Sjb-66tk - 702015-ab.pdf 6g292k

Model SJB-66TK, Serial Numbers 93197 and Below.

For Service in North America and Asia please call ..............................800 275-9522 Skyjack Inc. Service Center 3451 Swenson Ave,. St. Charles, IL. 60174 FAX 630 262-0006 For Parts in North America and Asia please call .................................. 800 965-4626 Skyjack Inc. Parts Center 990 Vernon Rd., Wathena, KS, 66090 FAX 888 782-4825 For Parts & Service in Canada please call ............................................800 265-2738 Skyjack Inc. 55 Campbell Rd., Guelph, Ontario, Canada N1H 1B9 FAX 519 837-3883 For Parts & Service in Europe please call .........................................31 297 255 526 Skyjack Europe Communicatieweg 29, 3641 SG Mijdrecht Netherlands FAX 31 297 256 948 702015-AB

Printed in Canada

SJB-66TK BOOM

OPERATING MAINTENANCE & PARTS MANUAL

Jan., 2000

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

TABLE OF CONTENTS

1

SECTION 1 INTRODUCTION PURPOSE OF EQUIPMENT ....................................................................................Page 1 USE OF EQUIPMENT ..............................................................................................Page 1 WARNINGS ..............................................................................................................Page 1 DESCRIPTION .........................................................................................................Page 1 WORK PLATFORM MAJOR COMPONENT IDENTIFICATION ................................Page 6 SECTION 2 OPERATION OPERATOR QUALIFICATIONS ................................................................................ Page 1 OPERATING CONTROLS IDENTIFICATION Base Controls - Electrical ....................................................................................Page 1 Base Controls - Mechanical ................................................................................. Page 3 Base Controls - Hydraulic ....................................................................................Page 4 Platform Controls - Electric ..................................................................................Page 4 OPERATING PROCEDURES Prestart Checks ...................................................................................................Page 6 Start and Operation .............................................................................................Page 6 Shutdown Procedure ...........................................................................................Page 7 Loading and Tie Down Procedure ........................................................................Page 8 SECTION 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS TABLE OF CONTENTS ............................................................................................Page 1 SECTION 4 TROUBLESHOOTING TROUBLESHOOTING INFORMATION ....................................................................Page 4

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SECTION 5 MAINTENANCE AND SERVICE OPERATORS RESPONSIBILITY FOR MAINTENANCE .......................................... Page 1 MAINTENANCE AND INSPECTION SCHEDULE .................................................... Page 1 OWNER’S ANNUAL INSPECTION RECORD .......................................................... Page 1 GENERAL MAINTENANCE HINTS ..........................................................................Page 1 REPLACEMENT PARTS ..........................................................................................Page 1 HYDRAULIC SYSTEM AND COMPONENT MAINTENANCE AND REPAIR ............Page 2 ELECTRICAL SYSTEM DIAGNOSTICS AND ADJUSTMENTS............................... Page 8 HYDRAULIC SYSTEM DIAGNOSTICS AND ADJUSTMENTS .............................. Page 24 STANDARD HOSE MUNBERING SYSTEM ........................................................... Page 37

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SECTION 6 PARTS LISTS LIST OF ILLUSTRATIONS .......................................................................................Page 2 LIST OF TABLES TABLE 1-1. SPECIFICATIONS AND FEATURES ................................ SECTION 1, Page 5 TABLE 5-1. MAINTENANCE AND INSPECTION SCHEDULE ............ SECTION 5, Page 3 TABLE 5-2. OWNER’S ANNUAL INSPECTION RECORD................... SECTION 5, Page 4 TABLE 5-3. TIRE SPECIFICATIONS ................................................... SECTION 5, Page 4 TABLE 5-4. MAXIMUM PLATFORM CAPACITIES ............................... SECTION 5, Page 4 TABLE 5-5. SPECIAL TOOLS .............................................................. SECTION 5, Page 4 TABLE 5-6. TORQUE SPECIFICATIONS ............................................ SECTION 5, Page 5 TABLE 5-7. STANDARD OPERATION TIMES ..................................... SECTION 5, Page 6 TABLE 5-8. GENERAL SPECIFICATIONS .......................................... SECTION 5, Page 7

SJB-66TK, Serial Number 93197 and below

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6 Page i

WARNING You are required by ANSI/SIA A92.5 1990 to read and understand YOUR RESPONSIBILITIES in the Manual Of Resposibilities before you use or operate this work platform. FAILURE TO COMPLY with your REQUIRED RESPONSIBILITIES in the use and operation of the work platform could result in DEATH OR SERIOUS INJURY.

OPERATOR SAFETY REMINDERS The National Safety Council reminds us that most accidents are caused by the failure of some individuals to follow simple and fundamental rules and precautions. 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. You, as a careful operator, are the best insurance against an accident. Therefore, proper usage of this work platform is mandatory. The following pages of this manual should be read and understood completely before operating the work platform. Any modifications from the original design are strictly forbidden without written permission from SKYJACK, Inc.

SERVICE POLICY AND WARRANTY SKYJACK, Inc. warrants each new work platform to be free of defective parts and workmanship for the first 12 months. Any defective part will be replaced or repaired by your local SKYJACK dealer at no charge for parts or labor. Refer to the Warranty Statement for extensions or exclusions. NOTE SKYJACK, Inc. is continuously improving and expanding product features on it’s equipment; therefore, specifications and dimensions are subject to change without notice.

This Safety Alert Symbol means Attention! Become Alert! Your Safety Is Involved!

DANGER ELECTROCUTION HAZARD THIS MACHINE IS NOT INSULATED. MAINTAIN SAFE CLEARANCES FROM ELECTRICAL POWER LINES AND APPARATUS. YOU MUST ALLOW FOR PLATFORM SWAY, ROCK OR SAG. THIS WORK PLATFORM DOES NOT PROVIDE PROTECTION FROM WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR.

The Safety Alert Symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

VOLTAGE RANGE (PHASE TO PHASE)

MINIMUM SAFE APPROACH DISTANCE (FEET)

0 TO 300V

(METERS)

AVOID

OVER 300V TO 50KV

10

3.05

OVER 50KV TO 200KV

15

4.6

OVER 200KV TO 350KV

20

6.1

OVER 350KV TO 500KV

25

7.62

OVER 500KV TO 750KV

35

10.67

OVER 750KV TO 1000KV

45

13.72

FAILURE TO AVOID THIS HAZARD WILL RESULT IN DEATH OR SERIOUS INJURY! Page ii


SECTION 1 INTRODUCTION PURPOSE OF EQUIPMENT The SKYJACK SJB-TK Boom Work Platforms are designed to transport and raise personnel and tools to overhead and below grade work areas.

USE OF EQUIPMENT The work platform (Fig. 1-2) is a highly maneuverable, mobile work station.The TK models are designed for both slab-type and rough terrain applications. Lifting and elevated driving MUST be on a flat, level, compacted surface.

WARNINGS The operator MUST read and completely understand the front labels (Figures 1-1A, 1-1B and 1-1C) and ALL other warnings in this manual and on the work platform. Compare the labels on the work platform with the labels found throughout Sections 1 and 2 of this manual. If any labels are damaged or missing, replace them immediately.

DESCRIPTION The work platform consists of four major assemblies, the platform, boom assembly, turret and drive chassis. An operator’s control console is located on the platform. A foot switch on the platform enables and disables the platform controls. (Auxiliary and emergency controls are located on the rotating turret and platform.) PLATFORM - The platform is constructed of a skidresistant see-thru deck surface and a 42" high tubular steel railing system with midrails and 6" toe boards. The platform can be entered at either access through a sliding midrail bar or optional hinged gate. The platform can be rotated 90 degrees from center in either direction. A 110 VAC GFI outlet is also located on the platform.


BOOM ASSEMBLY - The boom is mounted on the turret and consists of a 6 foot hydraulic boom jib, telescoping fly boom, telescoping mid boom, boom knuckle assembly and main boom. This mechanism uses double-acting hydraulic cylinders with holding valves to control movement of each boom. TURRET - The turret rotates 360 degrees continuously. Within the turret are two main cabinets. One cabinet contains the base control box, main hydraulic manifold and function valves, emergency hydraulic pump and motor, and the primary and emergency batteries. The other cabinet contains the engine, and hydraulic pumps. The hydraulic oil and fuel tanks are also mounted on the turret with access to filler neck and level gauges through the removeable covers. DRIVE CHASSIS -The base is a rigid one-piece weldment. Models equipped with dual fuel option have mounting straps for a propane tank on each side. The front axle has two non-driven wheels, steerable by a hydraulic cylinder (2WD models), or a hydraulic motor driven axle with an integrated cylinder for steering the wheels and spring-applied hydraulically-released parking brakes (4WD models). The rear axle is hydraulic motor driven (2WD models), or coupled to the front axle by a drive shaft (4WD models) and has spring-applied hydraulically-released parking brakes. PLATFORM CONTROL CONSOLE - Located on the platform, this control station contains controls for work platform motion, emergency stopping and emergency pump operation. OPTIONAL ACCESSORIES - The SKYJACK SJB-TK Boom Work Platforms are designed to accept a variety of optional accessories. These are listed in Table 1-1. Specifications and Features found later in this section. Operating instructions for these options (if required) can be found in Section 2 of this manual.

SECTION 1, Page 1

1

FAILURE TO AVOID THESE HAZARDS WILL RESULT IN SERIOUS INJURY OR DEATH.

Figure 1-1A. Front Labels SECTION 1, Page 2


Figure 1-1B. Front & Platform Labels SJB-66TK, Serial Number 93197 and below

SECTION 1, Page 3

Figure 1-1C. Front & Platform Labels SECTION 1, Page 4


TABLE 1-1. SPECIFICATIONS AND FEATURES SJB-66TK Specifications WEIGHT ........................................................................................................ 34000 lb. (11703kg) WORK HEIGHT (nominal) ....................................................................................... 72' (21.95m) RAISED PLATFORM HEIGHT (nominal) ................................................................ 66' (20.12m) STOWED HEIGHT .................................................................................................. 8’11" (2.59m) OVERALL WIDTH ......................................................................................................... 8' (2.44m) STOWED LENGTH ................................................................................................. 29’3" (8.92m) PLATFORM CAPACITY (Unrestricted) ................................................................. 600 lb. (272kg) PLATFORM SIZE (Standard)..................................................................... 30" x 96" (.76mx2.44) ELECTRICAL SYSTEM (Engine starting) ......................................................................... 12 volt GRADABILITY .....................................................................................................................30%+ TURRET ROTATION (Continuous) ....................................................................................... 360° TIRE SIZE ....................................................................................................... 15 x 19.5 Air Filled Features STANDARD EQUIPMENT 6 Foot Hydraulically Controlled Boom Jib (SJB-66TK) Variable Speed Drive and Function Controls Telescopic Knuckle Assembly Continuous Drive and Steer Directional Sensing 12 Volt DC Emergency Power Engine Anti-restart Protection Spring-Applied Hydraulically Released Parking Brakes ANSI and CSA Standards Compliance 110V Outlet on Platform with GFI Ford LRG 423 Gasoline Engine OPTIONAL EQUIPMENT Operator Horn All Function Motion Alarm Travel Alarm Flashing Amber Light Spring-Loaded Half Gate Spring Loaded Full Gate Dual Fuel (Gas/Propane) 3500 Watt Hydraulic Generator Cold Weather Start Package 30" x 72" and 30" x 120" Platform Options Four Wheel Drive Diesel Engine Chassis Lights Platform Work Lights Air or Hydraulic Line to Platform Platform Overload Sensing () 8 Meter Drive Cutout (Europe) SJB-66TK, Serial Number 93197 and below

SECTION 1, Page 5

WORK PLATFORM MAJOR COMPONENT IDENTIFICATION

PLATFORM

BOOM JIB FLY BOOM

MID BOOM

BOOM KNUCKLE

MAIN BOOM

TURRET

DRIVE CHASSIS

Figure 1-2. SKYJACK SJB-66TK Boom Work Platform SECTION 1, Page 6


SECTION 2 OPERATION OPERATOR QUALIFICATIONS Only trained and authorized persons should use this work platform. Safe use of this work platform requires the operator to understand the limitations and warnings, operating procedures and operator’s responsibility for maintenance. Accordingly, the operator MUST understand and be familiar with this operating manual, its warnings and instructions and ALL warnings and instructions on the work platform. Operator also MUST be familiar with employer’s work rules and related government regulations and be able to demonstrate his/her ability to understand and operate THIS make and model work platform in the presence of a qualified person.

OPERATING CONTROL IDENTIFICATION The following descriptions are for identification, explanation and locating purposes only. A qualified operator MUST read and completely understand these descriptions before operating this work platform. Procedures for operating this work platform are detailed in the ‘’OPERATING PROCEDURES’‘ section beginning on SECTION 2, Page 6 in this manual. Both standard and optional controls are identified in this section. Therefore, some controls may be included that are not furnished on your work platform.

Base Controls - Electrical

16. GLOW PLUG SWITCH (Diesel option) 17. COLD WEATHER START OPTION RECEPTACLE 18. 110 VOLT RECEPTACLE (Power to platform) or VOLT METER FOR GENERATOR OPTION

Base Control 4

1

3

2

4 5

8

7

6

16

15

9 17

18 14

13 12

11

10

Figure 2-1. Base Control and Label 1. 2. 3. 4. 5. 6. 7. 8.

OFF/PLATFORM/BASE SELECT KEY SWITCH ENGINE STOP/RUN/START SELECT SWITCH EMERGENCY STOP BUTTON CIRCUIT BREAKERS EMERGENCY PUMP SELECT TOGGLE SWITCH CHARGING AMPERAGE GAUGE ENGINE HOUR METER MANUAL PLATFORM STOWING TOGGLE SWITCH 9. MANUAL PLATFORM LEVELING SWITCH 10. PLATFORM ROTATE TOGGLE SWITCH 11. JIB UP/DOWN TOGGLE SWITCH 12. TURRET ROTATE TOGGLE SWITCH 13. BOOM RETRACT/EXTEND TOGGLE SWITCH 14. BOOM LIFT UP/DOWN TOGGLE SWITCH 15. BOOM KNUCKLE UP/DOWN TOGGLE SWITCH SJB-66TK, Serial Number 93197 and below

BASE CONTROL - This control station, located on the side of the rotating turret, contains the following controls: 1. OFF/PLATFORM/BASE SELECT KEY SWITCH Turning the key to the “ ” (off) position disconnects power from the control circuit. When the “ ” (platform) position is selected, power is directed to the control station on the platform. When in the “ ” (base) position, power is directed to the control station on the base. 2. ENGINE STOP/RUN/START SELECT SWITCH Turning the switch to the ” “ (start) position will engage the starter, once the engine starts, release the switch and it will return to the “ ” (run) position. To stop the engine turn the switch to the “ ” (stop) position. The engine must be running before any functions can be operated. 3. EMERGENCY STOP BUTTON - When struck, this red push-button switch disconnects power to the control circuit. In the event of an emergency or at work platform shut down, push button in. To restore power, simply pull button out.

WARNING Depressing the Emergency Stop Button instantly engages parking brakes. 4. CIRCUIT BREAKER - In the event of a power overload or positive circuit grounding, the circuit breaker will pop out. Make the necessary corrections, then depress the push-button to reset. SECTION 2, Page 1

2

5. EMERGENCY PUMP SELECT TOGGLE SWITCH In the event of an emergency, moving this toggle switch to the” ñ “ (up) position kills the engine, enables the 12 volt emergency pump and allows all functions to be operated. To resume normal operation, move the switch to the down position by closing the switch cover. 6. AMPERAGE GAUGE - With the engine running, this gauge monitors battery charging amperage. 7. HOUR METER - Activated by the engine oil pressure switch, this gauge measures engine running time. 8. MANUAL PLATFORM STOWING TOGGLE SWITCH - This feature is used to fold the platform below the boom arm for minimum stowed length. With the Off/Platform/ Base Select Key Switch in the “ “(base) position. Fully retract the Mid and Fly boom sections. Elevate the main boom slightly above horizontal to prevent the platform from ing the ground. Hold the Manual Platform Stowing Toggle Switch in the “ ñ “ (up) position (this switch must be held through the entire stowing procedure) and fully lower the boom jib. With the Manual Platform Leveling Switch, tilt the platform below the boom. Lower the boom to the desired position and release the Manual Stowing Switch. To resume normal operation, hold the Platform Stowing Toggle Switch in the “ ñ “ (up) position and raise the boom until there is sufficient ground clearance for the platform to swing out. Release the stowing switch and continue to raise the boom, the automatic leveling system will return the platform to its working position.

WARNING Before using the platform stowing feature. Remove all loose items from platform i.e. tools, work materials, etc. Check around platform for any obstacles that may be in the path of travel of the platform. DO NOT use the stowing feature with a person in the platform. 9. MANUAL PLATFORM LEVELING TOGGLE SWITCH - This switch is to be used with the Manual Platform Stowing Toggle Switch to level the platform or for stowing the platform below the boom. This switch will not operate unless the Platform Stowing Switch is being held in the “ ñ “ (up) position. 10. PLATFORM LEFT/RIGHT ROTATION TOGGLE SWITCH - This switch controls left and right rotation of the platform. To rotate the platform to the left, push and hold this toggle switch to the “ ï “ (left) position. Release switch to stop. To rotate the platform to the right, push and hold this toggle switch to the “ ð “ (right) position. SECTION 2, Page 2

11. JIB UP/DOWN TOGGLE SWITCH - This switch controls the up/down movement of the jib. To move the jib upward, push and hold this toggle switch to the “ñ “ (up) position. Release switch to stop. To move the jib downward, push and hold this toggle switch to the “ ò “ (down) position. Release switch to stop. 12. TURRET ROTATION TOGGLE SWITCH - This switch controls clockwise and counter-clockwise turret rotation. To rotate the turret clockwise, push and hold this toggle switch to the “ ò “ (cw) position. Release switch to stop. To rotate the turret counterclockwise, push and hold this toggle switch to the “ ñ “ (ccw) position. Release switch to stop. 13. BOOM RETRACT/EXTEND TOGGLE SWITCH This switch controls the retraction and extension of the telescoping boom arm. This function is automatically sequenced so the mid boom always extends first and retracts last. To retract the boom arm, push and hold this toggle switch to the “ ï “ (retract) position. Release switch to stop. To extend the boom arm, push and hold this toggle switch to the “ ð “ (extend) position. Release switch to stop. 14. BOOM UP/DOWN TOGGLE SWITCH - This switch controls the up/down movement of the boom section. To raise the boom section, push and hold this toggle switch to the “ ñ “ (up) position. Release switch to stop. To lower the boom section, push and hold this toggle switch to the “ ò “ (down) position. Release switch to stop. 15. BOOM KNUCKLE UP/DOWN TOGGLE SWITCH This switch controls the up/down movement of the boom knuckle section. The mid boom section must be completely extended and the knuckle enable light, located on the operators control console must be on before operation of the boom knuckle is allowed. To lower the knuckle section, push and hold this toggle switch to the “ ò “ (down) position. Release switch to stop. To raise the knuckle section, push and hold this toggle switch to the “ ñ “ (up) position. Release switch to stop. 16. GLOW PLUG TOGGLE SWITCH (Diesel option) This switch activates the diesel engine glow plugs. Prior to starting the engine hold this switch in the up position for 15-20 seconds. 17. COLD WEATHER START RECEPTACLE OPTION - This receptacle is used for A.C. connection on machines equipped with the Cold Weather Start Option. 18. 110 VOLT RECEPTACLE (Power to platform) or VOLT METER FOR GENERATOR OPTION - This 110 volt receptiacle provides power to platform on standard machines or replaced by a volt meter for machines equiped with the Hydraulic Generator Option. SJB-66TK, Serial Number 93197 and below

Engine Throttle Control Switches

Manual Hydraulic Fluid Shut-Off Valve

2

1

1

Figure 2-2. Engine Throttle Control Switches 1. 2.

ENGINE THROTTLE CONTROL SWITCH “A” ENGINE THROTTLE CONTROL SWITCH “B”

ENGINE THROTTLE CONTROL SWITCHES - These switches located on the engine tray side plate inside the engine cabinet are used to control the engine RPM for engine service, adjustment, or diagnostic testing. To allow full range of RPM at this control the Off/Platform/ Base Select Key Switch must be in the “ “ (platform) position. Machines with diesel option have only one switch and two available RPM ranges.

Figure 2-4. Hydraulic Fluid Shut-Off Valve 1.

HYDRAULIC FLUID SHUT-OFF VALVE

1. HYDRAULIC FLUID SHUT-OFF VALVE - This valve located in the hydraulic fluid supply line on the hydraulic tank turns off the supply of hydraulic fluid to the pumps. DO NOT start or run the engine with this valve closed. Drive Motor Disengage Lever (Early Models)

Base Controls - Mechanical Manual Fuel Shut-Off Valve

1

Figure 2-5. Drive Motor Disengage Lever 1.

1

Figure 2-3. Fuel Shut-Off Valve 1.

FUEL SHUT-OFF VALVE

1. FUEL SHUT-OFF VALVE - This valve located in the fuel supply line on the bottom of the fuel tank turns off the supply of fuel to the fuel pump.

DRIVE MOTOR DISENGAGE LEVER

1. DRIVE MOTOR DISENGAGE LEVER - This lever is located on the top side of the planetary gear box at the rear drive axle (2WD models), or on the top side of the transfer case on the front axle (4WD models) and is held in position with an allen head set screw. This lever is used to disengage the drive motor for winching the machine onto or off of a transport vehicle if desired. To disengage the drive motor the procedure below MUST be followed:

DANGER DO NOT attempt to disengage the drive motor without the wheels chocked. DO NOT release brakes prior to disengaging motor.


SECTION 2, Page 3

Step 1. Place machine on a flat level surface and chock wheels to prevent from rolling. Step 2. Remove set screw from lever and rotate lever towards rear of machine (2WD models) or towards front of machine (4WD models) to disengage drive motor. Reinstall set screw to hold lever in position. Step 3. Release the parking brakes using the brake release procedure described in the base hydraulic controls portion of this section.

CAUTION DO NOT tow. This procedure is intended for loading and unloading with a winch line only.

Base Controls - Hydraulic

Step 1. Firmly pull out the red plunger on the Brake Manifold until the knob remains out. Step 2. Grasp the black hand pump plunger and pump rapidly until firm resistance is felt and the brake pressure gauge reaches 700 psi. The brakes are now release. (Although the gauge reading may decrease the brakes will remain released until pressure drops below 300 psi.)

NOTE To return brakes to normal operation depress red plunger or operate any hydraulic function other than steering.

Platform Controls - Electrical Foot Switch

Parking Brake Manifold

1 2

1

Figure 2-6. Parking Brake Manifold 1. 2.

BRAKE OVERRIDE VALVE PLUNGER PARKING BRAKE RELEASE HAND PUMP

PARKING BRAKE MANIFOLD - This manifold is located near the Base Control on the rotating turret, and accessed by opening the hydraulic/electric cabinet door. It containes the following controls:

DANGER DO NOT release the brakes on an incline without the wheels chocked. 1. PARKING BRAKE OVERRIDE VALVE PLUNGER When this red plunger is pulled out, the brake hydraulic circuit is isolated allowing use of the parking brake hand pump. 2. PARKING BRAKE RELEASE HAND PUMP - The hand pump MUST be used to disengage the parking brakes. To release the parking brakes the procedure below MUST be followed: SECTION 2, Page 4

Figure 2-7. Foot Switch 1.

FOOT SWITCH

1. FOOT SWITCH - The foot switch is located on the platform. When the foot switch is depressed and held, power is brought to the controls on the operator’s control console. When the foot switch is released, the controls on the operator’s control console are cut out.

NOTE Engine will not start with foot switch depressed.

IMPORTANT NOTE The foot switch MUST be depressed and held to use any control on the operator’s control console.

WARNING Before releasing the foot switch, the controllers should be returned to the neutral position. Work platform motion will stop when the foot switch is released. When the foot switch is released the parking brakes are immediately engaged. SJB-66TK, Serial Number 93197 and below

Operator’s Control Console 15

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7

4

8

1. ENGINE STOP/RUN/START SELECT SWITCH - This rotating switch controls engine starting and operation. To start engine Do Not depress the foot switch.

6

10 11

5

2. ENGINE SPEED SELECT SWITCH - This three position switch is used to control engine running speed. When the foot switch is released, the engine returns to idle speed.

17

3. DRIVE/STEER CONTROLLER - This lever-type controller allows the operator to drive in forward and reverse and steer left and right.

1 16

12

13

14

2

3

4. JIB UP/DOWN AND PLATFORM ROTATE CONTROLLER - This lever-type controller allows the operator to choose the direction and vary the speed for jib up/down movement and platform right/left rotation.

Figure 2-8. Operator’s Control Console and Label 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17

ENGINE STOP/RUN/START SELECT SWITCH ENGINE SPEED SELECT SWITCH DRIVE/STEER CONTROLLER JIB UP/DOWN, PLATFORM ROTATE CONTROLLER BOOM KNUCKLE UP/DOWN CONTROLLER BOOM KNUCKLE ENABLE INDICATOR LIGHT ENGINE WARNING LIGHT TILT SENSOR INDICATOR LIGHT EMERGENCY PUMP SELECT TOGGLE SWITCH BOOM EXTEND/RETRACT CONTROLLER HORN TOGGLE SWITCH (Option) BOOM UP/DOWN, TURRET ROTATE CONTROLLER DUEL FUEL SELECT SWITCH (Option) EMERGENCY STOP BUTTON PLATFORM WORK LIGHTS and/or CHASSIS HEAD LIGHTS TOGGLE SWITCH (Option) GLOW PLUG SWITCH (Diesel option) HYDRAULIC GENERATOR OPTION TOGGLE SWITCH

OPERATOR’S CONTROL CONSOLE - This control station is located at the front of the platform. It contains the following controls:

IMPORTANT NOTE The foot switch MUST be depressed and held to use any control on the operator’s control console. Refer to Operating Procedures for detailed instructions on operating these controls.


5. BOOM KNUCKLE UP/DOWN CONTROLLER - This lever-type controller allows the operator to choose the direction and vary the speed of the knuckle up/down movement. This function is only available when the mid boom is fully extended and the Knuckle Enable Indicator Light is on. 6. KNUCKLE ENABLE INDICATOR LIGHT - This green indicator light informs the operator that the knuckle function is available to be used. The knuckle function will not operate until this light is on. 7. ENGINE WARNING LIGHT - This red light indicates that the engine oil pressure is low or the engine is overheating. 8. TILT SENSOR INDICATOR LIGHT & BUZZER - This red light and buzzer indicates that the work platform is on a slope. If machine is elevated at this time drive function will be inoperable. Return machine to fully lowered position and drive to flat level ground. Sensor will reset automatically and elevated driving will be restored. 9. EMERGENCY PUMP SELECT TOGGLE SWITCH In the event of an emergency, lifting the switch cover and holding this switch in the up position kills the engine and enables emergency boom functions to be operated using the 12 volt emergency pump. If the switch is released, power to the emergency pump is disconnected. 10. BOOM EXTEND RETRACT CONTROLLER - This lever-type controller allows the operator to extend or retract the boom and vary the speed of the function.

SECTION 2, Page 5

11. HORN TOGGLE SWITCH (Optional) - The horn can be sounded by pushing this toggle switch to the up position.

3. Check overhead clearances.

Start and Operation At the base control :

12. BOOM UP/DOWN AND TURRET ROTATE CONTROLLER - This lever-type controller allows the operator to choose the direction and vary the speed for boom up/down movement or turret right/left rotation. 13. DUEL FUEL SELECT SWITCH TOGGLE SWITCH (Option) - This switch allows the operator to select the fuel source to be used. 14. EMERGENCY STOP BUTTON - When struck, this red push-button switch disconnects power to the control circuit. In the event of an emergency or at work platform shut down, push button in. To restore power, simply pull button out.

WARNING Depressing the Emergency Stop Button instantly engages parking brakes.

1.

Pull out the Emergency Stop Button.

2.

Select “ ” (platform) with Off/Platform/Base Select Key Switch.

3.

Enter the platform by sliding the entry bar upward. Make sure the entry bar returns to midrail position. Close the gate (if so equipped).

Using the platform controls:

WARNING DO NOT operate any control on the operator’s control console without your safety belt fastened and properly securing the safety belt lanyard to the platform lanyard rings. Failure to avoid this hazard could result in death or serious injury!

15. PLATFORM WORK LIGHT and/or CHASSIS HEAD LIGHTS TOGGLE SWITCH (Optional) - This switch controls power to the platform mounted work lights and/ or the chassis mounted head lights.

4.

Attach the safety belt lanyards of each occupant to the platform lanyard rings.

5.

Pull out the Emergency Stop Button.

16. GLOW PLUG TOGGLE SWITCH (Diesel option) This switch activates the diesel engine glow plugs. Prior to starting the engine hold this switch in the up position for 15-20 seconds.

6.

Select desired fuel source using the Fuel Source Select Switch. (Machines with dual fuel option) Press and hold Glow Plug Switch for 15 to 20 seconds, then release. (Machines with diesel engine option)

7.

Turn Engine Stop/Run/Start Select Switch to the “ ” (start) position until engine starts, then release. DO NOT over crank the starter. (If engine fails to start after multiple attempts, consult the TROUBLE SHOOTING section in the Operational Maintenance and Parts Manual). NOTE Engine will not start if foot switch is depressed.

8.

Select desired engine RPM using the Engine Speed Select Switch.

17. HYDRAULIC GENERATOR TOGGLE SWITCH (Optional) - This switch operates the optional hydraulic 110 volt generator to supply power to the platform mounted 110 volt outlet.

OPERATING PROCEDURES Before operating any control, read and completely understand ALL Dangers, Warnings and Cautions on the work platform and in this operator’s manual. Pre-start Checks 1. Carefully read and completely understand ALL of Section 2, OPERATION in this manual and ALL warnings and instruction decals on the work platform.

The following controls on the Operator’s Control Console WILL NOT operate unless the Foot Switch is depressed and held.

2. Check for obstacles around the work platform and in the path of travel such as holes, drop offs, debris, ditches and soft fill.

NOTE When the operator is positioned over an axle, the direction the operator is facing will be FORWARD!

SECTION 2, Page 6


WARNING

18.

TO ROTATE THE TURRET CLOCKWISE: Slowly move the Boom Up/Down, Turret Rotate Controller to the “ ï “ (cw) position. Release the controller to stop.

19.

TO ROTATE THE TURRET COUNTERCLOCKWISE: Slowly move the Boom Up/ Down, Turret Rotate Controller to the “ ð “ (ccw) position. Release the controller to stop.

20.

TO EXTEND THE BOOM ARM: Slowly move the Boom Extend/Retract Controller to the“ ò “ (extend) position. Release the controller to stop. (This function is automatically sequenced so the mid boom will always extend first, followed by the fly boom.)

21.

TO RETRACT THE BOOM ARM: Slowly move the Boom Extend/Retract Controller to the“ ñ “ (retract) position. Release the controller to stop. (This function is automatically sequenced so the fly boom will always retract first followed by the mid boom.) The boom knuckle must be in the full up position to retract the mid boom.

22.

TO MOVE THE BOOM KNUCKLE DOWN: Slowly move the Knuckle Up/Down Controller to the “ ò ” (down) position. Release controller to stop. This function only becomes available when the mid boom has been fully extended, as indicated by the green Knuckle Enable Light on the control console.

23.

TO MOVE THE BOOM KNUCKLE UP: Slowly move the Knuckle Up/Down Controller to the “ ñ ” (up) position. Release controller to stop. This function only becomes available when the mid boom has been fully extended, as indicated by the green Knuckle Enable Light on the control console.

24.

TO SOUND THE HORN: Press the Horn Toggle Switch to the “ñ” (up) position.

25.

TO OPERATE USING THE EMERGENCY PUMP: Raise the cover on the Emergency Pump Select Toggle Switch. Press and hold the switch to the “ ñ ” (up) position. When the switch is released, power to the auxiliary pump will be disconnected. This function is intended to be used in the event of an engine failure to lower the work platform or move the machine to an appropriate location for repairs to be made. This function is not intended to be use for an extended period of time.

DO NOT drive the boom when the platform position does not allow the operator a clear view of the chassis •

•

•

The operator should not drive or steer while belowgrade, or in a position where he cannot see the chassis. Before the operator goes into a position where he cannot see the chassis, the operator and “the spotter” shall that the intended path of travel is clear of obstruction. This shall be done by driving the TK unit from a position in which the chassis is visible without changing the steering angle, along the length of the travel path. Area of operation should be marked off with cones or fenced off with black/yellow warning tape.

9.

TO DRIVE FORWARD: Slowly move the Drive/ Steer Controller handle to the “ ñ “ (forward) position. Release controller handle to stop.

10.

TO DRIVE IN REVERSE: Slowly move the Drive/Steer Controller handle to the “ ò “ (reverse) position. Release controller handle to stop.

11.

TO STEER: Move the Drive/Steer Controller handle in the direction you wish to steer.

12.

TO MOVE THE JIB UP: Slowly move the Jib Up/Down, Platform Rotate Controller to the “ ñ “ (up) position. Release the controller to stop.

13.

TO MOVE THE JIB DOWN: Slowly move the Jib Up/Down, Platform Rotate Controller to the “ ò “ (down) position. Release the controller to stop.

14.

TO ROTATE THE PLATFORM TO THE LEFT: Slowly move the Jib Up/Down, Platform Rotate Controller to the “ ï “ (left) position. Release the controller to stop.

15.

TO ROTATE THE PLATFORM TO THE RIGHT: Slowly move the Jib Up/Down, Platform Rotate Controller to the “ ð “ (right) position. Release the controller to stop.

16.

TO MOVE THE BOOM UPWARD: Slowly move the Boom Up/Down, Turret Rotate Controller to the “ ñ “ (up) position. Release the controller to stop.

17.

TO MOVE THE BOOM DOWNWARD: Slowly move the Boom Up/Down, Turret Rotate Controller to the “ ò “ (down) position. Release the controller to stop.


SECTION 2, Page 7

Shutdown Procedure 1.

Completely retract the boom and lower the platform.

2.

Push in the Emergency Stop Buttons.

3.

Rotate the Engine Stop/Run/Start Select Switch to the “ “ (stop) position.

4.

Rotate the Off/Platform/Base Key Switch to the “ “(off) position. Remove the key.

Loading and Tie Down Procedure 1.

With mid and fly boom sections fully retracted and trailer on firm level ground. Align the tires of the boom with the back end of the trailer.

3.

Select low speed on the platform throttle control and slightly raise jib and/or boom for ground clearance while loading. Slowly and carefully drive the machine on to the trailer.

4.

With machine loaded on trailer, tie down as recommended. (Refer to Figure 2-9.)

Figure 2-9. Recommended Tie Down Locations

SECTION 2, Page 8


SECTION 3 SYSTEM COMPONENT IDENTIFICATION AND SCHEMATICS TABLE OF CONTENTS

ELECTRICAL SYSTEM FIGURE 3-1. CONTROL CONSOLE DIAGRAM PARTS LIST WITH OPTIONS (Gas and Dual fuel) ........................................................................................................................................... 2 FIGURE 3-1. CONTROL CONSOLE DIAGRAM WITH OPTIONS (Gas and Dual Fuel) .......................................................................................................................................... 3 FIGURE 3-2. CONTROL CONSOLE DIAGRAM WITH OPTIONS (Diesel) ............................................................................................................................................................. 4 FIGURE 3-2. CONTROL CONSOLE DIAGRAM PARTS LIST WITH OPTIONS (Diesel) ............................................................................................................................................................. 5 FIGURE 3-3. LOAD SENSING OPTION DIAGRAM PARTS LIST () ............................................................. 6 FIGURE 3-3. LOAD SENSING OPTION DIAGRAM () .................................................................................. 7 FIGURE 3-4. BASE CONTROL/ELECTRICAL DIAGRAM........................................................................... 8 FIGURE 3-4. BASE CONTROL/ELECTRICAL DIAGRAM PARTS LIST ...................................................... 9 FIGURE 3-5. ENGINE COMPARTMENT WIRING DIAGRAM PARTS LIST (Gas and dual fuel)............................ 10 FIGURE 3-5. ENGINE COMPARTMENT WIRING DIAGRAM (Gas and dual fuel) ................................................ 11 FIGURE 3-6. ENGINE COMPARTMENT WIRING DIAGRAM (Deutz diesel) ........................................................ 12 FIGURE 3-6. ENGINE COMPARTMENT WIRING DIAGRAM PARTS LIST (Deutz diesel) .................................... 13 FIGURE 3-7. ELECTRICAL SCHEMATIC (Gas and dual fuel) .............................................................................. 15 FIGURE 3-8. ELECTRICAL SCHEMATIC (Deutz diesel)....................................................................................... 16 FIGURE 3-7/FIGURE 3-8. ELECTRICAL SCHEMATIC PARTS LIST .................................................................... 17

HYDRAULIC SYSTEM FIGURE 3-9/FIGURE 3-10. HYDRAULIC SCHEMATIC PARTS LIST .................................................................... 18 FIGURE 3-9. HYDRAULIC SCHEMATIC (4x2) ...................................................................................................... 19 FIGURE 3-10. HYDRAULIC SCHEMATIC (4x4 OPTION) ..................................................................................... 20 FIGURE 3-11. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION .................................................. 21 FIGURE 3-12. PLATFORM LEVELING MANIFOLD COMPONENT AND PORT IDENTIFICATION ...................... 22 FIGURE 3-13. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION ............................................... 22


SECTION 3, Page 1

3

FIGURE 3-1. CONTROL CONSOLE DIAGRAM PARTS LIST WITH OPTIONS (Gas and dual fuel) Index No.

Skyjack Part No.

1

702197

2

702198

3

702199

4

702200

5 6

704311 701934 703185 701936 703186 701935 703185 701937 703187 701931 (Ref.)

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

109698 103011 103012 702168 702278 700187 103036 702104 103041 702103 702613 102956 702185 702186 701943 700166 701929 701930 701933 702841

SECTION 3, Page 2

OEM Part No.

Description 1 2 3 4 5 6 7

CONTROLLER, Drive/steer (For components, refer to Figure 6-5.) CONTROLLER, Main lift/turret rotate (For components, refer to Figure 6-6.) CONTROLLER, Jib lift/platform rotate (For components, refer to Figure 6-7.) CONTROLLER, Knuckle/extension (For components, refer to Figure 6-8.) CIRCUIT BOARD, Platform leveling LIGHT, Red indicator • BULB, 12 Volt #1893 ALARM, Dual • BULB, 12 Volt #1815 LIGHT, Green indicator • BULB, 12 Volt #1893 LIGHT, Console illumination • BULB, 12 Volt #67 SWITCH, Anti-restart ignition SWITCH ASSEMBLY, Emergency stop (For components, refer to Figure 6-4.) RECEPTACLE, 110 Volt GFCI TERMINAL STRIP, Large TERMINAL STRIP, Small LEVEL SENSOR, Platform CABLE, 22 Ga. 4 wire shielded SWITCH, Foot STRAIN RELIEF, Straight plastic CABLE, 14 Wire control STRAIN RELIEF, 5/8" Straight CABLE, 49 Wire main control STRAIN RELIEF, 1-1/8" Straight PLUG, Knockout 7/8" WIRE DUCT, 1" COVER, 1" Wire duct RELAY, 12 Volt sealed DIODE, 1 Amp 400PIV SWITCH, Toggle 2 position momentary SWITCH, Toggle 2 position maintained SWITCH, Toggle 3 position maintained MANIFOLD ASSEMBLY, Platform leveling (For components, refer to Figure 6-13.)

Units per Assy.

1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 5 1 174" 1 1 93" 1 468" 1 1 129" 129" 5 6 2 AR 1 1


FIGURE 3-1. CONTROL CONSOLE DIAGRAM WITH OPTIONS (Gas and Dual Fuel) A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

1

10 LEGEND 24

28

2

4

49 Conductor Main Control Cable 8

14 14 Conductor Leveling Manifold Cable

3

1

4

23

5

9 25 26

29 21 22

6

11 7

19 20

7

12

6

3

28 5

8

18

9

2

30 10

13 27

11

4 28 19 12

27

14 16

TO PLATFORM WORK LIGHTS AND OR CHASSIS DRIVING LIGHTS (Optional)

13

15 17 14


SECTION 3, Page 3

FIGURE 3-2. CONTROL CONSOLE DIAGRAM WITH OPTIONS (Diesel) A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

1

10

28

24

LEGEND

4

2

49 Conductor Main Control Cable

8 14

14 Conductor Leveling Manifold Cable

3

1 4

23

5

9 25 26

28

6

21 22 11 7

12

7

19 20

6 5

8

3

29 18

27

9

2

30 10

13

11

4 28 19 12

27 14

16 TO PLATFORM WORK LIGHTS AND OR CHASSIS DRIVING LIGHTS (Optional)

13

15

17

14

SECTION 3, Page 4


FIGURE 3-2. CONTROL CONSOLE DIAGRAM PARTS LIST WITH OPTIONS (Diesel) Index No.

Skyjack Part No.

1

702197

2

702198

3

702199

4

702200

5 6

704311 701934 703185 701936 703186 701935 703185 701937 703187 701931 (Ref.)

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

OEM Part No.

109698 103011 103012 702168 702278 700187 103036 702104 103041 702103 702613 102956 702185 702186 701943 700166 701929 701930 702262 702841


Units per Assy.


CONTROLLER, Drive/steer (For components, refer to Figure 6-5.) CONTROLLER, Main lift/turret rotate (For components, refer to Figure 6-6.) CONTROLLER, Jib lift/platform rotate (For components, refer to Figure 6-7.) CONTROLLER, Knuckle/extension (For components, refer to Figure 6-8.) CIRCUIT BOARD, Platform leveling LIGHT, Red indicator • BULB, 12 Volt #1893 ALARM, Dual • BULB, 12 Volt #1815 LIGHT, Green indicator • BULB, 12 Volt #1893 LIGHT, Console illumination • BULB, 12 Volt #67 SWITCH, Anti-restart ignition SWITCH ASSEMBLY, Emergency stop (For components, refer to Figure 6-4.) RECEPTACLE, 110 Volt GFCI TERMINAL STRIP, Large TERMINAL STRIP, Small LEVEL SENSOR, Platform leveling analog CABLE, 22 Ga. 4 wire shielded SWITCH, Foot STRAIN RELIEF, Straight plastic CABLE, 14 Wire control STRAIN RELIEF, 5/8" Straight CABLE, 49 Wire main control STRAIN RELIEF, 1-1/8" Straight PLUG, Knockout 7/8" WIRE DUCT, 1" COVER, 1" Wire duct RELAY, 12 Volt sealed DIODE, 1 Amp 400PIV SWITCH, Toggle 2 position momentary SWITCH, Toggle 2 position maintained PLUG, Hole MANIFOLD ASSEMBLY, Platform leveling (For components, refer to Figure 6-13.)

1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 5 1 174" 1 1 93" 1 468" 1 1 129" 129" 5 5 3 3 1 1

SECTION 3, Page 5

FIGURE 3-3. LOAD SENSING OPTION DIAGRAM PARTS LIST () Index No.

Skyjack Part No.

OEM Part No.


Units per Assy.

NOT AVAILABLE AT TIME OF PRINTING

SECTION 3, Page 6


FIGURE 3-3. LOAD SENSING OPTION CONTROL CONSOLE DIAGRAM

NOT AVAILABLE AT TIME OF PRINTING


SECTION 3, Page 7

FIGURE 3-4. BASE CONTROL/ELECTRICAL DIAGRAM A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

31

30

1

2

3

13

4

8

6

5

9

5

16

17

5

3

33

1

15

21

23

15 4 6

14 20

2 8

12

12 7

27 5

7

8

14

10 14 28 19

34

15

9

12

18

10

22 32

24

29

11

21

11 26

12

25

13

LEGEND MAIN CONTROL CABLE

15

27

PROPORTIONAL VALVE BLOCK 14

TURRET MANIFOLD

21

TACH SENSOR ENGINE WIRING

SECTION 3, Page 8


FIGURE 3-4. BASE CONTROL/ELECTRICAL DIAGRAM PARTS LIST Index No.

1

Skyjack Part No.

11 12 13 14 15 16 17 18

(Ref.) 102753 104466 103141 103279 103225 701931 701925 701926 702402 (Ref.) 102769 103281 102853 701929 703005 105271 103227 111356 702434 701943 103012 103011 102921 700166 701547

19

701546

20

700552 114866 702104 702103 702112 702864 703097 700165 103257 103255 706293 706213 706649 706074 703720 706294

2 3 4 5 6

7 8 9 10

21 22 23 24 25 26 27 28 29 30 31 32 33 34

OEM Part No.


Units per Assy.


SWITCH ASSEMBLY, Keyed • SWITCH HEAD, Keyed • • KEY, #455 • , Switch N.O. • BASE, Switch 2 N.C. • , Switch N.C. SWITCH, Anti-restart ignition METER, Hour METER, Amp BREAKER, 12 Volt/15 amp SWITCH ASSEMBLY, Emergency stop • SWITCH HEAD, Emergency stop • BASE, Switch N.C. SWITCH, Toggle SPDT 3 position momentary SWITCH, Toggle SPDT 2 position momentary SWITCH, Toggle DPDT 2 position momentary PLUG, Recessed male 110 volt • PROTECTOR BOOT, Rubber LIMIT SWITCH, Plunger LIMIT SWITCH, Roller arm RELAY, 12 Volt sealed TERMINAL STRIP, Small TERMINAL STRIP, Large DIODE, 6 Amp/1000PIV DIODE, 1 Amp/400PIV CARD, EDA Controller • FUSE, 250 Volt, 3 amp CARD, MDSD Dual driver • FUSE, 125 Volt, 4 amp SWITCH, Machine tilt • FUSE, 250 Volt, 1 amp CABLE, 14 Conductor CABLE, 49 Conductor control VALVE ASSEMBLY, 4 Bank proportional MANIFOLD ASSEMBLY, System MANIFOLD ASSEMBLY, Brake CABLE, 22/2 Shielded CABLE, 18/3 CABLE, 18/4 SWITCH, Proximity RELAY, Time delay BUFFER, Signal CORE, Snap on ferrite LIGHT, Amber indicator LIMIT SWITCH, Plunger (booted)

1 1 1 2 1 1 1 1 1 3 1 1 1 7 AR 1 1 1 3 3 AR 12 4 6 28 1 1 1 1 1 1 AR 768” 1 1 1 222" AR 415” 1 1 1 1 1 1

SECTION 3, Page 9

FIGURE 3-5. ENGINE COMPARTMENT WIRING DIAGRAM PARTS LIST (Gas and dual fuel) Index No.

1 2 3 4 5 6 7 8 9 10 11 12 13

Skyjack Part No.

701643 701929 702104 700165 702314 FORD 115389 703866 FORD FORD FORD 703864 704616

SECTION 3, Page 10

OEM Part No.


THROTTLE CONTROL, Engine SWITCH, Toggle SPDT 2 position momentary CABLE, 14 Conductor CABLE, 22/2 Shielded BREAKER, 12 Volt 15 amp TERMINAL STRIP SENSOR, Magnetic tachometer SENSOR, Coolant temperature SWITCH, 6 PSI Oil pressure RELAY, 12 Volt starter WIRING HARNESS, Alternator ACTUATOR, Rotary (Governor) RELAY, Time delay

Units per Assy.

1 2 226" 222" 1 2 1 1 1 1 1 1 1


FIGURE 3-5. ENGINE COMPARTMENT WIRING DIAGRAM (Gas and dual fuel) 13

3

4

10

9 8

11

6

7

12

5

2

1


SECTION 3, Page 11

FIGURE 3-6. ENGINE COMPARTMENT WIRING DIAGRAM (Deutz diesel)

1 2

7

8

3

13

6

5

9

11

4

10

12

SECTION 3, Page 12


FIGURE 3-6. ENGINE COMPARTMENT WIRING DIAGRAM PARTS LIST (Deutz diesel) Index

Skyjack

Description

OEM

Units per

1 2 3 4 5 6 7

1 2 3 4 5 6 7 8 9 10 11 12 13

702104 700165 703179 701929 DEUTZ 102921 103012 701943 103255 703437 703348 703347 115389


CABLE, 14 Conductor CABLE, 22/2 Shielded SWITCH, Engine SWITCH, Toggle 2 position momentary CONNECTOR, 10 Pole engine DIODE, 6 Amp/1000PIV TERMINAL STRIP, Small RELAY, 12 Volt sealed CABLE, 18/4 OR, 12 Volt 80 amp MODULE, Throttle control ACTUATOR, Throttle control SENSOR, Magnetic tachometer

226" 222" 1 1 1 1 1 1 60" 1 1 1 1

SECTION 3, Page 13

NOTES

SECTION 3, Page 14


FIGURE 3-7. ELECTRICAL SCHEMATIC (Gas and dual fuel) 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

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

LATER MODELS WITH ENGINE TIME DELAY 706741 SJB-66TK, Serial Number 93197 and below

MARCH, 2000

SECTION 3, Page 15

FIGURE 3-8. ELECTRICAL SCHEMATIC (Deutz diesel) 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

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

706742 SECTION 3, Page 16

MARCH, 2000


FIGURE 3-7/FIGURE 3-8. ELECTRICAL SCHEMATIC PARTS LIST Index No.

Skyjack Part No.

02ACR 108CR 2G-56 2H-103 2H-114 2H-53 2H-55 2H-85 2P-56 3H-34 3H-35 3H-36 3H-37 3H-40 3H-41 3H-43 3H-44 3H-65 4H-15 4H-16 4H-32 4H-33 4H-38 4H-39 4H-47 4H-48 4H-70 4H-71 4H-72 4H-73 AM1 B1 B2 BCB-1 BI1 BP-22 BP-29 BP-46 BP27 CB1-CB3 CB4 D01A-1 D01A-2 D08 D107 D114 D116 D13-1-D14-2 D22-D31-2 D31-3 D32-D41 D47-D48 D59 D67 D68 D71 D76B D88 D94 D97-1-D97-2 ES1 ES2 FC1 FL22 FU1

703179 703058 117108 703190 703814 703190 703190 703867 703865 703798 703798 703189 703189 703799 703800 703808 703808 703189 $ $ 703822 703822 703821 703821 703812 703812 703819 703819 703820 703820 701926 703719 702032 701643 702532 703321 703321 703321 701936 702402 702314 102921 102921 700166 700166 700166 700166 700166 700166 102921 700166 102921 700166 700166 700166 700166 102921 700166 700166 700166 DEUTZ 703347 706074 703323 114866

OEM Part No.



RELAY, Oil/temp. shut off (diesel) OR, 12 VDC VALVE, Gas VALVE, 5 Degree braking VALVE, Steer dump VALVE, Load sense dump VALVE, High drive VALVE, Generator option VALVE, Propane VALVE, Jib down VALVE, Jib up VALVE, Platform rotate left VALVE, Platform rotate right VALVE, Platform down VALVE, Platform up VALVE, Telescope sequence VALVE, Telescope sequence VALVE, Brake VALVE, Reverse drive VALVE, Forward drive VALVE, Turret rotate left VALVE, Turret rotate right VALVE, Telescope in VALVE, Telescope out VALVE, Right steer VALVE, Left steer VALVE, Main boom down VALVE, Main boom up VALVE, Knuckle down VALVE, Knuckle up METER, Amperage BATTERY, Engine start BATTERY, Emergency pump CONTROL BOX, Governor ISOLATOR, Battery ALARM, Boom motion ALARM, Travel ALARM, All motion BEEPER/LIGHT, Tilt BREAKER, 12 Volt/ 15 AMP BREAKER, 12 Volt/ 15 AMP DIODE, 6A/1000 PIV DIODE, 6A/1000 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 6A/1000 PIV DIODE, 1A/400 PIV DIODE, 6A/1000 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 6A/1000 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV DIODE, 1A/400 PIV SOLENOID, Engine shut down SOLENOID, High throttle CORE, Snap on ferrite LIGHT, Flashing 12 volt (option) FUSE, 250 Volt, 1 amp

Units per Assy.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 4 7 1 10 2 1 1 1 1 1 1 1 2 1 1 1 2 1

Index No.

Skyjack Part No.

FU2 FU3 FP1 GP1 H1 HG1 K01-K39 K45 K46 LB1 LB2 LB3 LB4-LB5 LS1 LS2-LS4 LS6 LS8 OG1 OPS1

$ $ 115387 DEUTZ 703322 703404 701943 703437 701943 701935 701934 701937 703720 702434 111356 706294 702434 704735 FORD DEUTZ 704311 706649 706293 703864 701930 (Ref.) (Ref.) 700187 702198 703176 703176 702200 703170 702200 703170 102853 702199 703173 701930 701933 102853 701931 102853 702197 702434 701929 701931 703005 701929 701930 102853 701929 703348 704616 706213 115389 703866 DEUTZ 700552 702168 701925 $ $ 703545

PLCB1 PMW1 PS1 RA-1 S1 S2 S3-S4 S5 S7 S7-1 S7-2 S8 S8-1 S9 S9-1 S10 S11 S11-1 S12 S14 S15-S18 S19 S20 S21 S22 S23-S24 S25 S26 S27-S29 S33 S34 S35-S36 TCM1 TD1 TD2 TP1 TPS1 TS1 TS2 TT1 VM1 WL81 WL87

OEM Part No.


FUSE, 250 Volt, 3 amp FUSE, 125 Volt, 4 amp PUMP, Electric fuel ELEMENT, Glow plug HORN, 12 Volt (option) GENERATOR, Hydraulic (option) RELAY, 12 VDC sealed OR, Starter 12VDC 80 Amp RELAY, 12 VDC sealed LIGHT, Knuckle enable LIGHT, Engine oil/temp LIGHT, Console LIGHT, Glow plug LIMIT SWITCH, Telescope in LIMIT SWITCH, Plunger LIMIT SWITCH, Plunger (booted) LIMIT SWITCH, Fly boom in GUAGE, Oil pressure (option) SWITCH, Engine oil pressure SWITCH, Engine oil pressure CIRCUIT BOARD, Platform leveling BUFFER, Signal PROXIMITY SWITCH, Mid boom out ACTUATOR, Governor rotary TOGGLE SWITCH, 2 Pos. maintained SPDT SWITCH ASSEMBLY, Key SWITCH ASSEMBLY, Emergency stop SWITCH, Foot CONTROLLER, Main lift/turret rotate CIRCUIT BOARD, Main lift CIRCUIT BOARD, Turret rotate CONTROLLER, Knuckle up/down CIRCUIT BOARD, Knuckle controller CONTROLLER, Extend/retract CIRCUIT BOARD, Extend retract controller TOGGLE SWITCH, 3 Pos. momentary SPDT CONTROLLER, Jib lift/platform rotate CIRCUIT BOARD, Jib/platform controller TOGGLE SWITCH, 2 Pos. maintained SPDT TOGGLE SWITCH, 3 Pos. maintained SPDT TOGGLE SWITCH, 3 Pos. momentary SPDT SWITCH, Ignition TOGGLE SWITCH, 3 Pos. momentary SPDT CONTROLLER, Drive/steer LIMIT SWITCH, Directional sensing TOGGLE SWITCH, 2 Pos. momentary SPDT SWITCH, Ignition TOGGLE SWITCH, 2 Pos. momentary DPDT TOGGLE SWITCH, 2 Pos. momentary SPDT TOGGLE SWITCH, 2 Pos. maintained SPDT TOGGLE SWITCH, 3 Pos. momentary SPDT TOGGLE SWITCH, 2 Pos. momentary SPDT MODULE, Throttle control RELAY, Engine time delay RELAY, Mid boom time delay PICKUP, Magnetic tachometer SWITCH, Engine temperature SWITCH, Engine temperature SWITCH, Tilt SENSOR, Platform leveling HOUR METER, Engine METER, Volt (option) LIGHT, Platform work (option) LIGHT, Chassis driving (option) $ - Consult Factory

Units per Assy.

1 1 1 1 1 AR 1 1 1 1 2 2 1 4 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 2 1 1 3 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2

SECTION 3, Page 17

FIGURE 3-9/FIGURE 3-10. HYDRAULIC SCHEMATIC PARTS LIST Index No.

C1 C2 C3 C4 C5 C6 C7 C8

C9 CB1-20 CB21-22 CV1 CV2-3 CV4-8 CV9 CV10 DCM1 DS1-2 F1 F2 FC1 FC2 FC3 HC1 HP1 2H-53 2H-55 2H-85 2H-103 2H-114 3H-34 3H-35 3H-36

Skyjack Part No.

701991 702643 701375 702644 702052 702645 702043 702645 701912 702645 702153 702644 702143 702642 702913 703180 706537 706538 706677 706547 701827 706384 703817 703815 703809 703198 702160 702614 703801 702033 703047 702034 703825 706026 703868 703802 702031 703197 703190 703190 703867 703190 703814 703798 703798 703189

OEM Part No.


CYLINDER ASSEMBLY, Main lift • KIT, Seal repair CYLINDER ASSEMBLY, Knuckle • KIT, Seal repair CYLINDER ASSEMBLY, Mid boom extension upper • KIT, Seal repair CYLINDER ASSEMBLY, Mid boom extension lower • KIT, Seal repair CYLINDER ASSEMBLY, Fly boom extension • KIT, Seal repair CYLINDER ASSEMBLY, Platform leveling • KIT, Seal repair CYLINDER ASSEMBLY, Jib lift • KIT, Seal repair CYLINDER ASSEMBLY, Steering (2WD models) • KIT, Seal repair CYLINDER ASSEMBLY, Steering (4WD models) (For components, refer to Figure 6-49.) • Kit, Seal repair CYLINDER ASSEMBLY, Mid boom lock •KIT, Seal repair VALVE, Counterbalance 3000 psi VALVE, Counterbalance 1800 psi VALVE, Check VALVE, Check VALVE, Check VALVE, Check CHECK VALVE, In line PUMP/MOTOR ASSEMBLY, Emergency VALVE, Differential sensing FILTER ASSEMBLY, Charge pump • ELEMENT, Filter FILTER ASSEMBLY, High pressure • ELEMENT, Filter VALVE, Flow control, brake VALVE, Flow control, hydraulic generator VALVE, Flow control, platform rotate COOLER, Hydraulic oil HAND PUMP, Brake release VALVE, Load sense dump VALVE, High speed drive VALVE, Hydraulic generator (option) VALVE, Tilt braking VALVE, Steering dump VALVE, Jib down VALVE, Jib up VALVE, Platform rotation left

Units per Assy.

2 AR 2 AR 1 AR 1 AR 1 AR 2 AR 1 AR 2 AR 1 AR 1 AR 8 14 1 2 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Index No.

Skyjack Part No.

3H-37 3H-40 3H-41 3H-43 3H-44 3H-65 3H-V1 3H-V2 3H-V3 4H-15 4H-16 4H-32 4H-33 4H-38 4H-39 4H-47 4H-48 4H-70 4H-71 4H-72 4H-73 M1 M2 M3 O1 O P1 P2 POR1 PR1 PR2 PR3 PR4 RA1

703189 703799 703800 703808 703808 703189 $ $ $ $ $ 703822 703822 703821 703821 703812 703812 703819 703819 703820 703820 701544 702992 $ 703811 706712 701543 701545 $ 703191 703810 703810 703818 702061 701876 $ $ $ 703194 703807 703813 $ 703816 703197 703030 704949 703192

RV1 RV2 RV3 RV4 RV5 RV6 RV7 SV1-2 SV3-12 SV13 SV14 V1

OEM Part No.


VALVE, Platform rotation right VALVE, Platform leveling down VALVE, Platform leveling up VALVE, Extension sequencing VALVE, Retraction sequencing VALVE, Brake VALVE, System pressure adjusting VALVE, Load sense adjusting VALVE, Drive motor shift VALVE, Reverse drive (Includes 4H-16) VALVE, Forward drive (Includes 4H-15) VALVE, Turret rotate left (Includes 4H-33) VALVE, Turret rotate right (Includes 4H-32) VALVE, Boom extend (Includes 4H-39) VALVE, Boom retract (Includes 4H-38) VALVE, Steering right (Includes 4H-48) VALVE, Steering Left (Includes 4H-47) VALVE, Main boom down (Includes 4H-71) VALVE, Main boom up (Includes 4H-70) VALVE, Knuckle down (Includes 4H-73) VALVE, Knuckle up (Includes 4H-72) MOTOR, Drive MOTOR, Turret rotation MOTOR, Hydraulic generator (option) ORIFICE, .080 ORIFICE, .020 PUMP, Drive PUMP, System VALVE, Pressure override VALVE, Brake system pressure reducing VALVE, Mid boom extension pressure reducing VALVE, Fly boom extension pressure reducing VALVE, Pilot pressure reducing ACTUATOR, Platform rotation • KIT, Seal repair VALVE, Drive relief VALVE, Drive relief VALVE, Charge pump relief VALVE, Brake relief VALVE, Emergency pump relief VALVE, High speed drive relief VALVE, Turret rotate relief VALVE, Load sense shuttle VALVE, Load sense shuttle VALVE, Load sense shuttle VALVE, Brake shuttle VALVE, Brake release override

Units per Assy.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR 1 1 1 1 1 1 1 2 10 1 1 1

$ - Consult Factory SECTION 3, Page 18


FIGURE 3-9. HYDRAULIC SCHEMATIC (Machines with system pressure braking) A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

MA66R301


SECTION 3, Page 19

FIGURE 3-10. HYDRAULIC SCHEMATIC (Machines with drive pressure braking) A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

MA66R300 SECTION 3, Page 20


FIGURE 3-11. MAIN MANIFOLD COMPONENT AND PORT IDENTIFICATION

LR - LEVELING MANIFOLD RETURN PR - MAIN PUMP PRESSURE TEST PORT

LP - LEVELING MANIFOLD PRESSURE

FE - FLY BOOM EXTEND

SYS TO PROPORTIONAL CONTROL VALVES T TANK

ME - MID BOOM EXTEND PLS - LOAD SENCE SIGNAL TO PUMP

EA - TO PROPORTIONAL CONTROL VALVE

H/L DRIVE PUMP

P2 EMERGENCY PUMP P3 EMERGENCY PUMP

LS1 - BRAKE MANIFOLD

S2 - STEER LEFT S1 - STEER RIGHT

RV5 EMERGENCY PUMP RELIEF VALVE

2H-55 HIGH SPEED DRIVE VALVE

FG - FLY BOOM PRESSURE TEST PORT MR - MID BOOM RETRACT EB - TO PROPORTIONAL CONTROL VALVE FR - FLY BOOM RETRACT

2H-53 LOAD SENSE DUMP VALVE

MG - MID BOOM PRESSURE TEST PORT PR3 FLY BOOM EXTEND PRESSURE REDUCING VALVE

4H-48 LEFT STEER VALVE 4H-47 RIGHT STEER VALVE

MID BOOM RETRACT CHECK VALVE

FLY BOOM RETRACT CHECK VALVE 3H-43 EXTEND SEQUENCE VALVE 3H-44 RETRACT SEQUENCE VALVE


P1 FROM HIGH PRESSURE FILTER

2H-114 STEERING DUMP VALVE LEVELING MANIFOLD SUPPLY SHUTTLE VALVE EMERGENCY PUMP SUPPLY SHUTTLE VALVE

PR2 MID BOOM EXTEND PRESSURE REDUCING VALVE

RV6 HI/LOW DRIVE PILOT PRESSURE ADJUSTMENT MAIN PUMP CHECK VALVE

VALVE

FACTORY PRESSURE

RV5

2600 PSI

RV6

225 PSI

PR2

2100 PSI

PR3

2100 PSI

SECTION 3, Page 21

FIGURE 3-12. PLATFORM LEVELING MANIFOLD COMPONENT AND PORT IDENTIFICATION

3H-41 LEVELING CYLINDER VALVE (EXTEND)

FIGURE 3-13. BRAKE MANIFOLD COMPONENT AND PORT IDENTIFICATION

3H-40 LEVELING CYLINDER VALVE (RETRACT)

PR1 BRAKE PRESSURE REDUCING VALVE

SV14 - SHUTTLE VALVE

NOTE: For machines with Drive Pressure Braking ONLY. 3H-35 JIB CYLINDER VALVE (EXTEND) 3H-34 JIB CYLINDER VALVE (RETRACT)

3H-36 PLATFORM ROTATION VALVE (CW) 3H-37 PLATFORM ROTATION VALVE (CCW)

LS - LOAD SENSE LINE TO PROPORTIONAL CONTROL VALVE BLOCK

RETURN TO MAIN MANIFOLD

BR - TO BRAKES

SYSTEM PRESSURE FROM MAIN MANIFOLD 3H-103 TILT BRAKE VALVE

LOAD SENSE LINE TO PROPORTIONAL CONTROL VALVE BLOCK JIB CYLINDER (RETRACT)

JIB LEVELING CYLINDER (RETRACT) JIB LEVELING CYLINDER (EXTEND) FLY BOOM LEVELING CYLINDER (EXTEND)

PLATFORM ROTATION (CW) PLATFORM ROTATION (CCW)

DS1 and DS2 DIFFERENTIAL SENSING VALVES

JIB CYLINDER (EXTEND) FLY BOOM LEVELING CYLINDER (RETRACT) PLATFORM ROTATION FLOW CONTROL VALVE

SECTION 3, Page 22

FLOW CONTROL VALVE

RV3 RELEIF VALVE

T - RETURN TO TANK

PLS - LOAD SENSE LINE TO MAIN MANIFOLD

P - PRESSURE FROM DRIVE PUMP

V1 BRAKE RELEASE OVERRIDE VALVE 3H-65 BRAKE VALVE HP1 BRAKE RELEASE HAND PUMP

VALVE

FACTORY PRESSURE

PR1

600 PSI

RV4

700 PSI

CAVITY PLUG SJB-66TK, Serial Number 93197 and below

SECTION 4 TROUBLESHOOTING The following pages contain a Table of Troubleshooting information for locating and correcting most service trouble which can develope. Careful and accurate analysis of the system listed in the Table of Troubleshooting Information will localize the trouble more quickly than any other method. This manual can not 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, and then isolate and correct the specific problem.

TROUBLE

PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM NOTE: ALL TESTS SHOULD BE PERFORMED WITH BOOM OVER NON-STEERING AXLE ALL CONTROLS INOPERATIVE

1.

A battery disconnected or discharged. Loose or broken 6 Ga. wire from Battery to Ammeter AM1. Defective Ammeter AM1.

1.

Connect battery or recharge.

2.

Loose or broken wire #3 from Ammeter AM1 to Circuit Breaker CB1. Circuit Breaker CB1 tripped or defective. Loose or broken wire #5 from Circuit Breaker CB1 to Base Emergency Stop Switch S3. Open or defective Base Emergency Stop Button S3. Loose or broken wire #42 from Base Emergency Stop Switch S3 to Key Select Switch S2. Open or defective Key Select Switch S2-4. Loose or broken wire #60 from Base Terminal Block TB-1 to Relay K27. Loose or broken wire #42 from Key Select Switch S2-4 to Relay K27. Loose or broken wire #02 from Relay K27 to Base Terminal Block TB-1. Defective Relay K27. Loose or broken wire #02 from base Terminal Block TB-1 to Battery B1.

4.

Check Continuity. Replace if defective. Check Ammeter. Replace if defective. Check Continuity. Replace if defective.

13. 14.

Check Relay. Replace if defective. Check Continuity. Replace if defective.

1. 2.

Foot on Foot Switch S5. Defective Ignition Switch S19.

1. 2.

3.

Loose or broken wire #95 from Ignition Switch S19 to Relay K37. Defective Relay K37.

3.

Loose or broken wire #57 from Relay K37 to Base Terminal Block TB-2.

5.

Remove Foot from Foot Switch. Check Continuity. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

ENGINE WILL NOT CRANK FROM PLATFORM

4. 5.


3.

5. 6.

Reset Breaker, check for defective wiring. Replace if Defective Check Continuity. Replace if defective.

7.

Close Switch. Replace if defective.

8.

Check Continuity. Replace if defective.

9.

Close switch. Replace if defective. Check Continuity. Replace if defective.

10. 11. 12.

4.

Check Continuity. Replace if defective. Check Continuity. Replace if defective.

SECTION 4, Page 1

4

TROUBLESHOOTING (Cont.) TROUBLE

PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) ENGINE WILL NOT CRANK FROM BASE

1.

Loose or broken wire #08 from Key Select Switch S2-3 to Base Ignition Switch S25. Loose or broken wire #57 from Base Ignition Switch S25 to Base Terminal Block TB-2.

1.


2.


3.

Defective Switch S25.

3.

Check Switch. defective.

1.

Open or defective Key Select Switch S2-2. Loose or broken wire #115 from Key Select Switch S2-2 to Platform Stow Switch S26. Open or defective Platform Stow Switch S26. Loose or broken wire #07 from Platform Stow Switch S26 to Base Terminal Block TB-2. Loose or broken wire #07 from Base Terminal Block TB-2 to Platform Terminal Block TB-7. Loose or broken wire #07 from Platform Terminal Block TB-5 to Platform Emergency Stop Switch S4. Open or defective Platform Emergency Stop Switch S4.

1.

Close Switch. Replace if defective

2.

Check Continuity. Replace if defective

3.

Close Switch. Replace if defective

4.

Check Continuity. Replace if defective

5.


6.


7.

Close Switch. defective.

Loose or broken wire #60 from Platform Terminal Block TB-2 to Ignition Cut Out Relay K22.. Defective Ignition Cut Out Relay K22.. Loose or broken wire #96 from Ignition Cut Out Relay K22 to Ignition Relay K21. Defective Ignition Relay K21. Loose or broken wire #02 from Ignition Relay K21 to Base Terminal Block TB-1. Loose or broken wire #03 from Ammeter AM1 to Ignition Relay K21. Loose or broken wire #112 from Ignition Relay K21 to Circuit Breaker CB4. Tripped or defective Circuit Breaker CB4.

1.

Defective Ign.

2.

Check Relay. Replace if defective.

3.


4. 5.


6.


7.


8.

Reset Breaker, check for defective wiring. Replace if defective.

2.

NO POWER TO PLATFORM

2.

3. 4.

5.

6.

7.

ENGINE CRANKS BUT WILL NOT START

1.

2. 3.

4. 5.

6.

7.

8.

SECTION 4, Page 2

Replace if

Replace if



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) ENGINE CRANKS BUT WILL NOT START (Continued)

9.

Loose or broken wire #54 from Circuit Breaker CB4 to Engine Terminal Block. Loose or broken wire #54 from Engine Terminal Block to Time Delay TD1. Defective Time Delay TD1.

9.


10.


11.

Loose or broken wire #02 from Time Delay TD-1 to Engine Terminal Block. Loose or broken wire #77 from Time Delay TD-1 to Base Terminal Block TB-1. Loose or broken wire #77 from Base Terminal block TB-1 to Fuel relay K11. Defective Fuel relay K11.

12.

Check Time Delay. Replace if defective. Check Continuity. Replace if defective.

Loose or broken wire #02 from Fuel relay K11 to Base Terminal Block TB-1. Loose or broken wire #09 from Base Terminal Block Tb-1 to Fuel Relay K11. Loose or broken wire #105 from Fuel Relay K11 to Fuel Select Relay K12. Defective Fuel Select Relay K12.

16.

20.

23.

Loose or broken wires #50(L.P.) or #56(Gasoline) from Fuel Select Relay to Fuel Valves 2P-50(L.P.) or 2G-56(Gasoline). Defective Fuel valves 2P-50(L.P.) or 2G-56(Gasoline). Loose or broken wire #56 from Fuel select Relay K12 to Fuel Pump FP1(Gasoline mode only). Defective Fuel Pump FP1.

24.

No spark.

24.

1.

Loose or broken wire #94 from Platform Ignition Switch to Platform Terminal Block TB-6. Open Diode D-94 at Platform Ignition Switch S19. Loose or broken wire #60 from Platform Terminal Block TB-6 to Base Terminal Block TB-2.

1.


2.

Check Diode. defective.

3.


10.

11. 12.

13.

14.

15. 16.

17.

18.

19. 20.

21. 22.

ENGINE CRANKS BUT WILL NOT START FROM PLATFORM

2. 3.


13.


14.


15.


17.


18.


19.


21. 22.

23.

Check Fuel Valves. Replace if defective. Check Continuity. Replace if defective. Check Pump. Replace if defective. Refer to Ford Engine Service Manual.

Replace if

SECTION 4, Page 3


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) ENGINE STARTS BUT WILL NOT KEEP RUNNING

1.

Engine oil level low.

1.

2.

Loose or broken wire #54 from Engine Terminal Block to Oil Pressure Switch OPS2. Defective Oil Pressure Switch OPS1

2.

3.


Loose or broken wire #4 from Platform Emergency Stop Switch to Foot Switch S5. Open or defective Foot Switch S5.

1.


2.

3.

Loose or broken wire #10 from Foot Switch S5 to Platform Terminal Block TB-7.

3.

Close Switch. Replace if defective. Check Continuity. Replace if defective.

1.

Loose or broken wire #22 from Base Terminal Block TB-2 to Base Terminal block TB-1. Open Diode D22.

1.


2.

Loose or broken wire #46 from Base Terminal Block TB-1 to Load Sense Relay K05. Defective Load Sense Relay K05.

3.

Check Diode. Replace if defective. Check Continuity. Replace if defective.

Loose or broken wire #02 from load Sense Relay K05 to Base Terminal Strip TB-1. Loose or broken wire #09 from Base Terminal Block Tb-1 to Load Sense Relay K05. Loose or broken wire #53 from Load Sense Relay K05 to Load Sense Dump Valve Coil ZH-53. Defective Load Sense Dump Valve Coil ZH-53. Loose or broken wire #02 from Load Sense Dump Valve ZH-53 to Base Terminal Block TB-2.

5.

1.

Stuck or misadjusted Main Boom down End of Stroke Limit Switch.

1.


2.

Loose or broken wire #13 from Base Terminal Block TB-2 to Base Terminal Block TB-1. Loose or broken wire #13 from Base Terminal Block TB-2 to Relay K13. Defective Relay K13.

2.


3.


4.

Check Relay. defective.

3. CONTROLS INOPERATIVE FROM PLATFORM

1.

2.

NO BOOM OR STEER FUNCTIONS FROM PLATFORM OR BASE

2. 3.

4. 5.

6.

7.

8. 9.

NO MAIN BOOM DOWN FROM PLATFORM OR BASE

3.

4.

SECTION 4, Page 4

4.

Check oil Level. Refill to proper level. Check Continuity. Replace if defective. Replace if


6.


7.


8.

Check Continuity through Coil. Replace if defective. Check Continuity. Replace if defective.

9.

Replace if

Replace if



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) Loose or broken wire #13 from Base Terminal Block TB-2 to Base Terminal Block TB-1. Defective Main Boom Down Valve Coil 4H-70.

5.


6.

7.

Loose or broken wire #02 from Main Boom Down Valve 4H-70 to Base Terminal Block TB-3.

7.

Check Continuity Coil, reading should be 28 OHMS. Replace if defective. Check Continuity. Replace if defective.

1.

Stuck or misadjusted Main Boom Up End of Stroke Limit Switch L54. Loose or broken wire #14 from Base Terminal Block TB-2 to Base Terminal Block TB-1. Defective Relay K14.

1.


2.


3.

Loose or broken wire #14 from Base terminal Block TB-1 to Relay K14. Loose or broken wire #71 from Relay K14 to Main Boom Up Valve Coil 4H71. Defective Main Boom Up valve 4H71.

4.


7.

Loose or broken wire #02 from Main Boom Up Valve 4H71 to Base Terminal Block TB-3.

7.

NO BOOM FUNCTIONS FROM PLATFORM

1.

Loose or broken wire #22 from Platform Terminal Block TB-6 to Base Terminal Block TB-2.

1.


NO MAIN BOOM UP OR DOWN FROM PLATFORM

1.

Defective Switch S71 on Main Boom Joystick S7. Defective Circuit Board S7-1 on Main Boom Joystick S7.

1.

Check switch. Replace if defective. Refer to Section 5, Page 8 for OEM Controller Diagnostics.

NO MAIN BOOM UP FROM PLATFORM

1.

Defective Switch S-72 on Circuit Board S7. Loose or Broken wire #14 from Circuit Board S7 to Platform Terminal block TB-6. Loose or broken wire #14 from Platform Terminal Block TB6 to Base Terminal block TB2.

1.

NO MAIN BOOM DOWN FROM PLATFORM OR BASE CONTROLS (Continued)

NO MAIN BOOM UP FROM PLATFORM OR BASE CONTROLS

5.

6.

2.

3. 4.

5.

6.

2.

2.

3.


Replace if

5.


6.

Check Continuity through Coal, reading should be 28 OHMS. Replace if defective. Check Continuity. Replace if defective.

2.

2.

3.

Check Switch. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective.

SECTION 4, Page 5


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO MAIN BOOM DOWN FROM PLATFORM CONTROLS

1.

Defective Switch S-72 on Circuit Board S7. Loose or broken wire #13 from Circuit Board S7 to Platform Terminal Block TB6. Loose or broken wire #13 from Platform Terminal Block TB6 to Base Terminal Block TB2.

1.

3.


Defective Switch S73 on Turret Rotate Circuit Board S7-2. Defective Turret Rotate Circuit Board S7-2. Loose or broken wire #67 from Circuit Board S7-2 to Platform Terminal Block TB-6.

1.

Check Switch. Replace if defective. Refer to Section 5, Page 8 for OEM Controller Diagnostics. Check continuity. Replace if defective.

Loose or broken wire #32 from Base Terminal Block TB2 to Turret Rotate Left Valve 4H-32. Defective Turret Rotate Left Valve Coil 4H-32.

1.


2.

3.

Loose or broken wire #02 from Turret Rotate Left Valve 4H-32 to Base Terminal Block TB-3.

3.

Check Continuity through Coil. Reading should be 28 OHMS. Replace if defective. Check Continuity. Replace if defective.

1.

Loose or broken wire #33 from Base Terminal Block TB2 to Turret Rotate Left Valve 4H-33. Defective Turret Rotate Right Valve Coil 4H-33.

1.


2.

Loose or broken wire #02 from Turret Rotate Right Valve 4H-33 to Base Terminal Block TB-3. Defective Switch S-74 on Circuit Board S7-2. Loose or broken wire #32 from Circuit Board S7-2 to Platform Terminal Block TB6. Loose or broken wire #32 from Platform Terminal Block TB6 to Base Terminal Block TB2.

3.


2.

3.

NO TURRET ROTATE RIGHT OR LEFT FROM PLATFORM

1. 2. 3.

NO TURRET ROTATE LEFT FROM PLATFORM OR BASE CONTROLS

1.

2.

NO TURRET ROTATE RIGHT FROM PLATFORM OR BASE CONTROLS

2.

3.

NO TURRET ROTATE LEFT FROM PLATFORM

1. 2.

3.

NO TURRET ROTATE RIGHT FROM PLATFORM

1. 2.

3.

SECTION 4, Page 6

Defective Switch S-74 on Circuit Board S7-2. Loose or broken wire #33 from Circuit Board S7-2 to Platform Terminal Block TB6. Loose or broken wire #33 from Platform Terminal Block TB6 to Base Terminal Block TB2.

2.

2. 3.

1. 2.

Check Switch. Replace if defective. Check Continuity. Replace if defective.


3.


1.


2.

3.




PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO TELESCOPE IN FROM PLATFORM OR BASE CONTROLS

1.

2.

NO TELESCOPE OUT FROM PLATFORM OR BASE CONTROLS

3.

Loose or broken wire #02 from 3. Telescope In Valve 4H-38 to Base Terminal Block TB-3.

1.

Loose or broken wire #39 from 1. Base Terminal Block TB2 to Telescope In Valve 4H-39. Defective Telescope In Valve Coil 2. 4H-39.

2.

NO TELESCOPE IN OR OUT FROM PLATFORM

Check Continuity through Coil. Reading should be 28 OHMS. Replace if defective. Check Continuity. Replace if defective. Check Switch. Defective.

Replace if


1.

Defective Switch S91 on Telescope 1. Joystick S9. Defective Circuit Board S9-1 on 2. Telescope Joystick S9. Loose or broken wire #67 from 3. Telescope Joystick S9 to Platform Terminal Block TB-6.

Check Switch. Replace if defective. Refer to Section 5, Page 7 for OEM Controller Diagnostics. Check Continuity. Replace if defective.

Defective Switch S92 on Circuit 1. Board S9-1. Loose or broken wire #38 from 2. Circuit Board S9-1 to Platform Terminal Block TB6. Loose or broken wire #38 from 3. Platform Terminal Block to Base Terminal Block TB2.


Defective Switch S92 on Circuit 1. Board S9-1. Loose or broken wire #39 from 2. Circuit Board S9-1 to Platform Terminal Block TB6. Loose or broken wire #39 from 3. Platform Terminal Block TB6 to Base Terminal Block TB2.


Loose or broken wire #09 from 1. Terminal Block TB-1 to Mid Boom out Proximity Switch PS1. Defective Mid Boom Out Proximity 2. Switch PS1. Loose or broken wire #02 from Mid 3. Boom Out Proximity Switch PS1.


2.

1.

3.

1. 2.

3.

FLY BOOM WILL NOT EXTEND AFTER MID BOOM HAS EXTENDED

Replace if

Loose or broken wire #02 from 3. Telescope In Valve 4H-39 to Base Terminal Block TB-3.

2.

NO TELESCOPE OUT FROM PLATFORM

Check Switch. Defective.

3.

3.

NO TELESCOPE IN FROM PLATFORM

Loose or broken wire #38 from 1. Base Terminal Block TB2 to Telescope In Valve 4H-38. Defective Telescope In Valve Coil 2. 4H-38.

1.

2. 3.




Check Switch. Replace if defective Check Continuity. Replace if defective. SECTION 4, Page 7


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) FLY BOOM WILL NOT EXTEND AFTER MID BOOM HAS EXTENDED (Continued)

4.

Mid Boom Out Proximity PS1 Switch out of adjustment.

4.

5.

Loose or broken wire #25 from Mid Boom out Proximity Switch PS1 to Relay K04. Defective Relay K04.

5.

Loose or broken wire #02 from Relay K04 to Terminal Block TB1. Loose or broken wire #09 from Relay K04 to Terminal Block TB1. Loose or broken wire #61 from Relay K04 to Time Delay TD2. Defective Time Delay TD2.

7.

Loose or broken wire #02 from Time Delay TD2 to Base Terminal block TB1. Loose or broken wire #75 from Relay Time Delay TD2 to Relay K03. Defective Relay K03.

11.

Loose or broken wire #02 from Relay K03 to Terminal Block TB1. Loose or broken wire #09 from Relay K03 to Terminal Block TB1. Loose or broken wire #43 from Relay K03 to Sequence Valve 3H-43. Defective Coil on Sequence Valve 3H-43. Loose or broken wire #02 from Sequence Valve 3H-43 to Terminal Block TB-1. Loose or broken wire #09 from Terminal Block TB-1 to Fly in Limit Switch LS8. Defective Fly in Limit Switch LS8.

14.

Loose or broken wire #26 from Fly in Limit Switch LS8 to Relay K17. Defective Relay K17.

3.

Loose or broken wire #02 from Relay K17 to Base Terminal Block TB1.

5.

6. 7.

8.

9. 10. 11.

12.

13. 14.

15.

16.

17. 18.

MID BOOM WILL NOT RETRACT AFTER FLY BOOM HAS RETRACTED

1.

2. 3. 4. 5.

SECTION 4, Page 8

6.

Check for excessive clearance between Mid Boom and Knuckle. Shim as needed. Readjust Proximity Switch. Check Continuity. Replace if defective. Check Relay. Replace if defective. Check Continuity. Replace if defective.

8.


9.

Check Continuity. Replace if defective. Check Time delay. Replace if defective. Check Continuity. Replace if defective.

10.

12.


13.

Check Relay. Replace if Defective Check Continuity. Replace if defective.

15.


16.


17.


18.

1.


2.

Check Switch. Defective. Check Continuity. defective. Check Relay. defective. Check Continuity. defective.

4.

Replace if Replace if Replace if Replace if



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) MID BOOM WILL NOT RETRACT AFTER FLY BOOM HAS RETRACTED (Continued)

Loose or broken wire #09 from Terminal Block TB-1 to Knuckle Up End of Stroke Limit Switch LS6. Defective Knuckle Up End of Stroke Limit Switch LS6. Loose or broken wire #20 from Knuckle Up End of Stroke Limit Switch LS6 to Relay K17. Loose or broken wire #69 from Relay K17 to Relay K02. Defective Relay K02.

6.


7.


Loose or broken wire 02 from K02 to Base Terminal Block TB-1. Loose or broken wire #09 from K02 to Base Terminal Block TB-1. Loose or broken wire #44 from Relay K02 to Sequence Valve 3H44. Defective Sequence Valve Coil 3H44. Loose or broken wire #02 from Sequence Valve Coil 3H-44 to Base Terminal Block TB-1.

11.

1.

Defective Switch S-111 on CB S11-1.

1.


2.

Defective Circuit Board S11-1

2.

3.

Loose or broken wire #67 from Circuit Board S11-1 to Terminal Block TB-6 in Platform Control Box.

3.

Refer to Page 5-8, Figure 5-1 OEM Troubleshooting. Check Continuity. Replace if defective.

1.

Loose or broken wire #34 from Platform Terminal Block TB6 to Jib Down Valve 3H-34. Defective Jib Down Valve 3H-34.

1.


2.

3.

Loose or broken wire #02 from Jib Down Valve 3H-34 to Platform Terminal Block TB6.

3.


1.

Loose or broken wire #34 from Platform Terminal Block TB6 to Jib Up Valve 3H-35. Defective JIB Up Valve Coil 3H35. Loose or broken wire #02 from Jib Up Valve 3H-34 to Platform Terminal Block TB6.

1.


2.


6.

7. 8.

9. 10. 11. 12. 13.

14. 15.

NO JIB UP OR DOWN FROM PLATFORM

NO JIB DOWN FROM PLATFORM OR BASE CONTROLS

2.

NO JIB UP FROM PLATFORM OR BASE CONTROLS

2. 3.


8.

9. 10.

12. 13.

14. 15.

3.

Check Continuity. defective. Check Relay. defective. Check Continuity. defective. Check Continuity. defective. Check Continuity. defective.

Replace if Replace if Replace if Replace if Replace if


Replace if

SECTION 4, Page 9


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO JIB DOWN FROM PLATFORM

NO JIB UP FROM PLATFORM

NO PLATFORM ROTATE LEFT FROM PLATFORM OR BASE CONTROLS

1.

Defective Switch S-112 on Circuit Board S11-1.

1.


2.

Loose or broken wire #34 from Circuit Board S11-1 to Platform Terminal Block TB6.

2.


1.

Defective Switch S-112 on Circuit Board S11-1.

1.


2.


2.


1.

Loose or broken wire #36 from Platform Terminal block TB6 to Platform Rotate Left Valve 3H-36. Defective Platform Rotate Left Valve Coil 3H-36. Loose or broken wire #02 from Platform Rotate Left Valve 3H-36 to Platform Terminal Block TB-6. Open Diode D36.

1.


2.


4.


Loose or broken wire #37 from Platform Terminal block TB6 to Platform Rotate Left Valve 3H-37. Defective Platform Rotate Left Valve Coil 3H-37. Loose or broken wire #02 from Platform Rotate Left Valve 3H-37 to Platform Terminal Block TB-6. Open Diode D37.

1.


2.


4.


Defective Switch S113 on Joystick S11. Loose or broken wire #36 from Joystick S11 to Platform Terminal Block TB6.

1.


Defective Switch S114 on Joystick S11. Loose or broken wire #37 from Joystick S11 to Platform Terminal Block TB6.

1.

Loose or broken wire #75 from Time Delay TD2 to Base Terminal Block TB2.

1.

2. 3.

4. NO PLATFORM ROTATE RIGHT FROM PLATFORM OR BASE CONTROLS

1.

2. 3.

4.

NO PLATFORM ROTATE LEFT FROM PLATFORM

1. 2.

NO PLATFORM ROTATE RIGHT FROM PLATFORM

1.

NO KNUCKLE UP OR DOWN FROM PLATFORM OR BASE CONTROLS

1.

SECTION 4, Page 10

2.

3.

3.

2.

2.

Replace if

Replace if

Check Switch. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective.



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO KNUCKLE DOWN FROM PLATFORM OR BASE CONTROLS

1.

Loose or broken wire #30 from Base Terminal Block TB-2 to Knuckle Down Valve Coil 4H-30. Defective Knuckle Down Valve Coil 4H-30.

1.


2.

3.

Loose or broken wire #02 from Knuckle Down Valve Coil 4H-30.

3.


1. 2.

Open Diode D31-3. Loose or broken wire #31A from Base Terminal Block TB-1 to Knuckle Up Valve Coil 4H31A.Defective Knuckle Down Valve Coil 4H-30. Defective Knuckle Up Valve Coil 4H-31A.

1. 2.


3.

4.

Loose or broken wire #02 from Knuckle Up Valve Coil 4H-31A to Base Terminal Block TB-3.

4.


1.

Loose or broken wire #75 from Base Terminal Block TB-2 to Platform Terminal Block TB6. Loose or broken wire #75 from Platform Terminal Block TB6 to Relay K39. Defective Relay K39. Loose or broken wire #02 from Relay K39 to Platform Terminal block TB6. Loose or broken wire #10 from Platform Terminal block TB6 to Relay K39. Loose or broken wire #104 from Relay K39 to Joystick S8. Defective Switch S81 on Circuit Board S8-1. Defective Circuit Board S8-1.

1.


2.


3. 4.


5.


6.

9.


9.

Check Continuity. Replace if defective. Check Switch. Replace if defective. Refer to Section 5, Page 8 for Controller Diagnostics. Check Continuity. Replace if defective.

1.

Defective Switch S82 on Circuit Board S8-1. Loose or broken wire #30 from Circuit Board S8-1 to Platform Terminal Block TB6. Loose or broken wire #30 from TB6 to TB2.

1.

2.

NO KNUCKLE UP FROM PLATFORM OR BASE CONTROLS

3.

NO KNUCKLE UP OR DOWN FROM PLATFORM

2.

3. 4.

5.

6. 7. 8.

NO KNUCKLE DOWN FROM PLATFORM

2.

3.


7. 8.

2.

3.

Check Continuity. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective. SECTION 4, Page 11


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO KNUCKLE UP FROM PLATFORM

1. 2.

3. PLATFORM WILL NOT LEVEL UP OR DOWN FROM PLATFORM

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

PLATFORM WILL NOT LEVEL UP FROM PLATFORM

1.

2. 3.

PLATFORM WILL NOT LEVEL DOWN FROM PLATFORM

1.

2. SECTION 4, Page 12

Defective Switch S82 on Circuit Board S8-1. Loose or broken wire #31 from Circuit Board S8-1 to Platform Terminal Block TB6. Loose or broken wire #31 from TB6 to TB2.

1.

3.


Loose or broken wire #09 to Platform Stow Switch S26. Defective Platform Stow Switch S26. Loose or broken wire #90 from Platform Stow Switch S26 to TB2, #90-TB2 to TB6, #90-TB6 to K35.. Defective Relay K35.

1.

Check Continuity. Replace if defective. Check Switch. Replace if defective. Check Continuity. Replace if defective.

Loose or broken Wire #107 from Platform Terminal Block TB6 to Relay K35. Loose or broken wire #02 from Relay K35 to Platform Terminal Block TB-6.

5. 6.


Loose or broken wire #106 from Relay K35 to Leveling Circuit Board PLCB1 Defective Leveling Circuit Board PLCB1. Loose or broken wire #91 from Leveling Circuit Board PLCB1 to Level Sensor TS2. Loose or broken wire #92 from Leveling Board PLCB1 to Level Sensor TS2. Loose or broken wire #93 from Leveling Board PLCB1 to Level Sensor TS2. Loose or broken wire #02 from Leveling Board PLCB1 to Platform Terminal Block TB-6.

7.


8.

Refer to Page 5-16, Figure 5-6. Platform Leveling Diagnostics. Check Continuity. Replace if defective.

2.

2. 3. 4.

9.



10.


11.


12.


Loose or broken wire #41 from Leveling Board BLCB1 to Level Up Valve 3H-41 Defective Level Up Valve Coil 3H-41. Loose or broken wire #02 from Level Up Valve Coil 3H-41 to Platform Terminal Block TB-7.

1.


2.


Loose or broken wire #40 from Leveling Board PLCB1 to Level Down Valve 3H-40 Defective Level Down Valve Coil 3H-40.

1.


2.


3.



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) PLATFORM WILL NOT LEVEL DOWN FROM PLATFORM (Continued)

3.

Loose or broken wire #02 from Level Down Valve Coil 3H-40 to Platform Terminal Block TB-7.

3.


UNIT WILL NOT DRIVE

1.

Loose or broken wire #10 from TB& S5 to Relay K38. Defective Relay K38. Loose or broken wire #02 from Relay K38 to Platform Terminal Block TB-7. Loose or broken wire #89 from Drive Joystick S21 to Relay K38. Loose or broken wire #62 from Relay K38 to Relay K18 in Base. Defective Relay K18. Loose or broken wire #99 from Relay K18 to Terminal "L" on EDA Board. Loose or broken wire #64 from Drive Joystick S21 to Terminal 10 on MDSD Board. Loose or broken wire #102 from Drive Joystick S21 to Relay K20. Defective Relay K20. Loose or broken wire #51 from Relay K20 to Diode D28 on Terminal Block TB-1. Loose or broken wire #02 from Relay K20 to Lower Terminal Block TB-1. Loose or broken wire #52 from Relay K20 to Relay K19. Defective Relay K19. Loose or broken wire #02 from Relay K19 to Lower Terminal Block TB-1. Loose or broken wire #63 from Drive Joystick S21 to Terminal 11 on MDSD Board. Defective Potentiometer S21-4 on Drive Joystick S21. Broke or loose wire #09 to Terminal 1 on EDA Board. Loose or broken wire #02 to Terminal 2 on EDA Board. Loose or broken wire #98 from Terminal 10 on EDA Board to Magnetic Pickup TP1. Loose or broken wire #98A from Terminal 9 on EDA Board to Magnetic Pickup TP1.

1.

Check Continuity. Replace if defective. Check Relay. Replace if defective. Check Continuity. Replace if defective.

2. 3.

4. 5. 6. 7.

8.

9. 10. 11.

12.

13. 14. 15.

16.

17. 18. 19. 20.

21.


2. 3.

4. 5. 6. 7.

Check Continuity. Replace if defective. Check Continuity. Replace if defective. Check Relay. Replace if defective. Check Continuity. Replace if defective.

8.


9.


10. 11.

12.


13.


14. 15.

16.


17.

Check Potentiometer. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective.

18. 19. 20.

21.


SECTION 4, Page 13


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) UNIT WILL NOT DRIVE (Continued)

22.

Magnetic Pickup TP1 out of adjustment. Defective Magnetic Pickup TP1.

22.

24.

26. 27.

Loose or broken wire #09 from Terminal 1 on EDA Board to Terminal 1 on MDSD Board. Loose or broken wire #02 from Terminal 2 on EDA Board to Terminal 2 on MDSD Board. Blown Fuse FU2 on EDA Board. Defective EDA Board.

28. 29.

Blown Fuse FU3 on MDSD Board. Defective MDSD Board.

28. 29.

1.

Loose or broken wire #16 from Terminal 4 on MDSD Board to Forward Drive Valve Coil 4H-16. Defective Forward Drive Valve Coil 4H-16. Loose or broken wire #101 from Forward Drive Valve 4H-16 to Terminal 3 on MDSD Board. Defective MDSD Board.

1.


2.


4.

Refer to Page 5-10, Figure 5-3 MDSD Diagnostics.

Loose or broken wire #15 from Terminal 6 on MDSD Board to Reverse Drive Valve Coil 4H-15. Defective Reverse Drive Valve Coil 4H-15. Loose or broken wire #100 from Reverse Drive Coil 4H-15 to Terminal 5 on MDSD Board. Defective MDSD Board.

1.


2.


4.

Refer to Page 5-10, Figure 5-3 MDSD Diagnostics.

Loose or broken wire #09 from Lower Terminal Block TB-1 to MID Boom in Limit Switch LS1. Defective Mid Boom in Limit Switch LS1. Loose or broken wire #06 from Mid Boom in Limit Switch LS1 to High Drive/Tilt Over-ride Limit Switch LS2. Defective High Drive/Tilt Over-ride Limit Switch LS2. Loose or defective wire #59 from Tilt Over-ride/High Drive Limit Switch LS2 to Lower Terminal Block TB-1.

1.


2.


23. 24.

25.

NO DRIVE FORWARD

2. 3.

4. NO DRIVE REVERSE

1. 2. 3. 4.

NO HIGH DRIVE

1.

2. 3.

4. 5.

SECTION 4, Page 14

23.

Refer to Page 5-9, Figure 5-2 EDA Board Diagnostics. Refer to Page 5-9, Figure 5-2 EDA Board Diagnostics. Check Continuity. Replace if defective.

25.


26. 27.

Replace Fuse. Refer to Page 5-9, Figure 5-2 EDA Board Diagnostics. Replace Fuse. Refer to Page 5-10, Figure 5-3 MDSD Board Diagnostics.

3.

3.

3.

4. 5.




PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO HIGH DRIVE (Continued)

6.

Loose or broken wire #59 from Lower Terminal Block TB-1 to Terminal 5 on EDA Board. Loose or broken wire #59 from Lower Terminal Block TB-1 to Relay K06. Defective Relay K06. Loose or defective wire #02 from Relay K06 to Terminal Block TB-1. Loose or broken wire #09 from Terminal Block TB-1 to Relay K06. Loose or broken wire #55 from High Drive Relay K06 to High Drive Valve Coil 2H-55. Defective High Drive Valve Coil 2H-55. Loose or broken wire #02 from High Drive Relay K06 to Terminal Block TB-1.

6.


7.


8. 9.


10.


1.

Machine out of level.

1.

2.

2.

3.

Loose or broken wire #09 from Base Terminal Block to Tiltswitch Fuse FU1. Blown Tiltswitch Fuse FU1.

4.

Defective Tiltswitch TS1.

4.

5,

Loose or broken wire #28 from Tiltswitch TS1 to Base Terminal Block TB1. Open Diode D28.

5.

6.


Loose or broken wire #114 from Terminal Strip to Steer Dump Valve Coil 2H-114 or defective Diode D114. Defective Steer Dump Valve Coil 2H-114. Loose or broken wire #02 from Steer Dump Valve Coil 2H-114 to Terminal Block TB-1. Defective Steer Left Switch S21-1. Loose or broken wire #24 from Steer Left Switch S21-1 to Relay K25. Defective Relay K25.

1.


2.


Loose or broken wire #66 from Relay K25 to Steer Left Relay K08.

4.

7.

8. 9.

10. 11.

12. 13.

NO DRIVE ELEVATED OR TELESCOPED OUT

6. NO STEER LEFT OR RIGHT

1.

2. 3.

NO STEER LEFT

1. 2. 3. 4.


11.

12. 13.

3.

3.

1. 2. 3.

Check Continuity through coil. Replace if defective. Check Continuity. Replace if defective. Move machine to firm level ground. Check Continuity. Replace if defective. Check Continuity. Replace if defective. Check Switch. Replace if defective. Check Continuity. Replace if defective. Replace

if

Check Switch. Replace if defective. Check Continuity. Replace if defective. Check Relay. Replace if defective. Check Continuity. Replace if defective. SECTION 4, Page 15


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO STEER LEFT (Continued)

5.

Defective Steer Left Relay K08.

5.

6.

Loose or broken wire #02 from Steer Left Relay K08 to Terminal Block TB-1. Loose or broken wire #09 from Steer Left Relay K08 to Terminal Block TB-1. Loose or broken wire #48 from Steer Left Relay K08 to Steer Left Valve 4H-48. Defective Steer Left Valve Coil 4H-48. Loose or broken wire #02 from Steer Left Valve 4H-48 to Terminal Block TB-1. Open Diode D48.

6.

11.


Defective Steer Right Switch S21-2. Loose or broken wire #23 from Steer Right Switch S21-2 to Relay K24. Defective Relay K24.

1.


Loose or broken wire #58 from Relay K24 to Steer Right Relay K07. Defective Steer Right Relay K07.

4.

Loose or broken wire #02 from Steer Right Relay K07 to Terminal Block TB-1. Loose or broken wire #09 from Steer Right Relay K07 to Terminal Block TB-1. Loose or broken wire #47 from Steer Right Relay K07 to Steer Right Valve 4H-47. Defective Steer Right Valve Coil 4H-47. Loose or broken wire #02 from Steer Right Valve 4H-47 to Terminal Block TB-1. Open Diode D47 on Terminal Block TB-1.

6.

11.


Loose or broken wire #09 from Terminal Strip to Direction Sensing Switch S22. Defective Direction Sensing Switch S22.

1.


2.


7. 8. 9. 10. 11. NO STEER RIGHT

1. 2.

3. 4.

5. 6.

7.

8.

9. 10.

11. DRIVE AND STEER WILL NOT CHANGE DIRECTIONS

1.

2.

SECTION 4, Page 16


7.


8.


9.


10.

2.

3.

5.

Replace if

Check Relay. Replace if defective. Check Continuity. Replace if defective Check Relay. Replace if defective. Check Continuity. Replace if defective.

7.


8.


9.

Check continuity through Coil. Replace if defective. Check Continuity. Replace if defective.

10.

Replace if

Replace if



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) DRIVE AND STEER WILL NOT CHANGE DIRECTIONS (Continued)

3.

Loose or broken wire #17 from Direction Sensing Switch S22 to Terminal Block TB-2. Loose or broken Wire #17 from Terminal Block TB-2 to Relays K18, K19, K24 and K25.

3.


4.


BRAKES WILL NOT RELEASE

1.

Defective Switch S21-3 in Drive Joystick. Loose or broken wire #29 from Switch S21-3 in Drive Joystick to Terminal Block TB-2. Loose or broken wire #29 from Terminal Block TB-2 to Brake Relay K09. Defective Brake Relay K09.

1.

Check Switch. Replace if defective. Check Continuity. Replace if Defective.

Loose or broken Wire #02 from Brake Relay K09 to Terminal Block TB-1. Loose or broken Wire #09 from Brake Relay K09 to Terminal Block TB-1. Loose or broken wire #65 from Brake Relay K09 to Brake Valve 3H-65. Defective Brake Valve Coil 3H-65.

5.

Loose or broken wire #02 from Brake Valve Coil 3H-65 to Terminal Block TB-1. NOTE: Steps 10 & 11 for units equipped for brake release from boom pump only. 10. Loose or broken wire #29 from Base Terminal Block TB-1 to Diode D29. 11. Open Diode D29.

9.

1.

4.

2.

3.

4. 5.

6.

7.

8. 9.

BASE CONTROLS INOPERATIVE

2.

3.

4.

Defective Block S2-3 on Key Switch S2. Loose or broken wire #08 from Block S2-3 to Base Ignition Switch S25. Loose or broken wire #08 from Block S2-3 to Terminal Block TB-1. Loose or broken Wire #08 from Base Ignition Switch to Base Control Switches.


2.

3.

Check Continuity. Replace if Defective.

4.


6.


7.


8.

Check Continuity through coil. Replace if defective. Check Continuity. Replace if defective.

10.


11.


1.

Check Block. Replace if defective. Check Continuity. Replace if Defective.

2.

Replace if

3.


4.


SECTION 4, Page 17


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO START FROM BASE

1.

Defective Base Ignition Switch S25. Loose or broken Wire #68 from Base Ignition Switch S25 to Diode D68 on Terminal Block TB-1. Open Diode D68 on Terminal Block TB-1.

1.

3.

Check Diode. Replace if defective.

Defective Telescope Extend/ Retract Switch S16. Loose or broken wire #38 (retract) or wire #39 (extend) from Telescope Extend/Retract Switch S16 to Terminal Block TB-2. Open Diodes D38-1 (retract) or D39-1 (extend) on Terminal Block TB-2.

1.


3.


Defective Main Boom Up/Down Switch S15. Loose or broken wire #14 (up) or #13 (down) from Main Boom Up/ Down Switch S15 to Terminal Block TB-2. Open Diode D13-2 (down) or D141 (up) on Terminal Block TB-2.

1.


3.


Defective Turret Rotate Switch S20. Loose or broken wire #33 (right) or #32 (left) from Turret Rotate Switch S20 to Terminal Block TB-2. Open Diode D32 (left) or D33 (right) on Terminal Block TB-2.

1.


3.


1.

Defective Jib Up/Down Switch S17.

1.

2.

Loose or broken wire #35 (up) or #34 (down) from Jib up/down Switch S17 to Terminal Block TB2. Loose or broken wire #34 down or #35 uo from Base Terminal Block TB2 to Platform Terminal Block TB6. Open Diode D34 (down) or D35 (up) on Terminal Block TB-2.

2.


Defective Platform Rotate Switch S18. Loose or broken wire #37 (right) or #36 (left) from Platform Rotate Switch S18 to Terminal Block TB2.

2.

3. NO TELESCOPE FROM BASE

1. 2.

3.

NO MAIN BOOM FROM BASE

1. 2.

3. NO TURRET ROTATE FROM BASE

1. 2.

3. NO JIB UP OR DOWN FROM BASE

3.

4. NO PLATFORM ROTATE FROM BASE

1. 2.

SECTION 4, Page 18

2.

2.

2.

2.


3.


4.


1.


2.



PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO PLATFORM ROTATE FROM BASE (Continued)

3.

4. NO KNUCKLE UP OR DOWN FROM BASE

1. 2.

3. NO PLATFORM LEVEL UP/DOWN FROM BASE

1.

2. 3.

4.

5. BRAKES APPLY TOO QUICK ON LEVEL SURFACE

1. 2. 3.

Loose or broken wire #36 left or #37 right from Base Terminal Block to Platform Terminal Block TB6. Open Diode D36 (left) or D37 (right) on Terminal Block TB-2. Defective Knuckle Up/Down Switch S10. Loose or broken wire #31 (up) or #30 (down) from Knuckle Up/Down Switch S10 to Terminal Block TB2. Open Diode D30-2 (down) or D311 (up) on Terminal Block TB-2. Loose or broken wire #109 from Platform Stow Switch S26 to Platform Level Switch S34. Defective Platform Level Switch S34. Loose or broken wire #41 (up) or #40 (down) from Platform Level Switch S34 to Base Terminal Block TB-2. Loose or broken wire #41 (up) or #40 (down) from Platform Level Switch S34 to Platform Terminal Block TB-6. Open Diode D40 (down) or D41 (up) on Terminal Block TB-2. Loose or broken wire #28 from Tilt Switch TS1 to Relay K26. Defective Relay K26.

3.


4.

Check Diode. Replace if defective. Check Switch. Replace if defective. Check Continuity. Replace if defective.

1. 2.

3. 1.

2. 3.


5.

Check Diode. Replace if defective. Check Continuity. Replace if defective. Check Relay. Replace if defective. Check Continuity. Replace if defective. Check Continuity. Replace if defective.

1. 2. 3.

Loose or broken wire #2 from Relay K10 to Terminal Block TB-1. 8. Loose or broken wire #09 from Terminal Block TB-1 to Relay K10. 9. Loose or broken wire #103 from Relay K10 to 5 Degree Brake Valve 2H-103. 10. Defective 5 Degree Brake Valve Coil 2H-103. 11. Loose or broken wire #02 from 5 Degree Brake Valve 2H-103 to Terminal Block TB-1. SJB-66TK, Serial Number 93197 and below

7.

5. 6. 7.


4.

Loose or broken wire #2 from Relay K26 to Terminal Block TB-1. Loose or broken wire #10 from Platform Terminal Block TB-7 to Relay K26. Loose or broken wire #12 from Relay K26 to Relay K10. Defective Relay K10.

4.


4.

5. 6.

8. 9.

10. 11.

Check Continuity. defective. Check Relay. defective. Check Continuity. defective. Check Continuity. defective. Check Continuity. defective.

Replace if Replace if Replace if Replace if Replace if

Check Continuity through Coil. Replace if defective. Check Continuity. Replace if defective. SECTION 4, Page 19


PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) NO THROTTLE CONTROL FROM PLATFORM (STAYS AT IDLE 900 RPM)

1.

Loose or broken wire #10 from Platform Terminal Block TB-7 to Throttle Switch S14. Defective Throttle Switch S14.

1.


2.


NO LOW ENGINE RPM (1600 RPM'S)

1.

Loose or broken wire #88 from Throttle Switch S14 to Platform Terminal Block TB-6. Open Diode D88 from Throttle Switch S14 to wire #79. Loose or broken wire #79 from Platform Terminal Block TB-6 to Throttle Control BCB-1 Position "B". Loose or broken wire #88 from Throttle Switch S14 to Relay K36 Defective Relay K36. Loose or broken wire #02 from Relay K36 to Platform Terminal Block TB-7. Throttle Control BCB1 out of adjustment or defective.

1.


2.

Check Diode. Replace if Defective. Check Continuity. Replace if defective.

7.

Refer to Page 5-18, Figure 5-8 Barber/Colman Diagnostics.

1.

Defective Throttle Switch S14.

1.

2.

Defective Relay K36.

2.

3.

Loose or broken wire #10 from Platform Terminal Block TB-7 to Relay K36. Loose or broken wire #78 from Relay K36 to Terminal Block TB1. Open Diode D78 on Terminal Block TB-1. Loose or broken wire #113 from Diode D78 to Throttle Control BCB1 position "A". Throttle Control BCB1 out of adjustment or defective.

3.

Check Switch. Replace if Defective. Check Relay. Replace if Defective. Check Continuity. Replace if defective.

Loose or broken wire #116 from Throttle Switch S14 to Platform Terminal Block TB-6. Open Diode D116 on Platform Terminal TB-6. Throttle Control BCB1 out of adjustment or defective.

2.

2. 3.

4. 5. 6.

7. NO MID ENGINE RPM (2100 RPM'S)

4.

5. 6.

7. NO HIGH ENGINE RPM (2600 RPM'S)

1.

2. 3.

SECTION 4, Page 20

3.

4. 5. 6.

Replace if


4.


5.


6.


7.


1.


2.


3.




PROBABLE CAUSE

REMEDY

ELECTRICAL SYSTEM (Cont.) L. P. OR GASOLINE VALVES INOPERATIVE

1.

Loose or broken wire #09 from Base Terminal Block TB-1 to Relay K11. Defective Relay K11.

1.


2.

Check Relay. Replace if defective.

Loose or broken wire #02 from Relay K11 to Base Terminal Block TB1. Loose or broken wire #105 from Relay K11 to Relay K12. Loose or broken wire #77 from TB1 to K11.

3.


4.


Defective Relay K12. Loose or broken wire #50 from Relay K12 to Engine Terminal Block. Loose or broken wire #50 from Engine Terminal Block to L.P. Valve 2P-50. Defective L.P. Valve 2P-50.

1. 2.


3.


4.

Check Valve. Replace if defective.

1. 2.


3.


4.

5.

Defective Relay K12. Loose or broken wire #56 from Relay K12 to Engine Terminal Block. Loose or broken wire #56 from Engine Terminal Block to Fuel Pump FP1 or Gasoline Valve 2G56. Loose or broken wire 11 from Fuel Select Switch S33 to K12. Loose or broken wire #02 on R12.

6.

Defective S33 Switch.

6.

7.

Loose or broken wire #60 on S33.

7.

Check Continuity. defective. Check Continuity. defective. Check Switch. defective. Check Continuity. defective.

2. 3.

4. 5.

L. P. VALVE INOPERATIVE

1. 2.

3.

4. GASOLINE VALVE AND FUEL PUMP INOPERATIVE

1. 2.

3.

4.


5.

5.

Replace if Replace if Replace if Replace if

SECTION 4, Page 21

TROUBLESHOOTING TROUBLE

PROBABLE CAUSE

REMEDY

HYDRAULIC SYSTEM NOTE: ALL TESTS SHOULD BE PERFORMED WITH BOOM OVER NON-STEERING AXLE ALL FUNCTIONS INOPERATIVE

1.

Broken or defective Pump Coupling.

1.

Check Coupling. Replace if defective.

ALL BOOM FUNCTIONS INOPERATIVE

1.

Defective Shuttle Valve SV-3.

1.

2.


2.

3.


3.

4.


4.

5.

Defective Load Sense Dump Valve 2H-53. Defective Load Sense Adjusting Valve 3H-V2. Defective System Pressure Adjusting Valve 3H-V1. Defective System Pump P2.

5.

Check Shuttle Valve. Replace if defective. Check Shuttle Valve. Replace if defective. Check Shuttle Valve. Replace if defective. Check Shuttle Valve. Replace if defective. Check Valve. Replace if defective. Check Valve. Replace if defective. Check Valve. Replace if defective. Check Pump. Replace if defective.

Blocked Pilot Pressure Filter F3 in Apitech Manifold Inlet. Defective Pilot Pressure Reducing Valve PR4. Blown O-ring on any of the Pulsars. Check Valve CV-1 stuck shut.

1.

Defective Compensator Valve in Main Boom Section of Apitech Valve. Stuck Spool Valve 4H-70 or 4H71 in Main Boom Section of Apitech Valve. Defective Pulsar on Main Boom Up Valve 4H-71. Stuck or Defective Counter Balance Valves CB5 or CB7.

1.

Check Valve. Replace Main Boom Valve section if defective.

2.

Check Valve. Replace Main Boom Valve section if defective.

1.

Check Pulsar. Replace if defective. Check Valves. Replace if defective.

1.

Defective Pulsar on 4H-70 Valve.

1.

2.

Stuck or Defective Counter Balance Valves CB6 or CB8.

2.

1.

Defective Compensator Valve in Turret Rotate section of Apitech Valve. Relief Valve RV-7 out of adjustment. Stuck Spool Valve 4H-32 or 4H33 in Turret Swing section of Apitech Valve. Stuck or Defective Shuttle Valve SV13 in Turret Rotation Manifold MB6. Defective Turret Rotate Motor M2.

1.

6. 7. 8. NO MAIN BOOM, KNUCKLE, TELESCOPE OR TURRET ROTATE. ALL OTHER FUNCTIONS OPERATE

1. 2. 3. 4.

NO MAIN BOOM UP OR DOWN

1. 2.

NO MAIN BOOM UP

1. 2.

NO MAIN BOOM DOWN

NO TURRET ROTATE LEFT OR RIGHT

2. 3. 4. 5. SECTION 4, Page 22

6. 7 8.

2. 3. 4.

2.

2. 3.

Check Filter, clean or replace if blocked. Check Valve. Replace if defective. Check all Pulsars. Repair as needed. Check CV-1. Replace if defective.

Check Pulsar. Replace if defective. Check Valves. Replace if defective. Check Valve. Replace Turret Rotate section if defective. Check Adjustment. Adjust to 2000 PSI. Check Valve. Replace Turret Rotate section if defective.

4.

Check Valve. defective.

Replace if

5.

Check Motor. defective.

Replace if



PROBABLE CAUSE

REMEDY

HYDRAULIC SYSTEM (Cont.) NO TURRET ROTATE LEFT

1. 2.

NO TURRET ROTATE RIGHT

1. 2.

Defective Pulsar on Turret Rotate Left Valve 4H-32. Stuck or defective Counter Balance Valve CB22.

1.

Defective Pulsar on Turret Rotate Right Valve 4H-33. Stuck or defective Counter Balance Valve CB21.

1.

2.

2.

Check Pulsar. defective. Check Valve. defective. Check Pulsar. defective. Check Valve. defective.

Replace if Replace if Replace if

TURRET ROTATE BRAKE INOPERATIVE

1.


1.

2.

Defective Turret Rotate Brake BP1.

2.

NO MID OR FLY TELESCOPE IN OR OUT

1.

Defective Compensator Valve in Telescope Section of Apitech Valve. Stuck Spool Valve 4H-38 or 4H39 in Telescope section of Apitech Valve. Stuck or Defective Telescope Sequence Valve 3H-44.

1.

Check Valve. Replace Telescope Valve Section if defective.

2.

Check Valve. Replace Telescope Valve section if defective.

3.


Defective or Misadjusted Mid Boom Telescope Pressure Reducing Valve PR2. Stuck or Defective Counter Balance Valve CB2. Defective C-3 or C-4 Telescopic Cylinder.

1.

Check Valve. Replace if defective. Readjust to 2100 PSI.

2.

Check Valve. Replace if defective. Check Cylinder. Replace or repack if defective.

Stuck or defective Telescope Sequence Valve 3H-44. Stuck or Defective Counter Balance Valve CB1. Defective C-3 or C-4 Telescope Cylinder. Defective Mid Boom Lock Cylinder C9.

1.

Stuck or defective Telescope Sequence Valve 3H-43. Defective or misadjusted Fly Boom Telescope Pressure Reducing Valve PR3. Stuck or defective Counter Balance Valve CB4. Defective C-5 Fly Boom Telescope Cylinder

1.

Stuck or defective Counter Balance Valve CB3. Defective C-5 Fly Boom Telescope Cylinder.

1.

2. 3. NO MID BOOM TELESCOPE OUT

1. 2. 3.

NO MID BOOM TELESCOPE IN

1. 2. 3. 4.

NO FLY BOOM OUT

1. 2.

3. 4. NO FLY BOOM IN

1. 2.


3.

2. 3. 4.

2.

3. 4.

2.

Check Valve. defective. Check Brake. defective.

Replace if

Replace if Replace if

Replace if

Check Valve. Replace defective. Check Valve. Replace defective. Check Cylinder. Replace Repack if defective. Inspect Cylinder. Rebuild Replace as necessary.

if if or or

Check Valve. Replace if defective. Check Valve. Replace if defective. Readjust to 2100 PSI. Check Valve. Replace if defective. Check Cylinder. Replace or repack if defective. Check Valve. Replace if defective. Check Cylinder. Replace or repack if defective.

SECTION 4, Page 23


PROBABLE CAUSE

REMEDY

HYDRAULIC SYSTEM (Cont.) NO JIB UP OR DOWN

1. 2. 3. 4.

NO JIB UP

1.

4.



2.


1.

Check Flow Control. Clean if plugged. Replace if defective. Check Valve. Replace if defective.

3.

Plugged or defective Flow Control FC3. Defective Load Sense Shuttle Valve SV8. Defective rotary Actuator RA1

4.

Stuck or defective 3H-36 or 3H-37.

4.

Check Rotary Actuator. Replace if defective. Check Valve. Replace if defective.

1.

Stuck or defective Platform Rotate Left Valve 3H-36. Stuck or defective Counter Balance Valve CB15.

1.


2.


Stuck or defective Platform Rotate Right Valve 3H-37. Stuck or defective Counter Balance Valve CB16.

1.


2.


Defective Compensator Valve in Knuckle Section of Apitech Valve. Stuck Spool Valve 4H-72 or 4H-73 in Knuckle Section of Apitech Valve.

1.

Check Valve. Replace Knuckle Valve section if Defective. Check Valve. Replace Knuckle Valve section if defective.

Defective Pulsar on Knuckle Down Valve 4H-72. Stuck or defective Counter Balance Valve CB10 or CB12.

1. 2.

Check Valve. Replace if Defective. Check Valve. Replace if defective.

Defective Pulsar on Knuckle Up Valve 4H-73. Stuck or defective Counter Balance Valve CB9 or CB11.

1.


2.


1.

1.

1.

1.

1. 2.

SECTION 4, Page 24


1.

2.

NO KNUCKLE UP

3.

Stuck or defective JIB Down Valve 3H-34. Stuck or Defective Counter Balance Valve CB21.

1.

2.

NO KNUCKLE DOWN

Stuck or defective 3H-34 or 3H-35. Defective Load Sense Shuttle Valve SV12.


2. NO KNUCKLE UP OR DOWN


2.

2. NO PLATFORM ROTATE RIGHT

2.


2.

NO PLATFORM ROTATE LEFT


1.

2.

NO PLATFORM ROTATE LEFT OR RIGHT

1.

Stuck or defective JIB Up Valve 3H-35. Stuck or Defective Counter Balance Valve CB22.

2.

NO JIB DOWN

Defective DS1 Differential Sensing Valve. Defective JIB Shuttle Valve SV12.

2. 3.

2.



PROBABLE CAUSE

REMEDY

HYDRAULIC SYSTEM (Cont.) PLATFORM WILL NOT LEVEL UP OR DOWN

1.

Defective DS2 Differential Sensing Valve. Defective Load Sense Shuttle Valve SV9.

1.


2.


Defective Platform Level Down Valve 3H-40. Stuck or defective Counter Balance Valve CB17 or CB19.

1.


2.


Defective Platform Level UP Valve 3H-41. Stuck or defective Counter Balance Valve CB18 or CB20.

1.


2.


1. 2.

3.

Defective Brake Valve 3H-65. Defective or misadjusted Pressure Reducing Valve PR1. Defective Relief Valve RV4.

4.

Stuck Shuttle Valve SV14.

4.

Check Valve. Replace if defective. Check Valve. Replace if defective. Check Valve. Replace if defective. Check Valve. Replace if defective.

1.

1.


2.

Stuck or defective Brake Valve 3H-65. Brakes out of adjustment.

2.

Refer to Page 5-35, Figure 5-27 for Adjustment procedure.

1. 2.

Brakes will not release. Defective Relief Valve RV3.

1. 2.

3.

Defective Pressure Over-ride Valve P.O.R.1

3.

4.

4.

5.

Defective or stuck directional Valve 4H-15 or 4H-16. Defective Main Drive Pump P1.

6.

Defective Drive Motor M1.

6.

Refer to Brake Diagnostics. Refer to Page 5-24, Figure 5-13 for test procedure. Replace if defective. Refer to Page 5-24, Figure 5-13 for test procedure. Replace if defective. Check Valve. Replace if defective. Refer to Drive Pump Diagnostics Page 5-24, Figure 5-14. Refer to Page 5-24, Figure 5-14 Drive Motor Test Procedure. Replace if defective.

NO DRIVE FORWARD

1.

Defective Relief Valve RV1.

1.


Replace if

NO DRIVE REVERSE

1.

Defective Relief Valve RV2.

1.


Replace if

NO HIGH DRIVE

1.

Stuck or defective High Speed Drive Valve 2H-55. Relief Valve RV3 set too low.

1.

Check Valve. Replace if defective. Refer to Page 5-24 Drive Pump Test procedure. If pressure is lower than 300 PSI replace Relief Valve RV3.

2. PLATFORM WILL NOT LEVEL DOWN

1. 2.

PLATFORM DOES NOT LEVEL UP

1. 2.

BRAKES WILL NOT RELEASE

BRAKES WILL NOT ENGAGE

NO DRIVE FORWARD OR REVERSE

1. 2.

2.


3.

5.

2.

Replace if

Replace if

SECTION 4, Page 25


PROBABLE CAUSE

REMEDY

HYDRAULIC SYSTEM (Cont.) NO ELEVATED DRIVE

1.

Defective or misadjusted Hi/Low Drive Relief Valve RV6.

1.


NO STEER LEFT OR RIGHT

1.

Stuck or defective Steer Dump Valve 2H-114. Plugged Steer Orifice O1. Stuck or defective Steer Valve 4H-47 or 4H-48. Steer Cylinder C8 Leaking Internally.

1.

Check Valve. Replace if defective. Clean Orifice. Check Valve. Replace if defective. Check Cylinder. Replace if defective.

2. 3. 4.

SECTION 4, Page 26

2. 3. 4.

Replace if


SECTION 5 MAINTENANCE AND SERVICE OPERATOR’S RESPONSIBILITY FOR MAINTENANCE

OWNER’S ANNUAL INSPECTION RECORD

Death or injury can result if the work platform is not kept in good working order. Inspection and maintenance should be performed by competent personnel who are familiar with mechanical procedures. The operator should be assured that the work platform has been properly maintained and inspected before using it. Even if the operator is not directly responsible for the maintenance of this work platform, the operator should perform ALL the daily inspections found in Table 5-1. Maintenance and Inspection Schedule.

It is the responsibility of the owner to arrange daily, weekly, monthly and annual inspections of the work platform. Table 5-2. Owner’s Annual Inspection Record is to be used for recording the date of inspection, owners’ name and the person responsible for the inspection of this work platform.

NOTE Replace all worn, damaged or missing parts or labels discovered during this inspection.

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 5-1. Maintenance and Inspection Schedule indicates the areas of the work platform to be maintained or inspected and at what intervals the maintenance and inspections are to be performed.

GENERAL MAINTENANCE HINTS •

Before attempting any repair work, disconnect the batteries.

•

Preventive maintenance is the easiest and least expensive type of maintenance.

REPLACEMENT PARTS Use only original replacement parts. Parts such as batteries, chargers, wheels, railings, etc. with weight and dimensions different from original parts will affect stability of the work platform and must not be used without manufacturer’s consent. Use only original filled tires for models which must be so equipped. Consult manufacturer.

5


SECTION 5, Page 1

HYDRAULIC SYSTEM AND COMPONENT MAINTENANCE AND REPAIR

7.

All containers and funnels used in handling hydraulic oil must be absolutely clean. Use a funnel when necessary for filling the hydraulic oil reservoir, and fill the reservoir only through the filter opening. The use of cloth to strain the oil should be avoided to prevent lint from getting into the system.

8.

When removing any hydraulic component, be sure to cap and tag all hydraulic lines involved. Also, plug the ports of the removed components.

9.

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 ages. After the parts have been dried thoroughly, lay them on a clean, lint-free surface for inspection.

10.

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 assembly.

11.

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.

12.

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.

The 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.

2.

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.

3.

Samples of hydraulic oil should be drawn from the reservoir every six months. These samples should be about two quarts and should be taken while the oil is warmed through normal operation of the system. If possible, the sample should be analyzed by a qualified lubrication specialist to determine whether it is suitable for further use. The intervals between oil changes depend on operating conditions and on the care used in keeping the oil clean.

4.

5.

6.

Whenever there is a hydraulic system failure which gives reason to believe that there are metal particles of 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. DO NOT use synthetic or fire resistant oil in this work platform. Use ATF Dexron III (ESSO) or equivalent hydraulic oil. For conditions causing oil temperatures below -31°F (-35° C) and above 122°F (50° C) consult Skyjack, Inc.

SECTION 5, Page 2

MAINTENANCE. 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 regularly.

2.

Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir.

3.

Keep all connections tight.


Table 5-1. Maintenance and Inspection Schedule Daily Engine (11) Fuel leaks (1) Engine oil (4)

Weekly

á á

Monthly

á

Engine RPM (8) Fuel filter (7) Muffler (2)(3)(11) Air cleaner (1)(7) Fuel tank cap (2)(3) Coolant level (1)(12) Mechanical Struct. damage/welds (1) Parking brakes (2) Tires and wheels (1)(2)(3) Guides and wear pads (1)(2)(3) Railings and gate (2)(3) Bolts and fasteners (3)

á

á á á á á á á

Turret gear (1)(2)(3)(6) Turret gear box (1)(2)(3)(4) Pivot pins (1)

á

á

6 Months

á

á á

Rust (1) Whl brgs (2) King pins (1)(6)

3 Months

á á

á

á

á

Steer cylinders/tie rod ends(6) Axle gear oil (13) Electrical Battery fluid level (1) Joysticks and control switches (1)(2)(3) Cords and wiring (1)(3) Battery terminals (1)(3) Terminals and plugs (1)(3) Generator and receptacle (2) Limit switches (2) Tilt sensors (2) Directional sensing (2)

á á á á á á á á á

Emergency pump (2) Hydraulic Hydraulic oil level (1)(4) Hydraulic leaks/hoses (1)(3)

Hydraulic cylinders (1)(2)(3) Emergency lowering (2)

á

Lift capacity (5) Hydraulic oil/filter (7) Miscellaneous Labels (1)(9) Manuals (10)

á

á á á á á á á á á á á á á á á á á á á á á

á á á á á á á á á á

á

á á

Lift/lowering time (8)

* Yearly

á

á á

á

á á á á á á á á

NOTES: (1) Visually inspect (2) Check operation (3) Check tightness (4) Check oil level (5) Check relief valve setting. Refer to (6) Lubricate (7) Replace (8) See Table 5-7. General Specification Serial Number nameplate (9) Replace if missing or illegible (10) Proper Operating Manual MUST be in the manual tube (11) Refer to engine manual (12) Check only when cooled (13) Change oil using 80W90, GL5 * Record inspection


SECTION 5, Page 3

Table 5-2. Owner’s Annual Inspection Record

MODEL NUMBER__________________________ SERIAL NUMBER______________ RECORDING DATE RECORDING YEAR #

1

2

3

4

5

6

7

8

OWNERS NAME INSPECTED BY

Table 5-3. Tire Specifications Tire

Fill Specification

Model Size

Rating

Type

Pressure

SJB-66TK

15 x 19.5

14 Ply

Air

95 PSI

HIGH FLOTATION (Optional)

31 x 15.5 lug 31 x 13.5 rib

8 Ply 8 Ply

Air Air

85 PSI 85 PSI

Table 5-4. Maximum Platform Capacities

Model

Platform Capacity (unrestricted)

SJB-66TK

600# (272kg) 3 occupants

WITH OPTIONAL 10’ PLATFORM

500# (227kg) 2 occupants

NOTE: Refer to capacity label on work platform for additional information.

Table 5-5. Special Tools

DIAL INDICATOR

SKYJACK PART 707704

17mm ALLEN WRENCH

PURCHASE LOCALLY

PRESSURE GAUGE 0 - 5000 psi

PURCHASE LOCALLY

PRESSURE GAUGE 0 - 1000 psi

PURCHASE LOCALLY

CYLINDER ASSEMBLY TOOL - 3-1/2" Inside Diameter

SKYJACK PART 703872

CYLINDER ASSEMBLY TOOL - 4-1/2" Inside Diameter

SKYJACK PART 703873

SECTION 5, Page 4


Table 5-6. Torque Specifications

DIRECTIONAL VALVE MOUNTING SCREWS

28-32 in. lbs.

TURRET ROTATE GEAR MOUNTING BOLTS

375 ft. lbs.

WHEEL MOUNTING BOLTS

290 ft. lbs.

COUNTERWEIGHT BOLTS

240 ft. lbs.

AXLE MOUNTING BOLTS

205 ft. lbs.

HYDRAULIC PUMP MOUNTING BOLTS

75 ft. lbs.

SPEED REDUCER MOUNTING BOLTS

175 ft. lbs. Light Oil CARTRIDGE VALVES

SIZE

08

38

58

10

12

16

ft. lbs. (max)

20

20

20

25

35

50

in. lbs. (max)

240

240

240

300

420

600

COILS SIZE ft. lbs. (max)

4 to 5

in. lbs. (max)

48 to 60 SAE PLUGS

SIZE

2

4

5

6

8

10

12

16

ft. lbs. (max)

3

10

15

15

25

25

30

35

in. lbs. (max)

36

120

180

180

300

300

360

400


NOV. 1999

SECTION 5, Page 5

Table 5-7. Standard Operation times.

Function

Seconds Grnd. or Platform

Turret cw

155 - 170

Turret ccw

155 - 170

Lift up

95 - 105

Lift down

60 - 70

Knuckle down

70 - 80

Knuckle up

105 - 115

Mid Boom out*

30 - 40

Mid Boom in*

20 - 30

Fly Boom out*

30 - 40

Fly Boom in*

20 - 30

Jib up

40 - 50

Jib down

20 - 30

Platform cw

25 - 35

Platform ccw

25 - 35

Flow tolerances to be + or - 1.5%. * Times for telescoping functions are given with boom in a horizontal position.

SECTION 5, Page 6


Table 5-8. General Specifications - SJKB-66TK BATTERY (Primary) BATTERY (Emergency) AMBIENT NOISE LEVEL ENGINE RPM SETTINGS (Ford) ENGINE RPM SETTINGS (Diesel) FUEL (Standard) FUEL (Diesel option) GROUND CLEARANCE TRAVEL SPEED (Elevated) TRAVEL SPEED (Stowed)

12 Volt/850 CCA 12 Volt/1000 CCA 83db 900(idle), 1600, 2100, 2600 1600(idle), 2600 Non-blended unleaded No. 2 Diesel 12" (30.48cm) 0-.8mph (0-1.29kph) 0-3.5mph (0-5.63kph)

INSIDE TURNING RADIUS (2WD) INSIDE TURNING RADIUS (4WD) OUTSIDE TURNING RADIUS (2WD) OUTSIDE TURNING RADIUS (4WD)

8-’4" (2.5m) 11’-11" (3.6m) 18-’4" (5.6m) 19-’1" (5.8m)

POWER (Ford LRG 423) POWER-Option(Deutz Diesel)

63 Horsepower 57 Horsepower

PIVOTAL HEIGHT HORIZONTAL REACH TAILSWING FLOOR LOADING

27’ (8.2m) 58’-2" (17.7m) 3’ (.9m) Not Available at Printing

HYDRAULIC CAPACITY

55 gallons (208-liter)

FUEL CAPACITY

45 gallons (170-liter)


SECTION 5, Page 7

ELECTRICAL SYSTEMS DIAGNOSTICS AND ADJUSTMENTS O.E.M Controller Adjustments NOTE: These procedures cover all boom functions. 1.

Locate “THRESHOLD” potentiometer on joystick controller board for the function being adjusted and turn counterclockwise until it clicks.

2.

Locate “MAXOUT” potentiometer on joystick controller board for the function being adjusted and turn counterclockwise until it clicks.

3.

Start engine, set engine R.P.M. switch to high engine.

4.

Depress foot-switch, move the joystick for the function being adjusted slowly until the red LED light on the board just comes on.

5.

While holding joystick at the light on position, turn the “THRESHOLD” potentiometer clockwise until movement in the functions just starts.

6.

Turn the “THRESHOLD” potentiometer counterclockwise 1/2 turn.

7.

Move joystick to full stroke and hold.

8.

Turn the “MAXOUT” potentiometer clockwise until no increase in function speed can be felt.

9.

Turn the “MAXOUT” potentiometer an extra 1/2 turn clockwise.

10.

Paint potentiometer screws with fingernail polish to prevent vibration from changing settings. LED

LED

THRESHOLD ADJUSTMENT

MAXOUT ADJUSTMENT

Figure 5-1. OEM Controller PC Board. SECTION 5, Page 8


EDA BOARD DIAGNOSTICS 1.

Start engine from base.

2.

Fully retract boom and lower below horizontal.

3.

Using a Volt\Ohm meter, measure voltage at terminal 1 of the EDA board to a good chassis ground. Reading should be at least 12 volts.

4.

Measure voltage between terminals 1 and 2. Reading should be the same as in Step 1.

5.

Shut engine off.

6.

Locate terminals 9 and 10 on EDA board and remove the attached wires.

7.

Using a Volt\Ohm meter set to RX100 scale, measure resistance across the two wires removed in Step 9. Reading should be between 135 to 165 ohms. If reading is outside this range replace magnetic pickup.

8.

Reconnect wires to terminals 9 and 10.

9.

Restart engine from platform. Depress and hold foot switch.

10.

Select 2600 RPM’s with engine speed switches at the platform.

11.

Measure the voltage at the terminal labeled “L” on the EDA board. It should read 5.9 volts. If no voltage present, replace EDA board. If reading is 1.95 volts precede to step 12. If reading between 1.95 and 5.9 Volts, perform EDA board adjustment procedure. If reading does not change after performing adjustment procedure, replace EDA board.

12.

Measure voltage between terminal 5 and a good chassis ground. If no voltage present, check and repair the mid boom out and or high drive\tilt over ride circuit. If at least 12 volts present, replace EDA board.

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

12 INPUT GROUND NOT USED NOT USED HIGH DRIVE SIGNAL NOT USED NOT USED NOT USED MAGNETIC PICKUP GROUND MAGNETIC PICKUP SIGNAL NOT USED NOT USED

5.9 VOLTS WITH ENGINE AT 2600 RPM’s, BOOM FULLY RETRACTED AND BELOW HORIZONTAL

Figure 5-2. Multi-Purpose Controller (EDA) Card. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 9

MDSD BOARD DIAGNOSTICS 1.

Start engine from platform and select mid RPMs (2100 RPMs).

2.

Make sure main boom is fully retracted and below horizontal.

3.

Locate EDA and MDSD boards in base control cabinet.

4.

Depress and hold the foot switch.

5.

Using a Volt\Ohm meter, measure voltage at terminal 1 on MDSD board and a good chassis ground. You should read at least 12 volts. Repair wiring if no voltage present.

6.

Using a Volt\Ohm meter, measure voltage at terminal 1 and terminal 2 on MDSD board. You should read at least 12 volts. Repair wiring if no voltage present.

7.

Check fuse on MDSD board. Replace if blown.

8.

Using a Volt\Ohm meter, measure voltage at terminal “L” on EDA board and a good chassis ground. Record reading.

9.

Measure voltage at terminal 11 on MDSD board and a good chassis ground. It should read 1/2 the voltage measured at terminal “L” on EDA board. If no voltage present, refer to section 4 page 13 For “No drive” trouble in electrical trouble shooting.

10.

Measure voltage at terminal 10 on MDSD board and a good chassis ground. It should read the same voltage measured at terminal 11 on MDSD board. If not reading the same voltage, adjust drive joystick potentiometer until reading is the same voltage at terminal 11 on MDSD board. If no voltage present, refer to section 4 page 13 For “No drive” trouble in electrical trouble shooting.

11.

Using a Volt\Ohm meter, measure voltage at terminal 10 on MDSD board, while the joy stick is stroked forward and reverse. In forward the voltage on terminal 10 will increase. In reverse it will decrease. In both cases the increase or decrease should be smooth. If reading is erratic in either direction, replace drive joystick potentiometer.

12.

Locate and remove wire 16 from terminal 4 on MDSD board.

13.

Using a Volt\Ohm meter set on ohms scale, check continuity between wire 16 and terminal 3 on MDSD board. If continuity present continue to step 14. If no continuity present, refer to section 4 page 14 under “No Drive Forward” in electrical trouble shooting.

14.

Install a Volt\Ohm meter with a milliampere scale between terminal 4 and wire 16.

15.

Move drive joystick in the forward direction. It should read approximately 400ma as joystick is at threshold and increase as joy stick is moved farther. If there is no reading, replace MDSD board. If reading is low, perform MDSD adjustments. Refer to page 12 in this section for adjustment procedures.

16.

Remove meter from MDSD board and reinstall wire 16 to terminal 4.

17.

Locate and remove wire 15 from terminal 6 on MDSD board.

18.

Using a Volt\Ohm meter set on ohms scale, check continuity between wire 15 and terminal 5 on MDSD board. If continuity present continue to step 19. If no continuity present, refer to section 4 page 14 under “No Drive Reverse” in electrical trouble shooting.

19.

Install a Volt\Ohm meter with a milliampere scale between terminal 6 and wire 15.

20.

Move drive joystick in the reverse direction. It should read approximately 400ma as joystick is at threshold and increase as joy stick is moved farther. If there is no reading, replace MDSD board. If reading is low, perform MDSD adjustments. Refer to page 12 in this section for adjustment procedures.

21.

Remove meter from MDSD board and reinstall wire 15 to terminal 6.

SECTION 5, Page 10


FUSE

GROUND

MDSD - 2X/2

12 VOLT INPUT WIRE 101 DRIVE FORWARD WIRE 16 DRIVE FORWARD WIRE 100 DRIVE REVERSE WIRE 15 DRIVE REVERSE NOT USED NOT USED NOT USED WIRE 64 POTENTIOMETER WIPER SIGNAL WIRE 63 POTENTIOMETER CENTER SIGNAL NOT USED

Figure 5-3. Dual Solenoid Driver (MDSD) Card.


SECTION 5, Page 11

EDA AND MDSD BOARD ADJUSTMENT PROCEDURES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Set dip switches on SW1, SW2 and SW3 according to the chart on the BASE EDA BOARD SETTING page. Disconnect wire 59 from terminal 5 of EDA board. Set potentiometers P1 through P6 according to the chart on BASE EDA BOARD SETTING page. Switch base key switch to platform, pull out base emergency stop switch. Pull out platform control box emergency stop switch and turn ignition switch to on. DO NOT START ENGINE AT THIS TIME. Depress foot switch. Attach meter leads to the “Set” and “MO” terminals on the EDA board. Refer to BASE EDA BOARD SETTINGS page for terminal location. Adjust P6 on EDA board to 0 volts. Start engine and select 1600 RPM’s with engine speed switch. (Lower position) Attach meter leads to the “L” terminal of the EDA board and a good chassis ground. (The rest of the adjustments to the EDA board will be measured this way) Adjust P1 on EDA board to 1.26 volts. Select 2600 RPM’s with engine speed switch (Upper position). Adjust P2 on EDA board to 1.95 volts. NOTE: Dip switch sequence 1 - 4 on SW1 may have to be changed in order to obtain 1.95 volts. Reattach wire 59 to terminal 5 of the EDA board. Retract the boom completely and position boom below horizontal. Select 1600 RPM’s with engine speed switch (Lower position). Adjust P3 on EDA board to 3.35 volts. Select 2600 RPM’s with engine speed switch (Upper position). Adjust P4 on EDA board to 5.9 volts. NOTE: Dip switch sequence 1 - 4 on SW2 may have to be changed in order to obtain 5.9 volts. Disengage drive motor from axle 2WD or the transfer case on 4WD machines. (See page 2-3 For instructions.) WARNING

Place machine on level surface and block wheels to prevent machine from rolling. 20.

Start engine. Steps 21-33 will be performed with engine running and in high engine setting. Steps 34-47 will be performed with engine running and in low engine setting.

NOTE The following procedures require a volt/ohm meter capable of reading milliampere. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Remove wire 101 from terminal 3 of MDSD board. Attach milliammeter between wire 101 and terminal 3. Fully retract and lower the boom. Move drive joystick to the full forward position. Adjust P3 on MDSD board to 1175 milliampere (1.175A). Remove meter from wire 101 and terminal 3. Reattach wire 100 to terminal 3. Remove wire 100 from terminal 5 of MDSD board. Attach milliammeter between wire 100 And terminal 5. Fully retract and lower the boom. Move drive joystick fully to the reverse position. Adjust P4 on MDSD board to 1175 milliampere (1.175A). Remove meter from wire 100 And terminal 5. Reattach wire 100 to terminal 5.

SECTION 5, Page 12


33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47.

Reengage drive motor to axle. Extend boom approximately 3 feet to put machine in creep speed mode. Mark the side of a tire at a point closest to the ground. Fully stroke the drive joystick in the forward position. Using the mark on the side of the tire, time how long it takes to make 1/2 revolution. Adjust P5 on the MDSD board to obtain 1/2 revolution in 15 seconds. Fully stroke the drive joystick in reverse. Using the mark on the side of the tire, time how long it takes to make 1/2 revolution. Adjust P6 on the MDSD board to obtain 1/2 revolution in 15 seconds. Mark off 50 feet in an open area. Retract boom fully to put machine in high speed mode. Time how long it takes to travel 50 feet. Machine should travel 50 feet in 9 1/2 to 10 1/2 seconds. Adjust P3 on MDSD board for forward to obtain 50 feet in 9 1/2 to 10 1/2 seconds. Adjust P4 on MDSD board for reverse to obtain 50 feet in 9 1/2 to 10 1/2 seconds. If adjustment on P3 or P4 require increasing output, repeat steps 19 through 32.

WARNING Do not exceed 1200 milliampere (1.2A) on wire 100 or 101. Damage to drive coils will result!

48.

If output requires a reading higher than 1200 milliampere (1.2A) to obtain 50 feet in 9 1/2 to 10 1/2 seconds, check for binding in the drive system such as brakes dragging. Apply nail polish or RTV silicone, to prevent vibration from changing potentiometer settings.

MDSD - 2X/2

12 VOLT GRD 101 16 100 15

64 63

Figure 5-4. Dual Solenoid Driver (MDSD) Card. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 13

SET DIP SWITCHES ACCORDING TO CHART BELOW

PUSH SWITCH HERE TO SET SWITCH “ON”

PUSH SWITCH HERE TO SET SWITCH “OFF”

STRAIGHTENED PAPER CLIP

WIRE 59

SET POTS ACCORDING TO CHART BELOW TO ADJUSTING EDA BOARD CW until you hear the pot click CCW until you hear the pot click CW until you hear the pot click CCW until you hear the pot click CW until you hear the pot click

Figure 5-5. Dual Solenoid Driver (EDA) Card. SECTION 5, Page 14


LEVELING CIRCUIT DIAGNOSTICS 1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12. 13. 14.

15.

16. 17.

18. 19.

Open platform control box. Locate the leveling board. Locate the terminal labeled “Vs” and “GND” on level board. Refer to Figure 5-6 for location. Start engine and select low RPM’S. Move the main boom joystick in the up position until boom motion is just noticeable. Hold the joystick in this position. Measure voltage between the terminals labeled “Vs” and “GND” on platform leveling board. Refer to Figure 56. It should read 11-13 Volts. If no voltage present, repair wiring from terminal strip to leveling board or relay K35. If voltage present, proceed to Step 7. Shut engine off. Using a jumper wire, connect the terminal labeled “Vs” to a 12 volt source in the platform. Locate the terminals labeled “+” and “-”. Refer to Figure 5-6 for location. Measure voltage between the terminals “+” and “-”. It should read 6.2 Volts ± .2 Volts. If no voltage present, replace leveling board. If voltage present, proceed to step 11. Locate the terminal labeled “SIG”. Refer to Figure 5-6 for location. Measure voltage between the terminals labeled “SIG” and “-”. It should read 3.1 volts ± .2 volts. If no voltage present, repair broken wire between level sensor or replace level sensor. If voltage present, go to step 13. Remove cover from level sensor. Measure voltage at the terminals labeled “SIG” and “-” while gently tipping the top of the leveling sensor toward the platform. The voltage should start at 3.1 volts and increase to 4.8 Volts. If no voltage present or does not increase, repair broken wire between level sensor and leveling board or replace level sensor. If voltage present, proceed to step 15. Measure voltage at the terminals labeled “SIG” and “-” while gently tipping the top of the leveling sensor away from the platform. The voltage should start at 3.1 volts and decrease to 1.1 Volts. If no voltage present or does not decrease, repair broken wire between level sensor and leveling board or replace level sensor. If voltage present, proceed to step 16. Attach meter leads to the terminal labeled “PWM A” and a good “GND”. Gently tip the top of the leveling sensor toward the platform. The meter should read 3.1 Volts at threshold to 7.9 to 8.8 Volts at close to full sensor tilt. If no voltage present or does not fluctuate, replace leveling board. If voltage present proceed to Step 18. Attach meter leads to the terminal labeled “PWM B” and a “GND”. Gently tip the top of the leveling sensor away from the platform. The meter should read 3.1 Volts at threshold to 7.9 to 8.8 Volts at close to full sensor tilt. If no voltage present or does not fluctuate, replace leveling board. 11-13 VOLTS

TO LEVEL SENSOR 3.1 VOLTS

TO LEVEL SENSOR 6.2 VOLTS

Figure 5-6. Leveling Circuit Control Board. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 15

PLATFORM LEVELING ADJUSTMENT PROCEDURE NOTE: The potentiometers marked “HI A” and “HI B” are not used. No adjustments are needed on these potentiometers. 1. 2. 3.

4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14.

Locate leveling control board inside platform control box. Locate the potentiometers on the leveling control board marked “RAMP”, LOW”, and “MID”. Refer to Figure 5-7 for component location. Turn the “RAMP”, “LO” and “MID” potentiometer adjusting screws counter-clockwise until they click. NOTE: These are 25 turn potentiometers. If the click can not be heard turn the potentiometer 25 turns counterclockwise. Place a level on the floor platform, parallel to the boom. Using the platform leveling switch located at the Base Controls, level the Platform, using the level on the floor of the Platform as a guide. Remove the cover from the Level Sensor. Using a “Bulls Eye” Bubble Level on top of the Level Sensor, adjust Sensor mounting bolts to level the Sensor . From the Platform Controls, raise the Main Boom until platform is severely out of level. With the engine running in low R.P.M.’s and the Foot Switch depressed, move the Main Boom joystick in the up direction until boom just starts to move. Slowly release the Joystick until movement just stops but the function is still active. Hold the Joystick in this position. While holding the Main Boom Joystick in the position described in step 9, locate and adjust the “LOW” potentiometer on the Leveling Board until the Platform just starts to level. Continue to hold the Main Boom Joystick until the Platform has leveled itself. Switch the engine to HI R.P.M.’s. Operate the Main Boom up and down. Locate and adjust the “MID” potentiometer so the Platform maintains a level position at all lift up and down speeds. Shut engine off. NOTE: The following adjustments are to be made only if the Platform leveling reacts too fast or too slow or if the “SAT” potentiometer has been tampered with. NOTE: The following steps require 2 VOM meters.

15. 16. 17. 18. 19. 20.

21.

Locate on the Leveling Board, the terminals labeled “SIG”, “PWM A” and “GND”. Attach the Red lead from one of the meters to the “SIG” terminal and the Black lead to the “GND” terminal. Attach the Red lead of the second meter to the “PWM A” terminal and the Black lead to the “GND” terminal. Using a jumper wire, connect the terminal labeled “Vs” to a 12 volt source in the Platform Control Box. NOTE: Do not start engine at this time. At the Level Sensor, SLOWLY tilt the sensor AWAY from the Platform until the meter attached to the “SIG” terminal reads 1.1 volts. Hold the sensor in this position. Observe the reading on the meter attached to the “PWM A” terminal. It should read 7.9 volts. If the 7.9 volt signal appears before the 1.1 volt signal locate and turn the “SAT” potentiometer counter-clockwise 1/2 turn. Release the Level Sensor. Repeat Step 19, while observing meters. Adjust the “SAT” potentiometer until a 7.9 volt signal appears on the “PWM A” meter at the same time as the 1.1 volt signal appears on the “SIG” meter. Paint all potentiometer adjusting screws with nail polish or RTV Silicone to prevent vibration from changing settings.

SECTION 5, Page 16


Step 7 LEVEL ADJUSTERS

BUBBLE LEVEL

LEVEL SENSOR

Step 17 VOM METER

BLACK

RED Step 18

Step 15 VOM METER Step 22 Step 10 Step 13 BLACK

RED

Step 3

LEVELING BOARD

Figure 5-7. Leveling Circuit Control Board and Level Sensor. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 17

BARBER\COLMAN GOVERNOR DIAGNOSTICS 1.

At carburetor, check movement of throttle shaft. It should move freely and spring return to the idle position. Repair any binding of the throttle shaft.

2.

Locate the electrical connector in the actuator wires, between governor control box and the governor actuator on the carburetor.

3.

Disconnect the connector and using a volt\ohm meter set on the RX10 scale, measure resistance of the actuator coil. Resistance should be 2 OHMS ± .5 OHMS. If reading outside of this range, replace actuator. Reconnect connector.

4.

Start engine from base controls.

5.

At the governor control, measure voltage between terminals 1 and 2. It should read 12 volts ± 2 volts. If no voltage present repair wiring between control box and engine terminal strip.

6.

Activate speed switch “B” and measure voltage between terminal 8 on the governor control box and a good chassis ground. It should read 12 volts ± 2 volts. If no voltage present, repair wiring between speed switch “B” and control box.

7.

Activate speed switch “A” and measure voltage between terminal 7 on the governor control box and a good chassis ground. It should read 12 volts ± 2 volts. If no voltage present, repair wiring between speed switch “A” and control box.

8.

Measure voltage on terminals 5 and 6 and a good chassis ground. The voltage on each terminal should be the same and fluctuate with engine RPM’S. If no voltage present, repair wiring between governor control box and the distributorless ignition modules. Note: The absence of voltage on either terminal 5 or 6 will cause the governor to operate the engine at double the set RPM.

9.

Measure the voltage on terminal 3 and a good chassis ground. It should read 12 volts ± 2 volts. If no voltage present, replace governor control box.

10.

Attach voltmeter to terminals 3 and 4. Activate speed switches as listed in the table and measure voltage. If no voltage present, replace governor control box. If readings too high or too low, Perform governor adjustment procedure. See page 20 in this section.

SECTION 5, Page 18


SWITCH "B"

1.9 Volts

1600 RPM’s

SWITCH "A"

2.0-2.1 Volts

2100 RPM’s

SWITCH "A" & "B"

2.2 Volts

2600 RPM’s

2 OHMS GOVERNOR ACTUATOR ACTUATOR CONNECTOR

ORANGE - 83

TO D.I.S. MODULES TO SPEED SWITCH “A” TO SPEED SWITCH “B”

BROWN - 84

BROWN - 86 PINK - 113 GREEN - 79

82 - ORANGE 02 - WHITE

12 VOLTS

54

Figure 5-8. Barber Colman Governor Control Diagnostics. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 19

BARBER COLMAN GOVERNOR ADJUSTMENTS 1.

Start and run engine until at normal operating temperature.

2.

Set the “D”, “I” AND “GAIN” potentiometers as shown in Figure 5-9.

3.

Shut engine off. Disconnect governor actuator from the control box at the weather pack connector.

4.

Attach a tachometer to the engine and start.

5.

Adjust engine base RPM’s to 850 RPM’s, by loosening the three screws mounting the actuator and turning actuator housing.

6.

Shut engine off. Reconnect actuator to control box.

7.

Select platform with key switch and start engine from platform.

8.

Adjust engine governor to 900 RPM’s by jumping terminal 9 to 10 to increase RPM’s or terminal 9 to terminal 11 to decrease RPM’s.

9.

At the governor control , switch the toggle switch labeled “B” up and hold.

10.


11.

Release the toggle switch labeled “B” and switch the toggle switch labeled “A” up and hold.

12.


13.

While holding the toggle switch labeled “A” up switch the toggle switch labeled “B” up and hold.

14.


15.

Release toggle switches and recheck settings by switching toggle switches. Readjust if necessary. TOUCH JUMPER WIRE BETWEEN TERM. 9 AND 10 TO INCREASE ENGINE RPM’s

TOUCH JUMPER WIRE BETWEEN TERM. 9 AND 11 TO DECREASE ENGINE RPMs

SET POTENTIOMETERS TO: D = 35 I = 25 GAIN = 15

Figure 5-9. Barber Colman Governor Control. SECTION 5, Page 20


MAGNETIC PICK UP TEST PROCEDURE 1.

Locate magnetic pickup on engine bell housing. Trace leads from the magnetic pickup to the terminal strip on back of engine.

2.

Mark location of leads from the magnetic pickup and remove from terminal strip.

3.

Using a volt/ohm meter set on the RX100 scale, measure the resistance across the leads. Refer to Figure 5-10. It should read between 135 - 165 ohms. If reading is outside of this range, the pick up is defective.

4.

To test the magnetic pickup operation, with leads removed from the terminal strip, start engine and turn high engine switch to high (2600 RPM’s).

5.

With volt/ohm meter set to A.C. volts scale, measure voltage across leads. At 2600 RPM’s you should read at least 10 volts A.C.. If reading is below 10 volts A.C. the magnetic pickup is defective.

ENGINE TERMINAL STRIP

135 - 165 OHMS

Figure 5-10. Magnetic Tachometer Pickup. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 21

MAGNETIC PICKUP REPLACEMENT INSTRUCTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Locate and mark the location of the wires from the magnetic pickup to the terminal strip on the back of the engine. Remove wires from terminal strip. Loosen locknut securing the magnetic pickup to the engine bellhousing. Remove magnetic pickup from bellhousing by turning counter-clockwise. Remove locknut from defective pickup and install on the replacement pickup. Using the engine starter, “bump” the engine until a tooth on the flywheel is in the center of the pickup bore. Gently turn the replacement pickup clockwise until it just bottoms out on the flywheel tooth. Turn the magnetic pickup counter-clockwise 1/2 turn. NOTE: Do not exceed 1/2 turn or pickup will not sense the flywheel properly. Tighten lock nut against bellhousing. Attach pickup wires to the terminal strip on the back of the engine. Start engine from the platform and select high engine RPM’s (2600 RPM’s). Check voltage between terminal “L” on the EDA board and a good chassis ground (Refer to EDA/MDSD adjustment procedure for location). It should read 5.9 volts D.C. Perform EDA/MDSD adjustment procedure if voltage does not read 5.9 volts D.C.

ENGINE TERMINAL STRIP

MAGNETIC PICKUP

NOTE: On diesel engine the magnetic pickup will be located on the opposite side of the engine.

Figure 5-11 Magnetic Pickup Location (Ford engine shown) SECTION 5, Page 22


MID BOOM OUT PROXIMITY SWITCH ADJUSTMENT WARNING DO NOT attempt to adjust mid boom out proximity switch with engine running. Unexpected movement of the mid boom could occur. End Clearance Adjustment 1. 2.

With Mid Boom fully extended, remove proximity switch and measure from outside surface of knuckle to the wear pad insert. (distance “A”) Measure from the surface of the proximity mounting plate to the tip of the proximity switch. (distance “B”)The difference between distance A and B should be between 0.0625 (1.5mm) and 0.157 (4mm) for the switch to operate properly.

Point Adjustment 3. 4. 5.

With Mid Boom fully extended, loosen the proximity switch mounting hardware. Slide the switch toward the platform. Slowly slide the switch back towards the base of the machine, stopping 1/16” past the point when the indicator light comes on. 6. Tighten mounting hardware. NOTE: It may be necessary to add weight the platform to achieve proper adjustment.

Mid Boom

“A” Proximity Switch

Wear Pad Insert “B” Knuckle Knuckle Cross Section Knuckle

Mid Boom

Proximity Switch Mounting Plate

Wear Pad With Insert

Proximity Switch Cover

Figure 5-12 Mid Boom Out Proximity Switch Adjustment SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 23

HYDRAULIC SYSTEM DIAGNOSTICS AND ADJUSTMENTS DRIVE PUMP TEST PROCEDURE NOTE: Perform tests with basket over non-steer axle, boom below horizontal and fully retracted. 1.

Locate and remove the hose attached to the port labeled “Ps” on the drive pump.

2.

Cap hose to prevent contaminating hydraulic system.

3.

Install a 3000 PSI gauge into the port labeled “Ps” on the drive pump.

4.

Start engine from base controls.

5.

Check reading on gauge. It should read 350 PSI. If 350 PSI present, move to step 9. If no pressure present, go to next step.

6.

If no pressure present or below 350 PSI, replace relief valve RV3.

7.

If no pressure present or below 350 PSI after replacing relief valve RV3, replace the pressure over ride valve POR1.

8.

If no pressure present or below 350 PSI, replace drive pump.

9.

Locate and disconnect the forward drive hose from the top of the rotary manifold.

10.

Cap port in rotary manifold to prevent contaminating hydraulic system.

11.

Install a 10,000 PSI gauge into the hose.

12.

Start engine from platform.

13.

Select low engine RPM’S (1600 RPM’S).

14.

SLOWLY move drive joystick in the forward direction.

15.

Observe gauge reading. Gauge should read 4700 PSI. If 4700 PSI present drive pump is operating properly. If no pressure present, replace drive pump.

SECTION 5, Page 24


3

5

7

2

1

REVERSE PRESSURE GAUGE PORT 6 RV3 CHARGE PRESSURE RELIEF VALVE

FORWARD PRESSURE GAUGE PORT

Figure 5-13 Drive Pump Test Ports

11

DRIVE MOTOR CASE DRAIN

9

FORWARD DRIVE HOSE FRONT

CAP 10

REVERSE DRIVE HOSE

Figure 5-14 Rotary Manifold SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 25

Boom Function Pump Pressure Adjustments 1.

Tee a 3000 PSI gauge into the load sense line on the boom function pump. Refer to Figure 5-15 for location.

2.

Remove cap off the system pressure adjusting valve.

3.

Loosen lock nut on system pressure adjusting valve.

4.

Start engine from base.

5.

Raise jib arms above main boom.

6.

Locate the main boom down toggle switch. Depress and hold in the down position.

7.

Adjust system pressure adjusting valve to obtain 2500 PSI.

8.

Shut off engine.

9.

Tighten lock nut and reinstall cap.

10.

Remove gauge from load sense hose.

11.

Locate port on Apitech valve labeled “P”. Refer to Figure 5-16 for location.

12.

Tee a 3000 PSI gauge into the hose attached to the port labeled “P”.

13.

Remove cap from load sense pressure adjusting valve.

14.

Loosen lock nut on load sense pressure adjusting valve.

15.

Start engine.

16.

Adjust load sense pressure adjusting valve to obtain 250 PSI.

17.

Tighten lock nut and reinstall cap.

18.

Remove gauge from Apitech valve.

TEE A 3000 PSI GAUGE INTO LOAD SENSE LINE SYSTEM PRESSURE ADJUSTING VALVE

LOAD SENSE LINE

Figure 5-15. System Pressure Adjustment. SECTION 5, Page 26


APITECH VALVE

TEE A 3000 PSI GAUGE INTO “P” PORT OF APITECH VALVE

LOAD SENSE LINE

Figure 5-16. Proportional Valve Bank.

LOAD SENSE PRESSURE ADJUSTING VALVE

Figure 5-17. Load Sense Pressure Adjustment.


SECTION 5, Page 27

BOOM FUNCTION SPEED ADJUSTMENT

1.

Using a stop watch, time the full travel of the function to be adjusted. For turret rotate, mark a spot on the chassis and time how long it takes to make one complete revolution. Note: Time the function in both directions as each direction is capable of being adjusted.

2.

Locate the valve section to be adjusted. Refer to Figure 5-18.

3.

Loosen lock nuts on flow limiter adjustment screws. Refer to Figure 5-19.

4.

Using the chart, locate adjusting screw for the direction being adjusted.

5.

Turning adjusting screw clockwise slows down the function.

6.

Turning adjusting screw counterclockwise speeds up the function.

7.

Tighten lock nuts after completing adjustments.

TURRET ROTATE TELESCOPE VALVE KNUCKLE VALVE

LIFT VALVE LOAD SENSE LINE

Figure 5-18. Proportional Valve Bank.

SECTION 5, Page 28


VALVE SECTION

C1 PORT

C2 PORT

LIFT

DOWN

UP

KNUCKLE

DOWN

UP

TELESCOPE

RETRACT

EXTEND

TURRET ROTATE

LEFT

RIGHT

FLOW LIMITER FOR C2

FLOW LIMITER FOR C1

Figure 5-19. Boom Function Speed Adjustment.


SECTION 5, Page 29

MID AND FLY BOOM EXTEND PRESSURE ADJUSTMENTS 1)

Locate the port labeled “MG” on top of the turret manifold and install a 3000 PSI gauge. Refer to Figure 5-20 for port location.

2)

Disconnect wire 43 from mid out valve. Refer to Figure 5-21 for valve location.

3)

Start engine, set engine RPM’s to mid range (1600 RPM’s).

4)

Depress and hold telescope out toggle switch.

5)

When the mid boom comes to a stop, while holding the telescope out switch, adjust the mid boom out pressure reducer to 2100 PSI. Refer to Figure 5-21 for location.

6)

Stop engine and remove gauge and reconnect wire 43.

7)

Install a 3000 PSI gauge into the port labeled “FG”. Refer to Figure 5-22 for location.

8)

Start engine, set engine RPM’s to mid range (1600 RPM’s).

9)

Depress and hold telescope out toggle switch.

10)

When the fly boom comes to a stop, while holding the telescope out switch, adjust the fly boom out pressure reducer to 2100 PSI. Refer to Figure 5-23 for location.

11)

Stop engine and remove gauge.

SECTION 5, Page 30


INSTALL 3000 PSI GAUGE INTO PORT LABELED “MG”

FLY BOOM EXTEND GAUGE PORT

MID BOOM EXTEND GAUGE PORT

Figure 5-20. Main Manifold. (port “MG”)

MID BOOM OUT PRESSURE REDUCER

DISCONNECT WIRE 43 FROM MID OUT VALVE

Figure 5-21. Main Manifold. (mid boom out pressure reducer) SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 31

INSTALL 3000 PSI GAUGE INTO PORT LABELED “FG””

FLY BOOM EXTEND GAUGE PORT

MID BOOM EXTEND GAUGE PORT

Figure 5-22. Main Manifold. (port “FG”)

FLY BOOM OUT PRESSURE REDUCER

Figure 5-23. Main Manifold. (fly boom out pressure reducer) SECTION 5, Page 32


LOW DRIVE PRESSURE ADJUSTMENT 1)

Fully lower and retract boom.

2)

Tee a 1000 PSI gauge into the port marked Ps on the drive pump. Refer to Figure 5-24.

3)

Start engine, and check gauge reading with boom fully lowered and retracted. It should read 350 PSI.

4)

Extend telescope 6 feet. Adjust Hi/Low relief valve to 225 PSI. Refer to Figure 5-25.

5)

Remove gauge and test drive. With boom fully lowered and retracted high drive will be available. With the boom above horizontal or extended, only low drive will be available. TEE A 1000 PSI GAUGE INTO HOSE AT Ps PORT

Ps PORT

PILOT PRESSURE HOSE TO TURRET MANIFOLD

Figure 5-24. Drive Pump.

ADJUST HI/LOW RELIEF VALVE TO 225 PSI

LOAD SENSE DUMP VALVE

HI/LOW DRIVE VALVE

HI/LOW DRIVE PILOT PRESSURE ADJUSTMENT

Figure 5-25. Hi/Low Drive Pressure Adjustment. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 33

BRAKE ADJUSTMENT PROCEDURE Hydraulic 1. 2. 3. 4.

Block wheels to prevent machine from rolling. Disengage drive motor from axle. Refer to Section 2 Page 3 For instructions. Locate pressure reducer on brake manifold. Refer to Figure 5-26 for location Remove cap from pressure reducer and turn adjuster clockwise and GENTLY bottom out. WARNING Valve damage will occur if tightened too much!

5. 6. 7. 8. 9. 10. 11. 12.

Start engine and set engine speed switch to 1600 RPM’s (middle position). Move drive joystick in the forward position and hold. Locate relief valve on brake manifold and adjust to 700 PSI. Refer to Figure 5-26 for location. While holding drive joystick, locate and adjust the pressure reducing valve to 600 PSI. Refer to Figure 5-26 for location. Reengage motor to axle. Remove gauge. Remove wheel chocks. Test brake operation. Adjust manual brake valve to obtain 65 to 75 inches of travel from the center-line of a wheel to a fixed mark on the ground, after the joystick has been release in high engine and high drive.

RELIEF VALVE

RELIEF VALVE

PRESSURE REDUCING VALVE NOTE: With drive pressure braking system this valve is relocated.

Figure 5-26. Brake Manifold. SECTION 5, Page 34


BRAKE ADJUSTMENT PROCEDURES Mechanical Checking the adjustment of each brake on the rear axle requires the following procedure: 1.

Chock the wheels to prevent the work platform from rolling when the brake is released. Remove the thumb screws from the Rear Axle Cover and lift off to expose the rear axle.

2.

Remove the Center Plug (17mm allen head) (Item #1) from each brake cover.

3.

Starting with the left brake, insert the shaft of the Dial Indicator (Item #2, Skyjack part #700592) through the hole in the brake cover and carefully tighten the gauge holder (clockwise) until no threads are exposed.

4.

Rotate the dial on the Dial Indicator to “0".

5.

Locate the Parking Brake Release Hand Pump (refer to Section 2, Page 4). Follow the procedure to release the parking brakes.

6.

Read the Dial Indicator setting. The proper setting range is 1.8mm (0.080") to 2.2mm (0.085"). If the setting is within this range, pull out the Brake Override Valve Plunger to engage the brakes, then perform the same adjusting check on the right brake. Remove the Dial Indicator and reinstall Center Plug.

NOTE: If setting on either brake is not within the specified range, proceed to step 7. 7.

Remove the Dial Indicator. Pull out the Brake Override Valve Plunger to engage the brakes. With a M19 socket and wrench, adjust the Actuator Shaft (Item #3) by tightening (clockwise) the Actuator Shaft Nut (Item #4) to reach a lower setting or loosening (counterclockwise) the Actuator Shaft Nut (Item #4) to reach a higher setting.

8.

Repeat steps 3, 4, 5 and 6.

9.

Repeat step 6. If setting is still not within the specified range, repeat steps 7 and 8 until setting is within specified range.

NOTE: The brake will automatically return to normal operation when a drive function is selected.

4

Skyjack Part 2 No. 700592 3

1

Figure 5-27. Cross Section of Brake Assembly. SJB-66TK, Serial Number 93197 and below

SECTION 5, Page 35

MECHANICAL ADJUSTMENTS Boom Wear Pad Clearances

1.

Mid Boom base side wear pads = 0” Clearance.

2.

Mid Boom base top and bottom wear pads = 0.0625” (1.5mm) - 0.125 (3mm).

3.

Fly Boom base side wear pads = 0.0625” (1.5mm) - 0.125 (3mm).

4.

Fly Boom base top and bottom wear pads = 0.0625” (1.5mm) - 0.125 (3mm).

5.

All outer wear pads and plug style wear pads = Center boom sections and adjust wear pads to just make with boom.

2

4 5

2

5

1

3 4

Figure 5-28. Boom Wear Pad Locations.

SECTION 5, Page 36


STANDARD HOSE NUMBERING SYSTEM

H1104 0081 2-0

FITTING ARRANGEMENT (See Schedule Below)

LENGTH IN REVISION LEVEL FRACTIONS (1/4” INCREMENTS) I.E. 1=1/4” 2=1/2” 3=3/4” Using the number above as an example (H1104 0081 2 0). This hose requires a 37° JIC, female swivel fitting on one end. A medium length 90° JIC, female swivel fitting for the other end. The Hose must meet or exceed S.A.E. 100R13 hose specification, and be a total of 81-1/2” long. NOTE: Hose ends and hose must be from same manufacturer per S.A.E. J1273 Nov. ‘91, Sections 3.10 and 4.2. Hose ends and hose must be of the same size i.e. #4 size fittings must be used with #4 size hose. HOSE SIZE CHART SIZE I.D.

HOSE SIZE (See Chart Below)

LENGTH OF HOSE IN WHOLE INCHES

03

04

06

08

10

12

16

20

24

32

40

48

56

64

3/16"

1/4"

3/8"

1/2"

5/8"

3/4"

1"

1-1/4"

1-1/2"

2"

2-1/2"

3"

3-1/2"

4"

FITTING ARRANGEMENT SCHEDULE HOSE PREFIX HOSE END FITTING

HOSE END FITTING

S.A.E. HOSE SPECIFICATION

H1

FEMALE, 37 JIC, SWIVEL


100R1

H2



100R13

H3


45 , FEMALE, 37 JIC, SWIVEL

100R1

H4



100R13

H5


LONG 90 , FEMALE, 37 JIC, SWIVEL

100R1

H6


SHORT 90 , FEMALE, 37 JIC, SWIVEL

100R1

H7



100R1

H8



100R4

H9



100R4

H10


MALE PIPE THREAD FITTING

100R1

H11


MEDIUM 90 , FEMALE, 37 JIC, SWIVEL

100R13

H12



100R1

H13


REUSABLE MALE PIPE THREAD FITTING

300 PSI

H14

REUSABLE MALE PIPE THREAD FITTING

NO FITTING

300 PSI

H15

REUSABLE, FEMALE, 37 JIC, SWIVEL


300 PSI

H16

NO FITTING

NO FITTING

100R4

H17

NO FITTING

NO FITTING

300 PSI

H18


NO FITTING

300 PSI

H19



100R13

H20



100R4

H21



100R2AT

H22



100R2AT

H23



100R2AT

H24



100R13

H25



100R4


SECTION 5, Page 37

NOTES

SECTION 5, Page 38


SECTION 6 PARTS LIST GENERAL The information contained in this section is designed to aid the in locating and identifying replacement parts. Component parts of various assemblies and subassemblies comprising the work platform are illustrated and accompanied by a descriptive parts list. Exploded drawings are used to show relative location of component parts in disassembly order. If a part cannot be found in this section, order by work platform model number and serial number, giving a complete description of the part.

PARTS ORDERING INFORMATION When ordering replacement parts, the complete part number and description should be used to ensure proper identification and delivery of the desired item. This complete identification should also be used when requesting equipment information.

without identifying letters are used in all the assemblies or group shown at the beginning of the parts list. Descriptions preceded with an (•) indicates a serviceable component or attaching hardware for the higher level assembly.

QUANTITIES (Units per Assy.) The quantities of each part that are required to complete the assembly. If quantity is (AR), it is understood that the quantity may vary when machine is equipped with certain options. Order quantity as needed.

HARDWARE Standard screws, washers, nuts, etc. are not identified by a reference number. These parts are known as COMMON HARDWARE items and appear indented under the major items with which they are used. They should be ordered separately as listed, since they are not component parts of the pieces they attach to.

METHOD OF LISTING Parts are listed in order according to the reference number shown in the illustration, followed by a full description based upon the “NOUN FIRST” method. That is, the noun name of the part is listed first, then the modifying description information which serves to specifically identify the item. For example: PIN, Clevis. Assemblies or groups are shown at the beginning of a parts list and are identified with the letter references A, B, C, etc. Individual parts in these lists have corresponding letters after their description to identify which assembly or group it is used in. Individual parts

HOW TO ORDER REPAIR PARTS 1. Address all orders to your local SKYJACK dealer. 2. Specify model and serial number of the work platform (found on the serial number plate). 3. List the quantity needed. 4. List the length needed (if bulk item). 5. List the part number and description as shown in this manual for each item. 6. Show billing and shipping address and name of individual if possible. 7. Suggest best routing.

CUSTOMER___________________________________________________________________ DEALER______________________________________________________________________ MODEL NUMBER ______________________________________________________________ SERIAL NUMBER ______________________________________________________________ DATE PURCHASED ____________________________________________________________

USE ONLY SKYJACK AUTHORIZED REPLACEMENT PARTS!


SECTION 6, Page 1

6

LIST OF ILLUSTRATIONS

Description

Page

FIGURE 6-1. PLATFORM ASSEMBLY (30” x 96”) ................................................................................................ 6-4 FIGURE 6-2. PLATFORM ASSEMBLY (30” x 72”) ................................................................................................ 6-6 FIGURE 6-3. PLATFORM ASSEMBLY (30” x 120”) .............................................................................................. 6-8 FIGURE 6-4. PLATFORM CONTROL CONSOLE ASSEMBLY .................................................................. 6-10, 6-12 FIGURE 6-5. DRIVE FUNCTION CONTROLLER .............................................................................................. 6-14 FIGURE 6-6. MAIN BOOM LIFT AND TURRET ROTATION CONTROLLER ...................................................... 6-15 FIGURE 6-7. JIB LIFT AND PLATFORM ROTATION CONTROLLER ................................................................ 6-16 FIGURE 6-8. KNUCKLE LIFT AND BOOM TELESCOPIC CONTROLLER ........................................................ 6-17 FIGURE 6-9. BOOM ASSEMBLY (Jib and Rotary Actuator Section) ......................................................... 6-18, 6-20 FIGURE 6-10. LEVELING CYLINDER ASSEMBLY (Jib) .................................................................................... 6-23 FIGURE 6-11. JIB LIFT CYLINDER ASSEMBLY ................................................................................................ 6-24 FIGURE 6-12. BOOM ASSEMBLY (Fly Boom Section) ...................................................................................... 6-26 FIGURE 6-13. PLATFORM LEVELING MANIFOLD ASSEMBLY ........................................................................ 6-28 FIGURE 6-14. LEVELING CYLINDER ASSEMBLY (Fly Boom) .......................................................................... 6-31 FIGURE 6-15. FLY BOOM EXTENSION CYLINDER ASSEMBLY ...................................................................... 6-32 FIGURE 6-16. BOOM ASSEMBLY (Mid Boom Sections) ........................................................................... 6-34, 6-36 FIGURE 6-17. BOOM ASSEMBLY (Knuckle Section) ......................................................................................... 6-38 FIGURE 6-18. BOOM ASSEMBLY (Main Section) ..................................................................................... 6-40, 6-42 FIGURE 6-19. MID BOOM EXTENSION CYLINDER ASSEMBLY ..................................................................... 6-44 FIGURE 6-20. MID BOOM EXTENSION UPPER CYLINDER ASSEMBLY ........................................................ 6-46 FIGURE 6-21. MID BOOM EXTENSION LOWER CYLINDER ASSEMBLY ........................................................ 6-47 FIGURE 6-22. MID BOOM LOCK CYLINDER .................................................................................................... 6-48 FIGURE 6-23. KNUCKLE LIFT CYLINDER ASSEMBLY .................................................................................... 6-49 FIGURE 6-24. HYDRAULIC HOSE CONNECTIONS - Boom Assembly ............................................................ 6-50 FIGURE 6-25. TURRET ASSEMBLY ......................................................................................................... 6-52, 6-54 FIGURE 6-26. TURRET COVERS AND DOORS ...................................................................................... 6-56, 6-58 FIGURE 6-27. FUEL TANK ASSEMBLY ............................................................................................................. 6-60 FIGURE 6-28. HYDRAULIC TANK ASSEMBLY .................................................................................................. 6-61 FIGURE 6-29. ROTARY MANIFOLD ASSEMBLY ............................................................................................... 6-62 FIGURE 6-30. BRAKE MANIFOLD ASSEMBLY ................................................................................................. 6-64 FIGURE 6-31. MAIN MANIFOLD ASSEMBLY .................................................................................................... 6-66 FIGURE 6-32. 4 BANK PROPORTIONAL VALVE ASSEMBLY ........................................................................... 6-69 FIGURE 6-33. BASE CONTROL/ELECTRICAL ASSEMBLY ......................................................... 6-70, 6-72 FIGURE 6-34. ENGINE AND RELATED PARTS (Ford Gas and Dual Fuel) .............................................. 6-74, 6-76 FIGURE 6-35. DUAL FUEL SYSTEM (Ford Engine)(Option) .............................................................................. 6-78 SECTION 6, Page 2


LIST OF ILLUSTRATIONS Cont.

Description

Page

FIGURE 6-36. ENGINE AND RELATED PARTS (Deutz Diesel)(Option) ................................................... 6-80, 6-82 FIGURE 6-37. BOOM LIFT CYLINDER ASSEMBLY .......................................................................................... 6-85 FIGURE 6-38. TURRET HYDRAULIC CONNECTIONS ..................................................................................... 6-86 FIGURE 6-39. BASE, AXLES AND WHEELS (Standard 4 x 2) .......................................................................... 6-88 FIGURE 6-40. BASE, AXLES AND WHEELS (Optional 4 x 4) ............................................................................ 6-90 FIGURE 6-41. BASE ASSEMBLY HYDRAULIC CONNECTIONS (Standard 4x2) .............................................. 6-92 FIGURE 6-42. BASE ASSEMBLY HYDRAULIC CONNECTIONS (Optional 4 x 4) ............................................. 6-94 FIGURE 6-43. STEERING CYLINDER (Standard 4x2) ...................................................................................... 6-97 FIGURE 6-44. STEER AXLE ASSEMBLY (Standard 4x2) .................................................................................. 6-98 FIGURE 6-45. PLANETARY REDUCTION GEAR ASSEMBLY (Brevini) ........................................................... 6-100 FIGURE 6-46. PLANETARY REDUCTION GEAR ASSEMBLY (Sige) .............................................................. 6-101 FIGURE 6-47. DRIVE AXLE ASSEMBLY (Standard 4x2) ................................................................................. 6-102 FIGURE 6-48. RIGID AXLE ASSEMBLY (Optional 4x4) ................................................................................... 6-104 FIGURE 6-49. STEER AXLE ASSEMBLY (Optional 4x4) ................................................................................. 6-106 FIGURE 6-50. TRANSFER CASE ASSEMBLY (Optional 4x4) ......................................................................... 6-108 FIGURE 6-51. SPEED REDUCER ASSEMBLY ................................................................................................ 6-109 FIGURE 6-52. LABELS AND NAMEPLATES .................................................................................................... 6-111


SECTION 6, Page 3

FIGURE 6-1. PLATFORM ASSEMBLY (30” x 96”)

7

6

8 1

2

10 11 12

4

3

5 9

MA-TK-03 SECTION 6, Page 4


FIGURE 6-1. PLATFORM ASSEMBLY (30” x 96”) Index No.

A B C D E F 1

Skyjack Part No.

8

702946 703236 703232 703221 $ $ 703662 703738 703739 703644 $ $ 103909 103470 702600 103632 103995 104000 700625 700427 200463 700584 704119 700187 700188 103857 103980 700598 104000 (Ref.) 701023 703237 109388 112495 104000 701027 (Ref.) 702940 109388 112495 104000 701027 (Ref.)

9 10 11 12

103856 103980 104000 706142 706457 706980 706981

2

3

4 5

6

7

OEM Part No.


Units per Assy.

Description 1234567

PLATFORM ASSEMBLY, Standard PLATFORM ASSEMBLY, With half gate option PLATFORM ASSEMBLY, With full gate option PLATFORM ASSEMBLY, European, standard PLATFORM ASSEMBLY, European, with half gate PLATFORM ASSEMBLY, European, with full gate • WELDMENT, Platform, A • WELDMENT, Platform, B • WELDMENT, Platform, C • WELDMENT, Platform, D • WELDMENT, Platform, E • WELDMENT, Platform, F • • BOLT, Hex-hd ½-13 x 1-1/4" lg. • • WASHER, Lock ½” • PLATE, Info/warning • • BOLT, Self tap. 1/4-14 x 3/4" lg. • • WASHER, Flat 1/4" • • WASHER, Lock 1/4" • RAILING ASSEMBLY, Entry, A, D • • RAILING, Entry • • GUIDE, Railing • • BOLT, BHCS 1/4-20x1/2” • • SECURING ROD, Entrance guide • SWITCH, Foot • COVER, Foot switch • • BOLT, Hex-hd 1/4-20 x 1" lg. • • NUT, Hex 1/4-20 • • WASHER, Fender 9/32" x 1-1/4" x 1/16" thk. • • WASHER, Lock 1/4" GATE ASSEMBLY, Half Gate (option), B, E • WELDMENT, Half gate, LH • WELDMENT, Half gate, RH • HINGE, Spring • • BOLT, Hex-hd 1/4-20 x 3/8” lg. • • WASHER, Lock 1/4” • BUMPER, Rubber stop GATE ASSEMBLY, Full Gate (option), C, F • WELDMENT, Full gate • HINGE, Spring • • BOLT, Hex-hd 1/4-20 x 3/8” lg. • • WASHER, Lock 1/4” • BUMPER, Rubber stop CONSOLE ASSEMBLY, Platform control (For components, Refer to Figure 6-4.) • BOLT, Hex-hd 1/4-20 x 3/4" lg. • NUT, Hex 1/4-20 • WASHER, Lock 1/4" KICK PLATE WELDMENT, Hose ring BRACKET, Platform hose protector ROD, Platform hose protector $ - Consult factory

1 1 1 1 1 1 12 12 1 6 6 6 1 1 2 4 2 1 1 2 2 2 2 1 1 1 2 12 12 1 1 1 2 12 12 1 1 4 4 4 2 1 1 1

SECTION 6, Page 5


7

6

8 1

2

10

4

3

5 9




A B C D E F 1

Skyjack Part No.

8

$ $ $ $ $ $ $ $ $ $ $ $ 103909 103470 702600 103632 103995 104000 700625 700427 200463 700584 704119 700187 700188 103857 103980 700598 104000 (Ref.) 701023 703237 109388 112495 104000 701027 (Ref.) 702940 109388 112495 104000 701027 (Ref.)

9 10

103856 103980 104000 706142 706457

2

3

4 5

6

7

OEM Part No.


Units per Assy.

Description 1234567

PLATFORM ASSEMBLY, Standard PLATFORM ASSEMBLY, With half gate option PLATFORM ASSEMBLY, With full gate option PLATFORM ASSEMBLY, European, standard PLATFORM ASSEMBLY, European, with half gate PLATFORM ASSEMBLY, European, with full gate • WELDMENT, Platform, A • WELDMENT, Platform, B • WELDMENT, Platform, C • WELDMENT, Platform, D • WELDMENT, Platform, E • WELDMENT, Platform, F • • BOLT, Hex-hd ½-13 x 1-1/4" lg. • • WASHER, Lock ½” • PLATE, Info/warning • • BOLT, Self tap. 1/4-14 x 3/4" lg. • • WASHER, Flat 1/4" • • WASHER, Lock 1/4" • RAILING ASSEMBLY, Entry, A, D • • RAILING, Entry • • GUIDE, Railing • • BOLT, BHCS 1/4-20x1/2” • • SECURING ROD, Entrance guide • SWITCH, Foot • COVER, Foot switch • • BOLT, Hex-hd 1/4-20 x 1" lg. • • NUT, Hex 1/4-20 • • WASHER, Fender 9/32" x 1-1/4" x 1/16" thk. • • WASHER, Lock 1/4" GATE ASSEMBLY, Half Gate (option), B, E • WELDMENT, Half gate, LH • WELDMENT, Half gate, RH • HINGE, Spring • • BOLT, Hex-hd 1/4-20 x 3/8” lg. • • WASHER, Lock 1/4” • BUMPER, Rubber stop GATE ASSEMBLY, Full Gate (option), C, F • WELDMENT, Full gate • HINGE, Spring • • BOLT, Hex-hd 1/4-20 x 3/8” lg. • • WASHER, Lock 1/4” • BUMPER, Rubber stop CONSOLE ASSEMBLY, Platform control (For components, Refer to Figure 6-4.) • BOLT, Hex-hd 1/4-20 x 3/4" lg. • NUT, Hex 1/4-20 • WASHER, Lock 1/4" KICK PLATE WELDMENT, Hose ring $ - Consult factory

1 1 1 1 1 1 12 12 1 6 6 6 1 1 2 4 2 1 1 2 2 2 2 1 1 1 2 12 12 1 1 1 2 12 12 1 1 4 4 4 2 1

SECTION 6, Page 7


7

6

8 1

2

10

4

3

5 9




A B C D E F 1

Skyjack Part No.

8

$ $ $ $ $ $ $ $ $ $ $ $ 103909 103470 702600 103632 103995 104000 700625 700427 200463 700584 704119 700187 700188 103857 103980 700598 104000 (Ref.) 701023 703237 109388 112495 104000 701027 (Ref.) 702940 109388 112495 104000 701027 (Ref.)

9 10

103856 103980 104000 706142 706457

2

3

4 5

6

7

OEM Part No.


Units per Assy.

Description 1234567

PLATFORM ASSEMBLY, Standard PLATFORM ASSEMBLY, With half gate option PLATFORM ASSEMBLY, With full gate option PLATFORM ASSEMBLY, European, standard PLATFORM ASSEMBLY, European, with half gate PLATFORM ASSEMBLY, European, with full gate • WELDMENT, Platform, A • WELDMENT, Platform, B • WELDMENT, Platform, C • WELDMENT, Platform, D • WELDMENT, Platform, E • WELDMENT, Platform, F • • BOLT, Hex-hd ½-13 x 1-1/4" lg. • • WASHER, Lock ½” • PLATE, Info/warning • • BOLT, Self tap. 1/4-14 x 3/4" lg. • • WASHER, Flat 1/4" • • WASHER, Lock 1/4" • RAILING ASSEMBLY, Entry, A, D • • RAILING, Entry • • GUIDE, Railing • • BOLT, BHCS 1/4-20x1/2” • • SECURING ROD, Entrance guide • SWITCH, Foot • COVER, Foot switch • • BOLT, Hex-hd 1/4-20 x 1" lg. • • NUT, Hex 1/4-20 • • WASHER, Fender 9/32" x 1-1/4" x 1/16" thk. • • WASHER, Lock 1/4" GATE ASSEMBLY, Half Gate (option), B, E • WELDMENT, Half gate, LH • WELDMENT, Half gate, RH • HINGE, Spring • • BOLT, Hex-hd 1/4-20 x 3/8” lg. • • WASHER, Lock 1/4” • BUMPER, Rubber stop GATE ASSEMBLY, Full Gate (option), C, F • WELDMENT, Full gate • HINGE, Spring • • BOLT, Hex-hd 1/4-20 x 3/8” lg. • • WASHER, Lock 1/4” • BUMPER, Rubber stop CONSOLE ASSEMBLY, Platform control (For components, Refer to Figure 6-4.) • BOLT, Hex-hd 1/4-20 x 3/4" lg. • NUT, Hex 1/4-20 • WASHER, Lock 1/4" KICK PLATE WELDMENT, Hose ring $ - Consult factory

1 1 1 1 1 1 12 12 1 6 6 6 1 1 2 4 2 1 1 2 2 2 2 1 1 1 2 12 12 1 1 1 2 12 12 1 1 4 4 4 2 1

SECTION 6, Page 9

FIGURE 6-4. PLATFORM CONTROL CONSOLE ASSEMBLY

33 34

19

37

18 20

9 12

7

13 3

36 19

11

10

7

16

14

26

19 15 17 19

8

24 22

37

32

25

2 38 19

18

28 29 30 23

35 27 6

1 5

4 MA-TK-01

SECTION 6, Page 10


FIGURE 6-4. PLATFORM CONTROL CONSOLE ASSEMBLY Index No.

Skyjack Part No.

OEM Part No.

Units per Assy.

Description 1234567

A B C

702202 703391 703466

CONSOLE ASSEMBLY, Platform (dual fuel) CONSOLE ASSEMBLY, Platform (gas only) CONSOLE ASSEMBLY, Platform (diesel)

-

1 2

4 5 6 7

701581 701583 700481 700583 701582 700481 700583 701931 701776 109699 702200

1 1 4 4 1 4 4 1 1 1 2

8

702197

9

702199

10

702198

11

701935 703185 701934 703185 701936 703186 701937 703187 (Ref.) 102769 103279 701930 701933 701930 701929 701929 111181 701927 702262 704311 103955 701943 103962 104185 103012 103955 103011 103955 702185 702186 109698

• BOX WELDMENT, Control console • FACE WELDMENT, Control console • • BOLT, Mach-hd 1/4-20 x 1/2" lg. • • NUT, Lock 1/4-20 • TOP WELDMENT, Control console • • BOLT, Mach-hd 1/4-20 x 1/2" lg. • • NUT, Lock 1/4-20 • SWITCH, Ignition start • LABEL, Ignition switch • COVER, 110 Volt GFI • CONTROLLER, Extension and knuckle (For components, refer to Figure 6-8.) • CONTROLLER, Drive/steer (For components, refer to Figure 6-5.) • CONTROLLER, Jib/platform (For components, refer to Figure 6-7.) • CONTROLLER, Main boom/turret (For components, refer to Figure 6-6.) • LIGHT, Green indicator • • BULB, 12 Volt #1893 • LIGHT, Red indicator • • BULB, 12 Volt #1893 • DUAL ALARM, 12 Volt • • BULB, 12 Volt #1815 • LIGHT, Console • • BULB, 12 Volt #67 • SWITCH ASSEMBLY, Emergency stop • • HEAD, Emergency stop switch • • BASE, 2 N.C. • SWITCH, Toggle 2 position maintained, A, C • SWITCH, Toggle 3 position maintained, A, B • SWITCH, Toggle 2 position maintained, C • SWITCH, Toggle 2 position momentary, A, B • SWITCH, Toggle 2 position momentary, C • GUARD, Toggle switch • COVER, Toggle switch • PLUG, Knockout 1/2" • CIRCUIT BOARD, Platform leveling • • BOLT, Mach-hd #6-32 x 3/4" lg. • RELAY, Sealed 12 volt • • BOLT, Mach-hd #10-32 x 1/2" lg. • • WASHER, Lock #10 • STRIP, Terminal small • • BOLT, Mach-hd #6-32 x 3/4" lg. • STRIP, Terminal large • • BOLT, Mach-hd #6-32 x 3/4" lg. • WIRE DUCT, 1" • COVER, 1" Wire duct • RECEPTACLE, 110 Volt GFI Parts list continued on Page 13.

3

12 13 14 15

16 17 18 19 20 21 22 23

24 25 26 27


1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 AR 1 AR 1 4 5 1 1 5 2 1 2 129" 129" 1

SECTION 6, Page 11

FIGURE 6-4. PLATFORM CONTROL CONSOLE ASSEMBLY

33 34

19

37

18 20

9 12

7

13 3

36 19

11

10

7

16

14

26

19 15 17 19

8

24 22

37

32

25

2 38 19

18

28 29 30 23

35 27 6

1 5

4 MA-TK-01

SECTION 6, Page 12


FIGURE 6-4. PLATFORM CONTROL CONSOLE ASSEMBLY Index No.

28 29 30 31 32 33 34 35 36 37 38

Skyjack Part No.

OEM Part No.

103036 103041 102613 102956 700166 701766 701767 703458 701929 701930 703720


1234567

Units per Assy.

Parts list continued from Page 11. • STRAIN RELIEF, Strait 1/2" • STRAIN RELIEF, Strait 5/8" • STRAIN RELIEF, Strait 1" • PLUG, Knockout 7/8" • DIODE, 1 Amp/400 PIV • LABEL, Controller face • LABEL, Indicator face • LABEL, Glow plug, C • SWITCH, Toggle 2 position momentary (horn) • SWITCH, Toggle 2 position maintained (options) • INDICATOR LIGHT, Glow plug, C

1 1 1 1 6 1 1 1 1 AR 1

Description

SECTION 6, Page 13

FIGURE 6-5. DRIVE FUNCTION CONTROLLER

1

2

3

4

5

6

MA-TK-24 Index No.

1 2 3 4 5 6

Skyjack Part No.

OEM Part No.

Description 1234567

Units per Assy.

702197

CONTROLLER ASSEMBLY, Drive and steer

-

703175 703166 703167 703168 703172 703178

• • • • • •

1 1 1 1 3 1

SECTION 6, Page 14

KNOB, Maintained center BOOT, Controller handle MOUNTING PLATE, Plastic O-RING, Mounting seal SWITCH, Controller POTENTIOMETER ASSEMBLY


FIGURE 6-6. MAIN BOOM LIFT AND TURRET ROTATION CONTROLLER

1 2

3 4

6 5

7 MA-TK-23 Index No.

1 2 3 4 5 6 7

Skyjack Part No.

OEM Part No.

Units per Assy.

Description 1234567

702198

CONTROLLER ASSEMBLY, Main lift and turret rotate

-

703175 703166 703167 703168 703172 703176 703177

• • • • • • •

1 1 1 1 4 1 1


KNOB, Maintained center BOOT, Controller handle MOUNTING PLATE, Plastic O-RING, Mounting seal SWITCH, Controller CIRCUIT BOARD ASSEMBLY POTENTIOMETER ASSEMBLY

SECTION 6, Page 15

FIGURE 6-7. JIB LIFT AND PLATFORM ROTATION CONTROLLER

1 2 3 4

6

5


1 2 3 4 5 6 7

Skyjack Part No.

OEM Part No.

Description 1234567

Units per Assy.

702199

CONTROLLER ASSEMBLY, Jib lift/platform rotate

-

703165 703166 703167 703168 703172 703173 703174

• • • • • • •

1 1 1 1 4 1 1

SECTION 6, Page 16

KNOB, Controller handle BOOT, Controller handle MOUNTING PLATE, Plastic O-RING, Mounting seal SWITCH, Controller CIRCUIT BOARD ASSEMBLY POTENTIOMETER ASSEMBLY


FIGURE 6-8. KNUCKLE LIFT AND BOOM TELESCOPIC CONTROLLER

1

2

3 4 5

8 6 7

MA-TK-21 Index No.

1 2 3 4 5 6 7 8

Skyjack Part No.

OEM Part No.

Units per Assy.

Description 1234567

702200

CONTROLLER ASSEMBLY, Knuckle and telescopic

-

703165 703166 703167 703168 703169 703172 703170 703171

• • • • • • • •

1 1 1 1 1 2 1 1


KNOB, Controller handle BOOT, Controller handle MOUNTING PLATE, Plastic O-RING, Mounting seal MOUNTING PLATE, Flange SWITCH, Controller CIRCUIT BOARD ASSEMBLY SLAVE GEAR, Nylon

SECTION 6, Page 17

FIGURE 6-9. BOOM ASSEMBLY (Jib and Rotary Actuator Section)

9 8 1

6 21

17 7

10

20

12

4 5

13

11 14

2 19 17 22 15 3 16 18



FIGURE 6-9. BOOM ASSEMBLY (Jib and Rotary Actuator Section) Index No.

1

2 3 4 5

6 7 8

9 10

11

12

Skyjack Part No.

OEM Part No.

702018 706942 702061 701876 103909 103470 700390 700839 103995 104000 701487 701954 702875 701827 704603 700570 702168 103855 103857 704976 701222 706939 701221 702866 701187 103216 100904 702867 701811 103216 702143 704438 701358 103845 103404 704630 103873 104606 704429 701223 103887 103996 103404 704386 701259 103887 103996 103404 704386 701263 103887 103996 103404


Units per Assy.

Description 1234567

ACTUATOR ASSEMBLY, Rotary • ACTUATOR, Rotary (See NOTE A) • ACTUATOR, Rotary (See NOTE B) • KIT, Seal Repair • BOLT, Hex-hd 1/2-13 x 1.25 • WASHER, Lock 1/2" • VALVE BODY • • BOLT, Soc-hd 1/4-20 x 1-5/8" lg. • • WASHER, Flat 1/4" • • WASHER, Lock 1/4" • • O-RING, Seal • FITTING, Connecter #4orb - #4 • FITTING, Elbow 90° #4 female - #4 • VALVE, Counterbalance • CENTER BOLT, Rotary actuator • NUT, Hex 1-14 SENSOR, Platform leveling • BOLT, Hex-hd 1/4-20 x 1/2" lg. • BOLT, Hex-hd 1/4-20 x 1" lg. WELDMENT, Jib mounting plate, LH (See NOTE A) WELDMENT, Jib mounting plate, LH (See NOTE B) WELDMENT, Jib mounting plate, RH (See NOTE A) WELDMENT, Jib mounting plate, RH (See NOTE B) PARALLEL ASSEMBLY, Lower jib • WELDMENT, Lower jib parallel • BUSHING, 1-1/2" x 1-21/32" x 1-1/2" lg. • BUSHING, 1-1/2" x 1-21/32 x 1" lg. PARALLEL ASSEMBLY, Upper jib • WELDMENT, Upper jib parallel • BUSHING, 1-1/2" x 1-21/32" x 1-1/2" lg. CYLINDER ASSEMBLY, Jib (For components, refer to Figure 6-11.) WELDMENT, Pin (See NOTE A) WELDMENT, Pin (See NOTE B) • BOLT, Hex-hd 5/16-18 x 1/2" lg. • WASHER, Lock 5/16" JIB CYLINDER PIN • BOLT, Hex-hd 3/8-16 x 2-1/2" lg. • NUT, Lock 3/8-16 WELDMENT, Pin (See NOTE A) WELDMENT, Pin (See NOTE B) • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat • WASHER, Lock WELDMENT, Pin (See NOTE A) WELDMENT, Pin (See NOTE B) • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat • WASHER, Lock WELDMENT, Pin (See NOTE A) WELDMENT, Pin (See NOTE B) • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat • WASHER, Lock Parts List Continued on Page 21.

1 1 1 AR 12 12 1 3 3 3 2 2 2 2 1 2 1 2 2 1 1 1 1 1 1 4 2 1 1 4 1 2 2 2 2 1 1 1 2 2 2 2 2 1 1 2 2 2 1 1 2 2 2

SECTION 6, Page 19

FIGURE 6-9. BOOM ASSEMBLY (Jib and Rotary Actuator Section)

9 8 1

6 21

17 7

10

20

12

4 5

13

11 14

2 19 17 22 15 3 16 18



FIGURE 6-9. BOOM ASSEMBLY (Jib and Rotary Actuator Section) Index No.

13

14

15

16 17 18 19 20

21 22

Skyjack Part No.

OEM Part No.

704357 701276 103887 103996 103404 704357 701278 103887 103996 103404 702868 701250 101564 706928 106230 701288 704785 700583 703714 103864 103984 706460 704784 103472 104606

Units per Assy.

Description 1234567

Parts List Continued from Page 19. WELDMENT, Pin (See NOTE A) WELDMENT, Pin (See NOTE B) • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat • WASHER, Lock WELDMENT, Pin (See NOTE A) WELDMENT, Pin (See NOTE B) • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat • WASHER, Lock BRACKET ASSEMBLY, Leveling • WELDMENT, Leveling bracket • BUSHING, 1-3/4" x 1-15/16" x 1-1/2" CYLINDER ASSEMBLY, Leveling (For components, refer to Figure 6-10.) NUT, Lock 1-1/4-12 NUT, Lock 1-1/2-12 COVER WELDMENT, Level sensor • NUT, Lock 1/4-20 WEAR PAD, Jib parallel • BOLT, HHCS 5/16-18x1” • NUT, Lock 5/16-18 SLEEVE, Hose protection BRACKET, Level sensor • BOLT, HHCS 3/8-16x1” • NUT, Lock 3/8-16

2 2 2 2 2 1 1 2 2 2 1 1 2 1 4 5 1 2 2 4 4 1 1 3 3

NOTE A - Machines with Serial Number 93184 and above. NOTE B - Machines with Serial Number 93183 and below.


SECTION 6, Page 21

NOTES

SECTION 6, Page 22


FIGURE 6-10. LEVELING CYLINDER ASSEMBLY (Jib)

15 13 16 14

1 12 9 11 8

10 5 4

2 6 7 3 13 MA-TK-08

Index No.

1 2 3* 4* 5* 6* 7 8* 9* 10* 11 12 13 14

15 16

Skyjack Part No.

OEM Part No.

706928 702145 706927 700890 106228 106227 701968 701380 701377 109248 701967 702149 701288 101564 701969 701635 108429 103404 701827 702799 702644 703873


Units per Assy.

Description 1234567

CYLINDER ASSEMBLY, Platform leveling • WELDMENT, Cylinder barrel • WELDMENT, Cylinder rod • WIPER, Rod • SEAL, Rod • WEAR RING, Rod • O-RING, Gland • GLAND • SEAL, Piston • WEAR RING, Piston • O-RING, Piston • PISTON • Nut, Lock 1 1/2-12 • BUSHING, 1-3/4" x 1-15/16" x 1-1/2" VALVE BLOCK • O-RING • BOLT, Soc-hd 5/16-18 x 2-1/2" lg. • WASHER, Lock 5/16 VALVE, Counterbalance FITTING, Connector #8orb-#4 KIT, Seal repair TOOL, Cylinder assembly * Part of Seal Repair Kit.

1 1 1 1 1 1 1 1 1 1 1 1 6 1 2 4 4 2 2 AR AR

SECTION 6, Page 23

FIGURE 6-11. JIB LIFT CYLINDER ASSEMBLY

14

15 16 13

1

9

4 12

11 5 6 3 9 8 10 2

7



FIGURE 6-11. JIB LIFT CYLINDER ASSEMBLY Index No.

1 2 3 4 5* 6* 7* 8* 9* 10* 11* 12 13 14

15 16

Skyjack Part No.

OEM Part No.

Units per Assy.

Description 1234567

702143

CYLINDER ASSEMBLY, Jib lift

1

702147 702146 701281 702144 700571 106225 700573 700574 106226 701280 701639 106230 103216 701969 701635 103884 103404 701827 103070 702642 703872

• WELDMENT, Barrel • WELDMENT, Rod • GLAND • PISTON • SEAL, Rod • SEAL, Piston • WIPER, Rod • WEAR RING, Gland • WEAR RING, Piston • O-RING, Gland • O-RING, Piston • NUT, Lock 1-1/4 -12 • BUSHING, 1-1/2" x 1-21/32 x 1-1/4" lg. VALVE BLOCK • O-RING • BOLT, Hex-hd 5/16-18 x 2-1/2" lg. • WASHER, Lock 5/16 VALVE, Counterbalance FITTING, Connector #8orb-#6 KIT, Seal repair TOOL, Cylinder assembly

1 1 1 1 1 1 1 1 2 1 1 1 4 1 2 4 4 2 2 AR AR

* Part of Seal Repair Kit.


SECTION 6, Page 25

FIGURE 6-12. BOOM ASSEMBLY (Fly Boom Section)

14

13

11

12

16

15 2

18

3

10 17 8

9

4 1

6

7

5



FIGURE 6-12. BOOM ASSEMBLY (Fly Boom Section) Index No.

1

Skyjack Part No.

2

702869 702594 101564 101297 701922

3

702153

4

702888 701620 702889 701620 702172 701620 702181 704463 700582 704462 700582 702905 103996 103984 702904 700781 103996 103984 702816 702908 706143 103984 702911 700583 702649 703827 703862 703863 702911 700583 702858 100397 103996 103404 706402 104606 103472 706380 101632 103472 103999 (Ref.)

5 6 7 8 9 10

11

12 13

14

15

16

17

18

OEM Part No.

104606 702812 103472 SJB-66TK, Serial Number 93197 and below

Units per Assy.

Description 1234567

BOOM ASSEMBLY, Fly section • WELDMENT, Fly boom • BUSHING, 1-3/4" x 1-15/16" x 1-1/2" lg. • BOLT, 3/8-16 x 1-1/4" lg. CYLINDER ASSEMBLY, Fly boom extension (For components, refer to Figure 6-15.) CYLINDER ASSEMBLY, Platform leveling (For components, refer to Figure 6-14.) WEAR PAD, Fly boom base upper • BOLT, Flat-hd 3/8-16 x 3/4" lg. WEAR PAD, Fly boom base lower • BOLT, Flat-hd 3/8-16 x 3/4" lg. WEAR PAD, Fly boom side • BOLT, Flat-hd 3/8-16 x 3/4" lg. ATTACHMENT PLATE, Fly boom side wear pad PIN WELDMENT, Leveling cylinder • BOLT, Flat-hd 1/4-20 x 3/4" lg. PIN WELDMENT, Extension cylinder • BOLT, Flat-hd 1/4-20 x 3/4" lg. WELDMENT, Hose carrier tube mid/fly lower • WASHER, Flat 5/16" • NUT, Lock 5/16-18 WELDMENT, Hose carrier tube mid/fly upper • BOLT, Button-hd 5/16-18 x 3/8" lg. • WASHER, Flat 5/16" • NUT, Lock 5/18-18 STIFFENER, Hose carrier tube WELDMENT, Hose cover • PLATE, Clamp • NUT, Lock 5/16-18 • BOLT, Button-hd 1/4-20 x 1" lg. • NUT, Lock 1/4-20 HOSE CARRIER, Mid/fly (41 Links) • KIT, Link repair • BRACKET, Hose carrier • BRACKET, Hose carrier • BOLT, Button-hd 1/4-20 x 1" lg. • NUT, Lock 1/4-20 WELDMENT, Carrier tube mounting plate • NUT, Hex 5/16-18 • WASHER, Flat 5/16" • WASHER, Lock 5/16" COVER, Leveling manifold • NUT, Lock 3/8-16 • WASHER, Flat 3/8” BRACKET, Leveling manifold • BOLT, Hex hd 3/8-16x3/4” lg • WASHER, Flat 3/8” • WASHER, Lock 3/8” MANIFOLD ASSEMBLY, Leveling (For components refer to Figure 6-13.) • NUT, Lock 3/8-16 • BOLT, Hex hd 3/8-16x4 1/2” lg • WASHER, Flat 3/8”

1 1 2 1 1 1 1 4 1 4 2 4 2 1 1 1 1 1 4 4 1 5 4 4 1 1 2 2 2 2 1 38 1 1 8 8 1 4 4 4 1 2 2 1 4 4 4 1 2 2 2

SECTION 6, Page 27

FIGURE 6-13. PLATFORM LEVELING MANIFOLD ASSEMBLY 6 4

5

1 3 2

10 11 9

12

14 11 2

7

13

8



FIGURE 6-13. PLATFORM LEVELING MANIFOLD ASSEMBLY Index No.

Skyjack Part No.

A

703532

B

701642

1

703797 $ 703197 703189 703803 703799 703804 703800 703804 703798 703804 703801 703802 703870 703871 700764 700765 701998 701954 113348

2 3 4 5 6 7 8 9 10 11 12 13 14

OEM Part No.


Units per Assy.

Description 1234567

MANIFOLD ASSEMBLY, Leveling (Machines with Serial Number 93027 and above.) MANIFOLD ASSEMBLY, Leveling (Machines with Serial Number 93026 and below.) • BLOCK, Manifold, A • BLOCK, Manifold, B • SHUTTLE VALVE, Load sensing • VALVE, Platform rotation • • COIL, 12 Volt • VALVE, Platform leveling 4 GPM, retract • • COIL, 12 Volt • VALVE, Platform leveling 2 GPM, extend • • COIL, 12 Volt • VALVE, Jib lift, 6 GPM • • COIL, 12 Volt • VALVE, Differential sensing • VALVE, Flow control, A • PIPE PLUG, Hex socket, A • ORIFICE, B • PLUG, SAE #2 • PLUG, SAE #4 FITTING, Elbow 90° #8orb - #8 FITTING, Connector #4orb - #4 FITTING, Elbow 90° #4orb - #6

1 1

1 1 5 2 1 1 1 1 1 2 1 2 1 1 1 AR AR 2 8 1

SECTION 6, Page 29

NOTES

SECTION 6, Page 30


FIGURE 6-14. LEVELING CYLINDER ASSEMBLY (Fly Boom) 15 13 16 14

1 12 9 11 8

10 5 4

2 6 7 3 13 MA-TK-08

Index No.

1 2 3* 4* 5* 6* 7 8* 9* 10* 11 12 13 14

15 16

Skyjack Part No.

OEM Part No.

702153 702145 702244 700890 106228 106227 701968 701380 701377 109248 701967 702149 701288 101564 701969 701635 108429 103404 701827 702799 702644 703873


Units per Assy.

Description 1234567

CYLINDER ASSEMBLY, Platform leveling • WELDMENT, Cylinder barrel • WELDMENT, Cylinder rod • WIPER, Rod • SEAL, Rod • WEAR RING, Rod • O-RING, Gland • GLAND • SEAL, Piston • WEAR RING, Piston • O-RING, Piston • PISTON • Nut, Lock 1 ½-12 • BUSHING, 1-3/4" x 1-15/16" x 1-1/2" VALVE BLOCK • O-RING • BOLT, Soc-hd 5/16-18 x 2-1/2" lg. • WASHER, Lock 5/16 VALVE, Counterbalance FITTING, Connector #8orb-#4 KIT, Seal repair TOOL, Cylinder assembly * Part of Seal Repair Kit.

1 1 1 1 1 1 1 1 1 1 1 1 6 1 2 4 4 2 2 AR AR

SECTION 6, Page 31

FIGURE 6-15. FLY BOOM EXTENSION CYLINDER ASSEMBLY

15

1

3 12

17

6 18

8 11 6

16 5

26 7

13 9

19 4 10

10

14 15

9

2

24 25

22

20 23

21



FIGURE 6-15. FLY BOOM EXTENSION CYLINDER ASSEMBLY Index No.

Skyjack Part No.

(Ref.) 1 2 3 4 5* 6* 7* 8 9* 10* 11* 12 13

701912 701913 701915 701312 701314 700585 701315 701967 701917 701316 701317 701965 106230 701332 103871 103999 103472 701362 101328 701521 103473 103596 103472 103999 701518 103473 103999 701519 701533 104606 702578 701533 701969 701635 103884 103404 701827 702116 704535 703102 703103 704605 703594 702645

14 15 16

17

18

19 20

21 22 23 24 25 26

OEM Part No.

1 2 3 4 5 6 7

Units per Assy.

CYLINDER ASSEMBLY, Fly boom extension • WELDMENT, Barrel • WELDMENT, Rod • PISTON • GLAND • SEAL, Piston • WEAR RING, Piston • O-RING • SPACER • SEAL, Rod • WIPER, Rod • O-RING • NUT, Lock 1-1/4 -12 • GUIDE PLATE, Rod • • BOLT, Hex-hd 3/8-16 x 1-3/4" lg. • • WASHER, Lock 3/8" • • WASHER, Flat 3/8" • TUBE, Rod guide plate • BUSHING, 1-1/4" x 1-13/32" x 1" lg. GUIDE TUBE • BOLT, 3/8-16 x 1" lg. • BOLT, 3/8-16 x 2" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" GUIDE , Extension cylinder • BOLT, 3/8-16 x 1" lg. • WASHER, Lock 3/8" PAD, Extension cylinder guide • BOLT, Flat-hd 3/8-16 x 2" lg. • NUT, Lock 3/8" PAD, Extension cylinder lower guide • BOLT, Flat-hd 3/8-16 x 2" lg. VALVE BLOCK • O-RING • BOLT, Soc-hd 5/16-18 x 2-1/2" lg. • WASHER, Lock 5/16" VALVE, Counterbalance FITTING, connector #8orb-#8 HOSE ASSEMBLY STOP, SPACER, PVC stop DAMPENER, Guide tube • CLAMP, Gear #6 KIT, Seal repair

1 1 1 1 1 1 3 3 1 2 2 1 1 2 6 6 12 3 4 1 1 1 3 2 1 2 2 2 4 4 1 2 1 2 4 4 2 2 2 1 2 1 2 AR

Description

* Part of Seal Repair Kit. SJB-66TK, Serial Number 93197 and below

SECTION 6, Page 33

9 19

18

7

8

6

17

20

13

14

15

1

11

12

10

4

16

2

5

3

FIGURE 6-16. BOOM ASSEMBLY (Mid Boom Section)



FIGURE 6-16. BOOM ASSEMBLY (Mid Boom Section) Index No.

Skyjack Part No.

1

703735 702569 702696 702884 103473 103472 103999 103978 702885 103871 103472 103999 103978 701576 704661 703756 103952 703757 703758 703759 702886 703936 702887 103952 704628 103473 702929 702994 101632 104606 103012 103955 702794 103856 700583 704033 103995 700583 702666 103864 103996 103984 704040 (Ref.) 702772 103856 104000 702569 702696

2

3

4 5 6

7 8 9

10

11 12

13

14

15

OEM Part No.

1 2 3 4 5 6 7

Units per Assy.

WELDMENT, Mid boom WEAR PAD, Hose carrier 1/4" thk. (order separately) • BOLT, Flat-hd 1/4-20 x 1/2" lg. WEAR PAD, Mid boom tip upper • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" • NUT, Hex 3/8-16 WEAR PAD, Mid boom tip lower • BOLT, Hex-hd 3/8-16 x 1-3/4" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" • NUT, Hex 3/8-16 WEAR PAD PLUG, Mid boom WEAR PAD CUP, Mid boom WEAR PAD, Mid boom base upper • BOLT, Flat-hd 3/8-16 x 1" lg. SHIM, Wear pad 9/64” thk. SHIM, Wear pad 5/64” thk. SHIM, Wear pad 1/16” thk. WEAR PAD, Mid boom base upper • BOLT, Flat-hd 3/8-16 x 1" lg. WEAR PAD, Mid boom base lower • BOLT, Flat-hd 3/8-16 x 1" lg. PIN, Extension cylinder • BOLT, Hex-hd 3/8-16 x 1" • NUT, Jam 3/8-16 WELDMENT, Crossover plate • BOLT, Hex-hd 3/8-16 x 3/4" lg. • NUT, Lock 3/8-16 TERMINAL STRIP, Small • SCREW, Mach-hd #6 x 3/4" lg COVER, Crossover plate • BOLT, Hex-hd 1/4-20 x 3/4" lg. • NUT, Lock 1/4-20 TUBE WELDMENT, Hose carrier, upper • WASHER, Flat 1/4" • NUT, Lock 1/4-20 TUBE WELDMENT, Hose carrier lower • BOLT, Hex-hd 5/16-18 x 1" lg. • WASHER, Flat 5/16" • NUT, Lock 5/16-18 • COVER, Stud ASSEMBLY, Hose carrier restraint • RESTRAINT, Hose carrier • • BOLT, Hex-hd 1/4-20 x 3/4" • • WASHER, Lock 1/4" • WEAR PAD, Hose carrier 1/4" thk. • • BOLT, Flat-hd 1/4-20 x 1/2" lg.

1 8 2 1 4 4 4 4 1 4 4 4 4 4 4 1 4 AR AR AR 1 4 1 4 2 1 1 1 4 4 4 16 1 4 4 1 11 11 1 2 2 2 11 1 1 2 2 1 2

Description

Parts list continued on Page 37. SJB-66TK, Serial Number 93197 and below

SECTION 6, Page 35

9 19

18

7

8

6

17

20

13

14

15

1

11

12

10

4

16

2

5

3

FIGURE 6-16. BOOM ASSEMBLY (Mid Boom Section)



FIGURE 6-16. BOOM ASSEMBLY (Mid Boom Section) Index No.

Skyjack Part No.

OEM Part No.

Units per Assy.


Parts list continued from Page 35. 16 17

18

19 20

702434 703962 703723 701620 703832 703833 703834 703749 703832 703833 703834 701620 703724 703732 703748


LIMIT SWITCH • SCREW, #10-32 x 1/2" lg. WEAR PAD, Mid boom left side • BOLT, Flat-hd 3/8-16 x 3/4" lg. SHIM, Wear pad 9/64” thk. SHIM, Wear pad 5/64” thk. SHIM, Wear pad 1/16” thk. WEAR PAD, Mid boom right side SHIM, Wear pad 9/64” thk. SHIM, Wear pad 5/64” thk. SHIM, Wear pad 1/16” thk. • BOLT, Flat-hd 3/8-16 x 3/4" lg. BACKING PLATE, Mid boom side wear pad INSERT, Wear pad • BOLT, Flat-hd 1/4-20 x 5/8" lg.

1 2 1 2 AR AR AR 1 AR AR AR 2 2 1 1

SECTION 6, Page 37

11 13

6

3

10

15

5

16

4

12

18

14

1

17

2

3

7

8

9

FIGURE 6-17. BOOM ASSEMBLY (Knuckle Section)



FIGURE 6-17. BOOM ASSEMBLY (Knuckle Section) Index No.

1 2

3

4 5 6 7 8

9

10

11 12 13 14

15

16 17 18

Skyjack Part No.

OEM Part No.

703734 702890 103871 103472 103999 103978 702891 103596 103472 103999 103978 701579 704662 704627 703270 703069 704442 701555 703270 (Ref.) 702595 103887 103996 103404 702691 702569 702696 (Ref.) 702655 103855 104000 702569 702696 (Ref.) 702850 103887 103996 103404 702691 702569 702696 703004 103855 104000 703722 706293 706388 103855 104000 706415 706470 103885 104000 103995 706690 706721 706677


Units per Assy.


WELDMENT, Boom knuckle WEAR PAD, Knuckle tip upper • BOLT, Hex-hd 3/8-16 x 1-3/4" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" • NUT, Hex 3/8-16 WEAR PAD, Knuckle lower • BOLT, Hex-hd 3/8-16 x 2" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" • NUT, Hex 3/8-16 WEAR PAD PLUG, Knuckle WEAR PAD CUP, Knuckle PIN WELDMENT, Knuckle • BOLT, Flat-hd 3/8-16 x 3/4" lg. • SHIM, 3/32" thk. PIN WELDMENT, Cylinder (S/N 93184 and above) PIN WELDMENT, Cylinder (S/N 93183 and below) • BOLT, Flat-hd 3/8-16 x 3/4" lg. WEAR PAD BRACKET ASSEMBLY, Hose carrier • BRACKET WELDMENT, Hose carrier wear pad • • BOLT, Hex-hd 5/16-18 x 3/4" lg. • • WASHER, Flat 5/16" • • WASHER, Lock 5/16" • WEAR PAD, Hose carrier 1/2" thk. • WEAR PAD, Hose carrier 1/4" thk. • • BOLT, Flat-hd 1/4-20 x 1/2" lg. ANGLE BRACKET ASSEMBLY, Wear pad • ANGLE BRACKET, Hose carrier wear pad • • BOLT, Hex-hd 1/4-20 x 1/2" lg. • • WASHER, Lock 1/4" • WEAR PAD, Hose carrier 1/4" thk. • • BOLT, Flat-hd 1/4-20 x 1/2" lg. WEAR PAD BRACKET ASSEMBLY, Hose carrier • BRACKET WELDMENT, Hose carrier wear pad • • BOLT, Hex-hd 5/16-18 x 3/4" lg. • • WASHER, Flat 5/16" • • WASHER, Lock 5/16" • WEAR PAD, Hose carrier 1/2" thk. • WEAR PAD, Hose carrier 1/4" thk. • • BOLT, Flat-hd 1/4-20 x 1/2" lg. ACTUATOR, Limit switch • BOLT, Hex-hd 1/4-20 x 1/2" lg. • WASHER, Lock 1/4" MOUNTING PLATE, Proximity switch SWITCH, Proximity COVER, Proximity switch • BOLT, Hex-hd 1/4-20 x 1/2" lg. • WASHER, Lock 1/4" • PIN, Roll 1/8x5/8 WELDMENT, Lock cylinder cover • BOLT, HHCS 1/2-20x1/2 • WASHER, Lock 1/4 • WASHER, Flat 1/4 PIN, Lock WELDMENT, Locking plate CYLINDER ASSEMBLY, Mid boom lock (For components refer to Figure 6-22)

1 1 4 4 4 4 1 4 4 4 4 4 4 2 2 AR 1 1 2 1 1 2 2 2 1 3 2 1 1 2 2 1 2 1 1 2 2 2 2 6 2 1 2 2 1 1 1 2 2 2 1 2 2 2 2 1 1

SECTION 6, Page 39

21 17

26

5

4

3

6

28

25

2

7

8

12

11

20

10

27

13

24

9

22

29

18

1

11

14

23

15

16

19

FIGURE 6-18. BOOM ASSEMBLY (Main Section)



FIGURE 6-18. BOOM ASSEMBLY (Main Section) Index No.

1

2 3

4 5

6 7 8

9

10

11

12

13

14

Skyjack Part No.

OEM Part No.

702870 702055 103208 701328 701997 702060 103906 103470 703886 702823 101632 103999 702597 701794 702051 702434 103962 104185 (Ref.) 702640 103984 103996 702691 702569 702696 (Ref.) 702691 702569 702696 702850 103887 103996 103404 704449 103887 103996 103404 702646 103887 103404 702621 103887 103404 706294 703268 104185


Units per Assy.


BOOM ASSEMBLY, Main • WELDMENT, Main boom • BUSHING, 2" x 2-3/16" x 1-1/2" lg. • BUSHING, 2-1/4" x 2-7/16" x 1-3/4" lg. HYDRAULIC ASSEMBLY, Mid extend dual cylinder (For components, refer to Figure 6-19.) • MOUNTING PLATE, Extension cylinder • • BOLT, Hex-hd 1/2-13 x 1-3/4" lg. • • WASHER, Lock 1/2" HOSE ASSEMBLY, (H108-0019-00-0) (Refer to SECTION 5, Page 37) WELDMENT, Cover • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" FITTING, Bulkhead, elbow 45° #8 - #8 CAM, Main boom limit switch • SET SCREW, Soc-hd 1/4-20 x 3/8" lg. SWITCH ASSEMBLY, Limit • BOLT, Mach-hd 10-32 x 1/2" lg. • WASHER, Lock #10 GUIDE ASSEMBLY, Hose carrier • WELDMENT, Hose carrier guide • • NUT, Lock 5/16-18 • • WASHER, Flat 5/16" • WEAR PAD, Hose carrier 1/2" thk. • WEAR PAD, Hose carrier 1/4" thk. • • BOLT, Flat-hd 1/4-20 x 1/2" lg. WEAR PAD BRACKET ASSEMBLY, Hose carrier • WEAR PAD, Hose carrier 1/2" thk. • WEAR PAD, Hose carrier 1/4" thk. • • BOLT, Flat-hd 1/4-20 x 1/2" lg. BRACKET WELDMENT, Hose carrier wear pad • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat 5/16" • WASHER, Lock 5/16" PIN WELDMENT • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Flat 5/16" • WASHER, Lock 5/16" , Hose carrier • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Lock 5/16" , Hose carrier • BOLT, Hex-hd 5/16-18 x 3/4" lg. • WASHER, Lock 5/16" LIMIT SWITCH, Booted • BOLT, Mach-hd 10-32 x 3/4" lg. • WASHER, Lock #10 Parts list continued on Page 43.

1 1 4 2 1 2 3 3 2 1 4 4 2 1 2 1 2 2 1 1 2 2 2 4 2 1 2 6 2 1 2 2 2 2 2 2 2 3 2 2 3 2 2 1 2 2

SECTION 6, Page 41

21 17

26

5

4

3

6

28

25

2

7

8

12

11

20

10

27

13

24

9

22

29

18

1

11

14

23

15

16

19

FIGURE 6-18. BOOM ASSEMBLY (Main Section)



FIGURE 6-18. BOOM ASSEMBLY (Main Section) Index No.

Skyjack Part No.

OEM Part No.

Units per Assy.


Parts list continued from Page 41. 15 16

17 18 19

20 21 22

23

24

25

26 27

28

29

706329 103952 701724 101632 103999 702722 702507 701375 702651 703826 703828 703861 111231 703269 103984 702693 702692 702695 702674 103995 700853 702694 103857 103995 700853 702872 702607 701850 701998 702798 702796 701795 706336 101632 103999 103472 103011 104698 703784 103915 103999 103472 706294 111356 703268 104185 706979 702674


WELDMENT, Limit switch mount • BOLT, Flat-hd 3/8-16 x 1" lg. HOSE • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" COVER, Hose • NUT, Lock 1/2"-13 CYLINDER ASSEMBLY, Knuckle (For components, refer to Figure 6-23) HOSE CARRIER ASSEMBLY, Main (40 Links) • KIT, Link repair • BRACKET, Hose carrier • BRACKET, Hose carrier • BOLT, Button-hd 5/16-18 x 1" lg. • BOLT, Button-hd 5/16-18 x 1" lg. s.s. • NUT, Lock 5/16-20 HOSE CARRIER CHANNEL, Upper left HOSE CARRIER CHANNEL, Upper right HOSE CARRIER CHANNEL, Lower left • BOLT, Hex-hd 1/4-20 x 4" lg • WASHER, Flat 1/4" • WASHER, Lock 1/4" HOSE CARRIER CHANNEL, Lower right • BOLT, Hex-hd 1/4-20 x 1" lg • WASHER, Flat 1/4" • WASHER, Lock 1/4" MANIFOLD ASSEMBLY, Knuckle cylinder distribution • MANIFOLD, Distribution • FITTING, Elbow 90° #4orb - #4 • FITTING, Elbow 90° #8orb - #8 • FITTING, Elbow long 90° #8orb - #8 • FITTING, Plug #8orb MOUNTING PLATE, Non-Booted limit switch MOUNTING PLATE, Booted limit switch • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" TERMINAL STRIP, Large • BOLT, Mach-hd 10-32 x 3/4" lg. COVER WELDMENT, Distribution manifold • BOLT, Hex-hd 3/8-16 x 3-1/2" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" LIMIT SWITCH, Booted (Later machines) LIMIT SWITCH, Non-Booted (Early machines) • BOLT, Mach-hd 10-32 x 3/4" lg. • WASHER, Lock #10 MANIFOLD ASSEMBLY, Tee • BOLT, Hex-hd 1/4-20 x 3" lg.

1 2 1 2 2 1 2 2 1 38 1 1 4 4 8 1 1 1 5 10 5 1 6 12 6 1 1 4 1 1 2 1 1 2 2 2 .4 2 1 2 2 2 3 3 2 2 1 2

SECTION 6, Page 43

FIGURE 6-19. MID BOOM EXTENSION CYLINDER ASSEMBLY

2

4 6

7

5 1 11 3

9 8

10



FIGURE 6-19. MID BOOM EXTENSION CYLINDER ASSEMBLY Index No.

Skyjack Part No.

OEM Part No.

Units per Assy.


701997

HYDRAULIC ASSEMBLY, Mid extend dual cylinder

-

1

702043

1

2

702052

3 4 5 6

701946 702319 704167 702001 103473 103999 701538 701533 104606 701969 701635 108429 103404 701827 701998 704629

• CYLINDER ASSEMBLY, Mid extension lower (For components, refer to Figure 6-21.) • CYLINDER ASSEMBLY, Mid extension upper (For components, refer to Figure 6-20.) • TUBE ASSEMBLY, Crossover • TUBE ASSEMBLY, Crossover • FITTING, Elbow 90° #6orb - #8 • WELDMENT, Cylinder mount • • BOLT, Hex-hd 3/8-16 x 1" lg. • • WASHER, Lock 3/8" • WEAR PAD, Mid boom extension cylinder • • BOLT, Flat-hd 3/8-16 x 2" lg. • • NUT, Lock 3/8-16 • VALVE BLOCK, Extension cylinder • • O-RING • • BOLT, Soc-hd 5/16-18 x 2-1/2" lg. • • WASHER, Lock 5/16" • VALVE, Counterbalance • FITTING, Elbow 90° #8orb - #8 • PIN, Mid boom extension cylinder

7

8

9 10 11


1 1 1 4 2 8 8 8 2 2 1 2 4 4 2 2 2

SECTION 6, Page 45

FIGURE 6-20. MID BOOM EXTENSION UPPER CYLINDER ASSEMBLY

10

1 11 9 4 6

5 8 7 3

2


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

Skyjack Part No.

OEM Part No.


702052

CYLINDER ASSEMBLY, Mid boom upper extension

701341 702053 701317 701316 701314 701315 701965 701967 700585 106230 701312 101328 702645

• WELDMENT, Barrel • WELDMENT, Rod • WIPER, Rod • SEAL, Rod • GLAND • WEAR RING, Piston • O-RING, Gland • O-RING, Piston • SEAL, Piston • NUT, Lock 1-1/4 -12 • PISTON • BUSHING, 1-1/4" x 1-13/32" x 1" lg. KIT, Seal repair

Units per Assy.

1 1 1 1 1 3 1 1 1 1 1 2 AR

* Part of Seal Repair Kit. SECTION 6, Page 46


FIGURE 6-21. MID BOOM EXTENSION LOWER CYLINDER ASSEMBLY

10

1

11 9 4 7

6

5 8

3 2

MA-TK-12 Index No.

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

Skyjack Part No.

OEM Part No.

Units per Assy.


702043

CYLINDER ASSEMBLY, Mid boom lower extension

701534 702044 701317 701316 701314 701315 701965 701967 700585 106230 701312 702645

• WELDMENT, Barrel • WELDMENT, Rod • WIPER, Rod • SEAL, Rod • GLAND • WEAR RING, Piston • O-RING, Gland • O-RING, Piston • SEAL, Piston • NUT, Lock 1-1/4 -12 • PISTON KIT, Seal repair

1 1 1 1 1 3 1 1 1 1 1 AR

* Part of Seal Repair Kit. SJB-66TK, Serial Number 93197 and below

SECTION 6, Page 47

FIGURE 6-22. Mid Boom Lock Cylinder. 1 13 12 11 10 9 8 7

2 6 5 4 3

14

MA-TK-42 Index No.

1 2 3 4 5 6 7* 8* 9 10* 11* 12 13* 14

Skyjack Part No.

OEM Part No.


706677

CYLINDER ASSEMBLY, Lock

706685 100249 706687 706764 103830 700309 104661 701634 700310 108798 701963 700308 106449 706680 700451

• WELDMENT, Barrel • BUSHING • SPRING • SPACER • LOCKNUT • PISTON • SEAL, Piston • O-RING • SPACER • SEAL, Rod • O-RING • GLAND • WIPER, Rod • ROD, Cylinder KIT, Seal repair

Units per Assy.

1 2 1 1 1 1 1 1 1 1 1 1 1 1 AR

* Part of Seal Repair Kit. SECTION 6, Page 48


FIGURE 6-23. KNUCKLE LIFT CYLINDER ASSEMBLY 16

14 17

15 5 13

4 9 12

2

7 10

1 18 3 11 8 6 13 Index No.

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

Skyjack Part No.

701375 701376 701288 701967 701377 109248 701378 701379 701380 106228 700890 106227 701968 103208 701460 702819 701635 701956 701827 706520 702644 703873


OEM Part No.

MA-TK-14 Units per Assy.


CYLINDER ASSEMBLY, Knuckle • PISTON • NUT, Lock 1-1/2 - 12 • O-RING • SEAL, Piston • WEAR RING, Piston • WELDMENT, Rod • WELDMENT, Barrel • GLAND • SEAL, Rod • WIPER, Rod • WEAR RING, Rod • O-RING • BUSHING, 2" x 2-3/16" x 1-1/2" lg. VALVE BLOCK • BOLT, Soc-hd 5/16-18 x 1-1/4" lg. O-RING FITTING, Connector #6orb - #4 VALVE, Counterbalance SPACER, Cylinder 1/4” (Serial Number 93165 and below only) KIT, Seal repair TOOL, Cylinder assembly * Part of Seal Repair Kit

1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 2 2 2 2 AR AR

SECTION 6, Page 49

FIGURE 6-24. HYDRAULIC HOSE CONNECTIONS - Boom Assembly 15

37

16

2

38

20

8 43 44

39

18

29 1

41 42

17

3

5

19 45

4

37 36

42

21 20

Engine Side Hose Carrier 27

50

31

28

13

6

54

34

30

41

45

53

14

54

35

54

29 49

12

49 55

33 41

45

43

51 32

45 26

25 29

7

24 52

9

11

22 49

47 48 46

45

10

23

Base Control Side Hose Carrier



FIGURE 6-24. HYDRAULIC HOSE CONNECTIONS - Boom Assembly Index No.

Skyjack Part No.

1 2

702061 702143

3

702153

4

706928

5

701912

6

701997

7

701375

8

(Ref.)

9

702873

10

(Ref.)

11

12

702872 702607 701850 701998 702798 702796 706677

13 14 15 16 17

706688 706979 703877 703876 704517

18

703880

19

704535

20

703889

21

703883

22

704501

23

704533

24

704524

25

703875

26

703888

OEM Part No.



ACTUATOR, Rotary CYLINDER ASSEMBLY, Jib lift (For components, refer to Figure 6-11.) CYLINDER ASSEMBLY, Leveling (Fly Boom) (For components, refer to Figure 6-14.) CYLINDER ASSEMBLY, Leveling (Jib) (For components, refer to Figure 6-10.) CYLINDER ASSEMBLY, Fly boom (For components, refer to Figure 6-15.) CYLINDER ASSEMBLY, Mid boom dual (For components, refer to Figure 6-19.) CYLINDER ASSEMBLY, Knuckle (For components, refer to Figure 6-23.) CYLINDER ASSEMBLY, Mid boom lock MANIFOLD ASSEMBLY, Leveling (For components, refer to Figure 6-13.) VALVE ASSEMBLY, 4 Bank proportional (For components, refer to Figure 6-32.) MANIFOLD ASSEMBLY, Main (For components, refer to Figure 6-31.) MANIFOLD ASSEMBLY, Knuckle cylinder • MANIFOLD, Distribution • FITTING, Elbow 90° #4orb - #4 • FITTING, Elbow 90° #8orb - #8 • FITTING, Elbow 90° #8orb - #8 long • FITTING, Plug #8 CYLINDER ASSEMBLY, Mid Boom Lock (For components, refer to Figure 6-22.) MANIFOLD ASSEMBLY, Lock Cylinder MANIFOLD ASSEMBLY, Tee HOSE ASSEMBLY, Rotary actuator(H104 0144 00-0) HOSE ASSEMBLY, Jib cylinder (H104 0134 00-0) HOSE ASSEMBLY, Leveling cylinder (H304 0056 00-0) HOSE ASSEMBLY, Leveling cylinder (H104 0036 00-0) HOSE ASSEMBLY, Fly boom cylinder (H608 0024 00-0) HOSE ASSEMBLY, Fly boom cylinder (H108 0257 00-0) HOSE ASSEMBLY, Leveling manifold (H106 0257 00-0) HOSE ASSEMBLY, Crossover plate (H108 0687 00-0) HOSE ASSEMBLY, Crossover plate (H606 0702 00-0) HOSE ASSEMBLY, Knuckle cylinder (H508 0303 00-0) HOSE ASSEMBLY, Knuckle cylinder (H104 0036 00-0) HOSE ASSEMBLY, Mid boom cylinder (H108 0093 00-0)

FIGURE 6-24. HYDRAULIC HOSE CONNECTIONS - Boom Assembly Units per Assy.

1 1 1 1 1 1 2 1 1 1 1 1 1 4 1 1 2 1 1 1 2 2 2 2

Index No.

Skyjack Part No.

27

703886

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

707084 706568 707085 707086 707087 704534 706717 706716 702875 701954 103070 103073 102665 701998 702799 702856 701959 702116 702811 703046 702598 701956 702597 103322 701850 701999 702599 702124

OEM Part No.

Units per Assy.


HOSE ASSEMBLY, Mid boom cylinder (H108 0019 00-0) HOSE ASSEMBLY, Tee (H608 0225 00-0) HOSE ASSEMBLY, Tee (H104 0013 00-0) HOSE ASSEMBLY, Tee (H104 0015 02-0) HOSE ASSEMBLY, Lock Cylinder (H108 00344 00-0) HOSE ASSEMBLY, Lock Cylinder (H604 0013 00-0) HOSE ASSEMBLY, Lock Cylinder (H608 0022 00-0) TUBE, Hydraulic TUBE, Hydraulic FITTING, Elbow 90° #4 - #4 FITTING, Connector #4orb - #4 FITTING, Connector #8orb - #6 FITTING, Elbow 90° #6orb - #6 FITTING, Elbow 90° #8orb - #6 FITTING, Elbow 90° #8orb - #8 FITTING, Connector #8orb - #4 FITTING, Elbow 90° #8 - #8 FITTING, Bulkhead elbow 90° #8 - #8 FITTING, Connector #8orb - #8 FITTING, Bulkhead connector #6 - #6 FITTING, Reducer #8 - #6 FITTING, Bulkhead connector FITTING, Connector #6orb - #4 FITTING, Bulkhead elbow 45° #8 - #8 FITTING, Connector #4orb - #6 FITTING, Elbow 90° #4orb - #4 FITTING, Elbow 90° #6orb - #4 FITTING, Bulkhead connector #4 - #4 FITTING, Union #4 - #4

2 1 2 1 1 1 1 1 1 2 10 2 1 1 4 4 4 2 13 1 1 4 6 2 1 1 1 3 1

NOTE: Refer to Sandard Hose Numbering System (SECTION 5, Page 37) for explanation of hose numbering.

2 3 2 4 1 2 4 1 SECTION 6, Page 51

FIGURE 6-25. TURRET ASSEMBLY

6

4 5

31

3

19

13 23 1 26

25

27

29

7 18

14 15 32 25 28

17 9

16

24

8

20 2

30 12

21

10

11

22 MA-TK-16 SECTION 6, Page 52


FIGURE 6-25. TURRET ASSEMBLY Index No.

1

Skyjack Part No.

OEM Part No.

704345 703053 704061 702993

2

702194 704095 702240

3

702882 703029 703159

4

704333 704570 103909 700425 702378

6

103909 700425 702534 103909 702507 103470 702995

7

103473 103999 702215

5

8 9

10 11

12 13

14

103473 103999 103472 702032 702709 103596 103978 103999 703719 702708 103596 103978 103999 702788 702865 101632 103472 103999 700552 700583 103856


Units per Assy.


WELDMENT, Turret • BOLT, Hex-hd 3/4-10 x 5-1/2" lg. (Serial Number 93184 and above only) WELDMENT, Turret • BOLT, Hex-hd 3/4-10 x 7-1/4" lg. (Serial Number 93183 and below only) • WASHER, Flat 3/4" hardened WELDMENT, Counterweight (Serial Number 93184 and above only) WELDMENT, Counterweight (Serial Number 93183 and below only) ENGINE ASSEMBLY, Dual fuel (For components, refer to Figure 6-34.) ENGINE ASSEMBLY, Gasoline only (For components, refer to Figure 6-34.) ENGINE ASSEMBLY, Diesel (For components, refer to Figure 6-36.) CAP, Swing arm PLATE, Engine swing-out clamp (Serial Number 93184 and above only) • BOLT, Hex-hd 1/2-13 x 2" lg. • WASHER, Lock 1/2" PIVOT PIN, Engine tray (Serial Number 93183 and below only) • BOLT, Hex-hd 1/2-13 x 1-1/4" lg. • WASHER, Stop 1/2" WELDMENT, Engine stop rod • BOLT, Hex-hd 1/2-13 x 1-1/4" • NUT, Lock 1/2-13 • WASHER, 1/2" TANK ASSEMBLY, Fuel (For components, refer to Figure 6-27.) • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Lock 3/8" TANK ASSEMBLY, Hydraulic (For components, refer to Figure 6-28.) • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" BATTERY, 12 Volt emergency pump HOLD DOWN, Emergency battery • BOLT, Hex-hd 3/8-16 x 2" • NUT, Hex 3/8-16 • WASHER, Lock 3/8" BATTERY, 12 Volt engine HOLD DOWN, Engine battery • BOLT, Hex-hd 3/8-16 x 2" • NUT, Hex 3/8-16 • WASHER, Lock 3/8" LINER, Battery tray MANIFOLD ASSEMBLY, Rotary (For components, refer to Figure 6-29.) • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" SWITCH, Tilt • NUT, Lock 1/4-20 • BOLT, Hex-hd 1/4-20 x 3/4" lg. Parts List Continued on Page 55.

1 24 1 24 24 1 1 1 1 1 1 1 2 2 1 2 2 1 1 2 3 1 4 4 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 2 2

SECTION 6, Page 53

8

22

20

14

26

2

3

4

5

29

23

25

27

21

24

19

6

16

30

17

25 28 32

13

18

15

10

31

11

1

12

9

7

FIGURE 6-25. TURRET ASSEMBLY



FIGURE 6-25. TURRET ASSEMBLY Index No.

Skyjack Part No.

15

702864

16

702542 103472 103999 103978 703097

17

103915 103472 103999 702873

18 19 20

21 22 23

24

25 26 27 28

29

OEM Part No.

101632 103472 103999 702532 700838 104694 702652 702614 703181 703182 106052 103845 103404 703058 703062 (Ref.) 702874 702607 701850 702796 702116 702730 103863 700583 103995 103011 702459 702460 103962 104185 702667 103859 103980 104000 704453 701591

30 31

704464 701991

32

706688 702673 706712


Units per Assy.


Parts List Continued from Page 53. MANIFOLD ASSEMBLY, Main (For components, refer to Figure 6-31.) • BOLT, Hex-hd 3/8-16 x 6" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" • NUT, Hex 3/8-16 MANIFOLD ASSEMBLY, Brake (For components, refer to Figure 6-30.) • BOLT, Hex-hd 3/8-16 x 3-1/2" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" ASSEMBLY, Valve stack (For components, refer to Figure 6-32.) • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Flat 3/8" • WASHER, Lock 3/8" ISOLATOR, 120 Amp battery • BOLT, Soc-hd #8-32 x 3/8" lg. • WASHER, Flat #8 WELDMENT, Hose ring PUMP/MOTOR ASSEMBLY, Emergency lowering • PUMP, Emergency lowering • MOTOR, Emergency lowering • COUPLER • BOLT, 5/16 -18 x 1/2" lg. • WASHER, Lock 5/16" OR, 12 Volt BRACKET, or mounting ASSEMBLY, Turret control (For components, refer to Figure 6-33.) MANIFOLD ASSEMBLY, Lift cylinder distribution • MANIFOLD, Distribution • FITTING, Elbow 90° #8orb - #8 • FITTING, Hex-hd plug #8 • FITTING, Connector #8orb - #8 CABLE HOLD DOWN • BOLT, Hex-hd 1/4-20 x 3-1/2" lg. • NUT, Lock 1/4-20 • WASHER, Flat 1/4" TERMINAL STRIP, Large BACK PLATE, Terminal strip COVER, Terminal strip • SCREW, Mach-hd #10-32 x 1/2" lg. • WASHER, Lock #10 COVER, Terminal strip • BOLT, Hex-hd 1/4-20 x 1-1/2" lg. • NUT, Hex 1/4-20 • WASHER, Lock 1/4" PIN, Boom mount (Machines with Serial Number 93184 and above) PIN, Boom mount (Machine with Serial Number 93183 and below) PIN, Boom lift cylinder CYLINDER ASSEMBLY, Boom lift (For components, refer to Figure 6-37) MANIFOLD, Lock cylinder assembly • BOLT, Hex-hd 1/4-20 x 3" lg. • PLUG, Orifice

1 2 2 2 2 1 2 2 2 1 4 4 4 1 4 4 1 1 1 1 1 4 4 1 1 1 1 1 4 2 2 1 2 2 2 2 1 1 4 4 1 2 2 2 1 1 1 2 1 2 1

SECTION 6, Page 55

5

8

3

7

11

9

10

8

4

12

1

7

6

2

FIGURE 6-26. TURRET COVERS AND DOORS



FIGURE 6-26. TURRET COVERS AND DOORS Index No.

1

2

3

Skyjack Part No.

OEM Part No.

702493 702862 703094 702492 702862 703094 703954 703705 702710 703953 703704 703145

4

103873 104606 701027 703955 703706 702711

5

103873 104606 701027 (Ref.) 702746 702935 703220 702924 702936

6

(Ref.) 702746 702934 702924 702936


Units per Assy.


COVER WELDMENT, Fuel tank • SCREW, Self tapping 1/4-14 x 1" lg. • COVER, Shim 1/4" lg. COVER WELDMENT, Hydraulic tank • SCREW, Self tapping 1/4-14 x 1" lg. • COVER, Shim 1/4" lg. WELDMENT, Engine door (gas/dual fuel) (Serial Number 93139 and above) WELDMENT, Engine door (gas/dual fuel) (Serial Number 93067 thru 93138) WELDMENT, Engine door (gas/dual fuel) (Serial Number 93066 and below) WELDMENT, Engine door (diesel) (Serial Number 93138 and above) WELDMENT, Engine door (diesel) (Serial Number 93067 thru 93138) WELDMENT, Engine door (diesel) (Serial Number 93066 and below) • BOLT, Hex-hd 3/8-16 x 2-1/2" lg. • NUT, Lock 3/8-16 • BUMPER, Rubber WELDMENT, Control door (Serial Number 93139 and above) WELDMENT, Control door (Serial Number 93067 thru 93138) WELDMENT, Control door (Serial Number 93066 and below) • BOLT, Hex-hd 3/8-16 x 2-1/2" lg. • NUT, Lock 3/8-16 • BUMPER, Rubber LATCH ASSEMBLY, Engine door LATCH, Door ROD, Latch 16-1/8" (gas/dual fuel) (Serial Number 93138 and below) ROD, Latch 16-1/8" (diesel) (Serial Number 93138 and below) ACTUATOR, Latch (Serial Number 93138 and below) SPACER, Latch (Serial Number 93138 and below) LATCH ASSEMBLY, Control door LATCH, Door ROD, Latch 32-3/4" (Serial Number 93138 and below) ACTUATOR, Latch (Serial Number 93138 and below) SPACER, Latch (Serial Number 93138 and below) Parts List Continued on Page 59.

1 9 AR 1 9 AR 1 1 1 1 1 1 2 2 4 1 1 1 2 2 4 1 1 1 1 1 1 1 1 1 1 1

SECTION 6, Page 57

8 5

8

3

7

11

9

10

4

12

1

7

6

2

FIGURE 6-26. TURRET COVERS AND DOORS



FIGURE 6-26. TURRET COVERS AND DOORS Index No.

7

Skyjack Part No.

OEM Part No.

704108 702717

8

704090

9

703633 703634 702699

10

703639 703640 702701

11

703687

12

703689 703691 703688

703689 703690

Units per Assy.


Parts List Continued from Page 57. WELDMENT, Hinge (Serial Number 93139 and above) WELDMENT, Hinge (Serial Number 93138 and below) WELDMENT, Hinge clevis (Serial Number 93139 and above) WELDMENT, Engine side right shock mount (Serial Number 93067 and above) WELDMENT, Engine side left shock mount (Serial Number 93067 and above) WELDMENT, Engine side shock mount (Serial Number 93066 and below) WELDMENT, Control side right shock mount (Serial Number 93067 and above) WELDMENT, Control side left shock mount (Serial Number 93067 and below) WELDMENT, Control side shock mount (Serial Number 93067 and below) SHOCK, Gas charged 250 lb. (Serial Number 93067 and above, engine side only) STUD, Ball 13mm CLIP, Safety 250 lb. SHOCK, Gas charged 190 lb. (Serial Number 93066 and below) (Serial Number 93067 and above, control side only) STUD, Ball 13mm CLIP, Safety 190 lb.

4 4 4 4 1 1 1 1 1 1 2 2 2 AR

2 2

NOTE A - Be sure to include Model and Serial Numbers when ordering replacement doors. NOTE B - Decals and labels must be ordered separately.


SECTION 6, Page 59

FIGURE 6-27. FUEL TANK ASSEMBLY

4

1 7

2 5

3 6 MA-TK-18

Index No.

1 2 3 4 5 6 7

Skyjack Part No.

OEM Part No.


Units per Assy.

702995

TANK ASSEMBLY, Fuel

-

702996 703002 103339 703937 702236 702308 701862

• • • • • • •

1 1 1 1 1 1 1

SECTION 6, Page 60

TANK WELDMENT, Fuel LEVEL GAUGE, Fuel tank PLUG, 3/4" Magnetic FILL CAP, Fuel tank FITTING, Elbow 90° 1/4NPT female-1/4NPT male FITTING, Needle valve 1/4NPT PLUG, 3/8" NPT


FIGURE 6-28. HYDRAULIC TANK ASSEMBLY 8

4

1 11 6 7

14

5

10 15

2

13

3

9 Index No.

1

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Skyjack Part No.

OEM Part No.

12



702215

TANK ASSEMBLY, Hydraulic

702289 103855 103995 104000 103339 701885 702290 702505 702541 702396 702291 702560 702169 702214 703002 703036 703118 702382

• COVER WELDMENT, Hydraulic tank • • BOLT, Hex-hd 1/4-20 x 1/2" lg. • • WASHER, Flat 1/4" • • WASHER, Lock 1/4" • PLUG, 3/4" Magnetic • PIPE FITTING, 2" Ball valve • STRAINER, Hydraulic tank • GASKET, Hydraulic tank cover • FITTING, Elbow 90° 3/4NPT-#12 • FITTING, Connector 3/4NPT-#12 push lock • FILL CAP, Hydraulic tank • FITTING, 2" Close x 6" lg. • FITTING, Connector 3/4NPT-#12 • TANK WELDMENT, Hydraulic • LEVEL GAUGE, Hydraulic tank • FITTING, Elbow 90° 3/4NPT-#6 • FITTING, Connector #6-#6 • FITTING, Tee #6


1 18 18 18 2 1 1 1 2 2 1 1 1 1 1 1 1 1

SECTION 6, Page 61

FIGURE 6-29. ROTARY MANIFOLD ASSEMBLY

6

5

6

15

7 11

16

5 10 2 7

13

12 4

9 3

12

8

1

14 17



FIGURE 6-29. ROTARY MANIFOLD ASSEMBLY Index No.

1 2

Skyjack Part No.

OEM Part No.

1 2 3 4 5 6 7

702865

ASSEMBLY, Rotary manifold

-

704343 702042 704961

MANIFOLD, Rotary(Serial Number 93184 and above) MANIFOLD, Rotary(Serial Number 93183 and below) PLATE WELDMENT, Rotary Manifold mounting (Serial Number 93184 and above) PLATE, Rotary Manifold mounting (Serial Number 93183 and below) SWITCH, Directional sensing limit • BOLT, Soc-hd #10-32 x 3/4" lg. (Serial Number 93184 and above) SWITCH, Directional sensing limit • BOLT, Mach-hd #10-32 x 3/4" lg. (Serial Number 93183 and below) PLATE, Limit Switch mounting (Serial Number 93184 and above) FITTING, Connector #12orb - #12 FITTING, Elbow 90° female #12 - #12 FITTING, Connector #6orb - #4 FITTING, Elbow 90° #6orb - #6 FITTING, Elbow 90° #6orb - #4 FITTING, Plug #6 FITTING, Connector #6orb - #6 FITTING, Elbow 90° #12orb - #12 NOTE - Items 13 thru 17 are for machines with Dual Fuel Option only. FITTING, Adaptor 3/4NPT - 1/4NPT FITTING, Adaptor 3/4NPT - 3/8NPT FITTING, Elbow 90° female 1/4NPT-1/4NPT FITTING, Pipe nipple 1/4NPT x 2" lg. FITTING, Brass swivel #6orb - #4

1 1 1

706546 3

Units per Assy.

Description

706294 104698 702434 700549

4

706332

5 6 7 8 9 10 11 12

702118 702119 701956 103073 701999 104437 103069 702117

13 14 15 16 17

702820 702821 702500 702499 702239


1 1 2 1 2 1 3 3 2 1 2 2 1 3

1 1 1 1 1

SECTION 6, Page 63

FIGURE 6-30. BRAKE MANIFOLD ASSEMBLY

6 NOTE: For machines with Drive Pressure Braking ONLY. 16

14 19 18

18

2

20 1 2

21

11 10

17

3

18 12

5

2

7

13 4 9 8

15



FIGURE 6-30. BRAKE MANIFOLD ASSEMBLY Index No.

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21

Skyjack Part No.

OEM Part No.

Units per Assy.


703097

ASSEMBLY, Brake manifold

-

703725 103069 703370 703188 703189 703803 703190 703803 703191 703192 703193 703194 706026 706025 703197 703198 700764 700765 104437 706023 706024 704949 702382 701956 706553 703876 706552

• GAUGE, Pressure 800 psi • FITTING, Connector #6orb - #6 • MANIFOLD, Brake • • BLOCK, Manifold • • VALVE, Brake • • • COIL, 12 Volt • • VALVE, Tilt braking • • • COIL, 12 Volt • • VALVE, Pressure reducing • • VALVE, Brake release override • • VALVE, Brake release hand pump • • VALVE, Adjustable relief • • VALVE, Needle • • PLUG, Pipe 1/16 NPT • • VALVE, Shuttle • • VALVE, Check • • PLUG, SAE #2 • • PLUG, SAE #4 • • PLUG, SAE #6 BODY, C10-3 5000 PSI PLUG, Cavity C10-3 VALVE, Shuttle FITTING, Hydraulic Tee #6 female-#6-#6 FITTING, Hydraulic #6orb-#6 ASSEMBLY, Hose (H2204-0101-00-0) ASSEMBLY, Hose (H104 0036-00-0) ASSEMBLY, Hose (H606-0036-00-0)

1 5 1 1 1 1 1 1 1 1 1 1 1 1 2 1 21 3 5 1 1 1 1 3 1 1 1



SECTION 6, Page 65

16

6

4

5

4

10

17

15

17

2

1

18

23

21

10

13

14

24 22

11

20

12

3

19

7

8

FIGURE 6-31. MAIN MANIFOLD ASSEMBLY



FIGURE 6-31. MAIN MANIFOLD ASSEMBLY Index No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Skyjack Part No.

OEM Part No.

Units per Assy.


702864

MANIFOLD ASSEMBLY, Main

103073 701850 701954 702116 702813 701998 702117 103322 702118 701753 703806 703190 703803 703190 703803 703814 703803 703812 703805 703808 703805 703807 703809 703810 703813 703197 703811 703815 703816 703817 700764 700765 104437

• FITTING, Elbow 90° #6orb - #6 • FITTING, Elbow 90° #4orb - #4 • FITTING, Connector #4orb - #4 • FITTING, Connector #8orb - #8 • FITTING, Elbow 45° swivel #8 - #8 • FITTING, Elbow 90° #8orb - #8 • FITTING, Elbow 90° #12orb - #12 • FITTING, Connector #4orb - #6 • FITTING, Connector #12orb - #12 • MANIFOLD, Main • • BLOCK, Manifold • • VALVE, Load sense dump • • • COIL, 12 Volt • • VALVE, High speed drive • • • COIL, 12 Volt • • VALVE, Steering dump • • • COIL, 12 Volt • • VALVE, Steering • • • COIL, 12 Volt • • VALVE, Extension sequencing • • • COIL, 12 Volt • • VALVE, Emergency pump relief • • VALVE, Check • • VALVE, Extension pressure reducing • • VALVE, High speed drive relief • • VALVE, Shuttle • • ORIFICE, .080 Dia. • • VALVE, Check • • VALVE, Shuttle • • VALVE, Check • • PLUG, SAE #2 • • PLUG, SAE #4 • • PLUG, SAE #6


2 2 1 7 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 5 2 1 3 1 2 2 1 AR AR AR

SECTION 6, Page 67

NOTES

SECTION 6, Page 68


FIGURE 6-32. 4 BANK PROPORTIONAL VALVE ASSEMBLY 1 5

12

2 11 5 10 9

4

8 13 7 3 5 1 6 Index No.

1 2 3 4 5 6 (Ref.) 7 8 9 10 11 12 13

Skyjack Part No.

MA-TK-31 OEM Part No.

Units per Assy.


702873

ASSEMBLY, 4 Bank proportional valve

-

702117 103070 702116 701998 103322 109052 702112 703818 703819 703184 703820 703184 703821 703184 703822 703184 703823 703824

• FITTING, Elbow 90° #12orb - #12 • FITTING, Connector #8orb - #6 • FITTING, Connector #8orb - #8 • FITTING, Elbow 90° #8orb - #8 • FITTING, Connector #4orb - #6 • FITTING, Connector #12orb - #6 • VALVE ASSEMBLY, Proportional 4 bank • • VALVE, Pilot pressure reducing • • VALVE, Main lift • • • PULSAR • • VALVE, Knuckle • • • PULSAR • • VALVE, Extend/retract • • • PULSAR • • VALVE, Turret rotate • • • PULSAR • • INLET, Valve bank • • OUTLET, Valve bank

2 2 5 1 3 1 1 1 1 2 1 2 1 2 1 2 1 1


SECTION 6, Page 69

FIGURE 6-33. BASE CONTROL/ELECTRICAL ASSEMBLY

32 31 33

12

30 43 1 29 42 44 45 23 11 17 8 10

15 21

9

14

41

13

5

2

38 4

34

39

35 36

3

22 7

16

6 26

25 20 37 14 24

18

40

18

19

28

27



FIGURE 6-33. BASE CONTROL/ELECTRICAL ASSEMBLY Index No.

Skyjack Part No.

OEM Part No.

(Ref.) 1 2 3 4 5

6 7 8 9 10 11 12 13

14 15 16 17

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

703067 706421 702186 103012 103011 701943 701943 701943 700166 102921 102853 701929 111181 701928 701927 (Ref.) 102769 103281 702402 701925 701931 (Ref.) 102753 103279 103141 103225 103041 103036 700159 105271 113227 703005 701926 703077 701547 701546 102956 702613 702262 701445 702230 702737 702738 701943 701943


Units per Assy.


ASSEMBLY, Base control

-

• ENCLOSURE, Electrical • DUCT, Wire • COVER, Wire duct • STRIP, Terminal, small • STRIP, Terminal, large • RELAY, 12 Volt sealed (dual fuel) • RELAY, 12 Volt sealed (gas) • RELAY, 12 Volt sealed (diesel) • DIODE, 1 Amp/400PIV • DIODE, 6 Amp/1000PIV • SWITCH, Toggle 3 position momentary • SWITCH, Toggle 2 position momentary • GUARD, Toggle switch • GUARD, Toggle switch hinged • GUARD, Toggle switch hinged • ASSEMBLY, Emergency stop switch • HEAD, Emergency stop switch • BASE, N.C. • BREAKER, 15 Amp circuit • METER, Hour • SWITCH, Ignition • ASSEMBLY, Key switch • HEAD, Key switch • • KEY, #455 • BASE, 2 N.C. • , N.O. • , N.C. • STRAIN RELIEF, 5/8" • STRAIN RELIEF, Strait plastic • PLUG, Knockout 1-1/8" • PLUG, Recessed male 110 volt • • BOOT, Rubber • SWITCH, 2 position momentary DPDT • METER, Amperage • STRAIN RELIEF, 3/4" • CARD, Multi purpose controller (EDA) • CARD, Dual solenoid driver (MDSD) • PLUG, Knockout 7/8" • STRAIN RELIEF, Steel 1" - 1-1/8" • PLUG, Knockout 1/2" • PLUG, Knockout 3/8" • LABEL, Control • LABEL, Emergency lowering • LABEL, Manual stowing • RELAY, 12 Volt sealed (work light option) • RELAY, 12 Volt sealed (hydraulic generator option) Parts List Continued on Page 73.

1 134" 134" 7 1 29 28 27 28 5 7 1 7 1 1 1 1 1 3 1 1 1 1 1 1 2 1 3 2 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1

SECTION 6, Page 71

FIGURE 6-33. BASE CONTROL/ELECTRICAL ASSEMBLY

32 31 33

12

30 43 1 29 42 44 45 23 11 17 8 10

15 21

9

14

41

13

5

2

38 4

34

39

35 36

3

22 7

16

6 26

25 20 37 14 24

18

40

18

19

28

27



FIGURE 6-33. BASE CONTROL/ELECTRICAL ASSEMBLY Index No.

36 37 38 39

Skyjack Part No.

40 41

701943 703321 706213 706330 103980 706349 706074 706649

42 43 44 45

703458 703720 701929 111181

OEM Part No.


Units per Assy.


Parts List Continued from Page 71. • RELAY, 12 Volt sealed (horn option) • ALARM, 12 Volt (motion alarm options) • RELAY, Time delay • BRACKET, Time delay relay • • NUT, Hex 1/4-20 • • BOLT, Mch-hd 1/4-20x1-1/4” • CORE, Snap on ferrite • BUFFER, Signal Items 38 Thru 41 are for Machines with Diesel Option. • LABEL, Glow plug • LIGHT, Indicator amber • SWITCH, Toggle 2 position momentary • GUARD, Toggle switch

1 1 1 1 1 1 1 1

1 1 1 1

SECTION 6, Page 73

FIGURE 6-34. ENGINE AND RELATED PARTS (Ford Gas and Dual Fuel) 16

14

17 7

8 1

5 25 6 18

22 2 20 21 23 3 4

19

9

13 11

24



FIGURE 6-34. ENGINE AND RELATED PARTS (Ford Gas and Dual Fuel) Index No.

1

2

Skyjack Part No.

OEM Part No.

702912 701141 704543 703864 704100 704055 702370

3 4

702504 704576 702510

5

6 7 8

9

704306 701543 103970 103470 103468 701545 103908 103470 702543 (Ref.) 704561 702035 702036 702805 702536 706333 702664 702537 704177 703930

10

11

103473 103999 103978 702529 103473 103999 103978 704476 704559 704581 704580 702034 703825 101632 103999 103472


Units per Assy.


ENGINE, Ford LRG423 (gas only) ENGINE, Ford LRG423 (with Dual fuel kit) • CARBURETOR • ACTUATOR, Rotary WELDMENT, Engine tray (Serial Number 93184 and above.) WELDMENT, Engine tray (Serial Number 93139 thru 93183.) WELDMENT, Engine tray (Serial Number 93138 and below.) LATCH, Engine tray WELDMENT, Engine tray latch bolt (Serial Number 93184 and above.) WELDMENT, Engine tray latch bolt (Serial Number 93138 and below.) • PIN, Cotter 3/16" x 1-1/4" lg PUMP, Hydraulic drive • BOLT, Hex-hd 1/2-13 x 1-1/5" lg. • WASHER, Lock 1/2" • WASHER, Flat 1/2" PUMP, Hydraulic system • BOLT, Hex-hd 1/2-20 x 1-1/2" lg. • WASHER, Lock 1/2" BRACKET, Air cleaner mounting AIR CLEANER ASSEMBLY • ELEMENT, Air filter • ASSEMBLY, Air cleaner • BRACKET, Air cleaner assembly • SEAL ASSEMBLY, Air cleaner • REDUCER, Rubber 3" x 2.5" • REDUCER, Rubber 3" x 2" • CLAMP, Gear • ELBOW, 2" PVC WELDMENT, Filter mounting plate (Serial Number 93184 and above.) WELDMENT, Filter mounting plate (Serial Number 93183 and below.) • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Lock 3/8" • NUT, Hex 3/8-16 WELDMENT, High pressure filter bracket (not shown) (Serial Number 93183 and below.) • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Lock 3/8" • NUT, Hex 3/8-16 FILTER, High pressure hydraulic • ELEMENT, High pressure filter • BOLT, Hex-hd 1/4-20 x 4.5" lg. • STANDOFF (Serial Number 93184 and above.) FILTER, High pressure hydraulic • ELEMENT, High pressure filter • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" (Serial Number 93183 and below.) Parts List Continued on Page 77.

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 2 1 1 1 2 1 1 1 2 1 1 1 4 4 2 1 2 2 2 1 1 2 2 1 1 4 4 4

SECTION 6, Page 75

FIGURE 6-34. ENGINE AND RELATED PARTS (Ford Gas and Dual Fuel) 16

14

17 7

8 1

5 25 6 18

22 2 20 21 23 3 4

19

9

13 11

24



FIGURE 6-34. ENGINE AND RELATED PARTS (Ford Gas and Dual Fuel) Index No.

12

Skyjack Part No.

15

702033 703047 101632 103999 103472 701643 700549 104694 104185 104003 704589 702031 702160 702134 702327 702326 702538 702539 702540 702293 702396 702836 702544

16

704579

13

14

OEM Part No.

702545 17 18

19

20 21

22 23 24 25

704544 702672 111921 103999 706102 701929 702322 702533 700549 104694 104185 104003 702523 702522 103884 100397 103404 704397 115387 703658 105807 711086


Units per Assy.


Parts List Continued from Page 75. FILTER, Medium pressure hydraulic • ELEMENT, Medium pressure filter • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" THROTTLE CONTROL, Engine • BOLT, Soc-hd #10-32 x 3/4" lg. • WASHER, Flat #10 • WASHER, Lock #10 • NUT, Hex #10-32 ASSEMBLY, Oil cooler • COOLER, Oil • VALVE, Check • FITTING, Pipe bushing • FITTING, Close nipple 3/4" pipe • FITTING, Female tee 3/4" pipe • FITTING, Elbow 3/4" pipe 90° • FITTING, Nipple 3/4" x 2" lg. • FITTING, Nipple 3/4" x 4" lg. • FITTING, Street elbow 90° • FITTING, Push lock 3/4" - 3/4" • HOSE, 801-12 BRACKET, Oil cooler right (not shown) (Serial Number 93183 and below.) BRACKET, Coolant reservoir (Serial Number 93184 and above.) BRACKET, Oil cooler left (Serial Number 93183 and below.) MUFFLER, Exhaust MOUNT, Engine • BOLT, Hex-hd 3/8-16 x 1/2" lg. • WASHER, Lock 3/8" ASSEMBLY, Throttle control switch • SWITCH, Toggle 3 position momentary • LABEL, Throttle control • BRACKET, Toggle switch mount • BOLT, Soc-hd #10-32 x 3/4" lg. • WASHER, Flat #10 • WASHER, Lock #10 • NUT, Hex #10-32 STRAP, Hose carrier CARRIER, Hose • BOLT, Hex-hd 5/16-18 x 2-1/2" lg. • NUT, Hex 5/16-18 • WASHER, Lock 5/16" LATCH, Engine tray PUMP, Electronic fuel PIN, Hitch • LANYARD, 6 inch O-RING

1 1 4 4 4 1 4 4 4 4 1 1 1 4 2 3 1 2 1 1 2 7” 1 1 1 1 2 2 2 1 2 1 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1

SECTION 6, Page 77

FIGURE 6-35. DUAL FUEL SYSTEM (Ford Engine)(Option)

1 12 11

4

10

16

9 3

2

15 8

7

14

13

6

5



FIGURE 6-35. DUAL FUEL SYSTEM (Ford Engine)(Option) Index No.

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

Skyjack Part No.

OEM Part No.

704551 704543 704549 704550 107444 702253 103006 702237 702239 702821 702820 702499 702500 704546 704547 704545 704548

Units per Assy.


KIT, Dual fuel • CARBURETOR, LP • • VENTURI, #30 LP • BULKHEAD, LP • LOCKOFF, LP with filter • HOSE, LP Vapor TANK, 43.5 lb. Propane COUPLING, Quick connect LP FITTING, Brass female tee #4 FITTING, Brass swivel 90° #6 - #4 FITTING, Adaptor #12 - #6 FITTING, Adaptor #12 - #4 FITTING, Pipe nipple 1/4"npt x 2" lg. FITTING, Brass elbow 90° #4 - #4 HOSE ASSEMBLY, 42" Propane HOSE ASSEMBLY, 36" Propane HOSE ASSEMBLY, 19" Propane HOSE ASSEMBLY, 92" Propane

1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1



SECTION 6, Page 79

FIGURE 6-36. ENGINE AND RELATED PARTS (Deutz Diesel)(Option) 22

21 32 31 17

18

19

20

9 10 27

1 16 26

2 15 6 7 8

23

3 29 24 25 4 28 5 30 11 14

33 13



FIGURE 6-36. ENGINE AND RELATED PARTS (Deutz Diesel)(Option) Index No.

1 2 3

Skyjack Part No.

OEM Part No.

703056 703179 708485 704427 704056 702949

4 5

702504 704576 702510

6

7 8 9 10

11

704306 701543 103970 103470 103468 711086 701545 103908 103470 703222 (Ref.) 704560 706549 703312 703315 703325 703200 704177 703930

12

13

103473 103999 103978 702529 103473 103999 103978 704476 704559 704581 704580 702034 703825 101632 103999 103472


Units per Assy.


ENGINE, Air cooled diesel • SWITCH, Engine shutdown • PLATE, Flywheel WELDMENT, Engine tray (Serial Number 93184 and above.) WELDMENT, Engine tray (Serial Number 93139 thru 93183.) WELDMENT, Engine tray (Serial Number 93138 and below.) LATCH, Engine tray WELDMENT, Engine tray latch bolt (Serial Number 93184 and above.) WELDMENT, Engine tray latch bolt (Serial Number 93138 and below.) • PIN, Cotter 3/16" x 1-1/4" lg PUMP, Hydraulic drive • BOLT, Hex-hd 1/2-13 x 1-1/5" lg. • WASHER, Lock 1/2" • WASHER, Flat 1/2" O-RING PUMP, Hydraulic system • BOLT, Hex-hd 1/2-20 x 1-1/2" lg. • WASHER, Lock 1/2" BRACKET, Air cleaner mount AIR CLEANER ASSEMBLY • ELEMENT, Primary filter • ELEMENT, Secondary filter • ASSEMBLY, Air cleaner • MOUNTING BAND, Air cleaner • HUMP REDUCER, Air cleaner • WELDMENT, Air cleaner mount WELDMENT, Filter mounting plate (Serial Number 93184 and above.) WELDMENT, Filter mounting plate (Serial Number 93183 and below.) • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Lock 3/8" • NUT, Hex 3/8-16 WELDMENT, High pressure filter bracket (not shown) (Serial Number 93183 and below.) • BOLT, Hex-hd 3/8-16 x 1" lg. • WASHER, Lock 3/8" • NUT, Hex 3/8-16 FILTER, High pressure hydraulic • ELEMENT, High pressure filter • BOLT, Hex-hd 1/4-20 x 4.5" lg. • STANDOFF (Serial Number 93184 and above.) FILTER, High pressure hydraulic • ELEMENT, High pressure filter (Serial Number 93183 and below.) • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" Parts List Continued on Page 83.

1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 4 4 2 1 2 2 2 1 1 2 2 1 1 4 4 4

SECTION 6, Page 81

FIGURE 6-36. ENGINE AND RELATED PARTS (Deutz Diesel)(Option) 22

21 32 31 17

18

19

20

9 10 27

1 16 26

2 15 6 7 8

23

3 29 24 25 4 28 5 30 11 14

33 13



FIGURE 6-36. ENGINE AND RELATED PARTS (Deutz Diesel)(Option) Index No.

14

15 16 17 18 19 20

21 22

23

24 25

26

Skyjack Part No.

OEM Part No.

702033 101632 103999 103472 703313 703355 703282 703437 703348 (Ref.) 703216 703347 703467 703463 703287 704589 702031 702160 702134 702327 702326 702538 702539 702540 702293 702396 702836 (Ref.) 703623 703624 703625 703626 702523 702522 103884 100397 103404 704336 702942

27 28

29 30 31 32 33

703311 703483 701929 703480 702533 700549 104694 104185 104003 704397 103068 701943 103012 703658 105807


Units per Assy.


Parts List Continued from Page 81. FILTER, Medium pressure hydraulic • BOLT, Hex-hd 3/8-16 x 3/4" lg. • WASHER, Lock 3/8" • WASHER, Flat 3/8" CONVERTER, Exhaust BRACKET, Exhaust converter BRACKET, or OR, 12 Volt 80 amp MODULE, Throttle control solenoid ASSEMBLY, Throttle solenoid • BRACKET, Throttle control solenoid • SOLENOID, Throttle control • ROD, Throttle control linkage • BALL T, Throttle control rod BRACKET, Terminal block ASSEMBLY, Oil cooler • COOLER, Oil • VALVE, Check • FITTING, Pipe bushing • FITTING, Close nipple 3/4" pipe • FITTING, Female tee 3/4" pipe • FITTING, Elbow 3/4" pipe 90° • FITTING, Nipple 3/4" x 2" lg. • FITTING, Nipple 3/4" x 4" lg. • FITTING, Street elbow 90° • FITTING, Push lock 3/4" - 3/4" • HOSE, 801-12 ASSEMBLY, Dipstick • TUBE, Dipstick • BRACKET, dipstick tube • FITTING, Adaptor #18orb - #10 • FITTING, Elbow 90° #10 - #10 STRAP, Hose carrier CARRIER, Hose • BOLT, Hex-hd 5/16-18 x 2-1/2" lg. • NUT, Hex 5/16-18 • WASHER, Lock 5/16" WELDMENT, Intake bracket (Serial Number 93184 and above.) WELDMENT, Intake bracket (Serial Number 93183 and below.) PIPE, Exhaust ASSEMBLY, Throttle control switch • SWITCH, Toggle 3 position momentary • LABEL, Throttle control • BRACKET, Toggle switch mount • BOLT, Soc-hd #10-32 x 3/4" lg. • WASHER, Flat #10 • WASHER, Lock #10 • NUT, Hex #10-32 LATCH, Engine tray STANDOFF, Insulated RELAY, 12 VDC, Sealed TERMINAL STRIP, Small PIN, Hitch • LANYARD, 6 inch

1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 3 1 2 1 1 2 7” 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1

SECTION 6, Page 83

NOTES

SECTION 6, Page 84


FIGURE 6-37. BOOM LIFT CYLINDER ASSEMBLY 14

16

17

15

5 13

4 9 12

2

10

7

1 3 11 8 13

6

MA-TK-14 Index No.

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


Skyjack Part No.

701991 701992 701288 701967 701377 109248 701993 702089 701994 701990 701989 106219 701968 103208 701460 702819 701635 701956 701827 702643 703873

OEM Part No.


CYLINDER ASSEMBLY, Boom lift • PISTON • NUT, Lock 1-1/2 - 12 • O-RING • SEAL, Piston • WEAR RING, Piston • WELDMENT, Rod • WELDMENT, Barrel • GLAND • SEAL, Rod • WIPER, Rod • WEAR RING, Rod • O-RING • BUSHING, 2" x 2-3/16" x 1-1/2" lg. VALVE BLOCK • BOLT, Soc-hd 5/16-18 x 1-1/4" lg. O-RING FITTING, Connector #6orb - #4 VALVE, Counterbalance KIT, Seal repair TOOL, Cylinder assembly * Part of Seal Repair Kit

Units per Assy.

1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 2 2 2 AR AR

SECTION 6, Page 85

SECTION 6, Page 86 41

35

23

39

29

13

4

38 28

33

3

27

44

40

32

36

22

34

5

23

8

41

9

46

25

15

49

61

57

30

2

43

19

45 24 19

16

17

55

22

18

18

16

37

31

42

7

15

23

47

24

14

13

14

50

21

59

SIDE VIEW

10

17

15

TOP VIEW

48

56

58

20

14

26

53

51

63

54

22

62

52

12

20

50

6

55

60

1

11

FIGURE 6-38. TURRET HYDRAULIC CONNECTIONS

MA-TK-36


FIGURE 6-38. TURRET HYDRAULIC CONNECTIONS Index No.

Skyjack Part No.

1

701991

2

702033 703047 704476 704559

3

OEM Part No.

702034 703825 4 5 6

701545 701543 704343 702042

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

30 31 32

702607 703370 702112 701753 702214 702541 701954 702118 103322 701850 103070 103069 702116 701956 702119 702117 103073 701998 109052 103307 702234 702233 702439 702440 (Ref.) 702880 701884 702629 702630 702558 703255 702123 702122



CYLINDER ASSEMBLY, Boom lift (For components, refer to Figure 6-37.) FILTER ASSEMBLY, Medium pressure hydraulic fluid •ELEMENT, Filter FILTER ASSEMBLY, High pressure hydraulic fluid •ELEMENT, Filter (Serial Number 93184 and above) FILTER ASSEMBLY, High pressure hydraulic fluid •ELEMENT, Filter (Serial Number 93183 and below) PUMP, Hydraulic system PUMP, Hydraulic drive MANIFOLD, Rotary (Serial Number 93184 and above) MANIFOLD, Rotary (Serial Number 93183 and below) MANIFOLD, Distribution MANIFOLD, Brake VALVE ASSEMBLY, Proportional control MANIFOLD, Main TANK WELDMENT, Hydraulic fluid FITTING, Elbow 90° 3/4” NPT - #12 FITTING, Connector #4orb - #4 FITTING, Connector #12orb - #12 FITTING, Connector #4orb - #6 FITTING, Elbow 90° #4orb - #4 FITTING, Connector #8orb - #6 FITTING, Connector #6orb - #6 FITTING, Connector #8orb - #8 FITTING, Connector #6orb - #4 FITTING, Elbow 90° Female #12 - #12 FITTING, Elbow 90° #12orb - #12 FITTING, Elbow 90° #6orb FITTING, Elbow 90° #8orb - #8 FITTING, Connector #12orb - #6 FITTING, Connector #10orb - #6 FITTING, Elbow 45° 6000psi split flange #12 •KIT, Split flange seal FITTING, Elbow 45° 3000psi split flange •KIT, Split flange seal FITTING ASSEMBLY, Suction FITTING, Flange FITTING, Nipple 1-1/4NPT - 1-1/4 lg. FITTING, Elbow 90° 1-1/4NPT FITTING, Elbow 45° 1-1/4NPT FITTING, Connector 1-1/4NPT - 1-1/2” hose barb FITTING, Elbow 90° long #8orb - #6 FITTING, Connector #16orb - #6 FITTING. Connector #16orb - #12

Units per Assy.

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 5 4 6 5 6 3 6 1 5 5 2 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1

Index No.

33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Skyjack Part No.

702438 704582 702558 (Ref.) 702559 702562 704644 704527 704540 704514 704542 704519 703875 704520 704521 707088 704522 704534 704536 704525 704530 704507 704505 703874 704512 706588 706575 704528 704532 704523 703036 704503 704553 704538

OEM Part No.

Units per Assy.


FITTING, Elbow 90° #8orb - #12 FITTING, Connector #10 - #12 FITTING, Connector 1-1/4NPT - 1-1/2 hose barb ASSEMBLY, Suction pipe manifold FITTING, Nipple 2”NPT - 48” lg. FITTING, Elbow 90° 2”NPT PIPE MANIFOLD, Suction line ASSEMBLY, Hose (H606 0021 00-0) ASSEMBLY, Hose (H712 0013 02-0) ASSEMBLY, Hose (H1624 0086 00-0) ASSEMBLY, Hose (H812 0121 00-0) ASSEMBLY, Hose (H504 0117 00-0) ASSEMBLY, Hose (H104 0032 00-0) ASSEMBLY, Hose (H506 0060 00-0) ASSEMBLY, Hose (H506 0066 00-0) ASSEMBLY, Hose (H106 0016 00-0) ASSEMBLY, Hose (H506 0068 00-0) ASSEMBLY, Hose (H608 0022 00-0) ASSEMBLY, Hose (H608 0027 00-0 ASSEMBLY, Hose (H512 0117 00-0) ASSEMBLY, Hose (H606 0050 00-0) ASSEMBLY, Hose (H1312 0029 00-0) ASSEMBLY, Hose (H1312 0016 02-0) ASSEMBLY, Hose (H1006 0040 00-0) ASSEMBLY, Hose (H1412 0055 00-0) ASSEMBLY, Hose (H1512 0075 00-0) ASSEMBLY, Hose (H1512 0026 00-0) ASSEMBLY, Hose (H2012 0078 00-0) ASSEMBLY, Hose (H606 0086 00-0) ASSEMBLY, Hose (H506 0086 00-0) FITTING, Elbow 90° #12 - #6 ASSEMBLY, Hose (H1112 0093 00-0) ASSEMBLY, Hose (H604 0038 00-0) ASSEMBLY, Hose (H612 0039 00-0)

1 1 1 1 1 1 1 2 1 1 1 2 4 1 2 1 1 2 2 1 2 1 1 1 1 2 1 1 1 1 1 2 2 1


SECTION 6, Page 87

FIGURE 6-39. BASE, AXLES AND WHEELS (Standard 4 x 2)

3

4

1

2

12

5

9

6

13

10 14

7

11 8

MA-TK-02a SECTION 6, Page 88


FIGURE 6-39. BASE, AXLES AND WHEELS (Standard 4 x 2) Index No.

1 2

Skyjack Part No.

3

703117 702988 703053 702194 704257

4

703038

OEM Part No.

704137 704138

5

703040 103998 706530 701699

6

701047

7

701054 701055 701056 702309

8

9 10

11

701953 703415 700575 702913 701544 703057 702899 702192 706600

$ 704250 703586 706601 12 13 14

702633 704555 704556


Units per Assy.


WELDMENT, Chassis GEAR, Turret rotate • BOLT, Hex-hd 3/4-10 x 5-1/2" lg. • WASHER, Flat 3/4" hardened SPACER, Speed reducer (Serial number 93183 and below.) (Not required for serial number 93184 and above) ASSEMBLY, Speed reducer (For components, refer to Figure 6-51.) (For serial number 93116 and above.) • BOLT, Soc-hd 3/4-10 x 2" lg. • WASHER, Lock 3/4" (For serial number 93115 and below.) • BOLT, 5/8-11 x 2" lg. • WASHER, Lock 5/8" • SPACER, Bolt AXLE, Rigid drive (For components, refer to Figure 6-48.) PLANETARY, Gear reduction drive (For components, refer to Figure 6-45.) • BOLT, Hex-hd 8mm-1.25 x 45mm lg. • NUT, Hex 8mm-1.25 • WASHER, Lock 8mm AXLE, Steering (For components, refer to Figure 6-44.) PLATE, Axle mount • BOLT, Hex-hd 3/4-10 x 9" lg. • NUT, Lock 3/4-10 CYLINDER ASSEMBLY, Steering (For components, refer to Figure 6-43.) MOTOR, Hydraulic drive • BOLT, Hex-hd 9/16-12 x 2-1/2" lg. • WASHER, Lock 9/16 • NUT, Hex 9/16-12 WHEEL/TIRE ASSEMBLY, Standard (15 x 19.5 - 14 ply) (Machines with Serial Number 93179 and above.) WHEEL/TIRE ASSEMBLY, Standard (Machines with Serial Number 93178 and below.) WHEEL/TIRE ASSEMBLY, Rib flotation (option) (40/19 x 19.5 - 14 ply) WHEEL/TIRE ASSEMBLY, Lug flotation (option) (38/18 x 20 - 12 ply) WHEEL/TIRE ASSEMBLY, Std. Foam filled (option) (15 x 19.5 - 14 ply) BRACKET, LP Tank mounting (pair) WELDMENT, Steer cylinder inner pin WELDMENT, Steer cylinder outer pin NOTE:Size and load rating of replacement tires MUST be identical to that of original equipment to maintain safety and stability of machine. $ - Consult Factory

1 1 20 20 1

1

4 4 4 4 4 1 1 8 8 8 1 4 4 4 2 1 4 4 4 4

4 4 4 4 2 2 2

SECTION 6, Page 89

FIGURE 6-40. BASE, AXLES AND WHEELS (Optional 4 x 4)

4 3

1 2

11

11

5

8

9

6

10 7



FIGURE 6-40. BASE, AXLES AND WHEELS (Optional 4 x 4) Index No.

1 2

Skyjack Part No.

3

703117 702988 703053 702194 704257

4

703038

OEM Part No.

704137 704138

5

703040 103998 706530 701454

6

701453

7

701953 703415 700575 702041 702956 702991 702960 701544 702191 702192 706600

8

9

10

$ 704250 703586 706601 11

702633

Units per Assy.


WELDMENT, Chassis GEAR, Turret rotate • BOLT, Hex-hd 3/4-10 x 5-1/2" lg. • WASHER, Flat 3/4" hardened SPACER, Speed reducer (Serial number 93183 and below.) (Not required for serial number 93184 and above) ASSEMBLY, Speed reducer (For components, refer to Figure 6-51.) (For serial number 93116 and above.) • BOLT, Soc-hd 3/4-10 x 2" lg. • WASHER, Lock 3/4" (For serial number 93115 and below.) • BOLT, 5/8-11 x 2" lg. • WASHER, Lock 5/8" • SPACER, Bolt AXLE, Rigid drive (For components, refer to Figure 6-48.) AXLE, Drive/steer with transfer case (For components, refer to Figure 6-50.) PLATE, Axle mount • BOLT, Hex-hd 3/4-10 x 9" lg. • NUT, Lock 3/4-10 ASSEMBLY, Drive line • BOLT, Hex-hd 7/16-20 x 1-1/4" lg. • WASHER, Lock 7/16" • NUT, Lock 7/16-20 MOTOR, Hydraulic drive • BOLT, Hex-hd m14x2.0x45mm lg. • WASHER, Lock 9/16" WHEEL/TIRE ASSEMBLY, Standard (15 x 19.5 - 14 ply) (Machines with Serial Number 93179 and above.) WHEEL/TIRE ASSEMBLY, Standard (Machines with Serial Number 93178 and below.) WHEEL/TIRE ASSEMBLY, Rib flotation (option) (40/19 x 19.5 - 14 ply) WHEEL/TIRE ASSEMBLY, Lug flotation (option) (38/18 x 20 - 12 ply) WHEEL/TIRE ASSEMBLY, Std. Foam filled (option) (15 x 19.5 - 14 ply) BRACKET, LP Tank mounting (pair)

1 1 20 20 1

1

4 4 4 4 4 1 1 4 4 4 1 8 8 8 1 4 4 4

4 4 4 4 2

NOTE:Size and load rating of replacement tires MUST be identical to that of original equipment to maintain safety and stability of machine. $ - Consult Factory


SECTION 6, Page 91

FIGURE 6-41. BASE ASSEMBLY HYDRAULIC CONNECTIONS (Standard 4x2)

3

5

5 10

15

15 1

14

6

5

4 17 16

7

8

12

2

4 13

11

9



FIGURE 6-41. BASE ASSEMBLY HYDRAULIC CONNECTIONS (Standard 4x2) Index No.

Skyjack Part No.

1

(Ref.)

2 3

701544 702913

4 5 6 7 8 9 10 11 12 13 14 15 16 17

702117 701999 103073 702232 702233 700817 703223 114109 704523 704554 703878 703875 704541 704516

OEM Part No.

Units per Assy.


MANIFOLD, Rotary (For components see Figure 6-29.) MOTOR, Hydraulic drive CYLINDER, Steering (For components, refer to Figure 6-43.) FITTING, Elbow 90° #12orb - #12 FITTING, Elbow 90° #6orb - #4 FITTING, Elbow 90° #6orb - #6 FITTING, Elbow 90° split flange KIT, Split flange seal FITTING, Connector #14orb - #6 FITTING, Swivel tee #4 - #4 - #4 FITTING, Swivel tee #6 - #6 - #6 ASSEMBLY, Hose (H506 0086 00-0) ASSEMBLY, Hose (H606 0024 00-0) ASSEMBLY, Hose (H104 0078 00-0) ASSEMBLY, Hose (H104 0032 00-0) ASSEMBLY, Hose (H912 0043 02-0) ASSEMBLY, Hose (H212 0033 00-0)

1 1 2 4 6 1 2 2 2 2 1 1 1 2 2 1 2



SECTION 6, Page 93

FIGURE 6-42. BASE ASSEMBLY HYDRAULIC CONNECTIONS (Optional 4 x 4)

8

9

9 14

2

17 18

3 7

15

6

12 13 3 4

11 1 5 16 14

10 15

9



FIGURE 6-42. BASE ASSEMBLY HYDRAULIC CONNECTIONS (Optional 4 x 4) Index No.

Skyjack Part No.

1

(Ref.)

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

701544 702117 701999 103073 702232 702233 702323 700817 114109 702921 704516 704541 704554 703882 703881 703878 703879

OEM Part No.

Units per Assy.


MANIFOLD, Rotary (For components see Figure 6-29.) MOTOR, Hydraulic drive FITTING, Elbow 90° #12orb - #12 FITTING, Elbow 90° #4orb - #6 FITTING, Elbow 90° #6orb - #6 FITTING, Elbow 90° split flange KIT, Split flange seal FITTING, Connector #18orb - #4 FITTING, Connector #14orb - #6 FITTING, Swivel tee #6 - #6 - #6 FITTING, Union tee #6 - #6 - #6 ASSEMBLY, Hose (H212 0033 00-0) ASSEMBLY, Hose (H912 0043 02-0) ASSEMBLY, Hose (H606 0024 00-0) ASSEMBLY, Hose (H106 0047 00-0) ASSEMBLY, Hose (H106 0032 00-0) ASSEMBLY, Hose (H104 0078 00-0) ASSEMBLY, Hose (H104 0088 00-0)

1 1 4 2 1 2 2 2 4 2 1 2 1 2 2 1 1 1



SECTION 6, Page 95

NOTES

SECTION 6, Page 96


FIGURE 6-43. STEERING CYLINDER (Standard 4x2) 4

9

6

2

7 12 15

13

13

14 14

8

1

11

3 5 Index No.

1 2 3 4 5 6* 7* 8* 9* 10* 11 12 13 14 15

Skyjack Part No.

OEM Part No.

10 Description

1 2 3 4 5 6 7

702913

CYLINDER ASSEMBLY, Steer

702916 702915 700575 700243 700242 700578 701965 701634 700576 700585 700449 700509 102025 104114 701999 700456

•WELDMENT, Barrel •WELDMENT, Rod •NUT, Lock 3/4 - 10 •GLAND, Cylinder •PISTON, Cylinder •SEAL, Wiper •SEAL, O-Ring •SEAL, O-Ring •SEAL, Rod •SEAL, Piston •SPACER, Cylinder •NIPPLE, Grease •BEARING, Spherical •RING, Retaining •FITTING, Elbow 90° #6orb - #4 KIT, Seal repair * Part of Seal Repair Kit



1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 AR

SECTION 6, Page 97

FIGURE 6-44. STEER AXLE ASSEMBLY (Standard 4x2)

3

1

6 7

9 4

5

8

2



FIGURE 6-44. STEER AXLE ASSEMBLY (Standard 4x2) Index No.

1 2

3 4 5

6 7 8 9

Skyjack Part No.

OEM Part No.


Units per Assy.

702309

AXLE ASSEMBLY, Steering 2wd

-

704201 704202 707074 704203 704204 704205 704206 704207 704208 704209 704210 704190 704191 704192 704193 704194 704195 704211 704212 704213 704214

• AXLE WELDMENT • WHEEL HUB ASSEMBLY • • HUB • • CONE, Inner group • • CUP, Inner group • • CONE, Outer group • • CUP, Outer group • • SEAL, Dual element • • HUB COVER • L. H. YOKE & SPINDLE • R. H. YOKE & SPINDLE • ASSEMBLY, Tie Rod • • TUBE, Tie Rod • • TIE ROD END, L. H. • • TIE ROD END, R. H. • • JAM NUT, L. H. • • JAM NUT, R. H. • ASSEMBLY, King Pin • WASHER, Thrust • BUSHING, Tie rod arm • BUSHING, Cylinder mount arm

1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 2 2


SECTION 6, Page 99

FIGURE 6-45. PLANETARY REDUCTION GEAR ASSEMBLY (Brevini)

7

5

3

8

1

6

4


Skyjack Part No.

1 2 3 4 5 6 7 8

701841 $ 701849 $ $ 704233 701842 701030

OEM Part No.


LIP SEAL, Output housing HOUSING, Output O-RING SEAL RING GEAR HOUSING, Input GASKET, Input adapter LIP SEAL, Input adapter HOUSING, Input adapter

Units per Assy.

1 1 2 1 1 1 1 1

$ Consult factory

SECTION 6, Page 100


FIGURE 6-46. PLANETARY REDUCTION GEAR ASSEMBLY (Sige)

4

6

1

5

3


Skyjack Part No.

1 2 3 4 5 6

704234 $ 704235 $ $ 704236

OEM Part No.


O-RING, Output housing HOUSING, Output O-RING SEAL RING GEAR HOUSING, Input LIP SEAL, Input housing

Units per Assy.

1 1 2 1 1 1

$ Consult factory


SECTION 6, Page 101

9

15

2

14

13

5

1

3

6

5

11

8

10

20

19

7

16

4

5

12

17

18

5

FIGURE 6-47. DRIVE AXLE ASSEMBLY (Standard 4x2)



FIGURE 6-47. DRIVE AXLE ASSEMBLY (Standard 4x2) Index No.

Skyjack Part No.

OEM Part No.

701699 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

701836 704221 701848 701851 701843 701844 701852 701890 704231 704219 701853 704215 701845 701846 701847 704216 704217 704218 703045 706544



AXLE ASSEMBLY, Rigid drive •NUT, Pinion retaining •OIL SEAL, Pinion •SEAL, O-ring •SEAL, O-ring •WASHER, Oil plug •WASHER, Oil plug •SEAL, O-ring •SEAL. O-ring (housing) •BACKING RING, Seal •SEAL, O-ring (piston) •SEAL, Spring •COVER, Dust •ACTUATOR, Brake •BRAKE DISK, Intermediate •BRAKE DISK, Friction •SHAFT, Axle •SEAL, Hub oil •SEAL, O-ring •COVER, Brake •PISTON, Brake

Units per Assy.

1 1 1 1 5 2 2 2 4 2 2 2 2 6 10 2 2 2 2 2

SECTION 6, Page 103

9

15

20

2

14

13

5

1

3

6

5

11

8

10

21

19

7

16

4

5

12

17

18

5

FIGURE 6-48. RIGID AXLE ASSEMBLY (Optional 4x4)



FIGURE 6-48. RIGID AXLE ASSEMBLY (Optional 4x4) Index No.

Skyjack Part No.

OEM Part No.

701454 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

701836 701837 701848 701851 701843 701844 701852 701890 704231 704219 701853 704215 701845 701846 701847 704216 704217 704218 703045 704232 706544



AXLE ASSEMBLY, Rigid drive •NUT, Pinion retaining •OIL SEAL, Pinion •SEAL, O-ring •SEAL, O-ring •WASHER, Oil plug •WASHER, Oil plug •SEAL, O-ring •SEAL. O-ring (housing) •BACKING RING, Seal •SEAL, O-ring (piston) •SEAL, Spring •COVER, Dust •ACTUATOR, Brake •BRAKE DISK, Intermediate •BRAKE DISK, Friction •SHAFT, Axle •SEAL, Hub oil •SEAL, O-ring •COVER, Brake •FLANGE ASSEMBLY •PISTON, Brake

Units per Assy.

1 1 1 1 5 2 2 2 4 2 2 2 2 6 10 2 2 2 2 1 2

SECTION 6, Page 105

22

23

1

21

2

4

7

9

24

5

13

4

8

12

10

20

14

6

19

17

4

3

17

18

11

15

16

4

FIGURE 6-49. STEER AXLE ASSEMBLY (Optional 4x4)



FIGURE 6-49. STEER AXLE ASSEMBLY (Optional 4x4) Index No.

Skyjack Part No.

OEM Part No.

701453 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

701836 704221 701851 701843 701844 701852 701890 704231 704219 701853 704215 701845 701846 701847 704241 706539 704218 704238 704239 704240 703045 706537 706538 704243 706536 706535 (Ref.)


Units per Assy.


AXLE ASSEMBLY, Rigid drive

-

•NUT, Pinion retaining •OIL SEAL, Pinion •SEAL, O-ring •WASHER, Oil plug •WASHER, Oil plug •SEAL, O-ring •SEAL. O-ring (housing) •BACKING RING, Seal •SEAL, O-ring (piston) •SEAL, Spring •COVER, Dust •ACTUATOR, Brake •BRAKE DISK, Intermediate •BRAKE DISK, Friction •SHAFT ASSEMBLY, Axle • •T, Universal •SEAL, O-ring •SEAL, Oil •SEAL, Shaft •SEAL, Shaft •COVER, Brake •CYLINDER ASSEMBLY, Steer • •KIT, Seal repair •T, Axial •TIE ROD END •NUT, Steer arm •TRANSFER CASE (not shown) (For components, refer to Figure 6-50.)

1 1 1 5 2 2 2 4 2 2 2 2 6 10 2 4 2 4 2 2 2 1 AR 2 2 2

SECTION 6, Page 107

FIGURE 6-50. TRANSFER CASE ASSEMBLY (Optional 4x4 only)

5

1 2

3

4

3 Index No.

Skyjack Part No.

1 2 3 4 5

706540 706541 701843 706542 704220

SECTION 6, Page 108

OEM Part No.


SEAL, O-ring SEAL, Oil WASHER, Oil seal SEAL, Oil SEAL, O-ring


1 1 3 1 1


FIGURE 6-51. SPEED REDUCER ASSEMBLY 3

5

8 7

2

4 9

1

6 MA-TK-70

Index No.

1

2 3 4 5 6 7 8

9

Skyjack Part No.

OEM Part No.


Units per Assy.

703038

ASSEMBLY, Speed reducer

1

702989 702939 103996 103404 703019 706384 103307 701850 701954 703030 702992 103909 103470 704504

SPEED REDUCER • BOLT, SHCS 5/16 - 18 x 3.0 grade 5 • WASHER, Flat 5/16 SAE • WASHER, Lock 5/16 MANIFOLD, Rotation drive motor VALVE, Counter balance FITTING, Hydraulic 6400-6-10 FITTING, Hydraulic 6801-4 FITTING, Hydraulic 6400-4 VALVE, Shuttle cartridge MOTOR, Hydraulic • BOLT, HHCS 1/2 - 13 x 1.25 • WASHER, Lock 1/2 ASSEMBLY, Hose (H1204 0009 00-0) (Refer to SECTION 5, Page 37)

1 4 4 4 1 2 2 1 1 1 1 2 2 1


SECTION 6, Page 109

FIGURE 6-52. LABELS AND NAMEPLATES Index No.

Skyjack Part No.

704552 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

701604 701612 701697 702012 702461 702013 701776 702737 702739 702780 106705 109447 702005 701613 703727 702738 703854 704498

19

706483

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

701767 700107 700032 700026 700551 701605 700028 103125 106691 108666 700035 703760 114269 114271 110270 700438 702014 701603 701609 701611 701610 701606 702782 702322 702779 702781 703480 703262 703458 701766 702230 703068 706389

SECTION 6, Page 110

OEM Part No.


Units per Assy.

KIT, Service labels and nameplates 1 (Consists of items 1-30.) •LABEL, Skyjack 9.93 x 60.0 2 •LABEL, Skyjack 12.0 x 72.5 1 •LABEL, Blue/white striping 6” 492” •LABEL, TK (front of chassis) 1 •LABEL, Proportional valve (turret plate) 1 •LABEL, Explosive (fuel tank cover) 1 •LABEL, Ignition console 1 •LABEL, Emergency lowering 2 •LABEL, Tie down (near tie down ring) 2 •LABEL, Brake control (turret plate) 1 •LABEL, Do not alter (near all limit switches) 6 •LABEL, Made in USA 1 •LABEL, Danger brake release (turret plate) 1 •LABEL, Patent pending (knuckle) 2 •LABEL, ATF only (hydraulic tank cover) 1 •LABEL, Manual stowing 1 •LABEL, Caution stowing 1 •LABEL, Warning pinch point (behind engine) 1 (Serial number 93184 and above) •LABEL, Warning pinch point (behind engine) 1 (Serial number 93183 and below) •LABEL, Top console 1 •LABEL, Attach lanyard 2 •LABEL, Attach safety belt 1 •LABEL, Danger 1 •LABEL, Warning 1 •LABEL, Platform capacity 1 •LABEL, Design standard 1 •LABEL, Blue/white striping 190” •LABEL, Operator checklist 1 •LABEL, Use original parts 1 •LABEL, Annual inspection 1 •LABEL, Misuse of boom 1 TUBE, Manual storage 1 CAP, Manual tube 2 CLAMP, Manual tube 2 MANUAL, ANSI A92.5 1 MANUAL, Operator 1 LABEL, Sjb-66tk (chassis) 3 NAMEPLATE, Serial number (consult factory) 1 LABEL, 66tk 2 LABEL, 66tk 4x2 1 LABEL, 66tk 4x4 (option) 1 LABEL, Unleaded only (fuel tank cover) 2 LABEL, Gas/dual fuel throttle control (switch bracket) 1 LABEL, Gas Engine specifications (filter plate) 1 LABEL, Diesel only (option)(fuel tank cover) 2 LABEL, Diesel throttle control (option)(switch bracket) 1 LABEL, Diesel engine specifications (option) 1 LABEL, Diesel glow plug (option) 2 LABEL, Console face 1 LABEL, Turret control 1 LABEL, Brake manifold 1 LABEL, Caution adjustment 1 NOTE: Supply Model Number and Serial Number when ordering complete machine labels. SJB-66TK, Serial Number 93197 and below

FIGURE 6-52. LABELS AND NAMEPLATES

43 46

44 47 18 19

6

42 45

11 12 4 11 11 20

49

48

7

22

15

32 33 34 35 36

8 28

23

24 39 17

8

1

27

14

11

30

29

31

5

21

16

25 26

2

13 52 3

41 38 50

11

9

51 10 38

9 37

MA-TK-40 SJB-66TK, Serial Number 93197 and below

SECTION 6, Page 111

NOTES

SECTION 6, Page 112


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