on outrigger connector plug CN 14 at pin 1 If voltage present check for 12 Volts on wire 28A at 28ACR1 Relay and 28ACR2 Relay If voltage present check operation of relays If no voltage present check wire continuity Replace if defective Loose or broken wire 28E from control module CM1 at pin 3 6 to 28ECR1 auxiliary tilt relay and 28ECR2 auxiliary down enable relay Check for 12 Volts at P3 6 If voltage present check for 12 Volts at wire 28E at 28bECR1 and 28 2
65. Check switch Replace if defective Loose or broken wire 23 from steer right switch S7 2 to platform terminal block Check continuity Replace if defective Loose or broken wire 23 from platform terminal block to relay 23CR Check continuity Replace if defective Defective relay 23CR Check relay Replace if defective Loose or broken wire 04 from base terminal block to relay 23CR Check continuity Replace if defective Loose or broken wire 23A from relay 23CR to base terminal block Check continuity Replace if defective Loose or broken wire 02 from relay 23CR to base terminal block Check continuity Replace if defective Loose or broken wire 23A from base terminal block to steer right valve coil 4H 23A Check continuity Replace if defective Defective steer right valve coil 4H 23A Check coil Replace if defective Loose or broken wire 02 from steer right valve coil 4H 23A to base terminal block Check continuity Replace if defective Open diode D23A Check diode Replace if defective 4 1 20 Steer Left Inoperative 1 Defective steer left switch 57 3 joystick 57 Check switch Replace if defective 2 Loose or broken wire 24 from steer left switch S7 3 to platform terminal block Check continuity Replace if defective 3 Loose or broken wire 24 from platform terminal block to relay 24CR Check continuity Replace if defective Full Size RT s SKYJACK Page 15 Engine Powered
66. P SSL voL 96 1 AVISQSWIL T 7 0001 6 8 13M Lot 1 NO 310 4 EL MEUM C ee cna CC aye Ob Ldvo f eu 20 I zo LJ V ArBHdWnd gt wu 4 n UN i lal atl 4 daas Hg voe Hd QION31OS 3ATVA 91 204 Ae d samas 0 I 4 1 15 VOZ HE 1902 v MOILSAOP 215 l 9 5 69 I I 7 I l G3S019 ATIVWHON 2 go 3MOHLS JO 89 1 Se 1 Q 1 Hose _ MOTHOIH GION310S INYAL 79 I y 6 626 abl Hz 4 Vel age dIONSIOS3AWA gt Vip T P 2 TIVWS l gt VLL 60 60 1 0980 9 p x AVIAN 401 mopa m
67. Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams BBB Table 2 2 Maximum Platform Capacities Evenly Distributed CE First Extension Second Extension Number of Number of Number of Capacity Occupants Capacity Occupants Occupants 60376AF CE R N N am N LO T N T st Occupants and materials are not to exceed rated load Capacities listed are for standard machines equipped with 6 tires except for models 9250 and 9241 which are equipped with foam filled tires Refer to capacity label at sides of platform for additional information and for models equipped with options Ground Conditions s m 3 3 4 5 4 12 5 19 4 11 5 17 75 5 12 0 Papers and thin branches move flags wave 54 80 194 288 17 75 26 25 120 18 Dust is raised paper whirls up small branches sway BEAUFORT Wind Speed SCALE m km h ft s ph 108 139 389 500 35 5 _ 45 5 24 5 31 Tree branches move Power lines whistle It is difficult to open an umbrella 139 172 500 619 45 5 655 31 385 trees sway It is difficult to walk against the 60338AC 80 108 28 8 389 2625 35 5 18 _ 2425 Shrubs with leaves start swaying Wave crests are apparent in ponds or swamps SKYJACK Page 8 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 2d Maximum
68. This Page asas a Dt ma
69. This message occurs if the wrong switch is closed when the GP102 is waiting for the platform to be raised 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 Please Wait This message indicates that the GP102 is busy the delay will be short no more than 5s Total Data This message is displayed at the end of each phase to confirm the number of measurements recorded by the GP102 Mid Size amp Full Size SKYJACK Page 39 Rough Terrain Series Service and Maintenance Section 5 Procedures 5 4 7 Control Module Load Calibration Procedure 1 Move the aerial platform to 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 E
70. 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 Check that the battery voltage is not too low VEHICLE TILTED 1 1 These is not a true fault move the vehicle to level ground TESTING HWFS STARTUP These are not true faults unless they do not clear the start up tests should only occur for a short time OUTRIGGERS MANUALLY CONTROLLED 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 7 5 7 6 8 1 8 3 5 These are internal faults If the fault persists after the power has been reset the outrigger control module may need to be replaced 60412AB SKYJACK Page 26 Mid Size amp Full Size Rough Terrain Series 5 3 5 Hand Held Calibration Diagnostic Tool Key Functions WARNING Only trained and authorized personnel shall be permitted to service an aerial platform WARNING Read all instructions closely before attempting each phase of this procedure ru C lt gt ATED ESC EN
71. 10 35BRed Black Input From LS1 High Speed Limit Switch To Verify ON OFF Limits P2 11 02White Negative Input From Base Terminal Strip P2 12 10CRed Power Input From Base Terminal Strip P3 6 28EGreen White Output To 28ECR1 Aux Tilt Relay And 28ECR2 Aux Down Relay ______ Not Used Varied Input From Transducer Varied Input From Angle Transducer Not Used Not Used P4 6 910Black Positive Signal To Angle Transducer Negative Signal To Angle Transducer P4 8 900White Negative Signal To Pressure Transducer P4 9 910 Positive Signal To Pressure Transducer 60303AD SKYJACK Page 32 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 4 2 LED Error Codes Quick Reference Chart 7 8 STARTUP 00000 STARTUP FACTORY OVERRIDE 60405AA Reading the Codes In order to read the fault codes a Sequence of pauses and flashes can be seen on the LED mounted on the GP102 module The codes are continuously displayed by the LED until the fault is cleared the GP102 reset and no longer detects the fault or idle timeout becomes active The sequence 15 as follows 1 Quarter second flashes followed by quarter second pauses indicate the first digit 2 A1 5 second pause 3 Quarter second flashes followed by quarter second pauses indicate the second digit 4 A4second pause
72. 143905 3 7 Control Cable Assemblies Diagram INSERTS 1 16 INSERTS 17 32 View gt PIN 1 WHITE 02 PIN 17 GREEN 49 Parts List NY PIN 2 RED 7A PIN 18 BLUE RED 71 n PIN 3 ORANGE RED 09 PIN 19 WHITE BLACK RED 72 Oo SO OR PIN 4 BLUE WHITE 10 PIN 20 ORANGE GREEN 73 OO PIN 5 ORANGE 13 PIN 21 BLACK RED 74 OO OO 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 0041199 PIN 9 RED BLACK 18 PIN 25 RED BLACK WHITE 78 eo PIN 10 ORANGE BLACK 19 PIN 26 ORANGE BLACK WHITE 85 e PIN 11 BLACK WHITE RED 20 PIN 27 BLACK RED GREEN 60 TO STR PIN 12 BLACK WHITE 23 PIN 28 WHITE RED GREEN 10D PIN 13 BLUE BLACK 24 PIN 29 RED BLACK GREEN 70 fe 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
73. 4 3 37 Flash Code F46 4 3 38 Flash Code F47 Full Size RT s Engine Powered Table of Contents Continued es 38 ead acs 38 KIP DCUM 38 mici NTC 38 38 ES poss 38 38 geld alo deo E HP 39 cT HER 39 THREE 39 E 39 Ri tad iiic mc 39 Do non aa 39 PY MMC 39 c Y HON 39 40 40 xi eg els 40 ic 40 ac l el c 40 quee ere sadn tenes 40 rm No NoD HU n 40 LO ease reser as 41 ERR tr errr rrr 41 d PME RET INIT Mc 41 41 m 41 rae csi PM 41 SKYJACK Page 3 Sec
74. 5 Loose or broken wire 30A from relay 30CR to brake dump valve 2H 30A 1 or brake feed valve 2H 30A 2 Check continuity Replace if defective 6 Defective valve coil brake dump 2H 30A 1 or brake feed 2H 30A 2 Check continuity through coil Replace if defective SKYJACK Page 14 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 10 11 12 13 Loose or broken wire 02 from valve coil brake dump 2H 30A 1 or brake feed 2H 30A 2 to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 30 from relay 30CR to diode D30 at base terminal block TB 1 CE only Check continuity Replace if defective Open diode D30 Check diode Replace if defective Loose or broken wire 25 from diode D30 to base terminal block TB 1 Internal Brakes only Check continuity Replace if defective Loose or broken wire 25 from base terminal block TB 1 to quick brake valve coil 2H 25 Internal Brakes only Check continuity Replace if defective Defective quick brake valve coil 2H 25 Internal Brakes only Check continuity through coil Replace if defective Loose or broken wire 02 from quick brake valve 2H 25 to base terminal block TB 1 Internal Brakes only Check continuity Replace if defective 4 1 19 Steer Right Inoperative 1 2 3 10 11 Defective steer right switch S7 2 in joystick 57
75. Electrical System q jl Lei UK eee een ier eee eer ee ren ere eee ere 6 IANSVOSA UU m 6 NoFowor to Falon IE uuu tar oomen 6 4 1 4 All Functions Inoperative from Platform r 7 4 1 5 Engine will Not Crank Gies rdiet es 7 4 1 6 Engine will Not Crank from Platform Controls Additional for GM Dual Fuel 8 4 1 7 Engine will Not Crank from Base Controls GM dual 1 9 4 1 8 Engine will Not Crank from Base Controls Kubota 9 4 1 9 Engine Cranks but Stops Cranking after a few 9 4 1 10 Glow Plugs Inoperative from Engine 9 4 1 11 Glow Plugs Inoperative from Platform 10 4 1 12 Engine Cranks but will Not Start Kubota diesel 888 10 4 1 13 Engine Cranks but will Not Start GM dual 10 4 1 14 Mid Throttle Inoperative on demand GM Dual 12 BEM ETT o oom 12 4 1 16 High Throttle Inoperative additional for GM dual fuel a 13 4 1 17 Drive and Steer Inoperative MERE ee een ean Ce ere 13 4 1 18 Brakes will 14 4 1 19 Steer Right acces 15 414 20
76. Print This Page View Parts List 02 00 2A 10A 05
77. RED 00 BLACK GREEN 22 WHITE 02 GREEN 22 WHITE 02 M47681AA_S3 Full Size Rough Terrain Series SKYJACK Page 35 Models 9241 amp 9250 143905 Print View This Page Parts List 3 26 Horn Light Beeper amp Load Sensing Wiring Diagram o bD Z
78. Reprogramming Existing Tilt Switch 8 Reprogram the Tilt Switch a Press and hold the set Set up button is located on this up button for 3 seconds Red LED Light Indicators face next to harness Results Both LEDs will Green LED f be OFF b Both LEDs will flash Red LED Green LED C IMPORTANT Step c must be completed within a 5 second period or the switch will automatically exit program mode and return to normal operation using previously stored data 1 Ensure aerial platform is parked on firm level surface c Press and release set up button 3 times 2 Fully lower the platform d If 5 second period has expired prior 3 Chock or block wheels to keep the aerial platform from rolling forward or backward 9 Observe program delay stabilization time NOTE Red LED ID Only the red LED will The tilt circuit is only powered when O Green LED blink for 4 seconds 7 controls are powered up f Both LEDs will 4 Turn main disconnect switch to P ON position flash for 1 second A Results The switch is Red LED learning the new zero 5 Select off lift drive key switch to 5 V lift position position J Or B drive position g Both LEDs will turn 6 Pull out all emergency stop buttons on solid for 1 second Results The new OT Red LED 7 Verify switch is powered Red or green LED will zero position has been gt OF ereen eD
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82. 4 1 49 Individual Outrigger Functions Inoperative Auto level 1 Loose or broken wire 71 75 depending on function not working at pins 1 8 of outrigger control module plug P4 Check connections of outrigger functions not working refer to Section 5 for pin reference chart Replace if defective 2 No output from outrigger control module OCM1 at pins 1 8 of outrigger control module plug Turn off power to reset the outrigger control module Turn power back on and retest If problem persists replace outrigger control module 4 1 50 Auto level Inoperative 1 Loose or broken wire 35D from outrigger enable switch S9A to auto mode outrigger switch S24 Check continuity Replace if defective 2 Defective auto mode outrigger switch 524 Check switch Replace if defective 3 Loose or broken wire 10A at pin P2 12 on outrigger control module OCM1 Check for power at P2 12 If no voltage present check continuity of wire Replace if defective 4 Loose or broken wire 35 at pin P2 10 on outrigger control module OCM1 Check for power at P2 10 If no voltage present check continuity of wire Replace if defective 5 Loose or broken wire 02 at pin P2 11 on outrigger control module OCM1 Check for ground at P2 11 If no ground present check continuity of wire Replace if defective 6 Loose or broken wire 70 from auto mode outrigger switch S24 to pin P2 5 on outrigger control module OCM1 Check continuity Replace if defecti
83. 60401AB Mid Size amp Full Size SKYJACK Page 31 Rough Terrain Series Service and Maintenance Section 5 Procedures Load Sensing System CE 5 4 1 Control Module Pin Reference Chart P CD 8 9 Q0 uu Q2 4 1 CO 3 CD CD e 1 CO 3 OD 6 e NOA GP102 CONTROL MODULI The Calibration Connection PIN WIRE PLUG AND COLOUR WIRE FUNCTION P2 Not Used Not Used Input Power From Base Terminal Strip To Confirm Lower Control Is Selected Raise Platform Input Lower Platform Input ot Used ot Used Forward Direction Input 10E Black White 14D Black 13D Orange Not Used Not Used 7 16 White Black U 0 0 N 2 P2 1 NotUsed NotUed S O P2 2 102 Black White ____ Input Power From Base Terminal Strip To Confirm Lower Control Is Selected P2 3 14DBlack ____ jJRaisePlafoemInput P2 4 130 Lower Platform Input P2 5 NotUsed _ O P2 6 NotUsed NotUsed O P2 7 16 White Black Forward Direction Input 0 P2 8 1586 Reverse Direction Input P2 9 j NoetUsd P2
84. 62 53 D17841 _ oo QUTRIGGER LIMIT SWITCHES 8 y 10A 86A SIXTEEN PIN CONNECTOR PLUG INSTALLED TO CABTIRES ON MACHINE CN22 PIN 61 RED PIN2 62 GREEN PIN3 62 RED PIN 4 63 GREEN PIN 5 63 RED 1 PIN 6 64 GREEN lt PIN 7 64 RED 2 1 PIN 8 01 GREEN PIN 9 10A BLACK 2 PIN 10 10A BLACK TU RN 899 00D NO LEFT FRONT RIGHT FRONT RIGHT REAR LEFT REAR 2 TF dr TO CONTROL MODULE PIN 1 65 GREEN BLACK BACK VIEW PIN 2 65 WHITE E 76 071 072 078 77 074 D Deco PN 12 10A BLACK D PIN 5 68A WHITE PIN 13 N U PIN 11 10A BLACK fe f f f FRONT LEFT REAR LEFT D7 a TR MANIFOLD PIN 1 78 BLACK WHITE PIN 75 ORANGE BLACK PIN1 76RED BLACK 77 BLUE BLACK PIN 14 N U TENPINCONNECTORPLUG PIN 2 02 WHITE PIN 2 02 WHITE PIN 2 02 WHITE PIN 2 02 WH
85. Function Tests Platform Lower Neutral Raise Switch Emergency Stop Button Lift Enable Pushbutton Emergency Lowering Valve Test Emergency Lowering Models 71xx 8831 41 amp 9241 WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting 1 Raise the platform to an approximate height of 13 ft 4 m 2 Locate holding valve manual override knob at the base of each lift cylinder Depress and turn counterclockwise If necessary use emergency lowering access rod that is located on the base of the aerial platform Onhydraulic electrical compartment pull out and hold emergency lowering valve to fully lower the platform Result The platform should fully lower 4 To restore normal operation depress and turn holding valve manual override knobs clockwise Test Emergency Lowering Model 8243 8850 amp 9250 WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting 1 Raise the platform to an approximate height of 13 ft 4 m 2 In hydraulic electrical compartment depress and hold emergency lowering pushbutton to activate the auxiliary lowering valves Pull out and hold the emergency lowering valve to fully lower platform Result The platform should fully lower Mid Size amp Full Size
86. R R pteA BU E n CR TD CR CR CR CR CR 00 02 08 9 09 BYES G9 03 05 00 02 09 um m 448 TA A A GAA 9 498 9 E AN AN X 15B 16B 19 TWO SPEED MOTOR 20A BLACK 25 NOTE THE 1000uF CAPACITOR IS NOT REQUIRED ON MACHINES 02 WHITE amp EQUIPPED WITH WET BRAKES ENDOF STROKE 02 36A BLACK 368 BLKWHT um 20A Ar MAIN MANIFOLD HARNESS ENGINE HARNESS 9 2 00 WHITE 14 AWG PIN ORANGE 00 B ga 02 WHITE PIN 2 WHITEIBLACK 36 BLKWHT 03 BLUE 14 AWG PIN 3 02 WHITE m 09 ORANGEIRED PIN 4 32A ORANGE BLACK 3 Q Z 13A ORANGE PIN5 NU a 2 14B BLACK PIN 6 NIU Y 2 HIGH SPEED dz 188 BLUE PIN7 33 GREEN 10A BLUE 9 168 WHITE BLACK PIN 8 10A GREENIBLACK m 35 BROWN 17A PIN 9 2A RED BLACK 18A RED BLACK PIN 10 37 BLUE BLACK gt 29A BLACK WHITE PIN 11 07 RED TO HORNLIGHT BEEPER 24A BLUE BLACK PIN 12 05 BLUE 00 WHITE 25 ORANGEIGREEN BLACK TIED BACK 2 i BACK VIEW PLATFORM CONTROL BOX BACK VIEW 30A BROWN BLACK WHITE TIED BACK 19h GREEN FEMALE CABLE CONNECTOR FEMALE GREEN WHITE 16 8 WHITE BLACK 16 4 4 GREEN BLACK WHITE 77 amp 5 z 82 GREEN BLACK 5 17 ta O 6 RED GREEN
87. Replace if defective 6 Loose or broken wire from base terminal block 1 to emergency stop switch 54 Check continuity Replace if defective 7 Open or defective emergency stop switch S4 Check switch Replace if defective 4 1 3 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 S30 to base terminal block TB 1 Check continuity Replace if defective 3 Loose or broken wire 07 from base terminal block TB 1 to emergency stop switch S6 Check continuity Replace if defective 4 Open or defective emergency stop switch S6 Check switch Replace if defective SKYJACK Page 6 Full Size RT s Q Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 5 Loose or broken wire 7C from emergency stop switch S6 to platform base switch S10 Check continuity Replace if defective 6 Open or defective platform base switch 510 Select platform on switch Check switch Replace if defective 7 Loose or broken wire 7A from platform base switch S10 to platform emergency stop switch 54 Check continuity Replace if defective 8 Open or defective platform emergency stop switch S4 Check switch Replace if defective 4 1 4 All Functions Inoperative from Platform 1 Loose or broken wire 08 from emergency stop switch 54 to off lift drive key switch 53
88. Stuck or defective lowering valve 2H 13A Check valve Repair or replace if defective 5 Stuck or defective manual lowering valve V1 Check valve Repair or replace if defective 6 Open or defective brake feed valve 2H 30A 2 Check valve Repair or replace if defective 7 Open manual override on holding valve 2H 13A 1 or 2H 13A 2 or 2H 13A 3 or 2H 13A 4 Depress and turn manual override clockwise to close Replace if defective 8 Stuck holding valve 2H13A 1 or 2H13A 2 or 2H 13A 3 or 2H 13A 4 Check valves Repair or replace if defective 4 2 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 2H 13A 3 or 2H 13A 4 Check valves Repair or replace if defective 3 Plugged lowering orifice O1 Clean or replace orifice 4 2 14 Powered Extension Platform Inoperative 1 Defective powered extension pump Check pump Repair or replace if defective 2 Misadjusted or defective relief valve 5 Adjust valve Replace if defective 3 Stuck or defective deck extend valve 4H 26 or 4H 26A or retract valve 4H 27 or 4H 27A Check valves Repair or replace if defective 4 Defective powered extension cylinder C13 front or C14 rear Check cylinder Repair or replace if defective Full Size RT s SKYJACK Page 35 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Hydr
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91. 0 3 TARGET 0 7 tilt SLACK 0 5 If machine is tilted to 1 0 in the X and orientations the auto level function will attempt to level the X orientation 0 3 0 5 lt 1 0 but will not attempt to level the Y orientation 0 7 0 5 gt 1 0 RANGE 0 0 to 1 0 default 0 3 SKYJACK Page 29 Rough Terrain Series Service and Maintenance Section 5 Procedures IMPORTANT Each phase must be completed before the next phase can be carried out All phases must be completed before the aerial platform can be operated Always follow the instructions of the Calibration instrument Ensure aerial platform is parked on a firm and level surface 2 Elevate the scissors high enough to lay a level accross the base tubes Ensure there is no debris the base and the level sits flat Do not elevate aerial platform higher than the high speed tilt override limit switch 3 Manually operate the outriggers and level the machine 4 places left side right side front and rear All 4 outriggers must be firmly placed and all 4 tires are off the ground 4 Double check that the aerial platform is level at all 4 points 5 Connect the EZcal tool to the P1 connector on the CONTROL MODULE 6 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 display will show Access Level Code 0000 By using the Up Down butt
92. 00 from starter contactor 32ACR to engine ground Check continuity Replace if defective Loose or broken wire 103 from main power disconnect switch 51 to starter contactor 32ACR Kubota Diesel Check continuity Replace if defective Loose or broken wire 103 from main power disconnect switch 51 to starter contactor 32BCR GM Dual Fuel Check continuity Replace if defective Loose or broken wire 104 from starter contactor 32ACR to starter motor Kubota Diesel Check continuity Replace if defective Defective starter motor Check motor Repair or replace if defective 4 1 6 Engine will Not Crank from Platform Controls Additional for GM Dual Fuel T Loose or broken wire 10A from base terminal block TB1 to engine harness plug Check continuity Replace if defective 2 Loose or broken wire 10A from engine harness plug to GM engine connector 1 Check continuity Replace if defective 3 Loose or broken pink wire from GM engine connector 1 to fuse F7 Check continuity Replace if defective 4 Defective fuse F7 Check fuse Replace if defective 5 Loose or broken pink tan wire from fuse F7 to ECU connector pin 45 Check continuity Replace if defective 6 Loose or broken red wire from battery positive to ECU fuse F8 Check continuity Replace if defective 7 Defective fuse F8 Check fuse Replace if defective 8 Loose or broken red tan wire from fuse F8 to ECU connector pin 60 and pin 79 Che
93. 0007 LOCKING CAM 211 98 0008 COVER 211 CC 2S 146 TERMINAL GOLD ECO 1 EGO 2 3 EGO 4 TPS 1 TPS 2 AUX ANA PD1 FPP 1 FPP2 IVS AUX ANA PD2 AUX ANA CAN TERM CAN2 TER 5V CRA CRA CA CA SPEE SPE KNOC KNOC KNOC KNOC SPK CO SPK COIL SPK CO SPK CO SPK COIL 3A SPK COIL 3B SPK COIL 4A SPK COIL 4B NN 1 mr gt I Z NND Dr 0 AUX DIG AUX DIG 2 AUX DIG 3 VSW AUX ANA PU AUX ANA PU2 FRT AUX ANA PUS FPP 2 ONLY 5V EXT 2 5V RTN GOV GOV2 OIL PRES FRP AUX AND PUD PC TX PC RX ALT EXCITE TACH VBAT PRO VBA LS 2 15 315 4 15 515 6 15 7 15 815 GND TEMP STARTER RELAY EGOH BUZZE PW PWM5 RECIR C OU ZU S0 NN lt ine gt GND DBW DBW FPU AUX PWM3 REC AUX PW AUX PW AUX PW STARTER AUX PW AUX PWM4 REC DARANWDUI 2
94. 13 F ORANGERED 09 60 BLACKRED GREEN 27 19 WHITE BLACK RED 72 NOTE LIMIT SWITCH NOT USED ON 9J9241 23A BLACK WHITE PIN 11 07 RED 49A GREEN PIN 12 05 BLUE BLACK WHITE 9 ORANGE BLACK 0 2 5 ORANGE BLACK WHITE 26 18 BLUE RED 71 Sg 24A BLUE BLACK 06 60 BLACK W IS REDBLACK 9 291 ye og REDBLACKWHITE 25 ene ug BACK VIEW 25 ORANGE GREEN BLACK TIED BACK RED TIED BACK E gt aL a 30A BROWN BLACK WHITE TIED BACK RED WHITE TIED BACK Bel ORANGE BLACK TIED BACK 518 9 SKYJACK Page 42 M147867AC Full Size Rough Terrain Series Models 9241 amp 9250 143905 1 9 __ __ View Parts List Print This Page 3 32 Electrical Schematic ANSI CSA amp AS All Option with Kubota Diesel Engine
95. 2 CONNECTOR 1 51 GRAY DK BLUE 18 BLUE WHITE 18 82 GRAYZORANGE 18 BLUE PINK 18 CAN1 53 LT BLUE 18 LT GREEN RED 18 5V EXT 1 2 54 WHITE LT GREEN 18 BLACK LT GREEN 18 5V RTN 55 DK GREEN 18 DK BLUE ORANGE 18 FPP1 ___56 ORANGE 18 PURPLE YELLOW 18 FPP2 IVS 57 TAN BROWN 18 FUEL SELECT AUX DIG 1 58 GRAY 18 GREEN YELLOW 18 MIL 59 LT BLUE PINK 16 START COMMAND E 60 RED TAN 16 DK BLUE 18 AUX PWM 1 61 BROWN LT BLUE 18 PINK YELLOW 16 FUEL PUMP 62 BROWN LI GREEN 18 BLACK RED 16 FUEL PUMP es TWIST WIRES 10 TURNS 36 DEG FOOT FULL LENGTH UR 45 ALT EXCITE 8566801 S 66 T 1 68 YELLOW RED 18 RING 69 BLACK 16 YELLOW 18 gt 2 BLACK 16 BLACK 12 71 WHITE LT BLUE 18 PINK DK GREEN 16 GROUND 72 BLACK WHITE 18 73 BLACK YELLOW 18 IGNITION COIL PINK DK GREEN 18 78 WHITE BLACK 18 BLACK LT GREEN 18 ANA RTN P gt 76 IGC1 i LT GREEN RED 18 5V REF DIAGNOSTIC CONNECTOR 77 BROWN WHIIE 16 STARTER DK GREEN 18 PC TX 78 WHITE BROWN 16 SOLENOID ORANGE 18 PC RX 79 RED TAN 16 PINK DK GREEN 16 7 UNUSED 80 GREEN YELLOW 18 UNUSED 81 BLACK 16 WHITE 16 BLUE PINK 18 82 PINK WHITE 18 O BLUE WHITE 18 83 18 84 TAN BLACK 18 85 PINK YELLOW 16 ae _ RED TAN 14 RED 14 86 BLACK RED 16 PURPLE WHITE 18 CRANK SENSOR 87 16 20 88 DK BLUE 16 WHITE PURPLE 18 CPS1 80 PINK BLACK 18 90 BLACK 16 m WHITE 16 F12 o 87 RED TAN 16 STAR
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97. Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem 06 Check Elev This message is given if the elevation switch P210 is open at the start of calibration when the operator has confirmed the PLATFORM DOWN question If the platform is down check the elevation switch wiring 08 Check Elev This message is given ifthe 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 FO9 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 between 0 9V and 4 1V Check DIAGNOSTICS SENSORS to see the output 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 OV or 5V is probably due to a wiring problem 11 Not Up This message occurs at the start of calibration if the operator selects a function other than UP SKYJACK Page 36 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance F13 Low Height Range This message occurs at the end of calibration if
98. Check coupler Replace if defective Open relief valve R1 Check valve Replace if defective 4 2 2 Steering Inoperative 1 2 3 Stuck or defective brake feed valve 2H 30A 2 Check valve Repair or replace if defective Stuck or defective steer right valve 4H 23A or steer left valve 4H 24A Check valves Replace if defective Steer cylinder C7 damaged or bypassing internally Check cylinder Repair or replace if defective 4 2 3 Steer and First Drive Speed Inoperative 1 2 3 Small pump dump valve 2H 18A stuck open Check valve Repair or replace if defective Worn or defective small pump section of pump P1 Check pump Repair or replace if defective Check valve CV1 or CV2 stuck Check valves Clean or replace if defective 4 2 4 Lift and Second Drive Speed Inoperative 1 2 3 Large pump dump valve 2H 17A stuck open Check valve Repair or replace if defective Worn or defective large pump section of pump 1 Check pump Repair or replace if defective Check valve CV1 or CV2 stuck Check valves Clean or replace if defective 4 2 5 Drive Inoperative 1 Stuck or defective drive reverse valve 4H 15B or drive forward valve 4H 16B Check valves Repair or replace if defective 2 Defective motion control valve Check valve Repair or replace if defective 3 Missing or defective check balls in series parallel valve manifold 3H 20A Repair or replace bal
99. ELECTRIC PANEL 9 2 a 05 07 32 5 e gog Full Size Rough Terrain Series Models 9241 amp 9250 143905 TY BLACK N U 108 EO BLACKWHITE N U ALTERNATOR MAIN MAIN STARTER Hd A GLOW PLUG RELAY r PIN 30 103 RED SSL V PIN 87 91A RED PIN 86 31A REDWHITE PIN 85 02 WHITE BACK VIEW ELECTRIC PANEL BACK VIEW PIN2 34A GREEN WHITE 2 PIN 4 NIU PIN 4 32A GREEN BLACK 5 PIN 4 32A ORANGE BLACK PIN2 N U PINS NU PINS N U PIN 3 02 WHITE PIN6 NIU PING N U PIN 4 9A RED A J PINT NIU NI EN PIN 5 32A GREEN BLACK PIN8 NIU PIN 6 90 RED Er PIN9 2A BLACK RED PIN 9 2A RED BLACK PIN 10 37 PIN 10 37 BLUE BLACK PIN 11 07 RED PI
100. FRONT RIGHT FRONT RIGHT REAR SMALL VALVE h OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER HOLDING RETRACT RETRACT RETRACT RETRACT LARGE SMALL VALVE VALVE VALVE VALVE VALVE PUMP PUMP VALVE DI SYSTEM PRESSURE PUMP OC1 OIL COOLER QUICK DISCONNECT DUAL FUEL 3 lt gt Q purer RESERVOIR Full Size Rough Terrain Series Models 9241 amp 9250 143905 View Parts List M148310AD SKYJACK Page 21 SKYJACK Page 22 3 12 Hydraulic Schematic Cushman Axles Model 9250 Print
101. High Pressure This message indicates that the pressure is too high 4 5V or more at a measurement point Check DIAGNOSTICS SENSORS to check the pressure F46 Check Elev This message indicates that the elevation switch opened more than once during calibration lifting F47 Check Elev This message indicates that the elevation switch closed more than once during calibration lowering F48 Bad Pressure This message is given if the pressure sensor output P4 2 is out of range at the start of calibration The height sensor output must be between 0 5V and 4 5V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem F52 Too Few This message indicates that not enough measurements were recorded during calibration lifting or lowering F98 Out of Range This message indicates that the fine tune calibration is unacceptable This probably is due to the wrong load being in the platform i e specifying EMPTY if the platform is loaded or the other way round or Having the incorrect pressure transducer installed During calibration the following information messages may appear 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 amp RIGHT to select the flashing digits Press UP amp DOWN to change the flashing digits Press ENTER
102. Manual Storage Base Weldment Wheel Tire Assembly Steer Cylinder Assembly Tie Rod 1 1 9 Base To maximize stability it is essential to maintain proper pressure in all air filled tires Base Weldment Ensure there are no visible cracks in Check each tire with an air pressure gauge welds or structure and there are no signs and add air as needed of deformation Refer to Table 2 3 for wheel tire specifications Wheel Tire Assembly The aerial platform is either equipped with Axles air tires or foam filled tires Tire and or wheel Ensure axles are properly secured failure could result in an aerial platform there are no loose or missing parts all Component damage may also result fittings and hoses are properly tightened if problems are not discovered and repaired and there is no evidence of hydraulic in a timely fashion leakage Steer Cylinder Assembly WARNING Ensure steer cylinder assembly is properly Air filled tires are not permitted on some secured there are no loose or missing models Refer to Table 2 3 parts all fittings and hoses are properly tightened and there is no evidence of LN WARNING hydraulic leakage An over inflated tire can explode and Rod may cause death or serious injury Ensure there are no loose or missing parts tie rod end studs are locked and Check all tire treads and sidewalls for cuts there is no visible damage cracks punctures and unusual
103. PIN 10A BLUE WHITE PIN 3 10E BLUE WHITE 2 oE E STOP SWITCH N C CONTACT LED 2 LIGHT PIN 07 RED PIN 2 RED WHITE PIN X1 10A BLUE WHITE PIN X2 02 WHITE View Parts List BASE CONTROL STATION 6 WIRES 02 WHITE 07 RED 7A RED WHITE 10A BLUE WHITE 13 ORANGE RED 14 BLACK RED UP DOWN SWITCH 0 CONTACT PIN 4 13 ORANGE RED PIN 3 10E BLUE WHITE UP DOWN SWITCH N O CONTACT PIN 4 14 BLACK RED PIN 3 10E BLUE WHITE M147223AC Full Size Rough Terrain Series Models 9241 amp 9250 SKYJACK Page 19 143905 3 10 Base Control Console Wiring View BASE CONTROLS 9 WIRES Parts List 02 WHITE 7 RED RED WHITE 7C RED GREENIBLACK 10A BLUE WHITE 10D WHITE RED GREEN 10E BLUE WHITE 13D ORANGE
104. Powered extension emergency retraction switch TEMPERATURE SENSOR Coolant Dual Fuel Engines TEMPERATURE SWITCH Engine Kubota Diesel TEMPERATURE SENSOR Air intake Dual Fuel Engines METER Hour Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 5 Platform Control Console Wiring All Options ANSI CSA
105. Rough Terrain Series SKYJACK Page 35 Function Tests Section 1 Scheduled Maintenance aaa Base Control Console Platform Lower Neutral Raise Switch Emergency Stop Off Platform Base Button Key Switch Emergency Lowering Valve Test Emergency Powered 1 2 4 Test Main Power Disconnect Switch Extension Platform Retraction Switch Models 8850 amp CE 9250 1 On hydraulic electrical compartment turn main power disconnect switch to off position 1 Extend both powered extension platforms Result Engine should shut down and aerial to about 0 5 meter platform functions should not operate 2 Pushin emergency stop button to shut down the engine 3 Pull out emergency stop button WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform 4 Use the ladder to diSmount from platform 5 On hydraulic electric tray push the emergency powered extension platform retraction switch Result Extension platforms should retract SKYJACK Page 36 Mid Size amp Full Size Rough Terrain Series Section 2 MAINTENANCE TABLES AND DIAGRAMS Table of Contents Tables 2 1a Specifications and Features 5 2 210 Spain ton and UE uu M 3 210 Specification
106. S9A in the control console Check for continuity Replace if defective 2 Loose broken wire 350 from outrigger enable switch S9A to pin 5 on the outrigger control console plug Check for continuity Replace if defective 3 Defective outrigger enable switch 5 Check switch Replace if defective 4 1 42 All Outriggers Inoperative base controls 1 Defective outrigger enable switch S9B Check switch Replace if defective 4 1 43 Outriggers Inoperative Auto level A Led Power Indicator Light at Outrigger Control Module OCM1 Not on Constant 1 Loose or broken wire 710A from pin 1 of the tilt switch connector to pin P2 12 on the outrigger control module OCM1 Check for continuity Replace if defective 2 Loose or broken wire 10A from pin 1 of the tilt switch connector to main terminal block TB 1 Check for continuity Replace if defective Loose or broken wire 02 from pin 3 of the tilt switch connector to pin P2 11 on the outrigger control module OCM1 Check for continuity Replace if defective 4 Loose or broken wire 02 from pin 3 of the tilt switch connector to main terminal block TB 1 Check for continuity Replace if defective 5 Defective outrigger control module OCM1 Replace SKYJACK Page 28 Full Size RT s Q Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 44 All Outriggers Inoperative Auto Level B Led P
107. 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 I PIN 1 61 RED PIN 9 10A BLACK 2 RIGHT FRON PIN 2 62 GREEN PIN 10 10A BLACK 2 PIN 3 62 RED PIN 11 10 BLACK 2 PIN 4 63 GREEN 12 10A BLACK 2 PIN 5 63 RED PIN 13 N U a PIN 6 64 GREEN PIN 14 N U RIGHT REAR PIN 7 64 RED PIN 15 N U 8 01 GREEN PIN 16 65 GREEN BLACK zw LEFT REAR 5 TO CONTROL MODULE X PIN 1 65 GREEN BLACK m PIN 2 65 WHITE I PIN 3 66A WHITE PIN 4 67A WHITE 5 68A WHITE E PIN 6 N U O R UP SWITCH NO BLUE amp BROWN O R UP SWITCH NO BLUE amp BROWN BACK VIEW MALE PIN 1 BLACK PIN 2 BLACK WHITE 179 2 Ne Er eae PIN 3 BLUE ie PIN 2 BLACK WHITE 4 a Olla PINS BLUE PIN 4 BROWN RIGHT REAR OUTRIGGER BACK VIEW FEMALE 4 x on LEFT REAR OUTRIGGER PIN 3 GREEN 64 3 PIN 1 BLACK 10 PIN 4 RED 63 2 PIN 2 WHITE 68 PIN GREEN 01 4 PIN 4 RED 64 1 Nas O R DOWN SWITCH NC BLACK amp BLACK WHITE O R DOWN SWITCH NC BLACK amp BLACK WHITE E LEFT REAR OUTRIGGER SECTION VIEW RIGHT REAR OUTRIGGER SECTION VIEW SHOWN IN THE RETRACTED STATE SHOWN IN THE RETRACTED STATE 1 11449
108. SKYJACK 24 A Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 3 3 Auto Leveling Outrigger Setting and Error Codes Reading the Codes In order to read the fault codes a sequence of pauses and flashes can be seen on the LED mounted on the outrigger control module The codes are continuously displayed by the LED until the fault is cleared the outrigger control module is reset and no longer detects the fault or idle timeout becomes active The sequence 15 as follows 1 Half second flashes followed by half second pauses indicate the first digit 2 A2 5 second pause 3 Half second flashes followed by half second pauses indicate the second digit 4 A 5 second pause Hepeat steps 1 4 Since the outrigger control module only reports one error only one code can be read from the LED per instance If the error is cleared and another error is present it will then be presented LED Error Codes N 60402 Mid Size amp Full Size SKYJACK Page 25 Rough Terrain Series Service and Maintenance Section 5 Procedures Fae 5 3 4 Auto Leveling Outrigger Error Code Breakdown RELEASE OUTRIGGER DEMAND Check inputs on P2 pins 5 amp 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 Check input on P2 pin 10 auto level auto retract
109. SKYJACK Page 12 o Mid Size amp Full Size Rough Terrain Series Operator s Responsibility for Maintenance Service and Maintenance Maintenance and Inspection Schedule The actual operating environment of the work platform governs the use of the maintenance schedule The inspection points covered in Table 1 2 Maintenance and Inspection Checklist indicates the areas of the aerial platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed Owner s Annual Inspection Record It is the responsibility of the owner to arrange quarterly and annual inspections of the aerial platform Table 1 1 Owner s Annual Inspection Record is to be used for recording the date of the inspection owner s name and the person responsible for the inspection of the work platform Replacement Parts Use only original replacement parts Parts such as batteries wheels railings etc with weight and dimensions different from original parts will affect stability of the aerial platform and must not be used without manufacturer s consent All replacement tires must be of the same size and load rating as originally supplied tires to maintain safety and stability of aerial platform Consult SKYJACK s Service Department for optional tires specifications and installation WARNING Any unit that is damaged or not operat ing properly must be immediately tagged and removed from service u
110. Samer TIT TIT IMMERHIN 7 RENDIR a a a a 7 Junu mamaman nen eae 7 ENTE T DNE ITEM MNT 7 ID 7 I TS eet aden Rte ata ede esa 8 MIT T TT T m 9 MP UTENTI NIIT 9 Y L co ase PI I CL D TIPP 10 Maintenance and Inspection Schedule 13 Owner s Annual Inspection Record 13 E dds ea ta ease 13 Maintenance and Service Safety TipS ESTO D D o Lm 13 Hydraulic System amp Component Maintenance and 14 dial LINE TET TTE Tm 14 Service and Maintenance tii gt m 15 echt zi qo TET TREE 15 Viggo eio r E IK D TER 15 Maino Rm ciis ei m TERR NS 15 Schedule Maintenance Inspections 1 1 Scheduled Maintenance 18 l 28 Tables Wi Ganor Annual Ge FG Ui i ____ _ _____ _ 16 1 2 Maintenance and Inspection Checklist E gt ______________ _ _ 17 Mid Size amp Full Size SKYJACK Page 5 Rough Terrain Series
111. Steer Left Inoperative 15 4121 Drive ERTEILEN 16 4 122 DINO NODOTA E er 16 4 1 23 First Drive Speed and Steering 17 4 1 24 Second Drive Speed Inoperative pena Mie 17 4 425 Third Drive Speed SUE cine iiu pd ees 18 414 26 High Low Range Speed Inoperalive UU M 19 4 1 27 Up Circuit Inoperative from Platform or 19 4 1 28 Platform will Not Lift from Platform or Base Controls with Outriggers Extended 20 4 1 29 Platform will Not Lift from Platform or Base Controls with Outriggers Retracted lift operates correctly with Outriggers 22 4 1 30 Up Circuit Inoperative from Base 5 5 22 Up Circuit Inoperative from Base CE 22 4 1 32 Down Circuit Inoperative from Platform or 23 4 1 33 Down Circuit Inoperative from Base 51 5 24 4 1 34 Down Circuit Inoperative from Base 24 4 1 35 Powered Extension Platform Inoperative
112. amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance DIAGNOSTIC OUTPUTS MENU OPTIONS LAMP P2 7 STABLE P2 8 TILT P2 9 LRe P4 1 RRe P4 2 RFe P4 3 LFe P4 4 LRr P4 5 RRr P4 6 RFr P4 7 LFr P4 8 P4 9 MON Displays state of outrigger control box light Displays state of stable all legs touching the ground output Displays state of tilt Displays state of left rear outrigger extend valve Displays state of right rear outrigger extend valve Displays state of right front outrigger extend valve Displays state of left front outrigger extend valve Displays state of left rear outrigger retract valve Displays state of right rear outrigger retract valve Displays state of right front outrigger retract valve Displays state of left front outrigger retract valve Displays the voltage to the outrigger valve can only be seen when operating in auto level or retract DIAGNOSTIC LOG MENU OPTIONS MAX BATTERY OCM1 version EZcal version Displays maximum recorded battery supply voltage Displays part number and software version of GP106 Displays software version of EZcal ACCESS LEVEL MENU OPTIONS CODE xxxx ACCESS LEVEL 3 allows viewing only ACCESS LEVEL 2 allows setup 1 ADJUSTMENTS MENU OPTIONS factory set not adjustable Xtilt TRIP Ytilt TRIP TILT ENTRY TILT EXIT Xlevel TRIP Ylevel TRIP Displays the tilt trip point in the X orientation Displays the tilt trip
113. an unstable position When raising a portion of the equipment ensure that adequate support is provided Base 5 1 1 Hydraulic System and Brake Adjustment Procedure If Equipped 1 Ensure aerial platform is on a firm level surface and block wheels to prevent rolling in either direction 2 emergency main power disconnect switch to OFF position 3 Locate brake manifold in hydraulic electric side cabinet 4 Depress and turn red knurled knob on brake valve counter clockwise to a fully closed position or depress black knob current manifold 5 Grasp red plunger and rapidly depress until plunger can no longer be depressed and brake is fully released 6 Inspect caliper and brake pads for binding Pads should move freely on the pins 7 Remove from brake cylinder clevis and brake actuating lever Rotate actuating lever counter clockwise to the end of its stroke HOLD ACTUATOR ARM TO FULL COUNTER CLOCKWISE BRAKE ADJUSTER Diagram 5 1 Brake Adjustment 9 Reinstall clevis pin back into the clevis actuating lever 10 Remove plastic plug located on the end of the caliper shaft See Diagram 5 2 HOLD ACTUATOR ARM TO FULL COUNTER CLOCKWISE BRAKE ADJUSTER Diagram 5 2 Plug Removal and Replacement 11 Using a 1 4 Allen wrench turn brake adjuster counter clockwise until it bottoms out Turn Allen wrench clockwise 1 2 turn clockwise to set adjustment 12 Replace plastic plug
114. battery fluid level If plates are not covered by at least 1 2 in 13 mm of solution add distilled or demineralized water Replace battery if damaged or incapable of holding a lasting charge aN WARNING Use original or manufacturer approved parts and components for the aerial platform Mid Size amp Full Size Rough Terrain Series SKYJACK Page 19 Service and Maintenance Inspections Section 1 Scheduled Maintenance Typical Model 71xx shown Electrical Panel Emergency Lowering Access Rod Main Manifold Emergency Main Power Disconnect Switch Load Tilt Sensor
115. circuit breaker CB1 Check continuity Replace if defective 5 or defective circuit breaker Reset breaker Check for defective wiring Replace breaker if defective 6 Loose or broken wire 05 from breaker CB1 to relay 10BCR1 Check continuity Replace if defective 7 Loose or broken wire 05 from relay 31CR to base engine switch S30 Check continuity Replace if defective 8 Loose or broken wire 00 from battery B1 to base terminal block TB 1 Check continuity Replace if defective 9 Loose or broken wire 00 from base terminal block TB 1 to circuit breaker Check continuity Replace if defective 10 Tripped or defective circuit breaker CB3 Reset breaker Check for defective wiring Replace breaker if defective 11 Loose or broken wire 02 from circuit breaker to base terminal block TB 1 Check continuity Replace if defective 4 1 2 No Power to Platform ANSI CSA 1 Open or defective base engine switch S30 Check switch Replace if defective 2 Loose or broken wire 07 from base engine switch S30 to base terminal block TB 1 Check continuity Replace if defective 3 Loose or broken wire 07 from base terminal block TB 1 to emergency stop switch S6 Check continuity Replace if defective 4 Open or defective emergency stop switch S6 Check switch Replace if defective 5 Loose or broken wire 7A from emergency stop switch S6 to base terminal block TB 1 Check continuity
116. forward as if you were to drive forward This provides torque from drive motor to unreleased brake 4 brake slips and aerial platform starts to move in this condition either brake plates are worn or springs have broken Both brake plates and springs must be replaced to return brake to its original holding torque SKYJACK Page 6 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 1 5 System Lift and Pressure Adjustment All adjustments must be made with a calibrated hydraulic gauge Refer to the serial number nameplate located on the rear of the aerial platform for system and lift pressure values System Relief Pressure Adjustment 1 Locate right steer hydraulic line on main manifold Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 2 Tee in a calibrated 3000 psi gauge into the right steer line 3 Remove operator s control console from guardrail and disconnect it from scissors control cable 4 Locate electrical panel cable plug in 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 platform control console select drive position with lift drive switch 8 Engage
117. into each roller by hand or using a bearing packer and grease gun Ensure that grease is forced into all surfaces of the bearing NOTE Keep work area clean and visibly free from NOTE Fonts net ort all Use only recommended wheel bearing grease NLGI National Lubricating Grease Ensure aerial platform is parked on a firm Institute Grade 2 or equivalent level surface Chock or block the wheels to keep the aerial platform from rolling forward or backward The bearings must be packed before installing 13 Install replacement inner bearing in the and Using a suitable lifting device or outriggers then seat the new grease seal Flip hub over and if equipped lift the end of the aerial platform install replacement outer bearing 14 Install hub on the spindle CAUTION 15 Install replacement washer and replacement Use a suitably rated support stand to castle flanged nut Hand tighten the castle flanged support aerial platform while performing nut until it touches the washer Turn hub by hand the following operations to ensure smooth running No resistance should be felt at this time Turn emergency main power disconnect switch to off position 16 Take a torque wrench and set it at 30 ft Ib and while continuously rotating hub tighten castle Remove wheel assembly flanged nut While hub is being turned and nut tightened resistance will increase Hemove dust cap item 1 to access interna
118. its original holding torque 5 1 4 Winching and Towing Procedures and Brake System WARNING When towing do not drive onto a downward slope or brake the towing vehicle rapidly Disc Brake System Vn ERN P X dE E FI aem nca A x aci E Tli DM DES Diagram 5 4 Disc Brake System Disc Brake This device disengages the brake disc 1 when driving forward or in reverse A hydraulic brake cylinder 2 linked to a disc caliper 3 engages and disengages a brake disc on the rear axle drive shaft yoke The brake must be manually disengaged for pushing towing or winching Do not push or tow the work platform onto a downward slope or pull the platform down an incline towards the winch The special procedure for manually disengaging the parking brake is as follows WARNING Do not manually disengage parking brakes if work platform is on a slope im aw m TO I i 1 DER T 1 edil Diagram 5 5 Brake Release Hand Pump and Brake Valve Plunger 1 Ensure aerial platform is on a firm level surface 2 Locate brake feed valve 2H30A 2 on main manifold and disconnect electrical connectors from valve This will prevent the hydraulic system from releasing the brake 3 With engine running aerial platform in drive mode engine on high idle high torque selected and low speed range selected hold enable switch on controller and push controller
119. lowering VALVE Controlled lowering VALVE Auto reset Cushman axles SKYJACK Page 7 3 4 Electrical Component Parts List RELAY DIAGRAM COMMON COIL COIL CONTROL CONTROL 12 VOLT RELAY SPDT SINGLE POLE DOUBLE THROW NORMALLY 7 CLOSED CONTACT 69 COMMON COIL COIL CONTROL CONTROL 70 B 12 VOLT RELAY DPDT o DOUBLE POLE DOUBLE THROW NORMALLY 7 CUT NORMALLY CLOSED CLOSED CONTACT 99 NORMALLY OPEN CONTACT Full Size Rough Terrain Series Models 9241 amp 9250 143905 SKYJACK Page 8 3 4 Electrical Component Parts List Skyjack m Sm a e 1TD 2D37 9CR2 9CR3 9BCR 9CHR1 10ACR1 10ACR2 10BCR1 12BCR 13CR 13DCR 14CR 14DCR 15CR 16CR 17CR 17ACR 17DCR 18CR 20CR 23CR 24CR 28CR 28CHR1 28CR2 28ECR1 28ECR2 30CR 31CR 31ACR 32CR 32ACR 34BCR 35CR 49CR 56CR 61CR 65CR 2002CR Full Size Rough Terrain Series Models 9241 amp 9250 143905 103207 147131 127131 127131 111787 111787 103207 127035 103316 103207 127035 103316 103316 103316 103316 103316 103316 103316 103316 127131 103316 103316 103316 103316 103207 103207 103316 103207 103316 103316 103316 127035 103207 147125 142308 103316 103207 103316 143805 127131 127131 103316 103207 103207 111787 3002
120. on the company s website www skyjack com Operator The operator must read and completely understand both this operating manual and the safety panel label located on the platform and all other warnings in this manual and on the aerial platform Compare the labels on the aerial platform with the labels found within this manual If any labels are damaged or missing replace them immediately Service Policy and Warranty SKYJACK warrants each new SJRT series work platform to be free of defective parts and workmanship for the first 24 months Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor Contact the SKYJACK Service Department for warranty statement extensions or exclusions Optional Accessories The SKYJACK aerial platform is designed to accept a variety of optional accessories These are listed under Standard and Optional Features in Table 2 1 of the operating manual Operating instructions for these options if equipped are located in section 2 of the operating manual For non standard components or systems contact the SKYJACK Service Department at North America amp Asia Europe 2 800 275 9522 2 44 1691 676 235 630 262 0006 44 1691 676 239 Include the model and serial number for each applicable aerial platform Mid Size amp Full Size SKYJACK Page 7 Rough Terrain Series Service and Maintenance Operator s Responsibi
121. or D77 extend on outrigger board Check diode Replace if defective Loose or broken wire 73 from pin 4 on connector CN21 at outrigger board to valve coil 4H 73 retract or wire 77 from pin 4 to 4H 77 extend Check continuity Replace if defective Loose or broken wire 02 from valve coil 4H 73 retract or 4H 77 extend to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective SKYJACK Page 30 Section 4 Troubleshooting Information Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 4 1 48 Left Rear Outriggers Inoperative Manually 1 Defective left rear outrigger switch 523 at platform or S23A at base Check switch Replace if defective 2 Loose or broken wire 74 from outrigger control console to 5 on connector 20 at outrigger board retract or from wire 78 to pin 2 extend Check continuity Replace if defective 3 Open diode D74 retract or D78 extend on outrigger board Check diode Replace if defective 4 Loose or broken wire 74 from pin 6 on connector CN21 at outrigger board to valve coil 4H 74 retract or wire 78 from pin 3 to 4H 78 extend Check continuity Replace if defective 5 Loose or broken wire 02 from valve coil 4H 74 retract or 4H 78 extend to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective
122. performed e Place a check in the appropriate box after each inspection procedure is completed e Use the maintenance and inspection checklist and step by step procedures in section 5 to perform these inspections e inspection receives a fail tag and remove the aerial platform from service f any aerial platform component s has been repaired an inspection must be performed again before removing the tag Place a check in the repair column Legend P Pass F Fail R Repaired Mid Size amp Full Size Rough Terrain Series SKYJACK Page 15 Service and Maintenance Inspections Section 1 Scheduled Maintenance Table 1 1 Owner s Annual Inspection Record Model Number Serial Number EF __ Recording Year Owner s Inspected By 60564AA As described earlier in this section this decal is located on the control compartment cowling It must be completed after an annual inspection has been completed Do not use the aerial platform if an inspection has not been recorded in the last 13 months SKYJACK Page 16 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Service and Maintenance Inspections Table 1 2 MAINTENANCE AND INSPECTION CHECKLIST Serial Number Model Hourmeter Reading Date Time Name Printed Signature Each item shall be inspected using the the appropriate section of the Skyjack service manual
123. plug Check continuity Replace if defective Loose or broken wire 33 from engine harness plug to GM engine connector 2 Check continuity Replace if defective Loose or broken gray dark blue wire from GM engine connector to ECU connector pin 51 Check continuity Replace if defective Loose or broken purple light blue wire from ECU connector pin 5 to throttle actuator RA1 Check continuity Replace if defective 4 1 15 High Throttle Inoperative 1 Loose or broken wire 10 from key switch 53 to high low throttle switch 514 Check continuity Replace if defective 2 Defective high low throttle switch 514 Check switch Replace if defective SKYJACK Page 12 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 10 11 12 13 14 15 Loose or broken wire 34 from high low throttle switch 514 to diode D34 at relay 34BCR ANSI CSA only Check continuity Replace if defective Loose or broken wire 34 from high low throttle switch S14 to diode D34 at base terminal block TB 1 CE only Check continuity Replace if defective Open or loose diode D34 Check diode Replace if defective Loose or broken wire 34B from base terminal block TB 1 to relay 34BCR CE only Check continuity Replace if defective Defective relay 34BCR Check relay Replace if defective Loose or broken wire 42 from relay 34BCR to
124. present proceed to outrigger control module troubleshooting 16 Loose or broken wire 65 from outrigger control module at pin P2 8 to outrigger board CN22 pin 16 Check continuity Replace if defective 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 block TB 1 Check continuity Replace if defective 20 Loose or broken wire 36A from terminal block TB 1 to end of stroke limit switch LS4 Check continuity Replace if defective 21 Defective end of stroke limit switch LS4 Check switch Replace if defective 22 Loose or broken wire 36B from end of stroke limit switch LS4 to relay 14CR Check continuity Replace if defective 23 Defective relay 14CR Check relay Replace if defective 24 Loose or broken wire 14A from relay 14CR to relay 28CR Check continuity Replace if defective 25 Loose or broken wire 14B from relay 28CR to base terminal block Check continuity Replace if defective 26 Loose or broken wire 14B from base terminal block to lift valve solenoid 2H 14B Check continuity Replace if defective 27 Loose or broken wire 02 from lift valve solenoid 2H 14B to base terminal block Check continuity Replace if defective 28 Defective lift valve solenoid 2H 14B Check solenoid Replace if defective Full S
125. relay 10ACR1 Check continuity Replace if defective Defective relay 10ACR1 Check relay Replace if defective Loose or broken wire 02 from relay 10ACR1 to base terminal block 1 Check continuity Replace if defective Loose or broken wire 05 from base terminal block 1 to relay 32CR Check continuity Replace if defective Defective relay 32CR Check relay Replace if defective Loose or broken wire 43 from relay 32CR to relay 34BCR Check continuity Replace if defective Loose or broken wire 34A from relay 34BCR to engine harness plug Check continuity Replace if defective Loose or broken wire 34A from engine harness plug to high throttle solenoid HTS 34A Kubota Diesel Check continuity Replace if defective 4 1 16 High Throttle Inoperative additional for GM dual fuel 1 2 3 4 Loose or broken wire 34A from engine harness plug to GM engine connector 2 Check continuity Replace if defective Loose or broken gray orange wire from GM engine connector 2 to ECU connector pin 52 Check continuity Replace if defective Loose or broken light blue dark blue wire from ECU connector pin 6 to throttle actuator RA1 Check continuity Replace if defective Defective throttle actuator RA1 Check actuator Replace if defective 4 1 17 Drive and Steer Inoperative 1 Outriggers not fully retracted Fully retract outrigger cylinders 2 Key switch 53 in lift position Turn s
126. relay 16CR to base terminal block Check continuity Replace if defective Loose or broken wire 04 from base terminal block to relay 16CR Check continuity Replace if defective Loose or broken wire 16A from relay 16CR to time delay relay 1TD Check continuity Replace if defective Defective time delay relay 1TD Check relay Replace if defective Loose or broken wire 16B from time delay relay 1TD to forward valve coil 4H 16B Check continuity Replace if defective Defective forward valve coil 4H 16B Check coil Replace if defective Loose or broken wire 02 from forward valve coil 4H 16B to base terminal block Check continuity Replace if defective Open diode D16A 1 or D16A 2 Check diodes Replace if defective 4 1 23 First Drive Speed and Steering Inoperative 1 2 3 4 5 Loose or broken wire 21 from base terminal block to relay 17ACR ANSI CSA only Check continuity Replace if defective Loose or broken wire 21 from diode D24A to relay 17ACR CE only Check continuity Replace if defective Defective relay 17ACR Check relay Replace if defective Loose or broken wire 18A from relay 17ACR to small pump dump valve solenoid 2H 18A Check continuity Replace if defective Defective small pump dump valve coil 2H 18A Check coil Replace if defective Loose or broken wire 02 from small pump dump solenoid 2H 18A to base terminal block Check continuity Replace if
127. relays If voltage present check operation of relays If no voltage present check wire continuity Replace if defective 4 Defective pressure transducer PT1 or angle transducer AT1 or related wiring Refer to transducer troubleshooting charts 4 1 5 Engine will Not Crank from Platform 1 Openor defective key switch S3 Check switch Replace if defective 2 Loose or broken wire 10 from key switch S3 to start switch 15 Check continuity Replace if defective 3 Defective start switch S15 Check switch Replace if defective 4 Loose or broken wire 32 from start switch S15 to relay 32CR Check continuity Replace if defective 5 Defective relay 32CR Check relay Replace if defective Full Size RT s SKYJACK Page 7 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 6 7 8 9 10 11 12 13 14 15 Loose or broken wire 41 from relay 32CR to relay 10ACH1 Check continuity Replace if defective Loose or broken wire 02 from relay 10ACR1 to base terminal block Check continuity Replace if defective Loose or broken wire 05 from base terminal block to relay 32CR Check continuity Replace if defective Loose or broken wire 32A from relay 32CR to starter contactor 32ACR Check continuity Replace if defective Defective starter contactor 32ACR Check contactor Replace if defective Loose or broken wire
128. replace if defective 5 Defective disc brake pack 1 Internal brake Check brake pack Repair or replace if defective 6 Defective brake cylinder C5 or C6 External brake cylinders Check cylinder Repair or replace if defective 4 2 9 Brakes will Not Release Internal Brake 1 o rings internal to brake If release piston will not hold pressure brake will not release Check for hydraulic oil in axle Replace o rings if defective 2 Discs frozen These brakes are designed for only limited dynamic braking A severe emergency stop or prolonged reduced release pressure operation may result in this type of damage Check for abnormal wear Replace disc stack if defective 4 2 10 Brake Slips Internal Brake 1 Excessive pressure in hydraulic system If there is back pressure in the actuation line of the brake holding torque will be reduced Check filters hose size restrictions in other hydraulic components 2 brake if designed for dry use Wet linings generate 67 of the dry torque rating If the brake has oil in it check the type of oil hydraulic or gearbox i Gearbox oil ii Hydraulic oil Replace oil seal in brake Check motor seal Check piston seals NOTE Internal components will need to be inspected cleaned and replaced as required 3 Disc plates worn The thickness of the disc stack sets the torque level A thin stack reduces torque Check brake s holding torque is sufficient j Mak
129. 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 Lift Pressure Adjustment WARNING Fully lower the platform 1 Locate lift line on main manifold Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 2 Open manual lowering valve with platform fully lowered Remove lift line from main manifold 3 Install a 3000 psi gauge into lift line port fitting on main manifold Plug lift line going to lift cylinders 4 Loosen locknut on lift relief valve R2 Refer to Hydraulic Manifold Component and Port Identification found in Section 3 for location 5 Close the manual lowering valve 6 Using base controls in hydraulic electric cabinet depress and hold up pushbutton switch 7 Observe reading on pressure gauge Adjust lift relief valve R2 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 8 Release up pushbutton and retighten locknut on lift relief valve R2
130. switch Replace if defective Loose or broken wire 10D from platform emergency stop switch S4 to idle platform base key switch 510 Check continuity Replace if defective Defective idle platform base key switch S10 Check switch Replace if defective Loose or broken wire 10E from idle platform base key switch S10 to up down switch S2 Check continuity Replace if defective Loose or broken wire 14E from up down switch S2 to base terminal block Check continuity Replace if defective Defective up down switch 92 Check switch Replace if defective Loose or Open diode D14E 1 or D10E Tighten diode Check diode Replace if defective Loose or broken wire 10E from base terminal block to control module CM1 at pin P2 2 Check continuity Replace if defective 4 1 32 Down Circuit Inoperative from Platform or Base 1 Lift Off Drive switch 53 in drive position or defective Select lift position Check switch Replace if defective 2 Loose or broken wire 09 from lift off drive switch 53 to lift enable switch 59 Check continuity Replace if defective 3 Defective lift enable switch S9 Check switch Replace if defective 4 Loose or broken wire 9A from enable switch S9 to up down switch S5 Check continuity Replace if defective 5 Defective up down switch S5 Check switch Replace if defective 6 Loose or broken wire 13 from up down switch 55 to relay 13CR ANSI CSA Check continuity Replace if defecti
131. the elevation switch P210 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 F20 Height gt 0 This message occurs if the platform height is not 096 after the platform has been fully lowered at the end of calibration The platform must return to the same height each time it is fully lowered Check DIAGNOSTICS SYSTEM to check the height F28 Bad Height This message indicates a problem with the height sensor output P43 during calibration The height sensor output must be between 0 9V and 4 1V during calibration and between 0 4v and 4 6v during normal operation Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem F42 Low Pressure This message indicates that the pressure is too low 0 5V or less when the elevation switch opens during calibration Check DIAGNOSTICS SENSORS to check the pressure F43 High Pressure This message indicates that the pressure is too high 4 5V or more when the elevation switch opens during calibration Check DIAGNOSTICS SENSORS to check the pressure Mid Size amp Full Size SKYJACK Page 37 Rough Terrain Series Service and Maintenance Section 5 Procedures F44 Low Pressure This message indicates that the pressure is too low 0 5V or less at a measurement point Check DIAGNOSTICS SENSORS to check the pressure F45
132. the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate DIAGNOSTICS SENSORS can be used to check the height sensor output P43 when the platform is fully lowered and fully raised a difference of at least 1V is to be expected This message could occur if the UP switch was accidentally opened too early when the platform is not fully raised F15 Check Elev This message is given if the elevation switch P2 10 is open 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 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 F17 High Elev open This message is given if the elevation switch P210 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 F18 Low Elev close This message is given if the elevation switch P210 closed during lower at a too low height below 596 Check CALIBRATIONS HEIGHT CALS the ElevDown value shows the recorded height where the switch opened F19 High Elev close This message is given if
133. to 4H 75 extend Check continuity Replace if defective Loose or broken wire 02 from valve coil 4H 71 retract or 4H 75 extend to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective 4 1 46 Right Front Outrigger Inoperative Manually T 2 Defective right front outrigger switch S21 at platform or S21A at base Check switch Replace if defective Loose or broken wire 72 from outrigger control console to 8 on connector 20 at outrigger board retract or from wire 76 to pin 9 extend Check continuity Replace if defective Open diode D72 retract or D76 extend on outrigger board Check diode Replace if defective Loose or broken wire 72 from pin 9 on connector 21 at outrigger board to valve coil 72 retract or wire 76 from pin 10 to 4H 76 extend Check continuity Replace if defective Loose or broken wire 02 from valve coil 4H 72 retract or 4H 76 extend to pin 2 on connector CN21 at the outrigger board Check continuity Replace if defective 4 1 47 Right Rear Outriggers Inoperative Manually 1 2 Defective right rear outrigger switch S22 at platform or S22A at base Check switch Replace if defective Loose or broken wire 73 from outrigger control console to pin 3 on connector 2 at outrigger board retract or from wire 77 to pin 4 extend Check continuity Replace if defective Open diode D73 retract
134. to outrigger board Check continuity Replace if defective Loose or broken wire 62 from outrigger board to outrigger limit switch LS61 Check continuity Replace if defective Defective outrigger limit switch LS61 Check switch Replace if defective Loose or broken wire 61 from outrigger limit switch LS61 to outrigger board Check continuity Replace if defective Open diode D36 on outrigger board Check diode Replace if defective 4 1 30 Up Circuit Inoperative from Base ANSI CSA 1 2 3 4 5 Loose or broken wire 10A from base terminal block to base enable switch 10 Check continuity Replace if defective Defective base enable switch S10 Check switch Replace if defective Loose or broken wire 10E from base enable switch 510 to base up down switch 52 Check continuity Replace if defective Defective base up down switch 52 Check switch Replace if defective Loose or broken wire 14 from base up down switch S2 to base terminal block TB 1 Check continuity Replace if defective 4 1 31 Up Circuit Inoperative from Base CE 1 Loose or broken wire 7C from base emergency stop switch 56 to platform emergency stop switch 54 Check continuity Replace if defective SKYJACK Page 22 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued Defective platform emergency stop switch S4 Check
135. use the SETUPS TILT SETUPS to set the GP102 level 4 3 5 Flash Code 5 Bad Height 1 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 between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem 4 3 6 Flash Code 06 Check Elev 1 This message is given if the elevation switch P2 10 is open at the start of calibration when the operator has confirmed the PLATFORM DOWN question Ifthe platform is down check the elevation switch wiring 4 3 7 Flash Code F08 Check Elev 1 This message is given if the elevation switch P2 10 is closed at the end of the DYNAMIC lift when the platform should be fully raised This message would occur if the UP switch was accidentally opened near the start of the DYNAMIC lift Ifthe platform is fully raised check the elevation switch wiring 4 3 8 Flash Code F09 Bad Height 1 This message is given if the height sensor output P4 3 is out of range at the start of the DYNAMIC lift The height sensor output must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output 4 3 9 Flash Code F10 Bad Height 1 This message is given if the height sensor output P4 3 is out of range at the end of the DYNAMIC lift The height sensor output must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is p
136. when the entry is complete IMPORTANT The date 00 00 00 is not allowed Finished This message confirms that calibration is complete and successful 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 Lower Empty This message is displayed while the platform is being lowered to the next measurement height when an EMPTY platform is being calibrated SKYJACK Page 38 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 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 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
137. your aerial platform ensure there is enough fuel for expected use Ensure fuel filler cap is secure Ensure tank shows no visible damage and no evidence of fuel leakage Fuel Leaks Ensure there are no fuel leaks N DANGER Engine fuels are combustible Inspect the aerial platform in an open well ven tilated area away from heaters sparks and flames Always have an approved fire extinguisher within easy reach Ensure fuel pump fuel filter hoses and fittings show no visible damage and no evidence of fuel leakage Hydraulic Tank Hydraulic Tank Ensure hydraulic filler cap is secure Ensure tank shows no visible damage and no evidence of hydraulic leakage Hydraulic Ensure platform is fully lowered and Outriggers retracted and then visually inspect the sight gauge located on the side of the hydraulic oil tank Check oil level against label that indicates minimum and maximum oil levels Annual Inspection For hydraulic oil replacement procedure refer to section 5 Mid Size amp Full Size Rough Terrain Series SKYJACK Page 23 Service and Maintenance Inspections Section 1 Scheduled Maintenance Platform Control Console 1 1 7 Platform Assembly WARNING Ensure that you maintain three points of cont
138. 1 SKYJACK Page 33 Full Size Rough Terrain Series Models 9241 amp 9250 143905 Q View This Page Parts List 3 24 Powered Extension Platform Electrical Wiring Diagram Model 9250 h TO POWER DECK MOTOR CONTACTOR TO CONTACTOR 00 WHITE 103B BLACK 99 GREEN TO ENGINE pii u Te Y d i TO ELECTRIC PANEL NEGATIVE POWER DECK CONTACTOR 09 ORANGE RED 02 WHITE z 5 lt lt gt 5 gt Se 5 L3 0 27 gt O 0 lt gt x M50296AB SKYJACK Page 34 Full Size Rough Terrain Series Models 9241 amp 9250 143905 View This Page Parts List 3 25 Horn Light amp Beeper Wiring Diagram ANSI CSA Model 9250 V PE i HORN LIGHT amp BEEPER FL 22 imc X CRDI LIGHT DUAL FLASHING LIGHT OPTION 00 WHITE RL 29 22 GREEN ROTATING BEACON 29 RED FASTEN THE 00 WIRES ON THIS BOLT WITH HARDWARE SUPPLIED z HORN HORN s T WHITE E 00 WHITE 49A GREEN 49A GREEN u MAIN ELECTRICAL PANEL TO MAIN ELECTRICAL PANEL 2222202 6 6 U a 5 U 5 5 s BP 29 BEEPER BP 29 29 RED BEEPER TO MAIN ELETRICAL PANEL 00 BLACK 29
139. 1 82 2 21 2 34 150 137 5 176 3 81 3 5 4 47 64 117 68 133 74 x 168 1 63 x 2 97 1 73 3 39 1 88 x 4 27 dd 10 1 m 12 5m 14 9 m 17 1m 49 43 Length Platform Size 56 50 15 2m 60 5 67 5 75 82 Platform Lowered 1 54 1 71 m 1 91 2 08 m Please refer to Table 2 7 for tire specification and usage 3 5 mph 3 0 mph Normal Drive 5 6 km h 4 8 km h 0 35 mph Elevated Drive 0 56 km h 0 6 mph 0 97 km h 43 sec 41 sec 45 sec 46 sec 44 sec 2050 Low 3500 High 1400 Low 2800 High 1400 Low 2800 High N A 900 Idle 1400 Low 2800 High 27 35 Platform Elevated 8 2 10 7 13 1 2 0 mph 3 2 km h 56 sec 58 sec 53 sec 60348AG ANSI R Weights are approximate refer to serial nameplate for specific weight Values shown are for standard 4WD machines on air tires except for Model 8850 with a manual extension platform Mid Size RTs and no extension platforms Full Size RTs SKYJACK Page 2 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 1b Specifications and Features CE Mid Size RTs Full Size RTs Model 7127 7135 883 884 9241 9250 1 82 2 21 2 34 Platform Size 1 63 mx 2 97 1 73 m x 3 39 1 85 4 39 __ wem nam vam Dr
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141. 19 09 t SIA Xnv 6S v 89 29 Saud 110 95 uio3u Xnv 99 WMd XNY 9 L gs SA edd4 eS Ldd4 LG AS 08 1X3 AS L NVO Sv NYO vy 1 and xnv v 144 ev Od lt XL Od Ov l SdL Z SdL Ze 9 vl ve 193 193 18 1V8A 08 62 093 22 093 9 HODA VE 100 AdS 100 2 02 571 81 L MNVHO 91 SL di A31 vl GND L AOD Lk Z AOD 01 OulO3H S 6 HOVL 8 WMd 2 9 L Xv 9 z 91a xnv xnv 03385 9334 L Qd MOV18 MNId 68 MOTI3A N33H9 08 NMOUS NV I MOV1E S LIHM SZ v8 ama 17 es MOTI3A MNId 98 98 ana 88 MoTI3A 314Hfg OF 6 0v 18 N33H9 1 09 17 67 17 61 02 SL OINId 34018 vL 1 N3399 L Y3LIHM rS 31IHWN33HO 11 8 99 99 ana S a ama 17 9
142. 2 G j H y 9 is is 5 BACK VIEN PE FROM ELECTRIC PANEL 9 BE ped G awe l i 566 6 10C BLUE BLACK OOO QE BLUE WHITE ES E CONTROL MODULE P2 30 ORANGE DIN 1 N U MD BLACK C x PIN 2 10E BLUE WHITE 3 BUE DN 3 14D BLACK 6 WH E BLACK PIN 4 13D ORANGE 28 CREEN BLACK x LOAD SENSE CONTROL MODULE DN 5 28E GREEN WHITE PIN 6 N U 35B RED BLACK PIN 7 16 WHITE BLACK 49A GREEN x DIN 8 15 BLUE 60 BLACK WHITE PIN 9 N U N U RED PIN 10 358 RED BLACK N U RED WHITE PIN 11 02 WHITE N U ORANGE BLACK PIN 12 10C BLUE BLACK TO CONTROL MODULE P4 1 s x DN 1 A x X PIN 2 60 GREEN Lx PIN 3 288 GREEN CS T e e pm PIN 4 N U PIN 5 N U TO CONTROL MODULE Pj Dad PIN 6 910 PIN 1 22 RED PIN 7 902 WHITE PIN 2 29 BLACK 4 UE PIN 3 60 BLACK WHITE TO ANGLE TRANSDUCER AT 3 BLACK PIN 4 28 GREEN BLACK PN 1 910 PLUK 5 00 WHITE PN 2 288 GREEN 6 28E CREEN WHITE PIN 3 902 WHIT SS 777 S TT EB PRESSURE TRANSDUCER PIN 1 INPUT PIN 1 910A BLACK PIN 2 OUTPUT PIN 2 60A GREEN PIN 3 INPUT PIN 3 900 WHITE SKYJACK Page 36 Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 27 Electric
143. 2261 132244 131927 105501 108721 125244 114284 110460 113173 102863 134432 122419 104534 104534 106557 104534 106557 104534 104534 104534 113286 107271 113556 113752 3 3 Hydraulic Component Parts List Continued AB Skyjack KP ay Description Parts list continued from the previous page MANIFOLD BLOCK Controlled lowering MANIFOLD BLOCK Disc brake Cushman axles MANIFOLD BLOCK Outrigger MANIFOLD BLOCK Hydraulic generator valve option MANIFOLD BLOCK Front powered platform MANIFOLD BLOCK Rear powered platform MANIFOLD BLOCK Free wheeling valve MANIFOLD BLOCK Motion control MOTION CONTROL ASSEMBLY ORIFICE Main 096 diameter Model 9250 ORIFICE Lift cylinder 0 094 ORIFICE Controlled lowering 0 055 ORIFICE Lift line 0 120 Model 9241 COOLER Hydraulic generator option PUMP Hydraulic dual 0 488 0 854 PUMP Power platform PRESSURE SWITCH option trips at 2400 psi TRANSDUCER Pressure QUICK DISCONNECT System pressure RELIEF VALVE System RELIEF VALVE Lift RELIEF VALVE Lift cylinder Model 9241 RELIEF VALVE Cylinder Model 9250 RELIEF VALVE Lift cylinder Model 9241 RELIEF VALVE Cylinder Model 9250 RELIEF VALVE Cylinder Model 9250 RELIEF VALVE Cylinder Model 9250 RELIEF VALVE Power platform Set at 500psi VALVE Emergency
144. 42 143805 I L IL IL L L L L ILIA Ill ILL ILIA ILIA lll L RELAY Drive Time Delay DPDT SOLENOID Stop Diesel Engines RELAY Outrigger enable RELAY Outrigger enable proof CONTACTOR Powered Extension 12 Volt CE CONTACTOR 12 Volt powered extension platform option RELAY Engine run RELAY 12 Volt DPDT Hydraulic generator oil cooler RELAY Engine On SPDT ANSI CSA RELAY Engine On DPDT CE RELAY Joystick Enable Switch RELAY Down SPDT ANSI CSA RELAY Down down CE RELAY Up SPDT ANSI CSA RELAY Up CE RELAY Reverse Drive DPDT RELAY Forward Drive DPDT RELAY 2nd Speed Large pump SPDT RELAY Small Pump SPDT RELAY Outrigger lift disable RELAY 3rd Speed SPDT RELAY Series Parallel SPDT RELAY Right Steer SPDT RELAY Left Steer SPDT RELAY Tilt Switch DPDT RELAY Tilt CE RELAY Down enable CE RELAY Auxiliary tilt CE RELAY Auxiliary down enable CE RELAY Brake SPDT RELAY Choke Glow Plug SPDT RELAY Kubota Diesel Engine Glow Plug RELAY Engine Start DPDT SOLENOID Engine starter Kubota Diesel RELAY 12V 40A Starter GM RELAY Low High Throttle SPDT RELAY Tilt override DPDT RELAY Horn SPDT RELAY 12V 20A 35A Fuel pump GM RELAY Outrigger Drive Enable RELAY Outrigger lift enable SPDT REL
145. 50152AB HMC PI2 Full Size Rough Terrain Series Models 9241 amp 9250 143905 MAIN DISCONNECT 03 BLUE 14 AWG 62111111 BATTERY NEGATIVE 00 WHITE 14 AWG Full Size Rough Terrain Series Models 9241 amp 9250 143905 POWER DECK CONTACTOR 3 15 Main Manifold Wiring Diagram FREE WHEELING VALVE 30A BROWN FORWARD VALVE BLACK HEIRSHMAN PIN 16B WHITE BLACK PIN 2 02 WHITE RIGHT STEER VALVE BLACK HEIRSHMAN PIN 23A BLACK WHITE PIN 2 02 WHITE REVERSE VALVE GREY HEIRSHMAN PIN 1 15B BLUE PIN 2 02 WHITE LEFT STEER VALVE GREY HEIRSHMAN PIN 1 24A BLUE BLACK PIN 2 02 WHITE 2 WHITE T 0 42 BRAKE DUMP VALVE 30A BROWN 2x 02 WHITE LARGE PUMP DUMP VALVE 17A BLUE RED 02 WHITE V TO ELECTRIC PANEL 14 WIRES 00 WHITE 14 AWG 02 WHITE 03 BLUE 14 AWG 09 ORANGE RED gi W AT QUICK BRAKE VALVE 25 ORANGE GREEN SMALL PUMP DUMP VALVE 18A RED BLACK 02 WHITE e 2 30 BRAKE FEED VALVE E 30A BROWN 2x ua 02 WHITE zi LOWERING VALVE 13A ORANGE 2x 02 WHITE 2x HOLDING VALVE HARNESS 13A ORANGE 02 WHITE LIFT VALVE 14B BLACK 02 WHITE Print View This Page Parts List 13A ORANGE 14B BLACK 15B BLUE 16B WHITE BLACK 17A BLUE RED 18A RED BLACK 23A BLACK WHITE 24A BLUEJBLACK 25 ORANGE GREEN 30A BRO
146. 74 133441 BRAKE PACK alternate Cushman axles 120349 CYLINDER Lift Model 9241 120353 CYLINDER Lift Model 9250 120349 CYLINDER Lift Model 9241 120353 CYLINDER Lift Model 9250 120353 CYLINDER Lift Model 9250 120353 CYLINDER Lift Model 9250 120422 CYLINDER Brake 120422 CYLINDER Brake Parts list continued on the following page Full Size Rough Terrain Series SKYJACK Page 5 Models 9241 amp 9250 143905 120405 133474 107752 132694 132694 132694 132694 120255 120255 132249 132249 104624 104624 104624 104415 104415 104415 104415 132248 132248 132248 132248 300248 109568 104254 113875 110652 109311 114178 103137 130443 118345 130444 106688 118345 118345 118345 125430 125430 113494 118345 118345 125430 125430 SKYJACK Page 6 ILI L Il L L L L ll 3 3 Hydraulic Component Parts List Continued Skyjack we SEN Description Parts list continued from the previous page CYLINDER Steer Dana axles CYLINDER Steer Cushman axles CYLINDER Cushion CYLINDER Front Left outrigger CYLINDER Front Right outrigger CYLINDER Rear Right outrigger CYLINDER Rear Left outrigger CYLINDER Front extension platform CYLINDER Rear extension platform COUNTE
147. 76 2 LEGEND 31 REDWHITE 4 6 BLACK 14 30 2 WHITE RED 5 Q Hf j 4 BLUEBLACK 13 52 5 ORANGE 13 7D REDBLACK GREEN a9 121 Brack reo 14 MAIN MANIFOLD HARNESS 23 BLACKWHTE 12 BLUE WHITE 10 10D WHITERED GREEN 28 20 ORANGE GREEN 73 o 0000000 P 2 BLACKWHITERED 3 ORANGERED 60 BLACKREDGREEN 7 119 WHITE BLACK RED 72 Ons S ENGINE HARNESS ORANGE BLACK 0 0072 RDQ ORANGE BLACK WHITE O 18 PLATFORM CONTROL BOX P wE nee END 5 e j CONTROLS GROUND BLUE BLACK WHITE TO 0 EL 9J el Full Size Rough Terrain Series Models 9241 amp 9250 143905 2 147881 SKYJACK Page 41
148. 8XX 86 88 22 95 5 71277 RT 7127 eat RT 7135 80 48 21 26 SJR 8243 8243 SS 8850 Oil Type ae 8831 ATF Dexron 8841 8841 75 71 8831 8841E 9241 67 38 SJRT 9250 9250 All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water SKYJACK Page 18 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 5 Rough Terrain Scissor Fluids Continued ENGINE OIL Engine Type Qty Qty i Recommended Equivalent Kubota D902 Liters Gallons Viscosity API Service Designation Kubota D1105 10W30 API Service Designation CG 4 Kubota DF972 Engine Oil SAE 10W 30 CF 4 CF CD SH Nissan A15 6 16 1 6 10W30 API Service Designation SF CC All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water ENGINE COOLANT Qty Qty lant T Component Type Liters Gallons Coolant Type Kubota D902 KubotaDit05 D1105 Anti freeze Water Kubota lt A15 11 4 3 01 1 6 Extended life anti freeze Water All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water ENGINE FUEL Tank a Liquid Propane Model Qty Qty
149. 9 Remove gauge from lift line port fitting and reconnect lift line to main manifold N WARNING Ensure aerial platform does not lift more than rated load Mid Size amp Full Size Rough Terrain Series SKYJACK Page 7 Service and Maintenance 5 1 6 Change Hydraulic Oil NOTE Samples of hydraulic oil should be drawn from the reservoir and tested annually These samples should be taken when the oil is warmed through normal operation of the system The sample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use Oil change intervals will depend on the care used in keeping the oil clean and the operating conditions Dirt and or moisture cotamination will dictate that the oil should be changed more often Under normal use and operating conditions the hydraulic oil should be changed every two years Refer to Table 1 2 of this manual Ensure aerial platform is on a firm level surface fully lowered and outriggers if equipped fully retracted Allow hydraulic oil to warm up Turn main power disconnect switch to off position SKYJACK Page 8 Section 5 Procedures Place suitable container under the hydraulic tank Remove oil drain plug and allow all hydraulic oil to drain into container Install oil drain plug with new seal ring and tighten firmly Refill hydraulic tank with new oil as per specifications Refer to section 2 of
150. ALVE Large pump dump 103655 VALVE Outrigger holding 103656 VALVE Small pump dump 102626 VALVE Quick brake 112218 VALVE Free wheeling 103656 VALVE Brake dump 103655 VALVE Brake feed 104412 VALVE Hydraulic generator option 103655 VALVE Auxiliary lowering Model 9250 103655 VALVE Auxiliary lowering Model 9250 103655 VALVE Auxiliary lowering Model 9250 103655 VALVE Auxiliary lowering Model 9250 103623 VALVE Series parallel 139256 VALVE Reverse drive includes 4H 16B 139256 VALVE Forward drive includes 4H 15B 128318 VALVE Right steer includes 4H 24A 128318 VALVE Left steer includes 4H 23A 128318 VALVE ASSEMBLY Front platform extend option includes 4H 27A 128318 VALVE ASSEMBLY Rear platform extend option includes 4H 27 128318 VALVE ASSEMBLY Front platform retract option includes 4H 26A 128318 VALVE ASSEMBLY Rear platform retract option includes 4H 26 128318 VALVE ASSEMBLY Left front outrigger retract includes 4H 75 128318 VALVE ASSEMBLY Right front outrigger retract includes 4H 76 128318 VALVE ASSEMBLY Right rear outrigger retract includes 4H 77 128318 VALVE ASSEMBLY Left rear outrigger retract includes 4H 78 128318 VALVE ASSEMBLY Left front outrigger extend includes 4 71 128318 VALVE ASSEMBLY Right front outrigger extend includes 4H 72 128318 VALVE ASSEMBLY Right rear outrigger extend includes 4H 73 128318 VALVE ASSEMBLY Left rear outrigger extend includes 4H
151. ARRA ERU V DAE ERE 36 4 2 20 Left Rear 36 Mx DH 36 Load Sensing System 421 POT MM FER CEDE IU DIAS Du EI 37 452 Flasn code Not Ground MOD 37 toa a vo mu m 37 FA SO OU P 37 tos BET MODE o 37 0 7 37 FS SO s POT El u i sau 37 Fy ae EUER 37 togs FE OFI DOH sca 37 eTA ra EEE ETETE aE 37 SKYJACK Page 2 Full Size RT s Engine Powered 4 3 11 Flash Code 12 4 3 12 Flash Code F13 4 3 13 Flash Code F14 4 3 14 Flash Code F15 4 3 15 Flash Code F16 4 3 16 Flash Code F17 4 3 17 Flash Code F18 4 3 18 Flash Code F19 4 3 19 Flash Code F20 4 3 20 Flash Code F21 4 3 21 Flash Code F22 4 3 22 Flash Code F23 4 3 23 Flash Code F24 4 3 24 Flash Code F25 4 3 25 Flash Code F26 4 3 26 Flash Code F27 4 3 27 Flash Code F30 4 3 28 Flash Code 1 4 3 29 Flash Code 2 4 3 30 Flash Code F33 4 3 31 Flash Code F34 4 3 32 Flash Code F40 4 3 33 Flash Code F42 4 3 34 Flash Code F43 4 3 35 Flash Code F44 4 3 36 Flash Code F45
152. AY 12 Volt SPDT hydraulic generator RELAY 12 Volt DPDT hydraulic generator stop CONTACTOR Powered Extension Platform CE RELAY Powered Extension Platform CE SOLENOID Powered Extension Platform Motor RELAY 20A 35A 12V Power Parts list continued on the following page SKYJACK Page 9 3 4 Electrical Component Parts List Continued Skyjack 103613 104410 104410 104410 104410 104410 103613 106272 103613 103613 103613 103613 103613 103613 106272 104410 104410 104410 104410 142324 103613 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 128321 130440 103295 108789 103056 SKYJACK Page 10 Parts list continued from the previous page COIL Main Lowering Valve COIL Lift Cylinder Holding Valve ANSI CSA COIL Lift Cylinder Holding Valve COIL Lift Cylinder Holding Valve COIL Lift Cylinder Holding Valve Model 9250 COIL Lift Cylinder Holding Valve CE Model 9250 COIL Lift Valve COIL Large Pump Dump Valve COIL Outrigger Holding Valve COIL Small Pump Dump Valve COIL 12 Volt brake valve COIL Free wheeling Valve COIL Brake Dump Valve COIL Brake Feed Valve COIL Hydraulic generator option valve COIL Lift Cylinder Auxiliary Holding Valve Model 9250 COIL Lift Cylinder Auxiliary Holding Valve Model 9250 COIL Lift Cylinder Auxi
153. CAS LOAD NEUTRAL WHITE 120282515525 4z GROUND GREEN Eu t 7 Seb IT eee Owe E Olea 989 9606 9 iat 32 Q EEI CR nove 8 F C Wero 17BCR BSCR 21 x Oe sF cence TT 86 LOAD JUMP J17E U 5222225555555 sb a 9 0 MOVISAGENERATOR r U2 769 T G8 2 2 2 0 0 O O O ACO O 30 O 5A O 184 O 21 0029AO 24A O 02 00 TO OIL COOLER FAN SI1S A SHSANSNST1SASASASASNS T 28 L 86D BLACK CR CR CR CR 5 4 00 WHITE Bh 62 6 02 8 36 8621 s Op 4 Wp i 96 a ______ E 65 T 03 ly 02 BE GROUND 86C MESE OIL COOLER RELAY 10ACR2 f v gt 290V 15A GENERATOR TO HYDRAULIC GENERATOR SOLENOID PIN 30 85A ORG BLK WHT PIN 87 86D BLK 2 86C BLACK jan PIN85 10ABLUWHT PIN67a NIU RED 02 2 i asss M134191AD_1 Ful
154. Calibration Diagnostic Tool Key 27 5 2 6 Outrigger Control Modules INSU UNOS 28 5 3 7 Auto Leveling Outrigger Control Module Pin Reference 31 Load Sensing System CE 5 4 1 Gontr l Module 32 5 4 2 LED Error Codes Quick Reference 33 5 4 3 LED Error Codes Code Breakdown Charlt 34 5 4 6 Control Module Load Calibration Code Messages 8 Definitions 36 5 4 7 Control Module Load Calibration Procedure 40 u uuu 44 Mid Size amp Full Size SKYJACK Page 1 Rough Terrain Series Section 5 Procedures Service and Maintenance General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter Safety and Workmanship 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 in
155. Check continuity Replace if defective 4 Loose or broken wire 02 from glow plug relay 31ACR to base terminal block TB1 Check continuity Replace if defective 5 Loose or broken wire 103 from starter solenoid 32ACR to relay 31ACR Check continuity Replace if defective Full Size RT s SKYJACK Page 9 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 6 7 8 Loose or broken wire 91A from relay 31ACR to engine glow plugs EGP1 Check continuity Replace if defective Defective glow plug relay 31ACR Check relay Replace if defective Defective glow plugs Check glow plugs Replace if defective 4 1 11 Glow Plugs Inoperative from Platform Additional T 2 3 Loose or broken wire 10 from key selector switch S3 to glow plug switch 13 Check continuity Replace if defective Defective glow plug switch 13 Check switch Replace if defective Loose or broken wire 31 from glow plug switch 513 to glow plug relay 31CR Check continuity Replace if defective Loose or broken wire 02 from relay 31CR to base terminal block TB1 Check continuity Replace if defective Loose or broken wire 05 from base terminal block TB1 to relay 31CR Check continuity Replace if defective Loose or broken wire 31A from relay 31CH to glow plug relay 31ACR Check continuity Replace if defective Defective relay 31CR Check relay Replace
156. Check power unit Repair or replace if defective 4 1 36 Powered Extension Platform will Not Extend 1 Defective platform extend retract switch S11 or S114 Check switch Replace if defective 2 Loose or broken wire 26 or 26A from platform extend retract switch S11 or S11Ato platform extend valve coil 4H 26 or 4H 26A Check continuity Replace if defective Full Size RT s SKYJACK Page 25 Engine Powered Q Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 3 4 5 Open diode D26 or D26A Check diode Replace if defective Defective platform extend valve coil 4H 26 or 4H 26A Check coil Replace if defective Loose or broken wire 00 from platform extend valve coil 4H 26 or 4H 26A to battery cable 00 Check continuity Replace if defective 4 1 37 Powered Extension Platform will Not Retract 1 2 Defective platform extend retract switch S11 or S11A Check switch Replace if defective Loose or broken wire 27 or 27A from platform extend retract switch S11 or S11A to platform retract valve coil 4H 27 or 4H 27A Check continuity Replace if defective Open diode D27 or D27A Check diode Replace if defective Defective platform retract valve coil 4H 27 or 4H 27A Check coil Replace if defective Loose or broken wire 00 from platform retract valve coil 4H 27 or 4H 27A to battery cable 00 Check continuity Replace if defective 4 1 38 Hydraul
157. D BLOCK lt 1 ORIFICE 0 055 VALVE NN SIDE EXTENSION oTe DECK 226 OPTION H gt Wut C7 STEER 10 X X S CYLINDER MB1 MAIN MANIFOLD MANUAL LOWERING C16 SIDE EXTENSION VALVE MANIFOLD 1 2H 13A MAIN LM Y 1 W REAR LIFT CYLINDER Vi LOWERING Z MANUAL LOWERING VALVE C12 LEFT REAR C9 LEFT FRONT C10 RIGHT FRONT C11 RIGHT REAR VALVE PRESSURE SWITCH 7 RIGHT LEFT QUTRIGGER CYLINDER OUTRIGGER CYLINDER OUTRIGGER CYLINDER QUTRIGGER CYLINDER WT ly 2212 W gt Lo VALVE VALVE PRESSURE 27 CHECK CHECK CHECK CHECK GENERATOR OPTION SWITCH i F y m VALVE VALVE WWE MOTOR VANE 9 RELIEF ax De VALVE BE UA T B11 OUTRIGGER Tae 28 148 MANIFOLD BLOCK HYDRAULIC HYDRAULIC ae o 283082 4478 4475 4476 GENERATOR VALVE GENERATOR BRAKE J 458 LEFTREAR LEFTFRONT __ RIGHTFRONT RIGHT REAR MANIFOLD VALVE FEED REVERSE OUTRIGGER OUTRIGGER OUTRIGGER 4 OUTRIGGER 4 Mei VALVE DRIVE Bm L5 BD 2 VALVE gt lt EXTEND gt gt lt x M VALVE VADE VAE p CA 2H 17A LARGE B 8 T PUMP DUMP Pua EE mas Pea 001 OIL COOLER N lt gt DIESEL OPTION QW E y 9 4H71 4673 ENGINE CHECK mm LEFT REAR LEFT
158. E CONTROL MODULE P2 UM IS BETWEEN 61 amp 36 PIN 11 amp 12 PIN3 86AORGIBLKWHT 9 021 PIN 10 35 BROWNRED OME PIN 4 10A BLUE WHITE PIN 10 368 YELLOW PIN 11 02 WHITE ox a 21919 lt 5 PIN 5 09 ORANGE RED PIN 11 61 BLACK PIN BL ae OG E PIN 6 44 RED PIN 12 36 BLACKWHITE Midi 990 pv 31 8 32 A 10 5 6 2 24 08 V 9960690090000 4 56 56565 5555558 MI TEE EEE 010 2 21 oA CN Cc T l m MS 15 HERI TER eee EB Te HER T e ERAI HEUS lt gt lt gt 0 0 11 42 92 FMD lant 542 2 08 OD OAD Gt 82 05 92 T Sr i OOO r sF MOA 2 o y 10A EF CR CR A FT m CR CR CR pem 6 7 9 sn 40 8 s 40 s GOA ENABLE Bu T 49A Di6A D23A D24A e 23 m 40A 20 7 er for PADO 140 60 Dg UNA Di 1 00 02 0 ES E 35 0000000000000000 00000 2 20006000 Roo ost ooo CY 5 GS 8600 60 X 1 D19 sl 5 MS rug s 19 358 C SOC PI NOTE T
159. ET T PTT o E PINY 22 RED OKONO ROG NICO FM 8 6 5 i i AR i o 0 Um Bg sh awe owe B o lessee gb lee C2 co r r 4 1 cu co 9 1 LII RES N DENM Q fesses 181 Mee qm es D c d cu 098800080 IEE F OIG 5 SED 6090 amp Dg 5002 amp 0 gt E 17BCR E ME ME 8 AN T JNP KS 14 a 18 mm 12 13 10A CN 1 1 1 be N AX AX ae e n te eno ols 0 00 601 617 500 00 02 02 O 07 O 09 2 CACO 33 2 5 30 o WAOXMA O O TA 00 0 5
160. F15 Check Elev 1 This message is given if the elevation switch P2 10 is open when the platform has been fully lowered after the DYNAMIC lift This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered lf the platform is fully lowered check the elevation switch 4 3 15 Flash Code F16 Low Elev open 1 This message is given if the elevation switch P2 10 opened during lift at a too low height below 5 If it opens below 5 the pressure is probably too unpredictable to allow reliable detection of an overloaded platform when initially raised Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened 4 3 16 Flash Code F17 High Elev open 1 This message is given if the elevation switch P2 10 opened during lift at a too high height above 25 If it opens above 25 the platform is too high when the overloaded platform is detected Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened 4 3 17 Flash Code F18 Low Elev close 1 This message is given if the elevation switch P2 10 closed during lower at a too low height below 5 If it closes below 5 height sensor fault detection is compromised Check CALIBRATIONS HEIGHT CALS the ElevDown value shows the recorded height where the switch opened SKYJACK Page 38 Full Size RT s Engine Powered Section 4 Troublesho
161. GE 18 10 PURPLE YELLOW 18 12 13 WHITE ORANCE 18 14 BLUE PINK 18 15 BLUE WHITE 18 TPS1 ER TAN WHITE 18 148 c 19 LT GREEN RED 18 51 BLACK LT GREEN 18 B ECT 20 GREEN 18 LT GREEN 18 21 PURPLE WHITE 18 LT GREEN RED 18 22 WHITE PURPLE 18 dd Cu YELLOW GRAY 18 3 BOSCH IMAP 25 TWIST WIRES 16 TURNS 36 DEG FOOT FULL LENGTH BLACK LT GREEN 18 _ 24 TWIST WIRES 10 TURNS 36 DEG FOOT FULL LENGTH PINK DK GREEN 16 12V RELAYED POWER gt 25 RED WHITE 18 TAN DK GREEN 18 R AUX PD1 CONNECTOR 2 26 RED BLACK 18 RED BLACK 18 P VS 27 RED WHITE 18 VS 28 k TAN BLACK 18 AUX DIG 3 29 TAN RED 18 L AUX DIG 2 GRAY DK BLUE 18 GOV SELECT 1 7 31 YELLOW 18 GRAY ORANGE 18 J GOV SELECT 2 32 OIL PRESSURE SENSOR DK BLUE YELLOW 18 H AUX ANA 35 YELLOW RED 18 YELLOW DK BLUE 18 G AUX ANA PU2 34 LT BLUE 18 OPS1 TAN 18 F AUX PWM 2 25 BLACK 16 E GROUND 36 GRAY 18 D TACH 57 BROWN WHITE 16 C AUX 5 38 BLACK 12 WHITE BROWN 16 5 AUX PWM 5 RECIRC 39 _YELLOW GRAY 18 BLACK 16 BLACK 16 UNUSED 40 18 41 WHITEZRED 18 42 TAN BROWN 18 45 18 44 TAN BLACK 18 Z 45 PINK TAN 18 VEHICLE INTERFACE CONNECTORS 46 DK BLUE YELLOW 18 47 YELLOW DK BLUE 18 48 LT GREEN WHITE 18 49 LT GREEN PURPLE 18 LT GREEN PURPLE 18 5V EXT 2 FPP2 ONLY 5 LT GREEN BLACK 18 LT GREEN BLACK 18 5V RTN
162. HE 1000uF CAPACITOR IS NOT REQUIRED 0092000000000000000000 ON MACHINES EQUIPPED WITH WET BRAKES TWO SPEED MOTOR 20A BLACK SOME 00 00 09 Ow ma 100 0E 4 ANA 25 oom 76 160 184 M T i 20A 5 m lt a 3 UJ 5 MAIN MANIFOLD HARNESS ENGINE HARNESS 21 LOAD SENSE CONTROL MODULE HIGH SPEED e LEGEND 00 WHITE 14 AWG PIN 1 31A ORANGE 02 WHITE 5 02 WHITE PIN 2 34A WHITEIBLACK 10C BLUE BLACK BACK VIEW BACK VIEW en dO MAIN MANIFOLD HARNESS 03 BLUE 14 AWG PIN 3 02 WHITE 10E BLUE WHITE FEMALE FEMALE ENGINE HARNESS 09 ORANGE RED PIN 4 32A ORANGE BLACK 13D ORANGE C 9 13A ORANGE PIN 5 N U 14D BLACK ya 34 GREEN WHITE 16 8 WHITE BLACK 16 4 GREEN BLACK WHITE 77 PLATFORM CONTROL BOX 148 BLACK PIN 6 NIU 15 BLUE B GREENBACK lag oy Gy 815 158 BLUE 7 33 GREEN 16 WHITEIBLACK scr 5 go000009 31 RED WHITE 6 BLACK 14 430 C 2 WHITE RED Y 2 een s 4 13 96 5 H mI JC RED BLACK GREEN 29 96 5 36 BIKIWHT LOAD SENSE CONTROL MODULE us e 23 BLACK WHITE 12 4 BLUE WHITE 10 100 WHITE RED GREEN 28 20 ORANGE GREEN 73 22 18A RED PIN 10 37 BLUE BLACK REDI BLACK WHITERED
163. IESEL OPTION W J J J 4H71 ENGINE R CHECK me LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR i oF sw VANE TRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER BNEDIMP HOLDING RETRACT RETRACT RETRACT RETRACT LARGE SMALL ae VALVE VALVE VALVE VALVE VALVE PUMP PUMP i QDI SYSTEM PRESSURE PUMP 7 OCI OIL COOLER QUICK DISCONNECT lt FI s FILTER RESERVOIR A View Parts List M139727AC V Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 13 Hydraulic Schematic Dana Axles MC1 MOTION CONTROL VALVE ASSEMBLY Print This Page View Parts List
164. ITE PIN 6 NIU PIN 15 N U PIN 17B WHITE BLACK TO LIMIT SWITCHES PIN 16 65 GREEN BLACK PIN2 02 WHITE PIN 3 78 BLACK WHITE 2 o 2 Fi o PIN 1 65 GREEN BLACK BACK VIEW PIN 2 65A GREEN WHITE PIN 4 73 BLUE 2 78 0 0 76 PIN 5 77 BLUE BLACK PIN 3 66A BLUE WHITE PIN 6 74 BLACK GREY GREY GREY GREY PIN 4 67 RED WHITE PIN 5 68A WHITE L ON 7 71 ORANGE PINB 75ORANGEIBLACK PIN 6 NU QUTR CTRL BOX PIN 9 72 RED PIN 10 76 RED BLACK TO OUTRIGGER PCB CN20 PIN 1 35C WHITE BLACK PIN 2 78 BLACKIWHITE PIN 3 73 BLUE PIN 4 77 BLUE BLACK 8 Ee PIN 5 74 BLACK PIN 6 71 ORANGE d ojojojojojojojojo S
165. LUE 155 GREEN BLACK 32 76 RED GREEN 23 9 31 H 14 BLACK RED WHITE 31 75 WHITE RED 1212 30 6 13 ORANGE 5 O 13 BLUE BLACK 24 74 BLACK RED 41 29 RED BLACK GREEN NOT USED 10 BLUE WHITE 4 O 12 BLACK WHITE 23 73 ORANGE GREEN LO 28 WHITE RED GREEN NOT USED 09 ORANGE RED 3 O BLACK WHITE RED 20 72 WHITE BLACK RED 19 O 27 BLACK RED GREEN NOT USED 7A RED 2 10 ORANGE BLACK 19 71 BLUE RED ORANGE BLACK WHITE 85 0 wHTE 1000 9L REDBLACK 19 49 GREEN RED BLACK WHITE 78 BLUE BLACK WHITE GROUND TERMINAL STRIP M147234AE Full Size Rough Terrain Series SKYJACK Page 15 Models 9241 amp 9250 143905 3 6 Platform Control Console Wiring All Options CE
166. Limit Switch 1 1 8 Lifting Mechanism Scissor Guards If Equipped Ensure there are no loose or missing parts and there is no visible damage Sliders Ensure sliders are secure and there is no visible damage Ensure sliders path of travel are free from dirt and obstructions Raise the platform until there is adequate clearance to swing down the maintenance support Maintenance Support Ensure maintenance support is properly secured and shows no visible damage Scissor Assembly Ensure scissor assembly shows no visible 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 Maintenance Support Lift Cylinder Scissor Bumpers Ensure bumpers are secure and shows no sign of visible damage Lift Cylinder s Ensure each lift cylinder is properly secured there are no loose or missing parts and there is no evidence of damage Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Raise the platform until there is adequate clearance to swing up the maintenance support into storage bracket Fully lower the platform Mid Size amp Full Size Rough Terrain Series SKYJACK Page 25 Service and Maintenance Inspections Section 1 Scheduled Maintenance Typical Model 71xx shown Bottom View Ladder
167. MODELS SJ 9241 SJ 9250 Z w w w KEEP CLEAR Service Manual Full Size Rough Terrain Series 6 Part 143905AD February 2014 This manual is based on Serial Numbers ANSI CSA amp AS SJ 9250 90 000 513 TO 50 000 745 CE 5J 9241 55 000 001 TO 55 000 032 5J 9250 50 000 513 TO 50 000 745 Please refer to the website www skyjack com for older Serial Numbers Skyjack Service Center 3451 Swenson Ave St Charles Illinois 60174 USA Phone 630 262 0005 Toll Free 1 800 275 9522 Fax 630 262 0006 Email service dskyjack com Parts North America Toll Free 1 800 965 4626 Toll Free Fax 1 888 782 4825 E mail parts dskyjack com Skyjack Australia Pty Ltd 4 Coates Place Wetherill Park New South Wales 2164 Australia Tel 61 0 28786 3200 Fax 61 0 28786 3222 Parts amp Service Europe Unit 1 Maes Y Clawdd Maesbury Road Industrial Estate Oswestry Shropshire SY10 8NN UK Phone 44 1691 676 235 Fax 44 1691 676 238 E mail infofdskyjackeurope co uk Skyjack Brasil Alameda Jupiter 710 Loteamento American Park Empresarial Indaiatuba SP Brasil 13347 653 Tel 55 19 3936 0132 SERVICE AND MAINTENANCE Table of Contents Section 1 Scheduled Maintenance Table of Contents Section 2 Maintenance Tables Table of Contents Section 3 Schematics Table of Contents Section 4 Troubleshoo
168. N 11 07 RED PIN 12 05 PURPLE WHITE PIN 12 05 BLUE i 90 mE 32A Hn MAIN STARTER 103 RED 57 GLOW PLUG LIGHT E 90 RED m 91A RED 57 PRESSURE SWITCH 2A BLACK RED 2B WHITE STARTER MOTOR BLACKWHITE GLOW PLUG SWITCH deri 31A REDIWHITE PURPLE WHITE BACK VIEW FEMALE STARTER SOLENOID 37 32A GREENBLACK FRONT VIEW MALE UCM 7 WHITE PIGTAIL WIRE ON STARTER OFF ON START SWITCH D 05 PURPLE WHITE 07 RED 32A GREEN BLACK TEMPERATURE SWITCH 28 WHITE FUEL VALVE ON ENGINE a 37 BLUE WHITE i 57 BLACK WHITE lige FUEL VALVE GROUND 00 WHITE THROTTLE SOLENOID m 34A GREENWHITE Olg E 02 WHITE GLOW PLUG 91 RED 37 BLUE WHITE M147615AA_1 SKYJACK Page 39 Print This Page View Parts List 3 29 Engine Harnesses GM Dual Fuel Engine D j E P GCP 98 WAY CONNECTOR 211 98 2S 0009 CONNECTOR 211 90
169. NJURY 60023AD Mid Size amp Full Size SKYJACK Page 9 Rough Terrain Series Service and Maintenance Operator s Responsibility for Maintenance Safety Precautions Know and understand the safety precautions before going on to next section WARNING Failure to heed the following safety pre cautions could result in tip over falling crushing or other hazards leading to death or serious injury KNOW all national state provincial and local rules which apply to your aerial platform and job site TURN the emergency main power disconnect switch off when leaving the aerial platform unat tended Remove the key to prevent unauthorized use of the aerial platform WEAR all the protective clothing and personal safety devices issued to you or called for by job conditions DO NOT wear loose clothing dangling neckties scarves rings wristwatches or other jewelry while operat ing this aerial platform AVOID entanglement with ropes cords or hoses AVOID falling Stay within the boundaries of the guardrails DO NOT raise the aerial plat form in windy or gusty condi tions DO NOT increase the lateral surface area of the platform Increasing the area exposed to the wind will decrease aerial platform stability DO NOT drive or elevate th
170. NOTE EACH STRANDED m 55 N j OZ s w f 1 Ea WIRE AT THE TERMINAL STRIP MUST BE TERMINATED 9 wm TO OIL COOLER FAN WITH A FERRULE a 86D BLACK 00 WHITE sees TT poe gt cb Da TE 1 HYDRAULIC GENERATOR SOLENOID OAD BROWN GROUND GREENYELLOW m O HYDR GEN CONTROL CABLE is 85 GREEN 86 WHITE OIL COOLER RELAY 104052 PIN 30 85A ORG BLK WHT PIN 85 10A BLUWHT PIN 86 2A BLK RED PIN 87 86D BLK PIN 87a NU 110V 15A GENERATOR 09 BLACK 220V 15 GENERATOR M149512AC Full Size Rough Terrain Series SKYJACK Page 29 Models 9241 amp 9250 143905 3 20 Emergency Lowering System Wiring Diagram ANSI CSA Model 9250 B 0C J
171. Platform Capacities Evenly Distributed AS First Extension Second Extension MODEL Number of Capaci Number of Capaci Number of Occupants Occupants Occupants One Extension 7135 Sec denso 454 kg 159 kg 1 Not Available Platform Capacity Not Available Not Available One Extension One Extension 5820 Platform SOS Kd No Extension Platform 1134 kg Not Available 8831 neenon 908 kg 227 kg 2 Not Available Platform Two Extension Extension E One Extension 8841 Platform 681 kg Two Extension Platforms No Extension Platform One Extension Platform 681 kg Not Available Two Extension 60376AE AS Not Available 771 kg Not Available 908 kg NOTE Occupants AND materials are not to exceed rated load Capacities listed are for standard machines equipped with 6 tires except for model 9250A which is equipped with foam filled tires Refer to capacity label at sides of platform for additional information and for models equipped with options Mid Size amp Full Size SKYJACK Page 9 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 3a Tire Specifications ANSI CSA WARNING Air pressure can affect stability Temperature changes can affect air pressure It is important to visually inspect all tires for proper tire inflation prior to use Tires should be checked by end user on a daily basis Tire inflation pressures must b
172. R BALANCE VALVE Motion control COUNTER BALANCE VALVE Motion control CHECK VALVE Small pump CHECK VALVE Large pump CHECK VALVE Lift CHECK VALVE Left front outrigger CHECK VALVE Right front outrigger CHECK VALVE Right rear outrigger CHECK VALVE Left rear outrigger CHECK VALVE Motion control CHECK VALVE Motion control CHECK VALVE Motion control CHECK VALVE Motion control DC MOTOR 12V FILTER ASSEMBLY Return e ELEMENT Filter GENERATOR MOTOR Hydraulic option PUMP Cavity hand Cushman axles MOTOR Main 2 Speed hydraulic drive MANIFOLD BLOCK Main MANIFOLD BLOCK Emergency lowering MANIFOLD BLOCK Holding valve Model 9241 MANIFOLD BLOCK Holding valve ANSI CSA Model 9250 MANIFOLD BLOCK Holding valve CE Model 9250 MANIFOLD BLOCK Holding valve Model 9241 MANIFOLD BLOCK Holding valve Model 9250 MANIFOLD BLOCK Holding valve Model 9250 MANIFOLD BLOCK Holding valve Model 9250 MANIFOLD BLOCK Lower lift line MANIFOLD BLOCK Upper lift line Model 9250 MANIFOLD BLOCK Controlled lowering MANIFOLD BLOCK Holding valve Model 9250 MANIFOLD BLOCK Holding valve Model 9250 MANIFOLD BLOCK Lower lift line MANIFOLD BLOCK Upper lift line Model 9250 Parts list continued on the following page Full Size Rough Terrain Series Models 9241 amp 9250 143905 Full Size Rough Terrain Series Models 9241 amp 9250 143905 113494 111943 111970 103137 111291 111291 103615 13
173. RED 4E BLACK RED BASE CONTROLS CONTACT ORIENTATION BACK VIEW A UP DOWN SWITCH PLIFIBASE SWITCH N N O CONTACT MEE PIN 3 10E BLUE WHITE PIN 4 10D WHITEIRED GREEN Y er L UP DOWN SWITCH PLTFIBASE SWITCH N O CONTACT N C CONTACT PIN 4 13D ORANGE PINT 7ARED c PINS 10E BLUEWHTE PIN 2 7C RED GREENIBLACK C ME 02 LAS 07 10A E STOP SWITCH CONTACT LED 2 LIGHT PIN 1 07 RED PIN 2 7C REDWHITE PIN X1 10 BLUE WHITE PIN X2 02 WHITE SKYJACK Page 20 Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 11 Hydraulic Schematic Cushman Axles Model 9241 POWERED EXTENSION Print This Page
174. ROTTLE n m r5 12A yi x pH JOYSTICK CONTROL wmEMBE 08 7 7A 13 12 5 p LI d NORM HIGH ON 566 EMERGENCY STOP UP DOWN HIGH LOW RANGE g s E EB B B B EB SB B B ST Od COO GO O CONO OR B BS SS FS SEI LS LS B E E A 2 2272 t i tot LIFT CHOKE __ ene POM BACK VIEW BACK VIEW MALE MALE 8 WHITEBLACK 310 n GREEN WHITE 34 T GREEN BLACK WHITE 4 o 2 15 BLUE 2 5 GREEN BLACK 32 76 RED GREEN 3120 14 BLACK 16 RED WHITE 31 75 WHITE RED 2 9 13 ORANGE BLUE BLACK 24 74 BLACK RED 21 RED BLACK GREEN 70 Q Q 10 BLUE WHITE 4 12 BLACK WHITE 23 73 ORANGE GREEN 20 28 WHITE RED GREEN 100 09 ORANGE RED 3 11 BLACKWHITE RED 20 72 WHITE BLACK RED 19 O 27 BLACK RED GREEN 60 RED 219 0 ORANGE BLACK 19 71 BLUERED 26 _ ORANGE BLACK WHITE 85 7 02 WHITE 4119019 RED BLACK 1 GREEN 7 52 RED BLACK WHITE 78 O GROUND 00 BLUE BLACK WHITE GROUND TO TERMINAL STRIP M147223AE SKYJACK Page 16 Full Size Rough Terrain Series Models 9241 amp 9250
175. Repeat steps 1 4 Since GP102 only reports one error only one code be read from the LED per instance Ifthe error is cleared and another error is present it will then be presented Mid Size amp Full Size SKYJACK Page 33 Rough Terrain Series Service and Maintenance Section 5 Procedures 5 4 3 LED Error Codes Code Breakdown Chart Diagnostic sequence dependant on LED flash code No Last Caldate 63 2 1 Load Not Calibrated Height Not Calibration An EZcal is required 54 2 Up Down Select Inputs Active Together js EMS Inputs Check inputs on P2 pins 1 2 3 4 5 6 7 8 P 4 Short To Supply P3 4 Short To Supply P3 6 Short To Supply 46 Disconnect plug If fault clears there is a problem with the wiring from P3 4 or P3 6 to the rest of the vehicle Armguard Active Elevation Switch Shifted Elevation Switch Stuck 22 If the 23 flash code is triggered by armguard it will occur once then clean This is not a true 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 will not clear Check that the elevation switch correctly opens closes when the platform is raised lowered 3 4 Short To OV 3 6 Short OV Disconnect plug If fault clears there is a wiring fault from P3 4 or 6 to the rest of the vehicle Invalid Load Check Sensors 45 Check the voltage out of
176. Rough Terrain Series Service and Maintenance Operator s Responsibility for Maintenance Fall Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT exceed the rated capacity of the aerial platform Do make sure the load is evenly distrib uted on the platform DO NOT attempt to free a snagged platform with lower controls until personnel are removed from the platform DO NOT position the aerial platform against an other object to steady the platform DO NOT place materials on the guardrails or ma terials that exceed the confines of the guardrails unless approved by Skyjack Protection As per the ANSI A92 6 2006 standard The guard rail system of the aerial platform provides fall pro tection If occupant s of the platform are required to wear personal fall protection equipment PFPE occupants shall comply with instructions provided by the aerial platform manufacturer remanufac turer regarding anchorage s If additional fall protection is required an ployer or the authority having jurisdiction Skyjack recommends the use of a fall restraint system to keep an occupant within the confines of the plat form and thus not expose the occupant to any fall hazard requiring a fall arrest All personal fall protection equipment must com ply with applicable governmental regulations and must be inspected and used in accordance with the manufactur
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178. STEER STEER HYDRAULIC 01 MAIN LOWERING VALVE VALVE 9 _ gt aq CHECK CHECK CHECK CHECK GENERATOR OPTION m VALE VALVE VALE VALE m m FORWARD GENERATOR R2 LIFT DRIVE z MOR RELIEF Z5 VALVE 5 MB11 OUTRIGGER 2 48 a MANIFOLD BLOCK Bt 2H 86C n HYDRAULIC 5 HYDRAULIC WE 2H 30A 2 E 4H 78 4H 75 4H 76 GENERATOR VALVE M GENERATOR BRAKE 4H 45B LEFTREAR LEFTFRONT RIGHT FRONT RIGHTREAR _ MANIFOLD VALVE CHECK FEED REVERSE OUTRIGGER OUTRIGGER E OUTRIGGER OUTRIGGER J VALVE DRIVE EXTEND EXTEND EXTEND EXTEND VALVE lt lt lt lt VALVE VALVE VALVE VANE 2H 17A LARGE o Y PUMP DUMP Lact Pa 00101 COOLER VALVE 4 DIESEL OPTION 4H 71 4672 CHECK m LEFT REAR LEFT FRONT RIGHT FRONT RIGHT REAR RA 912 VALVE ET SEM QUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER p X ed HOLDING RETRACT RETRACT RETRACT RETRACT LARGE SMALL VIAE VALVE VALVE VALVE VALVE VALVE PUMP PUMP iba c DI SYSTEM PRESSURE PUMP CS OCT OILCOOLER QUICK DISCONNECT DUAL FUEL 3 lt gt mm RESERVOIR Full Size Rough Terrain Series Models 9241 amp 9250 143905 A M116174AJ SKYJACK Page 23 2H 30A 2 BRAKE FEED MANIFOLD VALVE 2H 17A DUMP VALVE PLUG 2 3 14 Hydraulic Manifold Components amp Port Identifica
179. Si vs v vo y Li INIL r f vo 1noino LIM S3NIHOVW kavo 2 2 NO 31ON HOllOVdvO 98 vor se GIONSIOSSAWA 5 933 m 65 GIONSIOSSAWA NU IMYA vro Deg sa Dime aeu eos 18 09 7 20 azi io sit 1 Aviad dd i 1 m m m 6L 48895 ver e GION310S IMYA 1 200 0L d 4 4 s 318WN3 xOUSAOn 84 w vr 001 i AB 5 5 802 ay p 9 4 2 ase ingins MOYHOIH MOYHOIH dS 9 94 t 5 625 se RN 1 5 40 HOSE SAWALAN 4 ape Ovi vel age 89 1 1 9 GION310S 3ATVA 1 ATONE vit vol voL Q AviHdWndTWWS z Dn _ ee 60 60 gt 9 7 ip yoves 98a lt 80
180. T To replace the ignitor with a service part make sure the ignitor has the same part cord No ID mark as the old one See the information label 1 Ignitor Check Chart Negative sin C Positive 0 33 to 1 3 11 to 47 1 8 to 7 3 kO 1110 47 infinity infinity 0 33 to 1 3 1 8 to 7 3 infinity 1 5 to 6 0 kO infinity 1 5 to 6 0 kO infinity infinity infinity infinity minimum minimum minimum minimum minimum minimum 2 megohm minimum 2 megohm minimum 2 megohm minimum 2 megohm minimum 2 megohm minimum 2 megohm minimum infinity infinity 60434AA SKYJACK Page 22 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance Outrigger Option 5 3 1 Auto Leveling Outrigger PC Board Layout
181. TER BUTTONS 290 To move back and forth between menu and sub menu LEFT RIGHT BUTTONS lt Select menus and setting to be adjusted UP DOWN BUTTONS Adjust setting values 5 J Outrigger Settings Mid Size amp Full Size SKYJACK Page 27 Rough Terrain Series Service and Maintenance Section 5 Procedures 5 3 6 Outrigger Control Module Instructions When EZcal hand held device is connected to the OCM1 control module a two line displays shows various menus and settings At any time the top line of the display describes the currently selected menu and the bottom line shows the currently selected item in that menu Six buttons on EZcal allow easy navigation through the menus and gt change the selected item the bottom line display ENTER enters the selected new menu when available top line display changes and V 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 amp logged data ACCESS LEVEL Select this menu enter correct code to enable adjustments and calibrations ADJUSTMENTS Select this menu to see and adjust OCM1 settings NOTE this menu provides for adjustments which might be needed for different wor
182. TER RELAY io 2 RED 16 LT BLUE PINK 18 86 15 PINK BLACK 18 85 STARTER BROWN LT BLUE 18 F7 PINK DK GREEN 16 vA K DK GREEN 16 15A IGNITION 5 PINK DK GREEN 16 VSW 18 PINK 18 F13 PINK DK GREEN 16 WHITE LT BLUE 18 RED 16 PINK DK GREEN 14 AXI FUS PINK DK GREEN 16 RED LT BLUE 16 85 2al 8 RED TAN 18 86 10A PURPLE LT BLUE 18 F9 RED 10 RED 16 87 POWERRELAY EPR 8MM RING LT BLUE DK BLUE 18 2002CR i RA1 RED 16 N ALTERNATOR PINK WHIIE 18 LT GREEN RED 18 BLK LT GREEN 18 BOSCH IHROTILE PINK YELLOW 16 TAN ORANGE 18 BROWN LT BLUE 18 BLUE WHITE 18 WHITE 18 BLUE PINK 18 ALTERNATOR PURPLE 16 B BLACK 16 RED LT BLUE 16 79 CAN TERM PRV1 FUEL PUMP RELAY RED 16 A 4o UNUSED TAN BLACK 18 85 UNUSED EPR CONNECTOR CAN 56CR GROUND NK YELLOW 16 87 ALTERNATOR PINK TAN 18 86 6MM RING
183. UNUSED 87 RED 16 sar BLACK 10 PINK DK GREEN 18 BROWN LT GREEN 18 BROWNZLT GREEN 18 PINK DK GREEN 18 P K DK GREEN 18 PINK YELLOW 16 PINK YELLOW 16 10MM RING PINK DK GREEN 16 JECTOR 4 1 4 JECTOR 3 Gl1 3 JECTOR 2 Gl1 2 PINK DK GREEN 18 15A FUEL PUMP GROUND 11 JECTOR 1 Gl1 1 M142448AA 2 m uojommorrrx izrm Full Size Rough Terrain Series Models 9241 amp 9250 143905 OUTRIGGER ELECTRIC PANEL 12 PIN CONNECTOR PLUG CN14 PIN 1 04 RED BLUE PIN 2 17 BLUE RED PIN 3 ORG BLK WHT PIN 4 10A BLUE WHITE PIN 5 09 ORANGE RED 7 01 RED BLUE PIN 02 WHITE PIN 9 02 WHITE PIN 10 36A BLACK PIN 11 61 BLACK 1 3 30 Electrical Panel Diagram ANSI CSA Option CONTROL MODULE 2 PIN 9 28 GREEN RED PIN 10 35 BROWNIRED PIN 11 02 WHITE 2x
184. WE AUXILIARY AUXILIARY AUXILIARY _ EXTENSION POWERED EXTENSION N 2 LOWERING LOWERING LOWERING LOWERING MANIFOLD BLOCK MANIFOLD BLOCK x TWOSTAGE 1 VALVE VALE 0 7 VAME On 427 2 HYDRAULIC PRESSURE Es MOTOR RETRACT i P ox 2H 13A4 gt 2949 HIM gt el y e C CUSHION HOLDING 57 04 7 44 Ote Homne TRANSDUCE 97 01 HOLDING Jui L OJE 4 CYLINDER 2 _ VALVE 20 d _ ANE DQ ZA HA m 03 5 _ EXTEND RETRACT EXTEND LIFT LIFT LIFT 4 VALVE VALVE VALVE E CB ORIFICE ORIFICE ORIFICE PRESSURE a ORIFICE x 0 094 z R6 0 094 R5 0 094 z R4 OVERLOAD 0 094 R3 RELIEF CASE DRAIN gt RELEF RELIEF TRANSDUCER gt gt RELIEF RESERVOIR VALVE 7 VALVE t VALVE Lose VALVE m VALVE W n LIFT LINE MBB MANIFOLD C5 BRAKE C7 STEER LIFT LINE CYLINDER CYLINDER MANIFOLD 9 0 v CONTROLLED CONTROLLED 4 CONTROLLED LowernNG LOWERING 0 LOWERING MANIFOLD ORIFICE VALVE biis 0 085 e CYLINDER MB MBI MAIN MANIFOLD MANUAL LOWERING VALVE MANIFOLD 1 LAM i h MANUAL LOWERING VALVE 4H 29A 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 uo
185. WN M129218AD SKYJACK Page 25 Print View This Page Parts List 3 16 Cooler Electrical Panel Diagram ANSI CSA Dual Fuel Engine 85 10A BLU WHT PIN 86 2A BLK RED PIN 87 86D BLK PIN 87a N U REAR LEFT FRONT RIGHT REAR RIGHT 1 1 076 071 072 078 077 oe FRONT LEFT C C JJ e C JJ A J17D mm Cr zm 62 zm 62 63 63 64 oH 64 1 104 104 9 65 El TO OIL COOLER FAN Tle JT 86D BLACK 00 WHITE Te s y Tie E BACK VIEW 55 5 5 5 58 st U uis r eo A E CITTA Rm xm OIL COOLER RELAY 10ACR PIN 30 85A ORGIBLK WHT E M134195AC 2 SKYJACK Page 26 Full Size Rough Terrain Series Models 9241 amp 9250
186. Y with 2 diodes DIODE ASSEMBLY with 4 diodes DIODE ASSEMBLY with 4 diodes DIODE Small DIODE Common MOTOR Powered Extension Platform 12 Volt UNIT Emission Control GM PLUG Engine glow Diesel Fuel Engines FUSE Powered Extension Platform 100 Amp FUSE Inverter Option 200 Amp FUSE Powered Extension Electrical Panel 10 Amp FUSE 20 Amp Dual Fuel Engines FUSE 5 Amp VSW GM FUSE 20 Amp ECM GM FUSE 15 Amp Fuel pump GM FUSE 10 Amp EPR GM FUSE 15 Amp Fuel pump GM FUSE 15 Amp Starter GM FUSE 60 Amp Alternator GM Parts list continued on the following page SKYJACK Page 11 3 4 Electrical Component Parts List Continued Skyjack Parts list continued from the previous page 115384 FAN Oil cooler 126677 FLASHING LIGHT 12 Volt 103743 FLASHER 142302 142309 137138 132884 132883 146652 106370 143527 124047 123629 147229 147229 147229 119375 115658 119296 115658 115658 115658 115658 115658 115658 115658 115658 142308 147125 143518 132804 133133 102838 142315 142299 142340 102863 134432 107098 107098 SKYJACK Page 12 PUMP Fuel GM ALTERNATOR Dual Fuel Engines ALTERNATOR Diesel Fuel Engines LIGHT Glow Plug Indicator Diesel Fuel Engines TIMER Glow Plug Diesel Fuel Engines HORN 12 Volt SOLENOID Hig
187. a below is clear of personnel and obstructions DO NOT exert side forces A ENSURE that there are aerial platform while elevated personnel or obstructions in the path of travel including blind spots DO NOT use the aerial platform as a crane It is prohibited gZ BE AWARE of blind spots when operating the aerial platform DO NOT sit stand or climb on the guardrails It is prohibited STUNT driving and horseplay are prohibited DO NOT climb on scissor arm assemblv It is ENSURE ALL tires are in good condition and lug prohibited nuts are properly tightened DO NOT alter or disable limit switches or other safety devices AWARE of overhead DO NOT use the aerial platform without obstructions or other possible guardrails locking pins and the entry gate chain hazards around the aerial bar in place platform when driving or lifting DO NOT raise the platform while the aerial platform is on a truck fork lift or other device or vehicle BE AWARE of crushing hazards Keep all body parts inside platform guardrail Mid Size amp Full Size SKYJACK Page 11
188. aay GION3TOS H3O9lHInO 72009 NMOG 1481 MEL 9 GL L 4 _ V w qION31OS 99 Sed as 1437 dniNouiigz 70 7 gt t a n lt lt 028 901 31IHA wawa 901 LL Zd 20 Tm 5 LL 01 L d 69 20 04 S zd 07 m OL mE b pe OLNY 20 9 24 6 dn L zn 6 6 ves 6 vd OSE 1 1 ose ose ose ose ase NI NMOHS OOL VOL 4 ose ose HIOOLNO 1NOHJ 1431 ves 1 1497 66 V9 0 ose 3LIHWN33H9 ose 1NOH4 1HOlH LNOH41HDIH 86 v99 Vos vol uv3u 1HOIH est J6 29 WS vor 1481 NMOG 141 96 1 9 vss Voi mS 56 8 69 u N3dO G4SO10 ATIVWHON 99 S3HOLIMS NMOG 6 6 Zd 82 1noino 96 dede m 1491 26 8 V NMOG 16 LL 1 LNOH4 LHD 06 9 c 1
189. ach phase must be completed before the next phase can be carried out All phases must be completed before the aerial platform can be operated IMPORTANT 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 214 7 Connect the Easy Cal tool to the P1 connector on the CONTROL MODULE 8 Thedisplay 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 display will show Access Level Code 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 Cus
190. act to mount dismount platform 1 Use the ladder of aerial platform to access platform 2 Close the gate Ensure there are no loose or missing parts and there is no visible damage Ensure all fasteners are securely in place Ensure all railings are properly positioned and secured Ensure gate is in good working order e Lanyard Attachment Anchors Ensure attachment rings are secure and have no visible damage AC Outlet on Platform Ensure outlet has no visible damage and free from dirt or obstructions SKYJACK Page 24 Platform Railing Platform Assembly Platform Control Console Ensure all switches and controller are returned to neutral and are properly secured Ensure there are no loose or missing parts and there is no visible damage Powered Extension Control Console If Equipped Ensure all switches are returned to neutral and are properly secured Ensure there are no loose or missing parts and there is no visible damage WARNING Ensure that you maintain three points of contact to mount dismount platform 3 Use the ladder to dismount from platform Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Slider Service and Maintenance Inspections Scissor Assembly Scissor Bumper
191. al Inverter Wiring Diagram INV1 D D j View This Page Parts List ELECTRIC PANEL 34CR O O O O VIOLET WIRE cC Gan 34 O O OUS S AC OUTLET c 100 100 POSTIVE NEGATIVE B1 BATTERY C N EXISTING CABLE Full Size Rough Terrain Series Models 9241 amp 9250 143905 c CA gt 9 G G Y S G 9 9 2 2 2 1 e 2 2 2 E TERMINAL BLOCK ANSI CSA 33 M124092AD SKYJACK Page 37 View This Page Parts List 3 28 Engine Wiring Diagram Kubota Diesel Engine gt ENGINE HARNESS FROM
192. any scheduled maintenance inspection procedure refer to service bulletins found in our web site www skyjack com for updates related to service and maintenance of this aerial platform Maintenance and Inspection Death or injury can result if the aerial platform is not kept in good working order Inspection and maintenance should be performed by competent personnel who are trained and qualified on mantenance of this aerial platform WARNING Failure to perform each procedure as pre sented and scheduled may cause death serious injury or substantial damage NOTE Preventive maintenance is the easiest and least expensive type of maintenance e Unless otherwise specified perform each maintenance procedure with the aerial platform in the following configuration Aerial platform parked on a flat and level surface Disconnect the battery by turning the main power disconnect switch to the OFF position e Repair any damaged or malfunction components before operating aerial platform e Keep records on all inspections Maintenance Instructions This manual consists of four schedules to be done for maintaining on an aerial platform Inspection schedule frequency is shown below Inspection Schedule Daily A Frequently A B Annually A B C Bi annually A B C D e Make copies of the maintenance and inspection checklist to be used for each inspection e Check the schedule on the checklist for the type of inspection to be
193. ates that there is not enough difference between the loaded amp empty pressure This message could also occur if the wrong pressure sensor was fitted eg a 5000psi sensor when a 2000psi one is needed This message could occur if the platform were not properly loaded during the STATIC LOADED phase or if the platform were not properly empty during the STATIC EMPTY phase Check CALIBRATIONS HEIGHT CALS the Height indicates the first height at which there was insufficient difference and the Up and Down values show the loaded pressure first and the difference between loaded and empty pressure Second SKYJACK Page 40 Full Size RT s Q Engine Powered Section 4 Troubleshooting Information Service and Maintenance Load Sensing System CE Continued 4 3 33 Flash Code F42 Low Pressure 1 This message indicates that the pressure is too low 0 5V or less when the elevation switch opens during the DYNAMIC lift This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 34 Flash Code F43 High Pressure 1 This message indicates that the pressure is too high 4 5V or more when the elevation switch opens during the DYNAMIC lift This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 35 Flash C
194. atform should fully retract Test Tilt Sensor If Equipped N WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting WARNING Ensure that there are no personnel or obstructions in the path of travel including blind spots 1 Move the aerial platform on to a slope not greater than 4 5 Rocker Switch Drive Steer Low High Throttle Switch lt gt Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button 2 Use the ladder to dismount from platform On control console slowly raise the platform Result When platform reaches an appropriate height a warning signal should sound and platform stop raising as lift and drive controls should be disabled Mid Size amp Full Size Rough Terrain Series SKYJACK Page 33 Function Tests aaa Base Control Console Platform Lower Neutral Section 1 Scheduled Maintenance Raise Switch Emergency Stop Button Lift Enable Pushbutton Emergency Lowering Valve 1 2 2 Base Control Console 1 On engine control console select start position to start the engine Test Emergency Stop 1 Push emergency stop button Result Engine should shut down and aerial platform functions should not operate 2 Pull out
195. aulic System Continued 4 2 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 2 16 All Outriggers Inoperative 1 Stuck or defective outrigger holding valve 2H 17B Check valve Repair or replace if defective 4 2 17 Left Front Outrigger Inoperative 1 Stuck or defective retract valve 4H 71 or extend valve 4H 75 Clean valve Replace if defective 2 Stuck or defective check valve CV5 Check valve Replace if defective 3 Bypassing outrigger cylinder C9 Repack cylinder Replace if defective 4 2 18 Right Front Outrigger Inoperative 1 Stuck or defective retract valve 4H 72 or extend valve 4H 76 Clean valve Replace if defective 2 Stuck or defective Check valve CV6 Check valve Replace if defective 3 Bypassing outrigger cylinder C10 Repack cylinder Replace if defective 4 2 19 Right Rear Outrigger Inoperative 1 Stuck or defective retract valve 4H 73 or extend valve 4H 77 Clean valve Replace if defective 2 Stuck or defective check valve CV7 Check valve Replace if defective 3 Bypassing outrigger cylinder C11 Repack c
196. autions You as a Careful operator are the best insurance against an accidenvt Therefore proper usage of this aerial platform is mandatory The following pages of this manual should be read and understood completely before operating the aerial platform Common sense dictates the use of protective clothing when working on or near machinery Use appropriate safety devices to protect your eyes ears hands feet and body Any modifications from the original design are strictly forbidden without written permission from SKYJACK Electrocution Hazard This aerial platform is not electrically insulated Maintain a Minimum Safe Approach Distance MSAD from energized power lines and parts as listed below The operator must allow for the platform to sway rock or sag This aerial platform does not provide protection from contact with or proximity to an electrically charged conductor DO NOT USE AERIAL PLATFORM AS A GROUND FOR WELDING DO NOT OPERATE AERIAL PLATFORM DURING LIGHTNING OR STORMS DANGER Avoid Power Lines Minimum Safe Approach Distance ANSI SIA A92 6 2006 CE Guidance Note Phase to Phase Feet 0 to 300V Avoid Contact eee Adhere strictly to the governmental rulings Over 50KV to 200 cable i and regulations applicable in your country Over 200KV to 350KV Over 350KV to 500KV Over 500 to 750KV Over 750KV to 1000KV 45 FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS I
197. back into the end of the caliper shaft 13 Depress red knurled knob on brake valve and turn clockwise to a fully open position 14 Remove Wheel blocks Turn emergency main power disconnect switch to ON position Operate drive several times to seat pads to brake disc Mid Size amp Full Size Rough Terrain Series SKYJACK Page 3 Service and Maintenance Section 5 Procedures 5 1 2 Brake Assembly and Disassembly If Equipped NOTE This literature services various models in this brake series The components shown in Diagram 5 3 may appear different than what is found in your brake Disassembly Refer to Diagram 5 3 1 Remove pressure plate from cover by removing cap screws A caution Pressure plate is under spring tension of approximately 1633 kgf 3600 Ib The two cap screws must be loosened evenly to relieve this force If a hydraulic press is available 2041 kgf 4500 Ib minimum the pressure plate can be held in position while removing the cap screws 2 Remove case seal from cover 3 Remove piston from pressure plate 4 Remove o rings and back up rings from piston 5 Before removing stator discs and rotor discs record the stacking arrangement for reassembly purposes Remove stator discs rotor discs return plate and shaft from cover 6 Before removing springs record the pattern and color for reassembly purposes Remove dowel pins springs and spring retainer from cover 7 P
198. be continually blinking learned d h The green LED will flash and then the red LED will turn on solid for 2 seconds Red LED Red LED O Green LED Green LED y y RedLED gt lt Red LED Green LED Green LED C J A Results The switch is verifying the new zero position SKYJACK Page 14 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures i The green LED will turn on solid Results The switch is ready for normal Service and Maintenance Red LED OS Green LED 24 operation 9 Turn main disconnect switch to TOL off position 10 Pushin emergency stop buttons 11 Remove chock or wheel blocks 12 Proceed to Test and Verify Tilt Circuit Mid Size amp Full Size Rough Terrain Series Test and Verify Tilt Circuit Set up button is located on this Light Indicators face next to harness Operations of Tilt Switch The following describes the LED s and what they indicate Illuminated whenever both tilt axes are within the specified degrees of the zero home learned position Flashes when transitioning in or out of tilt angle limits but built in time delay has not fully occurred Illuminated whenever tilt on one Red LED or more axes 15 more than the specified degrees out from the zero home position Green amp Red LED On together no blinking when fault detected Ti
199. ch Replace if defective 5 Loose or broken wire 68A from outrigger limit switch LS68 to outrigger control module at pin P2 1 Check continuity Replace if defective 6 Loose or broken wire 10A from outrigger board to outrigger limit switch LS67 Check continuity Replace if defective SKYJACK Page 20 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 7 Defective outrigger limit switch LS67 Check switch Replace if defective 8 Loose or broken wire 67A from outrigger limit switch LS67 to outrigger control module at pin P2 2 Check continuity Replace if defective 9 Loose or broken wire 10A from outrigger board to outrigger limit switch LS66 Check continuity Replace if defective 10 Defective outrigger limit switch LS66 Check switch Replace if defective 11 Loose or broken wire 66A from outrigger limit switch LS66 to outrigger control module at pin P2 3 Check continuity Replace if defective 12 Loose or broken wire 10A from outrigger board to outrigger limit switch LS65 Check continuity Replace if defective 13 Defective outrigger limit switch LS65 Check switch Replace if defective 14 Loose or broken wire 65A from outrigger limit switch LS65 to outrigger control module at pin P2 4 Check continuity Replace if defective 15 Check for power on wire 65 at outrigger control module at pin P2 8 voltage
200. ck continuity Replace if defective 9 Loose or broken black wire from engine ground to ECU connector pin 69 and 81 Check continuity Replace if defective 10 Loose or broken light blue pink wire from GM engine connector 1 to relay 2 Check continuity Replace if defective 11 Loose or broken pink black wire from ECU connector pin 89 to relay 32ACR Check continuity Replace if defective 12 Defective relay 32ACR Check relay Replace if defective 13 Loose or broken red wire from battery positive to starter fuse F12 Check continuity Replace if defective SKYJACK Page 8 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 14 Defective fuse 12 Check fuse Replace if defective 15 Loose or broken red tan wire from fuse F12 to relay 32ACR Check continuity Replace if defective 16 Loose or broken white wire from relay 32ACR to start solenoid 32BCR Check continuity Replace if defective 17 Defective starter solenoid 32BCR Check solenoid Replace if defective 18 Loose or broken battery cable from starter solenoid 32BCR to starter motor Check continuity Replace if defective 19 Defective starter motor Check motor Repair or replace if defective 4 1 7 Engine will Not Crank from Base Controls GM dual fuel 1 Loose or broken wire 10A from base terminal block TB1 to engine harness
201. d 77 ver VOL GIONJIOS3AWA 6 200 SNIH3MOT NIVIA T 1 gt szoa GIONTIOS gt szoa 3ATVA 7 gt GIONSIOS gz 9200 1 gt 2 I 9200 INYA Y cam eam 9c 4 4 T T T 4 20 4 1 00 OL 02 20 00 00 0 1 00 00 74 NHOH 4 ve Ist 8 2 NO amod AVIJHNHOH 62 um L E EN AZLAHVIIXnv zz 4 e 96 096 GIONTIOS 2 2158 85 AHVHIXQV V 16 GION310S m ONIGIOH 0 AON3 H3NW3 Xnv GIONJIOS3AWA gi 185 voz i 4 NITION W31SAS 90 m AONSOH3IA3 189 INYA 00 Wood 18 9 103NNOOSIG 15
202. defective 4 1 24 Second Drive Speed Inoperative 1 Defective second speed switch 57 1 in joystick 57 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 platform terminal block Check continuity Replace if defective 4 Loose or broken wire 19 from platform terminal block to diode D19 at relay 35CR Check continuity Replace if defective 5 Loose or Open diode D19 Tighten diode Check diode Replace if defective 6 Loose or broken wire 10A from base terminal block to high drive tilt override limit switch LS5 Check continuity Replace if defective Full Size RT s SKYJACK Page 17 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Misadjusted or defective high drive tilt override limit switch LS5 Adjust switch Replace if defective Loose or broken wire 35 from high drive tilt override limit switch LS5 to base terminal block Check continuity Replace if defective Loose or broken wire 35 from base terminal block to relay 35CR Check continuity Replace if defective Loose or broken wire 02 from relay 35CR to base terminal block Check continuity Replace if defective Defective relay 35CR Check relay Replace i
203. e 1 from relay 28CR ANSI CSA 28CR1 CE to pin 7 on connector CN14 at the outrigger board Check continuity Replace if defective Left rear outrigger limit switch LS64 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Right rear outrigger limit switch LS63 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Right front outrigger limit switch LS62 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Left front outrigger limit switch LS61 is out of adjustment or defective Check continuity through switch Adjust switch if out of adjustment Replace if defective Defective drive enable relay 61CR Check relay Replace if defective Loose or broken wire 4 from pin 1 on connector CN14 at the outrigger board to relay 30CR Check continuity Replace if defective 4 1 18 Brakes will Not Release 1 Loose or broken wire 30 from diodes D15A 2 and D16A 2 to relay 30CR Check continuity Replace if defective 2 Defective relay 30CR Check relay Replace if defective 3 Loose or broken wire 02 from relay 30CR to base terminal block TB 1 Check continuity Replace if defective 4 Loose or broken wire 4 from pin 1 on plug CN14 at outrigger board to relay 30CR Check continuity Replace if defective
204. e aerial platform if it is not on firm level surface Do not drive elevated near depressions or holes of any type loading docks debris drop offs and surfaces that may affect the stability of the aerial platform If operation in areas with holes or drop offs is absolutely necessary elevated driving shall not be allowed Position the aerial platform horizontally only with the platform fully lowered After ensuring that all 4 wheels or outriggers if equipped have contact with level firm surface the aerial platform can be elevated Af ter elevation the drive function must not be activated Elevated driving must only be done on a firm level sur face DO NOT ascend or descend a grade when elevated When fuly lowered ascending or descending only grades up to rated maximum listed in Table 2 1 are permissible DO NOT operate on surfaces not capable of holding the weight of the aerial platform including the rated load e g covers drains and trenches SKYJACK Page 10 Mid Size amp Full Size Rough Terrain Series Operator s Responsibility for Maintenance Service and Maintenance Safety Precautions Continued Know and understand the safety precautions before going on to next section DO NOT operate an aerial platform that has ladders scaffolding or other devices mounted on it to increase its size or work height It is DO NOT lower the platform prohibited unless the are
205. e checked weekly with a calibrated gauge If the measured pressure is less than the specification reinflate to the pressure specified below Tires must not be inflated above the recommended specification Do not intermix tires of different types on one aerial platform Use only tires of type originally supplied Fill Specification Tire Size Fill Ply Pressure Factory Type Rating kPa 10 16 5 75 6A 10 CARLISLE US LOADER EM 517 1 46A 10 16 5 OTR OUTRIGGER Air 10 5 Non Marking 517 1 31 15 5 15 45 GOODYEAR TERRA XTRAC 310 3 6F 10 16 5 OTR I En 10 Non Marking NX 31 15 5 15 GOODYEAR TERRA XTRAC 7 Factory preset 20 C Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal 10 16 5 CARLISLE US LOADER Foam 60378AE ANSI R conditions t Usage S tandard Or O ptional N A Not Available Backspace Rim Backspace Diagram Inboard Outboard Backspace Rim Size Contact Skyjack Service Serial Number Department 6 8 6F 7 amp FTF All models are 4 3 8 60380AC ANSI SKYJACK Page 10 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 3b Tire Specifications CE WARNING Air pressure can affect stability Temperature changes can affect air pressure is important to visually in
206. e is nothing wrong on the gasoline side of the system Disconnect fuel pump to test propane side Loose or broken wire 10A from engine harness plug to fuel select switch 533 Check continuity Replace if defective Defective fuel select switch 533 Check switch Replace if defective Loose or broken wire 50 from fuel select switch S33 to GM engine connector 1 Check continuity Replace if defective Loose or broken tan brown wire from GM engine connector 1 to ECU connector pin 42 Check continuity Replace if defective Loose or broken pink tan wire from fuse F7 to propane lock off 2P 56 Check continuity Replace if defective Loose or broken white black wire from ECU connector pin 75 to propane lock off 2P 56 Check continuity Replace if defective Defective propane lock off 2P 56 Check lock off Replace if defective Loose or broken pink dark green wire from fuse F10 to fuse F9 Check continuity Replace if defective Defective fuse F9 Check fuse Replace if defective Loose or broken red light blue wire from fuse F9 to propane regulator PRV1 Check continuity Replace if defective Loose or broken black wire from engine ground to propane regulator PRV1 Check continuity Replace if defective 4 1 14 Mid Throttle Inoperative on demand GM Dual Fuel 1 2 3 4 5 Open diode D17A or D18A Check diode Replace if defective Loose or broken wire 33 from base terminal block TB1 to engine harness
207. e scheduled maintenance inspections by areas checking each item in sequence for the conditions listed in this section e hydraulic tank filter fittings hoses emergency power unit if equipped and base surfaces AN WARNING e engine compartment fittings hoses main 5 pump filter To avoid injury do not operate an aerial e hydraulic cylinders platform until all malfunctions have been all hydraulic manifolds corrected underside of the base ground area under the aerial platform N WARNING Outriggers To avoid possible injury ensure aerial platform power is off during your visual and daily maintenance inspections 1 1 1 Labels Refer to the labels section in this manual and determine that all labels are in place and are legible Electrical Maintaining the electrical components is essential to good performance and service life of the aerial platform 1 1 2 Limit Switches Detecting limit switch malfunction is essential to safe aerial platform operation Ensure limit switches are properly secured with no signs of visible damage and i movement is n r Inspect the following areas for chafed corroded and loose wires base to platform cables and wiring harness engine compartment electrical panel e engine wiring harness hydraulic electrical wiring harnesses Visually inspect all limit switch located inside the scissor arms and the outrigger assemblies for the following broken
208. e sure the machine is parked on level ground i 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 SKYJACK Page 34 Full Size RT s Q Engine Powered Section 4 Troubleshooting Information Service and Maintenance Hydraulic System Continued With the engine running machine in drive mode engine on high idle high torque selected and low speed range selected hold the enable switch on the joystick and push the joystick forward as if you were to drive forward This provides torque from the drive motor to the unreleased brake v Ifthe 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 2 11 Brake Drags or Runs Hot Internal Brake 1 Low brake pressure Place pressure gauge in brake line Brakes use system pressure Minimum 335 psi required 2 Bearing failure If the bearing should fail a large amount of drag can be generated Replace bearing 4 2 12 Up Circuit Inoperative 1 Stuck or defective lift valve 2H 14B Check valve Repair or replace if defective 2 Stuck check valve Check valve Replace if defective 3 Misadjusted or defective lift relief valve R2 Adjust valve Replace if defective 4
209. el 2 21 MOD IDE LIB L uuu u 31 4 1 51 Auto All Up Inoperative Retract 32 Hydraulic System ael AlFunchons Nopera 33 O S 33 4 2 3 Steer and First Drive Speed 000000000 raras 2 4 2 4 Lift and Second Drive Speed 4 4 29 Non RaR A aS 33 42 2 8 23 34 Forward a asia Hp nema ic ae elo 34 34 4 2 9 Brakes will Not Release Internal 34 es ogee ail pit dels Brokaj u et 34 42 11 Brake Drags Runs Hot Internal Brake 35 Up wes ls i oom 35 2213 DEM D um tu 35 42 14 Powered Extension Platform Inoperative 35 4 2 15 Hydraulic Generator U LU 36 CIN 36 42 17 Len Fron Outrigger pri TTD I LI INI NENNEN 36 Right Front ISI IPTE 36 4 2 49 Hear Outrigger pa cas parade PERCHE
210. er s recommendations All personal fall protection equipment must be at tached only to approved anchorage points within the platform of the aerial platform WARNING Entering and exiting the aerial platform should only be done using the three points of contact Use only equipped access openings Enter and exit only when the aerial platform is in the fully retracted position Do use three points of contact to enter and exit the platform Enter and exit the platform from the ground only Face the aerial platform when entering or exiting the platform Three points of contact means that two hands and one foot or one hand and two feet are in contact with the aerial platform or the ground at all times during entering and exiting N WARNING An operator should not use any aerial platform that does not appear to be working properly has been damaged or appears to have worn or missing parts has alterations or modifications not approved by the manufacturer has safety devices which have been altered or disabled has been tagged or blocked out for non use or repair Failure to avoid these hazards could result in death or serious injury Jobsite Inspection Do not use in hazardous locations Perform a thorough jobsite inspection prior to operating the aerial platform to identify potential hazards in your work area Be aware of moving equipment in the area Take appropriate actions to avoid collision
211. erial platform should move slower than when it was in stowed position SKYJACK Page 32 Section 1 Scheduled Maintenance ocker Switch Drive Steer Low High Throttle Switch Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button Test Lowering Warning CE Select off lift drive key switch to lift position Fully lower the platform Result Platform should stop lowering at an approximate height of 2 5 meters and an alarm should sound Release platform raise off lower switch ensure area around scissor 15 clear then continue lowering the platform 4 Lower the platform fully Test Powerdeck Enable If Equipped 1 Select and hold extend retract switch to the EM extend position without selecting S enable switch Result Platform should not extend Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Function Tests Drive Steer Enable Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton Test Extension Platform s If Equipped 1 Extend each extension platform to about 30 5 Result Each extension platform should extend 2 Retract each extension platform fully Result Each extension pl
212. es ve vol vol 2 4 01 CN voL vor va lt e wawa vee A 50 y gt gt LO 4 N 9 55 lt S gets col v vie vie 551 z cn 5 L mE 20 v2 vz 80 N 0 LO VLA HOLIMS L AUVO3N 4018 AON3 H3W Becr 10H1NOO O AONI HINI 1 u o 5 ST View Parts List Print This Page ine th GM Dual Fuel Eng IONS WI 3 35 Electrical Schematic ANSI CSA amp AS No Opt gt j N LO e o LES
213. est ses 01 59 t ATIVWHON S3HOLIMS LINN H399Iu1n0 e ve 27 ovo 7 vor GION3 0 a s LOL e 1 TDi vi o 001 Y SNITI3A31 H3D9IHLA dd ag 99 ob HH 99 33 aa 1 86 ovig ana ve 14m 5 18 LHOWIHOI 26 1HOlH 248 96 St si Si ius 56 9 9 5 25 1 aue ps ovig aau 43345 que 6 945 7 ver voi o gt _ 22 GIONTIOS ag TIVWS ver lz GIONSIOSSAWA 6 1 8 1431 vee n H oz GIONSIOS INYA 06 02 200 16 1H lH VEZ Hr vee 0 gt eis H3TIOHINOO GION310S 3ATVA 98 7 4 MOLLSAOP gorup 99 vol vol v0 45 3908 88 26 gt I evela wa LIM S3NIHOVIA 81 700 310N 78 17 26 TM Vot i 4 GION3IOS 3AWA 1 V 21 200 i i 5 38019 ATIVIAMON 991
214. et 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 SKYJACK Page 16 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 4c Floor Loading Pressure AS Total Aerial Platform Total Aerial Platform Load min 7127 max 7127 min Outrigger Pads max min 7135 max 7135 min Outrigger Pads max min 8243 max 8243 min Outrigger Pads max min 8850 max 8850 min Outrigger Pads max min 8831 max 8831 min Outrigger Pads max min 8841 max 8841 min Outrigger Pads max min 9250 Outrigger Pads max 60379AE AS min Total aerial platform weight with no options with air filled tires max Aerial platform weight all options 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 w
215. ever use a malfunctioning aerial platform If malfunctions are discovered aerial platform must be tagged and placed out of service Repairs to aerial platform may only be made by a qualified service technician After repairs are completed operator must perform a inspection and a series of function tests again before putting aerial platform into service Prior to performing function tests be sure to read and understand Section 2 10 Start Operation of the operating manual 1 2 1 Platform Control Console 1 Turn main power disconnect switch to position on 2 Onbase control console pull out stop button Section 1 Scheduled Maintenance Rocker Switch Drive Steer Low High Throttle Switch Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button For CE select off platform base key switch to JA platform position On engine control console select off on start switch to on position For ANSI CSA with dual fuel engine select fuel 2 supply by moving fuel switch to either gasoline liquid propane gas position WARNING Ensure that you maintain three points of contact when using the ladder to mount dismount platform Use the ladder of aerial platform to access platform Close the gate On platform control console insert key into off lift drive key s
216. f defective Loose or broken wire 17 from relay 35CR to relay 17CR Check continuity Replace if defective Defective relay 17CR Check relay Replace if defective Loose or broken wire 02 from relay 17CR to base terminal block Check continuity Replace if defective Loose or broken wire 10A from base terminal block to relay 17CR Check continuity Replace if defective Loose or broken wire 17A from relay 17CR to base terminal block Check continuity Replace if defective Loose or broken wire 17A from relay 17CR to relay 17ACR Check continuity Replace if defective Defective relay 17ACR Check relay Replace if defective Loose or broken wire 02 from relay 17ACR to base terminal block Check continuity Replace if defective Loose or broken wire 17A from base terminal block to large pump dump valve solenoid 2H 17A Check continuity Replace if defective Loose or broken wire 02 from large pump dump valve solenoid 2H 17A to base terminal block Check continuity Replace if defective Defective large pump dump valve solenoid 2H 17A Check solenoid Replace if defective 4 1 25 Third Drive Speed Inoperative 1 High Low torque switch 41 in high torque position or defective Turn high low torque switch to low torque position Replace if defective 2 Defective third speed switch S7 6 in joystick 57 Check switch Replace if defective 3 Defective joystick S7 Check joystick Replace if de
217. failure of OCM1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module 60416AA Full Size RT s SKYJACK Page 29 Engine Powered Service and Maintenance Electrical System Continued 4 1 45 Left Front Outrigger Inoperative Manually l 2 Defective left front outrigger switch S20 at platform or S20A at base Check switch Replace if defective Loose or broken wire 71 from outrigger control console to pin 6 on connector 20 at outrigger board retract or from wire 75 to pin 7 extend Check continuity Replace if defective Open diode D71 retract or D75 extend on outrigger board Check diode Replace if defective Loose or broken wire 71 from pin 7 on connector CN21 at outrigger board to valve coil 4H 71 retract or wire 75 from pin 8
218. fective 4 Loose or broken wire 18B from controller S7 6 to low high torque switch 941 Check continuity Replace if defective 5 Loose or broken wire 18 from low high torque switch S41 to platform terminal block Check continuity Replace if defective 6 Loose or broken wire 18 from platform terminal block to relay 18CR Check continuity Replace if defective 7 Defective relay 18CR Check relay Replace if defective 8 Loose or broken wire 02 from relay 18CR to base terminal block Check continuity Replace if defective SKYJACK Page 18 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 9 10 11 12 Loose or broken wire 10A from base terminal block to relay 18 Check continuity Replace if defective Loose or broken wire 18A from relay 18CR to small pump dump valve 2H 18A Check continuity Replace if defective Loose or broken wire 02 from small pump dump valve 2H 18A to base terminal block Check continuity Replace if defective Defective small pump dump valve solenoid 2H 18A Check solenoid Replace if defective 4 1 26 High Low Range Speed Inoperative 1 2 3 10 11 12 13 14 Loose or broken wire 12 from joystick enable switch 57 7 to high low range switch S29 Check continuity Replace if defective Defective high low range switch S29 Check switch Replace if defect
219. ff drive switch S3 to lift enable switch S9 Check continuity Replace if defective 3 Defective lift enable switch 59 Check switch Replace if defective 4 Loose or broken wire 9A from enable switch S9 to up down switch 95 Check continuity Replace if defective 5 Defective up down switch S5 Check switch Replace if defective Full Size RT s SKYJACK Page 19 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 13 Loose or broken wire 14 from up down switch 55 to relay 14 ANSI CSA Check continuity Replace if defective Loose or broken wire 14 from up down switch S5 to diode D14 at base terminal block TB 1 CE Check continuity Replace if defective Loose or Open diode D14 CE Tighten diode Check diode Replace if defective Loose or broken wire 14D from base terminal block to relay 14DCR CE Check continuity Replace if defective Loose or broken wire 02 from relay 14CR ANSI CSA or 14DCR CE to base terminal block Check continuity Replace if defective Defective relay 14CR ANSI CSA or 14DCR CE Check relay Replace if defective Loose or broken wire 36A from pin 10 on connector CN14 at the outrigger board to terminal block TB 1 Check continuity Replace if defective Loose or broken wire 36A from termi
220. following points should be kept in mind when working on the hydraulic system or any component 1 Any structure has limits of strength and durability To prevent failure of structural parts of hydraulic components relief valves which limit pressure to safe operating values are included in the hydraulic circuits Tolerance of working parts in the hydraulic system is very close Even small amounts of dirt or foreign materials in the system can cause wear or damage to components as well as general faulty operation of the hydraulic system Every precaution must be taken to assure absolute cleanliness of the hydraulic oil Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles or foreign materials in the system drain and flush the entire system and replace the filter cartridges A complete change of oil must be made under these circumstances Whenever the hydraulic system is drained check the magnets in the hydraulic reservoir for metal particles If metal particles are present flush the entire system and add a new change of oil The presence of metal particles also may indicate the possibility of imminent component failure A very small amount of fine particles is normal 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
221. form TOGGLE SWITCH Left Front Outrigger Up down SWITCH Front left outrigger up down toggle TOGGLE SWITCH Right Front Outrigger Up down SWITCH Front right outrigger up down toggle TOGGLE SWITCH Right Rear Outrigger Up down SWITCH Rear right outrigger up down toggle TOGGLE SWITCH Left Rear Outrigger Up down SWITCH Rear left outrigger up down toggle SWITCH Auto Level Outrigger N O CONTACT Low high range Platform SWITCH Engine off on Engine panel 147053 102853 102853 102853 147054 147054 147054 102853 127132 102853 127132 102853 127132 102853 127132 102853 147054 124446 4 4 2 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Parts list continued on the following page Full Size Rough Terrain Series SKYJACK Page 13 Models 9241 amp 9250 143905 3 4 Electrical Component Parts List Continued Skyjack 102853 115574 102853 102853 114373 103141 103141 143743 113400 143827 103336 SKYJACK Page 14 1 1 Ll Parts list continued from the previous page SWITCH Engine glow plug Engine panel Diesel Fuel Engines SWITCH Gas Propane Fuel Select Toggle GM TOGGLE SWITCH Front powered platform enable TOGGLE SWITCH Rear powered platform enable TOGGLE SWITCH High Low Torque Platform N O CONTACT Emergency lowering switch CE Model 9250 N O CONTACT
222. form Scheduled Maintenance Inspection every 2 years Refer to Section 1 0 of this manual Perform scheduled inspection every three months or 150 hours T Refer to Skyjack s webiste www skyjack com for latest service bulletins prior to performing quarterly or yearly inspection Note copy of this page or visit the Skyjack web site www skyjack com for a printable copy Mid Size amp Full Size Rough Terrain Series SKYJACK Page 17 A Service and Maintenance Inspections Section 1 Scheduled Maintenance Model 71xx Model 88xx Platform Control Console Platform Assembly Scissor Assembly Limit Switch M CS 4 Hs EPOR eS 572 lt b XS SN wil A i S Outrigger Ladder Electrical Hydraulic Ladder Electrical Hydraulic m Compartment Compartment Limit Switch 1 1 Scheduled Maintenance Inspections Perform a visual inspection around the following Begin th
223. fting device as required Install wheel nuts or wheel bolts and hand tighten to center the rim Torque nuts or bolts to approximately 50 ft lb using the tightening sequence in procedure 5 1 7 Torque again to 100 ft lb using the same sequence Torque again to 140 ft lb using the same sequence Repeat the tightening sequence to confirm that none have changed from 140 ft lb If any are found below 140 ft lb repeat complete sequence until there is no change in torque values If possible drive the machine prior to checking torques Check torque values after 8 hours of operation and then at weekly intervals Mid Size amp Full Size Rough Terrain Series SKYJACK Page 9 Service and Maintenance Section 5 Procedures SKYJACK Page 10 5 1 9 Front Axle Hub Procedure 8 Flip hub over and then remove and discard inner For front axle hub components refer to your aerial bearing cone item 8 and grease seal item platform s parts manual 10 9 Remove and discard both inner and outer bearing cups items 6 amp 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 using information found in page 2 for further instructions 11 Press new bearing cups items amp 8 into hub 12 Pack replacement inner and outer bearings by either pressing wheel bearing grease
224. fuse Replace if defective Loose or broken pink dark green wire from fuse F10 to ignition coil IGC1 pin D Check continuity Replace if defective Loose or broken black wire from ignition coil GC1 pin C to engine ground Check continuity Replace if defective Defective ignition coil IGC1 Refer to section 5 of this manual for Ohm specifications Replace if defective Loose or broken pink dark green wire from fuse F10 to gas injectors Gl 1 2 GI 3 and GI 4 Check continuity Replace if defective Loose or broken pink white wire from ECU connector pin 82 to throttle actuator Check continuity Replace if defective Loose or broken tan orange wire from ECU connector pin 83 to throttle actuator Check continuity Replace if defective Loose or broken light green red wire from ECU connector pin 19 to throttle actuator RA1 Check continuity Replace if defective Loose or broken black light green wire from ECU connector pin 20 to throttle actuator RA1 Check continuity Replace if defective Loose or broken light blue dark blue wire from ECU connector pin 6 to throttle actuator RA1 Check continuity Replace if defective FUEL RELATED PROBLEMS GASOLINE ONLY 16 17 18 19 20 21 22 2 24 29 26 Loose or broken pink tan wire from fuse F7 to fuel pump relay 56CR Check continuity Replace if defective Loose or broken red wire from battery positive to fuel pum
225. h Terrain Series Section 5 Procedures 5 2 6 Fuse Block Layout GM Service and Maintenance cr 2002CR POWER RELAY 56CR 32ACR FUEL STARTER PUMP RELAY RELAY EMPTY F7 F8 5 AMP 20 AMP VSW ECU F11 F10 EMPTY 15 AMP 15 AMP FUEL PUMP IGNITION F9 F12 10 AMP 15 AMP F13 60A ALT EPR STARTER Mid Size amp Full Size Rough Terrain Series SKYJACK Page 21 Service and Maintenance Section 5 Procedures 5 2 7 Kubota Dual Fuel DF972 Resistance Checks Resistance of Pick Up Sensor 1 Disconnect connector from sensor 2 Measure the resistance with an ohmmeter 3 If resistance is not within factory specifications replace Resistance paci I 1 85 to 2 45 at 20 Specification Resistance of Ignition Coil A 1 Disconnect connector from ignition coil 2 Measure the resistance with an ohmmeter 3 l fresistance is not within factory specifications replace it T 1 87 to 2 530 at 20 C esistance E Specification 10 4 to 15 6Q at 20 A Terminal C High Tension Cord B Terminal Factory Resistance of Ignitor 1 Disconnect connector from ignitor 2 Measure the resistance with ohmmeter 3 If resistance is not within the factory specifications replace it omo IMPORTAN
226. h Throttle Diesel Fuel Engines COIL Ignition GM INVERTER 1500 WATT 110 220V CE INVERTER 1500 WATT ANSI SIA amp CSA POWER INDICATOR LIGHT Platform control console POWER INDICATOR LIGHT Base control console POWER INDICATOR LIGHT Platform control console LIMIT SWITCH 26 Ft lift Cut out LIMIT SWITCH End of stroke LIMIT SWITCH Elevation High Speed Cut out LIMIT SWITCH Outrigger Left Front Up LIMIT SWITCH Outrigger Right Front Up LIMIT SWITCH Outrigger Right Rear Up LIMIT SWITCH Outrigger Left Rear Up LIMIT SWITCH Outrigger Left Front Down LIMIT SWITCH Outrigger Right Front Down LIMIT SWITCH Outrigger Right Rear Down LIMIT SWITCH Outrigger Left Rear Down MOTOR Engine starter Dual Fuel Engines MOTOR Engine starter Diesel Fuel Engines SENSOR Manifold Absolute Pressure GM MODULE Outrigger Auto Level Control LIGHT Outrigger Indicator OIL PRESSURE SWITCH Diesel Fuel Engines SENSOR Heated exhaust oxygen GM SENSOR Oxygen post cat GM PROPANE REGULATOR VAPORIZER GM PRESSURE SWITCH option trips at 2400 psi TRANSDUCER Pressure CE ACTUATOR Throttle Body Dual Fuel Engines LIGHT Optional rotating amber beacon BEACON Rotating Amber Option Parts list continued on the following page Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 4 Electrical Component Parts List Continued Skyjack er o Parts list continued from the p
227. h in emergency stop button Result Engine should shut down and aerial platform functions should not operate Test Lift Enable 1 Pull out emergency stop button 2 Restart the engine 3 Select and hold raise off lower switch to raise position without pressing lift enable pushbutton Result Platform should not rise Mid Size amp Full Size Rough Terrain Series SKYJACK Page 29 Function Tests Section 1 Scheduled Maintenance Drive Steer Enable ocker Switch Trigger Switch Z Drive Steer Torque Switch Low High Throttle Switch Low High Speed Range m Switch Operation Light Horn Raise Off Lower Pushbutton Switch Glow Plug Choke Pushbutton Engine Start Pushbutton Emergency Stop Butt Lift Enable md Pushbutton Off Lift Drive Key Switch Test Platform Raising Lowering 3 Select off lift drive key switch to drive position IV WARNING Be aware of overhead obstructions 4 Without activating C4 enable trigger or other possible hazards around the switch attempt to drive and steer the aerial aerial platform when lifting platform Result Drive and steer functions should 1 Pressandhold enable pushbutton not operate then select and hold raise off lower j Test Steering switch to 5 raise position and raise the platform to an approximate height of 1 Activate and h
228. he 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 amp 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 bu
229. ic Generator Inoperative 1 Key switch S3 in drive position Turn switch to lift position 2 Loose or broken wire 9 from base terminal block TB 1 to generator relay 86 Check continuity Replace if defective 3 Loose or broken wire 9 from generator relay 86BCR to generator switch 12 Check continuity Replace if defective 4 Defective generator switch S12 Check switch Replace if defective 5 Loose or broken wire 85 from generator switch 12 to generator relay 86ACR Check continuity Replace if defective 6 Loose or broken wire 85 from generator relay 86ACR to generator relay 86BCR Check continuity Replace if defective 7 Loose or broken wire 86B from generator relay 86ACR to generator relay 86BCR Check continuity Replace if defective 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 relay 17CR Check continuity Replace if defective 12 Loose or broken wire 2A from relays 10ACR2 and 86BCR to relay Check continuity Replace if defective 13 Loose or broken wire 85A from circuit breaker CB4 to relay 86BCR Check continuity Replace if defective 14 Tripped or defective circuit breaker CB4 Reset circuit breaker Replace if defective SKYJACK Page 26 Full Size RT s Engine P
230. if defective 4 1 12 Engine Cranks but will Not Start Kubota diesel 1 2 3 4 Loose or broken wire 37 from base terminal block to diesel valve solenoid 2D37 Check continuity Replace if defective Loose or broken wire 57 from starter contactor 32ACR to diesel valve solenoid 2D37 Check continuity Replace if defective Defective fuel valve solenoid 2D37 Check solenoid Replace if defective Defective glow plug circuit See glow plugs inoperative above Repair if necessary 4 1 13 Engine Cranks but will Not Start GM dual fuel NOTE For additional engine troubleshooting refer to diagnostic trouble codes for use with the check engine light Loose or broken red wire from battery positive to relay 2002CR Check continuity Replace if defective 2 Loose or broken red tan wire from ECU fuse 8 to relay 2002CR Check continuity Replace if defective 3 Loose or broken white light blue wire from ECU connector pin 71 to relay 2002CR Check continuity Replace if defective 4 Defective relay 2002CR Check relay Replace if defective 5 Loose or broken pink dark green wire from relay 2002CR to ignition fuse F10 Check continuity Replace if defective SKYJACK Page 10 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 6 7 8 9 10 11 12 13 14 15 Defective fuse F10 Check
231. ithstand 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 Mid Size amp Full Size SKYJACK Page 17 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 5 Rough Terrain Scissor Fluids AXLE Oil Type Recommended Equivalent Oil 0 634 Gear Oil 80W 90 GL5 Front Rear Axle Type Chevron Gear Lubricant Delo ESI 80W 90 Caltex Gear Lubricant ESI 80W 90 Cushman Rear 1 0 264 Gear Oil ESI 80W 90 Caltex RPM Borate EP 80W 90 Texaco Star Gear Lubricant 80W 90 All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water CENTER DRIVE OIL P Qty Qty ter D T Recommended E alent Oil Center Drive Type Liters Gallons Oil Type mmen quivalent Oi Gear 80w 90 GL5 All fuel capacity quantities are in standard liter or US gallons liquid Use distilled water and 50 50 mix of anti freeze water HYDRAULIC OIL Qty Qty Liters Gallons SJRT 6
232. ive Loose or broken wire 20B from high low range switch S29 to high low torque switch 41 Check continuity Replace if defective Defective high low torque switch S41 Check switch Replace if defective Loose or broken wire 20 from high low torque switch S41 to relay 20CR Check continuity Replace if defective Defective relay 20CR Check relay Replace if defective Loose or broken wire 02 from relay 20CR to base terminal block Check continuity Replace if defective Loose or broken wire 10A ANSI CSA or wire 10C CE from base terminal block to relay 35CR Check continuity Replace if defective Defective relay 35CR Check relay Replace if defective Loose or broken wire 44 from relay 35CR to relay 20CR Check continuity Replace if defective Loose or broken wire 20A from relay 20CR to base terminal block TB 1 Check continuity Replace if defective Loose or broken wire 20A from base terminal block to series parallel valve coil 20 Check continuity Replace if defective Defective series parallel valve coil 3H 20A Check coil Replace if defective Loose or broken wire 02 from series parallel valve coil 3H 20A to base terminal block Check continuity Replace if defective 4 1 27 Up Circuit Inoperative from Platform or Base 1 Lift Off Drive switch 53 in drive position or defective Select lift position Check switch Replace if defective 2 Loose or broken wire 09 from lift o
233. ive Full 7 9m Full 7 9 m Tires Refer to Table 2 6 for tire specification and usage Elevated Drive 0 56 km h 0 97 km h 0 72 km h Kubota Diesel 1400 Low 2800 High 1400 Low 2800 High Engine RPM 60348 Weights approximate refer to serial nameplate for specific weight Values shown for standard 4WD aerial platforms on air tires with a manual extension platform Models 7127 amp 7135 and no extension platforms Models 8831 amp 8841 For models 9241 amp 9250 values shown are for standard 4WD on foam tires with two powered extension platforms Mid Size amp Full Size SKYJACK Page 3 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1 Specifications and Features AS Mid Size RTs Full Size RTs We 4 456 5 Platform Size 1 63 x 2 97 m 1 64 x 2 93 m 1 73 x 339 1 88 x 4 27 m wem sem wim vem em mm oen ura mre een asm mem memes vum wem 201m Refer to Table 2 6 for tire specification and usage REEL NENNEN 11217272779 Kubota Diesel 1400 Low 2800 High 60348 5 Weights approximate refer to serial nameplate for specific weight Values shown for standard 2WD aerial platforms foam filled tires with a manual exte
234. ize RT s SKYJACK Page 21 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 29 Platform will Not Lift from Platform or Base Controls with Outriggers Retracted 1 2 10 11 12 13 14 15 lift operates correctly with outriggers extended Outriggers not fully retracted Fully retract outrigger cylinders Loose or broken wire 1 from relay 28CR ANSI CSA or 28CR1 CE to pin 7 on connector CN14 at the outrigger board Check continuity Replace if defective Loose or broken wire 1 from outrigger board to outrigger limit switch LS64 Check continuity Replace if defective Defective outrigger limit switch LS64 Check switch Replace if defective Loose or broken wire 64 from outrigger limit switch LS64 to outrigger board Check continuity Replace if defective Loose or broken wire 64 from outrigger board to outrigger limit switch 1563 Check continuity Replace if defective Defective outrigger limit switch LS63 Check continuity Replace if defective Loose or broken wire 63 from outrigger limit switch LS63 to outrigger board Check continuity Replace if defective Loose or broken wire 63 from outrigger board to outrigger limit switch 1562 Check continuity Replace if defective Defective Limit Switch 1562 Check switch Replace if defective Loose or broken wire 62 from outrigger limit switch LS62
235. k activities SETUPS Select this menu to carry out initial set up of the OCM1 NOTE this menu provides for set ups which are needed to configure the OCM1 for a particular vehicle HELP MENU OPTIONS help message A message displays current OCM1 status indicating if everything is OK or if there is an error code see LED Error Codes Table 5 3 DIAGNOSTIC MENU OPTIONS SYSTEM Select this menu to see general OCM1 system information SWITCHES Select this menu to see switch input status OUTPUTS Select this menu to see OCM 1 output status LOG Select this menu to see logged information DIAGNOSTIC SYSTEM MENU OPTIONS OUTRIGGERS Displays various status during the auto level function TILT Displays vehicle tilt in X and Y orientations measured by integral sensor TILTED Displays whether vehicle is tilted YES or NO BATTERY Displays battery supply voltage on P2 12 DIAGNOSTIC SWITCHES MENU OPTIONS LR P2 1 High when the left rear outrigger is in contact with the ground RR P2 2 High when the right rear outrigger is in contact with the ground RF P2 3 High when the right front outrigger is in contact with the ground LF P2 4 High when the left front outrigger is in contact with the ground EXTEND P2 5 High to activate the auto level function RETRACT P2 6 High to activate the auto retract function ELEV P2 10 High when the scissor stack is stowed elevated input indicates that the vehicle is stowed SKYJACK Page 28 Mid Size
236. ker Switch Drive Steer Low High Throttle Switch lt gt Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button Test Brake WARNING Brake will engage instantly when controller handle is released causing aerial platform to stop immediately Ensure path of intended motion is clear Activate and hold d enable trigger Switch Drive aerial platform forward Test brake by releasing controller handle Result Aerial platform should come to a stop Drive aerial platform SI forward Test brake again by releasing 57 enable trigger switch only Result Aerial platform should come to an instant and abrupt stop Mid Size amp Full Size Rough Terrain Series 31 Function Tests Drive Steer Enable Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton Test Speed Limit WARNING Be aware of overhead obstructions or other possible hazards around the aerial platform when lifting 1 Ensure path of intended motion is clear LJ 2 Select off lift drive key switch to 3 lift position 3 Raise the platform to an approximate height of 13 ft 4 m 4 Select off lift drive key switch to drive position and attempt to drive forward or reverse Result A
237. l components of hub assembly 17 Using an open ended wrench loosen castle Pull cotter pin item 2 out of spindle arm item 11 flanged nut a 1 4 turn while turning the wheel hub and then remove castle nut item 3 washer item It should turn easily The nut should not come 4 and outer bearing cone item 5 Dispose of completely loose dust cap cotter pin castle nut washer and outer bearing cone 18 Using a torque wrench set to 15 ft lb tighten castle flanged nut Turn wheel hub and check for smooth turning Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 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 degrees Secure with new cotter pin Check again for smooth turning of wheel hub The wheel hub should turn but with slight resistance 20 Grab the top and bottom of the hub and check for play There should be no evidence of play 21 Install dust cap back on hub assembly 22 Install wheel assembly Torque nuts or bolts to 140 ft lb 23 Repeat steps 5 to 22 for the other hub assembly 24 Lower the aerial platform Mid Size amp Full Size SKYJACK Page 11 Rough Terrain Series Service and Maintenance 5 1 10 Electronic Tilt Switch Setup Procedure The followi
238. l Size Rough Terrain Series SKYJACK Page 27 Models 9241 amp 9250 143905 lt Print View This Page Parts List 3 18 Hydraulic Generator Electrical Panel Diagram ANSI CSA Diesel Engine BACK VIEW HYDRAULIC GENERATOR INTERNAL WIRING ___ OUTRIGGER ELECTRIC PANEL 12PIN CONNECTOR PLUG NORTH AMERICAN COLOURS LOAD BLACK LOAD NEUTRAL WHITE PIN 3 86A ORG BLK WHT GROUND GREEN Lors 1 EL 90762 OOO GG AOA Fors m m br sr SSessssSss m l 1 iS U U 110V 15A GENERATOR TO OIL COOLER FAN 860 BLACK 00 WHITE 220V 15 GENERATOR TI TO HYDRAULIC GENERATOR SOLENOID 86C BLACK 02 WHITE oe C HYDR GEN CONTROL CABLE l 09 BLACK 85 GREEN 86 WHITE OIL COOLER RELAY 10ACR2 PIN 30 854 ORG BLK WHT PIN 85 10A BLU WHT PIN 86 2A BLK RED PIN 87 86D BLK PIN 87a N U M141691AD SKYJACK Page 28 Full Size Rough Terrain Series Models 9241 amp 9250 143905 Print View This Page Parts List 3 19 Hydraulic Generator Electrical Panel Diagram CE OUTRIGGER ELECTRIC PANEL 12 PIN CONNECTOR PLUG PIN 3 86A ORG BLK WHT rr S lt Jet 2 69 lt gt 9083 9080 o 991909899
239. liary Holding Valve Model 9250 COIL Lift Cylinder Auxiliary Holding Valve Model 9250 SOLENOID Propane lockoff valve GM Dual Fuel Engine COIL Series Parallel Drive Valve COIL Reverse Drive Valve COIL Forward Drive Valve COIL Right Steer Valve COIL Left Steer Valve COIL Front Powered Extension Extend 12 Volt Includes 4H 27 COIL Rear Powered Extension Extend 12 Volt Includes 4H 27A COIL Front Powered Extension Retract 12 Volt Includes 4H 26 COIL Rear Powered Extension Retract 12 Volt Includes 4H 26A COIL 12 Volt front left outrigger up COIL 12 Volt front right outrigger up COIL 12 Volt rear right outrigger up COIL 12 Volt rear left outrigger up COIL 12 Volt front left outrigger down COIL 12 Volt front right outrigger down COIL 12 Volt rear right outrigger down COIL 12 Volt rear left outrigger down TRANSDUCER Angle CE BATTERY 12 Volt starting BATTERY 12 Volt auxiliary BEEPER 7 5 16 VDC ANSI CSA Parts list continued on the following page Full Size Rough Terrain Series Models 9241 amp 9250 143905 117967 103319 103319 117326 117326 117326 133133 130439 143530 115283 115280 148300 134417 127688 129434 127684 129284 134304 127685 127926 129303 132807 129213 105657 104313 134305 700166 102921 300248 146085 111282 119469 120658 121504 143806 143809 143808 143807 143808 143808 143810
240. librate Load from the menu and press the ENTER button 22 Atthis 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 Asking for confirmation that the platform is empty Check that the platform is empty 25 Byusing 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 Mid Size amp Full Size SKYJACK Page 41 Rough Terrain Series Service and Maintenance Section 5 Procedures 28 29 IMPORTANT If the lift switch is released earlier than full height position the calibration will have to be aborted and repeated from the beginning When the system detects the lift switch closed the display will show Calibrate Load Lift Empty After a delay the system will stop the platform lifting and will take height amp pressure measurements the display will show MEASURING xx When the measurements have been taken the platform will resume lifting NOTE T
241. lity for Maintenance Scope of this Manual a This manual applies to the ANSI SIA CSA and CE versions of the Mid Size and Full Size Rough Terrain aerial platform models listed on Table 2 1 Equipment identified with ANSI meets the ANSI SIA A92 6 2006 standard Equipment identified with CSA meets the CSA B354 2 01 standard Equipment identified with CE meets the requirements for the European countries i e Machinery Directive 98 37 EC and or 89 392 EE EMC Directive 89 336 EEC Directive 2000 14 EC and the corresponding EN standards b CSA Canada and CE Europe Operators are required to conform to national territorial provincial and local health and safety regulations applicable to the operation of this aerial platform c ANSI SIA United States Operators are required by the current ANSI SIA A92 6 standards to read and understand their responsibilities in the manual of responsibilities before they use or operate this aerial platform SKYJACK Page 8 Mid Size amp Full Size Rough Terrain Series Operator s Responsibility for Maintenance Service and Maintenance WARNING Failure to comply with your required responsibilities in the use and operation of the aerial platform could result in death or serious injury Operator Safety Reminders A study conducted by St Paul Travelers showed that most accidents are caused by the failure of the operator to follow simple and fundamental safety rules and prec
242. ls Refer to Section 5 for proper location 4 Stuck or defective main series parallel valve spool V3 in drive motor Check valve Repair or replace if defective 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 Full Size RT s SKYJACK Page 33 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Hydraulic System Continued 4 2 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 assembly MC1 Check valves Clean or replace if defective 4 2 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 assembly MC1 Check valves Clean or replace if defective 4 2 8 Brakes will 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 equipped Check valve Repair or replace if defective 4 Stuck or defective auto reset valve V6 If equipped Check valve Repair or
243. lt Circuit Test 1 Refer to section 2 for test tilt sensor procedure SKYJACK Page 15 Service and Maintenance Section 5 Procedures f 8 75 X Go Go Ga Ga Go Go G Go Go Ga GY Go Goy Gy Go Go Go Gy Go Go Go Go GY Go Gy Gy Go G AA AAA e O K LOCK TAB GA hiq GAGA GA GAGA GA Gy Gy Gal 5 N 16 30 Diagnostics Pin Wire Color Description Pin Wire Color Description DK GRN ORN DK GRN WHT EMPTY 1484 LTGRN WHT Outputtogasolinetempsensor EMPTY x 49 LTGRNPL Notused PPL LT BLUE LT BLU DK BLU Mid throttle input LT GRN High throttle input TAN DK GRN Input from oil pressure switch DK BLU ORN Signal from gasoline pressure sensor PPL YEL EMPTY o EMPTY ll Connected to pin 14 below G WHT ORN Connected to pin 14 below DK GRN To diagnostic connector PC 11 To diagnostic connector EMPTY 13 Not used Battery positive To injector 1 and 4 To injector 2 and 3 BLU PNK CAN to propane regulator BLU WHT CAN from propane regulator 15 16 17 EMPTY p EMPTY EMPTY LT GRN RED 5 volt from ECU to sensors 19 20 60 BLK LT GREEN PPL WHT V from crank p
244. ly Be sure to replace any lost hydraulic oil when completing the installation of the repaired component and bleed any air from the system when required All hydraulic connections must be kept tight A loose connection in a pressure line will permit the oil to leak out or air to be drawn into the system Air in the system can cause damage to the components and noisy or erratic system operation Maintenance Hints Three simple maintenance procedures have the greatest effect on the hydraulic system performance efficiency and life Yet the very simplicity of them may be the reason they are so often overlooked What are they Simply these 1 Change filters annually The filters will need to be changed more often depending on the operating conditions Dirty dusty high moisture environments may cause the hydraulic system to be contaminated more quickly 2 Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir 3 Keep all connections tight SKYJACK Page 14 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Service and Maintenance Inspections About this Section This section contains the maintenance and inspection schedule that is to be performed References are made to the procedures in section 5 that outline detailed step by step instructions for checks and replacements Service Bulletins Before performing
245. ly Indicates function activated No a necessary controlled Error occured while self diagnosing the off power to reset the outrigger control module Turn power hardware fail safe back on and see if the code has cleared If problem persists replace outrigger control module Low input 2 7 to outrigger control Check for minimum 9 volts between wire 02 at P2 11 and wire 2 7 10A at P2 12 at outrigger control module manually operating outriggers Startup error occurred while self 1 Turn off power to reset the outrigger control module Turn power diagnosing back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal failure of OCM1 1 Turn off power to reset the outrigger control module Turn power back on and see if the code has cleared If problem persists replace outrigger control module Internal
246. n 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 Mid Size amp Full Size SKYJACK Page 15 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams 7127 Outrigger Pads 7135 Outrigger Pads 8831 Outrigger Pads 8841 Outrigger Pads 9241 Outrigger Pads 9250 Outrigger Pads Table 2 46 Floor Loading Pressure Total Aerial Total Aerial Platform Load Platform Weight 60379AF CE R 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 carp
247. nal block TB 1 to end of stroke limit switch LS4 Check continuity Replace if defective Defective end of stroke limit switch LS4 Check switch Replace if defective Loose or broken wire 36B from end of stroke limit switch LS4 to relay 14CR Check continuity Replace if defective Defective relay 14CR Check relay Replace if defective Loose or broken wire 14A from relay 14CR to relay 28CR Check continuity Replace if defective Loose or broken wire 14B from relay 28CR to base terminal block Check continuity Replace if defective Loose or broken wire 14B from base terminal block to lift valve solenoid 2H 14B Check continuity Replace if defective Loose or broken wire 02 from lift valve solenoid 2H 14B to base terminal block Check continuity Replace if defective Defective lift valve solenoid 2H 14B Check solenoid Replace if defective Open diode D14B 1 Check diode Replace if defective 4 1 28 Platform will Not Lift from Platform or Base Controls with Outriggers Extended 1 Outriggers not extended enough Extend outriggers to take weight off tires refer to operator section 2 Loose or broken wire 10A from terminal block TB 1 to pin 4 on connector CN14 at the outrigger board Check continuity Replace if defective 3 Loose or broken wire 10A from outrigger board to outrigger limit switch LS68 Check continuity Replace if defective 4 Defective outrigger limit switch LS68 Check swit
248. nalogs Fault Bad Strain Monitors Fault Bad Slave Micro Fault HWFS Stalled Action a function to clear the idle timeout if it occurred Ensure the GP102 is correctly mounted incorrect mounting can cause the bad tilt sensor diagnostic to occur Otherwise there may be an internal problem with the 102 Mid Size amp Full Size SKYJACK Page 35 Rough Terrain Series Service and Maintenance Section 5 Procedures 5 4 6 Control Module Load Calibration Code Messages amp Definitions During calibration the following failure message may appear Refer to 5 3 6 for hand held calibration diagnostic tool key functions 01 Check HWFS This message is given if the GP102 startup tests have not completed Check HELP message for more information 02 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 Not Stopped This message is given if any function switch is closed Check DIAGNOSTICS SWITCHES to see which function switch is closed 04 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 5 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 between 0 9V and 4 1V
249. ng information is supplied for replacement or reprogramming of the electronic tilt switch Also included are test and verification instructions Follow the appropriate procedures below Tilt Switch Replacement V WS SS N UG Y Sex lt y u 4 1 Ensure aerial platform is parked on firm level surface 2 Fully lower the platform 3 Chock or block wheels to keep the aerial platform from rolling forward or backward 4 Pushin emergency stop buttons and turn main disconnect switch to off position 5 Disconnect tilt switch from 4 pin connector NOTE Ensure part number of old and new tilt switch are the same 6 Remove old tilt switch from mount 7 Install new switch to mount in the same orientation as the old switch and connect switch plug to 4 pin connector NOTE The tilt circuit is only powered when 8 10 11 12 Section 5 Procedures controls are powered up Turn main disconnect switch to ON position Select off lift drive key switch to E lift position Or 2 drive position 7 Pull out all emergency stop buttons Verify switch is powered Red or green LED will be continually blinking RedLED O E J Program the Tilt Switch Red LED Green LED a Press and release the set up but
250. ns AS WARNING Air pressure can affect stability Temperature changes can affect air pressure It is important to visually inspect all tires for proper tire inflation prior to use Tires should be checked by end user on a daily basis Tire inflation pressures must be checked weekly with a calibrated gauge If the measured pressure is less than the specification reinflate to the pressure specified below Tires must not be inflated above the recommended specification Do not intermix tires of different types on one aerial platform Use only tires of type originally supplied Fill Specification Tire Size Fill Type Psi kPa 6A 10 16 5 75 CARLISLE US LOADER Air 517 1 46A 10 16 5 OTR OUTRIGGER 75 Non Marking 517 1 10 16 5 60378AE AS Factory preset 20 C Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal conditions 1 Usage S tandard Or O ptional N A Not Available Rim Backspace Diagram Inboard Outboard SECTION A A MD Backspace Rim Size Serial Number Contact Skyjack Service Department 6A amp 6F 60380AE AS SKYJACK Page 12 Mid Size amp Full Size Rough Terrain Series Service and Maintenance 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 Wid
251. nsion platform Mid Size RTs and no extension platforms Full Size RTs SKYJACK Page 4 Mid Size amp Full Size Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 2a Maximum Platform Capacities Evenly Distributed ANSI CSA First Extension Second Extension MODEL Number of Capaci Number of Capacit Number of Occupants pacity Occupants p Occupants i 1500 Ib One Extension Not Available Platform 681 kg 1000 One Extension Not Available Platform 454 kg Not Available Capacity No Extension 2500 Ib Platform 1134 kg 2000 Ib One Extension Not Available Platform 908 kg Two Extension 1700 Ib 500 Ib 500 Ib Platforms 771 kg 227 kg 227 kg 1700 Ib No Extension 5 Not Available Platform 771 kg i 1500 Ib 500 Ib One Extension 5 2 Not Available Platform 681 kg 227 kg Two Extension 1500 Ib 5 500 Ib 2 8 2 Platforms 681 kg 227 kg 227 kg i 2000 Ib No Extension 5 Not Available Platform 907 kg N N N LO e TT N o LO TT e TT 1500 Ib 500 1 Snc tension 5 2 Not Available Platform 681 kg 227 kg Two Extension 1500 Ib 500 Ib 5 500 Ib 5 Platforms 681 kg 227 kg 227 kg 60376AE ANSI R 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 model
252. ntil proper repairs are completed Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this aerial platform All maintenance and service procedures should be performed in a well lighted and well ventilated area Anyone operating or servicing this aerial platform must read and completely understand all operating instructions and safety hazards in this manual and operating manual All tools supports and lifting equipment to be used must be of proper rated load and in good working order before any service work begins Work area should be kept clean and free of debris to avoid contaminating components while servicing All service personnel must be familiar with employer and governmental regulations that apply to servicing this type of equipment Keep sparks and flames away from all flammable or combustible materials Properly dispose of all waste material such as lubricants rags and old parts according to the relative law provisions obtaining in the country Before attempting any repair work turn Battery Disconnect Switch to the OFF position Preventive maintenance is the easiest and least expensive type of maintenance Mid Size amp Full Size Rough Terrain Series SKYJACK Page 13 Service and Maintenance Operator s Responsibility for Maintenance Hydraulic System amp Component Maintenance and Repair The
253. ode F44 Low Pressure 1 This message indicates that the pressure is too low 0 5V or less at a STATIC measurement point This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 36 Flash Code F45 High Pressure 1 This message indicates that the pressure is too high 4 5V or more at a STATIC measurement point This message would occur if the wrong pressure sensor was fitted or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure 4 3 37 Flash Code F46 Check Elev 1 This message indicates that the elevation switch opened more than once during the DYNAMIC lift 4 3 38 Flash Code F47 Check Elev 1 This message indicates that the elevation switch closed more than once during the DYNAMIC lower Full Size RT s SKYJACK Page 41 Engine Powered Q Section 5 PROCEDURES Table of Contents Service and Maintenance EXP 3 Base 5 1 1 Hydraulic System and BrakeAdjustment Procedure If Equipped 3 5 1 2 Brake Assembly and Disassembly If 4 aro ROCIO TS GU RTI mem 6 5 1 4 Winching and Towing Procedures and Brake 6 AIO System LITT and Pressure seit ebria
254. oken wire 13A from base terminal block to lowering valve solenoid 2H 13A Check continuity Replace if defective 18 Loose or broken wire 02 from lowering valve solenoid 2H 13A to base terminal block Check continuity Replace if defective 19 Defective lowering valve solenoid 2H 13A Check solenoid Replace if defective No Down Function Additional for machines with Load Sensing System CE 1 4 5 6 7 Loose or broken wire 02 from base terminal strip TB 1 to down enable relay 28CR2 or auxiliary down enable relay 28ECR2 Check continuity Replace if defective Defective down enable relay 28CR2 or auxiliary down enable relay 28ECR2 Check relay Replace if defective Loose or broken wire 28 from control module CM1 at pin P3 4 to down enable relay 28CR2 Check continuity Replace if defective Loose or broken wire 28E from control module CM1 at pin P3 6 to auxiliary down enable relay 28ECR2 Check continuity Replace if defective Loose or broken wire 10A from base terminal block to auxiliary down enable relay 28ECR2 Check continuity Replace if defective Loose or broken wire 13C from auxiliary down enable relay 28ECR2 to down enable relay 28CR2 Check continuity Replace if defective Loose or broken wire 13B from down enable relay 28CR2 to down relay 28DCR Check continuity Replace if defective 4 1 33 Down Circuit Inoperative from Base ANSI CSA 1 2 3 4 5 Loo
255. old enable trigger switch 1 ft 30 5 cm Release switch to stop and then press rocker switch on top of Result Platform should rise re 6 controller to 4 left and 7 2 Pressandhold ift enable pushbutton right then select and hold raise off lower switch Result Steer wheels should turn left and to E lower position and lower the right platform fully Release switch to stop Result Platform should lower Test Horn Test Enable Trigger Switch 1 Push horn pushbutton Result Horn should sound 1 Ensure outriggers are fully retracted 2 Ensure path of intended motion is clear SKYJACK Page 30 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Drive Steer Enable Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton Test Driving 1 Ensure path of intended motion is clear 2 Activate and hold Cd enable trigger switch Slowly move controller fully forward and then return handle to center position Result Aerial platform should move in forward direction and then come to a Stop ah 4 Slowly move controller fully backward and then return handle to center position Result Aerial platform should move in reverse direction and then come to a Stop Function Tests Roc
256. ons enter the Access Level Code 1 31 2 2 followed by pressing the ENTER button 8 display will show Access Level 2 By using Left Right buttons select the Setups from the menu and press the ENTER button 9 display will show Setups Change Defaults Select the Change Defaults from the menu and press the ENTER button 10 The display will show Defaults 0 Custom By using Up Down buttons select the Defaults Code Setting for your Model For Default Code Refer to Table 5 3 from the menu and press the ENTER button and followed by ESCAPE button 11 display will show Setups Change Defaults By using Left Right buttons select the Calibrate Level from the menu and press the ENTER 12 The display will show Calibrate Level Yes Enter No Select the Yes from the menu by press the ENTER button 13 The display will show Calibrate Level Tilt 0 0 0 0 Select the ESCAPE from the menu once 14 The display will show Setups Calibrate Level Select the ESCAPE from the menu once again 15 The Calibration procedure is complete unplug and remove the EZ Cal 16 Close the hydraulic electric cabinet SKYJACK Page 30 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 3 7 Auto Leveling Outrigger Control Module Pin Reference Chart P2 WU
257. ons with GM Dual Fuel Engine 45 3 35 Electrical Schematic ANSI CSA amp AS No Options with GM Dual Fuel Engine 46 3 36 Interface amp Engine Electrical Schematic GM Dual Fuel Engine 47 Full Size Rough Terrain Series SKYJACK Page 1 Models 9241 amp 9250 143905 3 1 Hydraulic Symbol Chart VARIABLE LINE CROSSING DISPLACEMENT SHUTTLE VALV Ei 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 ENGINE ADJUSTABLE FLOW DIVIDER FLOW CONTROL COMBINER LINER FIXED DISPLACEMENT CHECK VALVE PUMP COUNTER ROTARY BALANCE VALVE ACTUATOR THREE POSITION FOUR WAY OIL COOLER VALVE COIL PROPORTIONAL SERIES TWO POSITION PARALLEL TWO WAY HYDRAULIC NORMALLY TWO POSITION CLOSED CENTER MOTOR CLOSED THREE WAY OPEN PORT TWO POSITION THREE POSITION TWO WAY TWO POSITION FOUR WAY NORMALLY THREE WAY CLOSED CENTER OPEN CLOSED PORT VARIABLE PRESSURE MAIN LINES 50000 PILOT LINES 0900000 DISPLACEMENT TRANSDUCER HYDRAULIC MOTOR QUICK DISCONNECT Full Size R
258. or missing actuator arm missing fasteners Hydraulic loose wiring Maintaining the hydraulic components is essential to good performance and service life of the aerial platform SKYJACK Page 18 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Service and Maintenance Inspections Typical Model 71xx shown Emergency Lowering Access Rod Electrical Panel Emergency Main Power Disconnect Motion Control Manifold Main Manifold Switch E b Load Tilt gt Sensor
259. osition sensor 66 EMPTY WHT PPL EMPTY EMPTY 80 86 N IN EMPTY Ground from engine block RED WHT RED BLK Negative supply to power relay 2002CR EMPTY EGO 1 Heater ground EMPTY J EGO 2 Heater ground EMPTY J r _ 1 02 N N N 8 N cO Negative supply to propane lock off Negative supply to relay 10BCR2 Not used Battery positive To check engine light MIL Ground from engine block Positive to throttle actuator motor Negative from throttle actuator motor Negative supply to fuel pump relay 56CR Fuel pump excite wire EMPTY YEL Output to spark coil 1 EMPTY J YEL RED Output to spark coil 2 EMPTY p YEL GRY Output to IAT part of MAP TAN WHT Output to ECT G 0 41 WHT RED Output to EGT Negative supply to fuel pump 2 TAN BRN Propane selected 3 TAN RED Not used Not used 89 PNKBLK Negative supply to starter relay 32ACR 12 volt input 90 60594AA SKYJACK Page 16 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 2 2 Throttle Actuator GM PNK WHT TAN ORG DBW MOTOR DBW TPS1 SIGNAL D SENSOR GROUND PPL LT BLU BLK LT GRN
260. oting Information Service and Maintenance Load Sensing System CE Continued 4 3 18 Flash Code F19 High Elev close 1 This message is given if the elevation switch P2 10 closed during lower at a too high height above 25 When the switch is closed overload detection is normally disabled but if the switch closes above 25 the platform is too high to allow disabled overload Check CALIBRATIONS HEIGHT CALS the ElevUp value shows the recorded height where the switch opened 4 3 19 Flash Code F20 Height lt gt 0 1 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 4 3 20 Flash Code F21 Height lt gt 0 1 This message occurs if the platform height is not 0 before the platform is raised during either STATIC lift The platform must be at 0 height when it is fully lowered Check DIAGNOSTICS SYSTEM to check the height 4 3 21 Flash Code F22 Height lt gt 100 1 This message occurs if the platform height is not 100 after the platform has been fully raised during either STATIC lift The platform must return to the same height each time it is fully raised Check DIAGNOSTICS SYSTEM to check the height 4 3 22 Flash Code F23 Height lt gt 100 1 This message occurs if the platform height is not 100 before the platform is lowe
261. ough Terrain Series SKYJACK Page 3 Models 9241 amp 9250 143905 3 2 Electrical Symbol Chart ANGLE WIRE CROSSING HOURMETER KEY SWITCH WIRES JOINED 09 LIGHT FOOT SWITCH PRESSURE TRANSDUCER HYDRAULIC LIMIT SWITCH VALVE COIL TOGGLE SWITCH PROPORTIONAL LIMIT SWITCH GROUND HYDRAULIC amp HELD VALVE COIL CLOSED ELECTRIC 1 SWITCH MOTOR Sa BATTERY CIRCUIT LIMIT SWITCH BREAKER N C HELD OPEN SILICON CONTROLLED RECTIFIER STOP BUTTON LIMIT SWITCH INDICATOR _ RESISTOR SINGLE POLE POTENTIOMETER LEVEL SENSOR SINGLE THROWN RELAY DOUBLE POLE DOUBLE POLE SINGLE THROW DOUBLE THROW PROXIMITY SWITCH PNP TRANSISTOR SINGLE POLE DOUBLE THROW RELAY RELAY TRANSISTOR RELAY TRIPLE POLE PRESSURE DOUBLE THROW DIODE TRANSISTOR VACUUM RELAY SWITCH TEMPERATURE SWITCH SKYJACK Page 4 Full Size Rough Terrain Series Models 9241 amp 9250 143905 3 3 Hydraulic Component Parts List Skyjack LUE 103655 VALVE Main lowering 107269 VALVE Lift cylinder holding Model 9241 103655 VALVE Lift cylinder holding Model 9250 107269 VALVE Lift cylinder holding Model 9241 103655 VALVE Lift cylinder holding Model 9250 103655 VALVE Lift cylinder holding Model 9250 103655 VALVE Lift cylinder holding Model 9250 103655 VALVE Lift 114365 V
262. ower Indicator Light at Outrigger Control Module OCM1 Flashing Flash Code Probable Cause Remedy MM W are all up and machine is Level the machine 7 Machine is elevated 1 Lower the scissor stack below high speed limit switch 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 At least one outrigger is not fully 1 Fully retract all outriggers retracted 2 Defective outrigger rod limit switch LS61 LS62 LS63 LS64 or wiring 3 Defective diode D36 on outrigger board Outriggers are all down and the machine Move machine to less sloped terrain if it will not lift is not fully level Power on wire 70 or 79 at power on 1 Check for power on wire 70 or 79 at pin P2 5 or P2 6 of the outrigger control module Replace defective component 9 2 2 Replace defective or damaged switch es or wiring 3 Check for continuity Replace if defective 5 5 2 Power on wire 70 or 79 when 2 Check for power on wire 70 or 79 while manually operating an outrigger Low or no voltage on wire 35c Check battery and charging system to ensure minimum 9 volts Loose or broken wire on 35c Check for input voltage on wire 35c at pin P4 9 of outrigger control module 1 Excessive vibration Outrigger control module cannot read tilt sensor Defective outrigger control module Replace Outriggers are being manual
263. owered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 15 Loose or broken wire 3 from circuit breaker CB4 to circuit breaker CB1 Check continuity Replace if defective 16 Loose or broken wire 86C from relay 86BCR to generator valve coil 2H 86C Check continuity Replace if defective 17 Loose or broken wire 02 from base terminal block to generator valve coil 2H 86C Check continuity Replace if defective 18 Defective generator valve coil 2H 86C Check coil Replace if defective 4 1 39 Hydraulic Generator will Not Shut Off from Generator Switch 1 2 3 4 5 Defective generator switch 12 Check switch Replace if defective Loose or broken wire 86 from generator switch S12 to diode D86 Check continuity Replace if defective Open diode 086 Check diode Replace if defective Defective relay 86ACR Check relay Replace if defective Loose or broken wire 02 from base terminal block to relay 86ACR Check continuity Replace if defective 4 1 40 All Outriggers Inoperative Auto level and manual IV WARNING Scissors lift must be below high speed limit switch for outriggers to function NOTE For the outriggers to function the upper control console must be in the lift position No power on wire 44 at relay 35CR power is present ensure there is power on wire 35 and relay 35CR operates correctly 2 Loo
264. p relay 56CR Check continuity Replace if defective Loose or broken tan black wire from ECU connector pin 42 to fuel pump relay 56CR Check continuity Replace if defective Defective fuel pump relay 56CR Check relay Replace if defective Loose or broken pink yellow wire from fuel pump relay 56CR to fuse 11 Check continuity Replace if defective Defective fuse F11 Check fuse Replace if defective Loose or broken pink yellow wire from fuse F11 to fuel pump FP Check continuity Replace if defective Loose or broken pink yellow wire from fuse F11 to ECU connector pin 785 Check continuity Replace if defective Defective fuel pump Check fuel pump by putting 12 volts and a ground to it Replace if defective Loose or broken wire 3002 from fuel pump FP to GM engine connector 1 Check continuity Replace if defective Loose or broken black red wire from GM engine connector to ECU connector pin 86 Check continuity Replace if defective Full Size RT s SKYJACK 11 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued PROPANE ONLY 27 28 29 30 31 32 33 34 35 36 37 NOTE The fuel select switch is defaulted to gasoline The engine will run on gasoline if propane is selected from the switch and either the switch is bad or a wire is loose or broken from the switch This is providing ther
265. plug Check continuity Replace if defective 2 Loose or broken wire 10A from engine harness plug to base start switch S30 Check continuity Replace if defective 3 Defective base start switch S30 Check switch Replace if defective 4 Loose or broken wire 32A from base start switch S30 to GM engine connector 1 Check continuity Replace if defective 4 1 8 Engine will Not Crank from Base Controls Kubota diesel 1 Loose or broken wire 05 from base terminal block to base engine switch S30 Check continuity Replace if defective 2 Loose or broken jumper wire 05 on base engine switch S30 Check continuity Replace if defective 3 Defective engine start switch S30 Check switch Replace if defective 4 Loose or broken wire 32A from engine start switch S30 to starter contactor 32ACR Check continuity Replace if defective 4 1 9 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 terminal block TB 1 Check continuity Replace if defective 4 1 10 Glow Plugs Inoperative from Engine Controls 1 Loose or broken wire 07 from engine start switch S30 to glow plug switch S31 Check continuity Replace if defective 2 Defective glow plug switch S31 Check switch Replace if defective 3 Loose or broken wire 31A from glow plug switch S31 to glow plug relay 31ACR
266. point in the Y orientation Displays the tilt delay time Displays the tilt delay time Displays the tilt trip point in the X orientation during the auto level function Displays the tilt trip point the orientation which applies during the auto level function MACHINE SETUP MENU OPTIONS factory set not adjustable DEFAULTS Allows all adjustments amp machine settings to be set to defaults WARNING all GP106 settings will be changed use with caution CALIBRATE LEVEL Allows levelling of the integral tilt sensor of the GP106 when the vehicle is TILT MODE TILT FILTER Xlevel TARGET Ylevel TARGET tilt SLACK Mid Size amp Full Size positioned on level ground see Appendix Four Allows configuration of the GP106 tilt output P2 9 1 output turns on to light lamp when tilted 2 output turns off to cutout functions when tilted 3 output turns off to cutout functions when tilted AND elevated Displays the filter applied to the tilt measurements during the auto level function used to minimize the effect of vehicle vibrations on the tilt measurement Displays the tilt in the X orientation at which the auto level function will complete 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 will not attempt to level EXAMPLE Xtilt TARGET
267. red during either STATIC lift The platform must be at 100 height when it is fully raised Check DIAGNOSTICS SYSTEM to check the height 4 3 23 Flash Code F24 Too Many 1 This message occurs if too many static measurements are taken during either STATIC lift or lower It is likely that there is a problem with the lift cylinder pressure the GP102 should only need about 10 measurements for most vehicles The SETUPS HEIGHT SETUPS MIN LIFT time could be increased to force a longer time between static measurements but this should not be necessary 4 3 24 Flash Code F25 Check Elev 1 This message indicates a problem with the elevation switch P2 10 during the STATIC phases The switch is either staying closed to a higher height or staying open to a lower height than that recorded during the DYNAMIC phase 4 3 25 Flash Code F26 Check Elev 1 This message indicates a problem with the elevation switch P2 10 during the STATIC phases The switch is opening or closing at a different height than that recorded during the DYNAMIC phase Full Size RT s SKYJACK Page 39 Engine Powered Q Service and Maintenance Section 4 Troubleshooting Information Load Sensing System CE Continued 4 3 26 Flash Code F27 Bad Height 1 This message indicates a problem with the height sensor output P4 3 during the STATIC phases The height sensor output must be between 1 0V and 4 0V at all times Check DIAGNOSTICS SENSORS to see the ou
268. ress oil seal from cover Spring Chart Yellow Red Blue Spring 14 Spring 14 Spring 14 214300414 6 fo Assembly Refer to Diagram 5 3 1 Use an alkaline wash to clean parts before assembly 2 Press new oil seal into cover until it is flush with bearing shoulder Note direction of seal 3 Install shaft dowel pins spring retainer and new spring in cover Be sure to install springs according to pattern and color recorded during disassembly 4 Position new return plate on springs NOTE Be careful to avoid contaminating friction surfaces with oil 5 Install new rotor discs and new stator discs in the same sequence as recorded during disassembly 6 Install new back up rings and new o rings piston Note order of o rings and back up rings Insert piston into pressure plate r2 Install new case seal on cover 8 Position pressure plate on cover aligning dowel pins with holes in pressure plate 9 Install cap screws and tighten evenly to draw pressure plate to cover Torque cap scerws 74 6 N m 55 Ib ft NOTE A hydraulic press will simplify installation of pressure plate on cover Clamp pressure plate in position while tightening cap screws caution If hydrostatic testing is performed on brake assembly release pressure must not exceed 69 bar 1000 psi unless six additional bolts are used for supplemental clamping SKYJACK Page 4 Mid Size amp Full Size Rough Terrain Series
269. revious page 108788 119726 147054 147054 147053 147053 147053 147054 147053 132537 122869 122877 122877 122869 122869 122869 122872 147054 147054 102853 127132 147054 RESISTOR 3 Ohm 100W SWITCH Main Power Disconnect TOGGLE SWITCH Up Off Down Base control console N O CONTACT Off Lift Drive select key switch Platform N C CONTACT Off Lift Drive select key switch Platform N C CONTACT Emergency stop switch Platform ANSI CSA N C CONTACT Off Lift Drive select key switch Platform CE N O CONTACT Up Down switch Platform N C CONTACT Emergency stop switch Base control console CONTROLLER ASSEMBLY Drive steer SWITCH W ACTUATOR 2nd Speed e SWITCH Right steer SWITCH Left steer e SWITCH W ACTUATOR Reverse drive e SWITCH W ACTUATOR Forward drive SWITCH W ACTUATOR 3rd Speed SWITCH Enable push button N O CONTACT Horn switch Platform N O CONTACT Lift enable switch Platform SWITCH Outrigger enable SWITCH Outrigger enable SWITCH N O contact Base control console ANSI CSA SWITCH N O contact Base control console CE SWITCH N C contact Base control console CE TOGGLE SWITCH Front platform extend retract Platform TOGGLE SWITCH Rear platform extend retract Platform SWITCH Hydraulic Generator Platform N O CONTACT Choke switch or Glow plug switch Platform N O CONTACT Low high throttle switch Platform N O CONTACT Engine start switch Plat
270. robably due to a wiring problem 4 3 10 Flash Code F11 Not Up 1 This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP Select the UP function Full Size RT s SKYJACK Page 37 Engine Powered Q Service and Maintenance Section 4 Troubleshooting Information Load Sensing System CE Continued 4 3 11 Flash Code F12 Too Many 1 This message occurs if the DYNAMIC lift takes too long This message could occur if the UP switch was not released at the end of the dynamic lift machine takes more than two minutes to lift the GP102 may need modification to avoid this problem 4 3 12 Flash Code F13 Low Height Range 1 This message occurs at the end of the DYNAMIC lift 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 This message would occur if the UP switch was accidentally opened near the start of the DYNAMIC lift the platform is fully raised check the elevation switch wiring 4 3 13 Flash Code F14 Bad Height 1 This message occurs if the height sensor output P4 3 is out of range during the DYNAMIC lift The height sensor output must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of OV or 5V is probably due to a wiring problem 4 3 14 Flash Code
271. s Hic n 18 HOLIMS MOTO NOOV38 g Q 6279 LL els ONILVLOH L JE voi zm voi NO 4 4 4 1 80r d 0L 0L i 1 GIONSIOS3AWA 1 gt 4 UR 1 vm 50 oi vosa y vor GIONJIOS3AWA 4 A 1 112 anina 50 4 91 9t 80 GION31OS 3ATVA P 1 vos T 440 MS t 2 52 3NY0 L417 440 NIHSV14 vera HOLMS ADH 20 LM l w vo vor GIONSTOS AWWA 6204 NIYIN 7 Vel He 7 GIONFIOS P sod VVELHZ GIONFIOS 4200 T 7 GIONSIOS sod VEL HZ if GIONFIOS 1 4 4 NO amod zam 4 4 lt 27 vol 00 7 oL S 00 00 00 L 00 5 NHOH D NHOH 90 50 i am 1 6r N33u5 6r 80 AYLLY 0 4 ii 96 t 001 e GIONSIOS SNA gz 2158 98
272. s and Features 4 2 2a Maximum Platform Capacities Evenly Distributed 5 2 6 2 2b Maximum Platform Capacities Evenly Distributed w Optional 7 Tires 7 2 2c Maximum Platform Capacities Evenly Distributed CE r 8 2 24 Maximum Platform Capacities Evenly Distributed 9 u u ele 10 230 QU au p bet 11 108 12 2 4a Floor Loading Pressure 15 uuu _ _ 16 PAG Floor Loading Pressure AS 17 29 uuu k T 18 Bb TOUS LLL ai aA 20 Mid Size amp Full Size SKYJACK Page 1 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 1a Specifications and Features ANSI CSA Mid Size RTs Full Size RTs 7127 7135 8243 8850 8831 8841 9250 8 420 Ib 8 850 Ib 10 600 Ib 11 460 Ib 9 670 Ib 10 570 Ib 14 700 Ib 3819 kg 4014 kg 4808 kg 5198 kg 4386 kg 4794 kg 6668 kg 71 Eod 87 92
273. s and Schematics 2 5 Platform Control Console Wiring All Options ANSI CSA 15 3 6 Platform Control Console Wiring All Options 16 3 7 Control Cable Assemblies ie LT E m TM 17 3 9 Outrigger Hydraulic Generator Control Console 18 3 9 Base Control Console Wiring ANSI CSA mobi ein tore mde ba tu asas e dis 19 3 10 Base Control Console Wiring CE reg aa VM Pre 20 3 11 Hydraulic Schematic Cushman Axles Model 9241 21 3 12 Hydraulic Schematic Cushman Axles Model 9250 22 212 Hydraulic Schematic Dana Axles 23 3 14 Hydraulic Manifold Components amp Port Identifications 24 3 15 Main Manifold gd er EET mme 25 3 16 Oil Cooler Electrical Panel Diagram ANSI CSA Dual Fuel Engine 26 3 17 Hydraulic Generator Electrical Panel Diagram ANSI CSA Dual Fuel Engine 27 3 18 Hydraulic Generator Electrical Panel Diagram ANSI CSA Diesel Engine 28 3 19 Hydraulic Generator Electrical Panel Diagram
274. s equipped with options SKYJACK Page 6 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 25 Maximum Platform Capacities Evenly Distributed w Optional 7 Tires ANSI CSA First Extension Second Extension MODEL Number of Capacit Number of Capaci Number of Occupants diei d Occupants pd Occupants i 1500 Ib 500 Ib One Extension 2 Not Available Platform 681 kg 227 kg i 900 Ib 300 Ib One Extension 1 Not Available Platform 408 kg 136 kg i 2000 Ib No Extension Not Available Platform 908 kg i 1700 Ib 500 Ib One Extension 2 Not Available Platform 771 kg 227 kg Two Extension 1400 Ib 500 Ib 500 Ib Platforms 635 kg 227 kg 227 kg 1250 No Extension Not Available Platform 567 kg One Extension 1250 Ib 500 Ib Platform 567 kg 227 kg Two Extension 1250 Ib 500 Ib 500 Ib Platforms 567 kg 227 kg 227 kg No Extension 1500 Ib Platform 681 kg i 1500 Ib 500 Ib One Extension 2 Not Available Platform 681 kg 227 kg Two Extension 1500 Ib 500 Ib 500 Ib 227 kg 5 60376AE ANSI R Capacity Not Available Platforms 681 kg 227 kg N N N LO N T h Occupants and materials are not to exceed rated load Refer to capacity label at sides of platform for additional information and for models equipped with options Mid Size amp Full Size SKYJACK Page 7
275. se or broken wire 10A from base terminal block to base enable switch 10 Check continuity Replace if defective Defective base enable switch S10 Check switch Replace if defective Loose or broken wire 10E from base enable switch 510 to base up down switch 52 Check continuity Replace if defective Defective base up down switch 52 Check switch Replace if defective Loose or broken wire 13 from base up down switch S2 to base terminal block TB 1 Check continuity Replace if defective 4 1 34 Down Circuit Inoperative from Base CE 1 Loose or broken wire 7C from base emergency stop switch S6 to platform emergency stop switch 54 Check continuity Replace if defective 2 Defective platform emergency stop switch S4 Check switch Replace if defective SKYJACK Page 24 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 3 Loose or broken wire 10D from platform emergency stop switch S4 to idle platform base key switch 510 Check continuity Replace if defective 4 Defective idle platform base key switch 510 Check switch Replace if defective 5 Loose or broken wire 10E from idle platform base key switch 510 to up down switch 92 Check continuity Replace if defective 6 Loose or broken wire 13D from up down switch S2 to base terminal block TB 1 Check continuity Replace if defective 7 Defective up down
276. se or broken wire 44 from relay 35CR to pin 6 on connector CN14 on outrigger board Check for continuity Replace if defective 3 No power at wire 9 at pin 5 on connector CN14 on outrigger board power is present check for continuity on wire 9 back to base terminal block TB 1 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 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 17CR Check for continuity Replace if defective Full Size RT s SKYJACK Page 27 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 9 Loose or broken wire 17B from pin 1 or wire 02 from pin 2 on connector CN21 on outrigger board to outrigger holding valve coil 2H 17B Check for continuity Replace if defective 10 Defective outrigger holding valve coil 2H 17B Check coil Replace if defective 4 1 41 All Outriggers Inoperative Auto level and manual from platform controls 1 Loose or broken wire 35C from pin 1 on connector 20 on outrigger board through outrigger cables and plugs to the outrigger enable switch
277. sembly Tie Rod Ladder Outriggers If Equipped gt gt w gt gt w gt Manual T c 5 8 5 5 Platform Control Console Test Emergency Stop Test Lift Enable Test Platform Raising Lowering Test Enable Trigger Switch gt gt gt gt Test Steering Test Horn gt gt w Test Driving Test Brake Test Speed Limit Test Lowering Warning CE gt gt gt gt Test Powerdeck Enable If equipped gt Test Extension Platform s If equipped gt gt Test Tilt Sensor 11 Equipped m 6 5 9 0 Test Emergency Stop Test Base Lift Enable Test Lower Neutral Raise Switch gt gt gt Test Emergency Lowering Models 71xx 8831 41 amp 9241 gt Test Emergency Lowering Model 8243 8850 amp 9250 gt Test Emergnecy Powered Extension Platform Retraction Switch Model 8850 amp CE 9250 Test Main Power Discconect Switch gt gt gt Perform Visual and Daily Maintenance Inspections amp Functions Test Refer to Section 2 7 of the Operating Manual B Perform Scheduled Maintenance Inspection every three months 150 hrs Refer to Section 1 0 of this manual Perform Scheduled Maintenance Inspection every year Refer to Section 1 0 of this manual D Per
278. spect all tires for proper tire inflation prior to use Tires should be checked by end user on a daily basis Tire inflation pressures must be checked weekly with a calibrated gauge If the measured pressure is less than the specification reinflate to the pressure specified below Tires must not be inflated above the recommended specification Do not intermix tires of different types on one aerial platform Use only tires of type originally supplied Fill Specification Tire Size i Pressure Factory 10 16 5 6A CARLISLE US LOADER 10 16 5 OTR OUTRIGGER Non Marking kPa GOODYEAR TERRA XTRAC 98 m fefefe CARLISLE US LOADER er Foam Non t 9 _ o GOODYEAR TERRA XTRAC 60378AF CE R Factory preset 20 C Check pressures regularly as tires can lose pressure over time and over different ambient temperatures even under normal conditions T Usage S tandard Or O ptional N A Not Available Backspace Rim Backspace Diagram Inboard Outboard SECTION A A Backspace 7127 7135 8831 Rim Size 7 amp ATF All models are 135 mm N A 60380AE CE R Mid Size amp Full Size SKYJACK Page 11 Rough Terrain Series Service and Maintenance Section 2 Maintenance Tables and Diagrams Table 2 3c Tire Specificatio
279. switch 52 Check switch Replace if defective 4 1 35 Powered Extension Platform Inoperative 1 Loose or broken battery cable from main power disconnect switch S1 to fuse F2 100 Amp Check continuity Replace if defective 2 Open fuse F2 Check fuse Replace if open Loose or broken battery cable 103A from fuse F2 to contactor 9CH1 Check continuity Replace if defective 4 Defective contactor 9CR1 Check contactor Replace if defective 5 Loose or broken battery cable 103B from contactor 9CR1 to motor contactor 99CR Check continuity Replace if defective 6 Defective motor contactor 99CR Check contactor Replace if defective 7 Loose or broken wire 1038 from battery cable 1038 to fuse F5 Check continuity Replace if defective 8 Defective fuse F5 Check fuse Replace if defective 9 Loose or broken wire 103C from fuse F5 to powered platform enable switch S34 or S34A Check continuity Replace if defective 10 Loose or broken wire 103D from enable switch S34or 534 to platform extend retract switch S11 or S11A Check continuity Replace if defective 11 Defective platform extend retract switch 511 S11A Check switch Replace if defective 12 Defective platform enable switch 534 or 534 Check switch Replace if defective 13 Loose or broken battery cable 00 from platform power unit DCM1 to battery B1 Check continuity Replace if defective 14 Defective platform power unit DCM1
280. swoHo oma i L ca els ONILVLOH 82 DM we c iw oq ve 1 801 oL T GIONZIOS3AWA py G33d t S0 L vor I f nado vota j VOL GION310S 3ATVA f 1 S0 lt 01 80 GIONTIOS3AWA I 01 204 vo NOLLISOd 440 I I 82 veia 80 IHOMONIHSY14 oy 1221 5 NOLLONNS TIV 2 wen vol u3Hsvid GIONSIOS 6 200 Lu t VELHZ M I 1 GIONSIOS 1 8200 I IMYA DNIGIOH GIONSIOS BE NWA DNIGIOH x 1 r 9 20 1 NWA DNIGIOH t 7 0 GION310S 7 Ja s zoa ANWADNIGIOH 8 t vel He 1 9 pcc ve 4 4 4 4 voi 1 00 01 4 66 20 700 00
281. th Weight of Aerial Platform Capacity Weight of Aerial Platform Capacity LCP OUP Foot Print Area x 4 Tires Base Area SITISS Loo KEEP CLEAR 5195 2 64446 Width Width VA AY AY N lt E 9 gt 7 SCE eS Y N S 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 SKYJACK Page 14 Mid Size amp Full Size Rough Terrain Series Section 2 Maintenance Tables and Diagrams Service and Maintenance Table 2 4a Floor Loading Pressure ANSI CSA Total Aerial Platform Total Aerial Platform Load Weight Ib kg Ib kg psi kPa psf 3 60379AE ANSI R mi
282. the pressure transducer into P4 2 It should be between 0 5 zero pressure and 4 5V maximum pressure and should vary as the platform load amp position varies Waiting For B on P2 12 B Supply Too Low P4 1 Or P5 1 Short To OV Check that the battery voltage is not too low Verify battery voltage on P2 12 Disconnect plug P4 if the fault clears there is a wiring fault from P4 1 to the rest of the vehicle SKYJACK Page 34 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 4 4 LED Error Codes Code Breakdown Chart Continued Vehicle Tilted Vehicle Overloaded Too High Drive Prevented Too High Lift Up Prevented These are not true faults but an indication that vehicle movement is prevented Remove excessive load from the platform Lower the platform if close to maximum height Move the vehicle to level ground Invalid Height Check Sensor 65 Check the voltage out of the height transducer into P4 3 It should be between 4V and 4 6V and should vary as the platform position varies Testing HWFS 78 Start Up 77 These are not true faults unless they do not clear the start up tests should only occur for a short time Overload Functions Disabled Factory Override 67 These are not true faults the GP102 has been configured to suppress overload functionality Idle Timeout Active Always Off Fault Bad Tilt Sensor Fault Bad HWFS Fault Bad Slave A
283. this manual Check for leakage Clean up any oil that may have spilled during this procedure 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 v Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 5 1 7 Wheel Bolt Nut Inspection and Torquing Procedure is necessary to check the torque on all wheel nuts and wheel bolts at pre delivery after 8 hours of operation and at weekly intervals using the following procedure 1 2 Confirm that each wheel fastener is torqued to 140 5ft Ib All fasteners must be torqued using the tightening sequence shown below Diagram 5 4 Wheel Fastener Tightening Sequence Again confirm that each wheel fastener is torqued to the specified tolerance Re torque as necessary until all fasteners are properly torqued 5 1 8 Wheel Reinstallation and Torquing Procedure When a wheel tire assembly has been removed or replaced it will be necessary to follow the procedure below to ensure proper installation l Inspect wheel fastener threads for damage of defects Replace if defective Clean the mounting surfaces ofthe hub and wheel rim of debris rust excess paint etc Mount wheel on the hub centering mounting holes on the wheel studs or bolt holes Use appropriate li
284. ting Table of Contents Section 5 Procedures Table of Contents Mid Size amp Full Size SKYJACK Page 3 Rough Terrain Series Service and Maintenance Operator s Responsibility for Maintenance The Safety Alert Symbol identifies important safety messages on aerial platforms safety This Safety Alert Symbol means attention signs in manuals or elsewhere When you see this symbol be alert to the possibility of Become alert Your safety is involved personal injury or death Follow the instructions in the safety message V DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices IMPORTANT IMPORTANT indicates a procedure essential for safe operation and which If not followed may result in a malfunction or damage to the aerial platform SKYJACK Page 4 Mid Size amp Full Size Rough Terrain Series Section 1 SCHEDULE MAINTENANCE Table of Contents Operator s Responsibility for Maintenance 7 ES 7 0
285. tion 4 Troubleshooting Information Service and Maintenance Introduction The following pages contain a table of Troubleshooting Information for locating and correcting most service trouble which can develop Careful and accurate analysis of the systems listed in the table of Troubleshooting Information will localize the trouble more quickly than any other method This manual cannot cover all possible troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component in which the trouble 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 preceded by a num ber represents the probable cause The following line noted by a dash represents the remedy to the probable cause directly above it See example below for clarification 1 Probable Cause Remedy Full Size RT s SKYJACK Page 5 Engine Powered Q Service and Maintenance Section 4 Troubleshooting Information Electrical System 4 1 1 All Controls Inoperative 1 Battery disconnected or discharged Reconnect battery Recharge if discharged 2 Loose or dirty battery cables Clean and tighten battery cables 3 Open or defective main power disconnect switch 1 Close switch Replace if defective 4 Loose or broken wire 03 from main power disconnect switch 1 to
286. tions OUTRIGGER TO MANIFOLD RETURN FILTER SY T PUMP 24 LEFTSTEER 48 158 REVERSE DRIVE VALVE 4H 23A RIGHT STEER VALVE TO CYLINDER TO STEER CYLINDER TO MOTION CONTROL VALVE SKYJACK Page 24 Or TO EMERGENCY 2 LOWERING O 1 CV2 SMALL CHECK PUMP 2H 18A SMALL PUMP DUMP VALVE O1 LOWERING ORIFICE Model 9250 2H 30A 1 2H 13A 168 BRAKE DUMP FORWARD VALVE LOWERING DRIVE VALVE 1 gt VALVE kee TO OUTRIGGER MANIFOLD amp MANIFOLD PLUG LIFT VALVE TO LIFT CONTROL LOWERING BLOCK Main Manifold HYDRAULIC MANIFOLD Auto Reset Brake Manifold 2H 25 QUICK BRAKE HAND PUMP 4H 71A 4H 74A OUTRIGGER OUTRIGGER LEFT FRONT LEFT REAR 79A RETRACT RETRACT OUTRIGGER RIGHT FRONT RETRACT 4H 73A OUTRIGGER RIGHT REAR RETRACT OUTRIGGER 4H 77A RIGHT FRONT OUTRIGGER EXTEND Outrigger Manifold RIGHT REAR EXTEND CYLINDER 29 lt 2H 178 OUTRIGGER HOLDING VALVE N h VA View Parts List Print This Page TO EMERGENCY LOWERING MANIFOLD AB V6 BRAKE RELEASE OVERRIDE VALVE 4H 78A OUTRIGGER LEFT REAR EXTEND 4H 75A OUTRIGGER LEFT FRONT EXTEND OUTRIGGER CYLINDER M
287. to base terminal block Check continuity Replace if defective Loose or broken wire 04 from base terminal block to relay 15CR Check continuity Replace if defective Loose or broken wire 15A from relay 15CR to time delay relay 1TD Check continuity Replace if defective Defective time delay relay 1TD Check relay Replace if defective Loose or broken wire 15B from time delay relay 1TD to reverse valve coil 4H 15B Check continuity Replace if defective Defective reverse valve coil 4H 15B Check coil Replace if defective Loose or broken wire 02 from reverse valve coil 4H 15B to base terminal block Check continuity Replace if defective Open diode D15A 1 or D15A 2 Check diodes Replace if defective 4 1 22 Forward Drive Inoperative 1 Defective drive forward switch 57 5 in joystick 57 Check switch Replace if defective 2 Defective joystick S7 Check joystick Replace if defective SKYJACK Page 16 Full Size RT s Engine Powered Section 4 Troubleshooting Information Service and Maintenance Electrical System Continued 3 4 9 10 11 12 13 Loose or broken wire 16 from joystick S7 to platform terminal block Check continuity Replace if defective Loose or broken wire 16 from platform terminal block to relay 16CR Check continuity Replace if defective Defective relay 16CR Check relay Replace if defective Loose or broken wire 02 from
288. tom By using Left Right buttons select the X Group Code from the menu and press the ENTER button SKYJACK Page 40 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 13 display will show XK GROUP Refer to 5 4 8 for 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 X2 CURVE Refer to 5 4 8 for curve code 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 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 Ca
289. ton 3 times b Observe program delay stabilization time Only the red LED will blink for 4 seconds Both LEDs will flash for 1 second Results The switch is learning the new zero position OL OT d Both LEDs will turn on solid for 1 second Results The new zero position has been learned Red LED Green LED 2 Red LED Q3 Green LED amp Red LED amp P SKYJACK Page 12 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance e The green LED will flash and then the 43 Turn main disconnect switch to gt off position red LED will turn on solid for 2 seconds P 14 Pushin emergency stop buttons Red LED gt Of Red LED 15 Remove chock or wheel blocks Oy J O _ 16 Proceed to Test and Verify Tilt Circuit Results The switch is verifying the new zero position f The green LED will turn solid Results The switch e Red LED is ready for normal 5 OS ereen LED operation 2 Mid Size amp Full Size SKYJACK Page 13 Rough Terrain Series Service and Maintenance Section 5 Procedures
290. tput A reading of OV or 5V is probably due to a wiring problem 4 3 27 Flash Code F30 Bad Heights 1 This message indicates that the recorded heights not increasing during either STATIC lift or are not decreasing during either STATIC lower may be possible to cause this problem by repeatedly opening and closing the UP or DOWN switch during the STATIC phases 4 3 28 Flash Code F31 Reject Curve 1 The DYNAMIC pressure curve is unacceptable Aninitial pressure peak when the platform lifted cannot be found between 0 and 15 height Check the pressure sensor and lift cylinder hydraulics 4 3 29 Flash Code F32 Reject Curve 1 The DYNAMIC pressure curve is unacceptable There should be a lowest pressure about halfway through the lift ie near 50 height the lowest pressure measured is at too low a height Check the pressure sensor and lift cylinder hydraulics 4 3 30 Flash Code F33 Reject Curve 1 The DYNAMIC pressure curve is unacceptable There should be a lowest pressure about halfway through the lift ie near 50 height the lowest pressure measured is at too high a height Check the pressure sensor and lift cylinder hydraulics 4 3 31 Flash Code F34 Reject Curve 1 The DYNAMIC pressure curve is unacceptable There is not enough difference between the initial pressure peak and the minimum pressure Check the pressure sensor and lift cylinder hydraulics 4 3 32 Flash Code F40 Reject Delta 1 This message indic
291. ttons 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 SKYJACK Page 42 Mid Size amp Full Size Rough Terrain Series Section 5 Procedures Service and Maintenance 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 to YES then press ENTER Mid Size amp Full Size SKYJACK Page 43 Rough Terrain Series Service and Maintenance Section 5 Procedures 5 4 8 Curve Group Codes Chart SKYJACK Page 44 Model Number of Extension Decks 7027 7127 1 Manual Extension Deck 7027 7127 1 Powered Extension Deck 7135 1 Man
292. ual Extension Deck 7135 1 Powered Extension Deck 8831 No Extension Deck 8831 1 Manual Extension Deck 8831 1 Powered Extension Deck 8831 2 Manual Extension Decks 8831 2 Powered Extension Decks 8841 No Extension Deck 8841 1 Manual Extension Deck 8841 1 Powered Extension Deck 8841 2 Manual Extension Decks 8841 2 Powered Extension Decks 9250 No Extension Deck 9250 1 Powered Extension Deck 9250 2 Powered Extension Decks 6832RT 1 Manual Extension Deck 6826RT 1 Manual Extension Deck 9241 2 Powered Extension Decks 60403AD Mid Size amp Full Size Rough Terrain Series Reliable lift solutions by people who care www skyjack com
293. use of cloth to strain the oil should be avoided to prevent lint from getting into the system When removing any hydraulic component be sure to cap and tag all hydraulic lines involved Also plug the ports of the removed components NOTE Samples of hydraulic oil should be drawn from the reservoir and tested annually These samples should be taken when the oil is warmed through normal operation of the system The sample should be analyzed by a qualified lubrication specialist to determine if it is suitable for continued use 10 Oil change intervals will depend on the care used in keeping the oil clean and the operating conditions Dirt and or moisture cotamination will dictate that the oil should be changed more often Under normal use and operating conditions the hydraulic oil should be changed every two years Refer to Table 1 2 of this manual All hydraulic components must be disassembled in spotlessly clean surroundings During disassembly pay particular attention to the identification of parts to assure proper reassembly Clean all metal parts in a clean mineral oil solvent Be sure to thoroughly clean all internal passages After the parts have been dried thoroughly lay them on a clean lint free surface for inspection Replace all O rings and seals when overhauling any component Lubricate all parts with clean hydraulic oil before reassembly Use small amounts of petroleum jelly to hold O rings in place during assemb
294. ve Full Size RT s SKYJACK Page 31 Engine Powered Q Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 4 1 51 Auto All Up Inoperative Retract 1 Loose or broken wire 35D from outrigger enable switch S9A to auto mode outrigger switch S24 Check continuity Replace if defective 2 Defective auto mode outrigger switch 24 Check switch Replace if defective 3 Loose or broken wire 10A at pin P2 12 on outrigger control module OCM1 Check for power at P2 12 If no voltage present check continuity of wire Replace if defective 4 Loose or broken wire 35 at pin P2 12 on outrigger control module OCM1 Check for power at P2 10 If no voltage present check continuity of wire Replace if defective 5 Loose or broken wire 02 at P2 11 on outrigger control module OCM1 Check for ground at P2 11 If no ground present check continuity of wire Replace if defective 6 Loose or broken wire 70 from auto mode outrigger switch S24 to pin P2 5 on outrigger control module OCM1 Check continuity Replace if defective SKYJACK Page 32 Full Size RT s Q Engine Powered Section 4 Troubleshooting Information Service and Maintenance Hydraulic System 4 2 1 All Functions Inoperative T 2 3 4 Hydraulic oil level low Refill tank to proper level Defective pump P1 Check pump Repair or replace if defective Broken engine to pump coupler
295. ve 7 Loose or broken wire 13 from up down switch 55 to diode 013 at base terminal block 1 CE Check continuity Replace if defective 8 Loose or Open diode 013 Tighten diode Check diode Replace if defective 9 Loose or broken wire 13D to relay 13DCR CE Check continuity Replace if defective 10 Loose or broken wire 02 from relay 13CR ANSI CSA or 13DCR CE to base terminal block TB 1 Check continuity Replace if defective 11 Defective relay 13CR ANSI CSA or 18DCR CE Check relay Replace if defective 12 Loose or broken wire 10A from base terminal block to relay 13CR ANSI CSA only Check continuity Replace if defective 13 Loose or broken wire 13A from relay 13CR ANSI CSA or 13DCR CE to base terminal block Check continuity Replace if defective 14 Loose or broken wire 13A from base terminal block to holding valve solenoid 2H 13A 1 or 2H 13A 2 or 2H 13A 3 or 2H 13A 4 Check continuity Replace if defective Full Size RT s SKYJACK Page 23 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 15 Loose or broken wire 02 from holding valve solenoid 2H 13A 1 or 2H 13A 2 or 2H 13A 3 or 2H 13A 4 to base terminal block TB 1 Check continuity Replace if defective 16 Defective holding valve solenoid 2H 13A 1 2H 13A 2 or 2H 13A 3 2H 13A 4 Check solenoid Replace if defective 17 Loose or br
296. wear Check each wheel for damage and cracked welds Check each lug nut for proper torque to ensure none are loose SKYJACK Page 26 Mid Size amp Full Size Rough Terrain Series Section 1 Scheduled Maintenance Service and Maintenance Inspections Typical Model 71xx shown Bottom View Ladder Manual Storage Base Weldment Wheel Tire Assembly Steer Cylinder Assembly e Ladder 1 1 10 Manuals Ensure there are no loose or missing Ensure a copy of operating manual and other parts and there is no visible damage important documents are enclosed in manual t box Outriggers If Equipped storage Ensure there are no loose or missing Check to be sure manual storage box is parts and there is no visible damage present and in good condition Ensure manuals are legible and in good condition Always return manuals to the manual storage box after use Mid Size amp Full Size SKYJACK Page 27 Rough Terrain Series Function Tests Drive Steer Enable Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton 1 2 Function Tests Function tests are designed to discover any malfunctions before aerial platform is put into service The operator must understand and follow step by step instructions to test all aerial platform functions WARNING N
297. witch and select 5 lift position Pull out O emergency stop button A beeping sound should be audible and light should come on SKYJACK Page 28 Mid Size amp Full Size Rough Terrain Series o Section 1 Scheduled Maintenance Function Tests Drive Steer Enable Rocker Switch 10 11 Trigger Switch Torque Switch Low High Speed Range Switch Horn Pushbutton Glow Plug Choke Pushbutton Engine Start Pushbutton Lift Enable Pushbutton WARNING If beeping sound is not audible and light does not come on aerial platform must be tagged and placed out of service Select low high throttle switch to X77 low throttle position CAUTION Do not start the engine in the high throttle position To start the engine f ANSI CSA dual fuel engine is cold depress and hold choke pushbutton if equipped with engine start pushbutton to start the engine f diesel engine is cold select and hold glow plug pushbutton for 15 to 20 seconds or until indicator light goes off Depress and hold pushbutton to start the engine engine start Drive Steer Low High Throttle Switch lt gt Operation Light Raise Off Lower Switch Off Lift Drive Key Switch Emergency Stop Button If engine is not cold depress and hold TOL engine start pushbutton to start the engine Test Emergency Stop 1 Pus
298. witch to drive position 3 Defective drive contacts in key switch 53 Check contacts Replace if defective 4 Loose or broken wire 12 from key switch S3 to joystick enable switch S7 7 Check continuity Replace if defective Full Size RT s SKYJACK Page 13 Engine Powered Service and Maintenance Section 4 Troubleshooting Information Electrical System Continued 10 11 12 13 14 195 16 17 18 19 20 Defective joystick enable switch S7 7 Check switch Replace if defective Loose or broken wire 12A from joystick enable relay 12BCR to speed steer and direction switches 57 110 57 6 Check continuity Replace if defective Loose or broken wire 12B from joystick enable switch S7 7 to joystick enable relay 12BCR Check continuity Replace if defective Defective joystick enable relay 12BCR Check continuity Replace if defective Loose or broken wire 02 from joystick enable relay 12BCR to controller harness Check continuity Replace if defective Loose or broken wire 10A from base terminal block to relay 28CR ANSI CSA or relay 28ECR1 CE Check continuity Replace if defective Defective relay 28CR ANSI CSA or relay 28ECR1 CE Check relay Replace if defective Loose or broken wire 1B from relay 28ECR1 to relay 28CR1 CE only Check continuity Replace if defective Defective relay 28CR1 CE only Check relay Replace if defective Loose or broken wir
299. ylinder Replace if defective 4 2 20 Left Rear Outrigger Inoperative 1 Stuck or defective retract valve 4H 74 or extend valve 4H 78 Clean valve Replace if defective 2 Stuck or defective check valve CVA Check valve Replace if defective 3 Bypassing outrigger cylinder C12 Repack cylinder Replace if defective 4 2 21 Outriggers Drift In 1 Defective check valve left front CV4 right front CV5 right rear CV6 or left rear CV7 Clean valve Replace if defective 2 Outriggers cylinder bypassing left front C9 right front C10 right rear C11 or left rear C12 Repack cylinder Replace if defective SKYJACK Page 36 Full Size RT s Q Engine Powered Section 4 Troubleshooting Information Service and Maintenance Load Sensing System CE 4 3 1 Flash Code F01 Check HWFS 1 This message is given if the GP102 startup tests have not completed Check HELP message for more information 4 3 2 Flash Code 202 Not Ground Mode 1 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 4 3 3 Flash Code F03 Not Stopped 1 This message is given if the machine is not in ground mode P2 2 must be high Check DIAGNOSTICS SWITCHES to see which function switch is closed 4 3 4 Flash Code 4 Tilted 1 This message 15 given if the machine is tilted Calibration must be carried out with the machine level If the machine is level

Service Manual Full-Size Rough Terrain Series

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